Filling system and process based on deep-cone and paste storage thickener

Abstract

The application discloses a filling system and process based on a deep cone and paste warehouse thickener, and belongs to the field of mine engineering, and comprises a main thickening unit, a buffer storage unit and a dynamic working condition switching module, wherein the main thickening unit comprises a deep cone thickener and a shearing circulating pump; the buffer storage unit comprises a paste warehouse thickener; the dynamic working condition switching module is arranged above the main thickening unit and the buffer storage unit and used for switching the direction of underflow output; and a control unit is used for guiding the work of the dynamic working condition switching module. Through the arrangement of the buffer storage unit, temporary storage space is provided for downstream filling interruption, gravity settlement is resisted, and fluidity is retained; a system switching valve guides high-concentration underflow into the paste warehouse thickener, so that the thickness of a mud layer in the deep cone and the rake frame resistance are immediately reduced, continuous overpressure is avoided, and the system reliability is improved, the problem of insufficient dynamic storage capacity of the deep cone thickener caused by the limited volume of a settling zone is solved, a rake pressing accident is avoided, and the production continuity and reliability are ensured.

Description

Technical Field

[0001] This invention belongs to the field of mining engineering technology, and particularly relates to a filling system and process based on a deep cone and paste storage thickener. Background Technology

[0002] In the field of mine backfilling, deep cone thickeners, as core tailings thickening equipment, concentrate tailings slurry with a solids content of 15%~20% to a high-concentration underflow of 65%~75% through gravity settling and flocculation dewatering to meet the concentration requirements of paste backfilling. However, traditional deep cone thickeners have revealed defects in actual operation: although their cone structure optimizes the thickening efficiency, the limited volume of the settling zone results in insufficient dynamic storage capacity. When backfilling is suspended or downstream equipment fails, the system needs to be switched to circulation mode urgently to avoid rake accidents. Frequent start-up and shutdown of the circulation pump not only increases energy consumption by more than 30% but also accelerates equipment wear. In addition, downtime exceeding 4 hours can easily lead to rake accidents, forcing the thickener to continuously discharge material, which cannot adapt to the intermittent working conditions of mine backfilling and seriously restricts the reliability and continuity of production. Summary of the Invention

[0003] In view of the technical problems existing in the background art, this application provides a filling system based on a deep cone and paste storage thickener, comprising: The main concentration unit includes a deep cone thickener and a shear circulation pump; Buffer storage unit, including paste storage thickener; A dynamic operating condition switching module is installed above the main concentration unit and the buffer storage unit to switch the undercurrent output direction; The control unit is used to guide the operation of the dynamic operating condition switching module.

[0004] In some embodiments, the dynamic operating condition switching module includes: A first electric clamp valve is installed at the underflow outlet of the deep cone thickener to control the underflow delivery to the homogenizing mixing tank; A second electric clamp valve is installed between the deep cone thickener and the paste storage thickener to control the underflow to the paste storage thickener.

[0005] In some embodiments, the dynamic operating condition switching module further includes: A torque sensor is installed in the deep cone thickener to monitor the rake frame torque of the deep cone thickener in real time.

[0006] In some embodiments, the dynamic operating condition switching module further includes: A concentration meter is installed in the deep cone thickener to monitor the underflow concentration of the deep cone thickener in real time.

[0007] In some embodiments, the dynamic operating condition switching module includes a sensor group for monitoring slurry torque and concentration, and the control unit has a first state and a second state, wherein: In the first state, the dynamic working condition switching module is driven to deliver underflow to the homogenizing mixing tank; In the second state, the dynamic working condition switching module is driven to deliver underflow to the paste storage thickener.

[0008] In some implementations, the first state is configured such that the torque is less than the design safety value and the concentration is not lower than the target concentration.

[0009] In some implementations, the second state is configured such that the torque exceeds a design safety value.

[0010] This application also discloses a filling process based on a deep cone compactor and a paste storage thickener, including: Tailings slurry from the concentrator is pumped or flows by gravity to a deep cone thickener, where flocculants are added to promote solid-liquid separation. Real-time monitoring of underflow concentration and rake frame torque, and determination of the slurry's status in the control unit.

