Coal gangue and fly ash comprehensive treatment system and method

Abstract

The invention provides a coal gangue and fly ash comprehensive treatment system and method, and belongs to the technical field of solid waste comprehensive treatment. Comprising a material storage module, a coal gangue treatment module and a fly ash treatment module which are connected with the material storage module, and a material mixing module connected with the coal gangue treatment module and the fly ash treatment module, recovery and utilization of meagre coal are achieved through the dense medium coal separator, meanwhile, grading treatment in the multi-stage crushing and screening assembly is conducted, coal gangue with different particle sizes is stored and treated in a classified mode, coarse particles can flow back and be crushed again, medium particles are used for mine backfilling, and fine particles are subjected to thermal activation and used for building material preparation. Various components in the coal gangue are utilized to the maximum extent; the fly ash is processed into a finished product suitable for building material production through the procedures of scattering, screening, ball milling and the like, waste of the fly ash is avoided, it can be guaranteed that the two raw materials can fully play a role when the building material is prepared, and the comprehensive utilization rate of the whole system to the coal gangue and the fly ash is increased.

Description

Technical Field

[0001] The present invention belongs to the technical field of solid waste comprehensive treatment, and specifically relates to a comprehensive treatment system and method for coal gangue and fly ash. Background Art

[0002] With the rapid development of the coal industry, the emissions of coal gangue and fly ash have increased sharply, becoming the main solid wastes. Coal gangue is the rock waste generated during coal mining and washing, containing various minerals and a certain amount of carbonaceous components; fly ash is the powdery waste generated after coal combustion, containing various oxides such as silicon, aluminum, and iron.

[0003] On the one hand, a large amount of piled-up coal gangue and fly ash occupy a large amount of land resources, and due to substances such as sulfur contained in coal gangue, spontaneous combustion is likely to occur, releasing harmful gases and polluting the atmospheric environment; on the other hand, these wastes contain rich utilizable resources, and if not reasonably utilized, it is a great waste of resources.

[0004] Therefore, there is an urgent need for a comprehensive treatment system and method for coal gangue and fly ash. When the existing comprehensive treatment system for coal gangue and fly ash is in use, in terms of coal gangue treatment, the crushing and screening of coal gangue are not accurate enough, and there are often situations of over-crushing or insufficient crushing, resulting in increased energy consumption, serious equipment wear, and raw material waste. Summary of the Invention

[0005] In view of the above problems, the present invention provides a comprehensive treatment system and method for coal gangue and fly ash.

[0006] The technical solution of the present invention is: a comprehensive treatment system for coal gangue and fly ash, including a storage module, a coal gangue treatment module and a fly ash treatment module connected to the storage module, and a material mixing module connected to the coal gangue treatment module and the fly ash treatment module;

[0007] Inside the storage module, there is a first storage cavity for storing coal gangue and a second storage cavity for storing fly ash;

[0008] The coal gangue treatment module includes a heavy medium coal separator connected to the first storage cavity and used for screening lean coal, a multi-stage crushing and screening assembly connected to the heavy medium coal separator, a multi-stage storage tank connected to the multi-stage crushing and screening assembly, and a coal gangue thermal activation furnace connected to the multi-stage storage tank;

[0009] The multi-stage storage box includes a primary storage bin, a secondary storage bin and a tertiary storage bin connected to each discharge port of the multi-stage crushing and screening assembly, the primary storage bin is connected to the feed port of the multi-stage crushing and screening assembly through a reflux pipeline, the secondary storage bin is used to store coal gangue powder for reuse as mine backfill, and the tertiary storage bin is connected to the coal gangue thermal activation furnace;

[0010] The fly ash processing module includes a pulverizer connected to the second storage chamber, a vibrating screen connected to the pulverizer, and a ball mill connected to the vibrating screen;

[0011] The coal gangue thermal activation furnace and the discharge ports of the ball mill are both connected to the material mixing module.

[0012] Further, the multi-stage crushing and screening assembly includes a crushing and screening body with a feed inlet at the upper end and a discharge port at the lower end, two crushing units arranged in the crushing and screening body from top to bottom, a horizontal partition plate arranged in the crushing and screening body and corresponding to each crushing unit, the crushing unit includes a crushing box penetrating the horizontal partition plate and having a discharge port at the lower end, a plurality of crushing rollers arranged in the crushing box and meshing with each other, a rotating motor driving one of the crushing rollers, and a movable guide table driven by an external device is arranged at the lower end of the crushing box at the upper end;

[0013] Inclined screens are provided on the side walls of the crushing and screening body and at the upper ends of each crushing box. The upper ends of each horizontal partition plate are connected to the corresponding bottom ends of the inclined screens through blocking vertical plates. A discharge cover is hinged on the side walls of the crushing and screening body and at the lower ends of each inclined screen.

