Automatic treatment system for primary aluminum ash

Abstract

The invention discloses a primary aluminum ash automatic treatment system, and relates to the technical field of aluminum ash recycling, the primary aluminum ash automatic treatment system comprises a ball milling and screening all-in-one machine, an ultrasonic wave circular screen, a rotary furnace and an ash cooling barrel, the ball milling and screening all-in-one machine is used for receiving aluminum ash in a stock bin A, conducting ball milling on the aluminum ash in the stock bin A, conducting screening on the aluminum ash obtained after ball milling, and obtaining the aluminum ash in the stock bin A; the aluminum ash is conveyed to a stock bin A and a stock bin B on the basis of the first granularity of the aluminum ash, the aluminum ash in the stock bin B is divided into finished aluminum ash and coarse aluminum ash through an ultrasonic circular screen on the basis of the second granularity of the aluminum ash, the rotary furnace is used for receiving the coarse aluminum ash and coarse materials, flux is added to melt the coarse aluminum ash and the coarse materials at high temperature, and molten aluminum and fried aluminum ash are generated; the pneumatic conveying system is arranged among the ball mill, the screening machine, the ultrasonic screening machine and the rotary furnace, so that the whole process of aluminum ash treatment is automatic, dustless and low in consumption, and the recycling treatment cost of the aluminum ash is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of aluminum ash recovery, and in particular to a primary aluminum ash automatic processing system. Background Art

[0002] Aluminum ash is a by-product of aluminum smelting and forming. It is produced in all aluminum melting processes. The aluminum content in it accounts for about 1% to 12% of the total aluminum loss during production and use. The recycling of aluminum ash not only reduces environmental pollution but also improves the utilization rate of aluminum resources, which is highly economical and environmentally friendly.

[0003] Existing automated aluminum ash processing systems, such as a harmless secondary aluminum ash processing and recovery system disclosed in a Chinese patent application with publication number CN119076594A, include a control system, a stirring reaction equipment, an ammonia detector, a spreading device, an exhaust gas treatment device, a weighing module, a timing module, a flow valve and a temperature sensor. When processing aluminum ash, the aluminum ash processing and recovery system will also generate a certain amount of aluminum ash dust. The aluminum ash cannot be guaranteed to be dust-free and low-consumption during the recycling process, which increases the recycling cost of the aluminum ash. Summary of the Invention

[0004] In order to overcome the above-mentioned technical problems, the purpose of the present invention is to provide an automated aluminum ash processing system to solve the problem in the prior art that the aluminum ash processing and recovery system will generate a certain amount of aluminum ash dust when processing aluminum ash, resulting in the inability to ensure dust-free and low-consumption aluminum ash during the recycling process.

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

[0006] Specifically, an automated aluminum ash processing system is provided, including a ball mill and screening machine, an ultrasonic circular screen, a rotary furnace and a cold ash barrel, wherein the ball mill and screening machine is used to receive the aluminum ash in the silo A, and ball-mill the aluminum ash in the silo A, and screen the aluminum ash after ball milling, and transport the aluminum ash to the silo A and the silo B respectively based on the first particle size of the aluminum ash, the ultrasonic circular screen divides the aluminum ash in the silo B into finished aluminum ash and coarse aluminum ash based on the second particle size of the aluminum ash, the rotary furnace is used to receive the coarse aluminum ash and coarse material, and add flux to melt the coarse aluminum ash and coarse material at high temperature to generate aluminum liquid and roasted aluminum ash, the cold ash barrel is used to receive the roasted aluminum ash generated by the rotary furnace, and crush and screen the roasted aluminum ash, and the cold ash barrel transports the roasted aluminum ash to the rotary furnace and the silo A respectively based on the third particle size.

[0007] As a further solution of the present invention: the ball mill and screening integrated machine includes a driving shell, and a first ball mill and a second ball mill are arranged inside the driving shell. The first ball mill performs coarse ball milling on the aluminum ash, and the second ball mill performs fine ball milling on the aluminum ash after coarse ball milling.

[0008] As a further solution of the present invention: the first ball mill includes a first rotating cylinder, the outer side of the first rotating cylinder is fixedly connected to an elastic connecting rod, the end of the elastic connecting rod is fixedly connected to a first fixing ring, and the first fixing ring is fixedly connected to the inner wall of the drive housing.

[0009] As a further solution of the present invention: a first ball milling chamber is provided inside the first rotating drum, a first protrusion is fixedly connected to the inner wall of the first ball milling chamber, the interior of the first ball milling chamber is filled with a number of steel balls with a diameter of 40-60 mm, and a sieve hole of 1mm-5mm is opened on the surface of the first rotating drum.

[0010] As a further solution of the present invention: the second ball mill includes a second rotating drum, the inner side end of the second rotating drum is fixedly connected to a vibration spring, the end of the vibration spring is fixedly connected to a second fixing ring, and the second fixing ring is fixedly connected to the outer side of the first rotating drum.

[0011] As a further solution of the present invention: a second protrusion is fixedly connected to the inner wall of the second rotating drum, the interior of the second rotating drum is filled with a plurality of steel balls with a diameter of 5mm-15mm, and a 0.25mm sieve hole is opened on the surface of the second rotating drum.

[0012] As a further solution of the present invention: one end of the drive housing is connected to the feed end, and the other end of the drive housing is connected to the discharge end. The feed end is connected to the silo A, and the discharge end is connected to the silo B. The drive housing includes a feed barrel, and a threaded cavity is opened inside the feed barrel.

[0013] As a further solution of the present invention: the length of the first ball mill is equal to 1 / 2 to 2 / 3 of the length of the second ball mill.

[0014] As a further solution of the present invention: a threaded channel is provided inside the second rotating drum, and the length of the threaded channel is equal to the length of the first ball milling cavity inside the first rotating drum.

[0015] As a further solution of the present invention: a flame monitoring camera is installed inside the rotary kiln, and the flame monitoring camera collects flame images and melt images inside the rotary kiln in real time;

[0016] A machine learning model for identifying the internal temperature and melt mixing degree of the rotary furnace was trained using a CNN network model based on flame and melt images.

