A device and method for removing sludge from thickener overflow water

Abstract

The present application belongs to the technical field of dressing wastewater treatment, and particularly relates to a thickener overflow water deslagging device and method. The device comprises a flushing system, a multi-stage filtration system, an automatic control system, an intelligent conveying system and an impurity collection system. The automatic control system comprises a turbidimeter, a concentration meter and a flow meter. The multi-stage filtration system comprises a primary filtration unit, a secondary filtration unit and a tertiary filtration unit. The specific steps are as follows: system standby and real-time monitoring, turbidity exceeding the standard triggering a primary response, concentration exceeding the standard triggering deep treatment, dynamic optimization during operation, water quality recovery and system shutdown. The device and method realize the whole-process automatic control from'real-time monitoring, grading filtration, intelligent deslagging, safe collection and precise shutdown' through the closed-loop linkage of the five systems, without manual intervention, reducing labor intensity, improving production efficiency, and reducing the influence of human operation errors on the deslagging effect.

Description

Technical Field

[0001] This invention belongs to the field of mineral processing wastewater treatment technology, and particularly relates to a slag removal device and method for thickener overflow water. Background Technology

[0002] In mineral processing, thickeners are commonly used solid-liquid separation equipment. Their overflow water typically contains a certain amount of fine particulate impurities. If not effectively treated, this can affect the water quality of subsequent production processes and even cause equipment wear and pipe blockages. Traditional slag removal methods, such as sedimentation or filtration, suffer from incomplete slag removal and low efficiency. While some existing technologies have incorporated automation, improvements are still needed in slag removal accuracy, energy consumption control, and adaptability to complex operating conditions. For example, simple filters are easily clogged by impurities, requiring frequent manual cleaning and failing to meet the demands of continuous production. Furthermore, some slag removal methods relying on chemical agents not only increase processing costs but may also lead to secondary pollution. Summary of the Invention

[0003] The purpose of this invention is to provide a slag removal device and method for thickener overflow water, which solves the problems that the filter screen is easily clogged by impurities during the slag removal process, requiring frequent manual cleaning and relying on chemical agents, which not only increases the processing cost but may also lead to secondary pollution and poor adaptability to complex working conditions.

[0004] To achieve the above objectives, the present invention adopts the following technical solution:

[0005] A slag removal device for thickener overflow water includes a flushing system, a multi-stage filtration system, an automated control system, an intelligent conveying system, and an impurity collection system. The automated control system includes a turbidity meter, an impurity concentration meter, and a flow meter. A turbidity meter and a flow meter are installed at the overflow outlet of the overflow pipe. The multi-stage filtration system is fixed on the thickener overflow pipe, and a flushing system is fixed above it. The multi-stage filtration system includes a primary filtration unit, a secondary filtration unit, a tertiary filtration unit, and an overflow tank. The primary, secondary, and tertiary filtration units are arranged sequentially from top to bottom and are connected to filtration pipes. The primary filtration unit consists of a set of large-mesh filter screens; the secondary filtration unit uses a fine-mesh filter screen; and an impurity concentration meter is installed after the secondary filtration unit. The tertiary filtration unit uses a high-precision filter element. Each filtration unit has a differential pressure sensor installed inside, and the differential pressure sensor is connected to the automated control system via a signal transmission line. The system's data acquisition module is connected. When the differential pressure exceeds the set threshold, the automated control system receives the signal in a timely manner and issues corresponding control commands. An overflow trough is fixed at the end of the primary filtration unit, and the bottom of the overflow trough is connected to a conveying pipe. The intelligent conveying system includes a conveyor and a transfer trolley. The bottom of the conveying pipe abuts against the conveyor. The conveyor is driven by a motor, and a spiral scraper is fixed on the inner wall of the conveyor. The discharge end of the conveyor corresponds to the docking interface of the transfer trolley. Precise connection is achieved through intelligent positioning and docking mechanisms. The transfer trolley transports impurities to the impurity collection system. The motors of both the conveyor and the transfer trolley are connected to frequency converters, which are connected to the output control module of the automated control system. The transfer trolley is equipped with a positioning sensor and a communication module. The impurity collection system includes an impurity collection hopper and a compression plate. A compression plate is fixed on one side of the impurity collection hopper. The compression plate is raised and lowered by a motor. A liquid level sensor is installed inside the impurity collection hopper, and the liquid level sensor is connected to the automated control system through a signal line.

