Drum-type fly ash pelletizing system based on particle size monitoring

Abstract

The present application relates to a coal ash granulation device technical field, provide a kind of based on particle size monitoring's rotary drum type coal ash granulation system, including bunker unit, rotary drum unit and closed-loop control unit;Rotary drum unit includes rotary drum body, rotary drum support and inclination adjustment assembly, rotary drum body is arranged obliquely, its inside is hollow structure, inclination adjustment assembly is located at the bottom of rotary drum support;Bunker unit is located above rotary drum unit, it includes raw material bin, powder flow transfer pipeline and powder monitoring module;Powder monitoring module is arranged inside powder flow transfer pipeline, for obtaining the particle size distribution parameter of coal ash powder in the process of coal ash powder flow transfer;Closed-loop control unit is respectively connected with powder monitoring module and rotary drum unit circuit, for based on the particle size distribution parameter obtained and the target particle size of product particle set, the residence time of coal ash powder in rotary drum body is controlled by adjusting the inclination of rotary drum body, to generate the product particle in conformity with target particle size.

Description

Technical Field

[0001] This invention relates to the field of fly ash granulation equipment technology, and in particular to a rotary drum fly ash granulation system based on particle size monitoring. Background Technology

[0002] Fly ash, a major solid waste from coal-fired power plants, can be processed into granules with specific particle size and strength using granulation technology, and is widely used in building materials, soil improvement, and other fields. Rotary drum granulation systems have become one of the mainstream processes for fly ash granulation due to their continuous production capacity and high particle forming efficiency. However, existing rotary drum fly ash granulation devices still have certain limitations in use: 1. The granulation system mostly adopts a static parameter setting mode, with key parameters such as drum tilt angle and rotation speed relying on manual experience for preset settings, lacking the ability to respond to dynamic changes in raw material particle size. Especially when the particle size distribution of fly ash raw materials fluctuates, the system cannot adjust the residence time of fly ash in the drum in real time, resulting in large particle size deviations and low pass rates (usually below 75%) in the finished particles.

[0003] 2. Traditional methods require obtaining finished product testing data through sample production before parameter correction. This delayed adjustment mechanism results in significant raw material waste (statistics show that sample loss accounts for 15%-20%) and severely restricts the realization of continuous mass production. How to construct a dynamic coupling mechanism between raw material characteristics and process parameters has become a key technical bottleneck in improving the intelligent level of fly ash granulation. Summary of the Invention

[0004] In view of this, embodiments of the present invention provide a rotary drum fly ash granulation system based on particle size monitoring to eliminate or improve one or more defects existing in the prior art.

[0005] This invention provides a rotary drum fly ash granulation system based on particle size monitoring, comprising a hopper unit, a rotary drum unit, and a closed-loop control unit. The rotary drum unit includes a drum body, a drum support, and an angle adjustment component. The drum support is disposed at the bottom of the drum body to support the drum body's rotation along its axial direction. The angle adjustment component is disposed at the bottom of the drum support to adjust the angle of the drum body. The hopper unit is located above the rotary drum unit and includes a raw material hopper and a powder monitoring module. The powder monitoring module is disposed at the discharge end of the raw material hopper to acquire particle size distribution parameters of the incoming fly ash powder. The closed-loop control unit is electrically connected to both the powder monitoring module and the rotary drum unit. Based on the acquired particle size distribution parameters and the set target particle size, the control unit adjusts the angle of the rotary drum body to control the residence time of the fly ash powder inside the rotary drum body, thereby generating product particles that meet the target particle size.

[0006] In some embodiments of the present invention, the drum body is a segmented structure, which includes a premixing section, a compaction section, and a polishing section arranged sequentially along its axial direction from the inlet end to the outlet end; the drum unit is provided with a nozzle assembly, which is arranged along the axial direction of the drum body, and includes a dry nozzle array for spraying dry binder and / or a wet nozzle array for spraying liquid binder; the nozzle assembly also includes a first valve group module for adjusting the flow rate of the dry nozzle array and a second valve group module for adjusting the flow rate of the wet nozzle array.

[0007] In some embodiments of the present invention, the drum unit further includes a temperature detection module and a hot air temperature control component. The temperature detection module is installed on the inner wall of the drum body and is used to detect particle temperature data inside the drum body. The hot air temperature control component is used to adjust the hot air flow rate and / or temperature input to the drum body based on the particle temperature data. The drum unit further includes a humidity detection module and a drive component. The humidity detection module is installed on the inner wall of the drum body and is used to detect particle humidity data inside the drum body. The drive component is interconnected with the drum body and is used to adjust the rotation speed of the drum body based on the particle humidity data. The drive component is also used to control the residence time of fly ash powder inside the drum body by adjusting the rotation speed of the drum body.

[0008] In some embodiments of the present invention, the silo unit further includes a powder transfer pipe for connecting the drum unit to the raw material silo; the powder transfer pipe is also equipped with a pre-screening mechanism and a gravity detection module; the pre-screening mechanism is located above the powder monitoring module and is equipped with a screen mechanism for screening out large particulate impurities in the fly ash powder that interfere with the particle size distribution parameter; the screen mechanism is configured as a longitudinal multi-layer structure, and the screen aperture size of the multi-layer screen decreases sequentially from top to bottom; the gravity detection module is located below the powder monitoring module and is installed at the bottom of the powder transfer pipe for obtaining the weight of the screened fly ash powder; the gravity detection module is electrically connected to the first valve group module and the second valve group module respectively, and is used to adjust the binder flow rate of the nozzle assembly based on the obtained weight of the screened fly ash powder.

[0009] In some embodiments of the present invention, the closed-loop control unit includes a data processing module, which is configured such that the target particle size d, the tilt angle θ of the drum body, and the rotational speed n of the drum body satisfy the following relationship: Wherein, K is an extreme working condition calibration constant, with a value of 2125~2347, the target particle size is 5mm~50mm, the tilt angle of the drum body is 2°~5°, and the rotation speed of the drum body is 5rpm~20rpm.

[0010] In some embodiments of the present invention, the drum body is a three-section split structure, wherein the premixing section, the compacting section, and the polishing section are arranged coaxially, and a rotating connection mechanism is provided between the premixing section and the compacting section, and between the compacting section and the polishing section; the rotating connection mechanism includes an outer ring and an inner ring, the outer ring and the inner ring are arranged concentrically, and a plurality of rolling elements are provided between the outer wall of the inner ring and the inner wall of the outer ring, so that the sections of the split drum body are rotatably connected to each other.

