Biomass ash recovery supervision and resource utilization system for tobacco leaf baking

Abstract

The invention discloses a tobacco leaf curing biomass ash recovery supervision and resource utilization system, and relates to the technical field of agricultural waste treatment and resource utilization, and the system comprises a sealed recovery transfer module which recovers curing barn biomass ash and transfers the biomass ash; the standardized pretreatment module is used for sorting and adsorbing impurities and then screening out pure ash residues; the component detection and proportioning module detects nutrients, dosages are determined by means of a potassium nitrate accurate addition amount calculation formula, and mixing is performed; granulating, drying, cooling and screening the organic fertilizer processing module to obtain a semi-finished product; the quality detection supervision module detects and supervises the whole process and calculates the utilization rate to form a closed loop; according to the invention, a five-module closed-loop treatment system is constructed, sealed recovery transfer and standardized pretreatment operation are matched to prevent dust raising of ash and improve the purity, the product quality is controlled by virtue of accurate proportioning, and the whole process is traceable and refined ash treatment is promoted by virtue of layered supervision and an unqualified product backflow mechanism, so that the environmental burden is reduced, and the production efficiency is improved. And resource circulation is realized.

Description

Technical Field

[0001] This invention relates to the field of agricultural waste treatment and resource utilization technology, specifically a system for the recycling, monitoring, and resource utilization of biomass ash residue from tobacco curing. Background Technology

[0002] In tobacco production, curing is a crucial step in ensuring tobacco quality. This step consumes a large amount of biomass fuel, resulting in a significant amount of biomass ash. This ash contains nitrogen, phosphorus, potassium, and various trace elements, possessing the potential to be converted into agricultural fertilizer. Currently, the demand for waste resource utilization in agriculture is increasing, while environmental protection requirements are becoming increasingly stringent. Randomly discarding or landfilling biomass ash not only wastes resources but may also negatively impact the surrounding environment due to dust and rainwater runoff. However, tobacco curing ash is primarily generated at tobacco planting bases, and its treatment must be adapted to the actual operating conditions of these bases. Therefore, how to achieve a systematic treatment of this specific type of ash, from collection and purification to conversion and utilization, has become a critical issue that the tobacco industry needs to address in promoting green production.

[0003] Currently, the treatment of biomass ash residue from tobacco curing is mostly carried out using traditional, extensive methods. Common practices include simple collection and piling or direct landfilling. These methods lack specialized sealing and recycling measures. The ash residue is prone to dust generation during collection and transportation, and some soluble nutrients are lost with rainwater. The pretreatment stage relies solely on simple manual screening, which cannot completely remove large non-degradable impurities and ferromagnetic substances from the ash residue, affecting the quality of subsequent processed products. The nutrient ratio depends on fixed empirical proportions and is not dynamically adjusted according to the actual nutrient content of the ash residue, resulting in an unbalanced nutrient content in the produced organic fertilizer. In addition, the entire treatment process lacks a tiered supervision mechanism and utilization rate accounting methods, making it difficult to control product quality. Substandard products cannot be effectively reprocessed, which reduces resource utilization efficiency and fails to meet the quality requirements of tobacco cultivation for supporting fertilizers. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a system for the recycling, monitoring, and resource utilization of biomass ash residue from tobacco curing. This system achieves efficient resource utilization of biomass ash residue from tobacco curing by constructing a closed-loop system comprising five modules: sealed recycling and transportation, standardized pretreatment, component detection and proportioning, organic fertilizer processing, and quality inspection and monitoring. The system employs a sealed structure to prevent dust and nutrient loss, and ensures product quality and full-process traceability through precise proportioning and a tiered monitoring mechanism. This system not only reduces environmental burden but also promotes refined ash residue treatment and resource recycling, providing a comprehensive solution for green production in the tobacco industry.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a system for the recycling, monitoring, and resource utilization of biomass ash residue from tobacco curing, the system comprising:

