Ore pulp online monitoring and sampling system and method

Abstract

The invention discloses an ore pulp online monitoring and sampling system and method, and relates to the technical field of mineral separation automation. The system comprises a main pipeline, a branch switch, a multi-parameter monitoring unit, an intelligent dilution and particle size analysis unit, an automatic sample collection unit and a central controller. The method comprises the following steps: carrying out sampling and multi-parameter detection on ore pulp, carrying out feedforward dilution based on real-time concentration, carrying out feedback dilution by adopting a self-adaptive PID (Proportion Integration Differentiation) algorithm according to a shading degree so as to accurately control the concentration of the ore pulp, synchronously completing particle size analysis and automatic preparation of a wet filter cake sample, and returning all residual materials to a main process through a buffer tank and a Venturi tube. Synchronous online monitoring and intelligent self-adaptive dilution of the ore pulp concentration, the pH value and the granularity are achieved, the problems that monitoring parameters are isolated, dilution is inaccurate and the system integration degree is low are solved, and the automation level, data reliability and sample representativeness of the ore dressing process are improved.

Description

Technical Field

[0001] This invention belongs to the field of mineral processing automation technology, specifically relating to an online monitoring and sampling system and method for mineral slurry. Background Technology

[0002] In the mineral processing production process, real-time monitoring of key parameters such as slurry concentration, fineness (i.e., particle size distribution), and pH value, as well as the acquisition of representative wet laboratory samples, are crucial for achieving precise process control, optimizing process parameters, and improving economic efficiency. These parameters not only directly reflect the physical and chemical state of the slurry but also provide data support for adjusting and optimizing the production process. High-quality laboratory samples are the foundation for verifying and supplementing online monitoring data.

[0003] Currently, the above parameters are typically monitored using independently distributed devices: concentration, particle size, and pH value are measured by dedicated sensors or analyzers installed in different sections of the process. Meanwhile, to meet the sample concentration requirements of online laser particle size analyzers and other equipment, high-concentration slurries often need to be diluted. Existing dilution systems mostly operate using preset fixed dilution ratios. In the sample collection stage, although some automated sampling devices exist, obtaining representative wet-process samples synchronized with online monitoring data still largely relies on manual operation or equipment with limited automation.

[0004] The existing methods suffer from the following problems that urgently need to be addressed: First, the independent operation of each monitoring device and the asynchronous data acquisition prevent the formation of a unified understanding of the overall state of the slurry, making it difficult to support multi-parameter collaborative process optimization. Second, the dilution system lacks the ability to adapt to real-time changes in slurry concentration; a fixed dilution ratio can easily result in excessively high or low shading of the diluted sample, thus affecting the accuracy of particle size measurement and the representativeness of the sample. Furthermore, the sampling process suffers from insufficient automation and frequent manual intervention, which not only introduces subjective errors and sampling delays but also increases the workload of operators. Finally, due to the lack of effective integration between monitoring, pretreatment, and sampling, the overall system coordination is poor, data chains are broken, and it is difficult to achieve true closed-loop process control. Summary of the Invention

[0005] This invention proposes an online monitoring and sampling system and method for mineral slurry. Its purpose is to realize an integrated system that highly integrates multi-parameter synchronous monitoring, adaptive intelligent dilution and automatic sampling functions of mineral slurry, so as to overcome the problems of disconnection between various links and incomplete data chain in the existing technology, thereby providing a complete and reliable data foundation and sample support for realizing closed-loop control of the mineral processing process.

[0006] The technical solution of this invention is as follows:

[0007] An online monitoring and sampling system for slurry includes a main pipeline, branch switches, a multi-parameter monitoring unit, an intelligent dilution and particle size analysis unit, an automatic sample collection unit, and a central controller;

[0008] The branch switch is located at the inlet of the system branch and is used to control the slurry entering the system branch;

[0009] The multi-parameter monitoring unit is installed on a branch of the system and is used to measure the concentration and pH value of the slurry in real time.

[0010] The intelligent dilution and particle size analysis unit includes a feedforward dilution module and a feedback dilution module, which are used to perform two-stage dilution on a diverted stream of slurry and analyze its particle size.

[0011] The automatic sample collection unit is used to mix the other stream of slurry that has been diverted and to automatically prepare a wet filter cake sample;

[0012] The central controller is electrically connected to the branch switches, multi-parameter monitoring unit, intelligent dilution and particle size analysis unit, and automatic sample collection unit, and is used to control the operation of the system and to process and record data.

