Digital visual management system and method for barite powder production based on data analysis
The digital management system monitors the barite powder production process in real time, solving the problems of low efficiency and quality fluctuations under traditional management methods and achieving efficient and stable production optimization.
Patent Information
- Application Number
- CN202511148229.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-16
- Publication Date
- 2025-10-14
Smart Images
Figure CN120771990A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of barite powder production, and in particular to a digital visualization management system and method for barite powder production based on data analysis. Background Art
[0002] In the barite powder production process, traditional production management methods rely primarily on empirical judgment. This not only leads to low production efficiency and large quality fluctuations, but also makes it difficult to comprehensively monitor and optimize the production process. With the development of industrial automation and informatization, more and more manufacturers are beginning to seek digital means to improve production management. Barite powder is a key mineral resource widely used in industries such as oil and gas extraction, papermaking, and rubber. Every step in its production process has a direct impact on the quality of the final product. Therefore, how to achieve visual management of the production process through advanced digital technology has become a pressing issue for the industry. Summary of the Invention
[0003] Based on this, it is necessary to provide a digital visualization management system and method for barite powder production based on data analysis to solve at least one of the above technical problems.
[0004] To achieve the above objectives, a digital visualization management method for barite powder production based on data analysis includes the following steps: Step S1: placing the pre-treated barite ore on a conveying structure, conveying the barite ore to a crusher for crushing, and collecting crusher operating parameters and crushed materials; Step S2: feeding the crushed material into a grinding machine for grinding, and collecting the operating status of the grinding equipment during the grinding process; Step S3: The ground material slurry is sent to a cyclone for particle size classification, the qualified material slurry is sent to a screening device, and the unqualified material is returned to the grinder for re-grinding; Step S4: flotation treatment is performed on the pulp in a separation device to separate and obtain barite concentrate pulp; the concentrate pulp is sent to a dehydration process to obtain a finished barite powder; Step S5: The operating status of the grinding equipment, the operating parameters of the crusher and the finished barite powder are transmitted to the digital visual terminal, and the corresponding production parameter adjustment instructions are sent to the production equipment control unit for execution.
[0005] The present invention also provides a barite powder production digital visualization management system based on data analysis, for executing the barite powder production digital visualization management method based on data analysis as described above, the barite powder production digital visualization management system based on data analysis includes: The material crushing module is used to place the pre-treated barite ore on the conveying structure, transport the barite ore to the crusher for crushing, and collect the crusher operating parameters and the crushed material particle size data; The grinding processing module is used to send the particle size data of the crushed material to the grinding machine for grinding processing, and collect the operating status of the grinding equipment during the grinding process; The particle size classification module is used to send the ground material into the cyclone for particle size classification, and the qualified material is sent to the sorting device, and the unqualified material is returned to the grinder for re-grinding; The barite concentrate slurry separation module is used to mix qualified materials and water in proportion to form slurry in the separation device, and flotation treatment is performed on the slurry to separate the barite concentrate slurry; the concentrate slurry is sent to the dehydration process to obtain the finished barite powder; The production parameter adjustment module is used to transmit the operating status of the grinding equipment, the operating parameters of the crusher and the finished barite powder to the digital visual terminal, and send the corresponding production parameter adjustment instructions to the production equipment control unit for execution.
[0006] The beneficial effects of the present invention are: (1) Through a refined barite ore processing process, including crushing, grinding, grading, flotation and other steps, the high purity and uniform particle size distribution of the finished barite powder are ensured. Equipment operating parameters are collected and monitored in real time at each processing step, which can effectively identify abnormal fluctuations in production and ensure that each batch of barite powder produced meets quality standards, thereby improving production stability and controllability.
[0007] (2) Through the real-time transmission of information such as the operating status of production equipment, crusher parameters, and grinding equipment status through digital visual terminals, automatic comparative analysis is performed in combination with preset process parameters, which can quickly generate accurate production adjustment instructions and automatically optimize the production process. This technology significantly improves production efficiency, reduces manual intervention, and reduces equipment failure rates and production downtime.
[0008] (3) The system automatically adjusts equipment parameters to make the production process more flexible and efficient. It can respond to quality fluctuations in real time and automatically adjust key parameters such as grinder speed and crusher gap, thereby reducing energy consumption and material waste, improving the utilization rate of raw materials, and reducing production costs.
[0009] (4) The digital management system makes the production process transparent and provides real-time data feedback, which helps production managers to accurately monitor and optimize the production process. Through historical data analysis, it can provide a reference basis for subsequent production, effectively improving the level of intelligent production and decision-making support capabilities. BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Figure 1 A schematic flow chart of the steps of a digital visualization management method for barite powder production based on data analysis; Figure 2 for Figure 1 Detailed implementation steps of step S3 in FIG. Figure 3 This is a schematic diagram of barite powder production equipment; The purpose, features and advantages of the present invention will be further described with reference to the accompanying drawings and in conjunction with the embodiments. DETAILED DESCRIPTION
[0011] The following is a clear and complete description of the technical method of the present invention in conjunction with the accompanying drawings. It is obvious that the embodiments described are part of the embodiments of the present invention, but not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without making any creative efforts are within the scope of protection of the present invention.
[0012] In addition, the accompanying drawings are merely schematic illustrations of the present invention and are not necessarily drawn to scale. Identical reference numerals in the figures denote identical or similar parts, and thus repetitive descriptions thereof will be omitted. Some of the block diagrams shown in the accompanying drawings are functional entities that do not necessarily correspond to physically or logically separate entities. These functional entities may be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor and / or microcontroller approaches.
