Temperature grading-based low-energy consumption dust suppression production system for mixed materials and moisture control method

Abstract

The present application relates to the technical field of uniform material dust suppression production, and discloses a low-energy-consumption dust suppression production system for uniform material based on temperature grading and a moisture control method, which comprises a data acquisition module, a moisture compensation amount analysis module, a moisture supplement execution module and a dust suppression and energy saving cooperation module; the data acquisition module is used for collecting the temperature at different height positions at the inlet of the uniform material belt conveyor and performing corresponding pretreatment; the moisture compensation amount analysis module constructs a temperature compensation model based on the data in the data acquisition module and judges whether to issue a control instruction to the moisture supplement execution module; the moisture supplement execution module dispatches an execution mechanism to perform partitioned water application. Through raw material layered temperature collection and the pretreatment scheme of Kalman filtering, the system establishes a k1 and k2 parameter calibration method based on the type of raw material, so that the moisture compensation model adapts to different material characteristics, realizes rapid dust suppression in the first zone and accurate moisture supplement in the second zone, and takes into account the dust suppression effect and moisture uniformity.

Description

Technical Field

[0001] This invention relates to the field of dust suppression production technology for blended materials, specifically to a low-energy dust suppression production system and moisture control method for blended materials based on temperature grading. Background Technology

[0002] In the production technology of mixed materials in the metallurgical and building materials industries, such as the mixing and pelletizing process of bulk materials like iron ore powder and sintering raw materials, the large temperature fluctuation of raw materials leads to moisture fluctuations under the traditional fixed water addition mode, causing problems such as dust or excessive moisture and clumping.

[0003] For example, the main equipment in a mixing production line includes a dust collector, silos, unloaders, screw feeders, high-intensity mixers, and belt conveyors. The silos store different powdery or granular materials. The unloaders discharge the materials into the screw conveyor or belt conveyor feed port, from where the screw conveyor feeds the materials into the mixing mixer. After humidification and mixing, the materials are fed onto the belt conveyor and then transported to the material storage area.

[0004] During the production process, it is necessary to achieve homogenization of various materials, but the particle size, temperature, humidity, and weight of these materials vary. Large temperature fluctuations in raw materials (from 20℃ to 100℃) result in moisture fluctuations exceeding ±5% under traditional fixed water addition modes, leading to dust (moisture content <6%) or excessive moisture causing agglomeration. The high-power mixer often operates at full power to resist changes in raw material viscosity, resulting in significant energy consumption. Current technology only monitors material moisture content and does not consider the impact of temperature on moisture permeability and evaporation rate. Currently, similar homogenization production lines in China use microwave moisture meters for feedback control, but the response is lagging and cannot pre-compensate for temperature disturbances. Furthermore, the widespread use of mist cannons and water spraying for dust suppression exacerbates moisture unevenness. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a low-energy dust suppression production system and moisture control method for mixed materials based on temperature grading. It has the advantages of accurate moisture compensation and low-energy dust suppression, thus solving the aforementioned technical problems.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a low-energy dust suppression production system for mixed materials based on temperature grading, comprising a data acquisition module, a moisture compensation analysis module, and a moisture replenishment execution module;

[0007] The data acquisition module is used to collect the temperature at different heights at the inlet of the mixing and batching conveyor belt and perform corresponding preprocessing.

[0008] The moisture compensation analysis module constructs a temperature compensation model based on the data in the data acquisition module and determines whether to send a control command to the moisture replenishment execution module.

[0009] The water replenishment execution module schedules the execution mechanism to perform zoned water application;

[0010] It also includes a dust suppression and energy-saving coordinating module for real-time detection of the moisture content of the mixture. When the moisture content of the mixture When the system is within a preset range and meets a preset duration, energy-saving operation is performed.