[0013] As a further improvement to the slurry online monitoring and sampling system, the multi-parameter monitoring unit includes a nuclear concentration meter and an online pH meter installed on a branch of the system.

[0014] As a further improvement to the online slurry monitoring and sampling system: the intelligent dilution and particle size analysis unit includes a feedforward dilution tank, an ultrasonic dilution tank, a light-blocking sensor, and a laser particle size analyzer;

[0015] The inlet of the feedforward dilution tank is connected to the system branch via a first electromagnetic control valve, which has a water inlet.

[0016] The inlet of the ultrasonic dilution tank is connected to the outlet of the feedforward dilution tank via a second electromagnetic control valve, which has a water inlet.

[0017] The light-blocking sensor is located inside the ultrasonic dilution tank;

[0018] The laser particle size analyzer is connected to the ultrasonic dilution tank.

[0019] As a further improvement to the online slurry monitoring and sampling system, the ultrasonic dilution tank is also connected to a dispersant addition unit.

[0020] As a further improvement to the online slurry monitoring and sampling system, the ultrasonic dilution tank is also connected to an antifoaming agent addition unit.

[0021] As a further improvement to the online slurry monitoring and sampling system: the automatic sample collection unit includes a sampling mixing tank and a sampler;

[0022] The inlet of the sampling mixing tank is connected to the system branch via a third electromagnetic control valve;

[0023] The input port of the sampler is connected to the output port of the sampling mixing tank via a fourth electromagnetic control valve.

[0024] As a further improvement to the aforementioned online slurry monitoring and sampling system, it also includes a buffer tank and a Venturi tube.

[0025] The buffer tank is used to collect residual slurry and waste liquid generated by the system during rinsing with water.

[0026] The venturi tube is installed on the return water pipeline between the buffer tank and the main pipeline, and is used to return the material in the buffer tank to the main pipeline.

[0027] The present invention also provides a method for online monitoring and sampling of mineral slurry, which uses the aforementioned online monitoring and sampling system for mineral slurry and includes the following steps:

[0028] Step 1: Take samples of the slurry in the main pipeline and measure the concentration and pH value of the sampled slurry in real time;

[0029] Step 2: Divide the sampled slurry into streams, and perform intelligent dilution and particle size analysis on the first stream. The intelligent dilution includes feedforward dilution based on real-time concentration and feedback dilution based on real-time shading.

[0030] Step 3: Mix the second stream of primary slurry that has been diverted and automatically prepare a wet filter cake sample;

[0031] Step 4: Collect the residual slurry and waste liquid generated by the system and return them to the main pipeline;

[0032] During the execution of the above steps, the central controller controls the system and processes and records the data.

[0033] As a further improvement to the online slurry monitoring and sampling method, the intelligent dilution in step 2 specifically includes the following steps:

[0034] Step 2.1, concentration feedforward dilution;

[0035] Step a1: Read the slurry concentration value from the nuclear concentration meter in real time. ;

[0036] Step a2, intermediate concentration with preset target Compare and calculate the initial dilution ratio using the formula. :

[0037] ;

[0038] Step a3: Calculate the opening degree of the first electromagnetic control valve used to control the water addition to the feedforward dilution tank based on the pre-stored valve flow characteristic function. :

[0039] ;

[0040] In the above formula, , , These are constants calibrated experimentally. The water flow rate for the first electromagnetic control valve;

[0041] Step a4: Calculate the opening time of the first solenoid control valve. :

[0042] ;

[0043] In the above formula, This represents the required volume of water to be added; The volume of slurry entering the feedforward dilution tank; The water flow rate at the current valve opening is determined using a pre-calibrated valve flow rate-opening relationship curve, which is shown in the figure below. ,in and For valve characteristic constants;

[0044] Step a5: The central controller controls the first solenoid valve to open to the calculated degree. and opening time Water is introduced, and initial dilution and mixing are carried out in a feedforward dilution tank.

[0045] Step 2.2: Opacity feedback dilution and particle size measurement;

[0046] After the feedforward diluted slurry is mixed evenly, a certain amount of the primary diluted slurry enters the ultrasonic dilution tank through the second electromagnetic control valve.

