Online monitoring system and method in mineral soil conditioner production process

Abstract

The invention relates to the technical field of soil conditioners, in particular to an online monitoring system and method in the production process of a mineral soil conditioner. In the production process of the silicon-calcium-potassium-magnesium fertilizer, a calcium source activity coefficient in an initial decomposition stage is obtained; fitting a generation competition curve of calcium silicate at the current monitoring moment, and further obtaining a calcium source lack coefficient according to the change condition of the generation competition curve and the calcium source activity coefficient in combination with the calcium-aluminum ratio; and finally performing early warning according to the calcium source lack coefficient and adding a calcium source. According to the method, the calcium-aluminum ratio change condition of calcium oxide and aluminum oxide in the high-temperature calcination process and the change condition of stable products such as calcium silicate and calcium aluminate are monitored in real time, the consumption condition of calcium oxide is comprehensively evaluated, then the curing effect of follow-up calcium oxide on aluminum oxide can be accurately evaluated, a calcium source is added in time, the aluminum toxicity risk is reduced, and the product quality is improved. The online monitoring effect in the production process of the mineral soil conditioner is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of soil conditioners, and particularly to an on-line monitoring system and method in the production process of mineral soil conditioners. Background Art

[0002] Mineral soil conditioners refer to a type of conditioner that uses natural mineral materials to improve soil properties. Silicon-calcium-potassium-magnesium fertilizer is a mineral-source soil conditioner, which is made from refractory potassium ores such as potassium feldspar and calcium- and magnesium-containing ores through high-temperature conversion. During the production process, potassium feldspar will generate alumina after high-temperature calcination. , It will slowly dissolve in the soil to form Al³⁺, resulting in aluminum toxicity, which will further inhibit the growth of plant roots. Therefore, the monitoring of the product during the production process is crucial.

[0003] During the high-temperature calcination process, calcium oxide (CaO) in the raw materials or intermediate products will react with to form more stable aluminates, so as to appropriately reduce the risk of aluminum toxicity. By monitoring the calcium-aluminum ratio, that is, the production ratio of CaO to , it can help to judge whether additional calcium sources need to be added during the production process to promote solidification. However, the reactions between various elements and compounds are complex, and the changing trend of the calcium-aluminum ratio is difficult to predict and evaluate, resulting in the inability to accurately adjust the production process, and further leading to poor on-line monitoring effects in the production process of mineral soil conditioners. Summary of the Invention

[0004] In order to solve the technical problem of poor on-line monitoring effects in the production process of mineral soil conditioners, the purpose of the present invention is to provide an on-line monitoring system and method in the production process of mineral soil conditioners. The specific technical solutions adopted are as follows: An on-line monitoring method in the production process of mineral soil conditioners, the method comprising: Real-time monitoring of the calcium-aluminum ratio of calcium oxide and alumina and the reaction temperature during the production process, and the formation ratio of calcium silicate and calcium aluminate; the production process includes an initial decomposition stage and a main reaction stage; In the initial decomposition stage, according to the changing trend of the reaction temperature and the calcium-aluminum ratio, obtain the calcium source activity coefficient; at the current monitoring moment, according to the formation ratio and the changing trend of the calcium-aluminum ratio at each historical monitoring moment in the main reaction stage, fit the formation competition curve of calcium silicate; At the current monitoring moment, according to the change situation of the formation competition curve and the calcium source activity coefficient, combined with the calcium-aluminum ratio at the current monitoring moment, obtain the calcium source deficiency coefficient; give an alarm according to the calcium source deficiency coefficient and add calcium sources.

[0005] Further, the method for obtaining the calcium source activity coefficient includes: Fitting the calcium-aluminum ratio curve in the initial decomposition stage, and dividing the calcium-aluminum ratio curve into a descending section and an ascending section by using the minimum value in the calcium-aluminum ratio curve; Taking the negative correlation mapping result of the absolute value of the slope of the descending section as the first activity parameter; obtaining a second activity parameter according to the change rate of the reaction temperature in the corresponding time period of the ascending section and the reaction duration in the corresponding time period of the ascending section; Fusing the first activity parameter and the second activity parameter, and taking the normalized value of the fusion result as the calcium source activity coefficient.

[0006] Further, the method for obtaining the second activity parameter includes: Fitting the temperature curve section of the reaction temperature in the corresponding time period of the ascending curve section, and taking the product of the slope of the temperature curve section and the negative correlation mapping result of the reaction duration as the second activity parameter.

[0007] Further, the method for obtaining the generation competition curve includes: According to the deviation of the calcium-aluminum ratio at each monitoring moment in the main reaction stage from the calcium-aluminum ratio at the end of the initial decomposition stage, and combining the generation ratio at each monitoring moment, obtaining the generation competition parameter of calcium silicate at each monitoring moment; In the main reaction stage, sorting and fitting the generation competition parameters at all historical monitoring moments up to the current monitoring moment according to the time sequence to generate a generation competition curve.