[0011] As a preferred embodiment of the present invention, the data acquisition module obtains the temperature through infrared temperature sensors deployed at six different locations on the mixing and batching conveyor belt, removes outliers using a Kalman filter algorithm, and calculates the actual temperature of the raw materials using a weighted average. ;

[0012] The data acquisition module also includes the construction of the temperature change rate, which is the average temperature difference over the most recent 5 sampling periods, with each period being 0.5 seconds. The specific expression is as follows:

[0013]

[0014] in, Indicates the rate of temperature change. Indicates the first Temperature at each sampling time Indicates the first Temperature at each sampling time It represents the product of the sampling period and the duration of the sampling period.

[0015] As a preferred embodiment of the present invention, the specific expression for the temperature compensation model constructed by the moisture compensation analysis module based on the data in the data acquisition module is as follows:

[0016]

[0017] in, This indicates the temperature compensation value. Represents the static compensation coefficient. This represents the compensation coefficient for the rate of dynamic change. Indicates the actual temperature of the raw material. Indicates the rate of temperature change. Indicates the reference temperature.

[0018] As a preferred embodiment of the present invention, the specific steps for the moisture compensation analysis module to determine whether to send a control command to the moisture replenishment execution module are as follows:

[0019] It is necessary to increase the water supply and send a control command. No need to add more water.

[0020] As a preferred embodiment of the present invention, the water replenishment execution module includes primary water replenishment and secondary water replenishment when executing the replenishment strategy. The specific expression for the amount of water replenished in the primary water replenishment is as follows:

[0021]

[0022] in, This indicates the amount of water added in a single water replenishment. This indicates the instantaneous flow rate of the raw material collected by the belt scale. This indicates the temperature compensation value. Indicates the proportionality coefficient;

[0023] The specific expression for the amount of water replenished in the secondary replenishment is as follows:

[0024]

[0025] in, This indicates the amount of water added during the secondary water replenishment process.

[0026] This invention also provides a moisture control method for low-energy dust suppression production of mixed materials based on temperature grading, which, based on the above-mentioned low-energy dust suppression production system for mixed materials based on temperature grading, includes the following steps:

[0027] Step 1: Collect the temperature at different heights at the inlet of the mixing and batching conveyor belt, and perform corresponding pretreatment;

[0028] Step 2: Construct a temperature compensation model, determine whether to issue a control command to replenish water, and perform zoned water application.

[0029] Compared with the prior art, the present invention provides a low-energy dust suppression production system and moisture control method for mixed materials based on temperature grading, which has the following beneficial effects:

[0030] This invention obtains the actual temperature of the raw materials through a preprocessing scheme involving raw material stratification temperature acquisition and Kalman filtering. Establish a system based on raw material type , Parameter calibration method, and comprehensive construction of temperature compensation values This allows the moisture compensation model to be adapted to different material properties, based on The system performs primary and secondary water replenishment in stages, achieving rapid dust suppression in the primary zone and precise humidification in the secondary zone. It balances dust suppression effectiveness with moisture uniformity and, in conjunction with dynamic power control of the strong mixer, achieves energy saving while suppressing dust. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the system framework of the present invention;

[0032] Figure 2This is a schematic diagram of the process of the present invention;

[0033] Figure 3 This is a schematic diagram of the architecture of the present invention. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Please see Figures 1-3 A low-energy dust suppression production system for mixed materials based on temperature grading includes a data acquisition module, a moisture compensation analysis module, and a moisture replenishment execution module.

[0036] The data acquisition module is used to collect the temperature at different heights at the inlet of the mixing and batching conveyor belt and perform corresponding preprocessing.

[0037] The data acquisition module is deployed with sensors: six infrared temperature sensors (model: OS137-1, measurement accuracy ±0.5℃, scanning frequency 2 times / second) are symmetrically arranged on both sides of the inlet of the mixing and batching conveyor belt (belt width 1.2~1.8m). Two of them monitor the upper layer of the material flow (depth 0~5cm), two monitor the middle layer (depth 5~10cm), and two monitor the lower layer (depth 10~15cm), covering the entire cross-section of the material flow.

