Automatic processing system for primary aluminum dross

Abstract

This invention discloses an automated aluminum ash processing system, relating to the field of aluminum ash recycling technology. The system includes a ball mill and screening integrated machine, an ultrasonic circular screen, a rotary kiln, and a cold ash bin. The ball mill and screening integrated machine receives aluminum ash from bin A, ball mills the ash, and screens the milled ash. Based on the first particle size, the ash is conveyed to bins A and B respectively. The ultrasonic circular screen separates the ash in bin B into finished aluminum ash and coarse aluminum ash based on the second particle size. The rotary kiln receives the coarse aluminum ash and coarse material, adds flux, and melts them at high temperature to generate molten aluminum and roasted aluminum ash. By setting up a pneumatic conveying system between the ball mill, screening machine, ultrasonic screening machine, and rotary kiln, the entire aluminum ash processing process is automated, dust-free, and low-consumption, reducing the cost of aluminum ash recycling.

Description

Technical Field

[0001] This invention relates to the field of aluminum ash recycling technology, and more specifically to an automated primary aluminum ash processing system. Background Technology

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

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

[0004] In order to overcome the above-mentioned technical problems, the purpose of this invention is to provide an automated aluminum ash processing system to solve the problem that in the prior art, aluminum ash processing and recycling systems generate a certain amount of aluminum ash dust when processing aluminum ash, which leads to the inability to guarantee dust-free and low-consumption processes during aluminum ash recycling.

[0005] The objective of this invention can be achieved through the following technical solutions:

[0006] Specifically, it provides an automated aluminum ash processing system, including a ball mill and screening machine, an ultrasonic circular screen, a rotary kiln, and a cold ash bin. The ball mill and screening machine receives aluminum ash from silo A, ball mills the ash, and screens it. Based on the first particle size, the aluminum ash is conveyed to silos A and B respectively. The ultrasonic circular screen separates the aluminum ash in silo B into finished aluminum ash and coarse aluminum ash based on the second particle size. The rotary kiln receives the coarse aluminum ash and coarse material, adds flux, and melts them at high temperature to produce molten aluminum and roasted aluminum ash. The cold ash bin receives the roasted aluminum ash generated by the rotary kiln, crushes and screens it, and conveys the roasted aluminum ash to the rotary kiln and silo A respectively based on the third particle size.

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

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

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

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

[0011] As a further aspect of the present invention: the inner wall of the second rotating cylinder is fixedly connected with a second protrusion, the interior of the second rotating cylinder is filled with several steel balls with a diameter of 5mm-15mm, and the surface of the second rotating cylinder is provided with 0.25mm sieve holes.

[0012] As a further embodiment 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 hopper A, and the discharge end is connected to the hopper B. The drive housing includes a conveying cylinder, and the inside of the conveying cylinder is provided with a threaded cavity.

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

[0014] As a further aspect of the present invention: the interior of the second rotating drum is provided with a threaded channel, the length of which is equal to the length of the first ball mill cavity inside the first rotating drum.

[0015] As a further aspect 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 was trained using a CNN network model based on flame and melt images to identify the internal temperature and melt mixing degree of the rotary kiln.

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

[0018] The flame monitoring camera acquires images of the melt in real time, generates the 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] The beneficial effects of this invention are:

[0020] 1. In this invention, by setting up a pneumatic conveying system between the ball mill, screening machine, ultrasonic screening machine and rotary kiln, the entire process of aluminum ash treatment is automated, dust-free and low-consumption, thus reducing the cost of aluminum ash recycling and treatment.

[0021] 2. In this invention, the integrated ball mill and screening machine enables the integrated ball milling and screening of aluminum ash in automated processing. Since the first rotating drum is rotating, the steel balls falling onto its inner wall not only vibrate the drum but also create an oscillation effect. This causes the aluminum ash at the top of the first drum's inner cavity to fall under the oscillation, achieving a self-cleaning effect and ensuring the first drum's screening effect and efficiency for 1mm aluminum ash. The second ball mill is located outside the first rotating drum, allowing aluminum ash passing through the sieve holes of the first drum to directly enter the second ball mill. During the operation of the first drum, smaller diameter aluminum ash continuously enters the second ball mill, ensuring that the aluminum ash inside the first drum is all larger diameter. This also ensures the working effect of the steel balls in the first drum, ensuring that the aluminum ash in the first drum is of a diameter suitable for the working effect of the steel balls. Attached Figure Description

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

[0023] Figure 1 This is a process flow diagram of the automated aluminum ash processing system of the present invention;

[0024] Figure 2 This is a schematic diagram of the process for determining the amount of flux added to the rotary kiln using the LIBS online composition analyzer in the automated aluminum ash processing system of this invention.