[0008] Further, the method for obtaining the generation competition parameter includes: Obtaining the difference between the calcium-aluminum ratio at the end of the initial decomposition stage and the calcium-aluminum ratio at each monitoring moment in the main reaction stage, normalizing the difference as the competition weight; weighting the generation ratio at the corresponding monitoring moment in the main reaction stage by using the competition weight, and taking the weighted result as the generation competition parameter of calcium silicate at the corresponding monitoring moment.

[0009] Further, the method for obtaining the calcium source deficiency coefficient includes: At the current monitoring moment, determining the calcium silicate dominant generation curve and the calcium aluminate dominant generation curve according to the change trend of the generation competition curve, and obtaining the calcium source deficiency weight according to the change difference between the two generation curves and the overall slope of the generation competition curve, in combination with the calcium source activity coefficient; Obtaining a standard deviation parameter according to the deviation of the calcium-aluminum ratio at the current monitoring moment from the preset standard threshold; weighting the standard deviation parameter by using the calcium source deficiency weight, and taking the normalized value of the weighted result as the calcium source deficiency coefficient.

[0010] Further, the method for obtaining the calcium silicate-dominated generation curve and the calcium aluminate-dominated generation curve includes: Taking the maximum peak in the generation competition curve as a segmentation point, and using the segmentation point to divide the generation competition curve into a calcium silicate-dominated generation curve and a calcium aluminate-dominated generation curve.

[0011] Further, the method for obtaining the calcium source deficiency weight includes: Taking the slope of the generation competition curve as the current competition parameter of calcium silicate, weighting the current competition parameter by the calcium source activity coefficient, and taking the normalization result of the weighted result as the first competition intensity of calcium silicate; Taking the overall change amount of the calcium silicate-dominated generation curve as the numerator, taking the sum of the corresponding change amounts of the calcium silicate-dominated generation curve and the calcium aluminate-dominated generation curve as the denominator, and taking the fractional ratio as the second competition intensity of calcium silicate; Fusing the first competition intensity and the second competition intensity to obtain the calcium source deficiency weight at the current monitoring moment.

[0012] Further, the method for giving an early warning according to the calcium source deficiency coefficient and adding a calcium source includes: When the calcium source deficiency coefficient is greater than a preset threshold, give a calcium deficiency early warning, and determine the calcium source gap amount to be added according to the mass of aluminum oxide at the current monitoring moment.

[0013] An on-line monitoring system in the production process of a mineral soil conditioner, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, the steps of the on-line monitoring method in the production process of the mineral soil conditioner are implemented.

[0014] The present invention has the following beneficial effects: The present invention monitors in real time the calcium-aluminum ratio and reaction temperature of calcium oxide and aluminum oxide, and the generation ratio of calcium silicate and calcium aluminate in the production process; in the initial decomposition stage, according to the change trend of the reaction temperature and calcium-aluminum ratio, obtain the calcium source activity coefficient; at the current monitoring moment, according to the change trend of the generation ratio and calcium-aluminum ratio at each historical monitoring moment in the main reaction stage, fit the generation competition curve of calcium silicate; at the current monitoring moment, according to the change situation of the generation competition curve and the calcium source activity coefficient, combined with the calcium-aluminum ratio at the current monitoring moment, obtain the calcium source deficiency coefficient; give an early warning according to the calcium source deficiency coefficient and add a calcium source. By monitoring in real time the change situation of the calcium-aluminum ratio of calcium oxide and aluminum oxide and the change situation of stable products such as calcium silicate and calcium aluminate during the high-temperature calcination process, the present invention comprehensively evaluates the consumption situation of calcium oxide, and can thus accurately evaluate the subsequent solidification effect of calcium oxide on aluminum oxide, and timely add a calcium source to reduce the aluminum toxicity risk and improve the on-line monitoring effect in the production process of the mineral soil conditioner. Brief Description of the Drawings

[0015] In order to more clearly illustrate the technical solutions and advantages in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. 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 be obtained based on these drawings.

[0016] Figure 1 It is a flowchart of an on-line monitoring method in the production process of a mineral soil conditioner provided by an embodiment of the present invention; Figure 2 It is a schematic diagram of a calcium-aluminum ratio curve and a formation ratio curve provided by an embodiment of the present invention; Figure 3 It is a flowchart of a method for obtaining a calcium source deficiency coefficient provided by an embodiment of the present invention. Detailed Embodiments

[0017] In order to further elaborate on the technical means and effects adopted by the present invention to achieve the intended invention purpose, the following, in combination with the accompanying drawings and preferred embodiments, details the specific embodiments, structures, features and effects of an on-line monitoring system and method in the production process of a mineral soil conditioner proposed according to the present invention. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. In addition, the specific features, structures or characteristics in one or more embodiments can be combined in any suitable form.

[0018] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs.

[0019] The following specifically describes the specific solutions of an on-line monitoring system and method in the production process of a mineral soil conditioner provided by the present invention in combination with the accompanying drawings.