[0017] The flame monitoring camera collects flame images inside the rotary kiln in real time and generates the internal temperature of the rotary kiln based on the flame images;

[0018] The flame monitoring camera collects melt images in real time, generates melt mixing degree based on the melt images, and determines the magnetic field strength of the rotating magnetic field generator based on the melt mixing degree.

[0019] Beneficial effects of the present invention:

[0020] 1. In the present invention, by arranging a pneumatic conveying system between the ball mill, screening machine, ultrasonic screening machine and rotary kiln, the full automation, dust-free and low-consumption of aluminum ash treatment is achieved, thereby reducing the recovery and treatment cost of aluminum ash.

[0021] 2. In the present invention, the ball mill and screening integrated machine is set up, and the ball milling and screening in the automatic processing of aluminum ash can be integrated, and since the first drum is rotating, when the steel balls fall on the inner wall of the first drum, it can not only produce a vibration effect on the first drum, but also cause the first drum to produce an oscillation effect, so that the aluminum ash at the top of the inner cavity of the first drum will also fall under the action of the oscillation of the first drum, thereby achieving the self-cleaning effect of the first drum and ensuring the screening effect and screening efficiency of the first drum for 1mm aluminum ash. The second ball mill is set on the outside of the first drum, so the aluminum ash passing through the sieve holes on the first drum will directly enter the second ball mill. During the operation of the first drum, aluminum ash with a small diameter will continuously enter the second ball mill, ensuring that the aluminum ash inside the first drum is all aluminum ash with a larger diameter, which also ensures the working effect of the steel balls in the first drum, so that the aluminum ash in the first drum is all of a diameter that matches the working effect of the steel balls. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be further described below with reference to the accompanying drawings.

[0023] Figure 1 This is a process flow chart of the primary aluminum ash automatic processing system of the present invention;

[0024] Figure 2 This is a schematic diagram of a process for determining the amount of flux added to a rotary furnace by a LIBS online component analyzer in the primary aluminum ash automated processing system of the present invention;

[0025] Figure 3 This is a schematic diagram of the process of adjusting the uniformity of melt mixing inside a rotary furnace by a rotating magnetic field generator in conjunction with a permanent magnet array in the primary aluminum ash automated processing system of the present invention;

[0026] Figure 4 This is a schematic diagram of a process in which a flame monitoring camera in the primary aluminum ash automated processing system of the present invention generates the mixing uniformity of the melt inside the rotary furnace through a CNN network model;

[0027] Figure 5 This is a structural diagram of a ball mill integrated machine in a primary aluminum ash automated processing system of the present invention;

[0028] Figure 6 This is a schematic diagram of the internal structure of the drive housing of the primary aluminum ash automatic processing system of the present invention;

[0029] Figure 7 This is a structural diagram of the drive housing of the primary aluminum ash automatic processing system of the present invention;

[0030] Figure 8 This is a schematic structural diagram of the first ball mill of the primary aluminum ash automated processing system of the present invention;

[0031] Figure 9 This is a schematic structural diagram of the second ball mill of the primary aluminum ash automated processing system of the present invention;

[0032] Figure 10 It is a schematic diagram of the structure of the threaded channel in the second ball mill barrel of the primary aluminum ash automatic processing system of the present invention.

[0033] Explanation of reference numerals: 1. drive housing; 11. feed cylinder; 12. threaded cavity; 2. feed end; 3. discharge end; 4. drive gear ring; 5. support seat; 6. first ball mill; 61. first rotating cylinder; 62. elastic connecting rod; 63. first fixing ring; 64. first ball mill cavity; 65. first protrusion; 66. docking ring; 7. second ball mill; 71. second rotating cylinder; 72. vibration spring; 73. second fixing ring; 74. second protrusion; 75. threaded channel DETAILED DESCRIPTION

[0034] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0035] As an embodiment of the present invention, Figure 1-Figure 5 As shown, the present invention discloses an automatic processing system for primary aluminum ash, including a ball mill, which is used to receive aluminum ash in a silo A and ball-mill the aluminum ash in the silo A. It should be noted that the aluminum ash in the silo A is processed using a ball mill. The ball mill is composed of a cylinder, a grinding medium, a drive system, and a feeding / discharging device. The inner lining of the cylinder is made of a highly wear-resistant material (such as manganese steel or ceramic) for accommodating aluminum ash and grinding media (such as steel balls or ceramic balls). The drive system drives the cylinder to rotate through a motor, a reducer, and gears to provide the power required for grinding. The feeding device evenly feeds the aluminum ash into the interior of the cylinder, and the discharging device cooperates with the screening system to separate the crushed material according to particle size. During the operation of the ball mill, the aluminum ash is repeatedly impacted and rubbed by the grinding medium as the cylinder rotates, and is gradually broken into fine powder.

[0036] The connection between silo A and the ball mill is a circular pipe, which transports the aluminum ash to the inside of the ball mill through wind power.

[0037] The screening machine is used to screen the aluminum ash after ball milling, and transport the aluminum ash to silo A and silo B respectively based on the first particle size of the aluminum ash. The screening machine is used to screen the aluminum ash processed by the ball mill. The first particle size refers to aluminum ash with a particle size of less than or equal to 0.250 mm. The screening machine can transport aluminum ash with a particle size of less than or equal to 0.250 mm to silo B, and transport aluminum ash with a particle size greater than 0.250 mm back to silo A for further processing using the ball mill. It should be emphasized that the screening machine is the core sorting equipment in the ball milling of aluminum ash. Its function is to accurately classify the material after ball milling according to the physical properties of the aluminum ash particles (especially the particle size), thereby optimizing the resource recovery efficiency and forming a closed-loop circulation system. Specifically, the screening machine adopts The vibrating screen or drum screen structure is equipped with a high-strength stainless steel screen (aperture 0.250mm). It is driven by a motor to generate high-frequency vibration or rotational motion, so that the aluminum ash is evenly distributed on the screen surface and the particle size sorting is completed. When the aluminum ash processed by the ball mill enters the feed port of the screening machine, the screening machine uses multi-stage screening technology to separate the material into two flows: fine-particle aluminum ash with a particle size of less than or equal to 0.250mm (i.e., the first particle size standard) passes through the screen under the action of gravity and is transported to silo B through the bottom guide groove for subsequent activation treatment. Coarse-particle aluminum ash with a particle size greater than 0.250mm cannot pass through the screen and is pushed to the tail end of the screening machine with the movement of the screen surface. It is then sent back to silo A through the pneumatic conveying system and waits to enter the ball mill for secondary grinding again.

