A method for controlling the production of calcium carbide furnace in the calcium carbide process

Abstract

The present invention discloses a method for controlling the production of calcium carbide furnace in the calcium carbide process. This method monitors the actual material ratio of each raw material before entering the mixing device in real time, and adjusts the material ratio of the materials entering the mixing device in real time according to the monitoring results, so as to ensure that the materials entering the mixing device show a high degree of consistency in each period, which is conducive to the stability and consistency of the quality of calcium carbide produced by the calcium carbide furnace. In addition, the present invention also realizes the online, continuous and real-time monitoring of the feeding ratio. Therefore, the present invention can further realize the continuous batching and feeding of calcium carbide production raw materials, without mixing a certain amount of mixed raw materials at one time and then carrying out the same feeding.

Description

Technical Field

[0001] The present invention belongs to the technical field of calcium carbide production control, and specifically relates to a calcium carbide furnace production control method in a calcium carbide process. Background Art

[0002] Calcium carbide, primarily composed of CaC2, is a crucial raw material in the organic synthesis industry and plays a vital role in the chemical industry. The smelting process involves a high-temperature physical and chemical reaction. Coke and lime are placed in a furnace at a specific ratio, where a chemical reaction occurs at high temperatures to produce calcium carbide. Calcium carbide smelting involves introducing an electric current into the furnace through three-phase electrodes, generating arc resistance heat. This causes the raw materials to undergo a chemical reduction reaction at a specific temperature, producing calcium carbide.

[0003] When the existing calcium carbide furnace feeding device is working, it discharges a certain amount of material through the raw material weighing bucket corresponding to each raw material, and then transmits it to the silo on the top of the calcium carbide furnace through various levels of conveying mechanisms. Therefore, there is a problem of poor overall mixing uniformity of the raw materials. Therefore, the materials entering the reaction zone of the calcium carbide furnace also have the problem of uneven mixing, which leads to poor quality stability and consistency of the final produced calcium carbide. In order to solve the above problems, a calcium carbide furnace production control method that can improve the quality of calcium carbide is provided, and the present invention provides the following technical solutions. Summary of the Invention

[0004] The purpose of the present invention is to provide a calcium carbide furnace production control method in a calcium carbide process, so as to solve the problem in the prior art that the calcium carbide raw materials are poorly mixed during the batching and feeding stage, thereby affecting the quality of the produced calcium carbide.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A method for controlling production of a calcium carbide furnace in a calcium carbide process comprises the following steps:

[0007] Step 1: Add raw materials into the corresponding raw material weighing hoppers according to the set raw material ratio;

[0008] Step 2: The raw materials discharged from the raw material weighing bucket enter the vibrating feeder;

[0009] The image information at the outlet of the vibrating feeder is collected by a high-speed image acquisition unit;

[0010] For a type of raw material, a frame of image at the outlet of the corresponding vibrating feeder is acquired at every preset time interval t1;

[0011] The frame image is analyzed by the image analysis unit to obtain the predicted weight m of the raw material discharged by the vibrating feeder within the frame image analysis range at the time corresponding to the frame image;

[0012] Step 3: Update the predicted weight m of each raw material in sequence. The execution unit adjusts the amplitude of the vibrating feeder corresponding to each raw material according to the ratio between the updated predicted weights m of each raw material.

[0013] Further, the method for the image analysis unit to analyze the frame image to obtain the predicted weight m of the raw material discharged by the vibrating feeder within the analysis range of the frame image at the moment corresponding to the frame image is as follows:

[0014] Define an analysis range in the frame image, and the distribution of the raw material in the analysis range is a continuous rectangular structure;

[0015] Randomly define several sampling ranges within the analysis range. For one sampling range, obtain the particle size of the raw material particles completely within this sampling range;

[0016] Obtain the particle sizes of the raw material particles within all sampling ranges;

[0017] Calculate the weights of each raw material particle according to the density of the raw material particle and the particle sizes of each raw material particle;

[0018] Obtain a weight value mr1 through summation calculation;

[0019] According to the formula Calculate the predicted weight m of the raw material within the defined analysis range in the frame image;

[0020] where S is the area corresponding to the analysis range, Sy is the area corresponding to the sampling range, and α is a preset proportionality coefficient.

