A method and control system for controlling the formation of copper sulfate pentahydrate

Abstract

Embodiments of the present invention relate to the field of chemical engineering technology, and disclose a method and a control system for controlling the formation of copper sulfate pentahydrate. The method includes: when a double decomposition reaction is carried out in a reaction kettle, using a color matching algorithm to monitor the color of the solution in the reaction kettle in real time; when it is monitored that the color of the solution in the reaction kettle changes to a specified color, using the proportional relationship between turbidity and electrical signal to monitor the turbidity value of the solution in the reaction kettle, and adjusting the addition rate of the acidic solution and the stirring speed of the stirring device; when it is monitored that the turbidity value of the solution in the reaction kettle reaches a first specified threshold and the temperature of the solution in the reaction kettle drops to a second specified threshold, determining the crystallization material cleaning time according to the weight of the crystallization material in the reaction kettle; using a near-infrared measurement method to monitor the moisture content value of the crystallization material. Implementing the embodiments of the present invention can improve the production efficiency of copper sulfate pentahydrate.

Description

Technical Field

[0001] The present invention relates to the field of chemical engineering technology, and particularly relates to a method and a control system for controlling the generation of copper sulfate pentahydrate. Background Art

[0002] In the traditional production process of copper sulfate pentahydrate (commonly known as blue vitriol or chalcanthite), it mainly relies on untreated copper-containing etching waste liquid. This waste liquid usually comes from the etching link in the printed circuit board manufacturing process and contains high concentrations of copper ions and other impurities. When producing copper sulfate pentahydrate, first, through an acid-base neutralization reaction, the copper ions in the waste liquid are converted into copper hydroxide precipitate. Subsequently, the copper hydroxide containing impurities needs to undergo a double decomposition reaction with concentrated sulfuric acid to generate copper sulfate pentahydrate. After the double decomposition reaction is completed, it is necessary to make copper sulfate pentahydrate precipitate from the solution through stirring dynamic crystallization, and perform washing and acid reduction treatment to remove sulfuric acid and other soluble impurities attached to the surface of the product.

[0003] However, it is found in practice that due to the lack of standardized management of reaction control nodes in the material properties, pretreatment methods, and operations of each process in the traditional production process of copper sulfate pentahydrate, it is difficult to achieve the maximum utilization of resources and the full-automatic production of products, and the dependence on manual operation is high. This not only makes the product quality have unstable factors, but also causes a large amount of waste of manpower and material resources, restricting the improvement of production efficiency and product quality. Summary of the Invention

[0004] An embodiment of the present invention discloses a method and a control system for controlling the generation of copper sulfate pentahydrate, which can improve the production efficiency of copper sulfate pentahydrate.

[0005] A first aspect of an embodiment of the present invention discloses a method for controlling the generation of copper sulfate pentahydrate, the method comprising:

[0006] When a double decomposition reaction is carried out in a reaction kettle, the color of the solution in the reaction kettle is monitored in real time by using a color matching algorithm;

[0007] When it is monitored that the color of the solution in the reaction kettle changes to a specified color, the turbidity value of the solution in the reaction kettle is monitored by using the proportional relationship between turbidity and electrical signal, and the addition rate of the acidic solution and the stirring speed of the stirring device are adjusted;

[0008] When it is monitored that the turbidity value of the solution in the reaction kettle reaches a first specified threshold and the temperature of the solution in the reaction kettle drops to a second specified threshold, the crystallization material cleaning time is determined according to the weight of the crystallization material in the reaction kettle;

[0009] The moisture content value of the crystallization material is monitored by using a near-infrared measurement method;

[0010] After detecting that the moisture content value of the crystalline material is lower than the third specified threshold, the crystalline material is packed according to a preset packing weight to complete the discharging of copper sulfate pentahydrate.

[0011] The second aspect of the embodiments of the present invention discloses a control system, and the control system includes:

[0012] A first monitoring unit, configured to use a color matching algorithm to monitor the color of the solution in the reaction kettle in real time when the double decomposition reaction is carried out in the reaction kettle;

[0013] A monitoring and adjusting unit, configured to, when the first monitoring unit monitors that the color of the solution in the reaction kettle becomes a specified color, use the proportional relationship between turbidity and electrical signal to monitor the turbidity value of the solution in the reaction kettle, and adjust the adding speed of the acidic solution and the stirring speed of the stirring device;

[0014] A determining unit, configured to, when the monitoring and adjusting unit monitors that the turbidity value of the solution in the reaction kettle reaches a first specified threshold and the temperature of the solution in the reaction kettle drops to a second specified threshold, determine the cleaning time of the crystalline material according to the weight of the crystalline material in the reaction kettle;

[0015] A second monitoring unit, configured to monitor the moisture content value of the crystalline material by using a near-infrared measurement method;

[0016] A discharging unit, configured to, after the second monitoring unit monitors that the moisture content value of the crystalline material is lower than a third specified threshold, pack the crystalline material according to a preset packing weight to complete the discharging of copper sulfate pentahydrate.

[0017] As another optional implementation manner, in the second aspect of the embodiments of the present invention, the monitoring and adjusting unit includes:

[0018] An adjusting subunit, configured to, when the first monitoring unit monitors that the color of the solution in the reaction kettle becomes a specified color, reduce the adding speed of the acidic solution and increase the stirring speed of the stirring device to enter the fine-tuning stage of the solution reaction end point;

[0019] A conversion subunit, configured to convert the optical signal value into an electrical signal value after receiving the optical signal value reflected by the solution in the reaction kettle;

[0020] A first calculation subunit, configured to, after preprocessing the electrical signal value, substitute the electrical signal value into a turbidity mathematical calculation model to calculate the turbidity value of the solution in the reaction kettle; wherein, the turbidity mathematical calculation model includes the proportional relationship between turbidity and electrical signal;

[0021] A stop and monitoring subunit, configured to stop adding the acidic solution and monitor the solution temperature in the reactor when the turbidity value of the solution in the reactor reaches a first specified threshold and the color of the solution in the reactor changes to another specified color.

[0022] A third aspect of an embodiment of the present invention discloses a control system, which includes:

[0023] A memory storing executable program code;

[0024] A processor coupled to the memory;

[0025] The processor calls the executable program code stored in the memory and executes a method for controlling the generation of copper sulfate pentahydrate disclosed in the first aspect of an embodiment of the present invention.

[0026] A fourth aspect of an embodiment of the present invention discloses a computer-readable storage medium storing a computer program, wherein the computer program causes a computer to execute a method for controlling the generation of copper sulfate pentahydrate disclosed in the first aspect of an embodiment of the present invention.

[0027] A fifth aspect of an embodiment of the present invention discloses a computer program product, which, when running on a computer, causes the computer to execute some or all of the steps of any one of the methods for controlling the generation of copper sulfate pentahydrate in the first aspect.

[0028] A sixth aspect of an embodiment of the present invention discloses an application publishing platform for publishing a computer program product, which, when running on a computer, causes the computer to execute some or all of the steps of any one of the methods for controlling the generation of copper sulfate pentahydrate in the first aspect.

[0029] Compared with the prior art, the embodiments of the present invention have the following beneficial effects:

[0030] In the embodiments of the present invention, during the double decomposition reaction in the reaction kettle, the color matching algorithm is used to monitor the color of the solution in the reaction kettle in real time; when it is monitored that the color of the solution in the reaction kettle changes to a specified color, the proportional relationship between turbidity and electrical signal is used to monitor the turbidity value of the solution in the reaction kettle, and the addition rate of the acidic solution and the stirring rate of the stirring equipment are adjusted; when it is monitored that the turbidity value of the solution in the reaction kettle reaches the first specified threshold and the temperature of the solution in the reaction kettle drops to the second specified threshold, the crystallization material cleaning time is determined according to the weight of the crystallization material in the reaction kettle; the near-infrared measurement method is used to monitor the moisture content value of the crystallization material; after it is monitored that the moisture content value of the crystallization material is lower than the third specified threshold, the crystallization material is packed according to the preset packing weight to complete the discharging of copper sulfate pentahydrate. It can be seen that the embodiments of the present invention can improve the production efficiency of copper sulfate pentahydrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following will briefly introduce the drawings required in the embodiments. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.

