Detection method, system and device for reducing ring formation of zinc extraction rotary kiln

Abstract

The invention relates to the technical field of zinc extraction rotary kiln processing devices, in particular to a detection method, system and device for reducing ring formation of a zinc extraction rotary kiln, and the method comprises the following steps: step 1, cleaning the inner side wall of the rotary kiln, removing adhesive substances, constructing a 1: 1 three-dimensional geometric model by using 3D software according to the actual internal size of the rotary kiln, and calculating the actual internal size of the rotary kiln; the method comprises a first step of embedding equipment such as a thermal imager, a thermocouple, a combustor and an air pipe into a geometric model according to actual installation positions, and marking the monitoring range of the equipment, a second step of establishing a three-dimensional mapping relation of'equipment data-space coordinates', namely distributing exclusive space coordinate codes for each piece of detection equipment, and a third step of increasing the early warning advance by 80% through an industrial communication protocol, and aiming at different first-stage, second-stage and third-stage scenes, differentiated monitoring frequencies and triggering conditions are formulated, and air volume and air pressure linkage adjustment of the feeding combustion air duct is matched, so that resource waste or insufficient prevention and control caused by one-step regulation is avoided.

Description

Technical Field

[0001] This invention relates to the technical field of rotary kiln processing equipment for zinc extraction, and specifically to a method, system, and apparatus for detecting ring formation in rotary kilns for zinc extraction. Background Technology

[0002] In zinc extraction, the rotary kiln is a core thermal equipment, where the oxidation and reduction reactions of zinc concentrate are achieved through high-temperature roasting. However, due to factors such as fluctuations in material composition, uneven temperature distribution within the kiln, and differences in material flow rate, "rings" (rings) are easily formed inside the kiln (especially in the 10-20m high-incidence zone), which are ring-shaped hard lumps formed by molten material adhering to the kiln lining surface. Once formed, rings can block kiln channels, hinder the exchange of material and hot air, leading to a decrease in production capacity (reductions of up to 15%-30%), a surge in fuel consumption (an increase of over 20%), and in severe cases, requiring shutdown for cleaning, resulting in significant economic losses. Therefore, ring control is a core challenge in the operation and maintenance of zinc extraction rotary kilns.

[0003] The current core approach to ring formation control in the industry is "temperature monitoring + manual / mechanical control." However, the existing technology system has significant limitations and cannot meet the needs of precise control. Specific problems are as follows: ① The mainstream solution uses thermal imagers to monitor the surface temperature of the kiln and embedded thermocouples to collect local material temperatures. The data from these two types of equipment are independent. Thermal imagers can only present a two-dimensional temperature field on the surface of the kiln and cannot distinguish whether the temperature anomaly comes from "internal damage to the lining bricks" or "material accumulation on the surface." Although thermocouples can obtain local point temperatures, they can only mark the axial position (e.g., 14m from the kiln head) and cannot determine the circumferential angle (e.g., 180° or 270°) and radial depth (e.g., the surface of the material layer or the middle of the lining bricks). This results in high-temperature area positioning being only "linearly marked" and unable to form three-dimensional coordinates. ② The existing system can only trigger an early warning after the temperature exceeds the normal threshold and cannot trace the dynamic changes of the high-temperature area. This results in early warnings being mostly "post-event responses," making it difficult to intervene in a timely manner in the early stages of ring formation (e.g., the stage of slight material accumulation), thus missing the best control opportunity. Summary of the Invention

[0004] Technical problems to be solved In view of the above-mentioned shortcomings of the prior art, the present invention provides a method, system and device for detecting ring formation in zinc extraction rotary kilns, which can effectively solve the problems in the prior art.

[0005] Technical solution This invention provides a method for detecting ring formation in zinc extraction rotary kilns, characterized in that... Step 1: First, clean the inner wall of the rotary kiln, removing any adhering materials. Based on the actual internal dimensions of the rotary kiln, use 3D software to construct a 1:1 three-dimensional geometric model. Embed the thermal imager, thermocouples, burners, air ducts, and other equipment into the geometric model according to their actual installation positions, and mark the monitoring range of the equipment. Step 2: ① Establish a three-dimensional mapping relationship between "equipment data and spatial coordinates", that is, assign a unique spatial coordinate code to each detection device. ② Through industrial communication protocols, import the temperature field image of the thermal imaging system, the real-time temperature value of the thermocouple, and the verification data of the handheld infrared thermometer into the three-dimensional model in real time according to the spatial coordinate code. The corresponding position in the model is highlighted after reaching the threshold range. Step 3: Convert the axial coordinates, circumferential angles, temperature values, and other data of the high-temperature area into a standardized command format, perform a three-level early warning classification, and send the classification results to the controller of the pipeline auxiliary device via industrial Ethernet to generate corresponding three-level measures. Step 4: Generate an adjustment curve for the above data, store it synchronously in the 3D model, and maintain a high-frequency monitoring state. After the preset conditions are met, the detection feedback mechanism stops and resumes the daily monitoring state.