[0011] In some embodiments, after real-time monitoring of the underflow concentration and rake frame torque, and determining that they are in the control unit state, the filling process based on a deep cone and paste storage thickener further includes: If in the first state, the dynamic operating condition switching module is driven to open the first electric clamp valve; The underflow pump is sent to the homogenization mixing tank, and the binder and water-reducing agent are added simultaneously.

[0012] In some embodiments, after real-time monitoring of the underflow concentration and rake frame torque, and determining that they are in the control unit state, the filling process based on a deep cone and paste storage thickener further includes: If it is in the second state, the torque alarm will be triggered; The dynamic working condition switching module opens the second electric clamp valve and closes the first electric clamp valve, causing the deep cone thickener to discharge material to the paste storage thickener. When the material is discharged into the deep cone thickener, the torque decreases to a safe range, driving the dynamic working condition switching module back to the first state.

[0013] This application utilizes a shear circulation pump to re-transport the underflow from the bottom sand discharge port to the top. Mechanical shearing force breaks down the hard agglomerates between particles, preventing rake crushing accidents and reducing energy consumption caused by downtime for rake cleaning. A buffer storage unit provides temporary storage space for downstream filling interruptions, resisting gravity settling and retaining fluidity. When the shear circulation pump fails to reduce the torque inside the deep cone, the system switches valves to introduce high-concentration underflow into the paste storage thickener, immediately reducing the mud layer thickness and rake frame resistance within the deep cone, preventing continuous overpressure and improving system reliability. This also addresses the issue of insufficient dynamic storage capacity in the deep cone thickener due to the limited volume of the settling zone, eliminating the reliance on emergency switching of the circulation mode during filling pauses. The paste storage thickener absorbs system fluctuations, avoiding the energy consumption and equipment wear from frequent start-stop of the shear circulation pump. Ultimately, this improves the system's adaptability to intermittent mining conditions, prevents rake crushing accidents, and ensures continuous and reliable production.

[0014] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, the following are specific embodiments of this application. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of this application, the accompanying drawings used in this application will be briefly described below. Obviously, the drawings described below are merely some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without any creative effort.

[0016] Figure 1 This is a schematic diagram of the structure of a filling system based on a deep cone and paste storage thickener provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of the basic steps of a filling process based on a deep cone and paste storage thickener provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the steps in the first state of a filling process based on a deep cone and paste storage thickener provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of the steps in the second state of a filling process based on a deep cone and paste storage thickener provided in an embodiment of the present invention.

[0017] Explanation of reference numerals in the attached drawings: 10, deep cone thickener; 11, shear circulation pump; 20, paste storage thickener; 30, first electric clamp valve; 31, second electric clamp valve; 40, concentration meter; 50, homogenizing mixing tank. Detailed Implementation

[0018] The embodiments of the technical solution of this application will now be described in detail with reference to the accompanying drawings. These embodiments are only used to more clearly illustrate the technical solution of this application and are therefore merely examples, and should not be used to limit the scope of protection of this application.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.

[0020] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.

[0021] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0022] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.

[0023] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).

[0024] In the description of the embodiments of this application, the technical terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the embodiments of this application and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0025] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; 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; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0026] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0027] Reference Figure 1 A filling system based on a deep cone and paste storage thickener 20 includes: a main thickening unit, a buffer storage unit, a dynamic operating condition switching module, and a control unit, wherein: The main thickening unit includes a deep cone thickener 10 and a shear circulation pump 11; specifically, the main thickening unit consists of a deep cone thickener 10 and a shear circulation pump 11. The deep cone thickener 10 is a device that uses its steep cone angle and large height-to-diameter ratio to accelerate the solid-liquid separation of tailings slurry through gravity settling, while the shear circulation pump 11 is a device that uses mechanical shearing force to break down the tailings floc structure, agglomerate, and improve the uniformity of underflow concentration. In this embodiment, the shear circulation pump 11 is provided as a preferred solution for the pressure rake of the deep cone thickener 10.

[0028] The buffer storage unit includes a paste storage thickener 20. Specifically, the buffer storage unit uses a paste storage thickener 20, which is characterized by a wide-body shallow cone structure and a large-volume settling zone, thereby expanding the static storage space to achieve temporary storage of the paste. When the slurry enters the low-shear buffer unit (paste storage thickener 20) from the high-shear main thickening unit (such as the deep cone thickener 10), the shear stress drops sharply, and the interparticle forces become dominant. The hydrogen bonds on the surface of the tailings particles form a hydration film with water molecules, and a three-dimensional network structure is constructed through hydrogen bond networks or electrostatic attraction, causing the slurry to change from a fluid state to a solid-like gel state. The network structure of the slurry is dominated by short-range forces (such as liquid bridge forces and van der Waals forces), and its strength is sufficient to resist gravity settling, but not enough to cause hard agglomeration of particles, thus avoiding static caking.

