Full-automatic production process combining electric melting with magnesite-chrome brick product salting

Abstract

The invention belongs to the technical field of refractory material manufacturing, and particularly relates to a full-automatic production process combining electric melting with magnesite-chrome brick product salting, which comprises the steps of parameter initialization, salt liquid state intelligent closed-loop maintenance, self-adaptive dipping, leachate recovery, discharging, data archiving and the like. The method is characterized in that the concentration and temperature of a salt solution are dynamically adjusted through real-time sensing data, and the optimal dipping time is calculated based on brick body characteristics and real-time working condition modeling; the equipment comprises a mechanical main body, a salt liquid regulation and control system, a multi-parameter sensing system and an intelligent control cabinet, and the whole-process automation, precision and datamation of the salt leaching process are realized. The mode that a traditional salt leaching process depends on artificial experience and is extensive in control is thoroughly changed, product quality consistency, production efficiency and traceability are remarkably improved, energy consumption and labor intensity are reduced, and the method is an effective solution for intelligent upgrading of the refractory material industry.

Description

Technical Field

[0001] This invention relates to the field of refractory material manufacturing technology, and in particular to a fully automated production process for salt impregnation of electrofused and rebonded magnesia-chrome brick products. Background Technology

[0002] Electrofused magnesia-chrome bricks are widely used in high-temperature industrial kilns such as cement rotary kilns and glass melting furnaces due to their excellent high-temperature performance and erosion resistance. To further enhance their resistance to alkali erosion, a salt impregnation process is usually adopted, which involves impregnating the surface of the brick with a solution containing salts such as NaCl, allowing the salt to penetrate into the interior of the brick and form a protective layer at high temperatures.

[0003] Current traditional salt leaching processes rely heavily on manual labor or semi-automated equipment, which has many drawbacks: Salt concentration control relies on manual experience. The concentration gradually decreases due to evaporation and carryover. Manually checking and replenishing salt at regular intervals leads to large fluctuations in concentration, affecting the consistency of immersion results. The salt immersion time and temperature are not precisely controlled. The immersion time is determined by the operator's experience, and the salt solution temperature is unstable, which affects the salt penetration rate and depth. The salt leaching process lacks real-time monitoring and feedback, making it impossible to obtain key parameters such as salt concentration, temperature, and liquid level in real time, and making it difficult to achieve data-driven adaptive process adjustment. The lack of production process data, including the absence of records and traceability of parameters in the salt leaching process, hinders product quality analysis and process optimization. The process is labor-intensive and inefficient, with manual salt addition, stirring, testing, and recording requiring a large amount of manpower and prone to operational errors.

[0004] Therefore, there is an urgent need to develop a fully automated and intelligent salt leaching process and equipment for magnesia-chrome bricks to improve product consistency, reduce labor intensity, and achieve data-driven production management. Summary of the Invention

[0005] Based on the technical problems existing in the prior art, this invention proposes a fully automated production process for salt immersion of electrofused and rebonded magnesia-chrome brick products.

[0006] This invention proposes a fully automated salt leaching process for electrofused and bonded magnesia-chrome brick products. This process is a dynamic optimization process based on real-time data feedback and model calculation, and is executed in the following order: 1. Parameter initialization and brick loading (S1): The production task parameters for the current batch are input via a Human-Machine Interface (HMI) or received from the Manufacturing Execution System (MES), including the target brine concentration C0, target brine temperature T0, target liquid level H0, and brick type code (associated with porosity P and geometric dimensions). The magnesia-chrome bricks to be salted are vertically loaded onto a dedicated brick rack at preset intervals, ensuring sufficient gaps between the bricks for brine flow. The loaded brick racks are automatically transported by roller conveyors or chain conveyors to a preparatory station directly above the salt leaching tank.