[0013] It should be understood that although the terms "first," "second," and the like may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used solely to distinguish one element from another. For example, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element, without departing from the scope of the exemplary embodiments. The term "and / or" as used herein includes any and all combinations of one or more of the listed associated items.
[0014] To achieve this, please refer to Figures 1 to 3 , a digital visualization management method for barite powder production based on data analysis, comprising the following steps: Step S1: placing the pre-treated barite ore on a conveying structure, conveying the barite ore to a crusher for crushing, and collecting crusher operating parameters and crushed materials; Step S2: feeding the crushed material into a grinding machine for grinding, and collecting the operating status of the grinding equipment during the grinding process; Step S3: The ground material slurry is sent to a cyclone for particle size classification, the qualified material slurry is sent to a screening device, and the unqualified material is returned to the grinder for re-grinding; Step S4: flotation treatment is performed on the pulp in a separation device to separate and obtain barite concentrate pulp; the concentrate pulp is sent to a dehydration process to obtain a finished barite powder; Step S5: The operating status of the grinding equipment, the operating parameters of the crusher and the finished barite powder are transmitted to the digital visual terminal, and the corresponding production parameter adjustment instructions are sent to the production equipment control unit for execution.
[0015] In one embodiment, the pretreated barite ore is fed into a jaw crusher via a belt conveyor, the discharge particle size is controlled to be 20-40 mm, and the crusher motor power and discharge particle size data are collected; the crushed material is fed into a ball mill, the speed is set to 75% of the critical speed, and the spindle speed and bearing temperature are collected; the ground slurry is classified by a cyclone, the overflow enters a flotation machine, and the sand is returned to the ball mill; sodium oleate collector and frother are added during flotation to obtain concentrate slurry, which is dehydrated by a chamber filter press to obtain barite powder; the crusher power, grinder speed and finished product particle size data are sent to a digital terminal, and the control unit adjusts the equipment operation.
[0016] In another embodiment, the pretreated barite ore is fed into an impact crusher via a chain conveyor, the discharge particle size is controlled to be 15-30 mm, and the crusher vibration value and feed amount are collected; the crushed material is fed into a rod mill, the rotation speed is set to 70% of the critical speed, and the mill current and cylinder temperature are collected; the ground slurry is classified by a multi-product cyclone, the fine-grained slurry is directly fed into a flotation tank, and the coarse-grained slurry is returned to the rod mill for re-grinding; hydroxamic acid collectors and methyl isobutyl carbinol foaming agents are used during flotation, and the concentrate slurry is dehydrated by a plate and frame filter press to obtain barite powder; the crusher vibration value, mill current and finished product residue rate data are uploaded to a digital terminal, and the operating parameters are adjusted by the equipment control unit.
[0017] Preferably, placing the pretreated barite ore before the conveying structure in step S1 includes: The mined barite ore is transported to a water washing machine through a washing device, where the ore is washed with water to remove surface sediment and fine-grained gangue; The washed ore is graded and screened by a screening machine. The ore blocks with a particle size greater than 50 mm are transported to a heavy medium drum separator for sorting. The ore blocks with a particle size between 2 mm and 50 mm are transported to a jig for sorting. The ore blocks with a particle size less than 2 mm are transported to a shaking table for sorting. The source information and batch identification of the ore obtained after sorting are recorded in the sorting result recording unit, and the recorded ore is transported to the temporary storage silo.
[0018] In one embodiment, the mined barite ore is transported to a crawler feeder via a forklift and then to a drum ore washer, where it is rinsed with circulating clean water and a spray pipe to remove mud and fine-grained gangue adhering to the ore surface. During the rinsing process, the rinse water flow rate and drum speed are set so that the ore tumbles within the drum and comes into full contact with the water. After rinsing, it is graded and screened using a double-layer vibrating screen: Ore blocks with a particle size greater than 50 mm are directly conveyed to a heavy medium drum separator for density difference separation within the sorting trough; Ore blocks with a particle size between 2 mm and 50 mm are conveyed to a jig for specific gravity separation using pulsating water flow; and fine-grained ore with a particle size less than 2 mm is conveyed to a shaking table for stratified sorting based on specific gravity differences. The sorted ores of each particle size are labeled with batch numbers and source information using an automatic weighing and label printing unit, and these labeled ores are uniformly conveyed to a temporary storage silo for subsequent crushing.
[0019] In another embodiment, the mined barite ore is sent to a water flushing device via a belt conveyor, and the surface of the ore is cleaned by a spray water column to remove loose mud and sand; after classification by a screening machine, the ore blocks with a particle size greater than 50 mm are sent to a heavy medium separation equipment, the ore blocks with a particle size between 2 mm and 50 mm are sent to a jig, and the fine material with a particle size less than 2 mm is sent to a shaking table; after sorting, the batch information and source are recorded in a sorting result recording unit, and the ore is sent to a silo for storage.
[0020] Preferably, placing the pretreated barite ore before the conveying structure in step S1 includes: Collect environmental temperature and humidity data in the ore pre-processing area; Determine whether the ambient temperature and humidity are higher than the preset temperature and humidity thresholds; When the ambient temperature and humidity data are higher than the humidity threshold, the dehumidification device is started to dehumidify the pre-processing area until the ambient humidity is lower than the humidity threshold; The environmental conditioning device is controlled to adjust the temperature and humidity of the pretreatment area until the ambient temperature and humidity are both lower than the corresponding thresholds.