[0006] Sealed recycling and transfer module: Recovers ash and residue produced by biomass combustion in the curing barn, connects to the ash outlet of the curing barn through a sealed collection unit, and transfers the ash and residue to the standardized pretreatment module through a sealed transfer unit;

[0007] Standardized pretreatment module: Performs impurity sorting, magnetic adsorption and particle size screening operations on the ash slag conveyed by the sealed recycling and transfer module in sequence, and outputs pure ash slag that meets the preset particle size requirements;

[0008] Component detection and proportioning module: The total nutrient content of the pure ash residue output by the standardized pretreatment module is detected. Based on the preset target total nutrient content range of organic fertilizer, the amount of potassium nitrate to be added is determined by the precise addition formula of potassium nitrate. The pure ash residue, potassium nitrate and environmentally friendly adhesive are mixed evenly.

[0009] Organic fertilizer processing module: The mixture output from the component detection and proportioning module is granulated, dried, cooled and screened in sequence to output organic fertilizer semi-finished product;

[0010] Quality Inspection and Supervision Module: Conducts quality inspection on the semi-finished products output from the organic fertilizer processing module. Qualified products are used for fertilization, while unqualified products are returned to the component detection and proportioning module. At the same time, the entire process is supervised through a hierarchical management system, and the overall recycling rate is calculated using the formula for calculating the overall recycling rate.

[0011] Furthermore, the sealed collection unit of the sealed recycling and transfer module is connected to the ash discharge pipe of the drying oven through a sealed structure. The sealed transfer unit is equipped with a weighing component to record the initial ash and slag generation in real time during the transfer process and synchronize this data to the whole process monitoring system.

[0012] Furthermore, the standardized pretreatment module includes an impurity sorting unit, a magnetic adsorption unit, and a particle size screening unit. The impurity sorting unit removes large non-degradable materials from the ash residue. The magnetic adsorption unit directionally adsorbs ferromagnetic impurities from the ash residue. The particle size screening unit uses a standard screen of preset specifications and a vibration screening method to control the particle size of the ash residue. The amount of impurities remaining in the ash residue after screening does not exceed a preset threshold.

[0013] Furthermore, the formula for calculating the precise amount of potassium nitrate to be added in the component detection and proportioning module is as follows: ,in, Precise addition of potassium nitrate; For the quality of pure ash residue; The target total nutrient content range for organic fertilizer is defined as the pre-set range. This represents the actual total nutrient content of the pure ash residue; This represents the theoretical total nutrient content of potassium nitrate. Nutrient utilization rate correction coefficient adapted to the characteristics of ash and slag.

[0014] Furthermore, the component detection and proportioning module includes a component detection unit, a quantitative feeding unit, a metering unit, and a mixing unit. The component detection unit detects the total nutrient content of the pure ash residue, the quantitative feeding unit adds potassium nitrate, the metering unit adds an environmentally friendly binder, and the mixing unit performs material mixing operations. The stirring speed and stirring time of the mixing unit are within a preset range.

[0015] Furthermore, the organic fertilizer processing module includes a granulation unit, a drying unit, a cooling unit, and a screening unit. The granulation unit uses an extrusion granulator or a disc granulator, and the granulation pressure or rotation speed of the granulation unit is within a preset range. The drying unit uses a mesh belt dryer, and the drying temperature and drying time of the drying unit are within a preset range. The screening unit uses a double-layer screen to screen out organic fertilizer semi-finished products that meet the preset particle size requirements.

[0016] Furthermore, the quality inspection and supervision module includes a quality inspection unit, which inspects the moisture content, pH value, heavy metal content, and total nutrient content of the organic fertilizer semi-finished product.

[0017] Furthermore, the formula for calculating the full-process recycling rate in the quality inspection and supervision module is as follows: ,in, To achieve a high recycling rate throughout the entire process; The yield of organic fertilizer that has passed quality inspection; The total nutrient content of qualified organic fertilizer; The initial amount of ash and slag generated is recorded. This represents the total nutrient content of the initial ash residue.