[0038] The pneumatic conveying system is an automated device that uses compressed air or negative pressure airflow as a power source to efficiently convey powdered and granular materials in a closed pipeline. It includes a conveyor, an elevator, and a pipeline conveying system. In this primary aluminum ash automated processing system, the pneumatic conveying system is mainly used to transport the coarse aluminum ash (particle size > 0.250mm) separated by the screening machine from the tail end of the screening machine to silo A, forming a closed-loop cycle of "screening-returning-regrinding";

[0039] The core working principle of the pneumatic conveying system is based on the dynamics of gas-solid two-phase flow: when the coarse aluminum ash discharged from the screening machine enters the conveying pipeline evenly through the rotary valve or air lock, the airflow (positive or negative pressure) generated by the fan drives the material and air to mix to form a suspended state or dense phase flow state, and moves along the pipeline at a speed of 15-25m / s; during the conveying process, the aluminum ash particles maintain a flowing state under the combined action of the airflow shear force and inertia force, and are directionally transported to the target silo (silo A) through components such as elbows and diverter valves. After reaching the destination, the gas-solid mixture enters the cyclone separator, which uses centrifugal force to separate most of the aluminum ash from the air. The aluminum ash settles to silo A due to gravity, and the remaining dust-laden gas is purified by the bag filter and discharged to ensure that no dust is leaked. The pneumatic conveying system achieves a balance between conveying efficiency and energy consumption by adjusting the fan power, pipeline diameter and air speed (usually 1.5-2 times the material suspension speed).

[0040] In the aluminum ash treatment, the closed design of the pneumatic conveying system completely solves the dust dispersion problem of traditional mechanical conveying (such as belt conveyor). Combined with the dust removal device, the dust concentration in the workshop can be reduced to less than 10mg / m 3 , in compliance with environmental protection regulations, and is particularly suitable for explosion-proof scenarios where aluminum ash easily produces hydrogen when in contact with water;

[0041] The pneumatic conveying system reduces secondary crushing of aluminum ash particles through flexible airflow, avoiding ball mill overload caused by an increase in the proportion of fine powder in the return material, and improving grinding efficiency by approximately 20%-30%. The pneumatic conveying system has a flexible pipeline layout and can cross complex terrain or vertical space, saving factory space. The conveying distance can reach hundreds of meters, meeting the needs of large-scale production lines.

[0042] The pneumatic conveying system dynamically adjusts the conveying volume based on the inventory level in silo A and is linked to the ball mill's current and temperature data to achieve "on-demand material return" and avoid idling or overloading. For example, when the sensor detects that the reserve level in silo A is less than 30%, the system automatically increases the fan speed, increasing the conveying volume from 10t / h to 15t / h. Otherwise, it enters energy-saving standby mode. Wear-resistant ceramic-lined pipes and nitrogen inerting technology can cope with the high abrasiveness and flammability risks of aluminum ash.

[0043] Specifically, the core of the pneumatic conveying system's ability to achieve "on-demand return" by dynamically adjusting the conveying volume lies in dynamically adjusting the fan speed n through a PID controller based on the deviation between the real-time inventory level Vst in silo A and the target set value Vse (usually 30% of the total silo volume, i.e., Vst = 0.3Vse), combined with feedback signals from the ball mill current I and bearing temperature T.

[0044] The relationship between the conveying volume Q and the fan speed is:

[0045]

[0046] Where △P is the pipeline pressure drop, ρ is the air density, k is the system efficiency coefficient (with a value range of 0.6 - 0.8). When Vst < Vse, the controller increases n proportionally according to the deviation e = Vse - Vst. Specifically:

[0047] n target = n0 + Kp×e + Ki×∫edt + Kd×de / dt;

[0048] Where, n target is the target rotational speed, Kp, Ki, and Kd are PID parameters, n0 is the initial rotational speed value of the fan. The current I of the ball mill can be limited to 85% of the rated value of the ball mill. If the current I of the ball mill exceeds the threshold value, the rotational speed of the fan is automatically reduced to prevent overload.

[0049] The ultrasonic circular sieve divides the aluminum ash in bin B into finished aluminum ash and coarse aluminum ash based on the second particle size of the aluminum ash. Here, the second particle size refers to the aluminum ash with a particle size less than or equal to 0.125 mm. The ultrasonic circular sieve performs multi-stage screening on the aluminum ash through the combined action of high-frequency ultrasonic waves (20 - 40 kHz) and mechanical vibration. The classification accuracy can reach ±0.005 mm. The ultrasonic transducer converts electrical energy into high-frequency mechanical waves, causing the screen surface to vibrate with a micron-level amplitude (3 - 5 μm). By using the cavitation effect, the electrostatic adsorption and wet agglomeration between particles are broken, realizing real-time self-cleaning of the screen. Compared with traditional vibrating screens, the screen blockage rate is reduced by more than 90%, and the continuous operation time is extended from 2 hours to 48 hours. Bin B can transport the aluminum ash with a particle size less than or equal to 0.250 mm inside it to the ultrasonic circular sieve through a pneumatic conveying system. The ultrasonic circular sieve will screen the aluminum ash with a particle size of 0.250 mm. After screening out the aluminum ash with a particle size less than or equal to 0.125 mm, it is directly bagged, and the aluminum ash with a particle size greater than 0.125 mm is transported to the rotary furnace;