[0021] In one embodiment, temperature and humidity sensors installed in the ore pretreatment area collect ambient temperature and humidity data. The sensors use a wireless transmission module to upload the data in real time to a central control system. The control system includes a temperature and humidity determination module that compares the collected data with preset temperature and humidity thresholds to determine whether the environment exceeds the preset thresholds.
[0022] In one implementation of this embodiment, when temperature and humidity data exceed a set humidity threshold, the control system automatically activates a dehumidification device, which includes an industrial dehumidifier and an auxiliary fan. The fan works in conjunction with the dehumidifier to increase air circulation and accelerate the reduction of humidity. The control system monitors humidity changes in real time through a feedback mechanism until the humidity data returns to a preset range.
[0023] In one implementation of this embodiment, when humidity drops below a set threshold, the control system automatically activates a temperature and humidity control device, which includes a heater and a cooling device. The heater controls the temperature of the pretreatment area to ensure it does not exceed a preset upper limit, while the cooling device is used to reduce the temperature if it is too high. The temperature and humidity control device automatically adjusts its operating parameters using a PID control algorithm to ensure that the environmental conditions in the pretreatment area always meet production requirements.
[0024] In one embodiment, a zone-by-zone control system is implemented, allowing each zone to independently control temperature and humidity. The control system precisely adjusts the temperature and humidity within each zone based on real-time data from each zone, ensuring stability and efficiency throughout the production process.
[0025] It should be noted that if the temperature and humidity data in the pretreatment area change drastically, the system will start the emergency dehumidification mode, quickly start multiple dehumidification units and accelerate the reduction of humidity to avoid the impact of humidity fluctuations on subsequent production processes.
[0026] Preferably, step S1 includes the following steps: Step S11: before placing the pre-treated barite ore into the conveying structure, the barite ore is evenly distributed by a vibrating feeder; Step S12: When the conveying structure is started, the conveyor belt running speed is set to 0.8-1.2m / s, and the material flow is monitored in real time by a weighing sensor during the conveying process, and the flow data is fed back to the control system for automatic speed adjustment; Step S13: Before the barite ore enters the crusher, the iron impurities in the material are removed by the iron removal device, which is respectively installed above the conveyor belt and at the end roller; Step S14: During the operation of the crusher, the speed operating parameters of the crusher are synchronously collected, and the online particle size of the crushed material is detected by a laser particle size analyzer. The particle size data is compared with the preset target particle size range. When the particle size deviation exceeds ±5%, the crushing gap of the crusher is automatically adjusted.
[0027] In one embodiment, a vibrating feeder evenly distributes the pre-treated barite ore before placing it on the conveyor belt. The vibrating feeder utilizes electromagnetic vibration to evenly distribute the ore across the entire width of the conveyor belt, ensuring uniformity during subsequent processing. The vibration frequency is adjusted based on the particle size and weight of the ore to ensure that there is no accumulation or blockage during conveyance.
[0028] In one implementation of this embodiment, when the conveyor mechanism is activated, the conveyor belt's operating speed is set to 0.8-1.2 m / s. Load cells installed on the conveyor belt monitor the material flow rate in real time. The load cells measure the change in material weight per unit time, calculate the flow rate, and feed this flow rate data back to the central control system. Based on this feedback, the control system automatically adjusts the conveyor belt's speed by adjusting the motor's speed to ensure that the material flow rate matches the production process requirements and prevent excessively high or low flow rates from causing overload or idleness in subsequent processes.
[0029] In another embodiment, before the barite ore enters the crusher, an iron removal device is used to remove iron impurities from the material. This device includes an electromagnetic iron remover positioned above the conveyor belt and a permanent magnetic iron remover at the end of the conveyor belt. The electromagnetic iron remover has a magnetic field strength of 800-1200 gauss, effectively attracting iron impurities. The permanent magnetic iron remover uses a strong magnetic field to further remove iron material that is not captured by the electromagnetic iron remover.
[0030] In one implementation of this embodiment, the iron removal device monitors the iron removal effect in real time using a metal detector to ensure that the iron impurity content in the material is controlled within a predetermined range, preventing iron from affecting the subsequent crushing process. During the operation of the crusher, the crusher's speed operating parameters are synchronously collected, and the crushed material is subjected to online particle size measurement using a laser particle size analyzer. The laser particle size analyzer can detect the particle size distribution of the crushed material in real time, and the collected particle size data is compared with the preset target particle size range.
[0031] In one implementation of this embodiment, when the particle size deviation exceeds ±5%, the system automatically issues an adjustment command to restore the crushed particle size to the predetermined range by adjusting the crusher's crushing gap. The control system precisely adjusts the crusher's operating parameters based on real-time data to ensure stable and efficient crushing.
[0032] The vibrating feeder's frequency is set at 45 Hz to ensure uniform distribution of barite ore particles on the conveyor belt. Feedback from a load cell maintains the conveyor belt's speed at 1.0 m / s, keeping the material flow rate within ±2% of the set value. A permanent magnetic iron remover at the end of the conveyor removes over 99.5% of iron impurities throughout the entire process, ensuring the proper operation of the crusher and other equipment.