[0021] Further, the method for calculating the proportionality coefficient α includes the following steps:

[0022] Set a conveyor belt below the outlet of the vibrating feeder. When the vibrating feeder is working, start the corresponding conveyor belt;

[0023] Calculate the corresponding weight value mr1 and S / Sy value according to the above method;

[0024] Obtain the distribution range of the raw material within the area corresponding to the analysis range on the conveyor belt;

[0025] Measure the weight of the raw material within the corresponding distribution range to obtain the actual weight ms, and then according to the formula Calculate α.

[0026] Further, calculate the typical value of several α values after calculation, and use this typical value as the final proportionality coefficient α.

[0027] Further, mark the predicted weight m corresponding to each raw material as mi;

[0028] where \(1\leq i\leq k\), and \(k\) is the number of raw material types;

[0029] According to the time sequence, the predicted weights \(m_i\) corresponding to one raw material are successively marked as \(m_{i1}, m_{i2}, \cdots, m_{in}\); \(n\) is a positive integer, and \(1\leq j\leq n\);

[0030] Obtain the ratios of \(k\) \(m_{ij}\) calculated and collected at the same moment;

[0031] When the difference between the ratios of the corresponding \(k\) \(m_{ij}\) and the ratio of the set raw material ratio is greater than the preset percentage, it is considered that the corresponding ratio is abnormal;

[0032] When there is an abnormal ratio in a preset proportion among the consecutive preset number \(u\) of times, the amplitude of at least one vibrating feeder is changed to change the corresponding discharging speed, so as to adjust the ratios of the corresponding \(k\) \(m_{ij}\) to be equal to the set raw material ratio or the difference is less than the preset percentage.

[0033] Furthermore, a vibrating screen is arranged below the discharging end of the vibrating feeder, and the discharged raw materials enter their respective corresponding vibrating screens;

[0034] After the raw materials in the raw material weighing hopper enter the vibrating screen, the raw materials are screened by the vibrating screen, and the raw materials that do not meet the particle size requirements are discharged;

[0035] Continuously monitor the weight of the part of the discharged raw materials that do not meet the particle size;

[0036] Adjust the actual raw material weight \(D_s\) entering the vibrating feeder to \(D_s = D_y / \beta\);

[0037] where \(D_y\) is the weight of the corresponding raw material that needs to enter the calcium carbide furnace bunker according to the ratio calculation, and \(\beta\) is the ratio of the weight of the raw materials that do not meet the particle size to the weight of the raw materials discharged by the vibrating feeder within a certain period of time.

[0038] The present invention also discloses a calcium carbide furnace production control system in the calcium carbide process. This system is used to execute the above production control method, and this system includes the following component units:

[0039] A high-speed image acquisition unit, which is arranged near the discharging port of the vibrating feeder and is used to acquire the raw material discharge image at the discharging port of the vibrating feeder;

[0040] An image analysis unit, which analyzes the raw material discharge image acquired by the high-speed image acquisition unit to obtain the predicted weight of the material discharged by the vibrating feeder within a certain period of time;

[0041] An execution unit, which is used to adjust the amplitude of the vibrating feeder.

[0042] The beneficial effects of the present invention:

[0043] 1. The present invention monitors the actual material ratio of each raw material in real time before entering the mixing device, and adjusts the material ratio of the raw materials entering the mixing device in real time according to the monitoring results, so as to ensure that the materials entering the mixing device show a high degree of consistency in each period, which is conducive to the stability and consistency of the quality of calcium carbide produced by the calcium carbide furnace.

[0044] 2. The present invention realizes the online, continuous and real-time monitoring of the feeding ratio, so the present invention can further realize the continuous batching and feeding of the raw materials for calcium carbide production, without mixing a certain amount of mixed raw materials at one time and then feeding them in the same way.

[0045] 3. The present invention continuously monitors the weight of the large particle raw materials separated by screening, and reasonably and evenly supplements the raw materials entering the vibrating screen according to the weight of the large particle raw materials separated by screening, and ensures the uniformity of the raw materials entering the subsequent mixing on the premise of screening out the large particle raw materials that do not meet the particle size requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] The present invention will be further described below in conjunction with the accompanying drawings.