[0011] In some embodiments of the present invention, the premixing section, the compaction section, and the polishing section, which are separately configured, are each equipped with a temperature detection module, a hot air temperature control component, a humidity detection module, a drive component, and a nozzle component, for adjusting the temperature, humidity, and binder flow rate inside each section of the drum body, respectively. The data processing module is further configured to adjust the temperature, humidity, and binder flow rate inside each section of the drum body structure based on the acquired particle temperature data, particle humidity data, and the weight of the sieved fly ash powder. The premixing section is configured to meet the following conditions: humidity 15%~20%, temperature 80~85℃, and binder flow rate 2.5~3.0 L / min; the compaction section is configured to meet the following conditions: humidity 8%~12%, temperature 95~100℃, and binder flow rate 1.8~2.2 L / min; and the polishing section is configured to meet the following conditions: humidity 0%~5%, temperature 75~80℃, and binder flow rate 0.5~1.0 L / min.

[0012] In some embodiments of the present invention, the dry nozzle array is located inside the premixing section, and the wet nozzle array is located inside the premixing section, the compaction section, and the polishing section; the dry nozzle array is provided with a plurality of airflow atomizing nozzles, the spacing between each airflow atomizing nozzle is configured to be 200 mm, and the tilt angle is configured to be 45°; the wet nozzle array is provided with a plurality of fan-shaped atomizing nozzles, the spacing between each fan-shaped atomizing nozzle is configured to be 150 mm, and the tilt angle is configured to be 60°.

[0013] In some embodiments of the present invention, the tilt adjustment assembly includes a first lifting mechanism and a second lifting mechanism, which are arranged along the axial direction of the drum body and are respectively disposed at the bottom of the inlet end and the outlet end of the drum body; the top of the first lifting mechanism and the second lifting mechanism are each provided with a rotating shaft mechanism, which is respectively hinged to the bottom of the drum support; the first lifting mechanism and the second lifting mechanism adopt a double redundant hydraulic cylinder group or a hydraulic lifting support.

[0014] In some embodiments of the present invention, the granulation system further includes a premixing unit located between the silo unit and the drum unit, for mixing the binder and fly ash powder before entering the drum unit. The premixing unit includes a biaxial premixing mechanism, a first connecting mechanism, and a second connecting mechanism. The first connecting mechanism is located at the feed end of the biaxial premixing mechanism and is provided with a conveying mechanism and an airtight connecting flange for sealing communication between the silo unit and the biaxial premixing mechanism. The second connecting mechanism is located at the discharge end of the biaxial premixing mechanism and is provided with a conveying chute and an airtight connecting flange for sealing communication between the biaxial premixing mechanism and the drum unit.

[0015] According to the technical solution described in the embodiment of the present invention, the beneficial effects that can be obtained include at least the following: the silo unit and the drum unit in the particle size monitoring-based rotary drum fly ash granulation system (hereinafter referred to as the granulation system) of the present invention are arranged longitudinally, which can transport fly ash powder by gravity and reduce the bottom area occupied by the granulation system, thus improving the overall space utilization efficiency of the granulation system; the drum unit is equipped with an inclination adjustment component, which can control the fly ash powder in the drum body by adjusting the inclination angle of the drum body. The residence time inside the drum body changes the particle size of the generated product particles, which helps to improve the diversity of particle size of the finished product particles from the fly ash granulation system. The granulation system is equipped with a powder monitoring module, which can acquire the particle size distribution parameters of fly ash powder, which helps to improve the detection of fly ash powder in the fly ash granulation system. The granulation system is also equipped with a closed-loop control unit, which can adjust the residence time of fly ash powder inside the drum body based on the acquired powder particle size distribution parameters, thereby adjusting the particle size of the product particles, which helps to improve the uniformity of particle size and the pass rate of product particles.

[0016] Additional advantages, objects, and features of the invention will be set forth in part in the description which follows, and will also become apparent in part to those skilled in the art upon studying the description, or may be learned by practice of the invention. The objects and other advantages of the invention can be realized and obtained by means of the structures specifically pointed out in the specification and drawings.

[0017] Those skilled in the art will understand that the objectives and advantages achievable with this invention are not limited to those specifically described above, and that the above and other objectives achievable with this invention will become clearer from the following detailed description. Attached Figure Description

[0018] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, are not intended to limit the scope of the invention. The components in the drawings are not drawn to scale but are merely illustrative of the principles of the invention. For ease of illustration and description of certain parts of the invention, corresponding portions in the drawings may be enlarged, i.e., may appear larger relative to other components in an exemplary device actually manufactured according to the invention.

[0019] Figure 1 This is a schematic diagram of the overall structure of a rotary drum fly ash granulation system based on particle size monitoring in one embodiment of the present invention.

[0020] Figure 2 This is a schematic diagram of the nozzle assembly and drum unit of the granulation system in one embodiment of the present invention.

[0021] Figure 3 This is a schematic diagram of the hot air temperature control component and the drum unit of the granulation system in one embodiment of the present invention.

[0022] Figure 4 This is a schematic diagram of the three-section split structure of the drum body in one embodiment of the present invention.

[0023] Figure 5 This is a schematic diagram of the silo unit structure of the granulation system in one embodiment of the present invention.

[0024] Figure label: 1. Fly ash granulation system; 11. Silo unit; 111. Raw material silo; 112. Powder transfer pipeline; 112-1. Pre-screening mechanism; 112-2. Gravity detection module; 113. Powder monitoring module; 12. Drum unit; 121. Drum body; 121-1. Premixing section; 121-2. Compacting section; 121-3. Polishing section; 121-4. Rotation connection mechanism; 122. Drum support; 123. Inclination adjustment component; 123-1. First Lifting mechanism; 123-2, Second lifting mechanism; 124, Nozzle assembly; 124-1, Dry nozzle array; 124-2, Wet nozzle array; 124-3, First valve group module; 124-4, Second valve group module; 125, Temperature detection module; 126, Hot air temperature control assembly; 127, Humidity detection module; 128, Drive assembly; 14, Premixing unit; 141, Dual-axis premixing mechanism; 142, First connecting mechanism; 143, Second connecting mechanism. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the embodiments and accompanying drawings. Here, the illustrative embodiments and descriptions of this invention are used to explain the invention, but are not intended to limit the invention.