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

[0026] Figure 4 This is a schematic diagram of the process of generating the mixing uniformity of the melt inside the rotary kiln through a CNN network model in the automatic aluminum ash processing system of the present invention;

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

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

[0029] Figure 7 This is a schematic diagram of the structure of the drive housing of the automated aluminum ash processing system of the present invention;

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

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

[0032] Figure 10 This is a schematic diagram of the threaded channel structure in the second ball mill cylinder of the automated aluminum ash processing system of the present invention.

[0033] Explanation of reference numerals in the attached drawings: 1. Drive housing; 11. Feed cylinder; 12. Threaded cavity; 2. Feed end; 3. Discharge end; 4. Drive gear ring; 5. Support base; 6. First ball mill cylinder; 61. First rotating cylinder; 62. Elastic connecting rod; 63. First fixing ring; 64. First ball mill cavity; 65. First protrusion; 66. Connecting ring; 7. Second ball mill cylinder; 71. Second rotating cylinder; 72. Vibration spring; 73. Second fixing ring; 74. Second protrusion; 75. Threaded channel Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] As one embodiment of the present invention, such as Figures 1-5 As shown, this invention discloses an automated aluminum ash processing system, including a ball mill for receiving aluminum ash from silo A and ball milling the aluminum ash in silo A. It should be noted that the aluminum ash in silo A is processed by a ball mill, which consists of a cylinder, grinding media, a drive system, and a feeding / discharging device. The inner lining of the cylinder is made of a high wear-resistant material (such as manganese steel or ceramic) to contain the aluminum ash and grinding media (such as steel balls or ceramic balls). The drive system drives the cylinder to rotate through a motor, reducer, and gears to provide the power required for grinding. The feeding device uniformly feeds the aluminum ash into the inside of the cylinder, and the discharging device, in conjunction with the screening system, separates the pulverized material according to particle size. During the operation of the ball mill, the aluminum ash is repeatedly impacted and rubbed by the grinding media as the cylinder rotates, gradually breaking it into fine powder.

[0036] The connection between silo A and the ball mill is a circular pipe, which uses air power to transport aluminum ash into the ball mill.

[0037] The screening machine is used to screen aluminum ash after ball milling. Based on the first particle size of the aluminum ash, it conveys the aluminum ash to silos A and B respectively. 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 convey aluminum ash with a particle size of less than or equal to 0.250 mm to silo B, and aluminum ash with a particle size greater than 0.250 mm is conveyed back to silo A for further processing by the ball mill. It is important to emphasize that the screening machine, as the core sorting equipment in the ball milling process of aluminum ash, plays a role in accurately classifying the material after ball milling according to the physical characteristics of the aluminum ash particles (especially particle size), thereby optimizing 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 (0.250mm aperture). It is driven by a motor to generate high-frequency vibration or rotation, so that the aluminum ash is evenly distributed on the screen surface and the particle size is sorted. When the aluminum ash processed by the ball mill enters the feed inlet of the screening machine, the screening machine uses multi-stage screening technology to divide the material into two flows: fine aluminum ash particles with a particle size of less than or equal to 0.250mm (i.e., the first particle size standard) pass through the screen under gravity and are transported to the material bin B through the bottom guide channel for subsequent activation treatment. Coarse aluminum ash particles with a particle size greater than 0.250mm cannot pass through the screen and are pushed to the tail end of the screening machine with the movement of the screen surface. They are then sent back to the material bin A through the pneumatic conveying system to wait to enter the ball mill for secondary grinding.

[0038] The pneumatic conveying system is an automated device that uses compressed air or negative pressure airflow as a power source to efficiently convey powdery 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 convey the coarse aluminum ash (particle size > 0.250 mm) separated by the screening machine from the tail end of the screening machine to silo A, forming a closed-loop cycle of "screening-returning-re-grinding".

[0039] The core working principle of the pneumatic conveying system is based on gas-solid two-phase flow dynamics: when the coarse aluminum ash discharged from the screening machine enters the conveying pipeline evenly through the rotary valve or airlock, the airflow (positive or negative pressure) generated by the blower pushes the material to mix with the air to form a suspended or dense flow state, and moves along the pipeline at a speed of 15-25 m / s; during the conveying process, the aluminum ash particles maintain a flowing state under the combined action of airflow shear force and inertial force, and are directionally conveyed 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, where centrifugal force is used to separate most of the aluminum ash from the air. The aluminum ash settles into silo A due to gravity, and the residual dust-laden gas is purified by the bag filter before being discharged, ensuring no dust leakage. The pneumatic conveying system achieves a balance between conveying efficiency and energy consumption by adjusting the blower power, pipeline diameter, and air velocity (usually 1.5-2 times the material suspension velocity).