[0014] Description: The heavy medium coal separator separates lean coal and waste gangue particles in coal gangue through density differences. After achieving the dual goals of resource recovery and waste reduction, the waste gangue particles fall onto the corresponding inclined sieve filter through the feed inlet and are screened. The waste gangue particles with smaller particle sizes fall to the lower end of the inclined sieve filter, while the waste gangue particles with larger particle sizes fall into the first crushing box under the action of gravity. At this time, the corresponding crushing rollers are driven to rotate by the rotating motor, and each crushing roller rotates synchronously to perform the first crushing on the waste gangue particles with larger particle sizes. The crushed waste gangue particles uniformly fall onto the moving material guide table. Due to the drive of external equipment, the belt on the moving material guide table moves towards the side close to the inclined sieve filter. At this time, the waste gangue particles crushed for the first time will fall onto the second inclined sieve filter and be screened. The waste gangue particles with smaller particle sizes fall to the lower end of the second inclined sieve filter, while the waste gangue particles with larger particle sizes fall into the second crushing box under the action of gravity for the second crushing. The crushed waste gangue powder falls out through the discharge port and is then temporarily stored in the three-stage storage bin. When needed, it is fed into the coal gangue thermal activation furnace for high-temperature calcination to enhance its activity and resource utilization value. By opening the discharge cover plate corresponding to the first inclined sieve filter, the waste gangue particles after the first screening can be stored in the first-stage storage bin and re-added to the crushing and screening main body for crushing treatment. The waste gangue particles after the second screening are stored in the second-stage storage bin and recycled for mine backfilling. This structure, through the hierarchical cooperation of the inclined sieve filter and the crushing box, screens gangue particles of different particle sizes step by step, only targets and crushes the unqualified coarse particles, ensures that the raw materials are fully crushed, reduces raw material waste, avoids repeated crushing of fine particles, reduces energy consumption and equipment wear. Through the collaborative design of grading screening - crushing - material guiding, it realizes the efficient treatment and precise grading of coal gangue particles, and has the characteristics of energy saving, environmental protection, flexibility and high reliability. It also provides a stable and suitable raw material supply for downstream links such as mine backfilling and building material preparation through closed-loop circulation and resource diversion, and is a key link in the coal gangue resource utilization chain.

[0015] Further, the multi-stage crushing and screening assembly further includes an ultrasonic-assisted stirring unit located at the upper end of each of the moving material guide tables. The ultrasonic-assisted stirring unit includes a horizontally moving plate that slides left and right at the bottom end of the horizontal partition plate through a connecting rod, several ultrasonic stirring rods provided at the bottom end of the horizontally moving plate, and an ultrasonic generator connected to each of the ultrasonic stirring rods.

[0016] Description: When the waste gangue particles after the first crushing uniformly fall onto the moving material guiding table, the ultrasonic generator converts electrical energy into high-frequency mechanical vibration signals and transmits them to the ultrasonic stirring rod. At this time, the horizontal moving plate is driven by an external device to slide left and right. The bottom end of the ultrasonic stirring rod is immersed in the waste gangue particle layer on the material guiding table. Through the cavitation effect of ultrasonic waves and mechanical vibration, the aggregates are destroyed synergistically, restoring the free-flow state of the waste gangue particles, solving problems such as particle agglomeration, poor fluidity, and surface inertness in the traditional crushing and screening system, and significantly improving the classification accuracy and performance of resource-based products.

[0017] Furthermore, a sprinkling tray is provided on the inner wall of the crushing and screening main body corresponding to the upper ends of each of the moving material guiding tables. Several spraying pipes inclined towards the moving material guiding table are provided on the side wall of the sprinkling tray. A reagent box connected to each of the sprinkling trays through a connecting pipe is provided on the outer wall of the crushing and screening main body.

[0018] Description: When the waste gangue particles after the first crushing uniformly fall onto the moving material guiding table, the reagent in the reagent box is pumped into the sprinkling tray and the activator and dispersant are evenly sprayed onto the waste gangue particles through each spraying pipe. By reacting the activator with the silicon-aluminum minerals in the gangue, soluble silicate is generated, starting the release of active components in advance and reducing the requirement for thermal activation temperature. By using the dispersant, the surface tension of the waste gangue particles is reduced, preventing agglomeration and improving fluidity. At the same time, with the assistance of ultrasonic waves, the technical leap from "simple crushing" of coal gangue to "deep pretreatment" is realized, not only reducing the energy consumption and cost of subsequent thermal activation, but also significantly improving the performance and environmental friendliness of resource-based products, providing an efficient technical path for the high-value utilization of coal gangue.

[0019] Further, the particle size of the coal gangue stored in the primary storage bin is > 20 mm, the particle size of the coal gangue stored in the secondary storage bin is 5 - 20 mm, and the particle size of the coal gangue stored in the tertiary storage bin is < 5 mm.

[0020] Description: Coarse particles with a particle size > 20 mm are stored in the primary storage bin and returned to the crushing and screening assembly through the reflux pipeline for secondary crushing to ensure that the raw materials are fully pulverized and to avoid large particles affecting the subsequent processing efficiency. Medium particles with a particle size of 5 - 20 mm are stored in the secondary storage bin and directly used for mine backfilling. Since their particle size is moderate, it can ensure the filling density and will not cause problems such as dusting or leakage due to being too fine. Fine particles with a particle size < 5 mm are stored in the tertiary storage bin and sent to the coal gangue thermal activation furnace for high-temperature calcination. The ultra-fine particle size can increase the specific surface area, improve the thermal activation efficiency, and generate highly active silicon-aluminate, which is suitable for building materials applications.

[0021] Furthermore, the material mixing module includes a mixing intermediate body, a gangue powder storage bin connected to the mixing intermediate body through a downwardly inclined first feed pipe, a fly ash powder storage bin connected to the mixing intermediate body through a downwardly inclined second feed pipe, a mass flow meter and a solenoid valve provided on the first feed pipe and the second feed pipe. The discharge port of the gangue thermal activation furnace is connected to the gangue powder storage bin, and the discharge port of the ball mill is connected to the fly ash powder storage bin.