[0026] It should also be noted that, in order to avoid obscuring the invention with unnecessary details, only the structures and / or processing steps closely related to the solution according to the invention are shown in the accompanying drawings, while other details that are not closely related to the invention are omitted.

[0027] It should be emphasized that the term "including / comprises" as used herein refers to the presence of a feature, element, step, or component, but does not exclude the presence or addition of one or more other features, elements, steps, or components.

[0028] It should also be noted that, unless otherwise specified, the term "connection" in this article can refer not only to a direct connection, but also to an indirect connection involving an intermediary.

[0029] In the following description, embodiments of the invention will be illustrated with reference to the accompanying drawings. In the drawings, the same reference numerals represent the same or similar parts, or the same or similar steps.

[0030] To address the problems of large particle size deviation, low pass rate, and difficulty in achieving continuous mass production in existing fly ash granulation systems, this invention provides a rotary drum fly ash granulation system based on particle size monitoring (hereinafter referred to as the granulation system or fly ash granulation system). Unlike existing rotary drum granulation devices that rely on manual adjustment and experience-based adjustment of drum parameters, this invention's fly ash granulation system is equipped with an inclination angle adjustment component. This allows for particle size adjustment of the finished product without shutting down the granulation system, improving work efficiency and making it suitable for large-scale continuous production environments. The fly ash granulation system employs a feedforward control method and includes a powder monitoring module to acquire particle size distribution parameters in the incoming fly ash powder, providing a basis for parameter adjustment during the granulation process. Furthermore, this invention enables real-time dynamic parameter control. Through a closed-loop control unit, based on the detected particle size distribution parameters, the residence time of the fly ash powder inside the rotary drum is adjusted to regulate the particle size of the finished product, thereby improving the pass rate of the finished product particle size.

[0031] This invention provides a rotary drum fly ash granulation system based on particle size monitoring, such as... Figure 1As shown, the system includes a hopper unit 11, a drum unit 12, and a closed-loop control unit. The drum unit 12 includes a drum body 121, a drum support 122, and an angle adjustment component 123. The drum body 121 is arranged at an angle and has a hollow interior. The drum support 122 is located at the bottom of the drum body 121 and is arranged along the axial direction of the drum body 121 to support the drum body 121 to rotate along its axial direction, so that the fly ash powder and binder inside the drum body 121 can polymerize to form product particles. The angle adjustment component 123 is located at the bottom of the drum support 122 and is used to adjust the angle of the drum body 121. By adjusting the angle of the drum body 121, the residence time of the particles inside the drum body 121 can be directly changed to adjust the particle size of the generated product particles.

[0032] In the fly ash granulation process, the tilt angle adjustment component 123 can adjust the tilt angle of the drum body 121 to 5°, and the residence time of fly ash particles in the drum body 121 is 8~10 min, so that the particle size of the produced product particles is 1.0~2.0 mm; the tilt angle adjustment component 123 can adjust the tilt angle of the drum body 121 to 3.5°, and the residence time of fly ash particles in the drum body 121 is 12~15 min, so that the particle size of the produced product particles is 2.0~3.0 mm; the tilt angle adjustment component 123 can adjust the tilt angle of the drum body 121 to 2°, and the residence time of fly ash particles in the drum body 121 is 18~20 min, so that the particle size of the produced product particles is 3.0~5.0 mm. By adjusting the tilt angle of the drum body 121, the particle size of the generated product particles meets the target particle size, which is beneficial to improving the particle size yield of the fly ash granulation system 1 and is conducive to large-scale production and promotion.

[0033] The hopper unit 11 is located above the drum unit 12 and includes a raw material hopper 111, a powder transfer pipe 112, and a powder monitoring module 113. The raw material hopper 111 and the drum body 121 are interconnected through the powder transfer pipe 112. The hopper unit 11 is used to supply fly ash powder to the drum unit 12. The powder monitoring module 113 is located inside the powder transfer pipe 112 and is used to acquire the particle size distribution parameters of the fly ash powder during the fly ash powder transfer process. The powder monitoring module 113 can use a laser particle size analyzer to acquire the particle size distribution parameters in the powder.

[0034] As one feasible approach, the laser particle size analyzer can achieve online monitoring by sampling and testing. An automatic sampling mechanism is installed inside the powder flow pipeline 112 to complete the sampling and testing of the powder. The automatic sampling mechanism can achieve automatic sampling through negative pressure airflow or by using a precision peristaltic pump to extract powder samples from the pipeline. After sampling, the particle size distribution parameters of the collected samples are detected by the laser particle size analyzer to achieve online monitoring of the incoming fly ash powder. The sampling frequency of the automatic sampling mechanism can be adjusted according to actual needs, for example, it can be set to sample every 2 minutes or every 10 minutes.

[0035] As another feasible approach, a laser particle size analyzer can monitor the powder inside the transfer pipe 112 by setting an embedded optical window in the pipe wall. A conveying air pump is installed inside the transfer pipe 112 to supply flowing gas during powder conveying. The airflow ensures the powder is evenly distributed and circulated within the pipe, maintaining a stable particle size distribution during transport. During monitoring, the laser signal from the laser particle size analyzer passes through the optical window, is scattered by the powder inside the transfer pipe, and is received by the detector. By analyzing and calculating the laser signals sent and received by the laser particle size analyzer, online monitoring of the powder particle size distribution parameters can be achieved.

[0036] Laser particle size analyzers infer particle size distribution by detecting the scattering angle distribution of laser light by a group of particles, thus obtaining the particle size distribution parameters of fly ash powder. In actual powder monitoring, particle size distribution parameters can be quantitatively represented using D10, D50, and D90. Specifically, D10 represents the particle size value corresponding to a cumulative particle size distribution percentage of 10%, D50 represents the particle size value corresponding to a cumulative particle size distribution percentage of 50%, and D90 represents the particle size value corresponding to a cumulative particle size distribution percentage of 90%. For fly ash powder, a larger particle size value in D10, D50, or D90 indicates a larger overall particle size, meaning the incoming powder is coarser; a smaller particle size value in D10, D50, or D90 indicates a smaller overall particle size, meaning the incoming powder is finer.