[0040] In aluminum ash processing, pneumatic conveying systems, with their enclosed design, completely solve the dust dispersion problem of traditional mechanical conveying (such as belt conveyors). Combined with dust removal devices, they can reduce the dust concentration in the workshop to below 10 mg / m³. 3 It meets environmental protection regulations and is especially suitable for explosion-proof scenarios where aluminum ash easily generates hydrogen gas when it comes into contact with water;

[0041] The pneumatic conveying system reduces secondary crushing of aluminum ash particles through flexible airflow conveying, avoids overloading of the ball mill caused by the increased proportion of fine powder in the return material, and improves grinding efficiency by about 20%-30%. The pipeline layout of the pneumatic conveying system is flexible and can cross complex terrain or vertical space, saving factory area, and the conveying distance can reach hundreds of meters to meet the needs of large-scale production lines.

[0042] The pneumatic conveying system can dynamically adjust the conveying volume based on the inventory of silo A and link it with the current and temperature data of the ball mill to achieve "on-demand material return" and avoid idling or overload. For example, when the sensor detects that the storage volume of silo A is less than 30%, the system automatically increases the fan speed and increases the conveying volume from 10t / h to 15t / h. Conversely, it enters the energy-saving standby mode. The system uses wear-resistant ceramic-lined pipes and nitrogen inerting technology to cope with the high abrasiveness and flammability risk of aluminum ash.

[0043] Specifically, the core of the pneumatic conveying system to achieve "on-demand material return" by dynamically adjusting the conveying volume lies in the deviation between the real-time inventory Vst of silo A and the target set value Vse (usually 30% of the total volume of the silo, i.e., Vst = 0.3Vse), combined with the feedback signals of ball mill current I and bearing temperature T, and the dynamic adjustment of the fan speed n by the PID controller.

[0044] The relationship between the conveying capacity Q and the fan speed is as follows:

[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, and 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, 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. The second particle size refers to 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, with a classification accuracy of up to ±0.005 mm. The ultrasonic transducer converts electrical energy into high-frequency mechanical waves, causing the surface of the sieve mesh to vibrate with a micron-level amplitude (3 - 5 μm). The cavitation effect is used to break the electrostatic adsorption and wet agglomeration between particles, achieving real-time self-cleaning of the sieve mesh. Compared with traditional vibrating sieves, the sieve mesh 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 screens 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 kiln receives coarse aluminum ash and raw materials, and adds flux to melt them at high temperature, producing molten aluminum and roasted aluminum ash. It's important to note that the core principle of the rotary kiln in processing coarse aluminum ash is to utilize the synergistic effect of high-temperature melting and flux chemical action to break the physical bonds between aluminum and other oxides (such as SiO2 and MgO), thus achieving the aggregation and separation of metallic aluminum. When the coarse aluminum ash and flux (usually mixed at a mass ratio of 10:1-10:3) enter the rotary kiln cylinder from the feed end, the cylinder rotates at a speed of 1-3 r / min. Under the inclination angle of 2°-5°, the material gradually moves towards the high-temperature zone (1100-1300℃). Fluorescent flux plays three main roles 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℃ to 900-1000℃, significantly reducing energy consumption. Second, it promotes the aggregation of aluminum droplets. Fluoride ions (F-) in the flux adsorb onto the surface of the molten aluminum, reducing its interfacial tension and causing dispersed micron-sized aluminum droplets to aggregate into millimeter-sized aluminum beads, increasing the settling rate by 3-5 times. Third, it facilitates slag formation and separation. The flux reacts with impurity oxides to generate 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 at the discharge end for stratification (usually 10-30 minutes). The bottom layer of molten aluminum is siphoned to the ingot casting machine, the middle layer of flux can be recycled, and the top layer of roasted aluminum ash (containing Al2O3, Na2O, etc.) is transported to a cold ash bin for crushing and screening.

