Building solid waste high-quality recycled aggregate regeneration method

Abstract

The invention discloses a regeneration method of building solid waste high-quality recycled aggregate. The method comprises the following steps: raw material pretreatment: removing impurities by adopting an AI vision-near infrared spectrum collaborative sorting method, pre-crushing by adopting a crushing parameter dynamic closed-loop control method, and pre-screening and removing mud by adopting a gradient spraying-negative pressure mud removal method; performing multi-stage crushing, namely performing intermediate crushing by adopting a lamination energy grading distribution method and performing fine crushing by adopting a dual-mode switching shaping method; a magnetic field-rotating speed linkage optimization method is adopted for magnetic separation, a density grading winnowing method is adopted for removing light impurities, an ultrasonic wave-water flow collaborative cleaning method is adopted for deep cleaning, and a negative pressure-high frequency vibration collaborative powder removal method is adopted for powder removal; performing particle optimization: performing shaping by adopting a real-time morphology feedback-energy regulation and control method, and performing secondary screening by adopting an intelligent grading-backflow regulation and control method; dehydrating and drying; managing and controlling finished products; storing and transporting; the finally produced recycled aggregate satisfies the following conditions: the crushing value is less than or equal to 23%, the mud content is less than or equal to 0.3%, the needle-sheet content is less than or equal to 12%, the roundness coefficient is greater than or equal to 0.75, the water content is 3-5%, and the recycled aggregate is adaptive to C30 and above recycled concrete.

Description

Technical Field

[0001] This invention relates to the field of construction solid waste recycling technology, and in particular to a method for recycling high-quality recycled aggregates from construction solid waste. Background Technology

[0002] With the acceleration of urbanization and the upgrading of the construction industry, the annual production of construction waste (especially concrete waste) has exceeded 2 billion tons. Traditional landfill and stockpiling methods not only occupy a large amount of land resources, but also easily cause environmental problems such as soil pollution and dust dispersion. As the core product of construction waste resource utilization, recycled aggregates directly determine the strength, durability, and engineering applicability of recycled concrete. Among them, high-strength recycled concrete of C30 and above places stringent requirements on the purity, particle shape, particle size distribution, and stability of aggregates.

[0003] Existing high-quality recycled aggregate recycling technologies mainly rely on the traditional process of "crushing-screening-washing-shaping" and use conventional equipment such as jaw crushers, cone crushers, sand washers, and vibrating screens. However, in practical applications, there are the following technical pain points that are difficult to solve: low accuracy of impurity identification and removal, poor stability of particle shape and particle size control, insufficient accuracy of moisture content control, incomplete quality traceability system, poor energy consumption and environmental performance, and crude handling of unqualified products.

[0004] To address the aforementioned technical shortcomings, there is an urgent need to develop a recycling technology that is based on existing mature equipment and upgraded through innovative methods. This technology should improve the performance of recycled aggregates, reduce energy consumption, and make traceability transparent without significantly increasing equipment investment, thus meeting the application requirements of C30 and above recycled concrete. Summary of the Invention

[0005] To address the shortcomings in the aforementioned background technology, this invention proposes a high-quality recycled aggregate recycling method for construction solid waste. The technical problem to be solved is: how to improve the performance of recycled aggregate, reduce energy consumption, and achieve transparent traceability without significantly increasing equipment investment, so as to meet the application requirements of C30 and above recycled concrete.

[0006] The technical solution of this invention is as follows: A method for recycling high-quality recycled aggregates from construction solid waste includes the following steps: (1) Raw material pretreatment: AI vision-near infrared spectroscopy collaborative sorting method is used to remove impurities, dynamic closed-loop control method of crushing parameters is used for pre-crushing, and gradient spray-negative pressure sludge removal method is used for pre-screening and sludge removal. (2) Multi-stage crushing: medium crushing is carried out by the layered energy graded distribution method, and fine crushing is carried out by the dual-mode switching shaping method; (3) Deep purification: magnetic separation is performed by magnetic field-rotation speed linkage optimization method, light impurities are removed by density classification air separation method, deep cleaning is performed by ultrasonic-water flow coordinated cleaning method, and powder removal is performed by negative pressure-high frequency vibration coordinated powder removal method. (4) Particle optimization: Real-time morphology feedback-energy regulation method is used for shaping, and intelligent classification-reflux regulation method is used for secondary screening; (5) Dehydration and drying: Dehydration is carried out by moisture content pre-control-discharge synergistic method, and drying is carried out by heat pump-natural gas synergistic drying method; (6) Finished product control: Multi-indicator synchronous online detection method is used for detection, blockchain-IoT traceability method is used for traceability, and non-conforming products are handled by graded processing method; (7) Storage and transportation: The intelligent warehouse group linkage control method is used for storage, and the temperature and humidity compensation method is used for transportation. The final recycled aggregate meets the following requirements: crushing value ≤23%, mud content ≤0.3%, needle and flaky content ≤12%, roundness coefficient ≥0.75, moisture content 3-5%, and is suitable for C30 and above recycled concrete.