[0022] Note: The gangue powder after being processed by the gangue thermal activation furnace is stored in the gangue powder storage bin, and the fly ash after being processed by the ball mill is stored in the fly ash powder storage bin. When it is necessary to mix the gangue powder and fly ash to prepare building materials, open each solenoid valve, and the gangue powder flows through the first feed pipe into the mixing intermediate body, and the fly ash flows through the second feed pipe into the mixing intermediate body. During the process of adding the gangue powder and fly ash, the mass flow meter is used to monitor the flow rates of the gangue powder and fly ash in real time to ensure that the two are mixed according to a preset ratio, avoid manual errors, and improve the performance stability of the building materials products.

[0023] Furthermore, a lifting feeding plate is connected to the inner bottom ends of both the gangue powder storage bin and the fly ash powder storage bin through a first hydraulic lifting rod.

[0024] Note: When the gangue powder stored at the bottom end of the first feed pipe in the gangue powder storage bin needs to be added to the mixing intermediate body, the lifting feeding plate is raised or lowered through the extension and compression of the first hydraulic lifting rod, which can ensure that the gangue powder slides from the first feed pipe into the mixing intermediate body. The same applies to the addition method of fly ash in the fly ash powder storage bin. The above process can ensure that the gangue powder and fly ash can be fully utilized, avoid residue in the gangue powder storage bin and fly ash powder storage bin, cause waste, and improve the resource utilization efficiency.

[0025] Furthermore, the lifting feeding plate includes a mounting chassis connected to the upper end of the first hydraulic lifting rod, a rotating plate hinged to the mounting chassis on one side close to the first feed pipe, a rotating support rod hinged to the side wall of the mounting chassis, a sliding groove provided at the bottom end of the rotating plate, and the free end of the rotating support rod can slide in the sliding groove through a horizontally placed second hydraulic lifting rod.

[0026] Description: When coal gangue powder and fly ash remain on the lifting and feeding plate, driven by the second hydraulic lifting rod, the rotating support rod slides in the sliding groove, thereby lifting the free end of the lifting and feeding plate, pouring all the remaining coal gangue powder into the first guide pipe, and also pouring all the remaining fly ash into the second guide pipe and finally falling into the mixing intermediate body, avoiding waste of raw materials. Dynamic cleaning ensures accurate mixing ratio for each batch, improves the strength stability of building materials products, and can also be automatically cleaned to reduce manual intervention.

[0027] The present invention also discloses a comprehensive treatment method for coal gangue and fly ash. Based on the above comprehensive treatment system for coal gangue and fly ash, it includes the following steps:

[0028] S1. Storage of waste raw materials

[0029] Store the waste coal gangue in the first storage cavity and store the waste fly ash in the second storage cavity;

[0030] S2. Treatment of waste coal gangue

[0031] S2-1. Convey the coal gangue to the heavy medium coal separator through the existing sealed conveyor belt. The heavy medium coal separator separates the lean coal and waste gangue particles in the coal gangue by density difference. The separated lean coal is recycled, and the separated waste gangue particles are subjected to two crushing treatments through the multi-stage crushing and screening assembly. The crushed waste coal gangue powder is then temporarily stored in the three-stage storage bin;

[0032] S2-2. The waste gangue particles after the first crushing and screening can be stored in the first-stage storage bin and re-added to the crushing and screening main body for crushing treatment. The waste gangue particles after the second crushing and screening are stored in the second-stage storage bin and recycled for mine backfilling;

[0033] S2-3. Pass the waste coal gangue powder stored in the three-stage storage bin into the coal gangue thermal activation furnace for high-temperature calcination. The calcined gangue powder finished product is added to the coal gangue powder storage bin for storage;

[0034] S3. Treatment of waste fly ash

[0035] Pass the fly ash through the existing screw conveyor and perform dispersion treatment through the disperser in sequence to break up the fly ash agglomerates, separate large particle impurities through the vibrating screen, and perform ball milling treatment through the ball mill to obtain the fly ash finished product. Then, add the fly ash finished product to the fly ash powder storage bin for storage;

[0036] S4. Storage and addition of finished raw materials

[0037] When it is necessary to prepare building materials by mixing coal gangue powder and fly ash, the coal gangue powder and fly ash are mixed in the material mixing module according to a mass ratio of 3:7, and then subsequent operations are carried out.

[0038] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0039] (1) When the coal gangue fly ash comprehensive treatment system of the present invention is in use, the coal gangue and fly ash are separately stored through the storage module. In terms of coal gangue treatment, the recovery and utilization of lean coal are realized through the heavy medium coal separator. At the same time, through the classification treatment in the multi-stage crushing and screening assembly, coal gangue with different particle sizes is classified and stored and processed. The coarse particles can be recycled and crushed again, the medium particles are used for mine backfilling, and the fine particles are thermally activated for building material preparation, maximizing the utilization of various components in the coal gangue; in the fly ash treatment, after processes such as dispersing, screening and ball milling, the fly ash is processed into finished products suitable for building material production, avoiding the waste of fly ash. In the mixing module, the mixing ratio of the coal gangue powder and fly ash is accurately controlled by the mass flowmeter to ensure that the two raw materials can play their roles fully when preparing building materials, improving the comprehensive utilization rate of the coal gangue and fly ash of the entire system;

