Calcium carbide furnace batching method and batching system

Abstract

The invention belongs to the technical field of calcium carbide furnaces, and particularly relates to a calcium carbide furnace batching method and system. The calcium carbide furnace batching method comprises the following steps: S1, a raw material preparation stage; s2, ingredient parameters are set, wherein the ingredient parameters comprise fixed parameters; s3, automatic batching; S3.1, initialization; s3.2, weighing and proportioning the raw materials; and S3.3, conveying the ingredients. According to the batching method, automatic control over batching of the calcium carbide furnace can be achieved, the raw material proportioning error is greatly reduced, the batching process is optimized, the batching speed is increased, the labor intensity is reduced, and real-time monitoring, data tracing and remote regulation and control of the batching process are achieved.

Description

Technical Field

[0001] This invention belongs to the field of calcium carbide furnace technology, specifically relating to a method and system for batching materials for a calcium carbide furnace. Background Technology

[0002] Calcium carbide (CaC) is an important basic chemical raw material. Its production process is carried out in a calcium carbide furnace through a reduction reaction of lime (CaO) and semi-coke as the main raw materials in a high-temperature environment (above 1800℃).

[0003] As a core upstream process in calcium carbide production, the accuracy of raw material proportions and the efficiency of batching directly affect the quality of calcium carbide products (such as gas production and purity), production energy consumption, and furnace stability. Therefore, it is necessary to strictly control the proportion of raw materials in the calcium carbide furnace batching process to ensure stable reaction within the furnace and improve calcium carbide quality.

[0004] Currently, calcium carbide production enterprises use traditional batching methods in their furnaces, primarily relying on manual weighing and adjustment. This method has the following significant drawbacks: (1) Large ratio error: Manual operation inevitably introduces human error, resulting in deviation between the actual raw material ratio and the process setting value. This will not only cause unstable quality of calcium carbide products and insufficient gas generation, but may also cause furnace condition fluctuations, or even serious production accidents such as furnace failure. (2) Low production efficiency: The traditional batching process is scattered and slow, which makes it difficult to match the continuous and efficient production rhythm of large calcium carbide furnaces, thus restricting the overall capacity improvement and resulting in a decline in production efficiency; (3) High labor intensity and high safety risk: The on-site environment for batching and feeding is harsh, with high dust and noise. Workers need to operate in high temperature and high risk areas, which not only makes the labor intensity extremely high, but also threatens their safety. (4) Difficulty in data traceability: The existing batching is done manually, which makes it impossible to collect and store production data in real time; when product quality problems or production failures occur, it is difficult to conduct effective traceability analysis, which is not conducive to the continuous optimization of production processes.

[0005] In view of this, there is an urgent need for a precise, efficient, safe and traceable batching technology solution for calcium carbide furnaces to solve the technical defects of the traditional manual batching mode. Summary of the Invention

[0006] To address the technical problems existing in the current calcium carbide furnace batching process, such as large proportioning errors, low production efficiency, high labor intensity and safety risks, and difficulty in data traceability, this invention provides a calcium carbide furnace batching method and batching system.

[0007] The batching method of this invention realizes automated control of batching in calcium carbide furnaces, greatly reduces raw material ratio errors, optimizes the batching process, increases batching speed, reduces labor intensity, and enables real-time monitoring, data traceability, and remote control of the batching process.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A method for batching feedstock for a calcium carbide furnace includes the following steps: S1, Raw Material Preparation Stage The raw materials include quicklime and semi-coke, which are stored separately in raw material warehouses; S2, Set ingredient parameters The batching parameters include fixed parameters; the fixed parameters include the proportioning parameters, the total conveyor feeding time, the disc rotation cycle, the basic parameters of the furnace top silo, and the furnace top silo material selection mode. S3, Automatic Batching S3.1 Initialization When automatic batching starts, the equipment status is automatically reset; S3.2 Weighing and Batching The material level in the furnace top silo is monitored in real time. Based on the basic parameters and material selection mode of the furnace top silo set in step S2, the quicklime and semi-coke in the raw material silo of step S1 are transported to the weighing hopper until the weight of quicklime and semi-coke reaches the ratio parameters set in step S2. S3.3, Conveying and dispensing materials According to the total conveyor feeding time and disc rotation cycle in step S2, the quicklime and semi-coke that have reached the set proportion parameters in step S2 are synchronously transported to the designated furnace top silo via the transfer conveyor belt to complete the automatic batching.

[0009] Further specifying, in step S1, the raw material silos include lime silo 1, lime silo 2, semi-coke silo 1, and semi-coke silo 2; lime material with a particle size of 30-50mm is stored in lime silo 1, and lime material with a particle size of 40-70mm is stored in lime silo 2; semi-coke is stored in semi-coke silo 1 and semi-coke silo 2 respectively.

[0010] Further specifying, in step S2, The mixing parameters are as follows: the standard amount of quicklime is 1000 kg, and the weight of semi-coke is 520-570 kg; The total conveyor belt feeding time is 300 seconds; the disc rotation cycle is 136 seconds. Basic parameters of the furnace top silo: full capacity 4000kg; low material level threshold is 2500kg, and low-low material level threshold is 1000kg; Furnace top hopper material selection mode: pre-bound, fixed material selection with the corresponding target raw material hopper; including line 1, line 2 and line 3.