[0007] 2. Preconditioning and Closed-Loop Maintenance of Salt Solution State (S2): Intelligent closed-loop control of the brine state is implemented before the brick frame is lowered for immersion and throughout the entire production cycle: Concentration closed-loop control: The concentration sensor in the salt leaching tank continuously monitors the actual concentration C of the salt solution. The concentration control subroutine in the control module compares C with C0. When C is continuously lower than the set threshold (C0-ΔC1, where ΔC1 is the adjustable dead zone), it is determined that salt needs to be added. The control module calculates the precise amount of salt to be added according to the formula "salt addition amount m=ρ×V×(C0-C) / (η×(1-C))" (where ρ is the estimated value of the current salt solution density, which can be obtained through the concentration-temperature relationship model; V is the effective volume of the salt leaching tank; and η is the purity coefficient of industrial salt). After calculation, the screw conveyor of the salt addition device is automatically started to transport a quantitative amount of salt from the sealed salt silo to the discharge port in the tank. After salt addition is completed, the stirring mechanism is automatically started to run for a preset time t1 (e.g., 3-5 minutes) to ensure that the salt particles are fully dissolved. Then, it is allowed to stand for t2 time (e.g., 2 minutes) until the liquid flow is stable, and the concentration value C' is read again for verification. If it does not meet the standard, a second fine-tuning salt addition cycle is started. Meanwhile, the system has an over-concentration warning. When C>C0+ΔC2, it can prompt or automatically start the dilution program (replenishing deionized water).

[0008] To ensure the reliability of concentration closed-loop control, the system employs a feedforward + feedback composite control strategy. After calculating and executing the salt replenishment amount *m*, if the concentration still fails to reach the target window within the set maximum adjustment period, the system will determine this as an adjustment anomaly, automatically suspend subsequent feeding, and display an alarm message on the HMI stating "Concentration adjustment timed out, please check the salt replenishment device or sensor," while simultaneously recording the abnormal event. In the event of a concentration sensor malfunction or drastic fluctuations in reading, the control module automatically switches to a timed salt replenishment mode, estimating the salt replenishment amount based on historical batch data to maintain production until the fault is resolved, thus preventing production line downtime.

[0009] Temperature closed-loop control: The temperature sensor continuously monitors the temperature T of the brine. The control module uses the proportional-integral-derivative (PID) algorithm to compare T with T0 and outputs a control signal to the temperature control device. When T < T0 - ΔT, the immersion electric heating rod is started for heating; when T > T0 + ΔT, the cooling coil circulation system (which can be connected to a cooling water tower or a chiller) is started for cooling. Through PID parameter tuning, the temperature is accurately fluctuated within the range of T0 ± 0.5°C.

[0010] Liquid level closed-loop control: The ultrasonic liquid level gauge continuously monitors the liquid level height H of the brine. The control module compares H with H0. Since the immersion of the brick body will displace the liquid and cause the liquid level to rise, the system only detects the liquid level after the brick rack is completely lifted out of the liquid surface and the static drainage is completed. If H < H0 - ΔH (considering normal evaporation loss), the deionized water supply valve is automatically opened for water replenishment until the set liquid level is reached. During water replenishment, a short-term stirring can be联动 started to ensure uniformity.

[0011] 3. Adaptive impregnation process (S3): When the brine concentration C and temperature T are stable within the target range and the brick rack is in place, the impregnation program is started. The brick rack lifting mechanism descends at a constant low speed v (such as 0.05 - 0.1 m / s) to make the brick body smoothly and completely immersed in the brine. The impregnation time t is calculated in real time by the process adaptive model in the control module. The core calculation model is: t = K × [ln(P / (α × C × T)) + β]; t: The recommended impregnation time (seconds) of the bricks in this batch under the current working conditions; P: The average open porosity (%) of the bricks in this batch, from the brick type database or the input value of online detection; C: The measured brine concentration (%) at the start of impregnation; T: The measured brine temperature (°C or K, the unit of measurement needs to be unified) at the start of impregnation; α: The concentration-temperature coupling coefficient, used to correct the combined influence of concentration and temperature on the salt diffusion rate, calibrated through previous process experiments; <​​​​​​​​​​After the calculated immersion time t is reached, the brick frame lifting mechanism smoothly lifts the brick frame out of the liquid surface at a low speed v' (usually slightly lower than the descent speed to reduce disturbance), suspending it in the draining area above the tank. The draining time t_drip is set according to the brick's pore structure, brine viscosity, and ambient temperature, or automatically determined by monitoring the drip rate. The drained brine flows directly back into the immersion tank, reducing salt consumption and contamination.