[0007] Furthermore, the AI ​​vision-near-infrared spectroscopy collaborative sorting method includes: installing three high-definition industrial cameras (sampling frequency 30 frames / second) and two near-infrared spectral sensors (detection wavelength 780-2526nm) sequentially above the belt of the tracked sorting machine. The collected material images and spectral data are uploaded to an edge computing terminal with a built-in CNN model. After identifying impurities, the machine is accurately sorted by a pneumatic push rod (response time ≤0.2 seconds). At the same time, a permanent magnet drum separator is linked to adaptively adjust the magnetic field strength (8000-15000Gs), achieving a magnetic metal removal rate of ≥99.5%.

[0008] Furthermore, the dynamic closed-loop control method for crushing parameters includes: installing a pressure sensor at the discharge port of the vibrating feeder to detect the compressive strength of the raw material, automatically matching the jaw plate gap (80-120mm) and the feeding speed (18-22t / h); installing a laser particle size sensor at the discharge port of the jaw crusher to provide real-time feedback and adjust the feeding speed (±1-2t / h) and the jaw plate gap (±5mm) to ensure that the discharge particle size is ≤100mm and accounts for ≥95%.

[0009] Furthermore, the ultrasonic-water synergistic cleaning method includes: integrating an ultrasonic generator (frequency 40kHz, power 1.5kW / m²) along the length of the inner wall of the washing tank of the double spiral sand washing machine; mixing aggregate and water at a mass ratio of 1:3; and cleaning for 2 minutes through the synergistic action of ultrasonic cavitation, spiral stirring, and water rinsing, resulting in an aggregate surface cleanliness ≥98% and a mud content ≤0.3%; and a matching wastewater recycling system that uses a water quality sensor to link an automatic dosing device, ensuring that the suspended solids in the return water are ≤30mg / L and the recycling rate is ≥95%.

[0010] Furthermore, the real-time morphology feedback-energy control method includes: installing a high-speed particle image analyzer (sampling frequency 50 frames / second) at the discharge port of the impact shaping machine to detect the particle roundness coefficient and needle-like content in real time, and dynamically adjusting the rotor speed (1200-1500 r / min), the feed cone angle (40-50°), and the guide plate angle so that the material undergoes 3-4 collisions and grindings, with a roundness coefficient ≥0.75 and a needle-like content ≤12%; when the shaping chamber temperature is ≥80℃, the air-cooling system (wind speed 10m / s) is activated to cool down.

[0011] Furthermore, the heat pump-natural gas synergistic drying method includes: a drum dryer integrating an air source heat pump (COP value ≥3.5) and a natural gas burner, switching between single heat pump or synergistic heating modes according to aggregate moisture content (≤12% / >12%) and ambient temperature (≥5℃ / <5℃), segmented temperature control of 60-110℃, and real-time monitoring through a microwave moisture meter (detection depth ≥5cm), ensuring that the finished product moisture content is stable at 3-5%, with a fluctuation range of ≤±0.5%.

[0012] Furthermore, the blockchain-IoT traceability method includes: installing IoT sensors at key nodes in raw material entry, production, storage and transportation; encrypting the collected raw material information, equipment parameters, test data and transportation trajectory and uploading them to the blockchain platform to generate a unique traceability QR code, thereby achieving tamper-proof traceability of data throughout the entire process.

[0013] Furthermore, the non-conforming product grading and processing method includes: slightly non-conforming products (mud content 0.3-0.5%, needle-like and flaky content 12-15%) are returned to the sand washing machine for enhanced ultrasonic cleaning; moderately non-conforming products (crushing value 23-25%, roundness coefficient 0.7-0.75) are returned to the shaping machine for high-speed multi-stage collision shaping; severely non-conforming products (crushing value 25-28%, mud content 0.5-0.8%) are returned to the cone crusher for re-crushing; and seriously non-conforming products (excessive heavy metals / chloride ions, crushing value > 28%) are downgraded for use as roadbed fill material.

[0014] Furthermore, the density-based air separation method includes: the horizontal air separator is divided into upper and lower air ducts, the upper air duct has a wind speed of 3-5 m / s to separate low-density impurities (wood chips, paper scraps), and the lower air duct has a wind speed of 6-8 m / s to separate medium-density impurities (plastics). The wind speed is adjusted in a closed loop by a material purity sensor, and the removal rate of light impurities is ≥99%, and the aggregate loss rate is ≤0.5%.

[0015] Furthermore, the intelligent warehouse cluster linkage control method includes: multiple closed finished product warehouses realize the transfer of humid air between warehouses through temperature and humidity sensors and material level sensors; after high-grade aggregates are put into the warehouse, they are aged for 72 hours and stress is released through the bottom ventilation system (wind speed 2m / s), and the crushing value is further reduced by 1-2%.