[0050] The rotary furnace receives coarse aluminum ash and coarse material, adds flux, and melts them at high temperatures to produce molten aluminum and roasted aluminum ash. It should be noted that the core principle of the rotary furnace's treatment of coarse aluminum ash is to utilize the synergistic effect of high-temperature melting and flux chemistry to break the physical bond between aluminum and other oxides (such as SiO2 and MgO), achieving the aggregation and separation of metallic aluminum. Once the coarse aluminum ash and flux (typically mixed in a mass ratio of 10:1-10:3) enter the rotary furnace cylinder from the feed end, the cylinder rotates at a speed of 1-3 rpm. At an inclination angle of 2°-5°, the material gradually moves toward the high-temperature zone (1100-1300°C). Flux performs three major functions in this process: First, it lowers the melting point of the system. For example, cryolite (Na3AlF6) can reduce the melting point of aluminum ash from 2050°C to 900-1000°C, significantly reducing energy consumption. Second, it promotes the aggregation of aluminum droplets. The fluoride ions (F-) in the flux adsorb on the surface of the molten aluminum, reducing its interfacial tension, causing dispersed micron-sized aluminum droplets to aggregate into millimeter-sized aluminum beads, increasing the sedimentation rate by 3-5 times. Third, it facilitates slag separation. The flux reacts with impurity oxides to form low-density slag (such as Na2SiO3 and MgF2), which floats to the surface of the melt and separates from the bottom layer of molten aluminum. After smelting, the mixed melt is allowed to stand and separate at the discharge end (usually for 10-30 minutes). The bottom layer of molten aluminum is discharged to the ingot casting machine through a siphon device. The middle layer of flux can be recycled, while the upper layer of roasted aluminum ash (containing Al2O3, Na2O, etc.) is conveyed to a cold ash drum for crushing and screening.

[0051] The cold ash barrel receives the roasted aluminum ash generated by the rotary furnace and crushes and screens the roasted aluminum ash. The cold ash barrel transports the roasted aluminum ash to the rotary furnace and silo A respectively based on the third particle size, wherein the third particle size refers to aluminum ash with a particle size less than or equal to 15 mm. The cold ash barrel crushes and screens the roasted aluminum ash, and transports the aluminum ash with a particle size less than or equal to 15 mm to silo A through a pneumatic conveying system, and uses a ball mill for processing. The aluminum ash with a particle size greater than 15 mm is transported back to the rotary furnace for further processing. Through the recycling treatment of the rotary furnace and the cold ash barrel, the entire primary aluminum ash processing system can be guaranteed to be dust-free, the raw material utilization rate reaches 100%, no waste is generated, and the processing cost of the aluminum ash is greatly reduced.

[0052] As an embodiment of the present invention, Figure 1-Figure 5 As shown in FIG1 , a microwave transmitter is integrated inside silo A to activate the aluminum ash in silo A. It should be noted that the microwave transmitter can generate electromagnetic waves (frequency 300MHz-300GHz, commonly 2.45GHz) inside silo A. The electromagnetic waves will interact with the aluminum ash inside silo A. The microwaves quickly heat the aluminum (locally up to 600-800℃), causing the oxide film (Al2O3) on its surface to expand due to the difference in thermal expansion coefficient (Al: 23×10 -6 / ℃vs.Al2O3:8×10-6 / ℃) to produce micro cracks, exposing the fresh aluminum surface and improving the stripping efficiency of metal aluminum during ball milling. The non-thermal effect of microwaves promotes the O 2 - Ionic vibration is intensified, forming active sites. The subsequent acid leaching extraction rate can be increased from 75% in conventional heat treatment to over 90%. Microwave heating causes NaCl / KCl to melt rapidly (melting point 801 / 776°C) and partially vaporize, reducing salt adhesion and contamination of the ball milling media.

[0053] 8-12 magnetrons (power 3-6kW / group, total power 24-72kW) are arranged circumferentially on the inner wall of silo A, with an operating frequency of 2.45GHz±50MHz. Uniform microwave radiation is achieved through waveguide couplers and circulators. Based on the bulk density of aluminum ash inside silo A, the microwave penetration depth is calculated as follows:

[0054]

[0055] Where λ0 is the free space wavelength (λ0≈12.2cm at 2.45GHz), ε is the complex dielectric constant of aluminum ash, and ε is composed of ε' (real part of the complex dielectric constant) and ε" (imaginary part of the complex dielectric constant). If the average ε' of aluminum ash is 8.5 and ε" is 0.25, we can get D p ≈7.3cm. Based on this, the thickness of the ash layer in silo A is designed to be ≤15cm, ensuring full penetration of microwaves, which helps to fully activate the aluminum ash inside silo A and avoid uneven treatment.

[0056] Microwave emitters rely on the coupling of electromagnetic wave energy and dielectric properties of materials. Aluminum in aluminum ash is a good conductor. Under the microwave alternating electric field, it generates surface eddy currents due to the skin effect. The local temperature can rise to 600-800℃ within tens of seconds, resulting in the surface aluminum oxide layer (Al2O3) to be heated due to the difference in thermal expansion coefficient with the aluminum matrix (Al: 23×10 -6 / ℃vs.Al2O3:8×10 -6 / ℃) cracked, exposing the fresh aluminum surface; and aluminum oxide is a polar medium, and the O in its lattice 2 - ions vibrate at high frequencies under the action of microwave field, which promotes the transformation of crystal structure from γ type to highly active θ type, and the specific surface area is increased from 5m 2 / g increased to 15m 2 / g or more, for salts such as NaCl and KCl contained in aluminum ash, microwave heating can make them melt quickly (melting point 801℃ / 776℃) and partially vaporize, and the gaseous salts are converted into high-purity crystalline salts (Cl- recovery rate ≥95%) through the condensation recovery system, and the residual salt content is reduced from the initial 8%-15% to below 0.3%, effectively avoiding the problem of efficiency loss caused by salt adhesion to grinding media during ball milling.

[0057] The silo A can be divided into an upper cavity and a lower cavity, the lower cavity serves as a microwave cavity, and the upper cavity serves as a receiving cavity. The receiving threshold of the upper cavity is preset by technical personnel in this field. When the amount of aluminum ash received in the upper cavity reaches the set value, and the lower cavity completes microwave activation and is transported to the ball mill, the upper cavity can transport the aluminum ash inside it to the lower cavity, and microwave activation treatment is carried out in the lower cavity. An electromagnetic valve can be set between the upper cavity and the lower cavity to ensure that the connection between the upper cavity and the lower cavity can be automatically controlled.