[0006] Furthermore, a thermal imager is installed in the middle of the rotary kiln and in the smoke chamber at the kiln tail to capture the temperature distribution within a 10m radius around the kiln and along its axis. The equipment at the kiln tail focuses on the smoke chamber outlet and the material falling area. The thermal imaging system generates one frame of the kiln temperature field image every 5 seconds, and simultaneously outputs the average temperature and temperature difference data of key areas. This data is then compared with historical normal temperature curves. If the high temperature point persists for a certain period of time and exceeds the normal range, different warning measures are triggered according to the three-level warning system.

[0007] Furthermore, thermocouples are arranged axially at 2m intervals on the inner wall of the rotary kiln, and the probes penetrate 5-10cm into the material layer inside the kiln. Each set of thermocouples transmits data to the external central control system via a wireless transmission module. Every 2 hours, the staff uses a high-precision handheld infrared thermometer to check the temperature of the thermal imaging blind spots on the surface of the kiln.

[0008] Furthermore, the three-tiered early warning system and its response measures will be evaluated according to the following steps: Level 1 warning: The thermal imaging system detects a single point of high temperature at 1000-1050℃ for 5-10 minutes. Thermocouple data confirms the abnormal temperature and there are no obvious signs of material accumulation. Level 2 warning: Thermocouple monitoring shows a temperature difference of ≥120℃ between two adjacent points, thermal imaging shows that the high-temperature area is expanding, with an area of ​​≥2m² and a temperature of 1050-1300℃, and the negative pressure at the kiln tail exceeds the normal range by 0.2kPa; Level 3 warning: Thermal imaging shows high temperatures in three or more consecutive monitoring areas, with temperatures ≥1300℃, a sudden drop in kiln tail flue gas temperature ≥150℃, and a negative pressure increase ≥0.5kPa, confirming the formation of obvious rings.

[0009] Further, the first-level response measures are as follows: Initiate low-speed adjustment of the pipeline auxiliary device according to pre-calculated parameters, adjusting the contact position and area between the material sprayed from the duct and the rotary kiln. The thermal imaging system will report temperature changes in the high-temperature area every 2 seconds. If the temperature drops by ≥20℃, pause the adjustment, maintain the current duct position, and continue air supply for 30 minutes. If the temperature stabilizes at 900-950℃ after 30 minutes, control the duct to return to its initial position along the original path, restoring normal air supply. The second-level response measures are as follows: Initiate rapid adjustment of the pipeline auxiliary device according to pre-calculated parameters, adjusting the contact position and area between the material sprayed from the duct and the rotary kiln. The thermal imaging system will report temperature changes every 1 second. The system monitors the temperature changes in the high-temperature zone using embedded thermocouples in real time. If the temperature drops below 950℃ and thermal imaging shows that the high-temperature zone has shrunk to ≤0.5m², the pulse air supply will be switched to continuous low-volume air supply for 1 hour. The three-level response measures are as follows: the pipeline auxiliary device will be activated with the highest priority for emergency adjustment. Within one minute, the sprayed material range of the air duct will be moved away from its current position, and the air volume of the air duct will be immediately reduced by 30%-40% from the normal operating condition. At the same time, the secondary air valve of the burner will be closed, the kiln speed will be reduced to 0.8r / min, and the kiln head cooling fan will be started to control the temperature inside the kiln together with the cooling air supply structure.

[0010] This invention also introduces a detection system for reducing ring formation in zinc extraction rotary kilns: Acquisition module: Scans and models the interior of the rotating body using a laser scanner, and establishes a 3D model; Calculation module: Preprocesses relevant data, temperature and position data of the rotating body to obtain internal model data of the rotating body, as well as the temperature data of each detection device during use.

[0011] An apparatus for reducing ring formation in a zinc extraction rotary kiln includes a rotary kiln and an air duct. The air duct is positioned at the kiln head of the rotary kiln via a pipeline auxiliary device. A monitoring end is fixed to the top of the kiln head. The pipeline auxiliary device includes a horizontal rotation assembly, a connecting plate, an angle adjustment device, and a height adjustment device. The horizontal rotation assembly includes a base frame, a rotating plate rotatably positioned at the top center of the base frame, and a drive motor connected to the bottom of the rotating plate. The bottom of the connecting plate is fixed to the top of the rotating plate by a fixing strip. The angle adjustment device is fixed to the top of the connecting plate. The tilt adjustment device includes a side ring, a side groove formed on the side ring, and a rack fixed to the middle of the outer side of the side ring. Sliders are provided on both sides of the top of the rack, and a threaded rod is fixed to the middle of the bottom of the slider. The outer side of the bottom of the threaded rod is engaged with the rack. The top of the slider is fixedly connected to the height adjustment device. The height adjustment device includes a frame, a sliding plate disposed in the frame, and a drive wheel and an auxiliary wheel disposed in the sliding plate. The top of the sliding plate is fixedly connected to the output end of a cylinder, and the cylinder is fixed to the outer side of the top of the frame.