[0006] Preferably, the flushing system includes multiple high-pressure water guns.

[0007] A method for removing slag from thickener overflow water, the specific steps of which are as follows:

[0008] Step 1: System Standby and Real-time Monitoring

[0009] The automated control system continuously collects real-time data from the turbidity meter in the overflow pipe and the impurity concentration meter after the secondary filtration unit. The multi-stage filtration system and intelligent conveying system are in a dormant state. The flushing system automatically starts every 2-4 hours, with each flush lasting 30-60 seconds. High-pressure water jets impact the surface of the filter screen to remove attached impurities and ensure the filtration performance of the filter screen.

[0010] Step 2: Turbidity exceeding the standard triggers the primary response.

[0011] When the turbidity meter reading is >200ppm, the multi-stage filtration system, intelligent conveying system and impurity collection system are activated. The first-stage filtration unit starts to physically intercept large particulate impurities, and the second-stage filtration unit starts simultaneously to remove medium-sized suspended solids. The conveyor pushes the intercepted impurities to the impurity collection hopper for temporary storage.

[0012] Step 3: Concentration exceeding the standard triggers in-depth processing

[0013] When the impurity concentration meter reading after the secondary filtration unit exceeds 500 mg / L, the multi-stage filtration system is fully activated, the tertiary filtration unit starts immediately, and the filtration accuracy is improved to below 5 μm. The intelligent conveying system is enhanced, and the speed is dynamically adjusted when the concentration exceeds the standard. The spiral scraper inside the conveyor is activated to prevent the conveyor from being blocked due to high concentration impurities. When the weight of impurities reaches the set value, the system automatically reminds the management personnel to clean it.

[0014] Step 4: Dynamic Optimization During Operation

[0015] The automated control system performs a dual threshold judgment on the impurity concentration meter after the secondary filtration unit every 10 minutes: when the turbidity is >200ppm or the concentration is >500mg / L, the multi-stage filtration system and intelligent conveying system are maintained in operation. The intelligent conveying system receives PLC commands from the automated control system in real time, and the speed is adjusted according to the impurity situation in a gradient: calculation formula: speed RPM=20+K1×(turbidity value-standard value)+K2(concentration value-standard value), where K1 and K2 are adjustment coefficients;

[0016] Step 5: Water quality restoration and system shutdown

[0017] When the turbidity is ≤200ppm and the impurity concentration is ≤500mg / L, start the timer. When the stable time reaches 10-20 minutes, all systems will reset.

[0018] Preferably, the system shutdown in step five is a tiered shutdown, with the shutdown sequence as follows: the tertiary filtration unit shuts down, then the primary and secondary filtration units shut down after 1 minute, the intelligent conveying system shuts down after 3 minutes, and the impurity collection system shuts down after the compression plate starts compacting for 2 minutes.

[0019] Compared with the prior art, the beneficial effects achieved by the present invention are as follows:

[0020] (1) Through the synergistic effect of multi-stage filtration system and intelligent conveying system, as well as the precise control of the slag removal process by the automated control system, the filter screen is not easily clogged by impurities, and there is no need for frequent manual cleaning. It can efficiently remove impurities and slag in the overflow water, and the slag removal efficiency is significantly improved. The automated control system adopts dual threshold graded control. When the turbidity exceeds the standard, the basic filtration is started. When the concentration exceeds the standard, the deep treatment is triggered to ensure efficient removal of various impurities in the overflow water, avoid the problem of incomplete slag removal in the traditional manual slag removal method, and improve the water quality of the thickener overflow water.

[0021] (2) The multi-stage filtration system uses three-stage filtration units working together. Each stage of the filtration unit is activated according to the overflow water concentration, and each stage of the unit intercepts impurities in layers according to the particle size, thereby improving the overall filtration efficiency.

[0022] (3) The intelligent conveying system dynamically adjusts the rotation speed based on the impurity load to avoid energy waste;

[0023] (4) This method uses stability delay shutdown and staged shutdown to prevent water quality fluctuations from causing frequent start-ups and shutdowns that affect normal production;

[0024] (5) This method achieves full-process automated control from "real-time monitoring → graded filtration → intelligent slag removal → safe collection → precise shutdown" through the closed-loop linkage of five major systems: flushing system, multi-stage filtration system, intelligent conveying system, impurity collection system and automatic control system. It requires no manual intervention, reduces labor intensity, improves production efficiency, and reduces the impact of human operation errors on slag removal effect, thus meeting the requirements of high efficiency and reliability of industrial slag removal. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention;

[0026] Figure 2 This is a schematic diagram of the structure of a multi-stage filtration system in an embodiment of the present invention.