[0058] As an embodiment of the present invention, Figures 1-10 As shown, the ball mill and screening machine includes a drive housing 1, and a first ball mill 6 and a second ball mill 7 are provided inside the drive housing 1. The first ball mill 6 performs coarse ball milling on the aluminum ash, and the second ball mill 7 performs fine ball milling on the aluminum ash after the coarse ball milling. It should be noted that the first ball mill 6 is used for ball milling larger aluminum ash (usually with a diameter of 5mm-15mm), and the second ball mill 7 is used for ball milling smaller aluminum ash (usually with a diameter of 1mm-5mm).

[0059] It should also be noted that the first ball mill 6 performs coarse ball milling on the large aluminum ash, and the second ball mill 7 performs fine ball milling on the small aluminum ash, so that the ball mill and screening machine can perform adaptive ball milling on different aluminum ashes, ensuring the working efficiency and working effect of the ball mill and screening machine.

[0060] The first ball mill 6 includes a first rotating drum 61, and the outer side surface of the first rotating drum 61 is fixedly connected to an elastic connecting rod 62, and the end of the elastic connecting rod 62 is fixedly connected to a first fixing ring 63, and the first fixing ring 63 is fixedly connected to the inner wall of the driving shell 1. It should be noted that the elastic connecting rod 62 is used to install the first rotating drum 61 on the inner side of the driving shell 1 through the first fixing ring 63. The elastic connecting rod 62 is adaptively selected by technical personnel in this field according to existing materials to ensure that when the first rotating drum 61 rotates, the steel balls inside it can cooperate with the elastic connecting rod 62 to make the first rotating drum 61 vibrate when hitting the inner wall of the first rotating drum 61. That is to say, when the first rotating drum 61 rotates, the steel balls can make the first rotating drum 61 vibrate when ball milling the aluminum ash inside it.

[0061] The first rotating drum 61 is provided with a first ball milling chamber 64 inside, and the inner wall of the first ball milling chamber 64 is fixedly connected with a first protrusion 65. The interior of the first ball milling chamber 64 is filled with a plurality of steel balls with a diameter of 40-60 mm. The surface of the first rotating drum 61 is provided with a sieve hole of 1 mm-5 mm. It should be noted that the number of the first protrusions 65 is several and evenly distributed on the inner wall of the first ball milling chamber 64. When the first rotating drum 61 rotates, the first rotating drum 61 will scrape up the steel balls inside it through the first protrusion 65, so that the steel balls can reach the middle position of the inner cavity space of the first rotating drum 61, and then fall down to hammer and grind the aluminum ash inside the first rotating drum 61, thereby achieving the effect of ball milling and continuously reducing the diameter of the aluminum ash. Since the surface of the first rotating drum 61 is provided with a sieve hole of 1 mm-5 mm, preferably 1 mm, when the diameter of the aluminum ash inside the first rotating drum 61 is less than 1 mm, the aluminum ash will fall through the sieve hole. The sieve hole is determined by a person skilled in the art according to the outer surface of the first rotating drum 61. The area is adjusted adaptively to ensure that 1mm aluminum ash can be screened, and since the first drum 61 is rotating, when the steel ball falls on the inner wall of the first drum 61, it can not only produce a vibration effect on the first drum 61, but also cause the first drum 61 to produce an oscillation effect, so that the aluminum ash at the top of the inner cavity of the first drum 61 will also fall under the action of the oscillation of the first drum 61, thereby achieving the self-cleaning effect of the first drum 61 and ensuring the screening effect and screening efficiency of the first drum 61 for 1mm aluminum ash. The second ball mill 7 is arranged on the outside of the first drum 61, so the aluminum ash passing through the sieve holes on the first drum 61 will directly enter the second ball mill 7. During the operation of the first drum 61, aluminum ash with a small diameter will continuously enter the second ball mill 7, ensuring that the aluminum ash inside the first drum 61 is all aluminum ash with a larger diameter, which also ensures the working effect of the steel balls in the first drum 61, so that the aluminum ash in the first drum 61 is all of a diameter that fits the working effect of the steel balls.

[0062] The second ball mill 7 includes a second rotating drum 71, and the end portion of the inner side surface of the second rotating drum 71 is fixedly connected to a vibration spring 72, and the end portion of the vibration spring 72 is fixedly connected to a second fixing ring 73, and the second fixing ring 73 is fixedly connected to the outer side surface of the first rotating drum 61. It should be noted that the second rotating drum 71 is fixedly connected to the docking ring 66 on the side surface of the first rotating drum 61 through the vibration spring 72 and the second fixing ring 73. Since the second rotating drum 71 and the first rotating drum 61 are connected through the vibration spring 72, when the first rotating drum 61 generates a vibration effect, the first rotating drum 61 will also transmit the vibration to the second rotating drum 71 through the vibration spring 72, so that the second rotating drum 71 generates a vibration effect.

[0063] The inner wall of the second drum 71 is fixedly connected with a second protrusion 74, and the interior of the second drum 71 is filled with a number of steel balls with a diameter of 5mm-15mm. The surface of the second drum 71 is provided with a 0.25mm sieve hole. It should be noted that 0.25mm is the first particle size, and the specific particle size can be adaptively adjusted by those skilled in the art according to the diameter of the aluminum ash as needed. The working raw material of the aluminum ash inside the second drum 71 is the same as the working principle of the aluminum ash in the first drum 61, which will not be elaborated here. The difference is that the second drum 71 can screen aluminum ash with a diameter of 0.25mm. When the diameter of the aluminum ash is less than 0.25mm, it will pass through the sieve hole on the second drum 71 and enter the drive housing 1.

[0064] One end of the drive housing 1 is connected to the feed end 2, and the other end of the drive housing 1 is connected to the discharge end 3. The feed end 2 is communicated with the silo A, and the discharge end 3 is communicated with the silo B. The drive housing 1 includes a feeding cylinder 11, and a threaded cavity 12 is opened inside the feeding cylinder 11. It should be noted that a discharge port is provided at the bottom end of the discharge end 3 near the feeding cylinder 11. When aluminum ash with a diameter of 0.25 mm enters the feeding cylinder 11, the rotation of the feeding cylinder 11 cooperates with the threaded cavity 12, so that the aluminum ash can be transported to the discharge port on the discharge end 3, and then enter the silo B through the discharge port;

[0065] A driving ring gear 4 is fixedly connected to the side of the driving housing 1, and a support base 5 is installed on the outer side of the driving housing 1. A motor can be set on the support base 5, and the output shaft of the motor is engaged with the driving ring gear 4 through a gear. In this way, the power of the motor can be transmitted to the driving ring gear 4 through the gear, and then the driving housing 1 is driven to rotate through the driving ring gear 4.