[0032] Figure 1 is a schematic flowchart of a method for controlling the generation of copper sulfate pentahydrate disclosed in the embodiments of the present invention;

[0033] Figure 2 is a schematic flowchart of another method for controlling the generation of copper sulfate pentahydrate disclosed in the embodiments of the present invention;

[0034] Figure 3 is a schematic structural diagram of a control system disclosed in the embodiments of the present invention;

[0035] Figure 4 is a schematic structural diagram of another control system disclosed in the embodiments of the present invention;

[0036] Figure 5 is a schematic structural diagram of another control system disclosed in the embodiments of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0037] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0038] It should be noted that the terms "first", "second", "third", "fourth", etc. in the description and claims of the present invention are used to distinguish different objects, rather than to describe a specific order. The terms "comprising" and "having" and any variations thereof in the embodiments of the present invention are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that comprises a series of steps or units does not necessarily have to be limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products, or devices.

[0039] An embodiment of the present invention discloses a method and control system for controlling the formation of copper sulfate pentahydrate, which can improve the production efficiency of copper sulfate pentahydrate.

[0040] The following is a detailed description with reference to the accompanying drawings.

[0041] Embodiment 1

[0042] Please refer to Figure 1 , Figure 1 which is a schematic flowchart of a method for controlling the formation of copper sulfate pentahydrate disclosed in an embodiment of the present invention. As Figure 1 shown, the method for controlling the formation of copper sulfate pentahydrate may include the following steps.

[0043] 101. When the control system performs a double decomposition reaction in the reaction kettle, it uses a color matching algorithm to monitor the color of the solution in the reaction kettle in real time.

[0044] As an alternative embodiment, in the embodiments of the present invention, during a chemical reaction (especially a double decomposition reaction), the color of the solution may change with the progress of the reaction. The control system monitors the color of the solution in the reaction kettle in real time through a color matching algorithm (which may be based on image processing or spectral analysis). This monitoring helps to understand the progress of the reaction or whether a certain specific reaction stage has been reached.

[0045] As an alternative embodiment, in the embodiments of the present invention, through the color matching algorithm, the control system can capture the change in the color of the solution in the reaction kettle in real time, thereby indirectly reflecting the progress of the chemical reaction. At the same time, abnormal color changes may indicate inappropriate reaction conditions or other problems, and real-time monitoring helps to detect and handle them in a timely manner. And by judging the reaction stage through color changes, the reaction conditions can be optimized, and the reaction efficiency and product quality can be improved.

[0046] 102. When the control system monitors that the color of the solution in the reaction kettle changes to a specified color, it uses the proportional relationship between turbidity and electrical signal to monitor the turbidity value of the solution in the reaction kettle, and adjusts the addition rate of the acidic solution and the stirring speed of the stirring device.

[0047] As an alternative embodiment, in the embodiments of the present invention, when the color of the solution reaches a preset specified color, this usually means that the reaction has entered a specific stage. At this time, the control system starts to monitor the turbidity of the solution, which is usually related to the number of particles or the solute concentration in the solution. Through the proportional relationship between turbidity and the electrical signal (for example, using a turbidity sensor), the control system can accurately measure the turbidity. Based on these measurements, the control system can adjust the addition rate of the acidic solution and the stirring speed of the stirring device to optimize the reaction conditions.

[0048] As an alternative embodiment, in the embodiments of the present invention, when the color of the solution reaches a specified value, it indicates that the reaction has entered a specific stage, and at this time, the reaction conditions need to be adjusted to optimize the product quality. In this application, by adjusting the addition rate of the acidic solution and the stirring speed, the reaction rate and product distribution can be controlled, thereby improving the product quality. At the same time, precisely controlling the reaction conditions helps to reduce unnecessary energy consumption and waste emissions.

[0049] 103. When the control system monitors that the turbidity value of the solution in the reaction kettle reaches the first specified threshold and the temperature of the solution in the reaction kettle drops to the second specified threshold, the cleaning time of the crystalline material is determined according to the weight of the crystalline material in the reaction kettle.

[0050] As an alternative embodiment, in the embodiments of the present invention, when the turbidity reaches the first specified threshold and the temperature drops to the second specified threshold, this may mean that the reaction is nearly complete and crystallization begins. The control system will then determine the cleaning time according to the weight of the crystalline material in the reaction kettle. The cleaning time may depend on the quantity and nature of the crystals to ensure effective separation and recovery.

[0051] As an alternative embodiment, in the embodiments of the present invention, turbidity and temperature are important indicators for judging whether crystallization is complete. In this application, the optimal cleaning timing can be determined through these two parameters. Cleaning at the optimal timing can ensure the quality and quantity of the crystalline material, while reducing energy consumption and material loss during the cleaning process. At the same time, over-cleaning may cause damage or loss of the crystalline material, and this problem can be avoided by precisely controlling the cleaning time.

[0052] 104. The control system monitors the moisture content value of the crystalline material by using the near-infrared measurement method.

[0053] As an alternative embodiment, in the embodiments of the present invention, near-infrared measurement is a non-destructive analysis method that can be used to measure the moisture content in the material. The control system uses this method to monitor the moisture content of the crystalline material, which helps to understand the degree of dryness of the material and thus determine whether further drying treatment is required.

[0054] As an alternative implementation, in the embodiments of the present invention, by monitoring the moisture content in real time, the present application can ensure that the crystalline material reaches the required dryness before packing. At the same time, the dryness level is one of the important factors affecting product quality, and by precisely controlling the moisture content, the product quality can be improved.

[0055] 105. After the control system monitors that the moisture content value of the crystalline material is lower than the third specified threshold, the crystalline material is packed according to the preset packing weight to complete the discharging of copper sulfate pentahydrate.

[0056] As an alternative implementation, in the embodiments of the present invention, when the moisture content of the crystalline material is lower than the third specified threshold, it means that the material is dry enough to be packed. The control system will then pack the crystalline material according to the preset packing weight to complete the discharging process of copper sulfate pentahydrate (or other chemicals). This process ensures the quality of the product and the standardization of packaging.

[0057] As an alternative implementation, in the embodiments of the present invention, standardized packaging helps to improve the consistency and traceability of products, facilitating quality management and marketing. At the same time, by precisely controlling the packing weight and moisture content, material waste and consumption of packaging materials can be reduced.

[0058] As an alternative implementation, in the embodiments of the present invention, the control system can automatically identify two stirring modes of full tank and non-full tank according to the volume of copper hydroxide slurry in the reaction kettle to adjust the power of the stirrer. When the metering pump transports copper hydroxide slurry into the reaction kettle, the transportation amount is automatically selected for the stirring mode after being identified by the control system. After the feeding is completed, the acid addition metathesis reaction starts. Since the turbidity of the material exceeds the instrument range in the initial stage, the color recognition monitoring system intervenes in the control first. When the solution color changes from light green to ocean green, the turbidity on-line monitoring system is turned on, and the dual control system starts to make fine adjustments. The speed of adding dilute sulfuric acid slows down. When the solution color is dark green and the turbidity is below 1 NTU, at this time the material is completely converted from copper hydroxide to copper sulfate, the addition of dilute sulfuric acid is stopped, and stirring continues until the solution temperature drops to 45 °C, then the discharge port is opened for discharging. The material after crystallization is discharged through the discharge port into the gradient acid reduction washing equipment, and this equipment washes the mother liquor and impurities on the surface of the material clean through three-stage spray circulation washing. The washing water generated by the three-stage spray device will be stored separately and monitored by the on-line copper ion concentration monitoring equipment. When the copper content in the first-stage washing liquid exceeds 1000 mg / L, it will be transported to the copper sulfate mother liquor storage tank for use as the mother liquor. In subsequent washing, the second-stage spray washing water is used as the first-stage washing water, the third-stage washing water is used as the second-stage washing water, and the clean water source is used as the new third-stage washing water, and so on in a cycle. The utilization rate of the washing water is improved and the waste of water resources is reduced. The washed copper sulfate pentahydrate is transported to the drum dryer by the conveyor belt for drying the material. Through the real-time monitoring of the near-infrared on-line moisture meter, when the moisture content of the material in the dryer is lower than the set value, the drying of the material is completed. The dried material is packed by an automatic packing machine for sale.