[0018] Furthermore, the hierarchical management system of the quality inspection and supervision module includes operation positions, technical positions, and management positions. The operation positions are responsible for the practical operations of each module, the technical positions are responsible for component testing, process parameter adaptation, and data recording, and the management positions are responsible for full-process supervision, division of responsibilities, and cost control. The work data of each position corresponds one-to-one with the variables required for full-process accounting.

[0019] Furthermore, the quality inspection and monitoring module includes a sealed conveying unit. Unqualified organic fertilizer is returned to the component detection and proportioning module through the sealed conveying unit. After being recalculated by substituting the potassium nitrate precise addition amount into the formula, the mixing unit performs the proportioning and mixing operation again.

[0020] Compared with existing technologies, this system for the recycling, monitoring, and resource utilization of biomass ash residue from tobacco curing has the following advantages:

[0021] I. This invention constructs a closed-loop processing system comprising five modules: sealed recycling and transportation, standardized pretreatment, component detection and proportioning, organic fertilizer processing, and quality inspection and supervision. Combined with source-level sealed recycling and standardized pretreatment operations, it forms a complete chain from ash generation to final utilization. The sealed recycling and transportation module prevents ash dust and nutrient loss. The standardized pretreatment module improves ash purity through impurity sorting, magnetic adsorption, and particle size screening, solving the problems of environmental pollution and insufficient purity in traditional processing. The subsequent organic fertilizer processing module transforms the processed ash into qualified fertilizer products, realizing the resource recycling of idle waste. This reduces the environmental burden and provides a complementary waste treatment solution for tobacco production, adapting to the actual application needs of planting bases.

[0022] II. This invention achieves precise quantitative control over ash and slag treatment by combining a component detection and proportioning module with a precise potassium nitrate addition calculation formula, along with standardized operation of the quantitative feeding and metering unit. After obtaining the actual nutrient data of the ash and slag, the component detection unit dynamically calculates the amount of potassium nitrate to be added using a formula, replacing the traditional fixed proportion ratio and solving the problem of nutrient imbalance. The environmentally friendly binder is added quantitatively through the metering unit, and combined with the preset stirring parameters of the mixing unit, it ensures the stability of the organic fertilizer molding. This precise processing method makes the quality of the final organic fertilizer product controllable, avoiding product quality fluctuations caused by traditional extensive processing.

[0023] Third, this invention improves the supervision and traceability of ash and slag treatment by combining a hierarchical management system for quality inspection and supervision modules with a full-process recycling rate calculation formula and a non-conforming product return mechanism. The hierarchical management system clearly defines the responsibilities of operators, technicians, and managers, ensuring efficient collaboration in the operation, inspection, and control of each module. All data corresponds to the calculation variables, achieving full-process traceability. The recycling rate formula quantifies the system's operational effectiveness, and the return of non-conforming products for reprocessing ensures quality. This breaks through the limitations of traditional recycling supervision and the difficulty in quantifying utilization rates, promoting the transformation of ash and slag treatment from extensive to intensive methods.

[0024] Other advantages, objectives and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination or study, or may be learned from the practice of the invention. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0026] Figure 1 This is a flowchart of the overall system process.

[0027] Figure 2 A schematic diagram of the hierarchical management structure of the regulatory system;

[0028] Figure 3 This is a flowchart of the process for reflowing non-conforming products. Detailed Implementation

[0029] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structure, features and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0030] Example 1:

[0031] like Figure 1 As shown, the first embodiment of the present invention provides a system for the recycling, monitoring, and resource utilization of biomass ash residue from tobacco curing. This embodiment is applied to a small-to-medium-sized curing plantation in a mountainous tobacco-growing area. The plantation is equipped with three tobacco curing ovens and produces approximately 80 kg of biomass ash residue per day. The system requires efficient recycling and on-site conversion and utilization of the ash residue. The specific configuration and operation flow of each module are as follows:

[0032] In the sealed recycling and transfer module, the sealed collection unit uses a funnel-shaped collection hopper made of 304 stainless steel. The hopper opening connects to the ash outlet of each baking oven via a flange, and a silicone rubber sealing gasket is installed on the inside of the flange to prevent dust leakage. The sealed transfer unit uses a small electric transfer vehicle equipped with a pressure weighing device. The weight of the ash and slag, i.e., the initial amount of ash and slag generated, is recorded in real time during each transfer. The recorded data is wirelessly transmitted and synchronized to the plant's full-process monitoring platform tablet, allowing staff to monitor the transfer progress in real time. Considering the plant's average daily ash and slag volume, all ash and slag is transferred twice a day to prevent ash and slag from accumulating and clumping in the collection hopper.