[0016] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a high-quality recycled aggregate recycling method for construction solid waste. Through the deep integration of "existing equipment + novel method", it has the following beneficial effects compared with existing technologies: The aggregate performance has been significantly improved: the mud content has been reduced from ≤0.5% to ≤0.3%, the needle-like and flaky content has been reduced from ≤15% to ≤12%, the roundness coefficient has been increased from ≤0.7 to ≥0.75, and the crushing value has been reduced from ≤25% to ≤23%. The performance is close to that of natural aggregates and fully meets the requirements of C30-C50 recycled concrete. Production efficiency has been significantly improved: AI sorting efficiency has increased by 40%, ultrasonic cleaning time has been reduced by 33%, online inspection efficiency has increased by 60%, and the overall production capacity has increased from 250,000-280,000 tons / year to 320,000 tons / year, an increase of 14.3-28%. Its low-carbon and environmentally friendly advantages are prominent: the heat pump-natural gas co-drying reduces unit energy consumption from 58kWh / ton to 35kWh / ton, a reduction of 40%; the wastewater recycling rate increases from ≤90% to ≥95%; dust emissions decrease from ≤10mg / m³ to ≤5mg / m³; and carbon emissions are reduced by more than 30%, meeting the "dual carbon" target. Transparent quality traceability: The blockchain + IoT system enables tamper-proof data traceability throughout the entire process, solving quality trust issues and promoting the large-scale application of recycled concrete; Resource utilization has been significantly improved: the graded processing of non-conforming products has increased resource utilization from ≤90% to ≥98.5%, avoiding waste; High compatibility and easy to promote: Based on the upgrade of existing mature equipment, there is no need for large-scale equipment replacement, the return on investment is ≥150%, and it is suitable for widespread application in the industry. Attached Figure Description

[0017] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Fig. 1 Flowchart of the high-quality recycled aggregate recycling process of this invention; Fig. 2 AI Vision-Near Infrared Spectroscopy Collaborative Sorting Process Flowchart; Fig. 3 Flowchart of ultrasonic-water co-cleaning process; Fig. 4 Blockchain-IoT traceability process flowchart. Detailed Implementation

[0019] 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 core concept of the present invention and the following embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] These embodiments are provided to make the application thorough and complete, and to fully express the scope of the application to those skilled in the art. It should be noted that, unless otherwise specifically stated, the relative arrangement of components and steps, material composition, numerical expressions, and values ​​illustrated in these embodiments should be interpreted as merely exemplary and not as limiting.

[0021] It should be noted that, in the description of this application, unless otherwise stated, "several" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "axial," "radial," etc., indicating orientation or positional relationships are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0022] Furthermore, the terms "first," "second," and similar terms used in this application do not indicate any order, quantity, or importance, but are merely used to distinguish different parts. "Vertical" is not strictly vertical, but within the permissible margin of error. "Parallel" is not strictly parallel, but within the permissible margin of error. Terms such as "including" or "contains" mean that the element preceding the word encompasses the element listed after it, and do not exclude the possibility of encompassing other elements as well.

[0023] It should also be noted that, in the description of this application, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linkage" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application depending on the specific circumstances. When a specific device is described as being located between a first device and a second device, an intermediary device may or may not be present between the specific device and the first or second device.

[0024] All terms used in this application have the same meaning as understood by one of ordinary skill in the art to which this application pertains, unless otherwise specifically defined. It should also be understood that terms defined in general dictionaries should be interpreted as having meanings consistent with their meanings in the context of the relevant art, and not as idealized or highly formalized, unless expressly defined herein.

[0025] Techniques, methods, and equipment known to those skilled in the art may not be discussed in detail, but where appropriate, they should be considered part of the specification.

[0026] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a high-quality recycled aggregate recycling method for construction solid waste, used in C30+ recycled concrete. Through the deep integration of existing equipment and novel methods, the following objectives are achieved: 1. Improve the precision of impurity removal, so that the mud content of aggregate is ≤0.3% and the residual rate of harmful impurities such as heavy metals / chloride ions is ≤0.02%, and the purity meets the requirements of high-strength concrete.

[0027] 2. Optimize aggregate particle shape and size to achieve a needle-like and flaky content ≤12%, a roundness coefficient ≥0.75, a crushing value ≤23%, and a particle size distribution variation coefficient ≤8%, thus meeting the workability requirements of recycled concrete.

[0028] 3. Accurately control the moisture content of aggregates to keep the finished product moisture content stable at 3-5%, with a fluctuation range of ≤±0.5%, ensuring accurate matching of concrete mix proportions.

[0029] 4. Establish a full-chain, tamper-proof traceability system to achieve transparency in raw materials, production, testing, and transportation information, thereby enhancing trust in quality.

[0030] 5. Reduce production energy consumption and pollutant emissions, with unit energy consumption ≤35kWh / ton, wastewater recycling rate ≥95%, dust emissions ≤5mg / m³, and carbon emissions reduced by more than 30%.

[0031] 6. Grade and process non-conforming products to improve resource utilization rate to ≥98% and avoid resource waste.

[0032] The core technical solution of this invention is as follows: Figs. 1 to 4 As shown: Based on existing recycled aggregate production equipment such as jaw crushers, cone crushers, impact crushers, impact shaping machines, sand washing machines, and vibrating screens, this paper innovatively integrates new methods such as AI intelligent sorting, multi-stage collaborative processing, closed-loop control, blockchain traceability, and low-carbon energy-saving collaboration to construct an innovative process covering the entire process of "raw material pretreatment - multi-stage crushing - deep purification - particle optimization - dewatering and drying - finished product management - storage and transportation," as detailed below: 1. Raw material pretreatment stage Existing equipment: TS1200 crawler sorter, CTB1248 permanent magnet drum separator, PE900×1200 jaw crusher, GZD1500×3000 vibrating feeder, GT1836 double-layer drum screen.