[0012] Furthermore, the rotary kiln is provided with a kiln tail at its tail end, and a feed inlet is provided at the top of the kiln tail. The drive motor is fixed to the bottom frame by a mounting bracket.

[0013] Furthermore, the side ring is a hollow spindle-shaped tubular structure, and the side groove is opened in the middle of both sides of the side ring. A locking bolt is fixed at the bottom of the slider. The bottom end of the locking bolt is inserted into the side groove and locked in position by a nut. The bottom end of the slider is an arc-shaped structure, and one side of the threaded rod is connected to the output end of the first servo motor.

[0014] Furthermore, two sets of side plates are fixed on the inner sidewalls of both sides of the frame. The two sides of the sliding plate are arranged inside the side plates. A circular hole is opened in the middle of the sliding plate, and the auxiliary wheel and the driving wheel both protrude into the circular hole. The driving wheel is structurally an auxiliary wheel with a second servo motor, and the driving wheel and the auxiliary wheel are equidistantly distributed on the outside of the circular hole.

[0015] Beneficial effects This invention constructs a multi-dimensional monitoring network consisting of a thermal imaging system, embedded thermocouples, and a handheld infrared thermometer. Combined with 1:1 three-dimensional spatial modeling, it achieves "coordinate binding" between temperature data and the physical structure. This not only allows for rapid location of the axial position and circumferential angle of high-temperature areas but also precise identification of radial depth, avoiding "missed detections" due to monitoring blind spots. Simultaneously, the "historical data backtracking" function of the three-dimensional model can track the dynamic expansion trajectory of high-temperature areas, predicting the tendency for ring formation 2-3 hours in advance. Compared to the traditional "processing only after obvious ring formation appears" approach, the early warning time is increased by 80%, providing ample time for subsequent adjustments. Furthermore, differentiated monitoring frequencies and triggering conditions are established for different scenarios (Level 1, Level 2, and Level 3), and coordinated with the airflow and pressure adjustments in the feeding and combustion ducts, avoiding resource waste or insufficient control caused by "one-size-fits-all" control. This increases the accuracy of ring formation risk management from the traditional 50% to over 90%.

[0016] In this device, based on the three-axis structure consisting of "horizontal rotation component + tilt angle adjustment device + height adjustment device", its design is precisely matched to the control requirements of the air duct in the prevention of ring formation in zinc extraction rotary kiln. Through multi-dimensional flexible adjustment and stable transmission, it provides core support for the air duct to accurately connect with the working conditions inside the kiln and suppress the formation of rings. Attached Figure Description

[0017] 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.

[0018] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a front view of the structure of the present invention; Figure 3 This is a schematic diagram of the pipeline auxiliary device in this invention; Figure 4 This is an exploded view of the pipeline auxiliary device in this invention; Figure 5 This is an exploded view of the height adjustment device and tilt adjustment device in this invention; Figure 6 This is an exploded view of the horizontal rotation component and height adjustment device in this invention; Figure 7 This is a structural block diagram of the detection method of the present invention.

[0019] The labels in the diagram represent: 1. Rotary kiln; 11. Kiln head; 12. Kiln tail; 13. Feed inlet; 2. Piping auxiliary device; 21. Horizontal rotation assembly; 211. Base frame; 212. Drive motor; 213. Rotating plate; 214. Fixing strip; 22. Connecting plate; 23. Tilt adjustment device; 231. Side ring; 232. Side groove; 233. First servo motor; 234. Rack; 235. Threaded rod; 236. Locking bolt; 24. Height adjustment device; 241. Frame; 242. Sliding plate; 243. Side plate; 244. Auxiliary wheel; 245. Drive wheel; 246. Slider; 247. Second servo motor; 25. Cylinder; 3. Air duct; 4. Monitoring end. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0021] The present invention will be further described below with reference to embodiments.

[0022] Example 1: A method for detecting reduced ring formation in zinc extraction rotary kilns, refer to the attached document. Figure 7 , Step 1: First, clean the inner wall of the rotary kiln to remove any adhering materials. Based on the actual internal dimensions of the rotary kiln, use 3D software to construct a 1:1 three-dimensional geometric model. Embed the thermal imager, thermocouples, burners, air ducts, and other equipment into the geometric model according to their actual installation positions. Mark the monitoring range of the equipment and divide the axial area into sections: "kiln head (0-10m) - kiln middle (10-20m, high-incidence area of ​​ring formation) - kiln tail (20-30m)". Mark the corresponding equipment installation position in each section (e.g., the 12-18m section in the kiln is the monitoring coverage area of ​​the thermal imager).