[0033] The standardized pretreatment module is located in the processing workshop next to the baking plant. The impurity sorting unit uses an inclined conveyor belt with a 10mm grid, and the conveyor belt speed is set to 0.8m / s. Workers assist in removing large pieces of charcoal, baking residue straw, and other non-degradable materials from the ash residue. The removed impurities are collected and recycled as fuel. The magnetic adsorption unit is a strong magnetic roller installed at the end of the conveyor belt. The magnetic field strength of the roller surface reaches 12000Gs, which can directionally adsorb ferromagnetic impurities such as iron nails and iron wires mixed in the ash residue. The adsorbed impurities are periodically cleaned into a collection box by a scraper and centrally processed once a week. The particle size screening unit uses a vibrating screener with a single-layer 5mm standard stainless steel screen. The vibration frequency is adjusted to 50Hz and the amplitude to 5mm by a frequency converter. The residual impurities in the ash residue after screening are controlled to be below 0.8%, which meets the particle size requirements of pure ash residue. The screened pure ash residue is temporarily stored in a sealed silo with a top sealing cover. A pneumatic discharge valve is installed at the bottom of the silo to facilitate subsequent quantitative transportation to the component detection and proportioning module.

[0034] The component analysis and proportioning module utilizes a portable soil nutrient analyzer. Each time, a 100g sample of pure ash residue is taken from the pneumatic discharge valve of the sealed silo for total nutrient content analysis. A paper report is generated and archived after the analysis. Following the analysis, technicians determine the amount of potassium nitrate to add based on the preset target total nutrient content range for organic fertilizer using the precise potassium nitrate addition calculation formula. The precise potassium nitrate addition calculation formula is as follows: ,in, Precise addition of potassium nitrate; For the quality of pure ash residue; The target total nutrient content range for organic fertilizer is defined as the pre-set range. This represents the actual total nutrient content of the pure ash residue; This represents the theoretical total nutrient content of potassium nitrate. To adapt the nutrient utilization rate correction coefficient to the characteristics of the ash residue, a small screw feeder was used in the quantitative feeding unit. Potassium nitrate was precisely added according to calculations, with a feeding accuracy controlled within ±1%. The discharge port of the screw feeder was directly opposite the inlet of the mixing unit to reduce material loss. An environmentally friendly modified starch binder was used, quantitatively added via a peristaltic pump metering unit at 3% of the weight of the pure ash residue. The binder was first diluted with warm water to a concentration of 20% before addition to ensure uniform mixing with the ash residue. The mixing unit was a 500L twin-shaft paddle mixer with a stirring speed set at 350 rpm and a stirring time set at 18 minutes. During mixing, the material mixing status was monitored through an observation window to ensure thorough and uniform mixing of the pure ash residue, potassium nitrate, and binder.

[0035] In the organic fertilizer processing module, the granulation unit uses a small extrusion granulator with a die diameter of 3mm and a working pressure of 6MPa. This granulator extrudes the mixture into cylindrical particles 5-8mm in length. The particles are then conveyed to the drying unit via a conveyor belt. The drying unit is a single-layer mesh belt dryer with a belt speed of 0.5m / min, a drying temperature of 90℃, and a drying time of 30 minutes. A temperature sensor is installed inside the dryer to monitor the temperature in the drying zone in real time, ensuring the moisture content of the particles is controlled below 8%. The cooling unit uses an air-cooled conveyor belt, 5m long, with a speed of 1m / min. It uses ambient temperature air to lower the temperature of the dried particles to room temperature. During cooling, the particle thickness is controlled to 3cm to ensure uniform cooling. The screening unit uses double-layer stainless steel screens of 2mm and 5mm to screen out organic fertilizer semi-finished products with a particle size of 3-5mm. The fine powder that passes through the screen accounts for approximately 5% of the total material and is returned to the mixing unit for re-mixing and granulation, avoiding material waste.