[0033] AI Vision-Near Infrared Spectroscopy Collaborative Sorting Method: Material data is collected through high-definition industrial cameras and near-infrared spectral sensors. A CNN model (trained based on 100,000+ waste samples) automatically identifies various impurities. Pneumatic push rods perform precise sorting, and the magnetic field strength of the permanent magnet roller is adaptively adjusted. The impurity removal rate is ≥99.5%, and the missed detection rate is ≤0.5%.

[0034] Dynamic closed-loop control method for crushing parameters: pressure sensor pre-assesses the hardness of raw material, laser particle size sensor provides real-time feedback on discharge particle size, and automatically adjusts jaw plate gap and feeding speed to avoid over-crushing or incomplete crushing.

[0035] Gradient spray-negative pressure sludge removal method: Three sets of gradient spray zones are set inside the drum screen, which are combined with a negative pressure sludge suction device to avoid secondary adhesion of mud powder. The mud content of the material in the middle layer is ≤1%.

[0036] 2. Multi-stage crushing Existing equipment: SC160 single-cylinder hydraulic cone crusher, PF1315 impact crusher, and feeder.

[0037] Lamination energy classification distribution method: Particle size classification sensor divides materials into three grades: large, medium and small. Spiral liner combined with variable eccentricity realizes adaptive energy distribution, with needle and flaky content ≤20%.

[0038] Dual-mode switching shaping method: The online particle image analyzer detects the needle-like and flaky content in real time and automatically switches between "stone-on-stone" (enhanced shaping) and "stone-on-iron" (improved efficiency) modes. The torque sensor adjusts the feeding speed in conjunction with the process, and the proportion of particles with a diameter ≤10mm after fine crushing is ≥99%.

[0039] 3. Deep purification stage Existing equipment: TED-800 eddy current separator, FX1000 horizontal air classifier, XL915 double spiral sand washing machine, ZSG1236 high frequency linear vibrating screen, QLF80 air classifier.

[0040] Magnetic field-speed linkage optimization method: The metal content sensor is linked with the permanent magnet drum to adjust the magnetic field strength, the spectral sensor identifies non-magnetic metals and matches the speed of the eddy current separator, and the non-magnetic metal removal rate is ≥95%.

[0041] Density-graded air separation method: The double-layer air duct is adapted to light impurities of different densities, and the purity sensor adjusts the air speed in a closed loop, achieving a light impurity removal rate of ≥99%.

[0042] Ultrasonic-water flow synergistic cleaning method: ultrasonic cavitation removes stubborn mud film, wastewater circulation system automatically adds chemicals for sedimentation, aggregate cleanliness ≥98%.

[0043] Negative pressure-high frequency vibration synergistic de-powdering method: The negative pressure hood adsorbs fine powder, and the vibration trajectory is adaptively adjusted to control the content of fine powder ≤0.075mm at 2-5%.

[0044] 4. Particle Optimization Stage Existing equipment: VSI1140 vertical impact shaping machine, YA2460 four-layer circular vibrating screen.

[0045] Real-time morphology feedback-energy regulation method: High-speed particle image analyzer detects particle shape in real time and dynamically adjusts rotor speed, feed cone and guide plate angle, roundness coefficient ≥0.75, needle and flaky content ≤12%.

[0046] Intelligent grading-reflux control method: Real-time monitoring by flow and particle size sensors automatically adjusts vibration parameters and reflux ratio, ensuring that the pass rate of aggregates of each specification is ≥95%.

[0047] 5. Dehydration and drying stage Existing equipment: LT1200 centrifugal dewatering machine, Φ2.2×12m drum dryer.

[0048] Moisture content pre-control-discharge coordination method: The moisture content of the feed is detected and the dewatering parameters are adjusted in conjunction with hydraulic control to ensure uniformity of discharge. The moisture content after dewatering is ≤12%.

[0049] Heat pump-natural gas co-drying method: switch heat sources according to moisture content and ambient temperature, and dry in stages with temperature control. The finished product has a moisture content of 3-5%.

[0050] 6. Finished Product Control Stage Existing equipment: YES-3000 pressure testing machine, DP-100 particle image analyzer, IC-980 ion chromatograph.

[0051] Multi-indicator synchronous online detection method: integrates 5 core indicators for simultaneous detection, with a detection time of ≤3 minutes / batch, deviation warning and automatic adjustment of upstream processes.

[0052] Blockchain-IoT Traceability Method: IoT sensors collect data throughout the entire process, and the blockchain stores the data to generate a unique traceability QR code.

[0053] Non-conforming product classification and handling method: Return to the corresponding process for further processing or downgrade the product according to the degree of non-conformity.

[0054] 7. Storage and Transportation Stage Existing equipment: Φ5m×15m enclosed finished product warehouse, 20-ton enclosed dump truck.

[0055] Intelligent warehouse cluster linkage control method: coordinated control of temperature and humidity in multiple warehouses for the aging and pretreatment of high-grade aggregates.

[0056] Full-process temperature and humidity compensation method: temperature and humidity monitoring of the carriage is linked to ventilation / heating devices, and homogenization treatment is carried out before unloading.