[0037] Based on the fineness of the fly ash powder, the fly ash powder actually used can be roughly divided into three grades: Grade 1 fly ash has the finest particles, with a median particle size D50 of less than 20μm, and is widely used in high-performance concrete and high-strength cement products; Grade 2 fly ash has a median particle size D50 ranging from 20μm to 45μm, and is used in ordinary concrete and mortar admixtures; Grade 3 fly ash has coarser particles, with a median particle size D50 greater than 45μm, and is used in roadbed filling and block production. By detecting and differentiating the fineness of the incoming fly ash, it is possible to adapt to scenarios involving the manufacture of finished particles of different sizes. Including but not limited to this, the particle size distribution parameters detected by the laser particle size analyzer can also be displayed through particle size distribution data tables, distribution curves, specific surface areas, etc., to clearly and accurately reflect the changes in the particle size distribution parameters of the incoming fly ash powder.

[0038] By setting a powder monitoring module 113 inside the powder flow pipeline 112, the feedforward detection function of fly ash powder can be realized. The fly ash powder is detected before entering the drum body 121, which helps to ensure the timeliness of the detection data. Through feedforward detection, the drum unit 12 can be adjusted and controlled in advance, which is conducive to realizing the real-time adjustment of the drum body 121 and shortening the feedback cycle from the detection component to the control component.

[0039] The closed-loop control unit is electrically connected to the powder monitoring module 113 and the drum unit 12, respectively. Based on the acquired particle size distribution parameters and the set target particle size, it controls the residence time of fly ash powder inside the drum body 121 by adjusting the tilt angle of the drum body 121 to generate product particles that meet the target particle size. The closed-loop control unit enables automatic adjustment and control of the product particle size to obtain particles that meet the target size. It automatically adjusts the residence time of fly ash powder inside the drum body 121 according to the particle size distribution parameters and target particle size of the incoming fly ash powder, replacing the manual and experience-based adjustment methods of the prior art. This improves the intelligent and refined management of product particle size, helps reduce labor costs, increases production efficiency, and facilitates large-scale promotion and application.

[0040] In the above embodiments, the fly ash granulation system 1, through the tilt angle adjustment component 123, can change the tilt angle of the drum body 121 to adjust the residence time of the fly ash powder inside the drum body 121, thereby changing the particle size of the generated product particles. This is beneficial to improving the particle size diversity of the product particles produced by the fly ash granulation system 1, enabling it to manufacture products with different particle size specifications, and thus adapting to different granulation needs. The fly ash granulation system 1, through the powder monitoring module 113, can achieve monitoring of the incoming fly ash powder through feedforward detection. The advance acquisition of fly ash particle size distribution parameters, compared to post-processing detection of product particles, can shorten the control cycle of the fly ash granulation system 1, enabling real-time adjustment of the drum body 121. The fly ash granulation system 1, through a set closed-loop control unit, replaces manual adjustment and adjustment based on experience. Based on the acquired particle size distribution parameters and target particle size, it achieves automatic adjustment of the drum body 121, improving the intelligence level and adjustment accuracy of the fly ash granulation system 1, which is conducive to reducing labor costs and realizing large-scale promotion and application.

[0041] In some embodiments, such as Figure 2 As shown, the drum body 121 has a segmented structure, which includes a premixing section 121-1, a compaction section 121-2, and a polishing section 121-3 arranged sequentially along the axial direction of the drum body 121 from the inlet end to the outlet end. During the granulation process, the premixing section 121-1 serves as the coarse forming zone for the initial agglomeration and nucleation of fly ash particles. The compaction section 121-2 serves as the extrusion zone for granulation, where the particle structure is compacted through collisions between particles or between particles and the drum body 121. The polishing section 121-3 is used to polish the surface of the fly ash particles to remove the uneven surface structure.

[0042] The drum unit 12 further includes a nozzle assembly 124, which is disposed inside the drum body 121 and is used to spray a binder onto the fly ash powder. The nozzle assembly 124 is an array structure arranged along the axial direction of the drum body 121. The array structure includes a dry nozzle array 124-1 and a wet nozzle array 124-2, which are used to spray dry binder and / or liquid binder onto the fly ash powder. The nozzle assembly 124 also includes a first valve group module 124-3 and a second valve group module 124-4. The first valve group module 124-3 is disposed on the dry nozzle array 124-1 and is used to adjust the flow rate of the dry binder. The second valve group module 124-4 is disposed on the wet nozzle array 124-2 and is used to adjust the flow rate of the liquid binder. Compared to existing technologies that typically use only one type of nozzle array (generally a wet nozzle array 124-2), the nozzle assembly 124 in this invention is equipped with both a dry nozzle array 124-1 and a wet nozzle array 124-2. Using two types of nozzle arrays optimizes wetting and promotes nucleation. The dry nozzle array 124-1 is used to uniformly and rapidly cover the surface of fly ash particles with dry binder, which is beneficial for promoting the aggregation of powder within the premixing section 121-1 to form initial nuclei. The wet nozzle array 124-2 can provide a larger binder flow rate, which is beneficial for the growth and compaction of initial nuclei.

[0043] Setting up two types of spray arrays also improves the operability and adaptability of the granulation process. The physical and chemical properties of fly ash may fluctuate during granulation; setting up two nozzle arrays allows for flexible adjustments to the flow rates of the incoming fly ash powder by regulating the flow rate. For example, when the incoming fly ash is finer or drier, the spray flow rate of the dry nozzle array 124-1 can be increased to improve uniformity and ensure the number of initial nuclei formed. When larger particle sizes are required, the spray flow rate of the wet nozzle array 124-2 can be increased to improve the growth effect of the initial nuclei. Setting up two nozzle arrays also effectively reduces the amount of binder used. The sprayed dry binder ensures effective nucleation within the premixing section 121-1. The synergistic effect of the two binders, compared to using only one binder, achieves better granulation results and reduces the amount of binder used, thus lowering production costs.