[0038] Signal processing: A Kalman filter algorithm is used to remove outliers (such as instantaneous high-temperature points of metal impurities in the material flow, which are judged as abnormal if they deviate from the average temperature by ±2℃). Then, the weighted average temperature of the six sensors is calculated (top layer weight 0.3, middle layer weight 0.4, bottom layer weight 0.3) to obtain the actual temperature of the raw material. This avoids compensation errors caused by single-point temperature deviations;

[0039] The data acquisition module also includes constructing and calculating the temperature change rate, eliminating instantaneous temperature fluctuations, and addressing interference with the compensation quantity. The specific expression is as follows:

[0040]

[0041] in, Indicates the rate of temperature change. Indicates the first Temperature at each sampling time Indicates the first Temperature at each sampling time This represents the product of the sampling period and the duration of the sampling period.

[0042] The moisture compensation analysis module constructs a temperature compensation model based on the data in the data acquisition module and determines whether to send a control command to the moisture replenishment execution module.

[0043] The specific expression for the temperature compensation model constructed by the moisture compensation analysis module based on the data from the data acquisition module is as follows:

[0044]

[0045] in, This indicates the temperature compensation value. The static compensation coefficient is determined through orthogonal experiments based on the raw material type. For iron ore powder, the coefficient is 0.035~0.045% / ℃, and for sintering raw materials, it is 0.03~0.04% / ℃ (e.g., for iron ore powder at T=40℃). =0.04% / ℃ can compensate for moisture loss due to temperature rise (evaporation). This represents the dynamic change rate compensation coefficient, determined based on the thermal inertia coefficient of the raw materials. For iron ore powder, it is taken as 0.12~0.18%·s / ℃, and for sintering raw materials, it is taken as 0.1~0.15%·s / ℃ (e.g., when dT / dt=0.15℃ / s). =0.15%·s / ℃ can pre-compensate for the trend of continuous temperature increase. Indicates the actual temperature of the raw material. Indicates the rate of temperature change. This indicates the reference temperature (fixed at 25℃, corresponding to the optimal moisture penetration state of the raw material).

[0046] The specific steps taken by the moisture compensation analysis module to determine whether to send a control command to the moisture replenishment execution module are as follows:

[0047] The amount of water needs to be increased. No further water addition is needed. Control commands are sent. Compensation logic: If T > (Temperature is too high), ΔW is a positive value, so the amount of water added needs to be increased; if T < (Temperature is low), ΔW is negative, no water needs to be added; after the compensation amount is calculated, it is transmitted to the PLC (model: S7-1200) via RS485 communication protocol, and the control command is sent 3~5 seconds in advance to ensure that the moisture compensation takes effect when the material flow reaches the water addition zone.

[0048] The water replenishment module schedules the execution mechanism to apply water to designated zones.

[0049] Execution agency configuration:

[0050] Primary water filling area (ash silo outlet, 3m from temperature sensing area): Equipped with 4~6 high-pressure micro-mist nozzles (working pressure 3~5MPa, droplet size 50~100μm, coverage radius 0.3~0.5m), the nozzles are evenly arranged along the width of the belt (spacing 30~40cm), and connected to a variable frequency high-pressure pump (flow range 0.5~3m³ / h, adjustment accuracy ±0.05m³ / h);

[0051] Secondary water addition zone (mixing section, 5m away from primary water addition zone): equipped with 1 set of variable frequency controllable spray pipes (including electromagnetic flow meter, accuracy ±0.5%; fan-shaped nozzles, angle 30~60°, covering 100% of the material flow width), connected to a variable frequency centrifugal pump (flow range 0.2~2m³ / h, frequency adjustment range 20~50Hz).

[0052] The water replenishment execution module includes primary water replenishment and secondary water replenishment when executing the replenishment strategy. The specific expression for the amount of water replenished in the primary water replenishment is as follows:

[0053]

[0054] in, This indicates the amount of water added in a single water replenishment. This indicates the instantaneous flow rate of the raw material collected by the belt scale. This indicates the temperature compensation value. This represents the proportionality coefficient, which is usually taken as 0.05 to 0.08.