[0033] It should be noted that experimental tests were conducted to verify the accuracy of particle size control. Using particle size distribution data measured by a laser particle size analyzer, we found that when the crusher speed exceeds the preset range, the particle size deviation can reach ±8%. In this case, the system automatically adjusts the crusher gap, and after adjustment, the particle size deviation is controlled within ±3%, demonstrating the effectiveness of the system's automatic adjustment function.
[0034] Preferably, step S13 includes the following steps: Step S131: an electromagnetic iron remover is installed above the conveyor belt at a distance of 120-150 mm from the surface of the material. The magnetic field strength of the electromagnetic iron remover is set to 800-1200 Gauss, and the ratio of power-on time to power-off time is set to 3:1. Step S132: a permanent magnetic iron remover is installed at the end roller of the conveyor belt, and the surface magnetic field strength is set to 1500-1600 Gauss; Step S133: During the operation of the iron removal device, the iron removal effect is monitored in real time by a metal detector. When the concentration of iron impurities detected exceeds a preset threshold, the power-on time of the electromagnetic iron remover is automatically extended and the conveyor belt speed is reduced; Step S134: The iron impurities adsorbed by the electromagnetic iron remover are transported to the waste collection box through the iron unloading belt.
[0035] In one embodiment, an electromagnetic iron remover is positioned above the conveyor belt, 120-150 mm from the material surface. The magnetic field strength of the electromagnetic iron remover is set to 800-1200 gauss. The electromagnetic iron remover's power control system uses a timed control mechanism, with a power-on time to power-off time ratio of 3:1. When powered on, the electromagnetic iron remover generates a strong magnetic field, attracting iron impurities from the material. When powered off, the magnetic field disappears, and the iron impurities fall to a collection area below the conveyor belt.
[0036] A permanent magnetic separator is installed on the roller at the end of the conveyor belt. Its surface magnetic field strength is set to 1500-1600 gauss. The strong magnetic field of the permanent magnetic separator captures iron impurities that are not removed by the electromagnetic separator, ensuring the integrity of the iron removal process. The permanent magnetic separator works by directly attracting iron impurities through a static magnetic field, requiring no additional power supply and reducing energy consumption.
[0037] In another embodiment, a metal detector is provided to monitor the state of the material on the conveyor belt in real time during the operation of the iron removal device. The metal detector can detect the concentration of iron impurities in the material while the conveyor belt is running. Whenever the concentration of iron impurities detected exceeds a preset threshold, the metal detector triggers the control system to issue an alarm signal. Based on this signal, the control system automatically extends the power supply time of the electromagnetic iron remover and reduces the operating speed of the conveyor belt to increase the contact time between the material and the magnetic field, thereby improving the removal of iron impurities.
[0038] In one implementation of this embodiment, iron impurities adsorbed by the electromagnetic remover are transported to a waste collection bin via a discharge conveyor. This discharge conveyor activates after the electromagnetic remover is powered off, collects the adsorbed iron impurities, and automatically transports them to the waste collection bin via a roller mechanism. The waste collection bin is equipped with a full-load sensor. When the bin reaches a preset capacity, the system automatically stops the iron removal device to prevent overload and prompts the user to clean the waste.
[0039] It should be noted that the electromagnetic iron remover's magnetic field strength is set to 1000 gauss, with a power-on time of 20 seconds and a power-off time of 6 seconds, ensuring effective adsorption of iron impurities during transportation. Under the control of the metal detector, when the iron impurity concentration exceeds the preset threshold of 0.5%, the system automatically extends the electromagnetic iron remover's power-on time to 30 seconds and adjusts the conveyor belt speed to 0.8m / s to ensure maximum iron removal.
[0040] It should be noted that field tests were conducted. The magnetic field strength of the electromagnetic remover was set to 950 gauss, and the magnetic field strength of the permanent magnet remover was set to 1550 gauss. Under the control system's regulation, the electromagnetic remover's power-on time was extended to 35 seconds, and the conveyor belt speed was slowed to 0.7 m / s. Real-time monitoring by the metal detector revealed that the iron impurity concentration was successfully reduced from 1.2% to 0.2%, meeting quality requirements and demonstrating the effectiveness of the system's automatic adjustment.
[0041] Preferably, step S2 includes the following steps: Step S21: conveying the crushed material to the grinding machine feed port via a conveyor belt, and performing weight detection during the conveying process; Step S22: feeding the tested material into the grinding chamber of the grinder, starting the grinder, and recording the start-up time and initial speed; Step S23: When the grinding machine is running, the operating status of the grinding equipment is collected at preset time intervals and stored in a data recording unit; Step S24: After the grinding is completed, the particle size distribution of the ground material is detected, and the particle size distribution data and the operating parameters are stored in correspondence.
[0042] In one embodiment, crushed material is delivered to the grinder feed via a conveyor belt. The conveyor belt is equipped with a load cell that monitors material weight in real time and adjusts the conveyor speed based on flow data to ensure stable conveying. After the material enters the grinder, the system records the grinder's startup time and initial speed (500 rpm). After the grinder starts, the system adjusts the speed based on the material type to ensure optimal grinding.
[0043] In one implementation of this embodiment, during the grinding process, the control system collects grinding mill operating parameters, such as rotational speed and power consumption, every 30 seconds and stores them in a data recording unit for subsequent analysis. After grinding, an automatic sampling device collects a 100g sample and feeds it into a laser particle size analyzer to measure particle size distribution. The results are stored in association with the operating parameters with a timestamp.