[0036] The quality inspection unit of the quality inspection and supervision module samples and tests the semi-finished organic fertilizer products. Each batch sample is 500g. Test items include moisture content not exceeding 10%, pH value controlled between 6.5 and 7.5, cadmium content not exceeding 0.1mg / kg, and total nutrient content. Qualified semi-finished products are stored in woven bags lined with plastic film. The hierarchical management system employs two operators, responsible for the transfer operation of the sealing and transfer unit and the granulation operation of the granulation unit, respectively; one technical person, responsible for component testing, equipment parameter adjustment, and test data recording; and one management person, who views the entire process data through the monitoring platform and calculates the daily recycling rate using the full-process recycling rate calculation formula. This factory achieves a daily average recycling rate of 92% using this system. The full-process recycling rate calculation formula is: ,in, To achieve a high recycling rate throughout the entire process; The yield of organic fertilizer that has passed quality inspection; The total nutrient content of qualified organic fertilizer; The initial amount of ash and slag generated is recorded. This refers to the total nutrient content of the initial ash residue. For example... Figure 2 The hierarchical management system, by clearly defining the hierarchical relationships and responsibilities of operational, technical, and management positions, achieves closed-loop supervision from module-based practical operations to process data recording, and then to full-process monitoring and control and recycling rate calculation. If unqualified products are detected, such as batches with a moisture content of 12%, ... Figure 3 As stated above, after failing the quality inspection, the material is returned to the drying unit via a sealed conveyor belt, where the drying temperature is reset to 95°C and the drying time is 35 minutes for a second drying process until it passes the inspection. Then it is used for fertilization of tobacco plantations around the factory, with 150 kg of fertilizer applied evenly per acre.

[0037] In summary, this embodiment addresses the daily processing needs of 80kg of ash residue from small-to-medium-sized tobacco curing plants in mountainous tobacco-growing areas. Through a modular configuration adapted to the specific scenario, it achieves efficient ash residue recycling and on-site conversion. The sealed recycling and transfer module utilizes small sealed collection hoppers and electric transfer vehicles, balancing dust control with small-to-medium-scale transfer requirements. The standardized pretreatment module combines manual-assisted sorting with small vibrating screening equipment, ensuring effective impurity removal while controlling equipment input. The component detection and proportioning module employs portable analyzers and small mixing equipment, adapting to the on-site detection and proportioning conditions of the plant. The organic fertilizer processing module primarily uses small extrusion granulators and single-layer dryers to meet small-batch pellet production needs. The quality inspection and supervision module features a tiered staffing system and a non-conforming product return mechanism, ensuring product quality and preventing resource waste. The overall system is tailored to the site, capacity, and operational needs of small-to-medium-sized plants, achieving a closed-loop utilization of ash residue from collection to fertilization.

[0038] Example 2:

[0039] This embodiment is applied to a large-scale tobacco planting base in a plain area. The base is equipped with 25 modern tobacco curing ovens, producing approximately 500 kg of biomass ash residue per day. Continuous and automated recycling and processing of the ash residue is required. The specific configuration and operation flow of each module of the system are as follows:

[0040] The sealed recycling and transfer module adopts a combination of distributed collection and centralized transfer. Each baking oven's ash outlet is connected to a 100L automatic discharge sealed collection bin. An ultrasonic level sensor is installed inside the bin. When the ash content reaches 80% of the bin's capacity, the sensor sends a signal to the central control room's full-process monitoring system, alerting staff to arrange transfer. The sealed transfer unit uses an electric railcar with a 200kg load capacity. The railcar connects all collection bins to the pretreatment workshop. The railcar's operating speed is set at 1.2m / s, and it is equipped with high-precision weighing components with a weighing accuracy of ±0.05kg. After each transfer, the initial ash production data is automatically uploaded to the central control room system. Based on the average daily ash production, the railcar transfers once per hour, requiring only three transfers per day to complete all ash transfers. The system automatically generates a transfer log.