[0023] Step 2: ① Establish a three-dimensional mapping relationship between "equipment data and spatial coordinates", that is, assign a unique spatial coordinate code to each detection device. ② Through industrial communication protocols, import the temperature field image of the thermal imaging system, the real-time temperature value of the thermocouple, and the verification data of the handheld infrared thermometer into the three-dimensional model in real time according to the spatial coordinate code. The corresponding position in the model will be highlighted after reaching the threshold range. The monitoring data of the thermal imager in the kiln (number T1) will automatically correspond to the coordinate range of "axial 12-22m + circumferential 90°-270° + radial 1.45-1.75m (kiln surface and lining bricks)" in the model.

[0024] Step 3: Convert the axial coordinates, circumferential angles, and temperature values ​​of the high-temperature area into a standardized command format, perform a three-level early warning classification, and send the classification results to the controller of the pipeline auxiliary device via industrial Ethernet to generate corresponding three-level measures; install a thermal imager in the middle of the rotary kiln body and the kiln tail smoke chamber to capture the temperature distribution within a 10m range in the circumferential and axial directions of the kiln body; the kiln tail equipment focuses on the smoke chamber outlet and the material falling area. The thermal imaging system generates one frame of kiln body temperature field image every 5 seconds, and simultaneously outputs the average temperature and temperature difference data of key areas, and compares them with the historical normal temperature curve. If the high temperature point persists for a certain period of time and exceeds the normal range, different early warning measures are triggered according to the three-level early warning classification.

[0025] Step 4: Generate an adjustment curve for the above data, store it synchronously in the 3D model, and maintain a high-frequency monitoring state. After the preset conditions are met, the detection feedback mechanism stops and resumes the daily monitoring state.

[0026] A multi-dimensional monitoring network consisting of a thermal imaging system, embedded thermocouples, and a handheld infrared thermometer is constructed. Combined with 1:1 three-dimensional spatial modeling, temperature data is "coordinate-bound" to the physical structure. This not only allows for rapid location of the axial position and circumferential angle of high-temperature areas but also precise identification of radial depth, avoiding "missed detections" due to monitoring blind spots. At the same time, the "historical data backtracking" function of the three-dimensional model can track the dynamic expansion trajectory of high-temperature areas and predict the tendency of ring formation 2-3 hours in advance. Compared with the traditional mode of "processing only after obvious ring formation appears", the early warning time is increased by 80%, allowing sufficient time for subsequent control.

[0027] Example 2: The three-level early warning classification and its response measures are evaluated according to the following steps: Level 1 Warning: The thermal imaging system detects a single point of high temperature at 1000-1050℃ for 5-10 minutes. Thermocouple data confirms the abnormal temperature, and there are no obvious signs of material accumulation. The corresponding coordinate point in the model is displayed as a bright yellow dot. The Level 1 response measures are as follows: Start low-speed adjustment of the pipeline auxiliary device according to the pre-calculated parameters to adjust the contact position and area between the material sprayed from the air duct and the rotary kiln. The thermal imaging system provides feedback on the temperature change of the high-temperature area every 2 seconds. If the temperature drops by ≥20℃, the adjustment is paused, the current air duct position is maintained, and air is continuously supplied for 30 minutes. If the temperature stabilizes at 900-950℃ after 30 minutes, the air duct is controlled to return to the initial position along the original path, and normal air supply is restored. Level 2 Warning: Thermocouples detect a temperature difference ≥120℃ between two adjacent points, thermal imaging shows an expansion of the high-temperature area, with an area ≥2m² and a temperature of 1050-1300℃. Furthermore, the negative pressure at the kiln tail exceeds the normal range by 0.2kPa. The area marked in the model as "axial 14-16m + circumferential 180° + radial 1.45m" is highlighted in orange, and the abnormal area is marked with a dashed box. The Level 2 response measures are as follows: Rapidly adjust the auxiliary piping device according to the pre-calculated parameters, adjusting the contact position and area between the material sprayed from the duct and the rotary kiln. The thermal imaging system provides feedback on the temperature change of the high-temperature area every second. Embedded thermocouples monitor the material temperature in real time. If the temperature drops below 950℃ and the thermal imaging shows the high-temperature area shrinks to ≤0.5m², switch the pulse air supply to continuous low-volume air supply for 1 hour. Level 3 Warning: Thermal imaging shows high temperatures in three or more consecutive monitoring areas, with temperatures ≥1300℃, a sudden drop in kiln tail flue gas temperature ≥150℃, and a negative pressure increase ≥0.5kPa, confirming the formation of a clear ring. The corresponding area in the model is displayed as a bright red 3D block, with the estimated volume of the ring ("2m long × 60° circumference × 0.3m radial") and core temperature marked. The Level 3 response measures are as follows: The pipeline auxiliary device is activated for emergency adjustment with the highest priority. Within one minute, the spraying range of the air duct is moved away from its current position, the air volume of the air duct is immediately reduced by 30%-40% from normal operating conditions, the secondary air valve of the burner is closed, the kiln speed is reduced to 0.8r / min, and the kiln head cooling fan is started to control the kiln temperature together with the cooling air supply structure.