[0014] 5. Material Discharge and Data Archiving (S5): After the leaching process is complete, the conveying mechanism moves the brick rack carrying the impregnated bricks out of the salt immersion tank and transfers it to the drying area. The data storage unit within the control module synchronously records key data throughout the impregnation process, forming a complete production record. This record includes batch number, brick type, start / end time, concentration curve (sampling point data), temperature curve, liquid level changes, actual salt replenishment amount and time points, impregnation time t and model parameters used for calculation, actual execution time, and operator information. This data is stored in a structured format (such as SQL database records or CSV files) and can be queried, exported, or uploaded to the factory-level management system via a human-machine interface, enabling full quality traceability.

[0015] 6. Equipment self-cleaning and maintenance tips (S6): After each set batch is completed (e.g., every 10 batches) or at the end of each day's production, the system can execute a self-cleaning procedure: draining some of the old liquid, starting a high-pressure spray to clean the inner wall of the salt immersion tank and the sensor probe to prevent salt crystallization. At the same time, the system accumulates the operating time of key components (such as the circulating pump, heating rod, and stirring motor), and issues a preventative maintenance alarm before the preset maintenance cycle is reached.

[0016] Salt leaching equipment mainly includes the following parts: 1. Mechanical structural unit Salt immersion tank: A tubular tank welded from corrosion-resistant materials, with a capacity designed according to production capacity. Vertical guide rails are installed on both sides of the inner wall of the tank to guide the brick frame to rise and fall smoothly; the bottom of the tank is designed with a slight slope towards the drain valve to facilitate thorough emptying and cleaning; the outside of the tank is covered with an insulation layer to reduce heat loss.

[0017] Brick Frame and Conveying Mechanism: The brick frame is a high-strength stainless steel frame structure with multiple grids to support the bricks. The conveying mechanism includes roller conveyors for feeding and discharging materials and a lifting mechanism located directly above the salt immersion tank. The lifting mechanism consists of a servo motor (or frequency converter motor) with a reducer, a wire rope drum (or synchronous belt / sprocket), a high-precision encoder, and a hook. The encoder is used to provide real-time feedback on the position of the brick frame, enabling precise control of the lifting speed and position.

[0018] Salt replenishment device: Located on one side or above the salt immersion tank, it includes a sealed salt tank (with a level gauge), a shaftless screw conveyor, a drive motor and frequency converter, and a discharge pipe extending into the tank. The outlet of the discharge pipe is located below the liquid surface, which can reduce dust.

[0019] Stirring mechanism: Installed at the bottom of the salt immersion tank, it adopts a top-mounted explosion-proof motor to drive a long shaft, with multiple stirring blades installed on the shaft to ensure that the salt solution at the bottom and corners of the tank is fully mixed, preventing uneven local concentration or salt deposition.

[0020] Temperature control device: includes immersion flange electric heating rods evenly arranged on the sidewalls or bottom of the tank, titanium alloy cooling coils located in the heat exchange area inside the tank, an external circulation pump connected to the cooling coils, and a plate heat exchanger (or cooling tower). Thermocouples (temperature sensors) are directly inserted into the brine, close to the heating / cooling elements, to improve the temperature control response speed.

[0021] Water replenishment / drainage system: including deionized water pipeline, solenoid valve, flow meter (for precise water replenishment) and pneumatic / electric drain valve at the bottom of the tank.

[0022] 2. Sensing and Detection Unit Concentration sensor: An online conductivity sensor is used. The probe is vertically installed via a flange on the upper part of the side wall of the brine tank, below the lowest working liquid level and away from the direct scouring area of ​​the stirring blades, avoiding interference from bubbles and turbulence. The sensor has an automatic temperature compensation function and outputs a 4-20mA standard signal corresponding to the 0-saturation concentration range.