[0029] A dynamic operating condition switching module, located above the main thickening unit and the buffer storage unit, is used to switch the underflow output direction. Specifically, this module dynamically changes the slurry flow path based on valve control principles. During operation, it selectively guides the underflow from the main thickening unit to the buffer unit or external output through a mechanical opening and closing mechanism, thereby achieving mode switching to adapt to real-time changes in operating conditions. It should be noted that the dynamic operating condition switching module can have various configuration forms. For example, the module includes a rotary three-way valve structure. A servo motor drives the valve core shaft to rotate through a reduction gear set. The valve core has an L-shaped flow channel designed inside. When the underflow pressure in the main thickening unit reaches a set threshold, the control system sends a command to the servo motor, which drives the valve core to rotate 90°, switching the L-shaped flow channel from the port originally pointing to the buffer storage unit to the external output port. At this time, the slurry is directly guided to the outside. When it is necessary to return to the buffer unit, the valve core rotates 90° in the opposite direction, and the flow channel is aligned with the buffer unit port again. The valve core angle is fed back in real time via a position encoder throughout the process to ensure error-free flow channel switching. For example, the dynamic operating condition switching module includes a sliding gate array. Two sets of gates are rigidly connected to a linear motor via a linkage mechanism. Initially, gate A is open (connecting the main thickening unit and the buffer unit), and gate B is closed (blocking external output). When the external output mode is activated, the linear motor pushes the linkage mechanism, causing gate A to move down along the slide rail to close the buffer unit inlet, while gate B moves up to open the external output channel, forcing the slurry to be redirected for external output. When switching back to buffer mode, the linear motor moves in the opposite direction, lifting gate A and lowering gate B to restore the buffer unit passage. A mechanical limiter is installed at the end of the slide rail to prevent overtravel-induced seal failure.

[0030] The control unit guides the operation of the dynamic operating condition switching module. Specifically, the control unit is an automated monitoring device that monitors system parameters based on automatic control principles (such as closed-loop feedback mechanisms) and issues commands to drive the switching module to act, thereby achieving real-time response to avoid emergency shutdown.

[0031] In this process, the cooperation between the deep cone thickener 10 and the shear circulation pump 11 is as follows: the efficient settling of the deep cone thickener 10 may lead to bottom caking due to rapid particle accumulation. When the sensor alarms due to bottom caking, the shear circulation pump 11 is activated, causing the thickener underflow to be re-transported from the bottom sand outlet to the top of the thickener to form a shear circulation. Through continuous shearing, the hard agglomeration structure between particles is broken down, and the underflow concentration is homogenized, thereby maintaining the continuous operation of the deep cone thickener 10. This cooperation is based on the principle of mechanical shear force counteracting particle agglomeration, which helps to resolve the contradiction between high settling efficiency and bottom caking, thus helping to avoid rake accidents and reducing energy consumption and equipment wear caused by shutdown for rake cleaning.

[0032] The cooperative relationship between the main thickening unit (deep cone thickener 10 and shear circulation pump 11) and the buffer storage unit (paste storage thickener 20) is as follows: After forced particle separation in the high-shear environment of the main thickening unit, the shear stress drops sharply when the slurry enters the buffer storage unit. Hydrogen bonds between particles and water molecules form a hydration film, constructing a three-dimensional network gel structure through liquid bridging forces and van der Waals forces. This transition from high to low shear utilizes the phase transition principle dominated by particle forces, transforming the slurry from a fluid state to a near-solid gel state. This retains fluidity while resisting gravitational settling, thus solving the problem of insufficient dynamic storage capacity and providing temporary storage space for downstream filling interruptions.