[0020] Please refer to Figure 1 , which shows a flowchart of an on-line monitoring method in the production process of a mineral soil conditioner provided by an embodiment of the present invention, specifically including: Step S1, real-time monitoring of the calcium-aluminum ratio of calcium oxide and aluminum oxide and the reaction temperature during the production process, and the formation ratio of calcium silicate and calcium aluminate; the production process includes an initial decomposition stage and a main reaction stage.

[0021] It should be noted that the embodiments of the present invention are directed to the production monitoring of calcium-silicon-potassium-magnesium fertilizer type mineral soil conditioners, and the monitoring and adjustment during the production process are carried out within the main reaction stage. That is, in the following text, the current monitoring moment is within the main reaction stage, and it is warned whether there is a lack of calcium source and added within the main reaction stage.

[0022] For the convenience of understanding the subsequent solutions, the production process of calcium-silicon-potassium-magnesium fertilizer is briefly described first: Grind and mix potassium feldspar and calcium- and magnesium-containing ores, and then send the mixed raw materials into a rotary kiln for high-temperature calcination to promote the chemical reaction of minerals to form the required components. Then, after the temperature reduction is completed, the final reaction product is granulated and dried, etc. to obtain the conditioner; among them, the high-temperature calcination is mainly divided into an initial decomposition stage (room temperature - 900 °C), a main reaction stage (900 °C - 1300 °C), and a temperature reduction stage. The reaction in the temperature reduction stage has basically been completed; among them, the initial decomposition stage and the main reaction stage are determined by the first time the reaction temperature in the rotary kiln reaches 900 °C. In the initial decomposition stage, most ore raw materials begin to decompose: For example, the crystal lattice of potassium source ores such as potassium feldspar ( ) is damaged and gradually decomposes to release active alumina ( ) and silicon dioxide ( ); in the later stage of this stage, calcium source ores such as limestone ( ), dolomite ( ) or phosphogypsum ( ) etc. begin to decompose to generate calcium oxide (CaO) and other by-products. In the main reaction stage, the temperature further increases, the reaction rate accelerates, and the reaction between various calcium, aluminum, and silicon sources intensifies. Both alumina ( ) and silicon dioxide ( ) will react with calcium oxide (CaO) to produce relatively stable compounds such as calcium aluminate and calcium silicate, thereby avoiding the risk of aluminum toxicity caused by excessive accumulation of alumina.

[0023] In order to monitor and adjust the production process of calcium-silicon-potassium-magnesium fertilizer, an embodiment of the present invention first collects in real time the contents of various compounds in the rotary kiln at each monitoring moment during the production process, and takes the content ratio of calcium oxide and alumina as the calcium-aluminum ratio, and takes the content ratio of calcium silicate and calcium aluminate as the generation ratio; at the same time, the reaction temperature at each monitoring moment is collected in real time; among them, the calcium oxide content and the calcium silicate content are the numerators respectively.

[0024] It should be noted that the implementer can integrate a micro X-ray diffractometer or a near-infrared spectrometer in the rotary kiln to directly analyze the content of various compounds at each monitoring moment, or indirectly analyze and evaluate the content of various compounds by monitoring the process gas, and then integrate a temperature sensor in the rotary kiln to collect the reaction temperature at each monitoring moment, which are all existing technologies and will not be elaborated here; the monitoring frequency is set to once per minute, and the implementer can also customize it according to the actual application situation.

[0025] In an embodiment of the present invention, after obtaining the calcium-aluminum ratio, the formation ratio, and the reaction temperature at each monitoring moment, the corresponding time-series curves are further fitted for subsequent analysis; taking the calcium-aluminum ratio as an example, the calcium-aluminum ratio at each monitoring moment is mapped as a data point to the time stamp, and the calcium-aluminum ratio curve is fitted; similarly, the formation ratio curve and the reaction temperature curve can be obtained, which are all existing technologies and will not be elaborated here.

[0026] Please refer to Figure 2 , which shows a schematic diagram of a calcium-aluminum ratio curve and a formation ratio curve provided by an embodiment of the present invention; Figure 2 The dotted line in divides each stage in the high-temperature calcination process during the production process and reflects the general changing trends of the calcium-aluminum ratio curve and the formation ratio curve within each reaction stage; Among them, in the initial decomposition stage, the lattice of potassium feldspar is first destroyed to generate the product alumina, while the decomposition of the calcium source ore has not occurred or is slow, resulting in the content of alumina being significantly higher than that of calcium oxide and the calcium-aluminum ratio being low; in the later stage of the initial decomposition stage, when the temperature rises above 800 °C, the calcium source ore begins to decompose to generate calcium oxide, and the content of calcium oxide gradually increases. At this time, the calcium-aluminum ratio gradually rises; thus, the calcium-aluminum ratio curve as a whole shows a changing trend of first decreasing and then increasing; In the main reaction stage, calcium oxide will first react with silicon to form calcium silicate, thereby consuming calcium oxide and reducing the calcium-aluminum ratio; subsequently, calcium oxide reacts with alumina to form calcium aluminate, starting to consume alumina, thereby increasing the calcium-aluminum ratio; therefore, the calcium-aluminum ratio curve generally shows a changing trend of first decreasing and then increasing; at the same time, the formation ratio curves corresponding to calcium silicate and calcium aluminate should show a changing trend of first increasing and then decreasing.