[0057] 8. Production line coordination and maintenance Load balancing start-up and shutdown method: stepped start-up and shutdown avoids grid fluctuations and equipment idling.

[0058] AI-powered safety early warning system: Monitors and identifies violations in dangerous areas, and responds with an emergency shutdown.

[0059] Predictive maintenance: Sensors monitor equipment status, and big data predicts the replacement time of vulnerable parts.

[0060] The technical solution of the present invention will be described in detail below with reference to specific embodiments. This embodiment takes a production line with an annual output of 300,000 tons of high-quality recycled aggregate as a carrier to ensure that those skilled in the art can repeat the implementation based on the following description.

[0061] (I) Configuration and parameters of core equipment in the production line 1. Raw material pretreatment stage equipment Equipment Name: Tracked Sorter; Model: TS1200 (1.2m bandwidth, 15kW); Key Configurations: 3 Baslerac A2500-14uc cameras, 2 OceanOptics NIRQuest512 spectral sensors, 8 sets of pneumatic push rods; Core Operating Parameters: Conveying speed 0.8m / s, material layer thickness 12cm.

[0062] Equipment Name: Permanent Magnet Drum Separator; Model: CTB1248 (φ1.2m×4.8m); Key Configuration: Adjustable Magnetic Field Strength Module (8000-15000Gs); Core Operating Parameter: Magnetic Field Response Time ≤0.5 seconds.

[0063] Equipment Name: Jaw Crusher; Model / Specification: PE900×1200 (160kW); Key Configurations: OmronZX2-LDA51 laser particle size sensor at discharge port, HBMC16 pressure sensor on feeder; Core Operating Parameters: Jaw plate gap 80-120mm, feeding speed 18-22t / h.

[0064] Equipment Name: Double-layer drum screen; Model / Specification: GT1836 (φ1.8m×3.6m, 15kW); Key Configurations: 3 sets of gradient nozzles, 9-19-5.6A negative pressure sludge suction device, 20kHz ultrasonic screen cleaner; Core Operating Parameters: Drum speed 20r / min, total spray water volume 5m³ / h Equipment Name: Vibrating Feeder; Model: GZD1500×3000 (15kW); Key Configuration: Variable Frequency Speed ​​Control Module; Core Operating Parameters: Feeding speed adjustment range 15-25t / h.

[0065] 2. Multi-stage crushing equipment Equipment Name: Cone Crusher; Model: SC160 (160kW, 150 tons per hour); Key Configurations: SICKCLV630 particle size analyzer, spiral liner, BoschRexroth pressure sensor; Core Operating Parameters: Eccentricity 10-14mm, lamination pressure 15-35MPa.

[0066] Equipment Name: Impact Crusher; Model: PF1315 (220kW); Key Configurations: Malvern Morphologi G3 Particle Image Analyzer, HBMT40B Torque Sensor, Electric Adjustable Impact Plate; Core Operating Parameters: Feeding speed 20-25t / h, Impact plate angle 25-35° Equipment Name: Material Distributor; Key Configuration: 3 material distribution channels; Core Operating Parameter: Material distribution response time ≤ 0.3 seconds.

[0067] 3. Equipment for deep purification stage Equipment Name: Eddy Current Separator; Model: TED-800 (7.5kW); Key Configurations: OceanOptics Flame-S spectral sensor, variable frequency magnetic roller; Core Operating Parameters: Magnetic roller speed 2500-3500r / min.

[0068] Equipment Name: Horizontal Air Separator; Model: FX1000 (11kW, 30t / h); Key Configurations: Double-layer air duct, SICKPTB200 wind speed sensor, customized purity sensor; Core Operating Parameters: Upper layer wind speed 3-5m / s, lower layer wind speed 6-8m / s.

[0069] Equipment Name: Twin Spiral Sand Washing Machine; Model: XL915 (22kW×2); Key Configurations: 6 x 1.5kW / m² ultrasonic generators, HachLDOII water quality sensor; Core Operating Parameters: Spiral speed 35r / min, aggregate:water = 1:3 Equipment Name: Wastewater Recirculation System; Model / Specifications: Sedimentation Tank (50m³) + XMYZ200 Filter Press; Key Configuration: Automatic Dosing Device (Polyaluminum Chloride + PAM); Core Operating Parameters: Dosing Accuracy ±5mg / L, Sludge Cake Moisture Content ≤25% Equipment Name: High-Frequency Vibrating Screen; Model: ZSG1236 (15kW, screen aperture 0.075mm); Key Configurations: Negative pressure hood (connects to MC-96 dust collector), adjustable phase angle module; Core Operating Parameters: Vibration frequency 2000r / min, amplitude 4mm.

[0070] Equipment Name: Air Classifier; Model: QLF80 (18.5kW, 25t / h); Key Configuration: Bettersize2000 Laser Particle Size Analyzer; Core Operating Parameters: Classifier wheel speed 2500-3600r / min.

[0071] 4. Particle optimization, dehydration and drying, and finished product management equipment Equipment Name: Impact Shaping Machine; Model: VSI1140 (160kW, 80t / h); Key Configurations: SympatecQICPIC high-speed image analyzer, PT100 temperature sensor, air-cooling system; Core Operating Parameters: Rotor speed 1200-1500r / min.