[0055] Primary water addition zone: Based on the instantaneous flow rate Q (t / h) of the raw material collected by the belt scale (accuracy ±0.1%), the basic water addition is determined according to the proportion of micro-mist amount = Q×(0.05~0.08)m³ / t, and 30% of ΔW is added at the same time (for rapid dust suppression and preliminary moisture compensation). For example, when Q=100t / h and ΔW=0.63%, the primary water addition is 100×0.06+(0.63%×100) / 3=6.21m³ / h;

[0056] The specific expression for the amount of water added in the secondary water replenishment is as follows:

[0057]

[0058] in, This indicates the amount of water added in the secondary water replenishment process;

[0059] Secondary water supply zone: 70% of ΔW is added (for precise compensation of core moisture). The secondary water supply volume is calculated according to the formula: (ΔW × Q × 70%) / 100. For example, when ΔW = 0.63% and Q = 100t / h, the secondary water supply volume = (0.63 × 100 × 0.7) / 100 = 0.441m³ / h. The flow rate is fed back in real time by an electromagnetic flow meter, and the frequency of the variable frequency pump is adjusted by PLC to ensure that the flow error is < ±2%.

[0060] In addition, the present invention also includes a dust suppression and energy-saving synergistic module, specifically a capacitive moisture meter (accuracy ±0.2%) installed 1m from the outlet of the secondary water addition zone to monitor the moisture content of the mixture in real time. ;when When the current is within [12.5%, 13.5%] and continues for 30 seconds, the PLC controls the high-frequency inverter (model: VFD037M43A) to reduce the frequency from 50Hz to 35Hz and the power to 70% of the rated value; if the motor current and torque exceed the rated value by 80%, the frequency will be briefly increased to 40Hz to avoid overload.

[0061] The following is a detailed implementation process of the present invention:

[0062] Step 1: Temperature Sensing and Compensation Calculation:

[0063] (1) The raw material is fed into the mixing belt via the No. 1 and No. 2 belts of the ash silo (speed 1.2m / s). The infrared sensor array is started to scan the upper, middle and lower layers of the material flow synchronously, and collect temperature data once every 0.5 seconds.

[0064] (2) Perform Kalman filtering on the 6 temperature data points, remove outliers, and calculate the weighted average temperature T (e.g., if the collected data are 40.2℃ and 40.5℃ for the upper layer; 39.8℃ and 39.5℃ for the middle layer; and 38.9℃ and 39.2℃ for the lower layer, the average temperature after filtering is T=39.7℃).

[0065] (3) Calculate dT / dt (e.g., if the temperatures of the last 5 cycles are 39.2℃, 39.3℃, 39.5℃, 39.6℃, and 39.7℃, then dT / dt = (39.7 - 39.2) / (2.5) = 0.2℃ / s);

[0066] (4) Call the corresponding iron ore powder =0.04% / ℃ =0.15%·s / ℃, substituting into the formula, we get ΔW=0.04×(39.7-25)+0.15×0.2=0.588+0.03=0.618%, approximately 0.62%;

[0067] (5) The PLC converts the ΔW signal into a water valve opening command (opening adjustment accuracy ±1%) and sends it to the zone water supply device 4 seconds in advance.

[0068] Step 2: Add water for dust suppression in designated areas:

[0069] (1) Primary water addition zone: The belt scale collects Q=105t / h, the basic micro-mist volume=105×0.06=6.3m³ / h, and the superimposed 30% of ΔW (0.62%×105×0.3≈0.195t / h, i.e. 0.195m³ / h), the total water addition volume=6.3+0.195=6.495m³ / h. The PLC adjusts the high-pressure pump frequency to 42Hz, and the nozzle spray covers the entire cross section of the material flow, with a dust suppression efficiency of 92%.