[0023] To further improve measurement reliability in environments prone to brine crystallization, the concentration sensor employs an inductive conductivity sensor with an automatic cleaning function (such as the E+H Indumax CLS50), with a Teflon anti-stick coating applied to the sensor probe surface. To overcome the impact of brine crystallization on measurements, the PLC control program is set to initiate an automatic probe cleaning program every 2 hours (using compressed air or high-pressure water rinsing). During cleaning, the measured value remains the previous value, and the sensor is only used in control calculations after cleaning and the reading has stabilized. The concentration sensor is mounted via a flange inside a flow guide tube on the side wall of the brine tank. The flow guide tube ensures that the liquid flowing through the probe is representative and has a stable flow rate, avoiding interference from air bubbles.

[0024] Temperature sensor: A PT100 platinum resistance thermometer is used, which is installed at different locations in the tank (at least two points, and the average value is taken) via threads or flanges, penetrating deep into the brine solution.

[0025] Liquid level sensor: A non-contact ultrasonic liquid level gauge is used, which is installed in the center of the tank top cover to continuously measure the distance from the liquid surface to the probe. It can also be supplemented with an immersion hydrostatic level gauge for redundant calibration.

[0026] Position sensor: The encoder of the lifting mechanism is used to detect the height of the brick frame.

[0027] Other sensors include: low salt level alarm sensor, motor running current detection module (for fault early warning), and pipeline pressure sensor.

[0028] 3. Intelligent control unit (control cabinet): Core controller: An industrial programmable logic controller (PLC, such as Siemens S7-1500 series or equivalent) is used to perform all logic control, sequential control, PID calculation and communication tasks.

[0029] Data processing and storage module: It can be used for the data logging function built into the PLC, or connected to an industrial computer (IPC) to run process adaptive model algorithms, store massive amounts of process data, and generate production reports.

[0030] Human-Machine Interface: A high-performance touchscreen (HMI) is used to display an overview of the equipment, real-time process parameter curves (concentration, temperature, level, position), alarm list, and production record query interface. It also provides functions such as parameter setting, manual / automatic mode switching, and single-step operation.

[0031] Communication module: Supports industrial Ethernet (Profinet, Ethernet / IP), OPCUA and other protocols to achieve data interaction with the factory's MES / ERP system, receive production orders, and upload production results and equipment status.

[0032] Input / output modules: Digital input / output (DI / DO) modules are used to receive signals from buttons and limit switches and to control relays and indicator lights; analog input / output (AI / AO) modules are used to connect analog signals from various sensors and actuators.

[0033] Compared with the prior art, the present invention provides a fully automated production process for salt leaching of electrofused and rebonded magnesia-chrome brick products, which has the following beneficial effects: By controlling the concentration and temperature in real time through closed-loop control, the fluctuation of process parameters is kept within an extremely narrow range. Combined with an adaptive impregnation time model, this ensures that each brick can be impregnated under optimal conditions, greatly improving the consistency and reliability of product performance.

[0034] From feeding to discharging, from parameter adjustment to process monitoring, the entire process requires no manual intervention. Intelligent models replace human experience-based decision-making, reducing operational difficulty and reliance on skilled workers.

[0035] Detailed process data records establish electronic files for each batch of products. In the event of a quality problem, the cause can be quickly and accurately located, providing a solid data foundation for process optimization and quality improvement.

[0036] Precise salt replenishment and temperature control prevent waste of raw materials and energy; automation reduces labor costs and improves equipment utilization; preventative maintenance tips reduce the risk of unexpected downtime. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the internal structure of the salt immersion tank of the present invention; Figure 3 This is a hardware and network topology block diagram of the device control system of the present invention.