[0028] When the model marks the high-temperature area, the system automatically calculates the burner's adjustment parameters: based on the spatial distance between the burner and the high-temperature area in the model, the system generates adjustment instructions and simulates the adjusted flame coverage in the model to confirm that the flame center can avoid the high-temperature area and prevent local overheating from escalating.

[0029] Different monitoring frequencies and triggering conditions are formulated for different scenarios of Level 1, Level 2, and Level 3. The air volume and air pressure of the feeding and combustion duct are adjusted in conjunction with these settings to avoid resource waste or insufficient prevention and control caused by "one-size-fits-all" control. This improves the accuracy of handling ring formation risk from the traditional 50% to over 90%.

[0030] Example 3: A detection system for reducing ring formation in zinc extraction rotary kilns, used in the detection methods of Examples 1 and 2, with the following module: scanning and modeling the interior of the rotating body using a laser scanner, and establishing a three-dimensional model; Calculation module: Preprocesses relevant data, temperature and position data of the rotating body to obtain internal model data of the rotating body, as well as the temperature data of each detection device during use.

[0031] Testing equipment: thermal imager, thermocouples, and handheld infrared thermometer.

[0032] Example 4: Reference Figure 1-6 A device for reducing ring formation in a zinc extraction rotary kiln includes a rotary kiln 1 and an air duct 3. The air duct 3 is installed at the kiln head 11 of the rotary kiln 1 via a pipe auxiliary device 2. A monitoring end 4 is fixed to the top of the kiln head 11. The pipe auxiliary device 2 includes a horizontal rotation assembly 21, a connecting plate 22, an angle adjustment device 23, and a height adjustment device 24. The horizontal rotation assembly 21 includes a base frame 211, a rotating plate 213 rotatably disposed at the top center of the base frame 211, and a drive motor 212 connected to the bottom of the rotating plate 213. The bottom of the connecting plate 22 is fixed to the top of the rotating plate 213 by a fixing strip 214. The angle adjustment device 23 is fixed to the top of the connecting plate 22. The drive motor 21 is located inside the base frame 211 of the horizontal rotation assembly 21. 2. The transmission structure drives the rotating plate 213 to rotate stably at 360°. Combined with the connecting plate 22 fixed above the rotating plate 213, the air duct 3 can be adjusted without dead angles along the circumferential direction of the kiln head 11 of the rotary kiln 1. For the high temperature area in the circumferential direction marked by the three-dimensional model (such as the 120°-180° risk area of ​​ring formation), the drive motor 212 can drive the air duct 3 to rotate quickly to the target angle through precise speed control (with stable fixation by the mounting bracket). The adjustment deviation is ≤±1°. Compared with the traditional fixed-angle air duct 3, the circumferential coverage is increased by 300%, ensuring that the feeding combustion air is accurately delivered to the circumferential area where materials accumulate or the temperature is abnormal, avoiding the problem of uneven fuel distribution and local ring formation caused by the angle deviation of the air duct 3. The tilt adjustment device 23 includes a side ring 231, a side groove 232 formed on the side ring 231, and a rack 234 fixed to the middle of the outer side of the side ring 231. Slider blocks 246 are provided on both sides of the top of the rack 234. A threaded rod 235 is fixed to the middle of the bottom end of the slider 246. The outer side of the bottom end of the threaded rod 235 is engaged with the rack 234. The top of the slider 246 is fixedly connected to the height adjustment device 24. The tilt adjustment device 23 adopts a hollow spindle-shaped tubular side ring 231, designed in conjunction with the side grooves 232 and the arc-shaped slider 246. The first servo motor 233 drives the threaded rod 325 to engage with the rack 234, causing the slider 246 to slide along the side groove 232, thereby adjusting the tilt angle of the duct 3 (adjustment range can reach -15° to +15°). When abnormal temperatures occur in different axial areas of the kiln (such as material accumulation at 15-17m in the kiln or localized overheating at 113-5m in the kiln head), the tilt angle of the air outlet of the air duct 3 can be adjusted by precisely sliding the slider 246 along the side groove 232 (locking bolt 236 and nut lock the position deviation ≤ ±0.5cm). This allows the feeding combustion air to precisely cover the abnormal areas axially. For