[0047] Figure 1 is a schematic diagram of the framework structure of the production control system of the calcium carbide furnace in a calcium carbide process;

[0048] Figure 2 is a schematic flow diagram of the production control method of the calcium carbide furnace in a calcium carbide process. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0049] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0050] Example 1

[0051] A production control method for a calcium carbide furnace in a calcium carbide process, as Figure 2 shown, includes the following steps:

[0052] Step 1. Obtain the set raw material ratio and add the corresponding weight of raw materials into the corresponding raw material weighing hoppers;

[0053] Generally, the raw materials include carbonaceous materials and quicklime;

[0054] After the batching is completed, the raw materials in each raw material weighing hopper are discharged at the set discharge rate;

[0055] Step 2: The discharged raw materials enter the vibrating feeder. It should be noted that each type of raw material corresponds to a vibrating feeder;

[0056] When the vibrating feeder is working, the image information at the outlet of the vibrating feeder is collected by the high-speed image acquisition unit;

[0057] For one type of raw material, a frame of image at the outlet of its corresponding vibrating feeder is obtained every preset time interval t1;

[0058] For the convenience of understanding, it is further elaborated as follows: The image information at the outlet of the vibrating feeder refers to the image information between the start of the discharging end of the vibrating feeder and after the material drops a certain height. At this time, the material distribution is relatively loose, which is beneficial to the accuracy of subsequent analysis;

[0059] The image analysis unit analyzes the frame image to obtain the predicted weight m of the raw materials discharged from the vibrating feeder within the analysis range of the frame image at the moment corresponding to the frame image;

[0060] The method by which the image analysis unit analyzes the frame image to obtain the predicted weight m of the raw materials discharged from the vibrating feeder within the analysis range of the frame image at the moment corresponding to the frame image is as follows:

[0061] In the frame image, an analysis range is demarcated, and the distribution of the raw materials in the analysis range is a continuous rectangular structure;

[0062] Within the analysis range, several sampling ranges are randomly demarcated. For one sampling range, the particle size of the raw material particles completely within this sampling range is obtained;

[0063] The particle sizes of the raw material particles in all sampling ranges are obtained;

[0064] The weight of each raw material particle is calculated based on the density of the raw material particles and the particle size of each raw material particle;

[0065] A weight value mr1 is obtained through summation calculation;

[0066] According to the formula The predicted weight m of the raw materials within the demarcated analysis range in the frame image is calculated;

[0067] Where S is the area corresponding to the analysis range, Sy is the area corresponding to the sampling range, and α is a preset proportionality coefficient.

[0068] Furthermore, this embodiment discloses a method for calculating the preset proportionality coefficient α, and this method includes the following steps:

[0069] A conveyor belt is arranged below the outlet of the vibrating feeder. When the vibrating feeder is working, the corresponding conveyor belt is started to work;

[0070] Calculate the corresponding weight value mr1 and S / Sy value according to the above method;

[0071] Obtain the distribution range of the raw materials in the area corresponding to the analysis range on the conveyor belt (specifically, calculate the arrival time of the uppermost and lowermost materials in the analysis range on the conveyor belt according to the height of the uppermost and lowermost ends corresponding to the analysis range from the conveyor belt and the distance from the vibrating feeder, so as to determine this distribution range);

[0072] Measure the weight of the raw materials within the corresponding distribution range to obtain the actual weight ms, and then according to the formula Calculate to obtain α;

[0073] Furthermore, several α values can be calculated according to this method and then their typical value can be calculated, and this typical value is used as the final proportional coefficient α;

[0074] The typical value can be the median, the average value, or the average value of the remaining parameters after removing the parameters with large deviation values, etc.;

[0075] Since in actual analysis, raw material particles with a particle size smaller than the preset value cannot be processed, setting the sampling range and the proportional coefficient α can significantly reduce the calculation amount and improve the calculation efficiency while ensuring the accuracy.