[0027] Explanation of reference numerals in the attached drawings: 1. Flushing system; 2. Multi-stage filtration system; 21. Primary filtration unit; 22. Secondary filtration unit; 23. Tertiary filtration unit; 24. Overflow trough; 3. Automated control system; 4. Conveyor; 5. Transfer trolley; 6. Impurity collection hopper; 7. Compression plate; 8. Conveying pipe. Detailed Implementation

[0028] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0029] like Figure 1-2As shown, a slag removal device for thickener overflow water includes a flushing system 1, a multi-stage filtration system 2, an automated control system 3, a conveyor 4, a transfer trolley 5, and an impurity collection hopper 6. The automated control system 3 includes a turbidity meter, an impurity concentration meter, and a flow meter. A turbidity meter and a flow meter are installed at the overflow outlet of the overflow pipe. The multi-stage filtration system 2 is fixed on the thickener overflow pipe, and the flushing system 1 is fixed above the multi-stage filtration system 2. The flushing system 1 consists of multiple high-pressure water guns. The multi-stage filtration system 2 includes a primary filtration unit 21, a secondary filtration unit 22, a tertiary filtration unit 23, and an overflow tank 24. The primary filtration unit 21, the secondary filtration unit 22, and the tertiary filtration unit 23 are distributed sequentially from top to bottom. Filter unit 21, secondary filter unit 22, and tertiary filter unit 23 are connected to filter pipes. Primary filter unit 21 consists of a set of large-mesh filter screens to intercept large impurities. Secondary filter unit 22 is a fine filter screen that further filters smaller particles. An impurity concentration meter is installed after secondary filter unit 22. Tertiary filter unit 23 uses a high-precision filter element to remove fine particulate impurities. Each filter unit is equipped with a differential pressure sensor to monitor the pressure difference before and after filtration in real time. The differential pressure sensor is connected to the data acquisition module of the automatic control system 3 via a signal transmission line. When the differential pressure exceeds a set threshold, the automatic control system 3 promptly receives the signal and issues corresponding control commands, providing a prompt. When replacing the filter element or performing cleaning operations, an overflow trough 24 is fixed at the end of the primary filtration unit 21, and the bottom end of the overflow trough 24 is connected to a conveyor pipe 8. The bottom end of the conveyor pipe 8 abuts against the conveyor 4. The conveyor 4 is driven by a motor and is used to transport the impurities intercepted by the filter to a designated location. A spiral scraper is fixed to the inner wall of the conveyor 4 to clean the impurities adhering to the conveyor pipe wall. The discharge end of the conveyor 4 corresponds to the docking interface of the transfer trolley 5. Precise connection is achieved through intelligent positioning and docking mechanism. The transfer trolley 5 transports the impurities to the impurity collection hopper 6. The motors of both the conveyor 4 and the transfer trolley 5 are connected to frequency converters. The frequency converters are connected to the output control module of the automation control system 3 to adjust the conveying according to the actual situation such as the amount of material. Speed; simultaneously, the transfer trolley 5 is equipped with positioning sensors and communication modules, which feed back the location information to the automated control system 3 in real time to ensure the orderly progress of the entire conveying process; a compression plate 7 is fixed on one side of the impurity collection hopper 6, and the compression plate 7 is raised and lowered by a motor to realize the continuous process of impurity collection and compression; a liquid level sensor is set in the impurity collection hopper 6 to monitor the amount of impurities collected in real time. The liquid level sensor is connected to the automated control system 3 through a signal line. When the impurities are collected to a certain extent, the automated control system 3 controls the compression plate 7 to start the compression operation; the impurities are transported from the transfer trolley 5 to the impurity collection hopper 6, and the compression plate 7 compresses the collected impurities to reduce the volume of impurities for subsequent processing.