[0044] In some embodiments, such as Figure 3As shown, the drum unit 12 further includes a temperature detection module 125 and a hot air temperature control component 126. The temperature detection module 125 is installed on the inner wall of the drum body 121 and is used to detect the particle temperature data inside the drum body 121. The hot air temperature control component 126 is used to adjust the hot air flow rate and / or temperature input into the drum body 121 based on the particle temperature data. The temperature detection module 125 can use an infrared thermal imager for real-time temperature detection to improve accuracy. The hot air temperature control component 126 can use a hot air blower to provide hot air, and a hot air duct is set up to transmit the hot air generated by the hot air blower to the inside of the drum body 121. By controlling the opening and closing degree of the hot air duct outlet, the temperature inside the drum body 121 can be adjusted. For example, for every 10°C decrease in the temperature inside the drum body 121, the opening degree of the outlet increases by 8%~12% to increase the incoming hot air flow rate, thereby ensuring the thermal balance inside the drum body 121. Fly ash is manufactured in a stable temperature environment, which helps to improve the uniformity of the finished particles and prevent particle differences caused by temperature changes.

[0045] As one possible approach, the hot air duct can be equipped with three air outlets to correspond to the internal spaces of the premixing section 121-1, the compaction section 121-2, and the polishing section 121-3, respectively. Independent temperature regulation of different functional sections within the drum body 121 can be achieved by individually adjusting the opening and closing degree of each air outlet. For example, the temperature inside the premixing section 121-1 can be maintained at 80℃~85℃, which is beneficial for mixing fly ash and powder; the temperature inside the compaction section 121-2 can be maintained at 95℃~100℃, which helps improve the structural strength of the particles through extrusion and drying; and the temperature inside the polishing section 121-3 can be maintained at 75℃~80℃, which helps reduce the binder content on the particle surface and improve the polishing effect.

[0046] like Figure 4As shown, the drum unit 12 further includes a humidity detection module 127 and a drive assembly 128. The humidity detection module 127 is installed on the inner wall of the drum body 121 and is used to detect the particle humidity data inside the drum body 121. The drive assembly 128 includes a drive mechanism, a transmission mechanism, and a speed regulating mechanism. One end of the transmission mechanism is connected to the drive mechanism, and the other end is connected to the drum body 121, and is used to drive the drum body 121 to rotate. The speed regulating mechanism is connected to the transmission mechanism and is used to adjust the rotation speed of the drum body 121 based on the particle humidity data. The speed regulating mechanism is also used to control the residence time of fly ash powder inside the drum body 121 by adjusting the rotation speed of the drum body 121. The humidity detection module 127 can use a microwave humidity sensor for accurate humidity measurement. The linkage control of the temperature detection module 125 and the drive assembly 128 can improve the drying speed of the particles, which is beneficial to shorten the drying time required in the granulation process and improve the granulation efficiency. For example, for every 5% increase in the internal humidity of the drum body 121, the rotation speed of the drum body 121 increases by 10% to 15%. By increasing the rotation speed of the drum body 121, the drying speed of the particles can be increased, achieving the effect of rotating and spun-drying the particles.

[0047] On the other hand, the drive component 128 can also adjust the residence time of fly ash powder by adjusting the rotation speed of the drum body 121, thereby affecting the particle size of the finished product. Therefore, multiple parameters such as fly ash humidity, temperature and drum rotation speed inside the drum body 121 affect each other and all affect the particle size of the product. In the actual granulation process, comprehensive consideration and adjustment should be made.

[0048] In some embodiments, the closed-loop control unit includes a data processing module, which is configured such that the target particle size d, the tilt angle θ of the drum body 121, and the rotational speed n of the drum body 121 satisfy the following relationship: Wherein, K is the calibration constant for extreme working conditions, which can be set to 2125~2347; the target particle size is 5mm~50mm; the tilt angle of the drum body 121 is 2°~5°; and the rotational speed of the drum body 121 is 5rpm~20rpm. The data processing module can quantify and calculate multiple parameters affecting the particle size of the finished product, such as the tilt angle and drum rotational speed, during the granulation process, to obtain a scientifically reasonable control scheme. Compared to adjustments based on manual experience, automatic control using the data processing module makes parameter adjustments faster and more timely, and also avoids operational errors caused by humans. This helps reduce labor costs, improves the intelligence and automation level of the fly ash granulation system 1, and is conducive to large-scale promotion and application.

[0049] During the granulation process, the tilt angle and rotation speed of the drum body 121 are the main parameters affecting the residence time of particles inside the drum body 121. The residence time is the main parameter affecting the particle size of the finished product. Therefore, the data processing unit is used to uniformly control the particle size so that the particle size of the finished product meets the target particle size. For example, with a drum tilt angle of 5° and a drum speed of 18-20 rpm, the particle residence time is 8-10 minutes, and the corresponding finished particle size is 1.0-2.0 mm; with a drum tilt angle of 3.5° and a drum speed of 12-15 rpm, the particle residence time is 12-15 minutes, and the corresponding finished particle size is 2.0-3.0 mm; with a drum tilt angle of 2° and a drum speed of 5-8 rpm, the particle residence time is 18-20 minutes, and the corresponding finished particle size is 3.0-5.0 mm. By adopting a unified control method combining multiple parameters, the particle size range of the finished particles can be expanded, and fine adjustment of the finished particle size can also be achieved.

[0050] In some embodiments, such as Figure 5 As shown, the powder transfer pipe 112 is also equipped with a pre-screening mechanism 112-1 and a gravity detection module 112-2. The pre-screening mechanism 112-1 is located above the powder monitoring module 113 and is equipped with a screen mechanism to screen out large particulate impurities in the fly ash powder that interfere with the particle size distribution parameters. The screen mechanism is configured as a longitudinal multi-layer structure, and the screen aperture size of the multi-layer screen decreases from top to bottom. The screen aperture can be configured to be 1~3mm.

[0051] The gravity detection module 112-2 is located below the powder monitoring module 113 and is installed at the bottom of the powder flow pipe 112. It is used to acquire the weight of the sieved fly ash powder. The gravity detection module 112-2 is electrically connected to the first valve group module 124-3 and the second valve group module 124-4, respectively, and is used to adjust the binder flow rate of the nozzle assembly 124 based on the acquired weight of the sieved fly ash powder. By detecting the weight of the powder entering the drum body 121, the flow rate of the binder sprayed by the nozzle assembly 124 is automatically adjusted, ensuring that the amount of fly ash and binder during the granulation process remains within a certain ratio range. This avoids situations where there is too much or too little binder when the amount of fly ash powder changes, and maintains a stable humidity environment inside the drum body 121, which is beneficial for ensuring overall granulation quality and efficiency.