[0011] Further specifying, in step S2, the batching parameters also include adjustable parameters; the adjustable parameters include batching start threshold, valve synchronization time difference, batching ratio benchmark value, blockage judgment time, and lime configuration type.

[0012] Further specifying, in step S3.1, the equipment status reset includes weighing status reset and hopper status reset; The weighing hopper status is reset to: initial weight of 0kg, and the unloading valve pre-installed on each weighing hopper is in the closed state; Reset the status of the furnace top hopper: The initial material level of the furnace top hopper is set at 2000-3000kg; the proportioning parameters of each furnace top hopper and the material selection mode of the furnace top hopper are automatically loaded; when the material level of the furnace top hopper is ≤2500kg, the corresponding furnace top hopper triggers the feeding instruction and allows feeding.

[0013] Further specifying that in step S3.2, the material level of the furnace top silo is monitored in real time and compared with the batching start threshold. When the total number of silos with low material level indication is ≥3, batching is carried out in the order of "priority 1 → priority 2 → priority 3".

[0014] Further specified, priority 1 means that the material level in the furnace top hopper is ≤1000kg; Priority 2 is when the material level in the furnace top hopper is 1000kg < material level ≤ 2500kg and meets the rule of alternating use of quicklime in the quicklime configuration type; Priority 3: The material level in the furnace top hopper is 1000kg < material level ≤ 2500kg.

[0015] Further specifying that, in step S3.2, before starting the weighing and batching process, the weight of the corresponding raw materials in the raw material warehouse is checked to see if it meets the standard; When the weight of both quicklime bin 1 and quicklime bin 2 is ≥1000kg and the weight of both semi-coke bin 1 and semi-coke bin 2 is ≥the set value of the proportioning parameter, weighing and batching are started. Conversely, if any condition is not met, a material shortage alarm is triggered, the current feeding task is paused, and the corresponding raw materials are replenished to the raw material warehouse.

[0016] Furthermore, in step S3, during the automatic batching process, fixed and adjustable parameter information is collected in real time, fed back to the host computer, and stored.

[0017] A calcium carbide furnace batching system for forming the aforementioned calcium carbide furnace batching method includes a raw material preparation module, a weighing and batching module, an automatic batching module, a parameter setting module, a data acquisition module, a control module, and a host computer. Raw material preparation module: used to store quicklime and semi-coke in their respective raw material bins; Parameter setting module: used to set fixed parameters; fixed parameters include proportioning parameters, total conveyor belt feeding time, disc rotation cycle, furnace top hopper basic parameters, and furnace top hopper material selection mode; Weighing and batching module: Connected to the raw material preparation module, it is used to transport the lime and semi-coke stored in the raw material preparation module to the weighing hopper until the weight of the lime and semi-coke reaches the value set by the parameter setting module. Automatic batching module: Connected to the weighing and batching module, it is used to transport the lime and semi-coke from the weighing and batching module to the furnace top silo according to the parameters set by the parameter setting module. Data acquisition module: Connects to the raw material preparation module, weighing and batching module, automatic batching module and host computer respectively; used to transmit the data information collected in the raw material preparation module, weighing and batching module and automatic batching module to the host computer; Control module: Connected to the raw material preparation module, weighing and batching module, automatic batching module and host computer respectively; The host computer is also connected to the parameter setting module. The host computer is used to store the data information collected by the data acquisition module, compare it with the parameter setting module, and send action commands to the control module; The control module is used to control the operation of the raw material preparation module, weighing and batching module and automatic batching module according to the action commands of the host computer to complete the automatic batching.

[0018] Compared with the prior art, the beneficial effects of the present invention are: 1. The calcium carbide furnace batching method of the present invention achieves automatic batching through set batching parameters, with a raw material ratio error of ≤±0.5%, thus achieving precise batching and ensuring stable quality of calcium carbide products. This invention can greatly reduce raw material ratio errors, optimize the batching process, increase batching speed, and reduce labor intensity.

[0019] 2. The fixed parameters set in this invention include proportioning parameters, total conveyor belt feeding time, disc rotation cycle, furnace top silo basic parameters, and furnace top silo material selection mode to ensure stable operation of the batching process; at the same time, adjustable parameters are also set to optimize the batching process and increase the batching speed according to the working conditions of the calcium carbide furnace during operation, meet the raw material supply needs of continuous production of the calcium carbide furnace, reduce production waiting time, and improve production efficiency.

[0020] 3. The proportioning parameters of this invention are as follows: the baseline amount of quicklime is 1000 kg, and the weight of semi-coke is 520-570 kg; the basic parameters of the furnace top silo are: full capacity 4000 kg; low material level threshold is 2500 kg, and low-low material level threshold is 1000 kg. By precisely setting the proportions, the error is minimized, reducing raw material waste. In addition, this invention monitors the material level in the furnace top silo in real time and compares it with the batching start threshold. When the total number of silos indicating low material level is ≥3, batching is carried out in the order of "priority 1 → priority 2 → priority 3". Through the priority order of batching, the energy consumption in the calcium carbide furnace reaction process is reduced and the resource utilization rate is improved while ensuring the stable operation of the calcium carbide furnace.

[0021] 4. The automatic batching method provided by this invention realizes intelligent batching of raw materials, avoids safety risks such as dust leakage and equipment misoperation during the batching process, ensures production safety, and improves the safety and reliability of batching.