[0033] The collaborative relationship between the buffer storage unit and the dynamic operating condition switching module is as follows: when filling is paused, the switching module directs the underflow to the paste storage thickener 20, whose wide-body shallow cone structure expands the settling zone volume to accommodate the temporarily stored paste; after filling resumes, the dynamic operating condition switching module redirects the paste to the external output. This collaboration, based on the linkage between static storage space and dynamic path switching, absorbs system fluctuations by expanding the physical volume, solving the problem of the deep cone thickener 10's weak resistance to intermittent operating conditions due to the limited settling zone, and improving the system's adaptability to mine filling interruptions.

[0034] The cooperative relationship between the buffer storage unit and the shear circulation pump 11 is as follows: the shear circulation pump 11 breaks down the hard structure of tailings flocs through high-speed mechanical shearing, maintaining the uniformity of the underflow in the deep cone thickener 10, but its effect is limited by the severity of caking; when the shearing effect of the shear circulation pump 11 cannot reduce the internal torque of the deep cone thickener 10 (which may manifest as a decrease in underflow output or abnormal sensor data), the underflow is transported to the top central bucket of the paste storage thickener 20 for secondary settling and storage. In case of failure, the system switches valves to introduce high-concentration underflow into the paste storage thickener 20. On the one hand, by directly unloading, the high-concentration underflow is transferred to the paste bin, immediately reducing the mud layer thickness and static pressure in the deep cone, reducing the scraping resistance of the rake frame, thereby causing the torque to drop rapidly; on the other hand, the paste storage thickener 20 usually has a larger settling area and storage volume, which can accept high-concentration underflow and re-establish a stable dynamic balance of settling and compression, avoiding continuous overpressure in the deep cone, thereby improving the reliability of the system.

[0035] This application utilizes a shear circulation pump 11 to re-transport the underflow from the bottom sand discharge port to the top. Mechanical shearing force breaks down the hard agglomerates between particles, preventing rake-related accidents and reducing energy consumption due to downtime for rake cleaning. A buffer storage unit provides temporary storage space for downstream filling interruptions, resisting gravity settling and retaining fluidity. When the shear circulation pump 11 fails to reduce the torque inside the deep cone, the system switching valve introduces the high-concentration underflow into the paste storage thickener 20, immediately reducing the mud layer thickness and rake resistance inside the deep cone, preventing continuous overpressure and improving system reliability. This also addresses the problem of insufficient dynamic storage capacity in the deep cone thickener 10 due to the limited volume of the settling zone, eliminating the reliance on emergency switching of the circulation mode during filling pauses. The paste storage thickener 20 absorbs system fluctuations, avoiding energy consumption and equipment wear from frequent start-stop of the shear circulation pump 11. Ultimately, this improves the system's adaptability to intermittent mining conditions, prevents rake-related accidents caused by downtime, and ensures production continuity and reliability.

[0036] In some implementations, refer to Figure 1 The dynamic operating condition switching module includes: The first electric clamp valve 30 is installed at the underflow outlet of the deep cone thickener 10 to control the underflow to be delivered to the homogenizing mixing tank 50. Specifically, the first electric clamp valve 30 is installed at the underflow outlet of the deep cone thickener 10 and controls the underflow to be delivered directly to the homogenizing mixing tank 50 by quick opening and closing. When the filling demand is urgent, the valve opens so that the underflow enters the mixing tank through the shortest path, shortening the response time. The second electric clamp valve 31 is installed between the deep cone thickener 10 and the paste storage thickener 20 to control the underflow delivery to the paste storage thickener 20. Specifically, the second electric clamp valve 31 is installed in the connecting pipeline between the deep cone thickener 10 and the paste storage thickener 20. When the underflow concentration of the main unit meets the standard but filling is temporarily suspended, the valve opens to temporarily store the paste in the storage thickener, avoiding the risk of rake damage due to accumulation in the deep cone.

[0037] Emergency filling is achieved by directly supplying the mixing tank with the first electric clamp valve 30, and pressure unloading is achieved by the second electric clamp valve 31 to the storage buffer unit. The two are based on the fluid dynamic distribution strategy of the control unit to avoid the rake accident caused by the slurry retention in the deep cone.