[0047] The shading sensor detects the shading signal of the slurry in the ultrasonic dilution tank in real time. And transmit it to the central controller;

[0048] The central controller executes the shading feedback dilution control algorithm and adds water to the ultrasonic dilution tank for dilution via the second electromagnetic control valve.

[0049] As a further improvement to the online monitoring and sampling method for slurry, the shading feedback dilution control algorithm iteratively executes the following steps:

[0050] Step b1: Read the current shading value ;

[0051] Step b2: Based on the current shading value With target shading Calculate the shading error : ;

[0052] Step b3: Calculate the control output using an adaptive PID algorithm. :

[0053] Step b3-1: First, calculate the dynamic adjustment ratio. :

[0054] ;

[0055] In the above formula, Represents the initial scaling factor; and Represents the adaptive weighting coefficient;

[0056] Step b3-2, then calculate the control output. :

[0057] ;

[0058] In the above formula, Represents the integral coefficient; Represents the differential coefficient;

[0059] Step b3-3: Update the valve opening of the second solenoid control valve. :

[0060] ;

[0061] In the above formula, This means limiting the opening to between 0% and 100%;

[0062] Step b3-4, Termination Condition Determination: Dilution shall be stopped when the following conditions are met simultaneously:

[0063] Condition 1: Real-time shading Entering the 10%-20% range;

[0064] Condition 2: The standard deviation of the shading data within 3-5 seconds is less than 0.5%;

[0065] Once the conditions are met, stop adding water and end the shading feedback dilution control algorithm; otherwise, continue to the next cycle.

[0066] Compared with the prior art, the present invention has the following beneficial effects:

[0067] 1. This invention integrates multi-parameter monitoring, intelligent dilution and particle size analysis, and automatic sample collection into a single system, enabling synchronous and integrated monitoring and sampling of key parameters such as slurry concentration, pH value, and particle size. This effectively solves the problems of isolated monitoring equipment, asynchronous data collection, and low system integration in existing technologies, providing a complete and reliable data foundation and sample support for closed-loop control of the mineral processing process.

[0068] 2. This invention adopts a two-stage intelligent dilution control strategy of "concentration feedforward + shading feedback". The initial dilution ratio is calculated based on the real-time concentration value for feedforward dilution, and then feedback fine-tuning is performed by combining real-time detection by the shading sensor and adaptive PID algorithm to dynamically adjust the dilution process. This overcomes the shortcomings of traditional fixed dilution ratios that cannot adapt to changes in slurry concentration, and significantly improves the measurement accuracy and sample representativeness of the laser particle size analyzer.

[0069] 3. This invention introduces an adaptive PID algorithm into the shading feedback control. By dynamically adjusting the proportional coefficient, it enhances the control action to accelerate the response speed when the error is large, and suppresses overshoot to enhance stability when the error rate of change is large. This effectively addresses the nonlinearity and hysteresis of the slurry dilution process and improves the control accuracy and robustness of the system.

[0070] 4. The dispersant and defoamer addition unit used in this invention, combined with ultrasonic vibration treatment, effectively eliminates particle agglomeration and foam interference in the slurry, ensuring the accuracy and repeatability of particle size measurement results, and further improving the applicability and reliability of the system in complex industrial environments.

[0071] 5. This invention realizes fully automated collection and preparation of wet filter cake samples. The slurry is mixed and homogenized in multiple time periods through a sampling mixing tank, and then the sampler automatically completes the sample preparation by performing steps such as filtration, washing, and re-filtration. This not only improves the representativeness and consistency of the samples, but also greatly reduces the labor intensity and subjective errors caused by manual operation.

[0072] 6. By setting up a buffer tank and a venturi tube, this invention collects all residual slurry, filtrate and cleaning waste liquid generated during system operation and returns them to the main pipeline, realizing closed-loop management of materials throughout the entire process, avoiding slurry loss and environmental pollution, and also has an automatic cleaning function to ensure long-term stable operation of the system under harsh working conditions. Attached Figure Description

[0073] Figure 1 This is a schematic diagram of the slurry online monitoring and sampling system in a specific implementation.