[0022] 5. The calcium carbide furnace batching system constructed in this invention includes a raw material preparation module, a weighing and batching module, an automatic batching module, a parameter setting module, a data acquisition module, a control module, and a host computer. These modules work collaboratively, reducing manual intervention and labor intensity, and enabling real-time monitoring, data traceability, and remote control of the batching process, thereby achieving intelligent management and control of the calcium carbide furnace batching. Attached Figure Description

[0023] Figure 1 A schematic diagram of the batching process for a calcium carbide furnace; Figure 2 This is a schematic diagram of the feed batching system for a calcium carbide furnace. Detailed Implementation

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present invention. Rather, they are merely examples of methods consistent with some aspects of the invention as detailed in the appended claims.

[0026] The terminology used in this invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The singular forms “a,” “the,” and “the” used in this invention and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any and all possible combinations of one or more of the associated listed items.

[0027] In the description of this invention, it should be understood that the numerical labels before the steps do not indicate the order in which the steps are performed, but are only used to facilitate the description of this application and to distinguish each step, and therefore should not be construed as a limitation of this application.

[0028] See Figure 1 The present invention provides a method for batching feed for a calcium carbide furnace, comprising the following steps: S1, Raw Material Preparation Stage The raw materials include quicklime and semi-coke, which are stored separately in raw material silos. Quicklime comes in two sizes (30-50mm and 40-70mm) and is stored in four raw material silos: quicklime silo 1, quicklime silo 2, semi-coke silo 1, and semi-coke silo 2.

[0029] Specifically, quicklime with a particle size of 30-50mm is stored in quicklime bin 1, and quicklime with a particle size of 40-70mm is stored in quicklime bin 2; semi-coke is stored in semi-coke bin 1 and semi-coke bin 2 respectively.

[0030] Preferably, four level sensors are used to monitor the raw material inventory in the four bins in real time, and the real-time data of the raw material inventory is fed back to the host computer. When the raw material inventory is lower than the preset lower limit, the system automatically issues an audible and visual alarm to remind the operator to replenish the corresponding raw material in the corresponding bin; when the raw material inventory is higher than the preset upper limit, the system stops feeding raw materials to prevent overflow.

[0031] S2, Set ingredient parameters The calcium carbide furnace has multiple top hoppers. Before batching, the corresponding batching parameters are set according to the feeding characteristics and process requirements of each top hopper of the calcium carbide furnace.

[0032] In this invention, the ingredient parameters include fixed parameters and adjustable parameters.

[0033] The fixed parameters specifically include the total conveyor belt feeding time, the disc rotation cycle, the basic parameters of the furnace top hopper, the furnace top hopper material selection mode, and the proportioning parameters, as detailed below: Total conveyor belt feeding time: 300 seconds; refers to the total time it takes for raw materials to be transported from the weighing hopper below the raw material silo to the transfer belt; The disc rotation cycle is 136 seconds; this refers to the time it takes for the annular feeder to complete one revolution. Basic parameters of the furnace top hopper: full capacity 4000kg; low material level threshold 2500kg (based on this threshold to trigger a feeding instruction); very low material level threshold 1000kg (based on this threshold to trigger an emergency feeding instruction); Furnace top silo material selection mode: The material selection mode of each furnace top silo is pre-bound and fixed with the corresponding target raw material silo.

[0034] In this invention, there are 15 furnace top hoppers on the calcium carbide furnace, which are numbered 1#, 2#, 3#, ..., 10#, 11#, 12#, 13#, 14# and 15# in sequence.

[0035] Five furnace top silos are linked to lime silo 1 and semi-coke silo 1 (i.e., line 1), five furnace top silos are linked to lime silo 2 and semi-coke silo 2 (i.e., line 2), five furnace top silos are linked to lime silo 1 and semi-coke silo 1, or lime silo 2 and semi-coke silo 2 (line 1 or line 3). Preferably, the inner corner furnace top silos prioritize conveying lime with a particle size of 30-50mm, utilizing their faster feeding speed to avoid caking on the material surface and reduce material collapse.

[0036] In practice, three of the 15 furnace top silos are on standby, with 12 actually in operation. Therefore, taking furnace top silos #1-#12 as examples, the material selection rules for the 12 silos are set as follows: Furnace top silos #1, #2, #5, #7, #11, and #12 are preferentially suited for the raw materials of lime silo #1 (30-50mm lime material) and semi-coke silo #1 (i.e., line 1); furnace top silos #3, #4, #6, #8, #9, and #10 are suited for lime silo #2 (40-70mm lime material) and semi-coke silo #2 (i.e., line 2).

[0037] Proportioning parameters: The proportioning parameters of each furnace top silo are built into the control unit, including the target feed amount of semi-coke and the proportion of quicklime type. During initialization, the parameters are automatically loaded and associated with the corresponding raw material silo and furnace top silo numbers.

[0038] Preferably, the top charge bin uses a combination of quicklime bin 1 (30-50mm quicklime) and semi-coke bin 1. When the baseline quicklime content is 1000kg, the semi-coke weight is set to 520-570kg based on the calcium carbide furnace operating conditions. The top charge bin also uses a combination of quicklime bin 2 (40-70mm quicklime) and semi-coke bin 2. When the baseline quicklime content is 1000kg, the semi-coke ratio is uniformly set to 542kg.