[0030] A method for removing slag from thickener overflow water based on the above-mentioned slag removal device includes the following specific steps:

[0031] Step 1: System Standby and Real-time Monitoring

[0032] The automated control system 3 continuously collects real-time data from the turbidity meter in the overflow pipe and the impurity concentration meter after the secondary filter unit 22. The multi-stage filtration system 2, conveyor 4, transfer trolley 5, and pressure plate 7 are all in a dormant state. The flushing system 1 is automatically started every 2 hours, and each flushing lasts for 60 seconds. The high-pressure water jet impacts the surface of the filter screen to remove the attached impurities and ensure the filtration performance of the filter screen.

[0033] Step 2: Turbidity exceeding the standard triggers the primary response.

[0034] When the turbidity meter reading exceeds the set value by 200 ppm, and the turbidity meter suddenly increases to 320 ppm, the multi-stage filtration system 2, conveyor 4, transfer trolley 5, and impurity collection hopper 6 are activated. The first-stage filtration unit 21 is activated to physically intercept large particulate impurities, and the second-stage filtration unit 22 is activated simultaneously to remove medium-sized suspended matter. The conveyor 4 pushes the intercepted impurities to the impurity collection hopper 6 for temporary storage.

[0035] Step 3: Concentration exceeding the standard triggers in-depth processing

[0036] Three minutes later, the concentration rose to 680 mg / L, the three-stage filtration unit 23 started, and the filtration accuracy improved to below 5 μm; the conveyor 4 speed increased to 20 + 0.1 × (320 - 200) + 0.15 × (680 - 500) = 59 rpm, the concentration exceeding the standard signal triggered dynamic speed adjustment, the spiral scraper started, and the impurity volume exceeded 1 m³. 3 When the impurity compression plate 7 is activated, it prevents the conveyor from being blocked due to high concentration of impurities. When the weight of the impurities reaches 300kg, the system automatically reminds the management personnel to clean them up.

[0037] Step 4: Dynamic Optimization During Operation

[0038] Every 10 minutes, the automated control system 3 performs a dual threshold judgment on the impurity concentration meter after the secondary filter unit 22: when the turbidity is >200ppm or the concentration is >500mg / L, the multi-stage filtration system 2, conveyor 4 and transfer trolley 5 are kept running. The conveyor 4 and transfer trolley 5 receive PLC commands from the automated control system in real time, and the speed is adjusted according to the impurity situation in a gradient: calculation formula: speed RPM=20+K1×(turbidity value-standard value)+K2(concentration value-standard value), where K1 and K2 are adjustment coefficients;

[0039] Step 5: Water quality restoration and system shutdown

[0040] When the impurity concentration drops to 300 mg / L and the turbidity drops to 180 ppm, the timer is started. When the stable time reaches 10 minutes, all systems are reset.

[0041] The shutdown sequence is as follows: the third-stage filtration unit shuts down, the first-stage and second-stage filtration units shut down 1 minute later, the conveyor 4 and transfer trolley 5 shut down 3 minutes later, and the compression plate 7 starts to compact for 2 minutes before shutting down.

[0042] The device and method employ multi-stage units to intercept impurities in layers according to particle size, thereby improving the overall filtration efficiency. The measured slag removal rate reaches 98.2%, and the overflow water quality can be stably maintained below 200 ppm, and even below 100 ppm under some operating conditions.