[0074] The reference numerals in the figures include:

[0075] 1. Main pipeline; 2. Branch circuit switch; 3. Nuclear concentration meter; 4. Online pH meter; 5-1. First electromagnetic control valve; 5-2. Second electromagnetic control valve; 5-3. Third electromagnetic control valve; 5-4. Fourth electromagnetic control valve; 6. Feedforward dilution tank; 7. Sampling mixing tank; 8. Sampler; 9. Buffer tank; 10. Drain valve; 11. Venturi tube; 12. Opacity sensor; 13. Laser particle size analyzer; 14. Ultrasonic dilution tank; 15. Dispersant addition unit; 16. Defoamer addition unit; 17. Blade sampler; 18. Central controller. Detailed Implementation

[0076] The technical solution of the present invention will now be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0077] The present invention provides an online monitoring and sampling system for mineral slurry, the system structure of which is as follows: Figure 1 As shown. The system includes a main pipeline 1, branch switches 2, a nuclear concentration meter 3, an online pH meter 4, multiple electromagnetic control valves (including a first electromagnetic control valve 5-1, a second electromagnetic control valve 5-2, a third electromagnetic control valve 5-3, and a fourth electromagnetic control valve 5-4), a feedforward dilution tank 6, a sampling mixing tank 7, a sampler 8, a buffer tank 9, a drain valve 10, a venturi tube 11, a light-blocking sensor 12, a laser particle size analyzer 13, an ultrasonic dilution tank 14, a dispersant addition unit 15, an antifoaming agent addition unit 16, a blade sampler 17, and a central controller 18.

[0078] The connection relationships between the components are as follows:

[0079] The sampling port of the blade sampler 17 is connected to the main pipeline 1, and its discharge port is connected to the inlet of the system branch.

[0080] The branch switch 2 is located at the entrance of the system branch and is used to control the slurry entering the system branch.

[0081] The nuclear concentration meter 3 and the pH online detector 4 are sequentially installed on the system branch after the branch switch 2. The nuclear concentration meter 3 is used to measure the concentration of the slurry flowing through in real time, and the pH online detector 4 is used to measure the pH value of the slurry flowing through in real time.

[0082] The first electromagnetic control valve 5-1 is located on a system branch. Its input port is located after the pH online detector 4. Its first output port is connected to the input port of the feedforward dilution tank 6 for diverting a quantitative amount of slurry into the feedforward dilution tank 6. Its second output port is connected to the system branch behind it. The first electromagnetic control valve 5-1 also has a water inlet for drawing water to its first output port.

[0083] The first output port of the feedforward dilution tank 6 is connected to the input port of the second electromagnetic control valve 5-2 through a pipeline, and the second output port is connected to the input port of the buffer tank 9 through a drainage branch, on which a drainage valve 10 is provided.

[0084] The output port of the second electromagnetic control valve 5-2 is connected to the input port of the ultrasonic dilution tank 14; the second electromagnetic control valve 5-2 also has a water inlet for drawing water to its output port.

[0085] The ultrasonic dilution tank 14 is equipped with a light-shielding sensor 12, and its body is also connected to the addition ports of the dispersant addition unit 15 and the defoamer addition unit 16. The ultrasonic dilution tank 14 is also connected to the input and output ports of the laser particle size analyzer 13 for particle size detection. The output port of the ultrasonic dilution tank 14 is connected to the input port of the buffer tank 9 via a drainage branch, on which a drain valve 10 is installed.

[0086] The third electromagnetic control valve 5-3 is located on a branch of the system. Its input port is located after the first electromagnetic control valve 5-1, and its first output port is connected to the input port of the sampling mixing tank 7 to divert the raw slurry into the sampling mixing tank 7. Its second output port is directly connected to the buffer tank 9. The third electromagnetic control valve 5-3 also has a water inlet for drawing water to its first output port.

[0087] The first output port of the sampling mixing tank 7 is connected to the input port of the fourth electromagnetic control valve 5-4 via a pipeline. The output port of the fourth electromagnetic control valve 5-4 is connected to the input port of the sampler 8, and the fourth electromagnetic control valve 5-4 also has a water inlet for drawing water to its output port. The second output port of the sampling mixing tank 7 is connected to the input port of the buffer tank 9 via a drainage branch, and a drain valve 10 is installed on this drainage branch.

[0088] The output port of sampler 8 is connected to the input port of buffer tank 9 through a drainage branch, and a drainage valve 10 is installed on the drainage branch.

[0089] The outlet of the buffer tank 9 is connected to the inlet of the venturi tube 11 via a return water pipe, and the outlet of the venturi tube 11 is connected to the main pipeline 1. The buffer tank 9 is equipped with a motor for pressurization, which helps residual slurry and waste liquid to be smoothly discharged into the main pipeline 1 through the venturi tube 11 in the form of a jet.