[0066] The length of the first ball mill 6 is equal to 1 / 2 to 2 / 3 of the length of the second ball mill 7. A threaded channel 75 is provided inside the second rotating drum 71. The length of the threaded channel 75 is equal to the length of the first ball mill cavity 64 inside the first rotating drum 61. It should be noted that an extension rod (not shown in the figure) should be provided at the end of the first rotating drum 61, and the extension rod is fixedly connected to the inner end of the drive housing 1 through an elastic connecting rod 62 and a first fixing ring 63 with the inner cavity of the drive housing 1. The purpose of this arrangement is to ensure that the first ball mill 6 does not affect the impact operation of the steel balls inside the second rotating drum 71. Figure 10 As shown, when the aluminum ash in the first ball mill chamber 64 passes through the sieve hole, it will fall into the corresponding threaded channel 74 in the second rotating drum 71. When the threaded channel 74 rotates, the aluminum ash can be transported to the position corresponding to the second protrusion 74 in the second rotating drum 71. The threaded channel 74 can also prevent the steel balls inside it from entering the threaded channel 74, ensuring that the aluminum ash can be transported between the first ball mill 6, the second ball mill 7 and the drive housing 1.

[0067] It should be noted that the amplitude of the first ball mill 6 and the second ball mill 7 is between 1 mm and 2 mm. Therefore, the gap between the first ball mill 6 and the second ball mill 7 in the accompanying drawings is an exaggerated schematic diagram. The specific gap between the first ball mill 6 and the second ball mill 7 can be adaptively determined by those skilled in the art to ensure that it does not affect the vibration of the first ball mill 6 and the second ball mill 7.

[0068] As an embodiment of the present invention, Figure 1-Figure 5 As shown, a LIBS online component analyzer is installed at the feed port of the rotary kiln, and a permanent magnet array is embedded in the inner wall of the rotary kiln. The melt inside the rotary kiln is non-contact stirred by an external rotating magnetic field generator of the rotary kiln. The LIBS online component analyzer is used to detect the Si and Fe contents in the coarse aluminum ash and coarse material in real time, and the amount of flux added is determined based on the Si and Fe contents. It should be noted that the LIBS online component analyzer is installed 1-2m downstream of the feed port of the rotary kiln, tilted at 30° (to avoid direct impact of the material), and equipped with a nitrogen purge system (flow rate 5-10L / min) to prevent dust from adhering to the lens. The technical parameters of the LIBS online component analyzer include laser wavelength: 1064nm, pulse energy 100mJ, repetition frequency 10Hz; detection elements: Si (251.6nm spectral line), Fe (238.2nm spectral line), detection limit ≤0.05wt%; sampling frequency: once every x seconds (the specific acquisition frequency is adaptively adjusted by those skilled in the art according to actual conditions), and the data is collected through OPC UA protocol is used to transmit data to PLC. OPC UA is a cross-platform, secure and reliable data communication protocol widely used in the field of industrial automation. It aims to achieve standardized data interaction between devices, systems and upper-level management platforms. OPC UA supports Windows, Linux, embedded systems (such as PLC, RTU) and cloud deployment, and gets rid of the traditional OPC's dependence on Windows DCOM. It provides C / C++, Java, Python, .NET and other language SDKs to facilitate cross-platform integration. It is based on object-oriented information modeling and supports custom complex data types (such as structures and arrays). It has a built-in basic information model and can be expanded to industry-specific models (such as PackML and PLCopen). OPC UA realizes data interoperability between PLC (such as Siemens S7-1500), DCS and SCADA systems, and solves the compatibility issues of multi-vendor protocols (such as Modbus and Profinet). The LIBS online component analyzer of the rotary kiln (as OPC UA server) transmits Si / Fe content data to PLC (client) in real time, directly connecting data from the field layer (equipment) to the MES / ERP system, eliminating the intermediate conversion layer;

[0069] The inner wall of the rotary kiln is embedded with a permanent magnet array in the following manner: NdFeB permanent magnets (grade N52) are equidistantly embedded in the inner wall of the rotary kiln in the axial direction, with 12 magnets per circle and a spacing of 50 mm (the specific spacing can also be adjusted by those skilled in the art according to the specifications of the rotary kiln). The polarity is alternately arranged (NSNS) to form an axial magnetic field gradient. The surface of the permanent magnet is coated with a yttria-stabilized zirconia (YSZ) coating (thickness 1 mm). The resistance temperature is ≥1300°C, and the magnetic field strength in the melt area of the furnace is 50-100 mT.

[0070] The rotary kiln's external rotating magnetic field generator consists of three sets of water-cooled copper electromagnetic coils (120 turns per set, 6mm wire diameter) with a phase difference of 120° to form a rotating magnetic field. The driving parameters of the rotary kiln's external rotating magnetic field generator include frequency range: 1-50Hz (corresponding to melt speed 0.1-5r / s); current intensity: 0-200A (corresponding to magnetic field intensity 0.1-0.5T); power module: IGBT inverter, response time ≤10ms;

[0071] The specific process of real-time component detection and flux calculation by the LIBS online component analyzer is:

[0072] The LIBS online composition analyzer obtained Si and Fe contents (denoted as [Si], [Fe]) every 30 s, and the data were filtered using sliding window averaging (window size = 5);

[0073] The calculation formula for the amount of flux (cryolite Na3AlF6) added is:

[0074] M flux =k Si ×[Si]+k Fe ×[Fe]+M base ;

[0075] Among them, k Si =0.8(kg flux / %Si), k Fe =1.2(kg flux / %Fe), M base =mkg / t (m is the basic addition amount);

[0076] Rotating magnetic field stirring control:

[0077] Adjust the magnetic field parameters according to the melt viscosity and the total amount of [Si]+[Fe]:

[0078] f=Q+2([Si]+[Fe]), I=m+30([Si]+[Fe]);

[0079] Where f is the magnetic field frequency (Hz), I is the magnetic field current (A), and Q is the feed rate of the rotary kiln (t / h);

[0080] In summary, the LIBS online composition analyzer is used to detect the Si and Fe contents in coarse aluminum ash and coarse materials in real time. The amount of flux added is determined based on the Si and Fe contents, which can improve the removal efficiency of Si and Fe. By embedding a permanent magnet array in the inner wall of the rotary kiln, non-contact stirring optimization is achieved, which improves the mixing uniformity of the melt inside the rotary kiln, reduces the axial temperature difference in the rotary kiln from ±50°C to ±15°C, and reduces the fluctuation of thermocouple data by 60%. Non-contact stirring reduces mechanical wear, reduces the maintenance frequency of the rotary kiln, and indirectly reduces maintenance costs.