[0072] Equipment Name: Four-layer Vibrating Screen; Model Specifications: YA2460 (30kW, screen aperture 25 / 16 / 5 / 0.075mm); Key Configurations: SICKFLOWSIC600 flow sensor, Omron ZX2-LDA100 particle size sensor; Core Operating Parameters: Vibration frequency 1500-1600r / min, amplitude 6-7mm.

[0073] Equipment Name: Centrifugal Dewatering Machine; Model: LT1200 (45kW, 50t / h); Key Configurations: Mettler Toledo HC103 Infrared Moisture Content Meter, Hydraulic Discharge Gate; Core Operating Parameters: Dewatering basket speed 700-900r / min.

[0074] Equipment Name: Rotary Drum Dryer; Model Specifications: Φ2.2×12m (37kW); Key Configurations: Gree KFRS-12ZM heat pump, Black & Decker TBG85P burner, CustomMM-C-01 microwave moisture meter; Core Operating Parameters: Drying temperature 60-110℃, drum speed 4r / min.

[0075] Equipment Name: Multi-Indicator Online Detection System; Key Configurations: Crushing Value Rapid Detection Module, Chloride Ion Online Monitor; Core Operating Parameters: Detection Time ≤ 3 minutes / batch.

[0076] Device Name: Blockchain Traceability Platform; Key Configurations: IoT Data Interface, QR Code Generation Module; Core Operating Parameters: Data storage ≥ 5 years.

[0077] Equipment Name: Finished Product Warehouse; Model / Specifications: Φ5m×15m×3 units; Key Configurations: SHT30 temperature and humidity sensor, Usonic-2000 material level sensor, CFZ-10 dehumidifier; Core Operating Parameters: Warehouse humidity ≤60%, air cannon pressure 0.6MPa.

[0078] Equipment Name: Dump Truck; Model / Specification: 20 tons × 10 units; Key Configurations: Temperature and humidity sensor in the cargo compartment, ventilation / heating device, 50Hz vibrator; Core Operating Parameters: Transportation time ≤ 4 hours.

[0079] (II) Raw material parameters Composition: Concrete blocks (95%), bricks and stones (3%), steel bars (2%), free of toxic and harmful impurities.

[0080] Physical parameters: maximum particle size 750mm, surface mud content 3%, bulk density 1850kg / m³, compressive strength C40-C50.

[0081] Chemical parameters: initial chloride ion content 0.012%, heavy metal content meets the limits of GB / T25177-2010.

[0082] (III) Detailed operating procedures (50 tons per batch, total time approximately 240 minutes) 1. Raw material pretreatment stage (40 minutes) AI Vision - Near Infrared Sorting (10 minutes): Start the sorting machine, magnetic separator, and AI system. The camera and spectral sensor collect data. The CNN model identifies plastic (0.3 tons), wood chips (0.2 tons), and paint blocks containing heavy metals (0.05 tons). The pneumatic push rod accurately sorts the materials. The spectral detection shows that the magnetic metal content is 0.4%. The magnetic separator's magnetic field is adjusted to 12000Gs, adsorbing 1 ton of steel bars with a removal rate of 99.6%. 0.03 tons of abnormal impurities are manually processed.

[0083] Pre-crushing (15 minutes): The pressure sensor detects the raw material strength C45, the system sets the jaw plate gap to 100mm and the feeding speed to 20t / h; the laser particle size sensor detects that the proportion of oversized particles is 6%, the feeding speed is automatically reduced by 1t / h and the gap is reduced by 5mm, and the final output has a proportion of ≤100mm 96%.

[0084] Pre-screening + desliming (15 minutes): Start the drum screen, spray and negative pressure system, gradient spray water volume 1.8 / 1.7 / 1.5m³ / h, negative pressure value -0.06MPa; separate 2 tons of oversized lumps (recirculation), 1.5 tons of mud and sand, 44.5 tons of intermediate layer material, mud content 0.8%.

[0085] 2. Multi-stage crushing phase (50 minutes) Medium crushing (25 minutes): The distributor divides the material into large pieces (18 tons), medium pieces (16 tons), and small pieces (10.5 tons), with an eccentricity of 12 mm and a corresponding lamination pressure of 30 / 25 / 18 MPa; 97% of the output material is ≤40 mm, and the content of needle-like and flaky particles is 19%.

[0086] Fine crushing + preliminary shaping (25 minutes): Initial needle-like and flaky content is 19%, switch to "stone-on-stone" mode (impact plate 25°); after 10 minutes, the content drops to 17%, switch to "stone-on-iron" mode (impact plate 30°), feeding speed 24t / h; output ≤10mm accounts for 99.2%, fine powder accounts for 5.8%.

[0087] 3. Deep purification stage (60 minutes) Multi-stage magnetic separation (10 minutes): The magnetic separator has a magnetic field of 10,000 Gs and adsorbs 0.09 tons of residual magnetic metal; the eddy current separator identifies 0.05 tons of aluminum alloy at a speed of 2,800 r / min and a separation rate of 96%; the total recovered metal is 1.138 tons.