[0027] It should be noted that calcium aluminate and calcium silicate are reaction products in the main reaction stage, and there may be no corresponding monitoring data and thus no corresponding formation ratio in the initial decomposition stage.

[0028] Step S2, in the initial decomposition stage, according to the changing trends of the reaction temperature and the calcium-aluminum ratio, obtain the calcium source activity coefficient; at the current monitoring moment, according to the changing trends of the formation ratio and the calcium-aluminum ratio at each historical monitoring moment in the main reaction stage, fit the formation competition curve of calcium silicate.

[0029] Considering the formation of calcium oxide is crucial for subsequent reaction with alumina to form stable compounds through bonding and curing, thereby reducing the risk of aluminum toxicity; also considering that the variation trend of the calcium-aluminum ratio during the initial decomposition stage is mainly decreasing first and then increasing, the decreasing section reflects the dominant formation of alumina, and the increasing section reflects the dominant formation of calcium oxide; within the decreasing section, i.e., the main formation stage of alumina, the faster the formation rate of alumina, the slower the formation rate of calcium oxide and the lower the activity degree of the calcium source; within the increasing section, i.e., the main formation stage of calcium oxide, if the reaction temperature changes faster and the corresponding reaction duration is shorter, a dense calcium oxide layer may form on the surface while the calcium source decomposes rapidly, further hindering the decomposition of the internal raw materials, and insufficient reaction will also result in a lower activity degree of the calcium source.

[0030] Based on this, in the embodiments of the present invention, first, within the initial decomposition stage, according to the variation trends of the reaction temperature and the calcium-aluminum ratio, a calcium source activity coefficient is obtained; the calcium source activity coefficient reflects the formation rate of calcium oxide and prepares for subsequent analysis of the competitive binding situations of alumina and silica with calcium oxide to evaluate whether there is a lack of calcium source.

[0031] Preferably, in an embodiment of the present invention, considering that the slope can help evaluate the variation trend, if the absolute value of the slope of the decreasing section is larger, it indicates that the calcium-aluminum ratio decreases faster, the formation rate of alumina is faster, and it also indicates that the activity of the calcium source is lower; also considering that the variation rate of the reaction temperature and the reaction duration within the increasing stage can both reflect whether the decomposition of the calcium source is sufficient and, indirectly, the activity of the calcium source; based on this, the method for obtaining the calcium source activity coefficient includes: Fitting the calcium-aluminum ratio curve within the initial decomposition stage, and using the minimum value in the calcium-aluminum ratio curve to divide the calcium-aluminum ratio curve into a decreasing section and an increasing section; Taking the negative correlation mapping result of the absolute value of the slope of the decreasing section as the first activity parameter; obtaining a second activity parameter according to the variation rate of the reaction temperature within the corresponding time period of the increasing section and the reaction duration of the corresponding time period of the increasing section; Fusing the first activity parameter and the second activity parameter, and taking the normalized value of the fusion result as the calcium source activity coefficient.

[0032] Among them, in a preferred embodiment of the present invention, the method for obtaining the second activity parameter includes: Fitting the temperature curve section of the reaction temperature within the corresponding time period of the rising curve section, and taking the product of the slope of the temperature curve section and the negative correlation mapping result of the reaction duration as the second activity parameter.

[0033] As an example, first, within the initial decomposition stage, taking the minimum value in the calcium-aluminum ratio curve as the segmentation point, taking the curve section that generally shows a decreasing trend in the reverse time sequence direction of the segmentation point as the decreasing section, and taking the curve section that generally shows an increasing trend in the time sequence direction as the increasing section; Calculate the slope of the descending section based on the two-point formula and take the absolute value. Then, take the reciprocal of the absolute value of the slope to perform negative correlation adjustment for logical normalization, obtaining the first activity parameter. The greater the absolute value of the slope, the faster the generation rate of alumina and the smaller the first activity coefficient of the calcium source. Then, perform a reciprocal operation on the reaction duration corresponding to the rising curve section, and multiply the reciprocal by the slope of the temperature curve section of the reaction temperature within the corresponding time period of the rising curve section, obtaining the second activity parameter. The greater the slope and the shorter the reaction duration, the faster the change in reaction temperature and the less complete the reaction, and the smaller the second activity parameter of the calcium source. Finally, multiply and fuse the first activity coefficient and the second activity coefficient, and map the product into the hyperbolic tangent function for normalization, obtaining the activity coefficient of the calcium source at the end of the initial decomposition stage.

[0034] Considering that during the main reaction stage, the change in the production ratio of stable products such as calcium silicate and calcium aluminate reflects the distribution direction of calcium oxide and the competitive production of products, which can help evaluate whether calcium oxide is sufficient to solidify alumina and reduce the risk of aluminum toxicity. Also considering that the change in the calcium-aluminum ratio during the main reaction stage also reflects the consumption of calcium oxide and the solidification of alumina, which can help evaluate the competitive production of calcium silicate and calcium aluminate. Therefore, in an embodiment of the present invention, further at the current monitoring moment, according to the change trends of the production ratio and the calcium-aluminum ratio at each historical monitoring moment during the main reaction stage, fit the production competition curve of calcium silicate. The production competition curve of calcium silicate reflects the dominant situation of the production of calcium silicate and indirectly reflects the dominant direction of the consumption of calcium oxide, which can help subsequent evaluation of whether calcium oxide is sufficient to solidify alumina.