[0044] It should be noted that the load cell data indicates a stable material flow rate of 1000 kg / h. The conveyor belt speed is set at 0.9 m / s to ensure even material delivery to the grinder. The control system adjusts the grinder speed in real time based on this data, starting at 500 rpm and gradually increasing to 600 rpm over 30 minutes to ensure optimal grinding efficiency.
[0045] It should be noted that actual testing using a laser particle size analyzer revealed a particle size distribution range of 0.5 μm to 150 μm after grinding, within ±5% of the target particle size range, verifying the stability of the grinding process. During the five-hour experiment, the system automatically adjusted the grinder speed based on real-time operating data, ensuring that the particle size distribution remained within the specified range. Furthermore, the relationship between process parameters and particle size distribution remained consistent.
[0046] Preferably, step S23 includes the following steps: Step S231: When the grinding machine is running, the data collection interval is set to 30-120 seconds through the preset time controller, and the trigger conditions of the collection start signal and the collection end signal are set; Step S232: At each acquisition time point, the spindle speed of the grinding machine is measured using a Hall effect sensor. The sensor is installed at the end of the spindle 2-5 mm away from the rotor blade. The output frequency signal is converted into a speed value using a frequency counter. The measurement accuracy is set to ±0.1%, which is used as the operating status parameter of the grinding equipment. Step S233: Transmitting the collected operating status parameters to the data recording unit via the communication protocol.
[0047] In one embodiment, while the grinder is running, a timer is used to set the data collection interval to 30-120 seconds, and trigger conditions are set to start and end data collection. The trigger conditions can be a timing signal after the grinder is started or a trigger based on changes in material weight. At each data collection time point, a Hall effect sensor measures the grinder's spindle speed.
[0048] The sensor is mounted at the end of the spindle, 2-5 mm from the rotor blades. Its output frequency signal is converted to rotational speed data via a frequency counter with an accuracy of ±0.1%. This data serves as a parameter for the grinding machine's operating status. The collected rotational speed data is transmitted via a communication protocol to a data recording unit, which stores the data with a timestamp and uploads it to a central monitoring system.
[0049] It should be noted that the time controller is set to trigger data acquisition every 60 seconds, and the Hall effect sensor monitors the speed in real time, ensuring speed accuracy within ±0.1%. The data is transmitted to the data recording unit via the RS485 protocol, stored, and associated with other operating parameters.
[0050] It should be noted that experimental verification shows that the sensor collects data every 30 seconds. During testing, the Hall effect sensor accurately measured the rotational speed, which matched the preset target speed, ensuring the grinding machine's stable and efficient operation.
[0051] Preferably, step S24 includes the following steps: Step S241: After the grinding is completed, the material sample is collected from the grinding machine outlet at a set interval by an automatic sampling device, and the sampling amount each time is controlled to be 50-100g; Step S242: sending the collected material sample to a laser particle size analyzer for particle size distribution detection, setting the detection range to 0.1-500 μm and the scanning time to 60-180 seconds, as the particle size distribution data; Step S243: Output the particle size distribution data obtained by the detection in the form of a particle size distribution curve, and save the data in CSV format; Step S244: performing time stamp matching and storage on the particle size distribution data and the operating parameters in the corresponding grinding cycle, and establishing a particle size-process parameter correspondence data table.
[0052] In one embodiment, after grinding, an automatic sampling device collects material samples from the grinder outlet at set intervals (e.g., every 30 minutes). The sampling volume is controlled at 50-100 g per sample. The sampling device uses a vibrating screening mechanism to ensure uniform sampling and avoid sample bias. The collected material samples are then fed into a laser particle size analyzer for particle size distribution analysis. The laser particle size analyzer is set to a detection range of 0.1-500 μm and a scan time of 120 seconds.
[0053] In one implementation of this embodiment, the instrument automatically records the particle size distribution during each scan and exports the data immediately after the scan is completed. The particle size distribution data detected by the laser particle size analyzer is output as a particle size distribution curve, stored in a local data recording unit in CSV format, and a report file is generated. The particle size distribution data is timestamped and stored with corresponding operating parameters within the grinding cycle (such as rotational speed and power consumption). This data is uploaded to a central server via the data recording unit, generating a data table of particle size-process parameter correspondences for subsequent process optimization.
[0054] It should be noted that the sampling device takes samples once every 30 minutes, and the sampling volume is stable at 75g. The scanning time of the laser particle size analyzer is set to 120 seconds, and the output particle size data is saved in CSV format and associated with the grinder speed and power data at the corresponding time. The particle size-process parameter table is stored on the central server and managed through the database. It was found in the experiment that after 4 hours of grinding, the automatic sampling stability of the sampling device was high, and there was no uneven sampling or error. The matching degree between the scanning data of the laser particle size analyzer and the actual process parameters reached more than 95%, verifying the accuracy of data recording and storage.
[0055] Preferably, step S4 includes the following steps: Step S41: flotation treatment is performed on the pulp by a flotation machine, a collector and a frother are added to the pulp, and the pulp concentration is adjusted; Step S42: transporting the barite concentrate slurry obtained by separation to a thickener for concentration treatment, controlling the underflow concentration and removing the supernatant to separate the barite concentrate slurry; Step S43: sending the separated barite concentrate slurry into a filter press for dehydration to obtain a finished barite powder.