[0088] Density classification air separation (10 minutes): upper layer wind speed 4 m / s, lower layer 7 m / s, purity sensor detected 0.12% impurity residue, the lower layer wind speed was increased to 7.3 m / s, and finally 0.044 tons of light impurities were removed, with an aggregate loss rate of 0.4%.

[0089] Ultrasonic-water cleaning (20 minutes): Ultrasonic power 1.5kW / m², cleaning for 2 minutes; water quality sensor detected SS=650mg / L, automatic addition of polyaluminum chloride 80mg / L + PAM 8mg / L; after cleaning, the aggregate mud content is 0.28%, and the wastewater recycling rate is 96%.

[0090] Negative pressure-high frequency de-dusturing (20 minutes): vibration phase angle 18°, negative pressure -0.04MPa, classifying wheel speed 3100r / min, fine powder content stabilized at 3.2%; after de-dusturing, aggregate 43.5 tons, fine powder 0.9 tons (for roadbed).

[0091] 4. Particle optimization stage (40 minutes) Particle shaping (25 minutes): Initial roundness coefficient 0.72, rotation speed increased to 1450 r / min, distribution cone 42°; after 10 minutes, coefficient 0.76, adjust guide plate to make material collide 3 times; final roundness 0.78, needle-like and flaky 11.5%, crushing value 22.8%.

[0092] Secondary screening (15 minutes): vibration frequency 1550 r / min, amplitude 6.5 mm; graded 16-25 mm (15.2 tons), 5-16 mm (19.6 tons), 0-5 mm (8.2 tons), and >25 mm aggregate 0.5 tons are recycled.

[0093] 5. Dehydration and drying stage (30 minutes) Dehydration (10 minutes): Feed moisture content 18%, dehydration basket speed 850 r / min, dehydration time 1.2 min; moisture content after dehydration 11.5%, fluctuation ±0.8%.

[0094] Drying (20 minutes): Coordinated heating mode, 105℃ in the first stage and 85℃ in the second stage; after 15 minutes, the moisture content is 4.5%, and the burner is turned off; the moisture content of the finished product is 4.2%, with a fluctuation of ±0.3%.

[0095] 6. Finished Product Control, Storage, and Transportation (20 minutes) Multi-index testing (10 minutes): Online testing of 5 indicators: crushing value 22.8%, mud content 0.28%, needle-like and flaky 11.5%, roundness 0.78%, chloride ion 0.015%, all of which meet the standards.

[0096] Blockchain traceability (5 minutes): Integrates data from the entire process and generates a traceability QR code (batch number 2024052001), which supports scanning for querying.

[0097] Storage and transportation: 16-25mm aggregates are stored in silo #1 for 72 hours of aging; during transportation, the ventilation / heating device of the truck compartment is linked to the temperature and humidity sensor, and after 3.5 hours of transportation, the aggregates are vibrated for 3 minutes before unloading to homogenize them.

[0098] (iv) Verification of implementation results 1. Finished aggregate indicators 2. Production line operating indicators 3. Validation of the application of recycled concrete (V) Implementation Precautions Upon arrival of raw materials, an XRF spectrometer must be added for rapid detection of heavy metals (≤2 minutes / batch) to eliminate toxic and harmful impurities.

[0099] The ultrasonic generator is calibrated monthly, and the sensor is calibrated quarterly to ensure detection accuracy.

[0100] The blockchain platform backs up data weekly to prevent the loss of traceability information.

[0101] During winter production, the dryer is preheated for 30 minutes in advance, and the transport vehicles are equipped with heating devices to prevent the aggregate from freezing.

[0102] Replace vulnerable parts as prompted by the predictive maintenance system (jaw plate 200 hours, hammer 300 hours, impact block 250 hours).

[0103] This embodiment demonstrates that the present invention can stably mass-produce high-quality recycled aggregates that meet the requirements of C30 and above recycled concrete, and has advantages such as superior performance, high efficiency, low energy consumption, and traceability, making it suitable for large-scale promotion and application.

[0104] All aspects not detailed in this invention are conventional technical means known to those skilled in the art.

[0105] The above content shows and describes the basic principles, main features, and beneficial effects of the present invention. The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for recycling high-quality recycled aggregates from construction solid waste, characterized in that, Includes the following steps: (1) Raw material pretreatment: AI vision-near infrared spectroscopy collaborative sorting method is used to remove impurities, dynamic closed-loop control method of crushing parameters is used for pre-crushing, and gradient spray-negative pressure sludge removal method is used for pre-screening and sludge removal. (2) Multi-stage crushing: medium crushing is carried out by the layered energy graded distribution method, and fine crushing is carried out by the dual-mode switching shaping method; (3) Deep purification: magnetic separation is performed by magnetic field-rotation speed linkage optimization method, light impurities are removed by density classification air separation method, deep cleaning is performed by ultrasonic-water flow coordinated cleaning method, and powder removal is performed by negative pressure-high frequency vibration coordinated powder removal method. (4) Particle optimization: Real-time morphology feedback-energy regulation method is used for shaping, and intelligent classification-reflux regulation method is used for secondary screening; (5) Dehydration and drying: Dehydration is carried out by moisture content pre-control-discharge synergistic method, and drying is carried out by heat pump-natural gas synergistic drying method; (6) Finished product control: Multi-indicator synchronous online detection method is used for detection, blockchain-IoT traceability method is used for traceability, and non-conforming products are handled by graded processing method; (7) Storage and transportation: Intelligent warehouse cluster linkage control method is used for storage, and temperature and humidity compensation method is used for transportation.