example, for the risk zone of ring formation in the kiln, the tilt angle of the air duct 3 can be lowered by 5° to enhance the pushing force of the air on the material and reduce accumulation; for the overheated area at the kiln head 11, the tilt angle can be raised by 8° to disperse the impact force of the air and avoid a sudden rise in local temperature. This achieves dynamic matching between axial air pressure and material flow, improving the axial control accuracy of the air duct 3 to ±0.2°, which is 200% more adaptable than the traditional fixed tilt angle structure. The height adjustment device 24 includes a frame 241, a sliding plate 242 disposed within the frame 241, and a drive wheel 245 and an auxiliary wheel 244 disposed within the sliding plate 242. The top end of the sliding plate 242 is fixedly connected to the output end of the cylinder 25, and the cylinder 25 is fixed to the outer side of the top end of the frame 241. In the height adjustment device 24, the cylinder 25 drives the sliding plate 242 to slide up and down along the side plate 243. Combined with the array distribution of the drive wheel 245 (with a second servo motor 247) and the auxiliary wheel 244, it can drive the air duct 3 to achieve smooth lifting and lowering within the range of 0-0.8m along the radial (height direction) of the rotary kiln 1. When the thickness of the material layer in the kiln is affected by the risk of ring formation, When fluctuations occur (such as local accumulation leading to an increase in thickness of 10-15cm), cylinder 25 can quickly drive sliding plate 242 to rise and fall, adjusting the distance between the air outlet of air duct 3 and the surface of the material layer (controlled at the optimal feeding height of 5-10cm). This avoids the air duct being blocked by material due to excessive distance (the blockage rate of traditional fixed-height air duct 3 is reduced by 60%), and also prevents uneven feeding and fuel waste due to excessive distance (fuel utilization rate is improved by 12%-15%). At the same time, the array design of drive wheel 245 and auxiliary wheel 244 can assist the air duct 3 to move stably, avoiding feeding deviation caused by the shaking of air duct 3 during the lifting process, and improving radial adjustment stability by 80%. The rotary kiln 1 has a kiln tail 12 at its tail end, and a feed inlet 13 is opened at the top of the kiln tail 12. The drive motor 212 is fixed in the bottom frame 211 by a mounting bracket. The drive motor 212 in the horizontal rotation assembly 21 is independently fixed by a mounting bracket for easy troubleshooting. The slider 246 and the side ring 231 in the tilt adjustment device 23 are detachably connected by locking bolts 236, making replacement convenient after wear. The sliding plate 242 and the side plate 243 in the height adjustment device 24 slide together, so there is no need to disassemble the whole structure during maintenance. Compared with the traditional integrated adjustment structure, the replacement time of parts is shortened to within 30 minutes (originally 2-3 hours). At the same time, the drive motor 212, the first servo motor 233, the second servo motor 247 and other power components are independently driven. If one component fails, it will not affect the adjustment of other dimensions, reducing the overall failure rate of the equipment by 40%. The side ring 231 is a hollow spindle-shaped tubular structure, and the side grooves 232 are opened in the middle of both sides of the side ring 231. A locking bolt 236 is fixed to the bottom of the slider 246. The bottom end of the locking bolt 236 is inserted into the side groove 232 and locked in place by a nut. The bottom end of the slider 246 has an arc-shaped structure, and one side of the threaded rod 235 is connected to the output end of the first servo motor 233 for transmission. The side ring 231 adopts a hollow spindle-shaped tubular structure, which reduces the overall weight (30% weight reduction compared to a solid structure, reducing the drive load) while ensuring sufficient... Sufficient strength; the arc-shaped structure at the bottom of the slider 246 fits perfectly with the outer wall of the side ring 231, reducing sliding friction loss (extending the service life of the slider 246 from 6 months to 12 months); the sliding plate 242 slides with the side plate 243 on both sides, and with the array support of the drive wheel 245 and the auxiliary wheel 244, it avoids local deformation caused by the concentrated weight of the air duct 3 (reducing the deformation rate of the air duct 3 by 70%). The overall structure is suitable for the high temperature and vibration working environment of the rotary kiln 1, and the average life of the core components is increased from 8 months to 18 months, reducing equipment maintenance costs by 35%-40%.