[0040] (2) The hierarchical cooperation between the inclined screen filter in the multi-stage crushing and screening assembly and the crushing box only targets the unqualified coarse particles for crushing, avoiding repeated crushing of fine particles, reducing the running time and energy consumption of the equipment, reducing equipment wear, and thus reducing the equipment maintenance cost. In the process of coal gangue treatment, the activator and dispersant are sprayed through the sprinkling tray, and with the action of the ultrasonic-assisted stirring unit, the release of active components is started in advance, reducing the temperature requirement for subsequent thermal activation of coal gangue, and further reducing the energy consumption and cost in the thermal activation process. Description of the Drawings

[0041] Figure 1 is the overall structural schematic diagram of the present invention;

[0042] Figure 2 is the structural schematic diagram of the multi-stage crushing and screening assembly of the present invention;

[0043] Figure 3 is the installation structural schematic diagram of the horizontal partition plate in the crushing and screening main body of the present invention;

[0044] Figure 4 is the structural schematic diagram of the material mixing module of the present invention;

[0045] Figure 5 is the structural schematic diagram when the rotating plate is lifted of the present invention.

[0046] Among them, 1-storage module, 10-first storage chamber, 11-second storage chamber, 2-gangue processing module, 20-heavy medium coal separator, 21-multi-stage crushing and screening assembly, 210-feeding port, 2100-inclined screen filter, 2101-blocking vertical plate, 211-crushing and screening body, 212-crushing unit, 2120-discharging port, 2121-crushing box, 2122-crushing roller, 2123-movable guide table, 213-horizontal partition plate, 214-discharging cover plate, 215-ultrasonic assisted stirring unit, 2150-horizontal movable plate, 2151-ultrasonic stirring rod, 2152-ultrasonic generator, 217-sprinkling tray, 218-spraying pipe, 219-reagent box , 22-multi-level storage box, 220-first-level storage bin, 221-second-level storage bin, 222-third-level storage bin, 23-coal gangue thermal activation furnace, 24-feeding port, 25-connecting rod, 3-fly ash processing module, 30-disperser, 31-vibrating screen, 32-ball mill, 4-material mixing module, 40-mixing intermediate, 41-coal gangue powder storage bin, 410-first material guide pipe, 42-fly ash powder storage bin, 420-second material guide pipe, 43-mass flow meter, 44-solenoid valve, 45-lifting feed plate, 450-first hydraulic lifting rod, 451-mounting chassis, 452-rotating plate, 453-rotating support rod, 454-sliding groove, 455-second hydraulic lifting rod. DETAILED DESCRIPTION

[0047] In order to further understand the content of the present invention, the present invention is described in detail below through examples.

[0048] Example 1: Figure 1 As shown, a coal gangue fly ash comprehensive processing system includes a material storage module 1, a coal gangue processing module 2 and a fly ash processing module 3 connected to the material storage module 1, and a material mixing module 4 connected to the coal gangue processing module 2 and the fly ash processing module 3;

[0049] The storage module 1 is provided with a first storage chamber 10 for storing coal gangue and a second storage chamber 11 for storing fly ash.

[0050] like Figure 2 As shown, the gangue processing module 2 includes a heavy medium coal separator 20 connected to the first storage chamber 10 and used for screening lean coal, a multi-stage crushing and screening assembly 21 connected to the heavy medium coal separator 20, a multi-stage storage box 22 connected to the multi-stage crushing and screening assembly 21, and a gangue thermal activation furnace 23 connected to the multi-stage storage box 22, wherein the gangue thermal activation furnace 23 adopts the existing technology, for example, a WBL-10 type microwave high temperature furnace can be adopted;

[0051] The multi-stage storage box 22 includes a primary storage bin 220, a secondary storage bin 221 and a tertiary storage bin 222 connected to each discharge port of the multi-stage crushing and screening assembly 21. The primary storage bin 220 is connected to the feed port of the multi-stage crushing and screening assembly 21 through a reflux pipeline. The secondary storage bin 221 is used to store coal gangue powder for reuse as mine backfill. The tertiary storage bin 222 is connected to the coal gangue thermal activation furnace 23.

[0052] The fly ash processing module 3 includes a scattering machine 30 connected to the second storage chamber 11, a vibrating screen 31 connected to the scattering machine 30, and a ball mill 32 connected to the vibrating screen 31, wherein the scattering machine 30, the vibrating screen 31 and the ball mill 32 all adopt existing technologies, for example, the scattering machine 30 can adopt a FL series scattering classifier, the vibrating screen 31 can adopt a vibrating screen of model YA-1536, and the ball mill 32 can adopt a MQG series grid-type ball mill;

[0053] The discharge ports of the coal gangue thermal activation furnace 23 and the ball mill 32 are both connected to the material mixing module 4;

[0054] like Figure 2 , 3 As shown, the multi-stage crushing and screening assembly 21 includes a crushing and screening body 211 with a feed inlet 210 at the upper end and a discharge port 24 at the lower end, two crushing units 212 arranged in the crushing and screening body 211 from top to bottom, a horizontal partition plate 213 is arranged in the crushing and screening body 211 and corresponding to each crushing unit 212, the crushing unit 212 includes a crushing box 2121 which runs through the horizontal partition plate 213 and has a discharge port 2120 at the lower end, three crushing rollers 2122 arranged in the crushing box 2121 and meshing with each other, and a rotating motor driving one of the crushing rollers 2122, and a movable guide table 2123 driven by an external device is arranged at the lower end of the crushing box 2121 at the upper end, wherein the crushing roller 2122 and the rotating motor both adopt the existing technology, for example, the crushing roller 2122 can adopt a crushing roller of model 2PG-400×250, and the rotating motor can adopt a rotating motor of model Y132S-4;