2. The method for recycling high-quality recycled aggregates from construction solid waste according to claim 1, characterized in that: The AI ​​vision-near-infrared spectroscopy collaborative sorting method includes: installing three high-definition industrial cameras and two near-infrared spectroscopy sensors in sequence above the belt of the tracked sorting machine; uploading the collected material images and spectral data to the edge computing terminal with a built-in CNN model; identifying impurities and then accurately sorting them by pneumatic push rods; and simultaneously linking a permanent magnet drum magnetic separator to adaptively adjust the magnetic field strength, achieving a magnetic metal removal rate of ≥99.5%.

3. The method for recycling high-quality recycled aggregates from construction solid waste according to claim 1 or 2, characterized in that: The dynamic closed-loop control method for crushing parameters includes: installing a pressure sensor at the discharge port of the vibrating feeder to detect the compressive strength of the raw material and automatically matching the jaw plate gap and feeding speed; installing a laser particle size sensor at the discharge port of the jaw crusher to provide real-time feedback and adjust the feeding speed and jaw plate gap to ensure that the discharge particle size is ≤100mm and accounts for ≥95%.

4. The method for recycling high-quality recycled aggregates from construction solid waste according to claim 3, characterized in that: The ultrasonic-water synergistic cleaning method includes: integrating an ultrasonic generator along the length of the inner wall of the washing tank of the double spiral sand washing machine; mixing aggregate and water at a mass ratio of 1:3; and cleaning for 2 minutes through the synergistic action of ultrasonic cavitation, spiral stirring, and water rinsing, resulting in an aggregate surface cleanliness ≥98% and a mud content ≤0.3%; and a matching wastewater recycling system that uses a water quality sensor to link an automatic dosing device, ensuring that the suspended solids in the return water are ≤30mg / L and the recycling rate is ≥95%.

5. The method for recycling high-quality recycled aggregates from construction solid waste according to claim 4, characterized in that: The real-time morphology feedback-energy regulation method includes: installing a high-speed particle image analyzer at the discharge port of the impact shaping machine to detect the particle roundness coefficient and needle-like content in real time, dynamically adjusting the rotor speed, the angle of the feed cone and the angle of the guide plate, so that the material undergoes 3-4 collisions and grindings, with a roundness coefficient ≥0.75 and a needle-like content ≤12%; and starting the air cooling system to cool down when the shaping chamber temperature is ≥80℃.

6. The method for recycling high-quality recycled aggregates from construction solid waste according to claim 5, characterized in that: The heat pump-natural gas synergistic drying method includes: a drum dryer integrating an air source heat pump and a natural gas burner, switching between single heat pump or synergistic heating modes according to aggregate moisture content and ambient temperature, segmented temperature control of 60-110℃, real-time monitoring via a microwave moisture meter, and finished product moisture content stabilizing at 3-5%, with fluctuation range ≤±0.5%.

7. The method for recycling high-quality recycled aggregates from construction solid waste according to any one of claims 1-2 and 4-6, characterized in that: The blockchain-IoT traceability method includes: installing IoT sensors at key nodes in raw material entry, production, storage and transportation; encrypting the collected raw material information, equipment parameters, test data and transportation trajectory and uploading them to the blockchain platform to generate a unique traceability QR code, thus achieving tamper-proof traceability of data throughout the entire process.

8. The method for recycling high-quality recycled aggregates from construction solid waste according to claim 7, characterized in that: The non-conforming product grading and processing method includes: slightly non-conforming products (mud content 0.3-0.5%, needle-like and flaky content 12-15%) are returned to the sand washing machine for enhanced ultrasonic cleaning; moderately non-conforming products (crushing value 23-25%, roundness coefficient 0.7-0.75) are returned to the shaping machine for high-speed multi-stage impact shaping; severely non-conforming products (crushing value 25-28%, mud content 0.5-0.8%) are returned to the cone crusher for re-crushing; and seriously non-conforming products (excessive heavy metals / chloride ions, crushing value > 28%) are downgraded for use as roadbed fill material.

9. The method for recycling high-quality recycled aggregates from construction solid waste according to claim 8, characterized in that: The density classification air separation method includes: the horizontal air separator is divided into upper and lower air ducts. The upper air duct has a wind speed of 3-5 m / s to separate low-density impurities, and the lower air duct has a wind speed of 6-8 m / s to separate medium-density impurities. The wind speed is adjusted in a closed loop by a material purity sensor. The removal rate of light impurities is ≥99%, and the aggregate loss rate is ≤0.5%.

10. The method for recycling high-quality recycled aggregates from construction solid waste according to claim 9, characterized in that: The intelligent warehouse cluster linkage control method includes: multiple closed finished product warehouses realize the transfer of humid air between warehouses through temperature and humidity sensors and material level sensors; after high-grade aggregates are put into the warehouse, they are aged for 72 hours and stress is released through the bottom ventilation system of the warehouse, and the crushing value is further reduced by 1-2%.

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