[0052] In some embodiments, such as Figure 1 and Figure 2As shown, the drum body 121 has a three-section split structure. The premixing section 121-1, the compacting section 121-2, and the polishing section 121-3 are arranged coaxially. Rotational connection mechanisms 121-4 are provided between the premixing section 121-1 and the compacting section 121-2, and between the compacting section 121-2 and the polishing section 121-3. The rotational connection mechanism 121-4 includes an outer ring and an inner ring. The outer ring and the inner ring are arranged concentrically, and a plurality of rolling elements are provided between the outer wall of the inner ring and the inner wall of the outer ring, so that the sections of the split drum body 121 can be rotated and connected to each other. The rotating connecting mechanism 121-4 separates the various sections of the drum body 121 into independent chamber environments. This allows for different control operations for different granulation processes, improving the processing effect of each section. For example, the premixing section 121-1 can maintain a low speed to improve the mixing effect of fly ash powder and binder, while the polishing section 121-3 can maintain a high speed to improve the polishing effect of the particles. The drum body 121 is designed as a split structure, which facilitates independent control of the drum body 121. It allows for independent adjustment of the speed, temperature, humidity, and binder flow of each section of the drum body 121, enabling more flexible and precise state control.

[0053] Furthermore, the premixing section 121-1, the compaction section 121-2, and the polishing section 121-3, which are separately configured, are each equipped with a temperature detection module 125, a hot air temperature control component 126, a humidity detection module 127, a drive component 128, and a nozzle component 124, used to adjust the temperature, humidity, and binder flow rate inside each section of the drum body 121, respectively. The data processing module is also configured to adjust the temperature, humidity, and binder flow rate inside each section of the drum body 121 based on the acquired particle temperature data, particle humidity data, and the weight of the sieved fly ash powder. The premixing section 121-1 is configured to meet the following conditions: humidity 15%~20%, temperature 80~85℃, and binder flow rate 2.5~3.0 L / min; the compaction section 121-2 is configured to meet the following conditions: humidity 8%~12%, temperature 95~100℃, and binder flow rate 1.8~2.2 L / min. The polishing section 121-3 is configured to meet the following conditions: humidity 0%~5%, temperature 75~80℃, and binder flow rate 0.5~1.0 L / min. By independently adjusting the parameters of each section of the roller body, the porosity difference inside the particles can be reduced. Combined with the intelligent control unit of the closed-loop control unit, the standard deviation of particle density can be reduced from 0.35 g / cm³ to 0.12 g / cm³, which is beneficial to improving the consistency of the finished particles.

[0054] In some embodiments, the dry nozzle array 124-1 is located inside the premixing section 121-1, and the wet nozzle array 124-2 is located inside the premixing section 121-1, the compaction section 121-2, and the polishing section 121-3. The dry nozzle array 124-1 is provided with a plurality of airflow atomizing nozzles, the spacing between each airflow atomizing nozzle is configured to be 200 mm, and the tilt angle is configured to be 45°. The dry nozzle array 124-1 can be installed at 1 / 3 of the length of the feed end of the drum body 121, corresponding to the internal area of ​​the premixing section 121-1. The dry binder can be uniformly sprayed into the premixing section 121-1 by means of spiral feeding and airflow atomizing nozzles, which can improve the mixing effect of fly ash powder and dry binder inside the premixing section 121-1 and prevent nozzle clogging. The wet nozzle array 124-2 is equipped with several fan-shaped atomizing nozzles, with a spacing of 150mm and an inclination angle of 60°. The wet nozzle array 124-2 can be installed at 2 / 3 of the length of the drum body 121, corresponding to the internal area of ​​the compaction section 121-2. The wet binder can be uniformly sprayed into the compaction section 121-2 using a high-pressure plunger pump and fan-shaped atomizing nozzles. This increases the spray area of ​​the wet binder and reduces the amount of binder used, thus reducing binder consumption and improving overall economy. Including but not limited to this, the installation spacing and inclination angle of the nozzle array can be flexibly adjusted according to the actual production scenario and requirements.

[0055] As one possible approach, the nozzles described above can be detachably connected to the nozzle base via snap-fit ​​quick-connect couplings, which improves the convenience of nozzle replacement and facilitates maintenance and replacement. During installation, the nozzles are locked onto the base using pneumatic clamps to enhance stability. Furthermore, RFID tags can be installed on the nozzles to automatically identify and adjust the control parameters of each nozzle during operation, enabling intelligent and precise control of each nozzle and improving the control accuracy of the nozzle array.

[0056] In some embodiments, such as Figure 1As shown, the tilt adjustment assembly 123 includes a first lifting mechanism 123-1 and a second lifting mechanism 123-2. The first lifting mechanism 123-1 and the second lifting mechanism 123-2 are arranged along the axial direction of the drum body 121 and are respectively set at the bottom of the inlet end and the outlet end of the drum body 121 to achieve an adjustable tilt arrangement at both ends of the drum body 121. The top of the first lifting mechanism 123-1 and the second lifting mechanism 123-2 are both provided with a rotating shaft mechanism, which is respectively hinged to the bottom of the drum support 122. The first lifting mechanism 123-1 and the second lifting mechanism 123-2 adopt a double redundant hydraulic cylinder group or a hydraulic lifting support. The tilt adjustment assembly 123 is controlled by synchronous lifting through a servo valve, and the positioning accuracy is configured to be ±0.1mm, so that the straightness error of the axis of the drum body 121 is less than 0.05mm / m during the tilt adjustment process, which is beneficial to improving the accuracy and stability of tilt adjustment. The tilt angle adjustment component 123 adjusts the tilt angle of the drum body 121 by independently adjusting the height positions of the inlet and outlet ends. The tilt angle of the drum body 121 is configured to be 2°~5°. During operation, increasing the tilt angle of the drum body 121 can shorten the material processing time, which is suitable for manufacturing coarse particles with small particle size and low particle density; decreasing the tilt angle of the drum body 121 can extend the material processing time, which is suitable for manufacturing fine particles with high particle density and large particle size.