[0076] Step 3: Update the m corresponding to each raw material in turn according to the method in Step 2, and the execution unit adjusts the amplitude of the vibrating feeder corresponding to each raw material according to the ratio between the updated predicted weights m of each raw material, so as to adjust the discharging speed of the vibrating feeder corresponding to each raw material;

[0077] Specifically, for the convenience of expression, the predicted weights m corresponding to each raw material are respectively marked as mi;

[0078] where 1 ≤ i ≤ k, and k is the number of raw material types;

[0079] Mark the predicted weight mi of a raw material as mi1, mi2,..., min in sequence according to the time sequence; n is a positive integer, 1 ≤ j ≤ n;

[0080] The corresponding k mi1 are collected at the same moment;

[0081] Obtain the ratio of the k mij calculated at the same moment;

[0082] When the difference between the ratio of the corresponding k mij and the ratio of the set raw material ratio is greater than the preset percentage, it is considered that the corresponding ratio is abnormal;

[0083] When there is an abnormality in the ratio of a preset proportion in the continuous preset number u, the amplitude of at least one vibrating feeder is changed to change the corresponding discharge speed, and then the ratio of the corresponding k mij is adjusted to be equal to the set raw material ratio or the difference is less than the preset percentage.

[0084] The present invention monitors the actual material ratio of each raw material before entering the mixing device in real time, and adjusts the material ratio of the raw materials entering the mixing device in real time according to the monitoring results, so as to ensure that the raw materials entering the mixing device show a high degree of consistency in each period, which is beneficial to the stability and consistency of the quality of calcium carbide produced by the calcium carbide furnace.

[0085] In addition, since the online, continuous and real-time monitoring of the feeding ratio is realized, the present invention can further realize the continuous batching and feeding of the raw materials for calcium carbide production, without mixing a certain amount of mixed raw materials at one time and then feeding them in the same way.

[0086] Embodiment 2

[0087] On the basis of Embodiment 1, in this embodiment, a vibrating screen is arranged below the discharge end of the vibrating feeder, and the discharged raw materials enter their respective corresponding vibrating screens;

[0088] After the raw materials in the raw material weighing hopper enter the vibrating screen, the raw materials are screened by the vibrating screen, and the raw materials that do not meet the particle size requirements are discharged;

[0089] For a kind of raw material, the weight of the part that does not meet the particle size discharged is continuously monitored;

[0090] According to the ratio β of the weight of the raw materials that do not meet the particle size to the weight of the raw materials discharged by the vibrating feeder within a period of time, the raw material component entering the vibrating feeder is adjusted. Specifically, the actual raw material weight Ds entering the vibrating feeder is adjusted to Ds = Dy / β;

[0091] Where Dy is the weight of the corresponding raw material that needs to enter the calcium carbide furnace bin according to the ratio calculation.

[0092] By adding a vibrating screen to screen the raw materials and removing the raw materials that do not meet the particle size requirements, the quality of subsequent calcium carbide production can be improved. The present invention further continuously monitors the weight of the screened large particle raw materials, and reasonably and evenly supplements the raw materials entering the vibrating screen according to the weight of the screened large particle raw materials, so as to ensure the uniformity of the raw materials entering the subsequent mixing on the premise of removing the large particle raw materials that do not meet the particle size requirements.

[0093] It should be noted that this method is applicable to the raw materials produced in the same batch, which have the characteristic of similar particle size distribution.

[0094] Example 3

[0095] Furthermore, as Figure 1 shown, the present invention also discloses a production control system for executing the above production control method. The system includes the following constituent units:

[0096] A high-speed image acquisition unit, which is arranged near the discharge port of the vibrating feeder and is used to acquire the raw material discharge image at the discharge port of the vibrating feeder. The raw material discharge image acquired by the high-speed image acquisition unit is transmitted to the image analysis unit;

[0097] An image analysis unit, which is used to analyze the raw material discharge image acquired by the high-speed image acquisition unit and obtain the predicted weight of the material discharged by the vibrating feeder within a certain period of time;

[0098] An execution unit, which is used to adjust the amplitude of the vibrating feeder, thereby realizing the control of the discharge speed of the vibrating feeder.

[0099] The above content is only an example and illustration of the present invention. Those skilled in the art of this technology can make various modifications or supplements to the described specific embodiments or use similar methods for substitution. As long as they do not deviate from the invention or exceed the scope defined by this claim book, they shall fall within the protection scope of the present invention.