[0039] Initially, the proportioning parameters of each top charge hopper of the calcium carbide furnace are set according to the above proportions, and the proportioning parameter instructions are transmitted to the field control unit. After the calcium carbide furnace is running, the proportioning parameters of each top charge hopper can be adjusted in real time according to the furnace condition fluctuations.

[0040] Specifically, in the top charge bins of furnaces #1, #2, #5, #7, #11, and #12, the default standard amount of quicklime is 1000 kg, and the semi-coke ratio is set to 567 kg, 524 kg, 542 kg, 563 kg, 563 kg, and 567 kg respectively, depending on the furnace conditions. In the top charge bins of furnaces #3, #4, #6, #8, #9, and #10, the raw materials are adapted to the quicklime bin 2 (40-70 mm quicklime) and the semi-coke bin 2. The default standard amount of quicklime is 1000 kg, and the semi-coke ratio is uniformly set to 542 kg.

[0041] In this invention, the adjustable parameters include the batching start threshold, valve synchronization time difference, batching ratio benchmark value, blockage judgment time, and white lime configuration type. The specific settings for each adjustable parameter are as follows: Batching start threshold: The batching process is started when the number of furnace top silos that trigger the low material level indicator is ≥3. That is, during batching, there are 3 furnace top silos with material levels below the low material level threshold of 2500kg and above the low-low material level threshold of 1000kg. In actual batching, the specific furnace top silos that trigger the low material level indicator can be set according to the total feeding time and the energy consumption requirements of the equipment during the operation of the calcium carbide furnace, so as to avoid frequent batching start causing damage to the equipment. Preferably, the number of furnace top silos that trigger the low material level indicator is 3, 4, 5 or more.

[0042] Valve synchronization time difference: 5 seconds; refers to the time difference between the execution of action commands by each valve in the batching process. The purpose of this parameter setting is to compensate for the delay in equipment action and ensure the accuracy of valve coordinated action. It should be noted that the valve synchronization time difference parameter is adjustable. The smaller the valve synchronization time difference, the higher the action accuracy. In actual production, the valve synchronization time difference can also be 3 seconds, 4 seconds, 6 seconds or 8 seconds.

[0043] The baseline value for the ingredient ratio is 500kg, which refers to the baseline target amount of semi-coke. Before ingredient mixing, the ratio is automatically adjusted to the corresponding target value according to the set ratio parameters, and then automatically called during ingredient mixing.

[0044] Preferably, according to the set proportioning parameters, the target values ​​of semi-coke corresponding to the top charge bins of furnaces #1, #2, #5, #7, #11 and #12 are adjusted to 567kg, 524kg, 542kg, 563kg, 563kg and 567kg respectively; and the target value of semi-coke corresponding to the top charge bins of furnaces #3, #4, #6, #8, #9 and #10 is adjusted to 542kg.

[0045] Blockage detection time: The duration during which the raw material consumption rate remains at zero; at this point, the feed pipe is considered blocked. This timeframe is set according to the furnace operating conditions. Under low load conditions, where raw material consumption is slower, the time is appropriately increased; under high load conditions, where the feed rate is faster, the time is decreased. Preferably, the blockage detection time is 3000 seconds.

[0046] Lime Configuration Types: Each furnace top silo supports independent selection of lime type. Preferably, there are three lime configuration types: Type 1 (lime silo 1 silo), Type 2 (lime silo 2 silo), and Type 3 (lime silo 1 silo or lime silo 2 silo). That is, when selecting 1, it is feeding line 1; when selecting 2, it is feeding line 2; and when selecting 3, it is feeding line 1 or feeding line 2. At the same time, the lime mixing ratio parameters are automatically loaded according to the set mixing ratio parameters.

[0047] S3, Automatic Batching S3.1 Startup Initialization The system automatically resets the device status upon startup to ensure a unified and controllable initial state; specifically including: Weighing hopper status: Initial weight is set to 0kg; the unloading valve pre-installed on each weighing hopper is in the closed position; The status of the top charge bins in the calcium carbide furnace: The initial charge level of the 12 top charge bins is randomly set between 2000-3000 kg; the proportioning parameters and charge selection mode of each top charge bin are automatically loaded; at the same time, based on the low charge level threshold of the basic parameters of the top charge bins, when the charge level of the top charge bin is ≤2500 kg, the corresponding top charge bin triggers a charging instruction; simultaneously, in the display module of the control unit, the corresponding top charge bin is marked as "Charging Allowed"; Control status: The control unit is in a "ready" state; the emergency stop flag and alarm buffer are completely cleared; there are no active alarm messages.

[0048] S3.2 Weighing and Batching The material level in the furnace top silo is monitored in real time. Based on the basic parameters and material selection mode of the furnace top silo set in step S2, the quicklime and semi-coke in the raw material silo of step S1 are transported to the weighing hopper until the weight of quicklime and semi-coke reaches the ratio parameters set in step S2. S3.3, Conveying and dispensing materials According to the total conveyor feeding time and disc rotation cycle in step S2, the quicklime and semi-coke that have reached the set proportion parameters in step S2 are synchronously transported to the designated furnace top silo via the transfer conveyor belt to complete the automatic batching.