[0035] Preferably, in an embodiment of the present invention, considering that during the main reaction stage, when the calcium-aluminum ratio shows a downward trend and the production ratio of calcium silicate and calcium aluminate is higher, it indicates that calcium oxide is gradually consumed and preferentially combines with silicon oxide to form calcium silicate. At this time, it is the dominant stage of the production of calcium silicate, and its production competition parameter is larger. When the downward trend of the calcium-aluminum ratio is slow or shows an upward trend and the production ratio of calcium silicate and calcium aluminate is lower, it indicates that alumina begins to be consumed and begins to combine with alumina to form calcium aluminate. At this time, it is the dominant stage of the production of calcium aluminate, and the production competition parameter of calcium silicate is relatively lower. Based on this, the production competition parameter of calcium silicate at each historical monitoring moment during the main reaction stage can be obtained, and then its production competition curve in time series can be fitted. The method for obtaining the production competition curve includes: According to the deviation of the calcium-aluminum ratio at each monitoring moment during the main reaction stage from the calcium-aluminum ratio at the end of the initial decomposition stage, combined with the production ratio at each monitoring moment, obtain the production competition parameter of calcium silicate at each monitoring moment. During the main reaction stage, the generation competition parameters at all historical monitoring moments up to the current monitoring moment are sorted according to the time sequence and fitted to generate a competition curve.

[0036] Among them, in a preferred embodiment of the present invention, considering that in the early stage of the main reaction stage, the decrease in the calcium-aluminum ratio indicates that the consumption of calcium oxide is better than that of aluminum oxide, which indirectly indicates that the formation of calcium silicate is better than that of calcium aluminate. At the same time, the larger the formation ratio, it further indicates that the formation of calcium silicate is better than that of calcium aluminate. Based on this, the method for obtaining the generation competition parameter includes: Obtain the calcium-aluminum ratio at the end of the initial decomposition stage, subtract the difference between the calcium-aluminum ratios at each monitoring moment during the main reaction stage, normalize the difference as the competition weight; use the competition weight to weight the formation ratio at the corresponding monitoring moment during the main reaction stage, and take the weighted result as the generation competition parameter of calcium silicate at the corresponding monitoring moment.

[0037] As an example, taking any historical monitoring moment up to the current monitoring moment during the main reaction stage as an example, the calculation formula for the generation competition parameter is: ; where Q is the generation competition parameter of calcium silicate at the historical monitoring moment; is the calcium-aluminum ratio at the end of the initial decomposition stage; is the calcium-aluminum ratio at the historical monitoring moment; is the competition weight at the historical monitoring moment; B is the formation ratio at the historical monitoring moment.

[0038] It should be noted that the calcium-aluminum ratio at the end of the initial decomposition stage should be close to the maximum value of the calcium-aluminum ratio, so the difference should be greater than or equal to 0; the difference is normalized by dividing it by the minuend to obtain the competition weight, and then the competition weight is multiplied and combined with the formation ratio at the same corresponding historical monitoring moment to obtain the generation competition parameter of calcium silicate at the historical monitoring moment.

[0039] It should be noted that the fitting method of the generation competition curve is the same as the curve fitting method in step S1, which is already a prior art and will not be elaborated here.

[0040] Step S3, at the current monitoring moment, according to the change situation of the generation competition curve and the calcium source activity coefficient, combined with the calcium-aluminum ratio at the current monitoring moment, obtain the calcium source deficiency coefficient; give an alarm according to the calcium source deficiency coefficient and add calcium source.

[0041] Considering that the change situation of the generation competition curve not only reflects the competitive formation of calcium silicate and calcium aluminate, but also indirectly reflects the solidification situation of calcium oxide to aluminum oxide. When the generation competition curve always shows the situation dominated by calcium silicate, it indicates that the solidification effect of calcium oxide on aluminum oxide is not good, and there may be a situation where calcium oxide is insufficient to solidify aluminum oxide in the future; Also considering that at the end of the initial decomposition stage, the decomposition rate of the calcium source ore should be close to the peak value. At this time, the amount of calcium oxide produced by the decomposition of the calcium source ore is close to the maximum value, and the calcium-aluminum ratio is also close to the maximum value, which can provide a reference for the activity of calcium oxide at the beginning of consumption and the intensity of competition for chemical combination with compounds, while the calcium source activity coefficient can provide relevant information; also considering that the calcium-aluminum ratio at the current monitoring moment can intuitively provide the solidification situation of calcium oxide to alumina to a certain extent; Based on this, in the embodiment of the present invention, at the current monitoring moment, according to the change situation of the generation competition curve and the calcium source activity coefficient, combined with the calcium-aluminum ratio at the current monitoring moment, the calcium source deficiency coefficient is analyzed and evaluated; the calcium source deficiency coefficient combines the competitive generation situation of the stable products calcium silicate and calcium aluminate to indirectly evaluate whether the calcium source is lacking, and at the same time combines the real-time calcium-aluminum ratio at the current monitoring moment to directly evaluate whether the calcium source is lacking, so as to prepare for the subsequent calcium source deficiency warning.