[0041] The standardized pretreatment module is configured for automated production lines. The impurity sorting unit uses a combination of a vibrating screen and an air classifier. The vibrating screen has a 20mm mesh size, first separating large impurities larger than 20mm, such as unburnt wood chips. These large impurities can be crushed and reused as fuel for baking. The air classifier has a wind speed of 8m / s, separating light straw fragments from the ash. These light impurities are collected and used as auxiliary materials for organic fertilizer production. The overall impurity separation efficiency is over 95%. The magnetic adsorption unit is a three-stage high-intensity magnetic separator, installed at the outlet of the vibrating screen, the outlet of the air classifier, and the inlet of the particle size separator. The magnetic field strength of each stage of the separator reaches 15000Gs, and the adsorption efficiency of ferromagnetic impurities is over 98%. The adsorbed impurities are periodically discharged into a collection box through an automatic unloading valve and collected monthly by a professional organization for recycling and processing. The particle size screening unit adopts a grading vibrating screen equipped with a 5mm standard stainless steel screen. The vibration frequency is adjusted to 55Hz and the amplitude to 6mm by a frequency converter. The residual impurities in the ash residue after screening are controlled to be below 0.5%. The pure ash residue is transported to the raw material silo of the component detection and proportioning module through a closed pipeline. A level gauge is installed in the raw material silo. When the material level is lower than 30%, the standardized pretreatment module is automatically triggered to ensure continuous feeding.

[0042] The component detection and proportioning module is equipped with a laboratory-grade fully automated nutrient analyzer, capable of simultaneously detecting the content of nitrogen, phosphorus, potassium, and trace elements such as calcium and magnesium in ash. The sample size is set to 200g, and the detection data is automatically transmitted to the system control unit via a data cable. The control unit has a built-in formula for calculating the precise addition amount of potassium nitrate, which automatically calculates the amount of potassium nitrate to be added based on the preset target total nutrient content range of organic fertilizer and generates an ingredient list displayed on the central control screen. The quantitative feeding unit uses a large-scale variable frequency screw feeder, which automatically adjusts the feeding speed according to the calculation results, with an adjustment range of 0 to 50kg / h. A flow sensor is installed at the outlet of the screw feeder to provide real-time feedback on the feeding amount, ensuring feeding accuracy. The environmentally friendly binder uses a starch-cellulose composite binder, which is first diluted to a concentration of 15% in a mixing tank, and then added by metering using an electromagnetic flow meter. The addition amount is set to 2.5% of the weight of the pure ash. The binder pipeline is connected to the inlet of the mixing unit to achieve synchronous addition. The mixing unit is a large twin-shaft paddle mixer with a volume of 2000L. The mixing speed is set to 400r / min and the mixing time is set to 20 minutes. A torque sensor is installed in the mixer to judge the uniformity of material mixing by the change of torque. After the mixing is qualified, the discharge valve is automatically opened and the material is transported to the organic fertilizer processing module through a closed conveyor belt.

[0043] The organic fertilizer processing module is configured for continuous production. The granulation unit uses a 2.5m diameter disc granulator with a granulation speed adjusted to 35 rpm. The disc tilt angle is adjusted to 45°, and the water spray volume is controlled to ensure granule formation. The granule diameter is controlled between 2-6mm. A granule counter is installed at the granulator outlet to record the granulation volume in real time. The drying unit uses a three-layer mesh belt dryer, with each layer's mesh belt speed adjusted to 0.3m / min. The drying temperature is set to 85℃, and the drying time is set to 40 minutes. The dryer is divided into a preheating zone, a constant temperature zone, and a cooling zone, with the temperature of each zone independently regulated by a temperature control system to ensure the granule moisture content is reduced to below 7%. The cooling unit uses a 1.2m diameter, 8m long cooling cylinder. Room temperature air is circulated inside the cylinder, with a cooling speed set to 15 rpm and a cooling time set to 25 minutes, reducing the granule temperature to within 3℃ above or below ambient temperature. The cooled granules are then conveyed to the screening unit via a discharge valve. The screening unit uses a three-layer stainless steel screen with 1mm, 3mm and 5mm diameters to screen out organic fertilizer semi-finished products with a particle size of 2 to 5mm; fine powder with a particle size of less than 1mm accounts for about 3% of the total material and is returned to the mixing unit through the pipeline; particles with a particle size of 1 to 2mm and larger than 5mm are conveyed to the crusher to be crushed to a particle size of 2-5mm and then returned to the granulation unit for regranulation, so as to realize the full utilization of materials.