[0059] As an alternative embodiment, in the embodiment of the present invention, the metering pump starts feeding materials into the reaction kettle. After double identification by the liquid level gauge in the kettle and the metering pump, the system can select the full-tank stirring or non-full-tank stirring mode. When the feeding volume exceeds the set value, it is the full-tank stirring mode. At this time, the calculation formula for the mixer power is: mixer power = material density × agitator speed × container volume. After the feeding is completed, the system receives a signal and starts the dilute sulfuric acid pump. While adding acid to the kettle, the color recognition monitor is turned on and the power of the acid addition pump is controlled. When the color recognition monitor recognizes that the solution in the kettle suddenly changes from light green (color label #98FB98) to sea green (color label #2E8B57), the system controls the opening of the turbidity on-line monitor while reducing the power of the acid addition pump and the acid addition speed, entering the fine-tuning stage of the solution reaction end point. In the fine-tuning stage, the power of the pump is reduced, and the power of the agitator is increased, and the stirring speed is increased so that the added acid can react quickly. When the solution turbidity is below 1 NTU and the color is dark green (color label #006400), the acid addition is stopped, and the double decomposition reaction end point has been reached at this time. After the acid addition is stopped, the solution continues to be stirred for dynamic crystallization. When the thermometer detects that the temperature of the solution in the kettle drops to 45 °C, the agitator stops working and the discharge port is opened for discharging. When the temperature in the reaction kettle is lower than 45 °C, the discharge valve is opened, and the material enters the gradient acid reduction washing equipment for washing. After the material enters the weight-sensing conveyor belt, the current material weight is recorded. According to the conveyor belt power formula: power = material weight × friction coefficient × rotating wheel radius × transmission speed ÷ rotating wheel circumference ÷ 9550. On the premise of a fixed power, the conveyor belt transmission speed in the gradient acid reduction washing equipment can be calculated. Therefore, the material cleaning time = conveyor belt length ÷ transmission speed, and thus the cleaning time of each batch of materials can be calculated. The washing equipment sprays and washes the material in three stages and recovers the wash water after washing. The copper ion concentration on-line monitoring equipment monitors the copper content in the wash water in real time. When it is monitored that the copper content in the primary wash water exceeds the set value (taking 1000 mg / L as an example), the control system recovers it and transports it to the copper sulfate mother liquor storage tank. At this time, the secondary wash water serves as the primary, the tertiary wash water serves as the secondary wash water, and the clean water source serves as the tertiary wash water, and the cycle continues. After the material is washed in three stages, it enters the drum dryer through the conveyor belt at the outlet of the washing equipment. The conveyor belt is a weight-sensing conveyor belt. When the material input volume approaches the warning value of the dryer, the feeding is stopped and the material conveying weight at this time is recorded. The dryer tumbles and dries the material with hot air at 80 °C. When the near-infrared on-line moisture meter monitors that the material moisture is lower than the set value (taking lower than 20% as an example), the equipment stops drying and starts discharging. After the material drying is completed, the system opens the discharge port and conveys it to the packing machine through the conveyor belt for packing and selling. After each discharge, the conveyor belt records the discharge weight and feeds it back to the control system. The control system collects and summarizes the data, and adjusts the drying temperature and duration according to the summarized data to further achieve the energy-saving effect.The automatic packing machine weighs and quantitatively packs each bag of products according to a pre-set packing weight. When the remaining material weight in the equipment is less than one pack, the packing stops, and the packing work resumes after the next batch of materials is dried.

[0060] In Figure 1 the method for controlling the production of copper sulfate pentahydrate, taking the control system as the execution subject as an example for description. It should be noted that Figure 1 the execution subject of the method for controlling the production of copper sulfate pentahydrate can also be an independent device associated with the control system, which is not limited in the embodiments of the present invention.

[0061] It can be seen that implementing Figure 1 the described method for controlling the production of copper sulfate pentahydrate can improve the production efficiency of copper sulfate pentahydrate.

[0062] In addition, implementing Figure 1 the described method for controlling the production of copper sulfate pentahydrate helps to improve product quality and reduce production costs.

[0063] Embodiment 2

[0064] Please refer to Figure 2 , Figure 2 which is a schematic flowchart of another method for controlling the production of copper sulfate pentahydrate disclosed in the embodiments of the present invention. As Figure 2 shown, the method for controlling the production of copper sulfate pentahydrate may include the following steps:

[0065] 201. When it is detected that the liquid level in the dilute sulfuric acid storage tank is lower than the alarm line, the control system calculates the current required volume of concentrated sulfuric acid and the current required volume of added water according to the current required concentration of dilute sulfuric acid, the current required volume of dilute sulfuric acid, and the current concentration of concentrated sulfuric acid.

[0066] As an optional implementation manner, in the embodiments of the present invention, the present application can calculate the current required volume of concentrated sulfuric acid and the current required volume of added water according to the following formulas: current required volume of concentrated sulfuric acid = (current required concentration of dilute sulfuric acid × current required volume of dilute sulfuric acid) / current concentration of concentrated sulfuric acid, current required volume of added water = current required volume of dilute sulfuric acid - current required volume of concentrated sulfuric acid. For example, assuming that it is necessary to prepare 40 m³ of dilute sulfuric acid with a concentration of 70% and the concentration of concentrated sulfuric acid is 98%, the current required volume of concentrated sulfuric acid can be calculated as 70 * 40 / 98 ≈ 28.57 m³ (for simplicity of calculation, two decimal places are taken here, and more digits may be required according to the accuracy requirements in actual calculation), and then the current required volume of added water can be calculated as 40 m³ - 28.57 m³ = 11.43 m³.

[0067] 202. The control system controls the metering pump to quantitatively deliver the currently required volume of concentrated sulfuric acid and the currently required volume of water to be added to the sulfuric acid dilution cooler through the delivery pipeline.

[0068] 203. The control system obtains the density of dilute sulfuric acid measured by an online density hydrometer in the conveying pipeline.

[0069] 204. The control system matches the dilute sulfuric acid control concentration value corresponding to the dilute sulfuric acid density from a preset dilute sulfuric acid concentration specific gravity table according to the dilute sulfuric acid density, and executes step 205 or step 206.

[0070] 205. If the dilute sulfuric acid control concentration value does not match the currently required dilute sulfuric acid concentration, the control system recalculates the amount of concentrated sulfuric acid and water to be added and executes steps 207 to 215.

[0071] As an optional embodiment, in an embodiment of the present invention, during the preparation of dilute sulfuric acid, the present application can determine whether the concentration of dilute sulfuric acid is accurate by comparing the measured density value with the concentration specific gravity table in the system. For example, assuming that the density measured by the online density specific gravity meter is ρ, the concentration specific gravity table in the system gives the corresponding relationship between density and concentration. Then, the concentration value C corresponding to the measured density ρ can be found by a lookup table or interpolation method. If C does not match the expected concentration value, it is necessary to adjust the amount of sulfuric acid or water according to the difference between C and the expected concentration value to ensure that the final concentration of dilute sulfuric acid is accurate.

[0072] 206. If the dilute sulfuric acid control concentration value matches the currently required dilute sulfuric acid concentration, the control system transports the liquid in the sulfuric acid dilution cooler to the dilute sulfuric acid storage tank through the delivery pipeline when the temperature in the sulfuric acid dilution cooler reaches the specified temperature, and releases the liquid level alarm, and executes steps 207 to 215.

[0073] As an optional implementation mode, in the embodiment of the present invention, the present application can ensure that the concentration and volume of dilute sulfuric acid meet the production requirements, avoiding waste and shortage. At the same time, through accurate calculation and delivery, the production efficiency is improved and the energy consumption is reduced. Moreover, real-time monitoring and adjustment are performed to ensure the stable quality of dilute sulfuric acid, providing reliable raw materials for subsequent reactions.

[0074] When the reactor is performing double decomposition reaction, the control system calculates the cosine similarity between the color characteristics of the solution in the reactor and the specified color characteristics in real time.

[0075] 208. When the cosine similarity is greater than a fourth specified threshold, the control system determines that the color of the solution in the reaction kettle changes to a specified color.

[0076] As an alternative implementation, in the embodiments of the present invention, first, the color information captured by the system is usually presented in the form of the RGB (Red, Green, Blue) color space. However, for more accurate color matching, the system can convert the RGB color space into other color spaces, such as the HSV (Hue, Saturation, Value) or Lab color space. These color spaces have better performance in some aspects (such as hue discrimination, color perception consistency, etc.). After the color space conversion, the system can extract color features. These features may include hue, saturation, value, etc. (in the HSV color space), or luminance, a and b components (in the Lab color space). These features are used to describe the basic properties of the color and serve as the input for the subsequent matching process. In the system, a color label library is usually preset. This library contains various possible color labels and their corresponding color feature values. These color labels are determined according to the actual application requirements. For example, in this case, they may include light green (#98FB98), sea green (#2E8B57), and dark green (#006400), etc. Next, the algorithm uses a certain matching strategy to compare the color features captured by the sensor with the color features in the preset color label library. Common matching strategies include: Euclidean distance: Calculate the Euclidean distance between the color features captured by the sensor and each color feature in the preset color label library, and select the color label with the smallest distance as the matching result. Cosine similarity: Treat the color features as vectors, calculate the cosine similarity between the color features captured by the sensor and each color feature in the preset color label library, and select the color label with the highest similarity as the matching result. Threshold matching: Set a threshold range for each color feature. If the color features captured by the sensor fall within the threshold range of a certain color label, select that color label as the matching result. Finally, the system can output the matching result. This is usually a color label or color name, indicating which color in the preset color label library the color captured by the sensor is closest to.