[0055] On the side wall of the crushing and screening main body 211 and at the upper ends of each crushing box 2121, there are inclined screen filters 2100. The upper ends of each horizontal partition plate 213 and the bottom ends of the corresponding inclined screen filters 2100 are connected by barrier vertical plates 2101. At the lower position on one side of the side wall of the crushing and screening main body 211 corresponding to each inclined screen filter 2100, there is a hinged discharge cover plate 214; through the hierarchical cooperation of the inclined screen filter 2100 and the crushing box 2121, gangue particles of different particle sizes are screened step by step, and only the unqualified coarse particles are specifically crushed, ensuring the full crushing of raw materials, reducing raw material waste, avoiding repeated crushing of fine particles, reducing energy consumption and equipment wear. Through the collaborative design of hierarchical screening - crushing - guiding, the efficient treatment and precise classification of coal gangue particles are realized, with the characteristics of energy saving, environmental protection, flexibility and high reliability. Also, through closed - loop circulation and resource - based diversion, it provides a stable and suitable raw material supply for downstream links such as mine backfilling and building material preparation, which is a key link in the coal gangue resource utilization chain. Among them, the inclined screen filter 2100 at the upper end can filter out coal gangue particles with a particle size < 20mm, and the inclined screen filter 2100 at the lower end can filter out coal gangue particles with a particle size of 5 - 20mm. The inclined screen filter 2100 adopts existing technologies, for example, it can adopt a TS - 2020 metal screen;

[0056] As Figure 4 As shown, the material mixing module 4 includes a mixing intermediate 40, a coal gangue powder storage bin 41 connected to the mixing intermediate 40 through a downward - inclined first guide pipe 410, a fly ash powder storage bin 42 connected to the mixing intermediate 40 through a downward - inclined second guide pipe 420, mass flow meters 43 and solenoid valves 44 provided on the first guide pipe 410 and the second guide pipe 420. The discharge port of the coal gangue thermal activation furnace 23 is connected to the coal gangue powder storage bin 41, and the discharge port of the ball mill 32 is connected to the fly ash powder storage bin 42; the coal gangue powder after being processed by the coal gangue thermal activation furnace 23 is stored in the coal gangue powder storage bin 41, and the fly ash after being processed by the ball mill 32 is stored in the fly ash powder storage bin 42. When it is necessary to mix coal gangue powder and fly ash to prepare building materials, open each solenoid valve 44, and the coal gangue powder flows through the first guide pipe 410 into the mixing intermediate 40, and the fly ash flows through the second guide pipe 420 into the mixing intermediate 40. During the process of adding coal gangue powder and fly ash, the mass flow meters 43 are used to monitor the flow rates of coal gangue powder and fly ash in real - time, ensuring that the two are mixed according to a preset ratio, avoiding manual errors, and improving the performance stability of building material products. Among them, the mass flow meters 43 and the solenoid valves 44 both adopt existing technologies. For example, the mass flow meter 43 can adopt a mass flow meter 43 with a model of SITRANS F M MAG 5100, and the solenoid valve 44 can adopt a solenoid valve with a model of 212B12;

[0057] The particle size of the coal gangue stored in the primary storage bin 220 is > 20 mm, the particle size of the coal gangue stored in the secondary storage bin 221 is 5 - 20 mm, and the particle size of the coal gangue stored in the tertiary storage bin 222 is < 5 mm. The coarse particles > 20 mm stored in the primary storage bin 220 are returned to the crushing and screening assembly 21 through the reflux pipeline for secondary crushing to ensure that the raw materials are fully pulverized and to avoid large particles from affecting the subsequent processing efficiency. The medium particles of 5 - 20 mm stored in the secondary storage bin 221 are directly used for mine backfilling. Because of their moderate particle size, they can not only ensure the filling density but also avoid problems such as dusting or leakage caused by being too fine. The fine particles < 5 mm stored in the tertiary storage bin 222 are sent to the coal gangue thermal activation furnace 23 for high-temperature calcination. The ultra-fine particle size can increase the specific surface area, improve the thermal activation efficiency, and generate highly active aluminosilicate, which is suitable for building materials applications.

[0058] Example 2: A comprehensive treatment method for coal gangue and fly ash in this example is based on the comprehensive treatment system for coal gangue and fly ash in Example 1 and includes the following steps:

[0059] S1. Storage of waste raw materials

[0060] Store the waste coal gangue in the first storage cavity 10 and store the waste fly ash in the second storage cavity 11.

[0061] S2. Treatment of waste coal gangue

[0062] S2-1. Convey the coal gangue to the heavy medium coal separator 20 through an existing sealed conveyor belt. The heavy medium coal separator 20 separates the lean coal and waste gangue particles in the coal gangue by density difference. The separated lean coal is recycled. After the separated waste gangue particles fall onto the corresponding inclined screen filter 2100 through the feed inlet 2100 and are screened, the waste gangue particles with smaller particle size fall to the lower end of the inclined screen filter 2100, while the waste gangue particles with larger particle size fall into the first crushing box 2121 under the action of gravity. At this time, drive the corresponding crushing roller 2122 to rotate through the rotating motor, and each crushing roller 2122 rotates synchronously to perform the first crushing on the waste gangue particles with larger particle size. The crushed waste gangue particles uniformly fall onto the moving material guide table 2123. Due to the drive of external equipment, the belt on the moving material guide table 2123 moves towards the side close to the inclined screen filter 2100. At this time, the waste gangue particles crushed for the first time will fall onto the second inclined screen filter 2100 and are screened. The waste gangue particles with smaller particle size fall to the lower end of the second inclined screen filter 2100, while the waste gangue particles with larger particle size fall into the second crushing box 2121 under the action of gravity for secondary crushing. The crushed waste gangue powder falls out through the discharge port 24 and is then temporarily stored through the tertiary storage bin 222.