[0051] The cold ash bin receives the roasted aluminum ash generated by the rotary kiln and crushes and screens it. Based on the third particle size, the cold ash bin conveys the roasted aluminum ash to the rotary kiln and silo A respectively. The third particle size refers to aluminum ash with a particle size of less than or equal to 15mm. The cold ash bin crushes and screens the roasted aluminum ash, and aluminum ash with a particle size of less than or equal to 15mm is conveyed to silo A through a pneumatic conveying system for processing in a ball mill. Aluminum ash with a particle size greater than 15mm is conveyed back to the rotary kiln for further processing. Through the recycling process of the rotary kiln and the cold ash bin, the entire primary aluminum ash treatment system can be made dust-free, with a raw material utilization rate of 100% and no waste generated, which greatly reduces the aluminum ash treatment cost.

[0052] As one embodiment of the present invention, such as Figures 1-5 As shown, the internal structure of silo A integrates a microwave transmitter to activate the aluminum ash within it. It should be noted that the microwave transmitter generates electromagnetic waves (frequency 300MHz-300GHz, commonly 2.45GHz) inside silo A. These electromagnetic waves interact with the aluminum ash inside silo A, and the rapid heating of the aluminum by the microwaves (locally reaching 600-800℃) causes the surface oxide film (Al2O3) to detach due to the difference in thermal expansion coefficients (Al: 23×10⁻⁶). -6 / ℃ vs. Al2O3: 8×10-6 Microcracks are generated at / ℃, exposing the fresh aluminum surface and improving the peeling efficiency of metallic aluminum during ball milling. The non-thermal effect of microwaves promotes the formation of O in the Al2O3 lattice. 2 - Increased ion vibrations create active sites, which can increase the subsequent acid leaching extraction rate from 75% to over 90% compared to conventional heat treatment. Microwave heating causes NaCl / KCl to melt rapidly (melting point 801 / 776℃) and partially vaporize, reducing the adhesion and contamination of salt on the ball milling media.

[0053] Eight to twelve magnetrons (3-6 kW / group, total power 24-72 kW) are arranged circumferentially on the inner wall of silo A, operating at a frequency of 2.45 GHz ± 50 MHz. Uniform microwave radiation is achieved through waveguide couplers and circulators. The microwave penetration depth is calculated based on the aluminum ash packing density inside silo A using the following formula:

[0054]

[0055] Where λ0 is the free space wavelength (λ0≈12.2cm at 2.45GHz), ε is the complex permittivity of aluminum ash, which is composed of ε' (the real part of the complex permittivity) and ε” (the imaginary part of the complex permittivity). If the average ε'≈8.5 and ε”≈0.25 of aluminum ash, then D p ≈7.3cm. Based on this, the thickness of the ash layer inside silo A is designed to be ≤15cm to ensure full microwave penetration. This helps to fully activate the aluminum ash inside silo A with microwave and avoid uneven treatment.

[0056] Microwave transmitters utilize the coupling effect of electromagnetic wave energy and the dielectric properties of materials. In aluminum ash, metallic aluminum, as a good conductor, generates surface eddy currents due to the skin effect under an alternating microwave electric field. The local temperature can rise to 600-800℃ within tens of seconds, causing the surface alumina layer (Al2O3) to exhibit a difference in thermal expansion coefficients with the metallic aluminum substrate (Al: 23×10⁻⁶). -6 / ℃ vs. Al2O3: 8×10 -6 The aluminum oxide crystal cracked at a temperature of 100°C, exposing a fresh aluminum surface; while the alumina, as a polar medium, had O atoms in its lattice... 2 - Ions undergo high-frequency vibrations under the influence of a microwave field, prompting a transformation of the crystal structure from the γ-type to the highly reactive θ-type, increasing the specific surface area from 5 m² / s² under conventional heat treatment. 2 / g increased to 15m 2 For salts such as NaCl and KCl mixed in aluminum ash, microwave heating can rapidly melt them (melting point 801℃ / 776℃) and partially vaporize them. The gaseous salts are converted into high-purity crystalline salts (Cl- recovery rate ≥95%) through a condensation recovery system. The residual salt content is reduced from the initial 8%-15% to below 0.3%, effectively avoiding the problem of efficiency reduction caused by salts adhering to the grinding media during ball milling.

[0057] The hopper 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 can be preset by those skilled in the art. When the amount of aluminum ash received in the upper cavity reaches the set value, and the lower cavity has completed microwave activation and been transported to the ball mill, the upper cavity can then transport the aluminum ash inside to the lower cavity for microwave activation treatment. An electromagnetic valve can be installed between the upper and lower cavities to ensure that the connection between the upper and lower cavities can be automatically controlled.

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

[0059] It should also be noted that the first ball mill 6 performs coarse ball milling on large-volume aluminum ash, while the second ball mill 7 performs fine ball milling on small-volume aluminum ash. This allows the ball mill and screening machine to adapt to different types of aluminum ash, ensuring the working efficiency and effectiveness of the ball mill and screening machine.