[0090] The central controller 18 is electrically connected to the branch switch 2, nuclear concentration meter 3, pH online detector 4, first electromagnetic control valve 5-1, second electromagnetic control valve 5-2, third electromagnetic control valve 5-3, fourth electromagnetic control valve 5-4, shading sensor 12, laser particle size analyzer 13, dispersant addition unit 15, defoamer addition unit 16, and each drain valve 10, and is used to control the operation, data processing and storage of the entire system.

[0091] The online monitoring and sampling method based on the above-mentioned slurry online monitoring and sampling system includes the following steps:

[0092] Step 1: Take a sample of the slurry in the main pipeline 1 and perform preliminary multi-parameter testing on the sampled slurry.

[0093] The main slurry flows in the main pipeline 1. A blade sampler 17 continuously and automatically extracts a small, representative slurry sample from the main pipeline 1 and directs it into a branch line of the system. The central controller 18 controls the opening of the branch line switch 2. This slurry stream first flows through a nuclear concentration meter 3 and an online pH meter 4, respectively, to perform real-time measurements of the concentration and pH value of the raw slurry. The concentration value measured by the nuclear concentration meter 3... The unit is percentage (%). The pH value measured by the online pH meter 4 is dimensionless. The measured data is immediately transmitted to the central controller 18.

[0094] Step 2: Divide the sampled slurry into smaller streams, and perform intelligent dilution and particle size analysis on the first stream. This specifically includes:

[0095] The central controller 18 controls the first electromagnetic control valve 5-1 to divert the slurry, controlling a certain amount of slurry to enter the feedforward dilution tank 6, while the remaining slurry continues to flow to the sampling mixing tank 7.

[0096] Step 2.1, concentration feedforward dilution.

[0097] After the slurry enters the feedforward dilution tank 6, the central controller 18 executes the concentration feedforward dilution control program:

[0098] Step a1: Read the slurry concentration value of nuclear concentration meter 3 in real time. (unit:%).

[0099] Step a2, intermediate concentration with preset target (Unit: %, range 15%-25%, preferably 20%) were compared, and the initial dilution ratio was calculated using the formula. (Dimensionless):

[0100] ;

[0101] Step a3: Calculate the opening degree of the first solenoid control valve 5-1 based on the pre-stored valve flow characteristic function. (unit:%):

[0102] ;

[0103] In the above formula, , , For constants calibrated experimentally, the preferred constant is... , , , , Dimensionless The unit is h / m³; The water flow rate of the first electromagnetic control valve 5-1 is expressed in m³ / h.

[0104] Step a4: Calculate the opening time of the first solenoid control valve 5-1. (Unit: s):

[0105] ;

[0106] In the above formula, This represents the required volume of water to be added, in liters (L). The volume of slurry entering feedforward dilution tank 6 (a fixed value, determined by system design), unit: L; The water flow rate at the current valve opening, in L / s, is determined by a pre-calibrated valve flow rate-opening curve. The curve is as follows: ,in (Unit: L / s) and (Dimensionless) is the valve characteristic constant, which is determined experimentally.

[0107] Step a5: The central controller 18 controls the first solenoid control valve 5-1 to the calculated opening degree. and opening time Water is introduced and initially diluted and mixed in feedforward dilution tank 6.

[0108] Step 2.2: Opacity feedback dilution and particle size measurement.

[0109] After the feedforward diluted slurry is mixed evenly, a certain amount of primary diluted slurry enters the ultrasonic dilution tank 14 through the second electromagnetic control valve 5-2.

[0110] The shading sensor 12 detects the shading signal of the slurry in the ultrasonic dilution tank 14 in real time. (Unit: %) and transmitted to the central controller 18.

[0111] The central controller 18 executes a shading feedback dilution control algorithm, which cyclically performs the following steps:

[0112] Step b1: Read the current shading value (unit:%).

[0113] Step b2: Based on the current shading value With target shading (Unit: %, set at 15%, optimal working range 10%-20%) Calculate shading error (unit:%): .