[0063] S2-2. Open the discharge cover plate 214 corresponding to the first inclined sieve filter screen 2100, and the waste gangue particles after the first sieving can be stored in the primary storage bin 220 and then re-added to the crushing and screening main body 211 for crushing. The waste gangue particles after the second sieving are stored in the secondary storage bin 221 and recycled for mine backfilling;

[0064] S2-3. Feed the waste gangue powder stored in the tertiary storage bin 222 into the coal gangue thermal activation furnace 23 for high-temperature calcination. The calcined gangue powder finished product is added to the coal gangue powder storage bin 41 for storage;

[0065] S3. Treatment of waste fly ash

[0066] Use the existing screw conveyor to pass the fly ash through the disperser 30 for dispersion treatment to break up the fly ash agglomerates, separate large particle impurities through the vibrating screen 31, and perform ball milling treatment through the ball mill 32 to obtain the fly ash finished product. Then, add the fly ash finished product to the fly ash powder storage bin 42 for storage;

[0067] S4. Storage and addition of finished raw materials

[0068] When it is necessary to prepare building materials by mixing coal gangue powder and fly ash, open each solenoid valve 44. The coal gangue powder flows through the first guide pipe 410 to the mixing intermediate 40, and the fly ash flows through the second guide pipe 420 to the mixing intermediate 40. During the process of adding the coal gangue powder and fly ash, the mass flow meters 43 are used to monitor the flow rates of the coal gangue powder and fly ash in real time to ensure that the two are mixed in a mass ratio of 3:7.

[0069] Example 3: The difference between this example and Example 1 is as follows:

[0070] As Figure 2As shown in the figure, the multi-stage crushing and screening assembly 21 further includes an ultrasonic-assisted stirring unit 215 located at the upper ends of the respective movable material guiding platforms 2123. The ultrasonic-assisted stirring unit 215 includes a horizontally movable plate 2150 that slides left and right at the bottom end of the horizontal partition plate 213 through a connecting rod 25, 16 ultrasonic stirring rods 2151 provided at the bottom end of the horizontally movable plate 2150, and an ultrasonic generator 2152 connected to each ultrasonic stirring rod 2151. By the cavitation effect of ultrasonic waves and mechanical vibration working together to break the agglomerates and restore the free-flow state of the waste gangue particles, problems such as particle agglomeration, poor fluidity, and surface inertia in the traditional crushing and screening system are solved, significantly improving the classification accuracy and the performance of the resource-based products. Among them, both the ultrasonic stirring rod 2151 and the ultrasonic generator 2152 adopt existing technologies. For example, the ultrasonic stirring rod 2151 can adopt an ultrasonic stirring rod with the model UIP1000hdT, and the ultrasonic generator 2152 can adopt an ultrasonic generator with the model UIP2000hd;

[0071] At the upper ends of the respective movable material guiding platforms 2123 inside the inner wall of the crushing and screening main body 211, there are provided sprinkling trays 217. On the side walls of the sprinkling trays 217, there are 9 spraying pipes 218 inclined towards the movable material guiding platforms 2123. Outside the crushing and screening main body 211, there is a reagent box 219 connected to each sprinkling tray 217 through a connecting pipe. The activator and dispersant are evenly sprayed onto the waste gangue particles through each spraying pipe 218. By the reaction of the activator with the silicon-aluminum minerals in the gangue, soluble silicates are generated, starting the release of active components in advance and reducing the requirement for the thermal activation temperature. By the dispersant, the surface tension of the waste gangue particles is reduced to prevent agglomeration and improve fluidity. At the same time, with the assistance of ultrasonic waves, the technical leap from "simple crushing" of coal gangue to "deep pretreatment" is realized. Not only the energy consumption and cost of subsequent thermal activation are reduced, but also the performance and environmental friendliness of the resource-based products are significantly improved, providing an efficient technical path for the high-value utilization of coal gangue. Among them, the activator stored in the reagent box 219 is sodium hydroxide, and the dispersant is sodium hexametaphosphate.

[0072] Example 4: The difference between this example and Example 2 is that:

[0073] In step S2-1, when the waste gangue particles after the first crushing evenly fall onto the movable material guiding platform 2123, the ultrasonic generator 2152 converts electrical energy into high-frequency mechanical vibration signals and transmits them to the ultrasonic stirring rods 2151. At this time, the horizontally movable plate 2150 is driven by an external device to slide left and right, and the bottom ends of the ultrasonic stirring rods 2151 are immersed in the waste gangue particle layer on the material guiding platform 2123. By the cavitation effect of ultrasonic waves and mechanical vibration working together to break the agglomerates and restore the free-flow state of the waste gangue particles;

[0074] In step S2-1, when the waste gangue particles after the first crushing uniformly fall onto the moving material guiding table 2123, the reagent in the reagent box 219 is pumped into the spraying tray 217, and the activator and dispersant are uniformly sprayed onto the waste gangue particles through each spraying pipe 218. By reacting the activator with the silicon-aluminum minerals in the gangue, soluble silicate is generated, and the surface tension of the waste gangue particles is reduced by the dispersant to prevent agglomeration.