[0049] Preferably, the specific process of automatic ingredient dispensing is as follows: When it is necessary to feed materials into the furnace top silo, the first-level vibrating feeder under the corresponding raw material silo is started according to the material selection mode of the furnace top silo, and the corresponding lime and semi-coke are transported to the weighing hopper under the corresponding raw material silo. The weighing sensor on the weighing hopper collects the weight data of the corresponding raw materials in real time, compares the real-time weight data with the preset proportioning parameters, and dynamically adjusts the amplitude of the primary vibrating feeder to ensure the accurate proportioning of raw materials. When the raw material in the corresponding weighing hopper reaches the preset weight, that is, when the proportioning parameters set in step S2 are met, the corresponding primary vibrating feeder stops working; the control unit controls the start of the secondary vibrating feeder below the weighing hopper to transport the weighed raw materials (lime and semi-coke) in the weighing hopper to the transfer belt respectively; the transfer belt starts and transports the weighed raw materials to the designated calcium carbide furnace top hopper through the ring feeder.

[0050] Preferably, before weighing and batching (raw material feeding), the control unit automatically checks whether the weight of the material in the raw material bins meets the standard. Meeting the standard means that the weight of both lime bins is ≥1000kg and the weight of both semi-coke bins is ≥ the semi-coke target value of the proportioning parameters. If any of the above conditions are not met, a "material shortage alarm" is immediately triggered, suspending the current feeding task until material is replenished to the corresponding lime or semi-coke bins, and until the weight of the material in the raw material bins meets the standard and is confirmed by the host computer before weighing and batching proceeds.

[0051] During the batching process, the material level data monitored by the level sensor installed on the furnace top silo is compared with the set value of the batching parameters. When the material level data is between 1000kg and 2500kg, the furnace top silo is designated as a low-level silo, triggering a low-level indicator. When the total number of furnace top silos triggering low-level indicators is ≥3, the set batching start threshold is met, and batching proceeds in the order of "priority 1 → priority 2 → priority 3" to ensure priority replenishment of emergency silos, while also considering the efficiency of feeding and the load balance of feeding lines 1 and 2.

[0052] The feeding priority is determined based on the material level in the furnace top silo, with a very low material level alarm being the highest priority. Then, materials are added sequentially from the first low-level alarm to the next. Specifically, the priority levels are determined as follows: Priority 1 (Emergency Feeding Instruction): When the material level in the furnace top hopper is ≤1000kg, the furnace top hopper is a low-low level hopper. The low-low level hopper is a priority feeding hopper. When the calcium carbide furnace is running, if the material level monitored by the material level sensor installed on the furnace top hopper is ≤1000kg, the control unit will suspend the currently executing low-priority feeding task (i.e., priority 2 and priority 3 tasks), and automatically match the feeding according to the set proportion parameters and the corresponding furnace top hopper material selection mode to complete the feeding of the low-low level hopper.

[0053] Priority 2 (Feeding Instruction): When the material level in the furnace top silo is 1000kg < material level ≤ 2500kg, the furnace top silo is a low material level silo; and the low material level silo also meets the "alternating use rule of lime" (i.e., the lime batching type is type 3); at this time, the furnace top silo with alternating use of lime 1 and lime 2 is selected for feeding first to improve the mixing balance of raw materials; the corresponding feeding lines 1 and 2 are linked simultaneously to ensure the reasonable allocation of raw material resources; the feeding is automatically matched according to the set ratio parameters and the corresponding furnace top silo material selection mode to complete the feeding of the low material level silo.

[0054] Priority 3 (Regular Feeding): Low-level bins that do not meet the priority 2 condition, i.e., the level of the furnace top bin is 1000kg < level ≤ 2500kg; sorted according to the time the low-level indicator light is on, the earlier the indicator light is on, the higher the priority; automatically match feeding according to the set ratio parameters and the corresponding furnace top bin feeding mode to complete the feeding of the corresponding low-level bin.

[0055] The batching process also includes the following steps: real-time collection of parameter information set in step S2, such as batching time, raw material specifications, raw material usage, proportioning parameters, feeding time, target furnace top silo, and total conveyor feeding time, and feeding the collected parameter information back to the host computer and storing it.

[0056] Preferably, when the number of furnace top silos triggering the low material level indication is greater than 5, that is, there are more than 5 low material level silos, automatic feeding is initiated for batching. Specifically, based on the required batching parameters and material selection mode of the furnace top silos to be fed, the primary vibrating feeder under the corresponding raw material silo is activated to accurately convey the corresponding quicklime and semi-coke into their respective weighing hoppers; when the batching parameters are met, the weighed raw materials (quicklime and semi-coke) in the weighing hoppers are conveyed to the transfer belts respectively; the transfer belts are activated to convey the weighed raw materials to the designated calcium carbide furnace top silos via a ring feeder, thus achieving automatic batching.

[0057] It should be noted that the automatic batching method for calcium carbide furnaces provided by this invention can be either individual batching or continuous batching.

[0058] When the furnace condition of the calcium carbide furnace during production is considered, only one of the 12 furnace top hoppers is used for material preparation. At this time, the material is automatically matched and fed according to the corresponding proportion parameters and material selection mode of the furnace top hopper, and the material preparation of the furnace top hopper is completed independently.

[0059] When continuous feeding is required to the 12 top hoppers of the calcium carbide furnace based on the furnace condition during production, the control unit activates the preset continuous feeding mode. Based on the level values ​​fed back by the level sensors in each top hopper, and referring to the aforementioned proportioning parameters, top hopper material selection mode, feeding priority, and feeding method, raw materials are continuously supplied, achieving automatic feeding of the calcium carbide furnace.