[0038] In some implementations, refer to Figure 1 The dynamic operating condition switching module also includes: A torque sensor (not shown in the figure) is installed in the deep cone thickener 10 to monitor the rake frame torque of the deep cone thickener 10 in real time. Specifically, the torque sensor is integrated into the drive shaft end of the rake frame of the deep cone thickener 10, and monitors the rake frame torque in real time based on the strain effect of the metal elastomer. When the slurry solidifies and the resistance increases, the deformation of the elastomer causes the resistance of the strain gauge attached to it to change. The resistance change is converted into an electrical signal output through a Wheatstone bridge circuit, thereby dynamically reflecting the compaction state of the mud layer inside the thickener, and directly capturing the change in rake frame resistance. After this, the shear circulation pump 11 is first started to try to reduce the torque in the deep cone thickener 10. If the effect is not obvious (for example, the torque is still slowly rising), the control unit converts the torque signal into a diversion command, and then transfers the excess underflow to the paste storage thickener 20 through the second electric clamp valve 31, thereby using torque as a direct control quantity to guide the operation of the control unit.

[0039] In some implementations, refer to Figure 1 The dynamic operating condition switching module also includes: A concentration meter 40, installed within the deep cone thickener 10, is used to monitor the underflow concentration of the deep cone thickener 10 in real time. Specifically, the concentration meter 40 is integrated into the underflow discharge pipeline of the deep cone thickener 10, directly feeding back changes in the slurry solids content. When the concentration exceeds the threshold (indicating increased slurry viscosity that could easily cause pipe blockage), the opening of the second electric clamp valve 31 is immediately increased to transfer the high-concentration underflow to the paste storage thickener 20, utilizing its gravity compression to maintain slurry stability. Simultaneously, the opening of the first electric clamp valve 30 is reduced to decrease the risk of high-pressure transport. When the concentration is below the threshold but above the design standard value (for example, the threshold concentration is 74%, and the design standard value is 70%), the first electric clamp valve 30 is preferentially opened to accelerate the direct supply of underflow to the mixing tank, thereby improving filling efficiency. Thus, the underflow concentration serves as a second standard to guide the operation of the control unit, enabling the control unit to make judgments based on sensor parameters, thereby accurately guiding the operation of the dynamic operating condition switching module.

[0040] In some implementations, refer to Figure 1 The dynamic operating condition switching module includes a sensor group for monitoring slurry torque and concentration. The control unit has a first state and a second state, wherein: In the first state, the dynamic working condition switching module drives the underflow to the homogenization mixing tank 50. In the second state, the dynamic working condition switching module drives the underflow to the paste storage thickener 20.

[0041] Specifically, the control unit, as the core decision-making module of the system, dynamically switches between two working states based on a preset filling plan and real-time operating data (such as filling demand signals and equipment status). Taking the dynamic working state switching module, which includes a first electric clamp valve 30 and a second electric clamp valve 31, as an example, in the first state, the control unit drives the dynamic working state switching module to open the first electric clamp valve 30 and close the second electric clamp valve 31, so that the underflow of the deep cone thickener 10 is transported to the homogenization mixing tank 50 through the shortest path, thereby shortening the response time and ensuring a continuous supply of paste when the filling demand is urgent. In the second state, the control unit drives the dynamic working state switching module to close the first electric clamp valve 30 and open the second electric clamp valve 31 based on the buffer capacity signal of the paste storage thickener 20, diverting the underflow to the paste storage thickener 20 for temporary storage, thereby avoiding the risk of rake pressure caused by the accumulation inside the deep cone when the main unit's processing capacity exceeds the filling demand.

[0042] The control unit converts discrete filling commands into valve action logic. In the first state, filling requirements are prioritized, and in the second state, system safety is prioritized. This ensures that the overall system always matches the filling rhythm of the goaf and achieves adaptive control of the overall system operation.

[0043] In some implementations, refer to Figure 1The first state is configured such that the torque is less than the design safety value and the concentration is not lower than the target concentration. Its core purpose is to ensure the coordinated operation between the main thickening unit and the buffer storage unit, avoid equipment overload, and maintain the quality stability of the filling slurry. Specifically, in this state, the equipment maintains normal operation, and the deep cone thickener 10 continuously feeds material to the homogenizing mixing tank 50, thereby ensuring the normal feeding of the slurry. The purpose of requiring the concentration to be not lower than the target concentration value is to ensure that the concentration of the filling slurry meets the strength requirements and avoids reducing the compressive strength of the filling body due to excessive moisture. The control unit delays the underflow output until the thickening work is completed. If the torque is less than the design safety value but the concentration is lower than the target concentration, no material is fed to the homogenizing mixing tank.