[0075] Example 5: The difference between this example and Example 3 is that:

[0076] As Figure 5 shown, at the inner bottom ends of the coal gangue powder storage bin 41 and the fly ash powder storage bin 42, there are lifting feeding plates 45 connected through the first hydraulic lifting rods 450. Through the extension and compression of the first hydraulic lifting rods 450, the lifting feeding plates 45 can be raised or lowered, which can ensure that the coal gangue powder slides down from the first material guiding pipe 410 into the mixing intermediate 40. The same is true for the addition method of fly ash in the fly ash powder storage bin 42. The above process can ensure the full use of the coal gangue powder and fly ash, avoid residue in the coal gangue powder storage bin 41 and the fly ash powder storage bin 42, cause waste, and improve the resource utilization efficiency. Among them, the first hydraulic lifting rod 450 adopts the existing technology. For example, a hydraulic lifting rod with the model YHG-50×100-S can be used;

[0077] The lifting feeding plate 45 includes a mounting chassis 451 connected to the upper end of the first hydraulic lifting rod 450, and a rotating plate 452 hinged to the mounting chassis 451 on one side close to the first material guiding pipe 410. A rotating support rod 453 is hinged to the side wall of the mounting chassis 451. A sliding groove 454 is provided at the bottom end of the rotating plate 452, and the free end of the rotating support rod 453 can slide in the sliding groove 454 through the horizontally placed second hydraulic lifting rod 455; when the coal gangue powder and fly ash remain on the lifting feeding plate 45, through the driving action of the second hydraulic lifting rod 455, the rotating support rod 453 slides in the sliding groove 454, thereby lifting the free end of the lifting feeding plate 45, pouring all the remaining coal gangue powder into the first material guiding pipe 410, and also pouring all the remaining fly ash into the second material guiding pipe 420 and finally falling into the mixing intermediate 40, avoiding waste of raw materials, dynamically cleaning to ensure the accurate mixing ratio of each batch, improving the strength stability of building materials products, and also enabling automatic cleaning and reducing manual intervention. Among them, the second hydraulic lifting rod 455 adopts the existing technology. For example, a hydraulic lifting rod with the model YHG-50×100-S can be used.

[0078] Example 6: The difference between this example and Example 4 is that:

[0079] In step S4, when the coal gangue powder stored at the bottom end of the first material guiding pipe 410 in the coal gangue powder storage bin 41 needs to be added to the mixing intermediate 40, through the extension and compression of the first hydraulic lifting rod 450, the lifting feeding plate 45 is lifted or lowered, which can ensure that the coal gangue powder slides from the first material guiding pipe 410 into the mixing intermediate 40. The addition method of the fly ash in the fly ash powder storage bin 42 is the same;

[0080] When coal gangue powder and fly ash remain on the lifting feeding plate 45, through the driving action of the second hydraulic lifting rod 455, the rotating support rod 453 slides in the sliding groove 454, thereby lifting the free end of the lifting feeding plate 45, so that the remaining coal gangue powder is all poured into the first material guiding pipe 410, and the remaining fly ash is also all poured into the second material guiding pipe 420 and finally falls into the mixing intermediate 40.

Claims

1. A comprehensive treatment system for coal gangue and fly ash, characterized in that It comprises a material storage module (1), a gangue processing module (2) and a fly ash processing module (3) connected to the material storage module (1), and a material mixing module (4) connected to the gangue processing module (2) and the fly ash processing module (3); The material storage module (1) is provided with a first storage chamber (10) for storing coal gangue and a second storage chamber (11) for storing fly ash. The gangue processing module (2) comprises a heavy medium coal separator (20) connected to the first storage chamber (10) and used for screening lean coal, a multi-stage crushing and screening assembly (21) connected to the heavy medium coal separator (20), a multi-stage storage box (22) connected to the multi-stage crushing and screening assembly (21), and a gangue thermal activation furnace (23) connected to the multi-stage storage box (22); The multi-stage storage box (22) comprises a primary storage bin (220), a secondary storage bin (221) and a tertiary storage bin (222) connected to each discharge port of the multi-stage crushing and screening assembly (21); the primary storage bin (220) is connected to the feed port of the multi-stage crushing and screening assembly (21) via a return pipeline; the secondary storage bin (221) is used to store coal gangue powder for reuse as mine backfill; and the tertiary storage bin (222) is connected to the coal gangue thermal activation furnace (23); The fly ash processing module (3) comprises a pulverizer (30) connected to the second storage chamber (11), a vibrating screen (31) connected to the pulverizer (30), and a ball mill (32) connected to the vibrating screen (31); The discharge ports of the coal gangue thermal activation furnace (23) and the ball mill (32) are both connected to the material mixing module (4).

2. The integrated coal gangue and fly ash treatment system according to claim 1, characterized in that, The multi-stage crushing and screening assembly (21) comprises a crushing and screening body (211) having an inlet (210) at the upper end and a discharge port (24) at the lower end, two crushing units (212) arranged in the crushing and screening body (211) from top to bottom, a horizontal partition plate (213) arranged in the crushing and screening body (211) and corresponding to each crushing unit (212), the crushing unit (212) comprising a crushing box (2121) penetrating the horizontal partition plate (213) and having a discharge port (2120) at the lower end, a plurality of crushing rollers (2122) arranged in the crushing box (2121) and meshing with each other, a rotating motor driving one of the crushing rollers (2122), and a movable guide table (2123) driven by an external device is arranged at the lower end of the crushing box (2121) at the upper end; Inclined screens (2100) are provided on the side walls of the crushing and screening body (211) and at the upper ends of each crushing box (2121); the upper ends of each horizontal partition plate (213) are connected to the corresponding lower ends of the inclined screens (2100) via a barrier vertical plate (2101); and a discharge cover plate (214) is hingedly connected to the side walls of the crushing and screening body (211) and at the lower ends of each inclined screen (2100).