[0038] In the diagram: 1. Salt immersion tank; 2. Brick frame; 3. Sealed salt silo; 4. Top-mounted stirring motor; 5. Stirring blades; 6. Immersion electric heating rod; 7. Cooling coil; 8. Pneumatic drain valve; 9. Guide rail. Detailed Implementation

[0039] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0040] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0041] Example 1: Taking an intelligent salt leaching system that processes 100 standard magnesia-chrome bricks (230mm × 114mm × 65mm) in a single batch as an example, the working process is as follows: System Start-up and Preparation (S1): The operator selects "Automatic Production Mode" on the HMI, enters or scans the code to enter batch information, and the system retrieves the default process parameters from the database: target concentration C0=22% (weight percentage), target temperature T0=45℃, target liquid level H0=1600mm (tank depth 1800mm). After the operator confirms, the system starts.

[0042] Brine Conditioning (S2): The PLC reads the current sensor values: concentration C = 20.5% (low), temperature T = 42℃ (low), liquid level H = 1580mm (normal range). Assuming ΔC1 = 0.5%, C0 - ΔC1 ​​= 21.5%, and the current C < 21.5%, salt replenishment is performed. The system estimates ρ ≈ 1.15 g / cm³ (based on a 20.5% concentration), V = 5 m³, η = 0.985, and substitutes these values ​​into the formula to calculate the salt replenishment amount m ≈ 112 kg. The PLC controls the screw conveyor to run at a speed of 50 kg / min for approximately 2.24 minutes. After salt replenishment, the top-mounted stirring motor 4 is started and runs for 4 minutes. After standing for 2 minutes, the new concentration C' = 21.8% (meets the standard) is read, and the concentration control cycle is paused. The temperature control PID program runs synchronously, and after approximately 15 minutes, T stabilizes at 45.0 ± 0.3℃; no water replenishment is required.

[0043] Adaptive Impregnation (S3): Bricks on brick rack 2 are transported by the conveyor line to the preparatory position above salt impregnation tank 1. The PLC confirms that the salt concentration C=21.8% and the temperature T=45.2℃ (within the allowable process window) and calls the adaptive process model to calculate the optimal impregnation time. The core expression of the model is t=K×ln((Φ×C×T) / P) (where Φ is the diffusion efficiency factor and K is the time proportionality coefficient, both of which have been calibrated in advance). Substituting the data (P=18.5%, C=21.8%, T=318.35K, Φ=1.05, K=1550), the calculated t≈9263 seconds (approximately 154.4 minutes). Subsequently, the lifting mechanism drives brick rack 2 to descend smoothly at a speed of 0.08m / s, so that the magnesia-chrome bricks are completely immersed in the salt solution. The PLC starts the impregnation timer and monitors the salt solution parameters C and T throughout the process.

[0044] Process Monitoring and Completion: During the impregnation process, the PLC continuously monitors concentration (C) and temperature (T) to ensure they remain within allowable ranges (C: 22±1%, T: 45±1℃). If drift occurs, the fine-tuning control thread intervenes. System records show that throughout the entire 154-minute impregnation cycle, the standard deviation of concentration fluctuation was less than 0.3%, and the standard deviation of temperature fluctuation was less than 0.2℃, demonstrating that the closed-loop control system possesses good dynamic stability and anti-interference capabilities. After the designated time, the lifting mechanism raises brick rack 2 to the draining level at a speed of 0.05 m / s, and draining continues for 10 minutes.

[0045] Data recording and archiving (S5): All data is recorded completely, including timestamps, batch numbers, sensor readings, salt replenishment events, calculated and actual immersion times, lifting speeds, etc. The data is automatically stored and the curves can be viewed on the HMI.

[0046] Example 2, Troubleshooting and Maintenance Tips: Preventive maintenance reminder: After several batches of continuous production, the system data storage unit displays that the cumulative running time of the circulating pump has reached the preset maintenance cycle (e.g., 2000 hours). The HMI will pop up an alarm message "Preventive maintenance: Check the cooling circulating pump" to remind maintenance personnel to arrange maintenance.

[0047] Sensor Fault Handling: During the production of a certain batch, the concentration sensor reading fluctuated violently before returning to zero. The PLC diagnostic program determined that the sensor was faulty and immediately triggered a high-level alarm for "concentration sensor fault". The automatic production process was paused and switched to safety mode (heating was stopped, and manual lifting of brick rack 2 was allowed). At the same time, the HMI displayed fault diagnosis help information to guide maintenance personnel to check the sensor wiring and probe.