[0056] In one embodiment, the slurry is subjected to flotation processing in a flotation cell. Before entering the flotation cell, a collector and a frother are added to the slurry. The collector dosage is controlled at 100g / ton of slurry, and the frother dosage is controlled at 50g / ton of slurry. The slurry concentration is controlled by adjusting the feed rate to the flotation cell, with a target slurry concentration set at 20%.
[0057] After the flotation machine is started, the slurry enters the flotation cell. Air is introduced into the cell via an air pump, forming bubbles that come into contact with the slurry, causing mineral particles to adhere to the bubbles. The flotation process lasts for 30 minutes. The sorted barite concentrate slurry is then piped to the thickener. The underflow concentration of the thickener is controlled at around 35% by an automatic flow control valve.
[0058] The supernatant is discharged through the overflow, and the concentrate is transported through the bottom of the concentration zone to subsequent processing. During the concentration process, the underflow concentration rate is set at 2 m³ / h to ensure a stable barite concentrate concentration. The concentrated barite concentrate is then transported to a filter press for dewatering.
[0059] The filter press is set to automatic operation, with the filter plate spacing adjusted to 10 mm, the filtration pressure set to 0.8 MPa, and the filtration time set to 30 minutes. The filter press automatically discharges after each dehydration cycle, and the resulting barite powder is transported through the discharge port to the finished product bin. The dehydrated material is then dried to obtain the finished barite powder that meets the requirements.
[0060] It should be noted that the collector and frother added to the flotation machine are 50g / ton of pulp and 30g / ton of pulp respectively, and the pulp concentration is controlled at 18%. The operating power of the air pump in the flotation cell is set to 2.5kW to maintain a uniform distribution of bubbles. The slurry is processed in the flotation machine for 25 minutes to ensure effective flotation of barite minerals. Experiments have shown that by optimizing the flotation time to 40 minutes, the recovery rate of barite concentrate has increased by 10%. In the thickener, the underflow concentration is controlled at 32%, and the water quality of the supernatant when discharged meets the specified standards. During the operation of the filter press, the filter plate cleaning time is set to be cleaned every 5 rounds of filtration to ensure a continuous and stable filtration effect.
[0061] It is particularly important that step S42 includes the following steps: Step S421: feeding the barite concentrate slurry into the thickener, and adjusting the feeding speed so that the concentrate slurry forms a material layer in the thickener tank; Step S422: When the barite particles settle in the thickening tank, the rake rotates to push the sediment toward the bottom discharge port; Step S423: controlling the opening of the underflow discharge valve to maintain the underflow concentration and continuously discharge the concentrated concentrate slurry; Step S424: the supernatant is discharged from the overflow port, and the concentrated barite concentrate slurry is output through the bottom flow port.
[0062] In one embodiment, the barite concentrate slurry is fed into a thickener through a pipeline. The feed rate is adjusted so that the concentrate slurry forms a uniform material layer in the thickening tank. The feed rate is set to 20 tons / hour to ensure that the concentrate slurry is evenly distributed in the thickening tank and the material layer height is maintained at 50-60 cm. The control system monitors the material layer thickness in real time and dynamically adjusts it based on the liquid level sensor data of the thickening tank. When the barite particles begin to settle in the thickening tank, the rake starts to rotate, pushing the sediment to move toward the bottom discharge port. The rake speed is set to 2 rpm to ensure that the sediment moves evenly and continuously to the bottom, preventing uneven sedimentation caused by sediment accumulation.
[0063] The rake utilizes a mechanical transmission mechanism, powered by a hydraulic system, to steadily propel the material. The underflow discharge valve opening is controlled to maintain a stable underflow concentration. The valve opening is adjusted based on the real-time underflow concentration, maintaining a concentration between 30-35%. The underflow concentration is monitored every 10 minutes, and if it deviates from the set range, the valve opening is automatically adjusted. The concentrate slurry is continuously discharged, with an hourly discharge rate controlled at 18 tons, ensuring a stable and continuous concentration process.
[0064] The supernatant is discharged from the overflow port. After a period of concentration, the concentrated barite concentrate slurry is discharged through the underflow port. A level sensor at the overflow port monitors the level in real time to ensure that the supernatant discharge volume is consistent with the set value. The concentrated concentrate slurry is steadily discharged to subsequent processing equipment at a flow rate of 15 tons per hour, ensuring continuous production.
[0065] In one embodiment, the concentrate slurry feed rate is set at 25 tons / hour, and a level sensor ensures the material bed height is consistently maintained at 60 cm. Under this setting, the rake speed is 2 rpm, and the sediment accumulation is controlled within 500 kg during each sediment removal, ensuring uniform deposition and smooth discharge.
[0066] It should be noted that experimental data indicates that optimal concentration is achieved when the underflow concentration is controlled at 32%. The underflow discharge valve opening is set at 60% to ensure stable concentrate discharge. During thickener operation, the overflow level is controlled within ±10mm, ensuring stable supernatant discharge and concentrate flow.
[0067] It is particularly important that step S5 includes the following steps: Step S51: evaluating the finished product quality information of the barite powder finished product; Step S52: The operating status of the grinding equipment, the operating parameters of the crusher, and the quality information of the finished product are transmitted to the digital visual terminal via the communication network, and the terminal display screen displays the production status information in real time; Step S53: The digital visual terminal compares and analyzes the current production data according to the preset process parameters and generates corresponding parameter adjustment instructions; Step S54: Send the generated adjustment instruction to the control unit of each production device through the control network. After receiving the instruction, the control unit performs the corresponding device parameter adjustment operation.