Claims

1. A slag removal device for thickener overflow water, characterized in that, The system includes a flushing system, a multi-stage filtration system, an automated control system, an intelligent conveying system, and an impurity collection system. The automated control system includes a turbidity meter, an impurity concentration meter, and a flow meter. A turbidity meter and a flow meter are installed at the overflow outlet of the overflow pipe. A multi-stage filtration system is fixed to the overflow pipe of the thickener, and a flushing system is fixed above the multi-stage filtration system. The multi-stage filtration system includes a primary filtration unit, a secondary filtration unit, a tertiary filtration unit, and an overflow tank. The primary, secondary, and tertiary filtration units are arranged sequentially from top to bottom. The system comprises several filter pipes. The primary filter unit consists of a set of large-mesh filter screens, the secondary filter unit uses a fine filter screen, and an impurity concentration meter is installed after the secondary filter unit. The tertiary filter unit uses a high-precision filter element. Each filter unit has a differential pressure sensor installed inside. The differential pressure sensor is connected to the data acquisition module of the automated control system via a signal transmission line. When the differential pressure exceeds a set threshold, the automated control system receives the signal and issues corresponding control commands. An overflow trough is fixed at the end of each primary filter unit, and the bottom of the overflow trough is connected to a conveying pipe. The intelligent conveying system includes a conveyor and a transfer trolley. The bottom end of the conveyor pipe abuts against the conveyor, which is driven by a motor. A spiral scraper is fixed to the inner wall of the conveyor. The discharge end of the conveyor corresponds to the interface of the transfer trolley, achieving precise connection through intelligent positioning and docking mechanisms. The transfer trolley transports impurities to the impurity collection system. Both the conveyor and transfer trolley motors are connected to frequency converters, which are connected to the output control module of the automated control system. The transfer trolley is equipped with positioning sensors and a communication module. The impurity collection system includes an impurity collection hopper and a compression plate. The compression plate is fixed to one side of the impurity collection hopper and its lifting and lowering are controlled by a motor. Inside the impurity collection hopper... A liquid level sensor is installed, which is connected to the automated control system via a signal line. Every 10 minutes, the automated control system performs a dual threshold judgment on the impurity concentration meter after the secondary filtration unit: when the turbidity is >200ppm or the impurity concentration is >500mg / L, the multi-stage filtration system and intelligent conveying system are maintained in operation. The intelligent conveying system receives PLC commands from the automated control system in real time, and the speed is adjusted according to the impurity situation in a gradient: calculation formula: speed RPM = 20 + K1 × (turbidity value - standard value) + K2 (impurity concentration value - standard value), where K1 and K2 are adjustment coefficients.

2. The slag removal device for thickener overflow water according to claim 1, characterized in that, The flushing system includes multiple high-pressure water guns.

3. A method for removing slag from thickener overflow water based on the slag removal device described in claim 1, characterized in that, The specific steps are as follows: Step 1: System Standby and Real-time Monitoring The automated control system continuously collects real-time data from the turbidity meter in the overflow pipe and the impurity concentration meter after the secondary filtration unit. The multi-stage filtration system and intelligent conveying system are in a dormant state. The flushing system automatically starts every 2-4 hours, with each flush lasting 30-60 seconds. High-pressure water jets impact the surface of the filter screen to remove attached impurities and ensure the filtration performance of the filter screen. Step 2: Turbidity exceeding the standard triggers the primary response. When the turbidity meter reading is >200ppm, the multi-stage filtration system, intelligent conveying system and impurity collection system are activated. The first-stage filtration unit starts to physically intercept large particulate impurities, and the second-stage filtration unit starts simultaneously to remove medium-sized suspended solids. The conveyor pushes the intercepted impurities to the impurity collection hopper for temporary storage. Step 3: Excessive impurity concentration triggers deep processing When the impurity concentration meter reading after the secondary filtration unit exceeds 500 mg / L, the multi-stage filtration system is fully activated, and the tertiary filtration unit starts immediately, improving the filtration accuracy to below 5 μm. The intelligent conveying system is enhanced, and the speed is dynamically adjusted when the impurity concentration exceeds the standard. The spiral scraper inside the conveyor is activated to prevent high-concentration impurities from causing the conveyor to stall. When the weight of the impurities reaches the set value, the system automatically reminds the management personnel to clean it. Step 4: Dynamic Optimization During Operation The automated control system performs a dual threshold judgment on the impurity concentration meter after the secondary filtration unit every 10 minutes: when the turbidity is >200ppm or the impurity concentration is >500mg / L, the multi-stage filtration system and intelligent conveying system are maintained in operation. The intelligent conveying system receives PLC commands from the automated control system in real time, and the speed is adjusted according to the impurity situation in a gradient: calculation formula: speed RPM=20+K1×(turbidity value-standard value)+K2(impurity concentration value-standard value), where K1 and K2 are adjustment coefficients; Step 5: Water quality restoration and system shutdown When the turbidity is ≤200ppm and the impurity concentration is ≤500mg / L, start the timer. When the stable time reaches 10-20 minutes, all systems will reset.

4. The method for removing slag from thickener overflow water according to claim 3, characterized in that, In step five, the system shutdown is carried out in stages. The shutdown sequence is as follows: the tertiary filtration unit shuts down, then the primary and secondary filtration units shut down after 1 minute, the intelligent conveying system shuts down after 3 minutes, and the impurity collection system shuts down after the compression plate starts to compact for 2 minutes.

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