[0114] Step b3: Calculate the control output using an adaptive PID algorithm. (Dimensionless, used to adjust the change in valve opening):

[0115] Step b3-1: First, calculate the dynamic adjustment ratio. (Dimensionless):

[0116] ;

[0117] In the above formula, Represents the initial proportionality coefficient, dimensionless, with a value range of 2.0-3.0, preferably 2.5; and Represents the adaptive weighting coefficient. The value range is 0.08-0.12, with 0.1 being preferred. Value range: 0.03-0.07, preferred value: 0.05, unit: s; Represents the shading error at the current moment, in % %. Represents the rate of change of error, in units of % / s.

[0118] Step b3-2, then calculate the control output. :

[0119] ;

[0120] In the above formula, Represents the integral coefficient, dimensionless, with a value range of 0.05-0.15, preferably 0.1, unit: / s; Represents the differential coefficient, dimensionless, with a value range of 0.3-0.7, preferably 0.5, unit: s; Represents the integral term of error, unit: %·s. Represents the differential term of the error, in units of % / s.

[0121] Step b3-3: Update the valve opening of the second solenoid control valve 5-2. (unit:%):

[0122] ;

[0123] In the above formula, This means limiting the opening to between 0% and 100%.

[0124] Step b3-4, Termination Condition Determination: Dilution shall be stopped when the following conditions are met simultaneously:

[0125] Condition 1: Real-time shading Entering the 10%-20% range;

[0126] Condition 2: The standard deviation of the shading data within 3-5 seconds is less than 0.5%;

[0127] Once the conditions are met, stop adding water and end the shading feedback dilution control algorithm; otherwise, continue to the next cycle.

[0128] Furthermore, while dilution is carried out in the ultrasonic dilution tank 14, the dispersant addition unit 15 and the defoamer addition unit 16 inject dispersant and defoamer into the tank. Sodium hexametaphosphate is preferred as the dispersant, with an addition concentration of 0.1%-0.5% (mass-volume ratio); polydimethylsiloxane is preferred as the defoamer, with an addition concentration of 0.5%-1% (mass-volume ratio), which can eliminate air bubbles from organic agents and avoid interference with particle size measurement. The ultrasonic dilution tank 14 is stirred and ultrasonically vibrated at an ultrasonic power of 200-500W for 3-5 minutes to eliminate foam from the slurry and ensure sufficient particle dispersion.

[0129] Step b4: The slurry enters the laser particle size analyzer 13 for particle size determination, and the measured data is transmitted to the central controller 18. After the determination is completed, the residual waste liquid in the ultrasonic dilution tank 14 is discharged into the buffer tank 9 through the drain valve 10.

[0130] Step 3: Automatically collect samples from the second stream of slurry that has been diverted.

[0131] The central controller 18 controls the third electromagnetic control valve 5-3 to divert the raw slurry from the system branch into the sampling mixing tank 7. After being stirred and mixed in the sampling mixing tank 7, the continuously collected sample slurry from multiple time periods enters the sampler 8 via the fourth electromagnetic control valve 5-4. The sampler 8 automatically completes multiple cycles of "filtration – water addition – re-filtration" to ultimately prepare a wet filter cake sample. All filtrate and washing water generated during this process are also discharged into the buffer tank 9 through the drain valve 10.

[0132] Step 4: Collect the residual slurry and waste liquid generated by the system and return them to the main pipeline 1.

[0133] The remaining slurry in the system branches, as well as the residual slurry and waste liquid generated by each unit, all flow into buffer tank 9. After the system completes monitoring and sampling, the central controller 18 controls the branch switch 2 to close the system branch, and simultaneously controls the water intake of each electromagnetic control valve (5-1, 5-2, 5-3, 5-4) to add water to the system and equipment for cleaning to prevent blockage. The cleaning waste liquid is discharged into buffer tank 9. Buffer tank 9 is connected to Venturi tube 11 through a return water pipeline. Venturi tube 11 uses negative pressure to draw the residual slurry and waste liquid in buffer tank 9 back to main pipeline 1, realizing a closed-loop process.

[0134] The central controller 18 synchronously records, stores, and outputs all monitoring data (concentration, fineness, pH value) and sample collection events, forming a complete production quality record.

[0135] Example:

[0136] Taking a copper mine beneficiation plant as an example, the implementation process of the intelligent dilution control algorithm is explained in detail:

[0137] 1. System initialization configuration:

[0138] Target intermediate concentration: ,

[0139] Target shading level: ,

[0140] PID initial parameters: , , ,

[0141] Adaptive weighting coefficients: , ,

[0142] Optimal shading range: 10%-20%.