[0077] 209. When the control system monitors that the color of the solution in the reactor changes to the specified color, it reduces the addition rate of the acidic solution and increases the stirring speed of the stirring device to enter the fine-tuning stage of the solution reaction end point.

[0078] As an alternative implementation, in the embodiments of the present invention, during the double decomposition reaction in the reactor, the control system will monitor the color characteristics of the solution in the reactor in real time and compare them with the preset specified color characteristics (by calculating the cosine similarity). When the color feature matching degree reaches the preset threshold, the control system will adjust the addition rate of the acidic solution and the stirring speed to enter the fine-tuning stage of the reaction end point.

[0079] 210. After the control system receives the optical signal value reflected by the solution in the reactor, it converts the optical signal value into an electrical signal value.

[0080] 211. After the control system preprocesses the electrical signal value, it substitutes the electrical signal value into the turbidity mathematical calculation model to calculate the turbidity value of the solution in the reaction kettle. Among them, the turbidity mathematical calculation model includes the proportional relationship between turbidity and the electrical signal.

[0081] As an alternative implementation, in the embodiment of the present invention, the control system can receive the optical signal reflected by the solution in the reaction kettle and convert it into an electrical signal. After preprocessing, these electrical signals will be substituted into the turbidity mathematical calculation model to calculate the turbidity value of the solution.

[0082] 212. When the turbidity value of the solution in the reaction kettle reaches the first specified threshold and the color of the solution in the reaction kettle changes to another specified color, the control system stops adding the acidic solution and monitors the temperature of the solution in the reaction kettle.

[0083] As an alternative implementation, in the embodiment of the present invention, when light passes through the solution, it will scatter with the particles (such as suspended solids, colloids, etc.) in the solution. The system can evaluate the turbidity by measuring the intensity of the scattered light. The intensity of the scattered light is related to the number, size, and distribution of the particles in the solution. After the light passes through the solution, part of the light will be absorbed or scattered, and the remaining light will continue to propagate. The system can evaluate the turbidity by measuring the intensity of the transmitted light. The intensity of the transmitted light is inversely proportional to the clarity of the solution, that is, the higher the turbidity, the lower the intensity of the transmitted light.

[0084] As an alternative implementation, in the embodiment of the present invention, after receiving the electrical signal output by the detector, first, the system can preprocess the received electrical signal to eliminate noise and interference. This includes steps such as filtering, amplification, and calibration. Subsequently, according to the principle of scattered light or transmitted light, a mathematical model is established to describe the relationship between turbidity and the electrical signal. This model usually includes some parameters, such as the light source intensity, detector sensitivity, and characteristics of optical elements. Before formal use, the system needs to be calibrated. This is usually done by measuring a series of solutions with known turbidities and adjusting the parameters in the mathematical model so that the calculated turbidity value matches the actual value. After calibration, verification is also required to ensure the accuracy and reliability of the measurement results. During normal operation, the system will receive the electrical signal output by the detector in real time and use the calibrated mathematical model for calculation to obtain the real-time turbidity value. The control system can trigger corresponding control logics according to the magnitude of the turbidity value, such as stopping adding acid and adjusting the stirring speed.

[0085] 213. When it is detected that the turbidity value of the solution in the reactor reaches the first specified threshold and the temperature of the solution in the reactor drops to the second specified threshold, the control system substitutes the weight of the crystalline material in the reactor into the conveyor belt speed adjustment calculation formula to calculate the current conveyor belt driving speed.

[0086] In this embodiment, the conveyor belt speed adjustment calculation formula is the product of the conveyor belt power and the conveyor belt pulley circumference divided by the product of the crystalline material weight, the conveyor belt friction coefficient, and the conveyor belt pulley radius. When the power is fixed, the present application can adjust the driving speed to adapt to different material weights, that is, the control system can automatically calculate and adjust the driving speed of the conveyor belt according to the readings of the material weight sensor. For example, if the material weight doubles, then the driving speed needs to be reduced to half of the original to keep the power unchanged. For example, assume that if the material weight is 1000 kg, the friction coefficient is 0.3, the pulley radius is 0.2 m, the driving speed is V (unit: m / s), and the pulley circumference is π×0.4 m (assuming the pulley is circular), then the power formula becomes: P = 1000×0.3×0.2×V÷(π×0.4)÷9550.

[0087] As an alternative implementation, in the embodiments of the present invention, when both the turbidity value and the color characteristics of the solution reach the preset conditions, the control system stops adding the acidic solution and starts monitoring the temperature of the solution. When both the temperature and the turbidity meet specific conditions, the control system uses the conveyor belt speed adjustment calculation formula to calculate the current driving speed of the conveyor belt.

[0088] 214. The control system divides the current conveyor belt length by the current conveyor belt driving speed to calculate the crystalline material cleaning time.

[0089] As an alternative implementation, in the embodiments of the present invention, the present application can monitor the reaction process in real time to ensure that the reaction proceeds under the best conditions, improve the product quality and yield. At the same time, by adjusting the reaction conditions and parameters, the precise control of the reaction process is achieved, reducing energy consumption and waste generation. Moreover, by using the conveyor belt speed adjustment calculation formula and the cleaning time calculation, the processing flow of the crystalline material is optimized to improve production efficiency.

[0090] 215. After the control system performs three gradient acid reduction washes on the crystalline material in the reactor in sequence according to the crystalline material cleaning time, it detects whether the copper content in the primary washing liquid exceeds the set value. If so, it executes steps 216 to 220. If not, it executes steps 218 to 220.

[0091] 216. The control system recovers the primary washing liquid into the copper sulfate mother liquor storage tank.

[0092] 217. The control system respectively sets the secondary washing liquid as the new primary washing liquid, the tertiary washing liquid as the new secondary washing liquid, and the clean water source as the new tertiary washing liquid.

[0093] 218. When the control system starts the drying equipment to dry the crystalline material that has reached the drying weight standard, it receives the infrared reflection signal of the crystalline material.

[0094] 219. The control system substitutes the infrared reflection signal of the crystalline material into the infrared moisture calibration curve to determine the moisture content value of the crystalline material; wherein, the infrared moisture calibration curve includes the corresponding relationship between the intensity of the infrared reflection signal of the material and the moisture content.

[0095] As an alternative implementation manner, in the embodiments of the present invention, the present application can detect the moisture content of the material by emitting near-infrared rays and receiving the signal reflected by the material. For example, when the moisture content of the material is 25%, the system will receive a specific reflection signal intensity. Through the pre-established corresponding relationship between the reflection signal intensity and the moisture content (i.e., the calibration curve), the moisture content of the material can be calculated. When it is detected that the moisture content of the material is lower than the set value (such as 20%), the equipment will stop drying and start discharging.

[0096] As an alternative implementation manner, in the embodiments of the present invention, the present application effectively removes impurities and excess acid components in the crystalline material through gradient acid reduction washing, improving the product purity. At the same time, the washing liquid is recycled to the copper sulfate mother liquor storage tank to achieve the recycling of resources and reduce waste. And the infrared moisture calibration curve is used to monitor the moisture content of the crystalline material in real time to ensure that the drying effect meets the requirements.

[0097] 220. After the control system monitors that the moisture content value of the crystalline material is lower than the third specified threshold, it packs the crystalline material according to the preset packing weight to complete the discharging of copper sulfate pentahydrate and ends this process.

[0098] As an alternative implementation manner, in the embodiments of the present invention, the present application can be packed according to the preset packing weight to achieve the standardization and normalization of the product, which is convenient for storage and sales.

[0099] As an alternative implementation, in the embodiments of the present invention, the purpose of recording the discharge weight in this application is to collect data for analysis, so as to adjust and optimize the parameters in the production process. For example, if it is found through data analysis that the drying temperature of a certain batch of materials is high and the duration is long, but the moisture content is still high, then the control system can automatically adjust the drying temperature and duration of the next batch to reduce energy consumption and improve drying efficiency. Specifically, if the drying temperature of the previous batch of materials is 85 °C and the duration is 2 hours, but the moisture content is still higher than 20%, then the control system can reduce the drying temperature of the next batch to 80 °C and shorten the duration to 1.5 hours, and observe the effect. If the effect is good, this parameter can be maintained; if the effect is not good, continue to adjust.