[0060] The first ball mill cylinder 6 includes a first rotating cylinder 61. An elastic connecting rod 62 is fixedly connected to the outer side of the first rotating cylinder 61. A first fixing ring 63 is fixedly connected to the end of the elastic connecting rod 62. The first fixing ring 63 is fixedly connected to the inner wall of the drive housing 1. It should be noted that the elastic connecting rod 62 is used to install the first rotating cylinder 61 on the inner side of the drive housing 1 through the first fixing ring 63. The elastic connecting rod 62 is selected by those skilled in the art based on the available materials to ensure that when the first rotating cylinder 61 rotates, the steel balls inside it can vibrate in conjunction with the elastic connecting rod 62 when they hit the inner wall of the first rotating cylinder 61. In other words, when the first rotating cylinder 61 rotates, the steel balls can cause the first rotating cylinder 61 to vibrate when performing ball milling on the aluminum ash inside it.

[0061] The first rotating drum 61 has a first grinding chamber 64 inside. A first protrusion 65 is fixedly connected to the inner wall of the first grinding chamber 64. The first grinding chamber 64 is filled with several steel balls with a diameter of 40-60 mm. The surface of the first rotating drum 61 has 1 mm-5 mm sieve holes. It should be noted that there are several first protrusions 65, evenly distributed on the inner wall of the first grinding chamber 64. When the first rotating drum 61 rotates, it scrapes up the steel balls inside through the first protrusions 65, allowing the steel balls to reach the center of the inner cavity of the first rotating drum 61 before falling down. This hammers and grinds the aluminum ash inside the first rotating drum 61, achieving a ball milling effect and continuously reducing the diameter of the aluminum ash. Because the surface of the first rotating drum 61 has 1 mm-5 mm sieve holes, 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 holes. The sieve holes are determined by those skilled in the art based on the outer surface of the first rotating drum 61. The volume is adjusted to ensure that aluminum ash of 1mm can be screened. Since the first rotating drum 61 is rotating, when the steel balls fall on the inner wall of the first rotating drum 61, it not only vibrates the first rotating drum 61, but also causes the first rotating drum 61 to vibrate. In this way, the aluminum ash at the top of the inner cavity of the first rotating drum 61 will fall down under the action of the vibration of the first rotating drum 61, achieving the self-cleaning effect of the first rotating drum 61 and ensuring the screening effect and efficiency of the first rotating drum 61 for 1mm aluminum ash. The second ball mill 7 is set outside the first rotating drum 61, so the aluminum ash passing through the sieve holes of the first rotating drum 61 will directly enter the second ball mill 7. During the operation of the first rotating drum 61, the aluminum ash with a smaller diameter will continuously enter the second ball mill 7, ensuring that the aluminum ash inside the first rotating drum 61 is all aluminum ash with a larger diameter. This also ensures the working effect of the steel balls in the first rotating drum 61, so that the aluminum ash in the first rotating drum 61 is all of the diameter that matches the working effect of the steel balls.

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

[0063] 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 several steel balls with a diameter of 5mm-15mm. The surface of the second rotating drum 71 is provided with 0.25mm sieve holes. It should be noted that 0.25mm is the first particle size. The specific size can be adjusted by those skilled in the art according to the required diameter of aluminum ash. The working principle of the aluminum ash in the second rotating drum 71 is the same as that of the aluminum ash in the first rotating drum 61, which will not be described in detail here. The difference is that the second rotating 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 enter the drive housing 1 through the sieve holes on the second rotating drum 71.

[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 connected to the hopper A, and the discharge end 3 is connected to the hopper B. The drive housing 1 includes a conveying cylinder 11. The conveying cylinder 11 has a threaded cavity 12 inside. It should be noted that a discharge port is set at the bottom of the discharge end 3 near the bottom of the conveying cylinder 11. When aluminum ash with a diameter of 0.25mm enters the conveying cylinder 11, the aluminum ash can be conveyed to the discharge port on the discharge end 3 by the rotation of the conveying cylinder 11 and the threaded cavity 12, and then enter the hopper B through the discharge port.

[0065] A drive gear ring 4 is fixedly connected to the side of the drive housing 1. A support base 5 is installed on the outside of the drive housing 1. A motor can be installed on the support base 5. The output shaft of the motor meshes with the drive gear ring 4 through a gear. In this way, the power of the motor can be transmitted to the drive gear ring 4 through the gear, and then the drive gear ring 4 drives the drive housing 1 to rotate.