[0042] Preferably, in an embodiment of the present invention, the method for obtaining the calcium source deficiency coefficient includes: Please refer to Figure 3 , which shows a flowchart of a method for obtaining a calcium source deficiency coefficient provided by an embodiment of the present invention, specifically including: Step S301, at the current monitoring moment, according to the change trend of the generation competition curve, determine the calcium silicate dominant generation curve and the calcium aluminate dominant generation curve, and according to the change difference between the two generation curves and the overall slope of the generation competition curve, combined with the calcium source activity coefficient, obtain the calcium source deficiency weight.

[0043] In a preferred embodiment of the present invention, considering that the main reaction stage mainly includes the calcium silicate dominant generation stage and the calcium aluminate dominant generation stage, the change trend of the generation competition curve indirectly reflects the change situation of the competitive generation of calcium silicate in the two dominant stages. When the generation of calcium silicate is close to saturation or reaches the calcium aluminate dominant generation stage, the generation competition curve of calcium silicate will show a downward trend; therefore, the maximum peak value in the generation competition curve can be used as a segmentation point, and the generation competition curve is divided into a calcium silicate dominant generation curve and a calcium aluminate dominant generation curve by using the segmentation point.

[0044] It should be noted that the determination of the peak value is already a prior art and will not be elaborated here; among them, in the generation competition curve, the curve segment with a generally upward trend in the reverse time sequence direction of the segmentation point is the calcium silicate dominant generation curve, and the curve segment with a generally downward trend in the time sequence direction is the calcium aluminate dominant generation curve.

[0045] Considering that the overall change trend of the generation competition curve generally reflects the competitive generation advantage of calcium silicate, and the slope can reflect the change trend. When the slope is larger, it indicates that the competitive generation advantage of calcium silicate is greater, which may have a certain impact on the subsequent generation of calcium aluminate and may lead to a lack of calcium source insufficient to solidify alumina. At the same time, the calcium source activity coefficient also has a certain impact on the subsequent combination of calcium oxide with other compounds. The lower the calcium source activity coefficient, the greater the impact on the competitive generation of calcium silicate; Also considering the change difference of the generation competition parameters in the two dominant generation curves in the generation competition curve, it also reflects the consumption difference of calcium oxide on the side. When the change amount in the dominant generation curve of calcium aluminate is lower, it indicates that calcium oxide may be insufficient to solidify alumina to generate calcium aluminate, and the possibility of calcium source deficiency is higher; Based on this, in a preferred embodiment of the present invention, the method for obtaining the calcium source deficiency weight includes: Taking the slope of the generation competition curve as the current competition parameter of calcium silicate, weighting the current competition parameter by the calcium source activity coefficient, and taking the normalization result of the weighted result as the first competition intensity of calcium silicate; Taking the overall change amount of the dominant generation curve of calcium silicate as the numerator, taking the sum of the corresponding change amounts of the dominant generation curve of calcium silicate and the dominant generation curve of calcium aluminate as the denominator, and taking the fractional ratio as the second competition intensity of calcium silicate; Fusing the first competition intensity and the second competition intensity to obtain the calcium source deficiency weight at the current monitoring moment.

[0046] As an example, the calculation formula for the calcium source deficiency weight is: ; where P is the calcium source deficiency weight at the current monitoring moment; is the linear normalization function; G is the calcium source activity coefficient; is the slope of the generation competition curve, that is, the current competition parameter; is the first competition intensity of calcium silicate; is the overall change amount of the dominant generation curve of calcium silicate; is the overall change amount of the dominant generation curve of calcium aluminate; is the second competition intensity of calcium silicate.

[0047] In the above formula, specifically, the slope of the generation competition curve is obtained based on two points, and then the slope is multiplied by the calcium source activity coefficient and linearly normalized. The larger the normalized value, the greater the first competition intensity, indicating that at the current monitoring moment, the calcium silicate-dominated generation stage still exists, silicon oxide consumes a large amount of calcium oxide, has a greater impact on the subsequent curing of alumina, and the possibility of calcium source deficiency is greater; specifically, the absolute value of the difference between the endpoints of the two dominant generation curves is used as the overall change amount of the corresponding dominant generation curve. The overall change amount reflects the consumption of calcium oxide within the corresponding dominant generation stage from the side. When the proportion of calcium oxide consumed within the calcium silicate-dominated generation curve is larger, the second competition intensity is greater, which also indicates from the side that the impact on the subsequent curing of alumina is greater, and the possibility of calcium source deficiency is also greater; then the first competition intensity and the second competition intensity are multiplied and combined to obtain the calcium source deficiency weight.