[0100] As an alternative implementation, in the embodiments of the present invention, the control system collects data through sensors and instruments, such as discharge weight, drying temperature, drying duration, etc. These data will be stored in the database of the control system and can be summarized and displayed in the form of reports or charts.

[0101] It can be seen that implementing Figure 2 the described another method for controlling the formation of copper sulfate pentahydrate can improve the production efficiency of copper sulfate pentahydrate.

[0102] In addition, implementing Figure 2 the described another method for controlling the formation of copper sulfate pentahydrate can monitor and adjust the conditions and parameters of each production link in real time, improving the quality and output of the product.

[0103] Embodiment 3

[0104] Please refer to Figure 3 , Figure 3 which is a schematic structural diagram of a control system disclosed in the embodiments of the present invention. As Figure 3 shown, the control system 300 may include a first monitoring unit 301, a monitoring and adjustment unit 302, a determination unit 303, a second monitoring unit 304, and a discharge unit 305, wherein:

[0105] The first monitoring unit 301 is used to monitor the color of the solution in the reaction kettle in real time using a color matching algorithm when a double decomposition reaction occurs in the reaction kettle.

[0106] The monitoring and adjustment unit 302 is used to monitor the turbidity value of the solution in the reaction kettle using the proportional relationship between turbidity and electrical signal when the first monitoring unit 301 monitors that the color of the solution in the reaction kettle has changed to a specified color, and adjust the addition speed of the acidic solution and the stirring speed of the stirring device.

[0107] A determination unit 303, configured to determine the cleaning time of the crystalline material according to the weight of the crystalline material in the reactor when the monitoring and adjustment unit 302 monitors that the turbidity value of the solution in the reactor reaches a first specified threshold and the temperature of the solution in the reactor drops to a second specified threshold.

[0108] A second monitoring unit 304, configured to monitor the moisture content value of the crystalline material by using a near-infrared measurement method.

[0109] A discharging unit 305, configured to pack the crystalline material according to a preset packing weight to complete the discharging of copper sulfate pentahydrate after the second monitoring unit 304 monitors that the moisture content value of the crystalline material is lower than a third specified threshold.

[0110] As an alternative embodiment, in the embodiment of the present invention, during a chemical reaction (especially a double decomposition reaction), the color of the solution may change with the progress of the reaction. The first monitoring unit 301 monitors the color of the solution in the reactor in real time through a color matching algorithm (which may be based on image processing or spectral analysis). This monitoring helps to understand the progress of the reaction or whether a certain specific reaction stage has been reached.

[0111] As an alternative embodiment, in the embodiment of the present invention, the first monitoring unit 301 can capture the change in the color of the solution in the reactor in real time through a color matching algorithm, thereby indirectly reflecting the progress of the chemical reaction. At the same time, abnormal color changes may indicate inappropriate reaction conditions or other problems, and real-time monitoring helps to detect and handle them in a timely manner. And by judging the reaction stage through color changes, the reaction conditions can be optimized, and the reaction efficiency and product quality can be improved.

[0112] As an alternative embodiment, in the embodiment of the present invention, when the color of the solution reaches a preset specified color, this usually means that the reaction enters a specific stage. At this time, the monitoring and adjustment unit 302 starts to monitor the turbidity of the solution, which is usually related to the number of particles or the solute concentration in the solution. Through the proportional relationship between turbidity and an electrical signal (for example, using a turbidity sensor), the monitoring and adjustment unit 302 can accurately measure the turbidity. Based on these measurements, the monitoring and adjustment unit 302 can adjust the addition rate of the acidic solution and the stirring speed of the stirring device to optimize the reaction conditions.

[0113] As an alternative embodiment, in the embodiment of the present invention, when the color of the solution reaches a specified value, it indicates that the reaction enters a specific stage, and at this time, the reaction conditions need to be adjusted to optimize the product quality. The monitoring and adjustment unit 302 can control the reaction rate and product distribution by adjusting the addition rate of the acidic solution and the stirring speed, thereby improving the product quality. At the same time, precisely controlling the reaction conditions helps to reduce unnecessary energy consumption and waste emissions.

[0114] As an alternative embodiment, in the embodiments of the present invention, when the turbidity reaches the first specified threshold and the temperature drops to the second specified threshold, this may indicate that the reaction is approaching completion and crystallization begins. The determination unit 303 will then determine the cleaning time based on the weight of the crystalline material in the reaction kettle at this time. The cleaning time may depend on the quantity and nature of the crystals to ensure effective separation and recovery.

[0115] As an alternative embodiment, in the embodiments of the present invention, turbidity and temperature are important indicators for judging whether crystallization is complete. The determination unit 303 can determine the optimal cleaning timing through these two parameters. Cleaning at the optimal timing can ensure the quality and quantity of the crystalline material, while reducing energy consumption and material loss during the cleaning process. At the same time, excessive cleaning may cause damage or loss of the crystalline material, and this problem can be avoided by precisely controlling the cleaning time.

[0116] As an alternative embodiment, in the embodiments of the present invention, near-infrared measurement is a non-destructive analysis method that can be used to measure the moisture content in the material. The second monitoring unit 304 uses this method to monitor the moisture content of the crystalline material, which helps to understand the degree of dryness of the material and thus determine whether further drying treatment is required.

[0117] As an alternative embodiment, in the embodiments of the present invention, by continuously monitoring the moisture content, the second monitoring unit 304 can ensure that the crystalline material reaches the required degree of dryness before packing. At the same time, the degree of dryness is one of the important factors affecting product quality, and the product quality can be improved by precisely controlling the moisture content.

[0118] As an alternative embodiment, in the embodiments of the present invention, when the moisture content of the crystalline material is lower than the third specified threshold, this means that the material is dry enough to be packed. The discharging unit 305 will then pack the crystalline material according to the preset packing weight to complete the discharging process of copper sulfate pentahydrate (or other chemicals). This process ensures the quality of the product and the standardization of packaging.

[0119] As an alternative embodiment, in the embodiments of the present invention, standardized packaging helps to improve the consistency and traceability of the product, facilitating quality management and marketing. At the same time, by precisely controlling the packing weight and moisture content, material waste and consumption of packaging materials can be reduced.

[0120] As an alternative embodiment, in the embodiment of the present invention, the metering pump starts feeding into the reaction kettle. After double identification by the liquid level gauge and the metering pump in the kettle, the system can select the full-tank stirring or non-full-tank stirring mode. When the feeding volume exceeds the set value, it is the full-tank stirring mode. At this time, the calculation formula for the mixer power is: mixer power = material density × agitator speed × container volume. After the feeding is completed, the system receives a signal and turns on the dilute sulfuric acid pump. While adding acid to the kettle, the color recognition monitor is turned on and the power of the acid addition pump is controlled. When the color recognition monitor recognizes that the solution in the kettle suddenly changes from light green (color label #98FB98) to sea green (color label #2E8B57), the system controls the opening of the turbidity on-line monitor and at the same time reduces the power of the acid addition pump to reduce the acid addition speed, and enters the fine-tuning stage of the solution reaction end point. In the fine-tuning stage, the power of the pump is reduced, and the power of the agitator is increased, and the stirring speed is increased so that the added acid can react quickly. When the solution turbidity is below 1 NTU and the color is dark green (color label #006400), the acid addition is stopped, and at this time, the end point of the double decomposition reaction has been reached. After the acid addition is stopped, the solution continues to be stirred for dynamic crystallization. When the thermometer detects that the temperature of the solution in the kettle drops to 45 °C, the agitator stops working and the discharge port is opened for discharging. When the temperature in the reaction kettle is lower than 45 °C, the discharge valve opens, and the material enters the gradient acid reduction washing equipment for washing. After the material enters the weight-sensing conveyor belt, the current material weight is recorded. According to the conveyor belt power formula: power = material weight × friction coefficient × rotating wheel radius × transmission speed ÷ rotating wheel circumference ÷ 9550. On the premise of a fixed power, the conveyor belt transmission speed in the gradient acid reduction washing equipment can be calculated. Therefore, the material cleaning time = conveyor belt length ÷ transmission speed, and thus the cleaning time of each batch of materials can be calculated. The washing equipment sprays and washes the material in three stages and recovers the wash water after washing. The copper ion concentration on-line monitoring equipment monitors the copper content in the wash water in real time. When it is detected that the copper content in the primary wash water exceeds the set value (taking 1000 mg / L as an example), the control system recovers it and transports it to the copper sulfate mother liquor storage tank. At this time, the secondary wash water serves as the primary, the tertiary wash water serves as the secondary wash water, and the clean water source serves as the tertiary wash water, and the cycle continues. After the material is washed in three stages, it enters the drum dryer through the conveyor belt at the outlet of the washing equipment. The conveyor belt is a weight-sensing conveyor belt. When the material input volume approaches the warning value of the dryer, the feeding is stopped and the material conveying weight at this time is recorded. The dryer tumbles and dries the material with hot air at 80 °C. When the near-infrared on-line moisture meter monitors that the material moisture is lower than the set value (taking lower than 20% as an example), the equipment stops drying and starts discharging. After the material drying is completed, the system opens the discharge port and conveys it to the packing machine through the conveyor belt for packing and selling. After each discharge, the conveyor belt records the discharge weight and feeds it back to the control system. The control system collects and summarizes the data, and adjusts the drying temperature and duration according to the summarized data to further achieve the energy-saving effect.The automatic packing machine weighs and quantitatively packs each bag of products according to the preset packing weight. When the remaining material weight in the equipment is less than one pack, the packing stops, and the packing work resumes after the next batch of materials is dried.