[0066] The length of the first grinding cylinder 6 is equal to 1 / 2 to 2 / 3 of the length of the second grinding cylinder 7. The second grinding cylinder 71 has an internal threaded channel 75, the length of which is equal to the length of the first grinding chamber 64 inside the first grinding cylinder 61. It should be noted that an extension rod (not shown in the figure) should be provided at the end of the first grinding cylinder 61, and this extension rod is fixedly connected to the inner end of the drive housing 1 via an elastic connecting rod 62 and a first fixing ring 63. This arrangement ensures that the first grinding cylinder 6 does not affect the impact operation of the steel balls inside the second grinding cylinder 71. Figure 10 As shown, when aluminum ash in the first ball milling chamber 64 passes through the sieve holes, it will fall into the corresponding threaded channel 74 inside the second rotating drum 71. When the threaded channel 74 rotates, it can transport the aluminum ash to the position corresponding to the second protrusion 74 inside 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 milling drum 6, the second ball milling drum 7 and the drive housing 1.

[0067] It should be noted that the amplitude of the first ball mill cylinder 6 and the second ball mill cylinder 7 is between 1 mm and 2 mm. Therefore, the gap between the first ball mill cylinder 6 and the second ball mill cylinder 7 in the attached figure is an exaggerated schematic diagram. The specific gap between the first ball mill cylinder 6 and the second ball mill cylinder 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 cylinder 6 and the second ball mill cylinder 7.

[0068] As one embodiment of the present invention, such as Figures 1-5 As shown, a LIBS online component analyzer is installed at the feed inlet of the rotary kiln. A permanent magnet array is embedded in the inner wall of the rotary kiln. A rotating magnetic field generator outside the rotary kiln enables non-contact stirring of the melt inside. The LIBS online component analyzer is used to detect the Si and Fe content in the coarse aluminum ash and raw materials in real time. Based on the Si and Fe content, the amount of flux to be added is determined. It should be noted that the LIBS online component analyzer is installed 1-2m downstream of the rotary kiln feed inlet at a 30° angle (to avoid direct impact from materials) and is equipped with a nitrogen purging 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; detected elements: Si (251.6nm spectral line), Fe (238.2nm spectral line), detection limit ≤0.05wt%; sampling frequency: once every x seconds (the specific sampling frequency should be adaptively adjusted by those skilled in the art according to actual conditions), and data is transmitted via OPC. The UA protocol transmits data to the PLC. OPC UA is a widely used cross-platform, secure, and reliable data communication protocol in industrial automation, designed to achieve standardized data interaction between devices, systems, and upper-level management platforms. OPC UA supports Windows, Linux, embedded systems (such as PLCs and RTUs), and cloud deployment, eliminating the dependence of traditional OPC on Windows DCOM. It provides SDKs in multiple languages ​​such as C / C++, Java, Python, and .NET for easy cross-platform integration. Based on object-oriented information modeling, it supports custom complex data types (such as structures and arrays), has a built-in base information model, and can be expanded into industry-specific models (such as PackML and PLCopen). OPC UA enables data interoperability between PLCs (such as Siemens S7-1500), DCS, and SCADA systems, resolving compatibility issues between multiple vendor protocols (such as Modbus and Profinet). The LIBS online component analyzer in the rotary kiln (as an OPC protocol)... The UA server transmits Si / Fe content data to the PLC (client) in real time, enabling direct data connection from the field layer (equipment) to the MES / ERP system, eliminating intermediate conversion layers;

[0069] The method of embedding permanent magnet arrays on the inner wall of the rotary kiln is as follows: neodymium iron boron permanent magnets (N52 grade) are embedded axially and equidistantly on the inner wall of the rotary kiln, with 12 magnets per ring and a spacing of 50mm (the specific spacing can be adapted by those skilled in the art according to the specifications of the rotary kiln), arranged with alternating polarities (NSNS) to form an axial magnetic field gradient. The surface of the permanent magnets is coated with yttrium-stabilized zirconia (YSZ) coating (1mm thick), with a temperature resistance of ≥1300℃ and a magnetic field strength of 50-100mT in the molten area of ​​the furnace.

[0070] The external rotating magnetic field generator of the rotary kiln 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 external rotating magnetic field generator of the rotary kiln 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 supply module: IGBT frequency converter, response time ≤10ms.