[0048] Step S302, obtain a standard deviation parameter according to the deviation of the calcium-aluminum ratio at the current monitoring moment from the preset standard threshold; weight the standard deviation parameter by using the calcium source deficiency weight, and use the normalized value of the weighted result as the calcium source deficiency coefficient.

[0049] Considering the deviation of the calcium-aluminum ratio at the current monitoring moment from the standard, it can also reflect whether there is an aluminum toxicity risk, and reflects from the side whether the remaining calcium source is insufficient to cure alumina, that is, the calcium source deficiency situation. Based on this, the calcium source deficiency coefficient can be obtained by combining the deviation situation and the calcium source deficiency weight.

[0050] As an example, the difference between the preset standard threshold and the calcium-aluminum ratio at the current monitoring moment is linearly normalized. When the difference is greater than 0 and the larger it is, the larger the normalized value is, indicating that the calcium-aluminum ratio at the current monitoring moment is much lower than the preset standard, and the remaining calcium oxide may be insufficient to cure alumina, so the standard deviation parameter is larger; then the calcium source deficiency weight is multiplied by the standard deviation parameter, and the product is linearly normalized to obtain the calcium source deficiency coefficient.

[0051] It should be noted that in this example, the preset standard threshold is set to 0.5. The implementer can also determine the preset standard threshold according to the content ratio in the chemical reaction process of calcium oxide and alumina to generate calcium aluminate, and can further set relevant margins in combination with the chemical reactions that calcium oxide may participate in with other compounds to customize the preset standard threshold; this is already an existing technology and will not be elaborated further.

[0052] After obtaining the calcium source deficiency coefficient, calcium source deficiency warning can be further carried out and calcium source can be added.

[0053] In a preferred embodiment of the present invention, the method for warning and adding calcium source according to the calcium source deficiency coefficient includes: When the calcium source deficiency coefficient is greater than a preset threshold, calcium deficiency warning is carried out, and the calcium source gap amount is determined according to the quality of alumina at the current monitoring moment for addition; wherein, the preset threshold is set to 0.4, and the implementer can also customize it.

[0054] In an embodiment of the present invention, after the calcium deficiency warning, the implementer needs to monitor the content of alumina at the current monitoring moment based on the relevant equipment integrated in step S1, and calculate the calcium oxide gap according to the content ratio in the chemical reaction process of calcium oxide and alumina to form calcium aluminate, and then determine the calcium source input amount in combination with the calcium content in the calcium source ore, and further add the calcium source to the rotary kiln; the above process is already a well-known prior art to those skilled in the art and will not be elaborated.

[0055] The present invention also proposes an on-line monitoring system in the production process of a mineral soil conditioner, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, the steps of the above on-line monitoring method in the production process of the mineral soil conditioner are implemented.

[0056] In summary, the present invention monitors in real time the calcium-aluminum ratio of calcium oxide and alumina and the reaction temperature during the production process, and the formation ratio of calcium silicate and calcium aluminate; the production process includes an initial decomposition stage and a main reaction stage; in the initial decomposition stage, according to the change trend of the reaction temperature and the calcium-aluminum ratio, the calcium source activity coefficient is obtained; at the current monitoring moment, according to the change trend of the formation ratio and the calcium-aluminum ratio at each historical monitoring moment in the main reaction stage, the formation competition curve of calcium silicate is fitted; at the current monitoring moment, according to the change situation of the formation competition curve and the calcium source activity coefficient, combined with the calcium-aluminum ratio at the current monitoring moment, the calcium source deficiency coefficient is obtained; warning is carried out according to the calcium source deficiency coefficient and the calcium source is added. By monitoring in real time the change situation of the calcium-aluminum ratio of calcium oxide and alumina during the high-temperature calcination process and the change situation of stable products such as calcium silicate and calcium aluminate, the present invention comprehensively evaluates the consumption situation of calcium oxide, and thus can accurately evaluate the subsequent solidification effect of calcium oxide on alumina, and timely add the calcium source to reduce the risk of aluminum toxicity and improve the on-line monitoring effect in the production process of the mineral soil conditioner.

[0057] It should be noted that: the above sequence of embodiments of the present invention is only for description and does not represent the advantages and disadvantages of the embodiments. The processes depicted in the drawings do not necessarily require the specific order or continuous order shown to achieve the desired results. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0058] Each embodiment in this specification is described in a progressive manner, and the same or similar parts between each embodiment can be referred to each other. Each embodiment focuses on the differences from other embodiments.

Claims

1. An online monitoring method in the production process of a mineral soil conditioner, characterized in that: The method comprises: Real-time monitoring of the calcium-aluminum ratio of calcium oxide to aluminum oxide and the reaction temperature, and the generation ratio of calcium silicate to calcium aluminate during the production process; the production process includes an initial decomposition stage and a main reaction stage; In the initial decomposition stage, the calcium source activity coefficient is obtained according to the change trend of the reaction temperature and the calcium-aluminum ratio; at the current monitoring moment, the calcium silicate generation competition curve is fitted according to the generation ratio and the change trend of the calcium-aluminum ratio at each historical monitoring moment in the main reaction stage; At the current monitoring moment, the calcium source deficiency coefficient is obtained according to the change of the generated competition curve and the calcium source activity coefficient, combined with the calcium-aluminum ratio at the current monitoring moment; an early warning is issued and a calcium source is added according to the calcium source deficiency coefficient.