[0121] It can be seen that implementing Figure 3 the described control system can improve the production efficiency of copper sulfate pentahydrate.

[0122] In addition, implementing Figure 3 the described control system helps to improve product quality and reduce production costs.

[0123] Embodiment 4

[0124] Please refer to Figure 4 , Figure 4 which is a schematic structural diagram of another control system disclosed in the embodiments of the present invention. Among them, Figure 4 the control system is optimized from Figure 3 the control system. Compared with Figure 3 the control system, Figure 4 the monitoring and adjustment unit 302 of

[0125] The adjustment subunit 3021 is used to reduce the addition speed of the acidic solution and increase the stirring speed of the stirring equipment when the first monitoring unit monitors that the solution color in the reaction kettle changes to the specified color, so as to enter the fine-tuning stage of the solution reaction end point.

[0126] As an optional implementation manner, in the embodiments of the present invention, when the double decomposition reaction is carried out in the reaction kettle, the adjustment subunit 3021 will continuously monitor the color characteristics of the solution in the reaction kettle and compare them with the preset specified color characteristics (by calculating the cosine similarity). When the color characteristic matching degree reaches the preset threshold, the adjustment subunit 3021 will adjust the addition speed of the acidic solution and the stirring speed to enter the fine-tuning stage of the reaction end point.

[0127] The conversion subunit 3022 is used to convert the optical signal value into an electrical signal value after receiving the optical signal value reflected by the solution in the reaction kettle.

[0128] The first calculation subunit 3023 is used to preprocess the electrical signal value and then substitute the electrical signal value into the turbidity mathematical calculation model to calculate the solution turbidity value in the reaction kettle; among them, the turbidity mathematical calculation model contains the proportional relationship between turbidity and electrical signal.

[0129] As an alternative implementation, in the embodiments of the present invention, the conversion subunit 3022 may receive the optical signal reflected by the solution in the reaction kettle and convert it into an electrical signal. After preprocessing, these electrical signals will be substituted into the turbidity mathematical calculation model, and the first calculation subunit 3023 will calculate the turbidity value of the solution.

[0130] The stop and monitoring subunit 3024 is used to stop the addition of the acidic solution and monitor the temperature of the solution in the reaction kettle when the turbidity value of the solution in the reaction kettle reaches the first specified threshold and the color of the solution in the reaction kettle changes to another specified color.

[0131] As an alternative implementation, in the embodiments of the present invention, when light passes through the solution, it will scatter with the particles (such as suspended solids, colloids, etc.) in the solution. The first calculation subunit 3023 can evaluate the turbidity by measuring the intensity of the scattered light. The intensity of the scattered light is related to the number, size, and distribution of the particles in the solution. After the light passes through the solution, part of the light will be absorbed or scattered, and the remaining light will continue to propagate. The first calculation subunit 3023 can evaluate the turbidity by measuring the intensity of the transmitted light. The intensity of the transmitted light is inversely proportional to the clarity of the solution, that is, the higher the turbidity, the lower the intensity of the transmitted light.

[0132] As an alternative implementation, in the embodiments of the present invention, after receiving the electrical signal output by the detector, first, the conversion subunit 3022 can preprocess the received electrical signal to eliminate noise and interference. This includes steps such as filtering, amplification, and calibration. Subsequently, according to the principle of scattered light or transmitted light, a mathematical model is established to describe the relationship between turbidity and the electrical signal. This model usually includes some parameters, such as the light source intensity, detector sensitivity, characteristics of optical components, etc. Before formal use, the system needs to be calibrated. This is usually done by measuring a series of solutions with known turbidities and adjusting the parameters in the mathematical model so that the calculated turbidity value is consistent with the actual value. After calibration, verification is also required to ensure the accuracy and reliability of the measurement results. During normal operation, the first calculation subunit 3023 will receive the electrical signal output by the detector in real time and use the calibrated mathematical model for calculation to obtain the real-time turbidity value. The stop and monitoring subunit 3024 can trigger corresponding control logics according to the magnitude of the turbidity value, such as stopping the addition of acid, adjusting the stirring speed, etc.

[0133] Compared with Figure 3 the control system of Figure 4 the first monitoring unit 301 of

[0134] The second calculation subunit 3011 is used to calculate the cosine similarity between the color characteristics of the solution in the reaction kettle and the specified color characteristics in real time when the reaction kettle undergoes a double decomposition reaction.

[0135] A first determination subunit 3012, configured to determine that the color of the solution in the reactor has changed to a specified color when the cosine similarity is greater than a fourth specified threshold.

[0136] As an optional implementation manner, in the embodiments of the present invention, first, the color information captured by the system is usually presented in the form of an RGB (red, green, blue) color space. However, in order to perform color matching more accurately, the system can convert the RGB color space into other color spaces, such as the HSV (hue, saturation, value) or Lab color space. These color spaces have better performance in some aspects (such as hue discrimination, color perception consistency, etc.). After the color space conversion, the system can extract color features. These features may include hue, saturation, value, etc. (in the HSV color space), or luminance, a, and b components (in the Lab color space). These features are used to describe the basic attributes of the color and are used as the input for the subsequent matching process. In the system, a color label library is usually preset. This library contains various possible color labels and their corresponding color feature values. These color labels are determined according to actual application requirements. For example, in this example, they may include light green (#98FB98), sea green (#2E8B57), dark green (#006400), etc. Next, the algorithm uses a certain matching strategy to compare the color features captured by the sensor with the color features in the preset color label library. Common matching strategies include: Euclidean distance: Calculate the Euclidean distance between the color features captured by the sensor and each color feature in the preset color label library, and select the color label with the smallest distance as the matching result. Cosine similarity: Treat the color features as vectors, calculate the cosine similarity between the color features captured by the sensor and each color feature in the preset color label library, and select the color label with the highest similarity as the matching result. Threshold matching: Set a threshold range for each color feature. If the color features captured by the sensor fall within the threshold range of a certain color label, select that color label as the matching result. Finally, the system can output the matching result. This is usually a color label or color name, indicating which color in the preset color label library the color captured by the sensor is closest to.

[0137] Compared with Figure 3 the control system of Figure 4 the determination unit 303 of

[0138] A third calculation subunit 3031, configured to substitute the weight of the crystalline material in the reactor into the conveyor belt speed adjustment calculation formula to calculate the current conveyor belt driving speed; wherein, the conveyor belt speed adjustment calculation formula is the product of the conveyor belt power and the circumference of the conveyor belt driving wheel divided by the product of the weight of the crystalline material, the conveyor belt friction coefficient, and the radius of the conveyor belt driving wheel.

[0139] In this embodiment, the calculation formula for adjusting the conveyor belt speed is the product of the conveyor belt power and the circumference of the conveyor belt rotating wheel divided by the product of the weight of the crystalline material, the conveyor belt friction coefficient, and the radius of the conveyor belt rotating wheel. When the power is fixed, the third calculation subunit 3031 can adjust the transmission speed to adapt to different material weights, that is, the control system can automatically calculate and adjust the transmission speed of the conveyor belt according to the readings of the material weight sensor. For example, if the material weight doubles, the transmission speed needs to be reduced to half of the original to keep the power unchanged. For example, assuming that the material weight is 1000 kg, the friction coefficient is 0.3, the radius of the rotating wheel is 0.2 m, the transmission speed is V (unit: m / s), and the circumference of the rotating wheel is π×0.4 m (assuming the rotating wheel is circular), then the power formula becomes: P = 1000×0.3×0.2×V÷(π×0.4)÷9550.