[0081] As an embodiment of the present invention, Figure 1-Figure 5 As shown, a flame monitoring camera is installed inside the rotary furnace. The flame monitoring camera collects flame images and melt images inside the rotary furnace in real time. Based on the flame images and melt images, a CNN network model is used to train a machine learning model to identify the internal temperature and melt mixing degree of the rotary furnace. The flame monitoring camera collects flame images inside the rotary furnace in real time and generates the internal temperature of the rotary furnace based on the flame images. It should be noted that the flame monitoring camera uses a high-temperature resistant (≥1500℃) industrial-grade infrared-visible light dual-mode camera (such as FLIRAX8) and supports HDR Imaging (120dB), frame rate ≥30fps, resolution 1920×1080, flame monitoring camera adopts protective design, uses circulating cooling water (flow rate 10L / min, inlet temperature ≤25℃) to protect the lens, the flame monitoring camera is installed at the rear observation port of the rotary furnace, tilted 30° toward the center of the molten pool, and the field of view covers 80% of the melt surface. It is also important to note that K-type thermocouples (0-1600℃, accuracy ±1℃) need to be arranged along the axial direction of the rotary furnace body, one group every 0.5 meters, a total of 6 groups, to collect actual temperatures as training labels;

[0082] Data collection and preprocessing:

[0083] The flame monitoring camera pre-collects N sets of data (N is a positive integer greater than 0, and the number of N is adaptively adjusted by those skilled in the art based on the specific model training situation) (flame image + melt image + temperature label + mixing degree label), and divides them into training set, validation set, and test set according to the ratio of 8:1:1;

[0084] Use OpenCV Mask R-CNN to segment the flame and melt regions, crop the valid regions (flame: 500×500 pixels, melt: 800×600 pixels), and then perform enhancement and normalization on the valid regions. The enhancement and normalization processes include histogram equalization (to increase the contrast of low-light areas), Gaussian filtering (σ=1.5) to remove high-frequency noise, and normalization (scaling pixel values to [0, 1]).

[0085] CNN model construction and training:

[0086] The flame image and melt image are fed into separate CNN branches. After high-level feature fusion, the output is temperature (regression) and mixing degree (classification). The flame branch uses ResNet-18 (pre-trained weights) to output 512-dimensional features. The melt branch uses a custom lightweight network (4 layers of Conv + 2 layers of LSTM to capture temporal flow). The fusion layer: features are concatenated and then passed through a fully connected layer (256→64→2).

[0087] Model deployment and real-time inference:

[0088] Input flame image ROI, output molten pool average temperature T (±15°C error), input melt image ROI, output probability distribution (P(M=1)≥0.9 indicates complete mixing). If the average temperature T exceeds the set range (e.g., 1300±50°C), trigger gas valve opening adjustment (PID control, Δ opening = K_p·ΔT). If P(M=1)<0.8, increase magnetic field stirring frequency (Δf=5Hz) or extend melting time (Δt=5min).

[0089] Verification and continuous optimization:

[0090] Model predictions are compared with thermocouple / XRF data every 24 hours. If MAE remains >20°C or F1 is <0.85, model fine-tuning (10% new data) is triggered. Online learning frameworks (such as River) are integrated to incrementally update model parameters. Grafana displays temperature curves, mixing heat maps, and model confidence in real time. Audible and visual alarms are triggered when the temperature exceeds the limit (>1350°C) or the mixing drops sharply (ΔM>0.2 / 10min).

[0091] A machine learning model was trained using a CNN network model to identify the temperature and melt mixing degree inside the rotary furnace. The accuracy of traditional manual control has been reduced from ±80°C to ±25°C, and the gas valve response time has been shortened from minutes to seconds. The rotary furnace can provide a 5-10 minute advance warning of local overheating (>1350°C) or low-temperature solidification (<1250°C) risks. The material mixing index M inside the rotary furnace has been improved from 0.75-0.85 to 0.90-0.95. The standard deviation of the metal aluminum particle distribution has been reduced by 40%, and the melt content fluctuation has been reduced from ±3% to ±0.8%. The uniformity of Si / Fe impurity distribution has been doubled. Flame morphology recognition can automatically identify faults such as gas nozzle blockage and incomplete combustion.

[0092] The flame monitoring camera can also monitor flame stability in real time, increase the accuracy of hydrogen accumulation risk warning, reduce the accident rate, and reduce the operator's exposure time to high temperature environments, thereby improving the operator's personal safety.

[0093] As an embodiment of the present invention, Figure 1-Figure 5As shown, the flame monitoring camera collects melt images in real time, generates melt mixing degree based on the melt images, and determines the magnetic field strength of the rotating magnetic field generator based on the melt mixing degree. It should be noted that the flame monitoring camera adopts the above-mentioned technical solution, specifically:

[0094] The flame monitoring camera pre-collects N groups of data (N is a positive integer greater than 0, and the number of N is adaptively adjusted by technicians in this field based on the specific model training situation). It should be noted that the LIBS online composition analyzer needs to be used simultaneously to provide melt composition data (Al, Si, and Fe content) inside the rotary kiln.