[0068] In one embodiment, the quality of the finished barite powder is assessed using an online detection system that monitors the particle size, purity, and moisture content of the finished product in real time. The finished product is automatically sampled and evaluated every 10 minutes, with a sampling volume of 100g. The test data is uploaded to a central database in real time. The operating status of the grinding equipment, the operating parameters of the crusher, and the quality information of the finished product are transmitted to a digital visual terminal via a wireless network.
[0069] The terminal screen displays real-time production status information, including current particle size, concentration, and production progress. The digital visual terminal compares and analyzes preset process parameters with current production data and generates adjustment instructions. For example, if the finished product particle size deviation exceeds ±5%, the terminal generates corresponding adjustment instructions, including increasing or decreasing the grinding mill speed or adjusting the crusher gap. These generated adjustment instructions are sent to the control unit of each production equipment via the control network. Upon receiving the instructions, the control unit automatically adjusts the equipment parameters to ensure that the production process meets preset standards. After the adjustments, the equipment continues to operate, and its status is monitored through the terminal.
[0070] In another example, a particle size assessment of the finished product shows a particle size distribution between 0.5 and 100 μm, with a moisture content of 2%. The digital visual terminal displays the current particle size deviation as ±3%, generating adjustment instructions to increase the grinding mill speed to 600 rpm and adjust the crusher gap to 5 mm.
[0071] It should be noted that experimental data shows that when the moisture content exceeds 3%, the system will automatically adjust the operating parameters of the crusher and grinder to ensure that the moisture content remains between 2% and 3% to maintain production stability.
[0072] The present invention also provides a barite powder production digital visualization management system based on data analysis, for executing the barite powder production digital visualization management method based on data analysis as described above, the barite powder production digital visualization management system based on data analysis includes: The material crushing module 101 is used to place the pre-treated barite ore into a conveying structure, transport the barite ore to a crusher for crushing, and collect crusher operating parameters and crushed material particle size data; The grinding processing module 102 is used to send the particle size data of the crushed material to the grinding machine for grinding processing, and collect the operating status of the grinding equipment during the grinding process; The particle size classification module 103 is used to send the ground material into the cyclone for particle size classification, send the qualified material to the sorting device, and return the unqualified material to the grinder for re-grinding; The barite concentrate slurry separation module 104 is used to mix qualified materials and water in proportion to form a slurry in the separation device, and flotation the slurry to separate the barite concentrate slurry; the concentrate slurry is sent to the dehydration process to obtain the finished barite powder; The production parameter adjustment module 105 is used to transmit the operating status of the grinding equipment, the operating parameters of the crusher and the finished barite powder to the digital visual terminal, and send the corresponding production parameter adjustment instructions to the production equipment control unit for execution.
[0073] The foregoing description is intended only to provide specific embodiments of the present invention, which will enable those skilled in the art to understand and implement the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not intended to be limited to the embodiments shown herein, but is to be construed in the widest possible manner consistent with the principles and novel features disclosed herein.
Claims
1. A digital visualization management method for barite powder production based on data analysis, characterized in that, The following steps are involved: Step S1: placing the pre-treated barite ore on a conveying structure, conveying the barite ore to a crusher for crushing, and collecting crusher operating parameters and crushed materials; Step S2: feeding the crushed material into a grinding machine for grinding, and collecting the operating status of the grinding equipment during the grinding process; Step S3: The ground material slurry is sent to a cyclone for particle size classification, the qualified material slurry is sent to a screening device, and the unqualified material is returned to the grinder for re-grinding; Step S4: flotation treatment is performed on the pulp in a separation device to separate and obtain barite concentrate pulp; the concentrate pulp is sent to a dehydration process to obtain a finished barite powder; Step S5: The operating status of the grinding equipment, the operating parameters of the crusher and the finished barite powder are transmitted to the digital visual terminal, and the corresponding production parameter adjustment instructions are sent to the production equipment control unit for execution.
2. The digital visualization management method for barite powder production based on data analysis according to claim 1, wherein Placing the pre-treated barite ore in front of the conveying structure in step S1 includes: The mined barite ore is transported to a water washing machine through a washing device, where the ore is washed with water to remove surface sediment and fine-grained gangue; The washed ore is graded and screened by a screening machine. The ore blocks with a particle size greater than 50 mm are transported to a heavy medium drum separator for sorting. The ore blocks with a particle size between 2 mm and 50 mm are transported to a jig for sorting. The ore blocks with a particle size less than 2 mm are transported to a shaking table for sorting. The source information and batch identification of the ore obtained after sorting are recorded in the sorting result recording unit, and the recorded ore is transported to the temporary storage silo.
3. The digital visualization management method for barite powder production based on data analysis according to claim 2, wherein Placing the pre-treated barite ore in front of the conveying structure in step S1 includes: Collect environmental temperature and humidity data in the ore pre-processing area; Determine whether the ambient temperature and humidity are higher than the preset temperature and humidity thresholds; When the ambient temperature and humidity data are higher than the humidity threshold, the dehumidification device is started to dehumidify the pre-processing area until the ambient humidity is lower than the humidity threshold; The environmental conditioning device is controlled to adjust the temperature and humidity of the pretreatment area until the ambient temperature and humidity are both lower than the corresponding thresholds.