3. A comprehensive treatment system for coal gangue and fly ash according to claim 2, characterized in that The multi-stage crushing and screening assembly (21) further includes an ultrasonic-assisted stirring unit (215) located at the upper ends of the respective moving material guiding platforms (2123). The ultrasonic-assisted stirring unit (215) includes a horizontally moving plate (2150) that slides left and right at the bottom end of the horizontal partition plate (213) through a connecting rod (25), several ultrasonic stirring rods (2151) provided at the bottom end of the horizontally moving plate (2150), and an ultrasonic generator (2152) connected to each of the ultrasonic stirring rods (2151).

4. A coal gangue and fly ash comprehensive treatment system according to claim 2, characterized in that, A material spraying tray (217) is provided on the inner wall of the crushing and screening main body (211) corresponding to the upper ends of the respective moving material guiding platforms (2123). Several spraying pipes (218) inclined towards the moving material guiding platform (2123) are provided on the side wall of the material spraying tray (217). A reagent box (219) connected to each of the material spraying trays (217) through a connecting pipe is provided on the outer wall of the crushing and screening main body (211).

5. A comprehensive treatment system for coal gangue and fly ash according to claim 1, characterized in that, The particle size of the coal gangue stored in the primary storage bin (220) is > 20 mm, the particle size of the coal gangue stored in the secondary storage bin (221) is 5 - 20 mm, and the particle size of the coal gangue stored in the tertiary storage bin (222) is < 5 mm.

6. A comprehensive coal gangue and fly ash treatment system according to claim 1, characterized in that, The material mixing module (4) includes a mixing intermediate body (40), a coal gangue powder storage bin (41) connected to the mixing intermediate body (40) through a downwardly inclined first guide pipe (410), a fly ash powder storage bin (42) connected to the mixing intermediate body (40) through a downwardly inclined second guide pipe (420), a mass flow meter (43) and a solenoid valve (44) provided on the first guide pipe (410) and the second guide pipe (420). The discharge port of the coal gangue thermal activation furnace (23) is connected to the coal gangue powder storage bin (41), and the discharge port of the ball mill (32) is connected to the fly ash powder storage bin (42).

7. A coal gangue fly ash comprehensive treatment system according to claim 6, characterized in that, At the inner bottom ends of both the coal gangue powder storage bin (41) and the fly ash powder storage bin (42), a lifting feeding plate (45) is connected through a first hydraulic lifting rod (450).

8. A comprehensive treatment system for coal gangue and fly ash according to claim 7, characterized in that The lifting feeding plate (45) includes a mounting chassis (451) connected to the upper end of the first hydraulic lifting rod (450), a rotating plate (452) hinged to the mounting chassis (451) on a side close to the first guide pipe (410). A rotating support rod (453) is hinged to the side wall of the mounting chassis (451). A sliding groove (454) is provided at the bottom end of the rotating plate (452). The free end of the rotating support rod (453) can slide in the sliding groove (454) through a horizontally placed second hydraulic lifting rod (455).

9. A comprehensive treatment method for coal gangue and fly ash, based on the comprehensive treatment system for coal gangue and fly ash described in any one of claims 1-8, characterized in that, Including the following steps: S1. Storage of waste raw materials Store the waste coal gangue in the first storage cavity (10), and store the waste fly ash in the second storage cavity (11); S2. Treatment of waste coal gangue S2-1. Convey the coal gangue to the heavy medium coal separator (20) through the existing sealed conveyor belt. The heavy medium coal separator (20) separates the lean coal and waste gangue particles in the coal gangue by density difference. The separated lean coal is recycled, and the separated waste gangue particles are subjected to two-stage crushing treatment by the multi-stage crushing and screening assembly (21). The crushed waste gangue powder is then temporarily stored in the three-stage storage bin (222). S2-2. The waste gangue particles after the first crushing and screening can be stored in the first-stage storage bin (220) and re-added to the crushing and screening main body (211) for crushing treatment. The waste gangue particles after the second crushing and screening are stored in the second-stage storage bin (221) and recycled for mine backfilling. S2-3. The waste gangue powder stored in the three-stage storage bin (222) is fed into the coal gangue thermal activation furnace (23) for high-temperature calcination. The calcined gangue powder finished product is added to the coal gangue powder storage bin (41) for storage. S3. Treatment of waste fly ash The fly ash is conveyed through the existing screw conveyor and successively subjected to dispersion treatment by the disperser (30) to break up the fly ash lumps, separated from large particle impurities by the vibrating screen (31), and then ball milled by the ball mill (32) to obtain the fly ash finished product. Then, the fly ash finished product is added to the fly ash powder storage bin (42) for storage. S4. Storage and addition of finished raw materials When it is necessary to prepare building materials by mixing coal gangue powder and fly ash, the coal gangue powder and fly ash are mixed in the material mixing module (4) according to a mass ratio of 3:7, and then subsequent operations are carried out.

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