Claims

1. A calcium carbide furnace production control method in a calcium carbide process, characterized in that: The steps include: Step 1: Add raw materials into the corresponding raw material weighing hoppers according to the set raw material ratio; Step 2: The raw materials discharged from the raw material weighing hopper enter the vibrating feeder; The image information at the outlet of the vibrating feeder is collected by a high-speed image acquisition unit; For a type of raw material, a frame of image at the outlet of the corresponding vibrating feeder is acquired at every preset time interval t1; The frame image is analyzed by the image analysis unit to obtain the predicted weight m of the raw material discharged by the vibrating feeder within the frame image analysis range at the time corresponding to the frame image; Step 3: update the m corresponding to each raw material in turn, and the execution unit adjusts the amplitude of the vibrating feeder corresponding to each raw material according to the ratio between the updated predicted weights m corresponding to each raw material; The image analysis unit analyzes the frame image to obtain the predicted weight m of the raw material discharged by the vibrating feeder within the frame image analysis range at the moment corresponding to the frame image as follows: The analysis range is defined in the frame image, and the distribution of the raw materials in the analysis range is a continuous rectangular structure; Randomly define several sampling ranges within the analysis range, and for each sampling range, obtain the particle size of the raw material particles that are completely within the sampling range; Obtain the particle size of all raw material particles within the sampling range; The weight of each raw material particle is calculated based on the density of the raw material particles and the particle size of each raw material particle; A weight value mr1 is obtained by summing up the calculation; According to the formula Calculate and obtain the predicted weight m of the raw material within the analysis range defined in the frame image; Where S is the area corresponding to the analysis range, Sy is the area corresponding to the sampling range, and α is the preset proportional coefficient; A method for calculating the proportional coefficient α, the method comprising the following steps: A conveyor belt is set below the outlet of the vibrating feeder. When the vibrating feeder is working, the corresponding conveyor belt will be turned on. Calculate the corresponding weight value mr1 and S / Sy value according to the above method; Obtain the distribution range of raw materials on the conveyor belt within the area corresponding to the analysis range; Measure the weight of the raw materials within the corresponding distribution range to obtain the actual weight ms, and then use the formula Calculate α; A vibrating screen is installed below the discharge end of the vibrating feeder, and the discharged raw materials enter their corresponding vibrating screens; After the raw materials in the raw material weighing hopper enter the vibrating screen, the raw materials are screened by the vibrating screen, and the raw materials that do not meet the particle size requirements are discharged; Continuously monitor the weight of the discharged part that does not meet the particle size; Adjust the actual raw material weight Ds entering the vibrating feeder to Ds = Dy / β; Where Dy is the weight of the corresponding raw material that needs to enter the calcium carbide furnace silo according to the ratio, and β is the ratio of the weight of the raw material that does not meet the particle size within a period of time to the weight of the raw material discharged by the vibrating feeder.

2. The calcium carbide furnace production control method in a calcium carbide process according to claim 1, characterized in that: After calculating several α values, a typical value thereof is calculated, and the typical value is used as the final proportional coefficient α.

3. The calcium carbide furnace production control method in a calcium carbide process according to claim 2, characterized in that: The predicted weight m corresponding to each raw material is marked as mi; Where 1≤i≤k, k is the number of raw material types; The predicted weight mi corresponding to a raw material is marked as mi1, mi2, ..., min in chronological order; n is a positive integer, 1≤j≤n; Obtain the ratio of k mij collected and calculated at the same time; When the difference between the ratio of the corresponding k mij and the set raw material ratio is greater than the preset percentage, it is considered that the corresponding ratio is abnormal; When there is an abnormality in the ratio of the preset proportion in the consecutive preset number of times u, the corresponding discharge speed is changed by changing the amplitude of at least one of the vibrating feeders, and then the ratio of the corresponding k mij is adjusted to be equal to the set raw material ratio or the difference is less than the preset percentage.

4. A calcium carbide furnace production control system in a calcium carbide process, characterized in that: The system is used to execute the production control method according to any one of claims 1 to 3, and the system includes the following components: A high-speed image acquisition unit is provided near the discharge port of the vibrating feeder and is used to acquire an image of the raw material discharged from the discharge port of the vibrating feeder; An image analysis unit analyzes the raw material discharge image acquired by the high-speed image acquisition unit to obtain a predicted weight of the material discharged by the vibrating feeder within a certain period of time; The execution unit is used to adjust the amplitude of the vibrating feeder.

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