[0044] The quality inspection and supervision module is equipped with online testing equipment. A near-infrared detector is installed at the cooling unit outlet to monitor the moisture content and total nutrient content of the semi-finished organic fertilizer in real time. The test data is updated every 10 seconds and transmitted to the central control system. A rapid heavy metal detector is installed at the screening unit outlet to sample and test for heavy metals such as cadmium and lead every hour, and the test results are automatically archived. The hierarchical management system is configured with 5 operators working in two shifts, responsible for equipment inspection, material replenishment, and reporting of abnormalities; 3 technical personnel, including 2 testing personnel and 1 equipment maintenance personnel, are responsible for nutrient testing, test data recording, and daily equipment maintenance and parameter adaptation, respectively; 2 management personnel are responsible for monitoring the central control room system, statistical analysis of the entire process data, and generating daily utilization rate reports using the full-process recycling rate calculation formula. The base achieves an average daily recycling rate of 95% using this system. If a substandard product is detected, such as one with total nutrients below the preset lower limit, it will be returned to the component detection and proportioning module through a closed pipeline. The amount of potassium nitrate added will be recalculated, and the mixture will be mixed a second time according to the new proportion. After the mixture is qualified, it will enter the organic fertilizer processing module. The qualified organic fertilizer product will be packaged in 25kg bags using an automated packaging machine. After the production date and nutrient content are labeled, it will be used for fertilization of tobacco leaves in the base. When fertilizing, it will be applied in conjunction with the drip irrigation system at a rate of 200kg per mu.

[0045] In summary, this embodiment addresses the continuous processing needs of a large-scale tobacco planting base in a plain area, producing an average of 500 kg of ash residue per day. It improves processing efficiency and resource utilization through fully automated module configuration and process design. The sealed recycling and transfer module utilizes distributed collection bins and electric railcars to centrally transfer ash residue from multiple ovens. The standardized pretreatment module combines vibrating screening, airflow separation, and a three-stage strong magnetic separator to achieve efficient impurity removal. The component detection and proportioning module relies on a fully automated analyzer and variable frequency feeding equipment to achieve precise batching and automatic data transmission. The organic fertilizer processing module uses a disc granulator, a three-layer dryer, and a multi-layer screening system, combined with a material return design, to achieve continuous production and full material utilization. The quality inspection and monitoring module provides online detection and automated control, ensuring product quality and full-process traceability. The system is fully adaptable to the needs of large-scale bases for continuous production, efficient processing, and precise control, contributing to a green and circular tobacco planting industry.

[0046] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A system for monitoring and resource utilization of biomass ash residue from tobacco curing, characterized in that, The system includes: Sealed recycling and transfer module: Recovers ash and residue produced by biomass combustion in the curing barn, connects to the ash outlet of the curing barn through a sealed collection unit, and transfers the ash and residue to the standardized pretreatment module through a sealed transfer unit; Standardized pretreatment module: Performs impurity sorting, magnetic adsorption and particle size screening operations on the ash slag conveyed by the sealed recycling and transfer module in sequence, and outputs pure ash slag that meets the preset particle size requirements; Component detection and proportioning module: The total nutrient content of the pure ash residue output by the standardized pretreatment module is detected. Based on the preset target total nutrient content range of organic fertilizer, the amount of potassium nitrate to be added is determined by the precise addition formula of potassium nitrate. The pure ash residue, potassium nitrate and environmentally friendly adhesive are mixed evenly. Organic fertilizer processing module: The mixture output from the component detection and proportioning module is granulated, dried, cooled and screened in sequence to output organic fertilizer semi-finished product; Quality Inspection and Supervision Module: Conducts quality inspection on the semi-finished products output from the organic fertilizer processing module. Qualified products are used for fertilization, while unqualified products are returned to the component detection and proportioning module. At the same time, the entire process is supervised through a hierarchical management system, and the overall recycling rate is calculated using the formula for calculating the overall recycling rate.