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

[0072] The LIBS online component analyzer acquires the Si and Fe contents (denoted as [Si] and [Fe]) every 30 seconds, and the data filtering uses a sliding window average (window size = 5);

[0073] Formula for calculating the amount of flux (crystal Na3AlF6) added:

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

[0075] Where, k Si =0.8 (kg flux / % Si), k Fe =1.2 (kg flux / % Fe), M base = mkg / t (m is the amount added based on the base amount);

[0076] Rotating magnetic field stirring control:

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

[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, using an online LIBS component analyzer to detect the Si and Fe content in crude aluminum ash and raw materials in real time, and determining the amount of flux to add based on the Si and Fe content, 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, improving the mixing uniformity of the melt inside the rotary kiln. This reduces the axial temperature difference inside the rotary kiln from ±50℃ to ±15℃, reduces thermocouple data fluctuations by 60%, and reduces mechanical wear through non-contact stirring, thereby lowering the maintenance frequency of the rotary kiln and indirectly reducing maintenance costs.

[0081] As one embodiment of the present invention, such as Figures 1-5 As shown, a flame monitoring camera is installed inside the rotary kiln. This camera captures real-time images of the flame and melt inside the kiln. Based on these images, a CNN network model is trained to train a machine learning model that identifies the internal temperature and melt mixing degree of the rotary kiln. The flame monitoring camera captures real-time images of the flame inside the kiln, and the internal temperature is generated based on these images. It should be noted that the flame monitoring camera is a high-temperature resistant (≥1500℃) industrial-grade infrared-visible dual-mode camera (such as the FLIRAX8) that supports HDR. Imaging (120dB), frame rate ≥30fps, resolution 1920×1080. The flame monitoring camera adopts a protective design and uses circulating cooling water (flow rate 10L / min, inlet temperature ≤25℃) to protect the lens. The flame monitoring camera is installed at the observation port at the tail of the rotary kiln, tilted at 30° towards the center of the molten pool, and the field of view covers 80% of the molten surface. In addition, it should be noted that K-type thermocouples (0-1600℃, accuracy ±1℃) need to be arranged along the axis of the rotary kiln body, one group every 0.5 meters, for a total of 6 groups, to collect the actual temperature as training labels.

[0082] Data Acquisition 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 can be adaptively adjusted by those skilled in the art according to the specific model training situation) (flame image + melt image + temperature label + mixing degree label), which are divided into training set, validation set and test set in an 8:1:1 ratio;

[0084] The flame and melt regions were segmented using OpenCV Mask R-CNN. The effective regions were cropped (flame: 500×500 pixels, melt: 800×600 pixels). Then, the effective regions were enhanced and normalized. The enhancement and normalization processes included histogram equalization to improve the contrast of low-light areas, Gaussian filtering (σ=1.5) to eliminate high-frequency noise, and normalization (pixel values ​​scaled to [0,1]).

[0085] CNN Model Building and Training:

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

[0087] Model Deployment and Real-Time Inference:

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

[0089] Validation and continuous optimization:

[0090] Every 24 hours, the model predictions are compared with thermocouple / XRF data. If the MAE is consistently >20℃ or F1 <0.85, model fine-tuning (10% new data) is triggered. An online learning framework (such as River) is integrated to incrementally update the model parameters. Grafana displays the temperature curve, mixture heatmap, and model confidence in real time. When the temperature exceeds the limit (>1350℃) or the mixture drops sharply (ΔM>0.2 / 10min), an audible and visual alarm is triggered.

[0091] A machine learning model trained using a CNN network model was developed to identify the internal temperature and melt mixing degree of a rotary kiln. This improved the temperature range from ±80℃ under traditional manual control to ±25℃, reduced the gas valve response time from minutes to seconds, and enabled the rotary kiln to provide early warnings of local overheating (>1350℃) or low-temperature solidification (<1250℃) risks 5-10 minutes in advance. The material mixing degree index M inside the rotary kiln increased from 0.75-0.85 to 0.90-0.95, reduced the standard deviation of aluminum particle distribution by 40%, decreased melt content fluctuation from ±3% to ±0.8%, and doubled the uniformity of Si / Fe impurity distribution. Through flame morphology recognition, faults such as gas nozzle blockage and incomplete combustion can be automatically identified.

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

[0093] As one embodiment of the present invention, such as Figures 1-5As shown, the flame monitoring camera acquires real-time images of the melt, generates a 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 uses the aforementioned technical solution, specifically:

[0094] The flame monitoring camera pre-collects N sets of data (N is a positive integer greater than 0, and the number of N can be adaptively adjusted by those skilled in the art 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, Fe content) inside the rotary kiln;

[0095] The degree of mixing is defined as:

[0096]

[0097] Among them Al 实际 The content of Al collected by the LIBS online component analyzer. 目标 For the target content preset by those skilled in the art, M=1 indicates complete mixing, and M<0.8 requires magnetic field mixing to be triggered;

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

[0099] ResNet-50 (pre-trained weights) outputs a 1024-dimensional feature vector, adds a Bi-LSTM layer (128 hidden units) to capture the temporal features of melt flow, and a fully connected layer (256→64→1) outputs a mixture degree M∈[0,1].