[0143] Stability threshold: standard deviation < 0.5%, duration > 3 seconds.

[0144] 2. Detailed algorithm execution process:

[0145] Phase 1: Concentration feedforward dilution.

[0146] The concentration of the primary slurry was measured by nuclear concentration meter 3. .

[0147] Feedforward control calculation:

[0148] ;

[0149] Based on the valve flow characteristic function, the following is calculated: Opening time s.

[0150] Phase Two: Opacity Feedback Dilution.

[0151] Initial light shielding level 14 upon entering the ultrasonic dilution vessel ;

[0152] Error calculation: %

[0153] Adaptive parameter adjustment:

[0154] ;

[0155] Control output (primarily considering the proportional term): (Opening adjustment amount). The valve is opened wide for rapid dilution.

[0156] Phase 3: Precise Approximation Phase.

[0157] when , %, error change rate % / s;

[0158] Adaptive parameter adjustment:

[0159] ;

[0160] The control output is reduced, achieving smooth and precise control.

[0161] Phase Four: Termination of Judgment.

[0162] Real-time shading Entering the optimal range;

[0163] Light blocking data for the last 5 seconds: 15.8%, 15.6%, 15.4%, 15.3%, 15.5%;

[0164] Standard deviation calculation: ;

[0165] The stabilization time reaches 4 seconds, which is greater than 3 seconds.

[0166] Once all termination conditions are met, stop adding water and start the laser particle size analyzer 13 for measurement.

[0167] 3. Performance verification data:

[0168] After 500 hours of industrial operation testing:

[0169] Average dilution completion time: 38 ± 5 seconds

[0170] Light-blocking control accuracy: 14.8%-15.8% (±0.5%)

[0171] Particle size measurement repeatability: D50 coefficient of variation < 1.5%,

[0172] System availability: >99.2%.

[0173] It should be noted that, as will be apparent to those skilled in the art, the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics thereof. The scope of the present invention is defined by the claims rather than the foregoing description.

Claims

1. A slurry online monitoring and sampling system, characterized in that: It includes a main pipeline (1), a branch switch (2), a multi-parameter monitoring unit, an intelligent dilution and particle size analysis unit, an automatic sample collection unit, and a central controller (18). The branch switch (2) is installed at the inlet of the system branch and is used to control the slurry entering the system branch; The multi-parameter monitoring unit is installed on a branch of the system and is used to measure the concentration and pH value of the slurry in real time. The intelligent dilution and particle size analysis unit includes a feedforward dilution module and a feedback dilution module, which are used to perform two-stage dilution on a diverted stream of slurry and analyze its particle size. The automatic sample collection unit is used to mix the other stream of slurry that has been diverted and to automatically prepare a wet filter cake sample; The central controller (18) is electrically connected to the branch switch (2), the multi-parameter monitoring unit, the intelligent dilution and particle size analysis unit and the automatic sample collection unit, and is used to control the operation of the system and to process and record data.

2. The slurry online monitoring and sampling system as described in claim 1, characterized in that: The multi-parameter monitoring unit includes a nuclear concentration meter (3) and an online pH meter (4) installed on a branch of the system.

3. The slurry online monitoring and sampling system as described in claim 1, characterized in that: The intelligent dilution and particle size analysis unit includes a feedforward dilution tank (6), an ultrasonic dilution tank (14), a light-blocking sensor (12), and a laser particle size analyzer (13). The inlet of the feedforward dilution tank (6) is connected to the system branch through the first electromagnetic control valve (5-1), which has a water inlet. The inlet of the ultrasonic dilution tank (14) is connected to the outlet of the feedforward dilution tank (6) through the second electromagnetic control valve (5-2), and the second electromagnetic control valve (5-2) has a water inlet; The shading sensor (12) is located inside the ultrasonic dilution tank (14); The laser particle size analyzer (13) is connected to the ultrasonic dilution tank (14).

4. The slurry online monitoring and sampling system as described in claim 3, characterized in that: The ultrasonic dilution vessel (14) is also connected to a dispersant addition unit (15).

5. The slurry online monitoring and sampling system as described in claim 3, characterized in that: The ultrasonic dilution tank (14) is also connected to an antifoaming agent addition unit (16).