2. The system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The sealed collection unit of the sealed recycling and transfer module is connected to the ash discharge pipe of the drying room through a sealed structure. The sealed transfer unit is equipped with a weighing component to record the initial ash and slag generation in real time during the transfer process and synchronize this data to the whole process monitoring system.

3. The system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The standardized pretreatment module includes an impurity sorting unit, a magnetic adsorption unit, and a particle size screening unit. The impurity sorting unit removes large non-degradable materials from the ash residue. The magnetic adsorption unit directionally adsorbs ferromagnetic impurities from the ash residue. The particle size screening unit uses a standard screen of preset specifications and a vibration screening method to control the particle size of the ash residue. The amount of impurities remaining in the ash residue after screening does not exceed a preset threshold.

4. The system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The formula for calculating the precise addition amount of potassium nitrate in the component detection and proportioning module is as follows: ,in, Precise addition of potassium nitrate; For the quality of pure ash residue; The target total nutrient content range for organic fertilizer is defined as the pre-set range. This represents the actual total nutrient content of the pure ash residue; This represents the theoretical total nutrient content of potassium nitrate. Nutrient utilization rate correction coefficient adapted to the characteristics of ash and slag.

5. A system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The component detection and proportioning module includes a component detection unit, a quantitative feeding unit, a metering unit, and a mixing unit. The component detection unit detects the total nutrient content of the pure ash residue, the quantitative feeding unit adds potassium nitrate, the metering unit adds an environmentally friendly binder, and the mixing unit performs the material mixing operation. The stirring speed and stirring time of the mixing unit are within a preset range.

6. The system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The organic fertilizer processing module includes a granulation unit, a drying unit, a cooling unit, and a screening unit. The granulation unit uses an extrusion granulator or a disc granulator, and the granulation pressure or speed of the granulation unit is within a preset range. The drying unit uses a mesh belt dryer, and the drying temperature and drying time of the drying unit are within a preset range. The screening unit uses a double-layer screen to screen out organic fertilizer semi-finished products that meet the preset particle size requirements.

7. A system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The quality inspection and supervision module includes a quality inspection unit, which inspects the moisture content, pH value, heavy metal content, and total nutrient content of the organic fertilizer semi-finished product.

8. A system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The formula for calculating the full-process recycling rate in the quality inspection and supervision module is as follows: ,in, To achieve a high recycling rate throughout the entire process; The yield of organic fertilizer that has passed quality inspection; The total nutrient content of qualified organic fertilizer; The initial amount of ash and slag generated is recorded. This represents the total nutrient content of the initial ash residue.

9. A system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The hierarchical management system of the quality inspection and supervision module includes operation positions, technical positions, and management positions. The operation positions are responsible for the practical operations of each module, the technical positions are responsible for component testing, process parameter adaptation and data recording, and the management positions are responsible for full-process supervision, division of authority and responsibility and cost control. The work data of each position corresponds one-to-one with the variables required for full-process accounting.

10. A system for monitoring and resource utilization of biomass ash residue from tobacco curing according to claim 1, characterized in that, The quality inspection and supervision module includes a sealed conveying unit. Organic fertilizer that fails the inspection is returned to the component detection and proportioning module through the sealed conveying unit. After being recalculated by substituting the potassium nitrate precise addition amount into the formula, the mixing unit performs the proportioning and mixing operation again.

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