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

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

[0102] Determine the target mixing degree M 目标 =0.95, with an allowable fluctuation range of ±0.03, and then a PID algorithm is used to supply 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, and frequency is limited to 1-50Hz;

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

[0104] If the mixing density is too low (M<0.92): the current increase 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 decrease the stirring intensity;

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

[0107] The foregoing has provided a detailed description of one embodiment of the present invention, but this description is merely a preferred embodiment and should not be construed as limiting the scope of the invention. All equivalent variations and modifications made within the scope of the claims of this invention should still fall within the patent coverage of this invention.

Claims

1. A system for the automated handling of primary aluminum dross, characterized in that, The application relates to a ball-milling and screening integrated machine which is used for receiving aluminum ash in a stock bin A, ball-milling the aluminum ash in the stock bin A, screening the ball-milled aluminum ash, and conveying the aluminum ash to the stock bin A and the stock bin B based on the first particle size of the aluminum ash. An ultrasonic round screen is used for classifying the aluminum ash in the stock bin B into finished aluminum ash and coarse aluminum ash based on the second particle size of the aluminum ash. A rotary furnace is used for receiving the coarse aluminum ash and coarse material, adding flux to high-temperature melt the coarse aluminum ash and the coarse material, generating aluminum water and roasted aluminum ash. A cold ash bucket is used for receiving the roasted aluminum ash generated by the rotary furnace, crushing and screening the roasted aluminum ash, and conveying the roasted aluminum ash to the rotary furnace and the stock bin A based on the third particle size. The ball-milling and screening integrated machine comprises a driving shell (1), the inside of the driving shell (1) is provided with a first ball-milling cylinder (6) and a second ball-milling cylinder (7), the first ball-milling cylinder (6) is used for rough ball-milling the aluminum ash, and the second ball-milling cylinder (7) is used for fine ball-milling the aluminum ash after the rough ball-milling. The first ball-milling cylinder (6) comprises a first rotary cylinder (61), the outer side of the first rotary cylinder (61) is fixedly connected with an elastic connecting rod (62), the end of the elastic connecting rod (62) is fixedly connected with a first fixed ring (63), and the first fixed ring (63) is fixedly connected with the inner wall of the driving shell (1). The second ball-milling cylinder (7) comprises a second rotary cylinder (71), the inner side of the second rotary cylinder (71) is fixedly connected with a vibration spring (72), the end of the vibration spring (72) is fixedly connected with a second fixed ring (73), and the second fixed ring (73) is fixedly connected with the outer side of the first rotary cylinder (61).

2. The primary aluminum dross automated processing system of claim 1, wherein, The inside of the first rotary cylinder (61) is provided with a first ball-milling cavity (64), the inner wall of the first ball-milling cavity (64) is fixedly connected with a first protrusion (65), the inside of the first ball-milling cavity (64) is filled with a plurality of steel balls with a diameter of 40-60 mm, and the surface of the first rotary cylinder (61) is provided with sieve holes with a size of 1 mm-5 mm.

3. The primary aluminum dross automated processing system of claim 1, wherein, The inner wall of the second rotary cylinder (71) is fixedly connected with a second protrusion (74), the inside of the second rotary cylinder (71) is filled with a plurality of steel balls with a diameter of 5 mm-15 mm, and the surface of the second rotary cylinder (71) is provided with sieve holes with a size of 0.25 mm.

4. The primary aluminum dross automated processing system of claim 1, wherein, One end of the driving shell (1) is connected with a feeding end (2), the other end of the driving shell (1) is connected with a discharging end (3), the feeding end (2) is communicated with the stock bin A, the discharging end (3) is communicated with the stock bin B, and the driving shell (1) comprises a feeding cylinder (11) provided with a threaded cavity (12) in the inside.

5. The primary aluminum dross automated processing system of claim 2, wherein, The length of the first ball-milling cylinder (6) is equal to 1 / 2-2 / 3 of the length of the second ball-milling cylinder (7).

6. The primary aluminum dross automated processing system of claim 5, wherein, The inside of the second rotary cylinder (71) is provided with a threaded channel (75), and the length of the threaded channel (75) is equal to the length of the first ball-milling cavity (64) in the inside of the first rotary cylinder (61).

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