[0095] The degree of mixing is defined as:

[0096]

[0097] Among them, Al 实际 is the Al content collected by LIBS online composition analyzer, Al 目标 The target content is preset by those skilled in the art, M = 1 indicates complete mixing, and M < 0.8 requires triggering magnetic field mixing;

[0098] The method for determining the magnetic field strength of the rotating magnetic field generator based on the melt mixing degree is:

[0099] ResNet-50 (pre-trained weights), outputting a 1024-dimensional feature vector, adding a Bi-LSTM layer (128 hidden units) to capture the melt flow temporal characteristics, a fully connected layer (256→64→1), and outputting the mixing degree M∈[0,1];

[0100] Use Smooth L1 Loss to balance outlier sensitivity;

[0101] The mixing degree-magnetic field strength control strategy is:

[0102] Determine the target mixing degree M 目标 =0.95, with an allowable fluctuation range of ±0.03, and then the PID algorithm is used to deliver the current I corresponding to the magnetic field strength that needs to be adjusted. 调控 ; Constraints need to be set in advance: current intensity is limited to 0-200A, frequency is limited to 1-50Hz;

[0103] Process one frame every 33ms (30fps) and output the current M. If |M-0.95|>0.03, trigger magnetic field adjustment;

[0104] The mixing degree is too low (M<0.92): increase the current ΔI=Q(0.95-M). For example, when M=0.90, Q is the feed rate of the rotary kiln; for example, when Q=30t / h, ΔI=30×0.05=1.5A, then the current required to increase the stirring magnetic field is 1.5A;

[0105] Excessive mixing (M>0.98): Reduce the frequency Δf = -5Hz and reduce the stirring intensity;

[0106] By analyzing the degree of mixing in real time through melt images and dynamically adjusting the magnetic field intensity, the system realizes intelligent closed-loop control of the smelting process. The magnetic field drives the melt to improve uniformity, reduces the energy consumption required for magnetic field-driven melt, and reduces the cost of aluminum ash treatment.

[0107] The above is a detailed description of an embodiment of the present invention. However, the content described is only a preferred embodiment of the present invention and should not be considered to limit the scope of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.

Claims

1. A primary aluminum ash automatic processing system, characterized by: include: A ball mill and screening machine is used to receive aluminum ash from silo A, ball mill the aluminum ash in silo A, screen the milled aluminum ash, and transport the aluminum ash to silo A and silo B respectively based on the first particle size of the aluminum ash; An ultrasonic circular screen is used to separate the aluminum ash in the silo B into finished aluminum ash and coarse aluminum ash based on the second particle size of the aluminum ash. A rotary furnace receives coarse aluminum ash and coarse materials, adds flux to melt the coarse aluminum ash and coarse materials at high temperature, and generates molten aluminum and roasted aluminum ash; The cold ash barrel receives the roasted aluminum ash generated by the rotary furnace and crushes and screens the roasted aluminum ash. The cold ash barrel transports the roasted aluminum ash to the rotary furnace and silo A respectively based on the third particle size.

2. The primary aluminum ash automatic processing system according to claim 1 is characterized in that: The ball mill and screening integrated machine comprises a drive housing (1), wherein a first ball mill (6) and a second ball mill (7) are arranged inside the drive housing (1); the first ball mill (6) performs coarse ball milling on aluminum ash, and the second ball mill (7) performs fine ball milling on the aluminum ash after the coarse ball milling.

3. The primary aluminum ash automatic processing system according to claim 2, characterized in that: The first ball mill (6) comprises a first rotating cylinder (61), the outer side surface of the first rotating cylinder (61) is fixedly connected to an elastic connecting rod (62), the end of the elastic connecting rod (62) is fixedly connected to a first fixing ring (63), and the first fixing ring (63) is fixedly connected to the inner wall of the drive housing (1).

4. The primary aluminum ash automatic processing system according to claim 3 is characterized in that: A first ball milling cavity (64) is provided inside the first rotating drum (61), a first protrusion (65) is fixedly connected to the inner wall of the first ball milling cavity (64), the interior of the first ball milling cavity (64) is filled with a plurality of steel balls with a diameter of 40-60 mm, and a sieve hole of 1 mm to 5 mm is opened on the surface of the first rotating drum (61).

5. The primary aluminum ash automatic processing system according to claim 2, characterized in that: The second ball mill (7) comprises a second rotating cylinder (71), the inner side end of the second rotating cylinder (71) is fixedly connected to a vibration spring (72), the end of the vibration spring (72) is fixedly connected to a second fixing ring (73), and the second fixing ring (73) is fixedly connected to the outer side of the first rotating cylinder (61).

6. The primary aluminum ash automatic processing system according to claim 1 is characterized in that: The inner wall of the second rotating drum (71) is fixedly connected with a second protrusion (74), the interior of the second rotating drum (71) is filled with a plurality of steel balls with a diameter of 5mm-15mm, and the surface of the second rotating drum (71) is provided with a 0.25mm sieve hole.

7. The primary aluminum ash automatic processing system according to claim 1, characterized in that: One end of the drive housing (1) is connected to a feed end (2), and the other end of the drive housing (1) is connected to a discharge end (3). The feed end (2) is communicated with a silo A, and the discharge end (3) is communicated with a silo B. The drive housing (1) includes a feed barrel (11), and a threaded cavity (12) is provided inside the feed barrel (11).

8. The primary aluminum ash automatic processing system according to claim 2, characterized in that: The length of the first ball mill (6) is equal to 1 / 2 to 2 / 3 of the length of the second ball mill (7).

9. The primary aluminum ash automatic processing system according to claim 6, characterized in that: A threaded channel (75) is provided inside the second rotating cylinder (71), and the length of the threaded channel (75) is equal to the length of the first ball milling cavity (64) inside the first rotating cylinder (61).

10. The primary aluminum ash automatic processing system according to claim 1, characterized in that: A flame monitoring camera is installed inside the rotary kiln to collect flame images and melt images inside the rotary kiln in real time; A machine learning model for identifying the internal temperature and melt mixing degree of the rotary furnace was trained using a CNN network model based on flame and melt images. The flame monitoring camera collects flame images inside the rotary kiln in real time and generates the internal temperature of the rotary kiln based on the flame images; The flame monitoring camera collects melt images in real time, generates melt mixing degree based on the melt images, and determines the magnetic field strength of the rotating magnetic field generator based on the melt mixing degree.

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