[0060] The calcium carbide furnace feeding method provided by this invention further includes the following steps: When the control unit, various material level sensors, or conveying equipment malfunction, or other abnormal situations occur, operators can switch to manual mode via the on-site operating station or the host computer (located in the central control room). Operators can manually control the start and stop of each piece of equipment and the conveying of raw materials, manually completing the batching operation according to the corresponding proportion parameters and material selection mode of each furnace top hopper. Simultaneously, the control unit issues a fault alarm, and maintenance personnel can promptly troubleshoot the fault based on the alarm prompts. After the fault is resolved, the system can switch back to automatic batching mode to ensure the normal operation of the calcium carbide furnace.

[0061] In the above calcium carbide furnace batching method, the control unit refers to the DCS system, and the preferred DCS system is the Hollysys MACS M6.5 system.

[0062] See Figure 2 The present invention also provides a calcium carbide furnace batching system for forming the above-mentioned calcium carbide furnace batching method. The calcium carbide furnace batching system includes a raw material preparation module, a weighing and batching module, an automatic batching module, a parameter setting module, a data acquisition module, a control module, and a host computer; Raw material preparation module: used to store quicklime and semi-coke in their respective raw material bins; specifically, there are multiple raw material bins, used to store quicklime and semi-coke respectively; preferably, there are 4 raw material bins, namely quicklime bin 1, quicklime bin 2, semi-coke bin 1 and semi-coke bin 2, which respectively store quicklime of 30-50mm, quicklime of 40-70mm, semi-coke and semi-coke.

[0063] Parameter setting module: used to set fixed parameters; fixed parameters include proportioning parameters, total conveyor belt feeding time, disc rotation cycle, furnace top hopper basic parameters, and furnace top hopper material selection mode; Weighing and batching module: Connected to the raw material preparation module, it is used to transport the lime and semi-coke stored in the raw material preparation module to the weighing hoppers until the weight of the lime and semi-coke reaches the value set by the parameter setting module. Specifically, the weighing and batching module includes multiple primary vibrating feeders and weighing hoppers. Each raw material bin is matched with one primary vibrating feeder and one weighing hopper. The primary vibrating feeder is located between the raw material bin and the weighing hopper, and transports the raw materials stored in each raw material bin to the corresponding weighing hopper through the primary vibrating feeder.

[0064] Automatic batching module: Connected to the weighing and batching module, it is used to transport the lime and semi-coke from the weighing and batching module to the furnace top silo according to the parameters set by the parameter setting module. Specifically, the automatic batching module includes a two-stage vibrating feeder, a conveyor belt, and a ring feeder. The input end of the two-stage vibrating feeder is connected to the output end of the weighing hopper, and the output end of the two-stage vibrating feeder is connected to the furnace top silo via the conveyor belt and the ring feeder. The two-stage vibrating feeder is used to connect the weighing hopper and the conveyor belt. The conveyor belt is used to transport the batched raw materials to the furnace top silo through the ring feeder. With the assistance of the ring feeder, short-distance, closed-loop conveying is achieved to prevent dust leakage. Preferably, the secondary vibrating feeder is also connected to a variable frequency speed control motor, which adjusts the amplitude of the secondary vibrating feeder to adapt to the feeding and material intake requirements of different furnace top silos. Preferably, the conveyor belt is also connected to a drive motor, which drives the conveyor belt to work. A belt misalignment detection device, an emergency stop switch, and a material detection sensor are also installed on the conveyor belt. The belt misalignment detection device prevents the conveyor belt from running off-track, and the material detection sensor monitors the material conveying status of the conveyor belt, providing a data basis for raw material conveying. It should be noted that the belt misalignment detection device is an existing, mature detection device for the belt.

[0065] The data acquisition module connects to the raw material preparation module, weighing and batching module, automatic batching module, and host computer. It transmits data collected from these modules to the host computer. Specifically, the data acquisition module includes level sensors, weighing sensors, and material level sensors. One level sensor is installed on each raw material silo and each furnace top silo, for a total of 16 level sensors across the four raw material silos and 12 furnace top silos. Preferably, the level sensors are ultrasonic, with a measurement accuracy of ±1%. The weighing hopper is used to hold and weigh the raw materials during batching. One weighing sensor is installed on each weighing hopper and each raw material silo, for a total of 8 weighing sensors.

[0066] Control module: Connected to the raw material preparation module, weighing and batching module, automatic batching module and host computer respectively; The host computer is also connected to the parameter setting module. The host computer is used to store the data information collected by the data acquisition module, compare it with the parameter setting module, and send action commands to the control module; The control module is used to control the operation of the raw material preparation module, weighing and batching module and automatic batching module according to the action commands of the host computer to complete the automatic batching.

[0067] In the specific batching process, the host computer sends working instructions to the control module according to the set proportioning parameters, controlling the weighing and batching module and the automatic batching module to start. Weighing, batching, and conveying are performed based on the basic parameters and selection mode of the furnace top silo. Taking the No. 1 furnace top silo as an example, the baseline target mass of quicklime is 500 kg, and the target value of semi-coke is adjusted to 567 kg. The furnace top silo selection mode adopts the feeding line 1 (quicklime comes from quicklime silo 1, and semi-coke comes from semi-coke silo 1). The control module controls the primary vibrating feeders on the corresponding quicklime silo 1 and semi-coke silo 1 to open, unloading the quicklime from quicklime silo 1 into the weighing hopper below quicklime silo 1, and unloading the semi-coke from semi-coke silo 1 into the weighing hopper below semi-coke silo 1. Inside; at the same time, the weighing sensors on the two weighing hoppers monitor the weight of lime and semi-coke in real time until the weight of lime is 500 kg and the weight of semi-coke is 567 kg, then control the corresponding primary vibrating feeder to close and stop unloading; then the secondary vibrating feeder, the conveyor belt and the ring feeder are started to discharge the lime and semi-coke in the corresponding weighing hoppers onto the conveyor belt, and then the ring feeder transports the lime and semi-coke to the corresponding No. 1 furnace top silo.