[0140] As an alternative implementation, in the embodiments of the present invention, when both the turbidity value and the color characteristics of the solution reach the preset conditions, the control system stops adding the acidic solution and starts monitoring the temperature of the solution. When both the temperature and the turbidity meet specific conditions, the control system uses the conveyor belt speed adjustment calculation formula to calculate the current transmission speed of the conveyor belt.

[0141] The fourth calculation subunit 3032 is used to divide the current conveyor belt length by the current conveyor belt transmission speed to calculate the cleaning time of the crystalline material.

[0142] As an alternative implementation, in the embodiments of the present invention, the present application can monitor the reaction process in real time to ensure that the reaction proceeds under the best conditions, improve the product quality and yield. At the same time, by adjusting the reaction conditions and parameters, precise control of the reaction process is achieved, reducing energy consumption and waste generation. Moreover, by using the conveyor belt speed adjustment calculation formula and the cleaning time calculation, the processing flow of the crystalline material is optimized to improve production efficiency.

[0143] Compared with Figure 3 the control system of Figure 4 the second monitoring unit 304 of

[0144] The receiving subunit 3041 is used to receive the infrared reflection signal of the crystalline material when starting the drying equipment to dry the crystalline material that reaches the drying weight standard.

[0145] The second determination subunit 3042 is used to substitute the infrared reflection signal of the crystalline material into the infrared moisture calibration curve to determine the moisture content value of the crystalline material; wherein, the infrared moisture calibration curve includes the corresponding relationship between the intensity of the infrared reflection signal of the material and the moisture content.

[0146] As an alternative embodiment, in the embodiments of the present invention, the present application can detect the moisture content of the material by emitting near-infrared rays and receiving the signals reflected back by the material. For example, when the moisture content of the material is 25%, the receiving subunit 3041 will receive a specific reflected signal intensity. Through the pre-established correspondence between the reflected signal intensity and the moisture content (i.e., the calibration curve), the second determination subunit 3042 can calculate the moisture content of the material. When it is detected that the moisture content of the material is lower than the set value (such as 20%), the device will stop drying and start discharging materials.

[0147] As an alternative embodiment, in the embodiments of the present invention, the present application effectively removes impurities and excess acid components in the crystalline material through gradient acid reduction washing, improving the product purity. At the same time, the washing liquid is recycled to the copper sulfate mother liquor storage tank to achieve the recycling of resources and reduce waste. And the moisture content of the crystalline material is monitored in real time using the infrared moisture calibration curve to ensure that the drying effect meets the requirements.

[0148] Compared with Figure 3 the control system of Figure 4 the control system includes:

[0149] The detection unit 306 is used to detect whether the copper content in the primary washing liquid exceeds the set value after the determination unit 303 determines the cleaning time of the crystalline material according to the weight of the crystalline material in the reaction kettle and before the second monitoring unit 304 monitors the moisture content value of the crystalline material using the near-infrared measurement method, and after the crystalline material in the reaction kettle is subjected to three gradient acid reduction washings in sequence according to the cleaning time of the crystalline material.

[0150] The recovery unit 307 is used to recover the primary washing liquid to the copper sulfate mother liquor storage tank when the detection unit 306 detects that the copper content in the primary washing liquid exceeds the set value.

[0151] The setting unit 308 is used to set the secondary washing liquid as the new primary washing liquid, the tertiary washing liquid as the new secondary washing liquid, and the clean water source as the new tertiary washing liquid respectively.

[0152] Compared with Figure 3 the control system of Figure 4 the control system includes:

[0153] The calculation unit 309 is used to calculate the current required volume of concentrated sulfuric acid and the current required volume of added water according to the current required concentration of dilute sulfuric acid, the current required volume of dilute sulfuric acid, and the current concentration of concentrated sulfuric acid before the first monitoring unit 301 monitors the color of the solution in the reaction kettle in real time using the color matching algorithm, if it is detected that the liquid level in the dilute sulfuric acid storage tank is lower than the alarm line.

[0154] As an optional implementation, in an embodiment of the present invention, the calculation unit 309 can calculate the current required volume of concentrated sulfuric acid and the current required volume of water to be added according to the following formula: the current required volume of concentrated sulfuric acid = (the current required dilute sulfuric acid concentration × the current required volume of dilute sulfuric acid) / the current concentrated sulfuric acid concentration, the current required volume of water to be added = the current required volume of dilute sulfuric acid - the current required volume of concentrated sulfuric acid, respectively. For example, assuming that 40m³ of dilute sulfuric acid with a concentration of 70% needs to be prepared, and the concentration of concentrated sulfuric acid is 98%, it can be calculated that the current required volume of concentrated sulfuric acid = 70*40 / 98≈28.57 m³ (to simplify the calculation, two decimal places are taken here, and more digits may need to be taken according to the accuracy requirements in the actual calculation), and then the current required volume of water to be added = 40m³-28.57 m³=11.43 m³ can be calculated.

[0155] The control unit 310 is used to control the metering pump to quantitatively deliver the currently required volume of concentrated sulfuric acid and the currently required volume of water to be added to the sulfuric acid dilution cooler through the delivery pipeline.

[0156] The acquisition unit 311 is used to acquire the density of dilute sulfuric acid measured by an online density hydrometer in the delivery pipeline.

[0157] The matching unit 312 is used to match the dilute sulfuric acid control concentration value corresponding to the dilute sulfuric acid density from a preset dilute sulfuric acid concentration specific gravity table according to the dilute sulfuric acid density.

[0158] The recalculation unit 313 is used to recalculate the addition amount of concentrated sulfuric acid and water if the dilute sulfuric acid control concentration value does not match the currently required dilute sulfuric acid concentration.

[0159] As an optional implementation, in an embodiment of the present invention, during the preparation of dilute sulfuric acid, the matching unit 312 can determine whether the concentration of the dilute sulfuric acid is accurate by comparing the measured density value with the concentration specific gravity table in the system. For example, assuming that the density measured by the online density specific gravity meter is ρ, the concentration specific gravity table in the system gives the corresponding relationship between density and concentration. Then, the concentration value C corresponding to the measured density ρ can be found by a lookup table or interpolation method. If C does not match the expected concentration value, the recalculation unit 313 needs to adjust the amount of sulfuric acid or water according to the difference between C and the expected concentration value to ensure that the final concentration of the dilute sulfuric acid is accurate.

[0160] The conveying and releasing unit 314 is used to convey the liquid in the sulfuric acid dilution cooler to the dilute sulfuric acid storage tank through the conveying pipeline and release the liquid level alarm if the dilute sulfuric acid control concentration value matches the currently required dilute sulfuric acid concentration and the temperature in the sulfuric acid dilution cooler reaches a specified temperature.

[0161] As an alternative implementation, in the embodiments of the present invention, the present application can ensure that the concentration and volume of dilute sulfuric acid meet the production requirements, avoiding waste and shortage. At the same time, through precise calculation and transportation, the production efficiency is improved and the energy consumption is reduced. Moreover, through real-time monitoring and adjustment, the quality of dilute sulfuric acid is ensured to be stable, providing reliable raw materials for subsequent reactions.

[0162] It can be seen that implementing Figure 4 the described another control system can improve the production efficiency of copper sulfate pentahydrate.

[0163] In addition, implementing Figure 4 the described control system can monitor and adjust the conditions and parameters of each production link in real time, improving the quality and output of products.

[0164] Embodiment Five

[0165] Please refer to Figure 5 , Figure 5 which is a schematic structural diagram of another control system disclosed in the embodiments of the present invention. As Figure 5 shown, the control system may include:

[0166] A memory 501 storing executable program code;

[0167] A processor 502 coupled to the memory 501;

[0168] Wherein, the processor 502 calls the executable program code stored in the memory 501 and executes Figures 1 - 2 any method for controlling the generation of copper sulfate pentahydrate.

[0169] The embodiments of the present invention disclose a computer-readable storage medium storing a computer program, wherein the computer program causes a computer to execute Figures 1 - 2 any method for controlling the generation of copper sulfate pentahydrate.

[0170] The embodiments of the present invention also disclose a computer program product, wherein when the computer program product runs on a computer, it causes the computer to execute some or all of the steps of the methods in the above method embodiments.