4. The digital visualization management method for barite powder production based on data analysis according to claim 1, wherein Step S1 includes the following steps: Step S11: before placing the pre-treated barite ore into the conveying structure, the barite ore is evenly distributed by a vibrating feeder; Step S12: When the conveying structure is started, the conveyor belt running speed is set to 0.8-1.2m / s, and the material flow is monitored in real time by a weighing sensor during the conveying process, and the flow data is fed back to the control system for automatic speed adjustment; Step S13: Before the barite ore enters the crusher, the iron impurities in the material are removed by the iron removal device, which is respectively installed above the conveyor belt and at the end roller; Step S14: During the operation of the crusher, the speed operating parameters of the crusher are synchronously collected, and the online particle size of the crushed material is detected by a laser particle size analyzer. The particle size data is compared with the preset target particle size range. When the particle size deviation exceeds ±5%, the crushing gap of the crusher is automatically adjusted.
5. The digital visualization management method for barite powder production based on data analysis according to claim 4, wherein Step S13 includes the following steps: Step S131: an electromagnetic iron remover is installed above the conveyor belt at a distance of 120-150 mm from the surface of the material. The magnetic field strength of the electromagnetic iron remover is set to 800-1200 Gauss, and the ratio of power-on time to power-off time is set to 3:
1. Step S132: a permanent magnetic iron remover is installed at the end roller of the conveyor belt, and the surface magnetic field strength is set to 1500-1600 Gauss; Step S133: During the operation of the iron removal device, the iron removal effect is monitored in real time by a metal detector. When the concentration of iron impurities detected exceeds a preset threshold, the power-on time of the electromagnetic iron remover is automatically extended and the conveyor belt speed is reduced; Step S134: The iron impurities adsorbed by the electromagnetic iron remover are transported to the waste collection box through the iron unloading belt.
6. The digital visualization management method for barite powder production based on data analysis according to claim 1, wherein Step S2 includes the following steps: Step S21: conveying the crushed material to the grinding machine feed port via a conveyor belt, and performing weight detection during the conveying process; Step S22: feeding the tested material into the grinding chamber of the grinder, starting the grinder, and recording the start-up time and initial speed; Step S23: When the grinding machine is running, the operating status of the grinding equipment is collected at preset time intervals and stored in a data recording unit; Step S24: After the grinding is completed, the particle size distribution of the ground material is detected, and the particle size distribution data and the operating parameters are stored in correspondence.
7. The digital visualization management method for barite powder production based on data analysis according to claim 6, wherein Step S23 includes the following steps: Step S231: When the grinding machine is running, the data collection interval is set to 30-120 seconds through the preset time controller, and the trigger conditions of the collection start signal and the collection end signal are set; Step S232: At each acquisition time point, the spindle speed of the grinding machine is measured using a Hall effect sensor. The sensor is installed at the end of the spindle 2-5 mm away from the rotor blade. The output frequency signal is converted into a speed value using a frequency counter. The measurement accuracy is set to ±0.1%, which is used as the operating status parameter of the grinding equipment. Step S233: Transmitting the collected operating status parameters to the data recording unit via the communication protocol.
8. The digital visualization management method for barite powder production based on data analysis according to claim 6, wherein Step S24 includes the following steps: Step S241: After the grinding is completed, the material sample is collected from the grinding machine outlet at a set interval by an automatic sampling device, and the sampling amount each time is controlled to be 50-100g; Step S242: sending the collected material sample to a laser particle size analyzer for particle size distribution detection, setting the detection range to 0.1-500 μm and the scanning time to 60-180 seconds, as the particle size distribution data; Step S243: Output the particle size distribution data obtained by the detection in the form of a particle size distribution curve, and save the data in CSV format; Step S244: performing time stamp matching and storage on the particle size distribution data and the operating parameters in the corresponding grinding cycle, and establishing a particle size-process parameter correspondence data table.
9. The digital visualization management method for barite powder production based on data analysis according to claim 1, wherein Step S4 includes the following steps: Step S41: flotation treatment is performed on the pulp by a flotation machine, a collector and a frother are added to the pulp, and the pulp concentration is adjusted; Step S42: transporting the barite concentrate slurry obtained by separation to a thickener for concentration treatment, controlling the underflow concentration and removing the supernatant to separate the barite concentrate slurry; Step S43: sending the separated barite concentrate slurry into a filter press for dehydration to obtain a finished barite powder.
10. A digital visualization management system for barite powder production based on data analysis, characterized in that: For executing the digital visualization management method for barite powder production based on data analysis according to claim 1, the digital visualization management system for barite powder production based on data analysis comprises: The material crushing module is used to place the pre-treated barite ore on the conveying structure, transport the barite ore to the crusher for crushing, and collect the crusher operating parameters and the crushed material particle size data; The grinding processing module is used to send the particle size data of the crushed material to the grinding machine for grinding processing, and collect the operating status of the grinding equipment during the grinding process; The particle size classification module is used to send the ground material into the cyclone for particle size classification, and the qualified material is sent to the sorting device, and the unqualified material is returned to the grinder for re-grinding; The barite concentrate slurry separation module is used to mix qualified materials and water in proportion to form slurry in the separation device, and flotation treatment is performed on the slurry to separate the barite concentrate slurry; the concentrate slurry is sent to the dehydration process to obtain the finished barite powder; The production parameter adjustment module is used to transmit the operating status of the grinding equipment, the operating parameters of the crusher and the finished barite powder to the digital visual terminal, and send the corresponding production parameter adjustment instructions to the production equipment control unit for execution.