[0057] In some embodiments, such as Figure 1 As shown, the granulation system further includes a premixing unit 14, which is located between the hopper unit 11 and the drum unit 12. The premixing unit 14 is used to mix the binder and fly ash powder before they enter the drum unit 12. The premixing unit 14 includes a biaxial premixing mechanism 141, a first connecting mechanism 142, and a second connecting mechanism 143. The first connecting mechanism 142 is located at the feed end of the biaxial premixing mechanism 141 and is equipped with a conveying mechanism and an airtight connecting flange for sealing communication between the hopper unit 11 and the biaxial premixing mechanism 141. The second connecting mechanism 143 is located at the discharge end of the biaxial premixing mechanism 141 and is equipped with a conveying chute and an airtight connecting flange for sealing communication between the biaxial premixing mechanism 141 and the drum unit 12. In the longitudinal direction of the granulation system, the hopper unit 11, the premixing unit 14 and the drum unit 12 adopt a longitudinal Z-shaped layout, which helps to reduce the bottom space occupied by the granulation system and improve the utilization efficiency of the longitudinal space. The longitudinal Z-shaped layout conforms to the gravity flow of fly ash and helps to improve the flow efficiency of fly ash powder.

[0058] Furthermore, the conveying mechanism of the first connecting mechanism 142 can be a variable frequency screw feeder, the rotation speed of which can be configured to 5~15 rpm to achieve quantitative conveying of fly ash powder. The conveying chute of the second connecting mechanism 143 is equipped with a gravity chute and a pneumatic gate valve. The gravity chute is used to guide the fly ash powder falling by gravity into the interior of the drum body 121, while the pneumatic gate valve is used to control the opening of the feed inlet of the drum body 121, which is beneficial to adjust and control the amount of powder entering the drum body 121. The inclination angle of the gravity chute can be configured to 55°, and a 15mm thick polyurethane wear-resistant layer can be provided on the inner side of the gravity chute to improve the flow effect of fly ash powder.

[0059] In some embodiments, the granulation system is further equipped with a sawdust removal unit, which uses a high-speed visual inspection device to scan the fly ash powder during the flow process in real time, enabling the accuracy of sawdust identification in the fly ash powder to be above 99.2%. After identifying sawdust impurities, a Φ2mm diameter airflow nozzle and a 0.6MPa high-pressure pulsed airflow are used to directionally blow away the sawdust from the fly ash powder, removing 98% of the sawdust impurities and improving the cleanliness of the fly ash powder.

[0060] According to the technical solution described in the embodiment of the present invention, the beneficial effects that can be achieved include at least: (1) The fly ash granulation system is equipped with an inclination adjustment component, which can adjust the residence time of fly ash powder inside the drum body to control the particle size of the finished product particles, which is conducive to expanding the application scenarios of the fly ash granulation system.

[0061] (2) The fly ash granulation system is equipped with a powder monitoring module, which can realize the feedforward detection function of fly ash powder, which is conducive to ensuring the timeliness of detection data, realizing the real-time adjustment of the drum body, and shortening the feedback cycle from the detection component to the control component.

[0062] (3) The fly ash granulation system is equipped with a closed-loop control unit, which makes the parameter adjustment faster and more timely, and can also avoid operational errors caused by personnel. This is conducive to reducing labor costs, improving the intelligence and automation level of the fly ash granulation system, and promoting its large-scale application.

[0063] (4) The nozzle assembly of the fly ash granulation system is equipped with a dry nozzle array and a wet nozzle array, which can improve the mixing effect of fly ash powder and binder, and reduce the consumption of binder, which is conducive to improving the overall economic benefits.

[0064] (5) The drum body of the fly ash granulation system is set as a three-section split structure, which can make the internal chamber environment of the drum body independent of each other. This is conducive to different control operations for different granulation processes and to improving the flexibility and accuracy of parameter adjustment during granulation.

[0065] Those skilled in the art will understand that the exemplary components, systems, and methods described in conjunction with the embodiments of the invention herein can be implemented in hardware, software, or a combination of both. Whether implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of the invention. When implemented in hardware, it can be, for example, electronic circuits, application-specific integrated circuits (ASICs), appropriate firmware, plug-ins, function cards, etc. When implemented in software, the elements of the invention are programs or code segments used to perform the desired tasks. The programs or code segments can be stored in a machine-readable medium or transmitted over a transmission medium or communication link via data signals carried on a carrier wave.

[0066] It should be clarified that the present invention is not limited to the specific configurations and processes described above and shown in the figures. For the sake of brevity, detailed descriptions of known methods are omitted here. In the above embodiments, several specific steps are described and shown as examples. However, the method process of the present invention is not limited to the specific steps described and shown. Those skilled in the art can make various changes, modifications, and additions, or change the order of steps, after understanding the spirit of the present invention.

[0067] In this invention, features described and / or illustrated for one embodiment may be used in the same or similar manner in one or more other embodiments, and / or combined with or in place of features of other embodiments.