[0044] In some implementations, refer to Figure 1 The second state is configured when the torque exceeds the design safety value. When the torque of the stirring shaft of the deep cone thickener 10 exceeds the preset safety threshold, it indicates that the viscosity of the slurry is too high or the deposition of solid particles has caused a sharp increase in mechanical resistance. At this time, the underflow to the homogenizing mixing tank 50 must be interrupted immediately to avoid rake accidents or structural damage. Specifically, the torque sensor monitors the load change of the stirring shaft of the deep cone thickener 10 in real time. When the torque value continues to rise, the shear circulation pump 11 is first started to apply high-frequency shear force to the slurry to reduce the viscosity of the slurry and relieve the torque load. If the torque rises to reach or exceed the design safety value (for example, preset to 85% of the maximum load torque of the drive device), the control unit immediately switches to the second state based on the threshold judgment logic, and drives the dynamic working condition switching module to guide the underflow to the paste storage thickener 20 for buffer storage. When the torque exceeds the limit, regardless of whether the underflow concentration meets the standard, the system will be forced to switch to the second state to ensure that equipment safety takes precedence over filling efficiency. At the same time, the paste storage thickener 20, as a buffer unit, receives the high-viscosity underflow and stabilizes the slurry state through its internal slow settling and re-concentration function. After the torque returns to normal, the control unit switches back to the first state to continue the filling operation. This realizes real-time warning and autonomous obstacle avoidance of equipment overload, and improves the robustness and continuous operation capability of the system.

[0045] This application also discloses a filling process based on a deep cone atomizer and paste storage thickener, referring to... Figure 2 ,include: S101. Tailings slurry from the concentrator is pumped or flows by gravity to a deep cone thickener, where flocculants are added to promote solid-liquid separation. S102. Real-time monitoring of underflow concentration and rake frame torque, and determination of the slurry's status in the control unit.

[0046] Specifically, real-time monitoring involves the coordinated data acquisition of concentration meters and torque sensors. The purpose is to dynamically perceive the operating conditions of the deep cone thickener, providing the control unit with decision-making support to avoid equipment overloading and ensure slurry quality. Concentration meters (such as ultrasonic densitometers) continuously detect the slurry density in the underflow pipe of the deep cone thickener and convert it into a mass concentration value (e.g., 72%–76%). Simultaneously, the torque sensor monitors the resistance torque of the rake drive shaft. When tailings particles deposit or excessive flocculation leads to a sudden increase in viscosity, the resistance torque exceeds a preset safety threshold (e.g., 85% of the motor's rated torque). Based on the above parallel signals, the control unit executes state switching logic: if the concentration is ≥ the target value (e.g., 72%) and the torque is < the design safety value, the first state (underflow is delivered to the homogenization mixing tank) is maintained; if the torque is ≥ the design safety value, a forced switch to the second state (underflow is guided to the paste storage thickener for buffer storage) is initiated.

[0047] In some implementations, refer to Figure 3 After S102, real-time monitoring of the underflow concentration and rake frame torque, and determination of its status in the control unit, a filling process based on a deep cone and paste storage thickener further includes: S103. If in the first state, the dynamic working condition switching module is driven to open the first electric pipe clamp valve. S104, pumped underflow to homogenization mixing tank, with binder and water-reducing agent added simultaneously.

[0048] Specifically, when the control unit determines that the operating conditions are safe and stable (i.e., the torque is lower than the design safety threshold and the concentration meets the standard), the conveying channel from the deep cone thickener to the homogenization mixing tank is precisely opened to ensure that the high-concentration underflow is efficiently delivered to the subsequent mixing process.

[0049] In some implementations, refer to Figure 4 After S102, real-time monitoring of the underflow concentration and rake frame torque, and determination of its status in the control unit, a filling process based on a deep cone and paste storage thickener further includes: S203. If in the second state, a torque alarm is triggered. Specifically, the control unit immediately activates an audible and visual alarm signal to warn the operator in real time that the equipment is at risk of overload and to avoid a rake-crushing accident due to delayed response. S204. Drive the dynamic working condition switching module to open the second electric clamp valve and close the first electric clamp valve, so that the deep cone thickener can discharge material to the paste storage thickener. Specifically, after the second electric clamp valve is opened, the underflow is pumped to the paste storage thickener by the pump. The storage unit uses its large volume characteristics to temporarily store the slurry, so as to temporarily store the slurry when there is a risk of mud layer compaction in the deep cone thickener, avoid the rake accident and maintain the concentration stability. S205. When the torque inside the deep cone thickener decreases to a safe range, the dynamic operating condition switching module returns to the first state. Specifically, by continuously discharging underflow to reduce the mud layer height, the rake frame torque returns to the safe threshold as the mud layer shear resistance decreases. The control unit switches back to the direct filling mode based on the negative feedback adjustment principle, ensuring that the system returns to steady-state operation. This achieves a self-adjusting working mode after emergency treatment, which is beneficial to the continuous and stable operation of the system. The above description is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions, and improvements made by those skilled in the art within the scope of the technology disclosed in the present invention, within the spirit and principles of the present invention, should be included within the scope of protection of the present invention.