[0171] Those of ordinary skill in the art can understand that all or part of the steps in the various methods of the above embodiments can be completed by instructing relevant hardware through a program, and this program can be stored in a computer-readable storage medium. The storage medium includes read-only memory (ROM), random access memory (RAM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), one-time programmable read-only memory (OTPROM), electrically-erasable programmable read-only memory (EEPROM), compact disc read-only memory (CD-ROM) or other optical disc memories, magnetic disc memories, magnetic tape memories, or any other computer-readable medium capable of carrying or storing data.

[0172] The above has introduced in detail a method and a control system for generating copper sulfate pentahydrate disclosed in the embodiments of the present invention. Specific examples are used herein to elaborate on the principle and implementation manner of the present invention. The description of the above embodiments is only used to help understand the method and its core idea of the present invention; at the same time, for those of ordinary skill in the art, according to the idea of the present invention, there will be changes in the specific implementation manner and application scope. In summary, the content of this specification should not be construed as a limitation to the present invention.

Claims

1. A method for controlling the generation of copper sulfate pentahydrate, characterized in that: include: When the reactor is performing a double decomposition reaction, the color of the solution in the reactor is monitored in real time using a color matching algorithm; When it is detected that the color of the solution in the reactor changes to a specified color, the turbidity value of the solution in the reactor is monitored by using the proportional relationship between turbidity and the electrical signal, and the adding speed of the acidic solution and the stirring speed of the stirring device are adjusted; When it is monitored that the turbidity value of the solution in the reactor reaches a first specified threshold value and the temperature of the solution in the reactor drops to a second specified threshold value, determining a crystallization material cleaning time according to the weight of the crystallization material in the reactor; The moisture content of the crystallized material is monitored using near infrared measurement method; After monitoring that the moisture content of the crystallized material is lower than a third specified threshold, packaging the crystallized material according to a preset packaging weight to complete the discharge of copper sulfate pentahydrate; When the color of the solution in the reactor is detected to be a specified color, the turbidity value of the solution in the reactor is monitored by using the proportional relationship between the turbidity and the electrical signal, and the adding speed of the acid solution and the stirring speed of the stirring device are adjusted, including: When it is monitored that the color of the solution in the reactor changes to a specified color, the adding speed of the acidic solution is reduced, and the stirring speed of the stirring device is increased to enter the solution reaction endpoint fine-tuning stage; After receiving the light signal value reflected by the solution in the reaction kettle, converting the light signal value into an electrical signal value; After preprocessing the electrical signal value, the electrical signal value is substituted into a turbidity mathematical calculation model to calculate the turbidity value of the solution in the reactor; wherein the turbidity mathematical calculation model includes a proportional relationship between turbidity and electrical signal; If the turbidity value of the solution in the reactor reaches a first specified threshold value and the color of the solution in the reactor changes to another specified color, the addition of the acidic solution is stopped, and the temperature of the solution in the reactor is monitored; The step of determining the crystallization material cleaning time according to the weight of the crystallization material in the reactor comprises: The weight of the crystallized material in the reactor is substituted into the conveyor belt speed adjustment calculation formula to calculate the current conveyor belt transmission speed; wherein the conveyor belt speed adjustment calculation formula is the product of the conveyor belt power and the circumference of the conveyor belt rotating wheel divided by the product of the weight of the crystallized material, the conveyor belt friction coefficient and the conveyor belt rotating wheel radius; The current conveyor belt length is divided by the current conveyor belt transmission speed to calculate the crystal material cleaning time.

2. A method for controlling the generation of copper sulfate pentahydrate according to claim 1, characterized in that: The method of using a color matching algorithm to monitor the color of the solution in the reactor in real time includes: Calculating in real time the cosine similarity between the color feature of the solution in the reactor and the specified color feature; When the cosine similarity is greater than a fourth specified threshold, it is determined that the color of the solution in the reaction kettle becomes a specified color.

3. A method for controlling the generation of copper sulfate pentahydrate according to claim 1, characterized in that: The method of monitoring the moisture content of the crystallized material by using a near infrared measurement method comprises: When the drying equipment is started to dry the crystallized material that has reached the dry weight standard, an infrared reflection signal of the crystallized material is received; Substituting the infrared reflection signal of the crystallized material into the infrared moisture calibration curve, the moisture content value of the crystallized material is determined; wherein the infrared moisture calibration curve includes the corresponding relationship between the infrared reflection signal intensity of the material and the moisture content.

4. A method for controlling the generation of copper sulfate pentahydrate according to claim 1, characterized in that: After determining the crystallization material cleaning time according to the weight of the crystallization material in the reactor and before monitoring the moisture content of the crystallization material by using the near infrared measurement method, the method further includes: After the crystallized material in the reactor is subjected to three gradient acid reduction washings in sequence according to the crystallized material washing time, detecting whether the copper content in the primary washing liquid exceeds the set value; if so, recovering the primary washing liquid to the copper sulfate mother liquor storage tank; The secondary washing liquid is set as the new primary washing liquid, the tertiary washing liquid is set as the new secondary washing liquid, and the clean water source is set as the new tertiary washing liquid.

5. A method for controlling the generation of copper sulfate pentahydrate according to any one of claims 1 to 4, characterized in that: Before using the color matching algorithm to monitor the color of the solution in the reactor in real time, the method further includes: If the liquid level in the dilute sulfuric acid storage tank is detected to be lower than the alarm line, the current required volume of concentrated sulfuric acid and the current volume of water to be added are calculated according to the current required concentration of dilute sulfuric acid, the current required volume of dilute sulfuric acid and the current concentration of concentrated sulfuric acid; Controlling the metering pump to quantitatively deliver the currently required volume of concentrated sulfuric acid and the currently required volume of water to be added to the sulfuric acid dilution cooler through the delivery pipeline; Obtaining the density of dilute sulfuric acid measured by an online density hydrometer in the delivery pipeline; According to the density of the dilute sulfuric acid, a dilute sulfuric acid control concentration value corresponding to the density of the dilute sulfuric acid is matched from a preset dilute sulfuric acid concentration specific gravity table; If the dilute sulfuric acid control concentration value does not match the currently required dilute sulfuric acid concentration, recalculate the amount of concentrated sulfuric acid and water to be added; If the dilute sulfuric acid control concentration value matches the currently required dilute sulfuric acid concentration, when the temperature in the sulfuric acid dilution cooler reaches the specified temperature, the liquid in the sulfuric acid dilution cooler is transported to the dilute sulfuric acid storage tank through a delivery pipeline, and the liquid level alarm is released.

6. A control system, characterized in that: The control system comprises: A first monitoring unit is used to monitor the color of the solution in the reactor in real time by using a color matching algorithm when the reactor is performing a double decomposition reaction; A monitoring and adjustment unit, configured to monitor the turbidity value of the solution in the reactor by using the proportional relationship between turbidity and the electrical signal, and adjust the adding speed of the acidic solution and the stirring speed of the stirring device when the first monitoring unit detects that the color of the solution in the reactor changes to a specified color; a determination unit, configured to determine a crystallization material cleaning time according to a weight of the crystallization material in the reactor when the monitoring and adjustment unit detects that the turbidity value of the solution in the reactor reaches a first specified threshold value and the temperature of the solution in the reactor drops to a second specified threshold value; The second monitoring unit is used to monitor the moisture content of the crystallization material using a near infrared measurement method; A discharging unit, configured to pack the crystallized material according to a preset packing weight to complete the discharging of copper sulfate pentahydrate after the second monitoring unit monitors that the moisture content of the crystallized material is lower than a third specified threshold value; The monitoring and adjusting unit comprises: an adjusting subunit, configured to reduce the adding speed of the acidic solution and increase the stirring speed of the stirring device when the first monitoring unit detects that the color of the solution in the reactor changes to a specified color, so as to enter a solution reaction endpoint fine-tuning stage; A conversion subunit, configured to convert the optical signal value into an electrical signal value after receiving the optical signal value reflected by the solution in the reaction kettle; A first calculation subunit is used for pre-processing the electrical signal value and then substituting the electrical signal value into a turbidity mathematical calculation model to calculate the turbidity value of the solution in the reactor; wherein the turbidity mathematical calculation model includes a proportional relationship between turbidity and electrical signal; The stop and monitor subunit is used to stop adding the acidic solution and monitor the temperature of the solution in the reactor if the turbidity value of the solution in the reactor reaches a first specified threshold value and the color of the solution in the reactor changes to another specified color.

7. The control system according to claim 6, characterized in that: The control system comprises: A memory storing executable program code; a processor coupled to the memory; The processor calls the executable program code stored in the memory to execute the method for controlling the generation of copper sulfate pentahydrate according to any one of claims 1 to 5.

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