6. The slurry online monitoring and sampling system as described in claim 1, characterized in that: The automatic sample collection unit includes a sampling mixing tank (7) and a sampler (8); The inlet of the sampling mixing tank (7) is connected to the system branch via the third electromagnetic control valve (5-3); The input port of the sampler (8) is connected to the output port of the sampling mixing tank (7) through the fourth electromagnetic control valve (5-4).

7. The slurry online monitoring and sampling system as described in claim 1, characterized in that: It also includes a buffer tank (9) and a venturi tube (11); The buffer tank (9) is used to collect residual slurry generated by the system and waste liquid generated by water flushing; The Venturi tube (11) is installed on the return water pipeline between the buffer tank (9) and the main pipeline (1) to return the material in the buffer tank (9) to the main pipeline (1).

8. A method for online monitoring and sampling of mineral slurry, employing the online monitoring and sampling system for mineral slurry as described in any one of claims 1-7, characterized in that, Includes the following steps: Step 1: Take a sample of the slurry in the main pipeline (1) and measure the concentration and pH value of the sampled slurry in real time; Step 2: Divide the sampled slurry into streams, and perform intelligent dilution and particle size analysis on the first stream. The intelligent dilution includes feedforward dilution based on real-time concentration and feedback dilution based on real-time shading. Step 3: Mix the second stream of primary slurry that has been diverted and automatically prepare a wet filter cake sample; Step 4: Collect the residual slurry and waste liquid generated by the system and return them to the main pipeline (1); During the above steps, the central controller (18) controls the system and processes and records the data.

9. The online monitoring and sampling method for slurry as described in claim 8, characterized in that: The smart dilution in step 2 specifically includes the following steps: Step 2.1, concentration feedforward dilution; Step a1: Read the slurry concentration value from the nuclear concentration meter (3) in real time. ; Step a2, intermediate concentration with preset target Compare and calculate the initial dilution ratio using the formula. : ； Step a3: Based on the pre-stored valve flow characteristic function, calculate the opening degree of the first electromagnetic control valve (5-1) used to control the water addition of the feedforward dilution tank (6). : ； In the above formula, , , These are constants calibrated experimentally. The water flow rate is the first electromagnetic control valve (5-1); Step a4: Calculate the opening time of the first solenoid control valve (5-1). : ； In the above formula, This represents the required volume of water to be added; The volume of slurry entering the feedforward dilution tank (6); The water flow rate at the current valve opening is determined using a pre-calibrated valve flow rate-opening relationship curve, which is shown in the figure below. ,in and For valve characteristic constants; Step a5: The central controller (18) controls the first solenoid control valve (5-1) to open according to the calculated degree. and opening time Water is introduced and initially diluted and stirred in the feedforward dilution tank (6); Step 2.2: Opacity feedback dilution and particle size measurement; After the feedforward diluted slurry is mixed evenly, a certain amount of primary diluted slurry enters the ultrasonic dilution tank (14) through the second electromagnetic control valve (5-2). The shading sensor (12) detects the shading signal of the slurry in the ultrasonic dilution tank (14) in real time. And transmit to the central controller (18); The central controller (18) executes the shading feedback dilution control algorithm and adds water to the ultrasonic dilution tank (14) for dilution through the second electromagnetic control valve (5-2).

10. The online monitoring and sampling method for slurry as described in claim 9, characterized in that, The shading feedback dilution control algorithm repeatedly executes the following steps: Step b1: Read the current shading value ; Step b2: Based on the current shading value With target shading Calculate the shading error : ; Step b3: Calculate the control output using an adaptive PID algorithm. : Step b3-1: First, calculate the dynamic adjustment ratio. : ； In the above formula, Represents the initial scaling factor; and Represents the adaptive weighting coefficient; Step b3-2, then calculate the control output. : ； In the above formula, Represents the integral coefficient; Represents the differential coefficient; Step b3-3: Update the valve opening of the second solenoid control valve (5-2). : ； In the above formula, This means limiting the opening to between 0% and 100%; Step b3-4, Termination Condition Determination: Dilution shall be stopped when the following conditions are met simultaneously: Condition 1: Real-time shading Entering the 10%-20% range; Condition 2: The standard deviation of the shading data within 3-5 seconds is less than 0.5%; Once the conditions are met, stop adding water and end the shading feedback dilution control algorithm; otherwise, continue to the next cycle.

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