[0068] During production, the material level in each furnace top silo is monitored in real time by level sensors. When the monitored level data is compared with the set value of the batching parameters, a low level indication is triggered when the level data is between 1000kg and 2500kg. If the total number of furnace top silos triggering low level indications is ≥3, the host computer sends an action command to the control module. The control module then controls the raw material preparation module, weighing and batching module, and automatic batching module according to the host computer's action command, batching materials in the order of "priority 1 → priority 2 → priority 3". The control module's control of the raw material preparation module, weighing and batching module, and automatic batching module is described above.

[0069] Specifically, the control module is connected to the weighing sensor, primary vibrating feeder, frequency converter, secondary vibrating feeder, drive motor of the conveyor belt, ring feeder, material level sensor, and host computer to meet the requirements of multi-device collaborative control and data acquisition and transmission, and ensure stable system operation. Preferably, the control module is the control unit, specifically the Hollysys MACS M6.5 system.

[0070] The parameter setting module is built into the host computer, which includes a display module, a parameter setting module, a data processing module, a storage module, and a remote control module.

[0071] The display module is a visual interface that displays the real-time operating status of each device (motor start / stop), material level in the furnace top hopper, batching progress, weighing data, and proportioning parameters. At the same time, the display module uses dynamic icons to show the operating status of the equipment (green indicates standby operation, red indicates startup, and yellow indicates malfunction), making it easy for operators to intuitively grasp the production situation.

[0072] Parameter setting module: Supports setting batching parameters via the touchscreen of the host computer (Holysys MACS V6.5 configuration software), specifically covering fixed and adjustable parameters. In actual production, the material selection mode and lime configuration type of each furnace top hopper are pre-adjusted according to the feeding characteristics of each hopper, and the adjustments are synchronized to the Hollysys DCS system to ensure batching accuracy and process continuity. Simultaneously, a field operation station is set up at the calcium carbide furnace production site. The field operation station is connected to the host computer, allowing batching parameters to be set via its touchscreen, achieving dual-end setting.

[0073] Data processing module: Analyzes the data acquired by the data acquisition module during the batching process. Specifically, it compares the real-time acquired data with the set parameters and feeds the comparison results back to the host computer. The host computer then sends action commands to the control module to control the automatic batching of the calcium carbide furnace top silo. The specific process of the host computer sending action commands to the control module to control the automatic batching of the calcium carbide furnace top silo is described in the control module's working process.

[0074] Storage module: Used to store data from the data acquisition module, as well as the operating status of equipment in the batching process. Specifically, the collected data is stored on the host computer's data server for a storage time of ≥1 year. The data stored on the host computer can be queried, statistically analyzed, and exported. In actual production, data can be queried by time, batch, raw material type, etc., and production reports (daily, weekly, and monthly reports) can be generated to provide data support for production management and process optimization.

[0075] Remote control module: Used to connect the host computer to a local area network or the Internet, enabling remote control. Operators can view the batching process in real time from the central control room or remote terminal. In case of an emergency, an emergency stop command can be issued remotely to ensure production safety.

[0076] The host computer also includes a fault alarm and diagnosis module: based on the collected data, it makes judgments. When abnormal situations such as insufficient raw materials, equipment failure (e.g., motor overload causing shutdown, sensor failure causing data loss), or excessive mixing ratio deviation occur, the host computer automatically issues an audible and visual alarm and displays the fault type, fault location, and fault time on the host computer's display module; at the same time, it outputs fault diagnosis results to assist maintenance personnel in quickly locating the cause of the fault and improving maintenance efficiency.

[0077] The batching system for the calcium carbide furnace of the present invention uses the same batching method as the batching method for the calcium carbide furnace. Automatic batching of the calcium carbide furnace can be achieved by referring to the above method, and will not be described in detail here.

[0078] The above specific embodiments are merely illustrative examples of the implementation of the technical solution of the present invention. The descriptions above are merely schematic. Modifications or substitutions made by those skilled in the art without creative effort are all within the technical concept of the present invention and fall within the protection scope of the present invention.

Claims

1. A method for batching feedstock in a calcium carbide furnace, characterized in that, Includes the following steps: S1, Raw Material Preparation Stage The raw materials include quicklime and semi-coke, which are stored separately in raw material warehouses; S2, Set ingredient parameters The batching parameters include fixed parameters; the fixed parameters include the proportioning parameters, the total conveyor feeding time, the disc rotation cycle, the basic parameters of the furnace top silo, and the furnace top silo material selection mode. S3, Automatic Batching S3.1 Initialization When automatic batching starts, the equipment status is automatically reset; S3.2 Weighing and Batching The material level in the furnace top silo is monitored in real time. Based on the basic parameters and material selection mode of the furnace top silo set in step S2, the quicklime and semi-coke in the raw material silo of step S1 are transported to the weighing hopper until the weight of quicklime and semi-coke reaches the ratio parameters set in step S2. S3.3, Conveying and dispensing materials According to the total conveyor feeding time and disc rotation cycle in step S2, the quicklime and semi-coke that have reached the set proportion parameters in step S2 are synchronously transported to the designated furnace top silo via the transfer conveyor belt to complete the automatic batching.