2. The online monitoring method in the production process of mineral soil conditioner according to claim 1, characterized in that: The method for obtaining the calcium source activity coefficient comprises: Fitting the calcium-aluminum ratio curve in the initial decomposition stage, and dividing the calcium-aluminum ratio curve into a descending section and an ascending section using the minimum value in the calcium-aluminum ratio curve; The negative correlation mapping result of the absolute value of the slope of the descending segment is used as the first activity parameter; the second activity parameter is obtained according to the change rate of the reaction temperature in the corresponding period of the ascending segment and the reaction time of the corresponding period of the ascending segment; The first activity parameter and the second activity parameter are fused, and a normalized value of the fusion result is used as the calcium source activity coefficient.

3. The online monitoring method in the production process of mineral soil conditioner according to claim 2, characterized in that: The method for obtaining the second activity parameter includes: The temperature curve segment of the reaction temperature in the period corresponding to the rising curve segment is fitted, and the product of the slope of the temperature curve segment and the negative correlation mapping result of the reaction time is used as the second activity parameter.

4. The online monitoring method in the production process of mineral soil conditioner according to claim 1, characterized in that: The method for obtaining the competition curve comprises: According to the calcium-aluminum ratio at each monitoring moment in the main reaction stage, the deviation of the calcium-aluminum ratio relative to the end of the initial decomposition stage, combined with the generation ratio at each monitoring moment, the generation competition parameter of calcium silicate at each monitoring moment is obtained; In the main reaction stage, the generated competition parameters at all historical monitoring moments up to the current monitoring moment are sorted in time sequence to generate a competition curve.

5. The online monitoring method in the production process of mineral soil conditioner according to claim 4, characterized in that: The method for obtaining the generated competition parameters includes: Obtain the calcium-aluminum ratio at the end of the initial decomposition stage, subtract the difference of the calcium-aluminum ratio at each monitoring moment in the main reaction stage, normalize the difference and use it as the competition weight; use the competition weight to weight the generation ratio at the corresponding monitoring moment in the main reaction stage, and use the weighted result as the competition parameter for the generation of calcium silicate at the corresponding monitoring moment.

6. The online monitoring method in the production process of mineral soil conditioner according to claim 1, characterized in that: The method for obtaining the calcium source deficiency coefficient includes: At the current monitoring moment, the calcium silicate dominant generation curve and the calcium aluminate dominant generation curve are determined according to the change trend of the generation competition curve, and the calcium source deficiency weight is obtained according to the change difference between the two generation curves and the overall slope of the generation competition curve, combined with the calcium source activity coefficient; According to the deviation of the calcium-aluminum ratio at the current monitoring moment relative to a preset standard threshold, a standard deviation parameter is obtained; the standard deviation parameter is weighted using the calcium source deficiency weight, and the normalized value of the weighted result is used as the calcium source deficiency coefficient.

7. The online monitoring method in the production process of mineral soil conditioner according to claim 6, characterized in that: The method for obtaining the calcium silicate dominant generation curve and the calcium aluminate dominant generation curve comprises: The maximum peak value in the generation competition curve is used as a segmentation point, and the generation competition curve is divided into a calcium silicate-dominated generation curve and a calcium aluminate-dominated generation curve using the segmentation point.

8. The method for online monitoring in the production process of mineral soil conditioner according to claim 7, characterized in that: The method for obtaining the calcium source deficiency weight comprises: The slope of the generated competition curve is used as the current competition parameter of calcium silicate, the current competition parameter is weighted by the calcium source activity coefficient, and the normalized result of the weighted result is used as the first competition intensity of calcium silicate; The overall change of the calcium silicate dominant generation curve is taken as the numerator, the sum of the corresponding changes of the calcium silicate dominant generation curve and the calcium aluminate dominant generation curve is taken as the denominator, and the fraction ratio is taken as the second competitive intensity of calcium silicate; The first competition intensity and the second competition intensity are integrated to obtain the calcium source deficiency weight at the current monitoring moment.

9. The online monitoring method in the production process of mineral soil conditioner according to claim 1, characterized in that: The method for giving an early warning and adding a calcium source according to the calcium source deficiency coefficient comprises: When the calcium source deficiency coefficient is greater than a preset threshold, a calcium deficiency warning is issued, and the calcium source gap amount is determined for addition according to the quality of alumina at the current monitoring moment. 10.Online monitoring system in the production process of mineral soil conditioner, characterized in that: The method comprises a memory, a processor and a computer program stored in the memory and executable on the processor, wherein when the processor executes the computer program, the steps of the online monitoring method in the production process of the mineral soil conditioner as claimed in any one of claims 1 to 9 are implemented.

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