[0070] (2) Secondary water addition zone: 70% of the superimposed ΔW (0.62%×105×0.7)≈0.456t / h, i.e. 0.456m³ / h), the electromagnetic flowmeter monitors the flow rate in real time, and the PLC adjusts the frequency of the centrifugal pump to 30Hz to ensure that the flow rate is stable at 0.456m³ / h, and the moisture content deviation between the upper and lower layers of the material flow is <0.4%;

[0071] Step 3: Energy-saving operation of the strong mixer:

[0072] (1) Real-time feedback of capacitive moisture meter =13.2%, and after 30 seconds, the PLC sends a signal to the high-power mixer frequency converter;

[0073] (2) The frequency converter reduces the frequency from 50Hz to 35Hz and the power from 110kW (rated) to 77kW (70% of rated) within 10s.

[0074] (3) Monitor the motor current and torque in real time (rated torque 280 N·m). If the torque rises to 224 N·m (80% of the rated torque), briefly increase the frequency to 40 Hz. After the torque drops to 200 N·m, resume operation at 35 Hz.

[0075] This invention also provides a moisture control method for low-energy dust suppression production of mixed materials based on temperature grading, which, based on the above-mentioned low-energy dust suppression production system for mixed materials based on temperature grading, includes the following steps:

[0076] Step 1: Collect the temperature at different heights at the inlet of the mixing and batching conveyor belt, and perform corresponding pretreatment;

[0077] Step 2: Construct a temperature compensation model, determine whether to issue a control command to replenish water, and perform zoned water application.

[0078] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A low-energy dust suppression production system for mixed materials based on temperature grading, characterized in that: It includes a data acquisition module, a moisture compensation analysis module, and a moisture replenishment execution module; The data acquisition module is used to collect the temperature at different heights at the inlet of the mixing and batching conveyor belt and perform corresponding preprocessing. The moisture compensation analysis module constructs a temperature compensation model based on the data in the data acquisition module and determines whether to send a control command to the moisture replenishment execution module. The water replenishment execution module schedules the execution mechanism to perform zoned water application; It also includes a dust suppression and energy-saving co-processing module for detecting the moisture content of the mixture. When the moisture content of the mixture When the system is within a preset range and meets a preset duration, energy-saving operation is performed. The data acquisition module obtains temperature data through infrared temperature sensors deployed at six different locations on the mixing and batching conveyor belt. It then uses a Kalman filter algorithm to remove outliers and calculates the actual temperature of the raw materials using a weighted average. ; The data acquisition module also includes the construction of the temperature change rate, which is the average temperature difference of the most recent 5 sampling periods, with each period being 0.5 seconds. The specific expression is as follows: ； in, Indicates the rate of temperature change. Indicates the first Temperature at each sampling time Indicates the first Temperature at each sampling time This represents the product of the sampling period and the duration of the sampling period. The specific expression for the temperature compensation model constructed by the moisture compensation analysis module based on the data from the data acquisition module is as follows: ； in, This indicates the temperature compensation value. Represents the static compensation coefficient. This represents the compensation coefficient for the rate of dynamic change. Indicates the actual temperature of the raw material. Indicates the rate of temperature change. Indicates the reference temperature; The specific steps for the moisture compensation analysis module to determine whether to send a control command to the moisture replenishment execution module are as follows: It is necessary to increase the water supply and send a control command. No additional water is needed; The water replenishment execution module includes primary water replenishment and secondary water replenishment when executing the replenishment strategy. The specific expression for the amount of water replenished in the primary water replenishment is as follows: ； in, This indicates the amount of water added in a single water replenishment. This indicates the instantaneous flow rate of the raw material collected by the belt scale. This indicates the temperature compensation value. Indicates the proportionality coefficient; The specific expression for the amount of water replenished in the secondary replenishment is as follows: ； in, This indicates the amount of water added during the secondary water replenishment process.

2. A method for controlling moisture in low-energy dust suppression production of mixed materials based on temperature grading, based on the low-energy dust suppression production system of mixed materials based on temperature grading as described in claim 1, characterized in that: Includes the following steps: Step 1: Collect the temperature at different heights at the inlet of the mixing and batching conveyor belt, and perform corresponding pretreatment; Step 2: Construct a temperature compensation model, determine whether to issue a control command to replenish water, and perform zoned water application.

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