[0033] Two sets of side plates 243 are fixed on the inner sidewalls of both side frames 241. The two sides of the sliding plate 242 are located within the side plates 243. A circular hole is opened in the middle of the sliding plate 242, and both the auxiliary wheel 244 and the drive wheel 245 protrude from this circular hole. The drive wheel 245 is structurally an auxiliary wheel 244 with a second servo motor 247. The drive wheel 245 and the auxiliary wheel 244 are equidistantly arranged outside the circular hole. The three-axis structure's power components (drive motor 212, first...) The servo motor 233, the second servo motor 247, and the cylinder 25 can be linked to the three-dimensional spatial model and temperature monitoring system via signals: when the thermal imager or thermocouple detects a high-temperature / ring-forming risk area inside the kiln (such as axial 16m + circumferential 180° + radial 1.45m), the system can directly send adjustment commands to the three-axis structure, driving motor 212 to rotate the air duct 3 to 180°, the first servo motor 233 to adjust the tilt angle to -3°, and the cylinder 25 to drive the air duct 3 to descend to 1.45m. The height adjustment process can be completed within 30 seconds (traditional manual adjustment takes 5-10 minutes), improving the response speed by 60%. This ensures that the risk of ring formation can be precisely controlled through the air duct 3 in the early stages of ring formation, thus suppressing the spread of risk. The locking bolt 236 in the tilt adjustment device 23, together with the nut, locks the position of the slider 246, preventing the air duct 3 from tilting due to vibration during feeding (the offset is controlled within ±0.1°). The side plate 243 in the height adjustment device 24 limits the sliding plate 242 and supports the drive wheel 245 and the auxiliary wheel 244, preventing the air duct 3 from tilting during lifting (tilt deviation ≤ ±0.5mm). This stable transmission characteristic ensures that the air duct 3 maintains a precise position after adjustment, avoiding uneven feeding and abnormal local temperature caused by the offset of the air duct 3, thereby reducing new ring formation causes and reducing the ring recurrence rate by 25%-30%. At the same time, it avoids equipment damage caused by the air duct 3 shaking and colliding with the kiln lining (reducing the kiln lining maintenance frequency by 50%).

[0034] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the protection scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for detecting reduced ring formation in zinc extraction rotary kilns, characterized in that, Step 1: First, clean the inner wall of the rotary kiln, removing any adhering materials. Based on the actual internal dimensions of the rotary kiln, use 3D software to construct a 1:1 three-dimensional geometric model. Embed the thermal imager, thermocouples, burners, air ducts, and other equipment into the geometric model according to their actual installation positions, and mark the monitoring range of the equipment. Step 2: ① Establish a three-dimensional mapping relationship between "equipment data and spatial coordinates", that is, assign a unique spatial coordinate code to each detection device. ② Through industrial communication protocols, import the temperature field image of the thermal imaging system, the real-time temperature value of the thermocouple, and the verification data of the handheld infrared thermometer into the three-dimensional model in real time according to the spatial coordinate code. The corresponding position in the model is highlighted after reaching the threshold range. Step 3: Convert the axial coordinates, circumferential angles, temperature values, and other data of the high-temperature area into a standardized command format, perform a three-level early warning classification, and send the classification results to the controller of the pipeline auxiliary device via industrial Ethernet to generate corresponding three-level measures. Step 4: Generate an adjustment curve for the above data, store it synchronously in the 3D model, and maintain a high-frequency monitoring state. After the preset conditions are met, the detection feedback mechanism stops and resumes the daily monitoring state.

2. The method for detecting reduced ring formation in a zinc extraction rotary kiln according to claim 1, characterized in that, A thermal imager is installed in the middle of the rotary kiln and in the smoke chamber at the kiln tail to capture the temperature distribution within a 10m radius around the kiln. The equipment at the kiln tail focuses on the smoke chamber outlet and the material falling area. The thermal imaging system generates one frame of the kiln temperature field image every 5 seconds, and simultaneously outputs the average temperature and temperature difference data of key areas. The data is compared with the historical normal temperature curve. If the high temperature point persists for a certain period of time and exceeds the normal range, different warning measures are triggered according to the three-level warning classification.

3. The method for detecting reduced ring formation in a zinc extraction rotary kiln according to claim 1, characterized in that, Thermocouples are arranged axially at 2m intervals on the inner wall of the rotary kiln, and the probes penetrate 5-10cm into the material layer inside the kiln. Each set of thermocouples transmits data to the external central control system through a wireless transmission module. Every 2 hours, the staff uses a high-precision handheld infrared thermometer to check the temperature of the blind spots on the thermal imaging of the kiln surface.

4. The method for detecting reduced ring formation in a zinc extraction rotary kiln according to claim 1, characterized in that, The assessment of the Level III early warning classification and its response measures shall be conducted according to the following steps: Level 1 warning: The thermal imaging system detects a single point of high temperature at 1000-1050℃ for 5-10 minutes. Thermocouple data confirms the abnormal temperature and there are no obvious signs of material accumulation. Level 2 warning: Thermocouple monitoring shows a temperature difference of ≥120℃ between two adjacent points, thermal imaging shows that the high-temperature area is expanding, with an area of ​​≥2m² and a temperature of 1050-1300℃, and the negative pressure at the kiln tail exceeds the normal range by 0.2kPa; Level 3 warning: Thermal imaging shows high temperatures in three or more consecutive monitoring areas, with temperatures ≥1300℃, a sudden drop in kiln tail flue gas temperature ≥150℃, and a negative pressure increase ≥0.5kPa, confirming the formation of obvious rings.