[0068] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, various modifications and variations of the embodiments of the present invention are possible. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A rotary drum fly ash granulation system based on particle size monitoring, characterized in that, It includes a hopper unit (11), a drum unit (12), and a closed-loop control unit; The drum unit (12) includes a drum body (121), a drum support (122), and a tilt adjustment assembly (123). The drum support (122) is located at the bottom of the drum body (121) to support the drum body (121) to rotate along its axial direction. The tilt adjustment assembly (123) is located at the bottom of the drum support (122) and is used to adjust the tilt angle of the drum body (121). The drum body (121) is a three-section split structure, which includes a premixing section (121-1), a compaction section (121-2) and a polishing section (121-3) arranged sequentially from the inlet end to the outlet end along its axial direction. The drum unit (12) is provided with a nozzle assembly (124) inside. The nozzle assembly (124) is arranged along the axial direction of the drum body (121) and includes a dry nozzle array (124-1) for spraying dry adhesive and a wet nozzle array (124-2) for spraying liquid adhesive. The nozzle assembly (124) further includes a first valve group module (124-3) for adjusting the flow rate of the dry nozzle array (124-1) and a second valve group module (124-4) for adjusting the flow rate of the wet nozzle array (124-2); the dry nozzle array (124-1) is located inside the premixing section (121-1), and the wet nozzle array (124-2) is located inside the premixing section (121-1), the compaction section (121-2), and the polishing section (121-3); The drum unit (12) further includes a temperature detection module (125) and a hot air temperature control component (126). The temperature detection module (125) is installed on the inner wall of the drum body (121) and is used to detect the particle temperature data inside the drum body (121). The hot air temperature control component (126) is used to adjust the hot air flow rate and temperature input into the drum body (121) based on the particle temperature data. The drum unit (12) further includes a humidity detection module (127) and a drive component (128). The humidity detection module (127) is installed on the inner wall of the drum body (121) and is used to detect the particle humidity data inside the drum body (121). The drive component (128) is connected to the drum body (121) and is used to adjust the rotation speed of the drum body (121) based on the particle humidity data, thereby controlling the residence time of fly ash powder inside the drum body (121). The silo unit (11) is located above the drum unit (12), and includes a raw material silo (111) and a powder monitoring module (113). The powder monitoring module (113) is located at the discharge end of the raw material silo (111) and is used to obtain the particle size distribution parameters of the incoming fly ash powder. The silo unit (11) also includes a powder flow pipe (112) for connecting the drum unit (12) and the raw material silo (111). The powder flow pipe (112) is also equipped with a pre-screening mechanism (112-1) and a gravity detection module (112-2). The gravity detection module (112-2) is electrically connected to the first valve group module (124-3) and the second valve group module (124-4) respectively, and is used to adjust the binder flow rate of the nozzle assembly (124) based on the obtained weight of the screened fly ash powder. The closed-loop control unit is connected to the powder monitoring module (113) and the drum unit (12) respectively. It is used to control the residence time of fly ash powder inside the drum body (121) by adjusting the tilt angle of the drum body (121) based on the acquired particle size distribution parameters and the set target particle size of the product particles, so as to generate product particles that meet the target particle size. The closed-loop control unit includes a data processing module, which is configured such that the target particle size d, the tilt angle θ of the drum body (121), and the rotational speed n of the drum body (121) satisfy the following relationship: Wherein, K is the calibration constant for extreme working conditions, with a value of 2125~2347, the target particle size is 5mm~50mm, the tilt angle of the drum body (121) is 2°~5°, and the rotation speed of the drum body (121) is 5rpm~20rpm; The premixing section (121-1), the compaction section (121-2), and the polishing section (121-3), which are configured as separate units, are each equipped with a temperature detection module (125), a hot air temperature control component (126), a humidity detection module (127), a drive component (128), and a nozzle component (124) to adjust the temperature, humidity, and binder flow rate inside each section of the drum body (121), respectively. The data processing module is further configured to adjust the temperature, humidity, and binder flow rate inside each section of the drum body (121) based on the acquired particle temperature data, particle humidity data, and the weight of the sieved fly ash powder. The premixing section (121-1) is configured to meet the following conditions: humidity 15%~20%, temperature 80~85℃, and binder flow rate 2.5~3.

0. The compaction section (121-2) is configured to meet the following conditions: humidity 8%~12%, temperature 95~100℃, and binder flow rate 1.8~2.2 L / min; the polishing section (121-3) is configured to meet the following conditions: humidity 0%~5%, temperature 75~80℃, and binder flow rate 0.5~1.0 L / min.

2. The rotary drum fly ash granulation system based on particle size monitoring according to claim 1, characterized in that, The pre-screening mechanism (112-1) is located above the powder monitoring module (113). It is equipped with a screen mechanism to screen out large particulate impurities in fly ash powder that interfere with the particle size distribution parameters. The screen mechanism is configured as a longitudinal multi-layer structure, and the screen hole size of the screen mechanism decreases from top to bottom. The gravity detection module (112-2) is located below the powder monitoring module (113). The gravity detection module (112-2) is installed at the bottom of the powder transfer pipe (112) and is used to obtain the weight of the sieved fly ash powder.

3. The rotary drum fly ash granulation system based on particle size monitoring according to claim 1, characterized in that, The premixing section (121-1), the compacting section (121-2), and the polishing section (121-3) are arranged coaxially, and a rotating connecting mechanism (121-4) is provided between the premixing section (121-1) and the compacting section (121-2), and between the compacting section (121-2) and the polishing section (121-3). The rotating connection mechanism (121-4) includes an outer ring and an inner ring. The outer ring and the inner ring are arranged concentrically, and a plurality of rolling elements are provided between the outer wall of the inner ring and the inner wall of the outer ring, so that the segments of the split drum body (121) are rotatably connected to each other.

4. The rotary drum fly ash granulation system based on particle size monitoring according to claim 1, characterized in that, The dry nozzle array (124-1) is provided with a plurality of airflow atomizing nozzles, the spacing between each airflow atomizing nozzle is configured to be 200mm, and the tilt angle is configured to be 45°. The wet nozzle array (124-2) is provided with a number of fan-shaped atomizing nozzles, the spacing between each fan-shaped atomizing nozzle is configured to be 150mm, and the tilt angle is configured to be 60°.

5. The rotary drum fly ash granulation system based on particle size monitoring according to claim 1, characterized in that, The tilt adjustment assembly (123) includes a first lifting mechanism (123-1) and a second lifting mechanism (123-2). The first lifting mechanism (123-1) and the second lifting mechanism (123-2) are arranged along the axial direction of the drum body (121) and are respectively located at the bottom of the inlet end and the outlet end of the drum body (121). The top of the first lifting mechanism (123-1) and the second lifting mechanism (123-2) are both provided with a rotating shaft mechanism, which is hinged to the bottom of the drum support (122). The first lifting mechanism (123-1) and the second lifting mechanism (123-2) adopt a dual redundant hydraulic cylinder group or a hydraulic lifting support.

6. The rotary drum fly ash granulation system based on particle size monitoring according to claim 1, characterized in that, The granulation system also includes a premixing unit (14), which is located between the silo unit (11) and the drum unit (12) and is used to mix the binder and fly ash powder together before entering the drum unit (12). The premixing unit (14) includes a biaxial premixing mechanism (141), a first connecting mechanism (142), and a second connecting mechanism (143). The first connecting mechanism (142) is located at the feeding end of the biaxial premixing mechanism (141), and it is provided with a conveying mechanism and an airtight connecting flange for sealing and communicating with the hopper unit (11) and the biaxial premixing mechanism (141). The second connecting mechanism (143) is located at the discharge end of the biaxial premixing mechanism (141), and it is provided with a material conveying chute and an airtight connecting flange for sealing and communicating with the biaxial premixing mechanism (141) and the drum unit (12).

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