[0050] It should be noted that this application is not limited to the above-described embodiments. The above embodiments are merely examples, and any embodiments with the same structure and effect as the technical concept within the scope of this application are included in the technical scope of this application. Furthermore, various modifications that can be conceived by those skilled in the art to the embodiments, and other ways of constructing by combining some of the constituent elements of the embodiments, without departing from the spirit of this application, are also included in the scope of this application.

Claims

1. A filling system based on deep cone and paste storage thickener, characterized in that, include: The main concentration unit includes a deep cone thickener (10) and a shear circulation pump (11). Buffer storage unit, including paste storage thickener (20); A dynamic operating condition switching module is installed above the main concentration unit and the buffer storage unit to switch the undercurrent output direction; The control unit is used to guide the operation of the dynamic operating condition switching module; The dynamic working condition switching module includes a sensor group for monitoring the torque and concentration of the slurry. The control unit has a first state and a second state. In the first state, the dynamic working condition switching module is driven to deliver underflow to the homogenizing mixing tank (50). In the second state, the dynamic working condition switching module is driven to deliver underflow to the paste storage thickener (20). Furthermore, the first state is configured such that the torque is less than the design safety value and the concentration is not lower than the target concentration. When the torque value continues to rise, the shear circulation pump is first started to apply shear force to the slurry. If the torque rises to the point of reaching or exceeding the design safety value, the control unit sets the system to the second state based on threshold judgment logic. The second state is configured such that the torque exceeds the design safety value.

2. The filling system based on deep-cone and paste storage thickener according to claim 1, characterized in that, The dynamic operating condition switching module includes: The first electric clamp valve (30) is installed at the underflow outlet of the deep cone thickener (10) to control the underflow delivery to the homogenizing mixing tank (50); A second electric clamp valve (31) is installed between the deep cone thickener (10) and the paste storage thickener (20) to control the underflow to the paste storage thickener (20).

3. A filling system based on a deep cone and paste storage thickener according to claim 2, characterized in that, The dynamic operating condition switching module also includes: A torque sensor is installed in the deep cone thickener (10) to monitor the rake frame torque of the deep cone thickener (10) in real time.

4. A filling system based on a deep cone and paste storage thickener according to claim 2, characterized in that, The dynamic operating condition switching module also includes: A concentration meter (40) is installed in the deep cone thickener (10) to monitor the underflow concentration of the deep cone thickener (10) in real time.

5. A filling process based on a deep cone aerator and a paste storage thickener, characterized in that, include: Tailings slurry from the concentrator is pumped or flows by gravity to a deep cone thickener, where flocculants are added to promote solid-liquid separation. Real-time monitoring of underflow concentration and rake frame torque, and determination of the slurry's status in the control unit; If in the first state, the dynamic operating condition switching module is activated to open the first electric clamp valve. The underflow pump delivers the material to the homogenization mixing tank, while simultaneously adding binder and water-reducing agent; When the torque value continues to rise, start the shear circulation pump to apply shear force to the slurry; If the torque rises to or exceeds the design safety value, the control unit puts the system into the second state based on the threshold judgment logic, thus triggering a torque alarm. When the system is in the second state, the dynamic working condition switching module opens the second electric clamp valve and closes the first electric clamp valve, so that the deep cone thickener discharges material to the paste storage thickener. When the material is discharged into the deep cone thickener, the torque decreases to a safe range, driving the dynamic working condition switching module back to the first state; The first state is configured such that the torque is less than the design safety value and the concentration is not lower than the target concentration. The second state is configured such that the torque exceeds the design safety value.

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