2. The method for batching feed for a calcium carbide furnace according to claim 1, characterized in that, In step S1, the raw material silos include lime silo 1, lime silo 2, semi-coke silo 1 and semi-coke silo 2; lime material with a particle size of 30mm-50mm is stored in lime silo 1, and lime material with a particle size of 40mm-70mm is stored in lime silo 2; semi-coke is stored in semi-coke silo 1 and semi-coke silo 2 respectively.

3. The method for batching feed for a calcium carbide furnace according to claim 1, characterized in that, In step S2 The mixing parameters are as follows: the standard amount of quicklime is 1000 kg, and the weight of semi-coke is 520-570 kg; The total conveyor belt feeding time is 300 seconds; the disc rotation cycle is 136 seconds. Basic parameters of the furnace top silo: full capacity 4000kg; low material level threshold is 2500kg, and low-low material level threshold is 1000kg; Furnace top hopper material selection mode: pre-bound, fixed material selection with the corresponding target raw material hopper; including line 1, line 2 and line 3.

4. The method for batching feed for a calcium carbide furnace according to claim 1, characterized in that, In step S2, the batching parameters also include adjustable parameters; the adjustable parameters include batching start threshold, valve synchronization time difference, batching ratio benchmark value, blockage judgment time, and lime configuration type.

5. The method for batching feed for a calcium carbide furnace according to claim 1, characterized in that, In step S3.1, the equipment status reset includes weighing status reset and hopper status reset; The weighing hopper status is reset to: initial weight of 0kg, and the unloading valve pre-installed on each weighing hopper is in the closed state; Reset the status of the furnace top hopper: The initial material level of the furnace top hopper is set at 2000-3000kg; the proportioning parameters of each furnace top hopper and the material selection mode of the furnace top hopper are automatically loaded; when the material level of the furnace top hopper is ≤2500kg, the corresponding furnace top hopper triggers the feeding instruction and allows feeding.

6. The method for batching feed for a calcium carbide furnace according to claim 4, characterized in that, In step S3.2, the material level of the furnace top silo is monitored in real time and compared with the batching start threshold. When the total number of silos with low material level indication is ≥3, batching is carried out in the order of "priority 1 → priority 2 → priority 3".

7. The method for batching feed for a calcium carbide furnace according to claim 6, characterized in that, Priority 1 is when the material level in the furnace top hopper is ≤1000kg; Priority 2 is when the material level in the furnace top hopper is 1000kg < material level ≤ 2500kg and meets the rule of alternating use of quicklime in the quicklime configuration type; Priority 3: The material level in the furnace top hopper is 1000kg < material level ≤ 2500kg.

8. The method for batching feed for a calcium carbide furnace according to claim 2, characterized in that, In step S3.2, before starting the weighing and batching process, check whether the weight of the corresponding raw materials in the raw material warehouse meets the standard. When the weight of both quicklime bin 1 and quicklime bin 2 is ≥1000kg and the weight of both semi-coke bin 1 and semi-coke bin 2 is ≥the set value of the proportioning parameter, weighing and batching are started. Conversely, if any condition is not met, a material shortage alarm is triggered, the current feeding task is paused, and the corresponding raw materials are replenished to the raw material warehouse.

9. The method for batching feed for a calcium carbide furnace according to claim 4, characterized in that, In step S3, during the automatic batching process, fixed and adjustable parameter information is collected in real time, fed back to the host computer, and stored.

10. A calcium carbide furnace batching system for forming the calcium carbide furnace batching method of claim 1, characterized in that, It includes a raw material preparation module, a weighing and batching module, an automatic batching module, a parameter setting module, a data acquisition module, a control module, and a host computer; Raw material preparation module: used to store quicklime and semi-coke in their respective raw material bins; Parameter setting module: used to set fixed parameters; fixed parameters include proportioning parameters, total conveyor belt feeding time, disc rotation cycle, furnace top hopper basic parameters, and furnace top hopper material selection mode; Weighing and batching module: Connected to the raw material preparation module, it is used to transport the lime and semi-coke stored in the raw material preparation module to the weighing hopper until the weight of the lime and semi-coke reaches the value set by the parameter setting module. Automatic batching module: Connected to the weighing and batching module, it is used to transport the lime and semi-coke from the weighing and batching module to the furnace top silo according to the parameters set by the parameter setting module. Data acquisition module: Connects to the raw material preparation module, weighing and batching module, automatic batching module and host computer respectively; used to transmit the data information collected in the raw material preparation module, weighing and batching module and automatic batching module to the host computer; Control module: Connected to the raw material preparation module, weighing and batching module, automatic batching module and host computer respectively; The host computer is also connected to the parameter setting module. The host computer is used to store the data information collected by the data acquisition module, compare it with the parameter setting module, and send action commands to the control module; The control module is used to control the operation of the raw material preparation module, weighing and batching module and automatic batching module according to the action commands of the host computer to complete the automatic batching.

Images