5. The method for detecting reduced ring formation in a zinc extraction rotary kiln according to claim 4, characterized in that, The first-level response measures are as follows: Initiate low-speed adjustment of the pipeline auxiliary device according to the pre-calculated parameters, adjusting the contact position and area between the material sprayed from the duct and the rotary kiln. The thermal imaging system should report temperature changes in the high-temperature area every 2 seconds. If the temperature drops by ≥20℃, pause the adjustment, maintain the current duct position, and continue air supply for 30 minutes. If the temperature stabilizes at 900-950℃ after 30 minutes, control the duct to return to its initial position along the original path, restoring normal air supply. The second-level response measures are as follows: Initiate rapid adjustment of the pipeline auxiliary device according to the pre-calculated parameters, adjusting the contact position and area between the material sprayed from the duct and the rotary kiln. The thermal imaging system should report high temperature changes every 1 second. Temperature changes in the high-temperature zone are monitored in real time by embedded thermocouples. If the temperature drops below 950℃ and thermal imaging shows that the high-temperature zone shrinks to ≤0.5m², the pulse air supply will be switched to continuous low-volume air supply for 1 hour. The three-level response measures are as follows: the pipeline auxiliary device is activated for emergency adjustment with the highest priority. Within one minute, the sprayed material range of the air duct is moved away from its current position, the air volume of the air duct is immediately reduced by 30%-40% from the normal operating condition, the secondary air valve of the burner is closed, the kiln speed is reduced to 0.8r / min, and the kiln head cooling fan is started at the same time to control the temperature inside the kiln together with the cooling air supply structure.

6. A detection system for reducing ring formation in zinc extraction rotary kilns, used to implement the detection method described in any one of claims 1-5, characterized in that: Acquisition module: Scans and models the interior of the rotating body using a laser scanner, and establishes a 3D model; Calculation module: preprocesses the relevant data of the rotating body, as well as the temperature and position data, to obtain the internal model data of the rotating body, as well as the temperature data of each detection device during use; Testing equipment: thermal imager, thermocouples, and handheld infrared thermometer.

7. A device for reducing ring formation in a zinc extraction rotary kiln, characterized in that, The system includes a rotary kiln (1) and an air duct (3). The air duct (3) is installed at the kiln head (11) of the rotary kiln (1) via a pipe auxiliary device (2). A monitoring end (4) is fixed at the top of the kiln head (11). The pipe auxiliary device (2) includes a horizontal rotating assembly (21), a connecting plate (22), an inclination adjustment device (23), and a height adjustment device (24). The horizontal rotating assembly (21) includes a base frame (211), a rotating plate (213) rotatably installed at the top center of the base frame (211), and a drive motor (212) connected to the bottom of the rotating plate (213). The bottom of the connecting plate (22) is fixed to the top of the rotating plate (213) via a fixing strip (214). The inclination adjustment device (23) is fixed to the top of the connecting plate (22). The inclination adjustment device (23) includes a side ring (23). 1) A side groove (232) is opened on the side ring (231) and a rack (234) is fixed to the middle of the outer side of the side ring (231). The rack (234) has sliders (246) on both sides of the top end. A threaded rod (235) is fixed to the middle of the bottom end of the slider (246). The bottom outer side of the threaded rod (235) is meshed with the rack (234). The top end of the slider (246) is fixedly connected to the height adjustment device (24). The height adjustment device (24) includes a frame (241), a sliding plate (242) set in the frame (241), and a drive wheel (245) and an auxiliary wheel (244) set in the sliding plate (242). The top end of the sliding plate (242) is fixedly connected to the output end of the cylinder (25). The cylinder (25) is fixed to the outer side of the top end of the frame (241).

8. The apparatus for reducing ring formation in a zinc extraction rotary kiln according to claim 7, characterized in that, The rotary kiln (1) is provided with a kiln tail (12) at the tail end, and a feed inlet (13) is provided at the top of the kiln tail (12). The drive motor (212) is fixed in the bottom frame (211) by a mounting bracket.

9. The apparatus for reducing ring formation in a zinc extraction rotary kiln according to claim 8, characterized in that, The side ring (231) is a hollow spindle-shaped structure, and the side groove (232) is opened in the middle of both sides of the side ring (231). The bottom of the slider (246) is fixed with a locking bolt (236). The bottom end of the locking bolt (236) is inserted into the side groove (232) and locked in place by a nut. The bottom end of the slider (246) is an arc-shaped structure. One side of the threaded rod (235) is connected to the output end of the first servo motor (233).

10. The apparatus for reducing ring formation in a zinc extraction rotary kiln according to claim 9, characterized in that, Two sets of side plates (243) are fixed on the inner sidewalls of the frame (241) on both sides. The two sides of the sliding plate (242) are arranged in the side plate (243). A circular hole is opened in the middle of the sliding plate (242), and the auxiliary wheel (244) and the driving wheel (245) both protrude into the circular hole. The driving wheel (245) is structurally an auxiliary wheel (244) with a second servo (247). The driving wheel (245) and the auxiliary wheel (244) are equidistantly arranged on the outside of the circular hole.

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