[0048] Example of control logic depth (concentration control subroutine), which executes every 30 seconds, with the following flow: Data acquisition and filtering: Read the concentration sensor AI value and obtain the current effective concentration value C_now through digital filtering; Status assessment: Check whether the equipment is in "automatic operation" or "ready" status and is not in the settling period after salt replenishment; Deviation calculation: Calculate Δ = C0 - C_now; Dead zone detection: If |Δ|≤ΔC1 (e.g., 0.5%), it is considered unbiased, and the current loop is terminated; Low concentration treatment: If Δ > ΔC1, proceed with salt replenishment logic: a. Check the salt silo level; if the level is low, trigger an alarm and exit the system. b. Calculate the salt replenishment amount m_batch, set the maximum salt replenishment amount per batch m_max, and if m_batch>m_max, then execute according to m_max; c. Start the screw conveyor and calculate the running time based on the conveying capacity; d. Log the salt replenishment event in the HMI; e. After salt replenishment is complete, start the top-mounted stirring motor 4 and run T_mix (e.g., 240 seconds); f. Set the "wait after salt replenishment" flag and start the delay timer T_wait (e.g., 180 seconds), during which the concentration control judgment is paused; High concentration warning: If Δ < -ΔC2 (e.g., 1%), a "concentration too high" warning will be issued. Manual inspection or initiation of a dilution procedure is recommended (this must be confirmed before execution). Results verification: After the waiting period, the "wait after salt replenishment" flag is cleared, and the new concentration value is read in the next control cycle to verify the control effect.

[0049] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A fully automated production process for salt impregnation of electrofused and rebonded magnesia-chrome brick products, characterized in that, Based on the use of salt leaching equipment, the following steps are included: S1: Parameter initialization and brick loading: Set the target process parameters and load the magnesia-chrome bricks onto the brick rack (2) and transport them to the salt immersion station; S2: Intelligent closed-loop maintenance of brine state: The brine state in the immersion tank (1) is monitored in real time by concentration sensor, temperature sensor and liquid level sensor. The control module automatically controls the salt replenishment device, temperature control device and water replenishment valve according to the deviation between the monitoring data and the target value, so that the brine concentration, temperature and liquid level are stable within the preset range. S3: Adaptive impregnation: Control the brick frame (2) to descend so that the brick body is immersed in the salt solution. The impregnation time t is dynamically calculated by the control module based on the brick body porosity P, real-time salt solution concentration C and temperature T through a preset process adaptive model, and the impregnation is performed according to this time. S4: Drainage and recycling: After impregnation, lift the brick rack (2) and drain the liquid. The liquid is returned to the salt immersion tank (1). S5: Material discharge and data archiving: Remove the brick rack (2), and the control module records and stores all key process data of this impregnation process to form a traceable production batch report.

2. The fully automated salt leaching process for electrofused rebonded magnesia-chrome brick products according to claim 1, characterized in that, The concentration closed-loop control in step S2 includes: when the monitored concentration C is lower than the target concentration C0 by a certain threshold, the control module calculates the required amount of salt to be added according to the formula m=ρ×V×(C0-C) / (η×(1-C)), drives the salt replenishment device to add salt precisely, and then starts the stirring and settling program and verifies the concentration after salt replenishment.

3. The fully automated salt immersion production process for electrofused rebonded magnesia-chrome brick products according to claim 1, characterized in that, The process adaptive model in step S3 is t=F(P,C,T,α,β,K), where the function F contains logarithmic operations, and α,β,K are model parameters calibrated through process experiments.

4. The fully automated salt leaching process for electrofused reconstituted magnesia-chrome brick products according to claim 1, characterized in that, The key process data recorded in step S5 includes at least the time series of salt concentration values, temperature values, liquid level values, time and weight of salt replenishment events, calculated and actual immersion time, and brick type information. The data is stored in a structured format and supports querying and exporting.

5. The fully automated salt leaching process for electrofused rebonded magnesia-chrome brick products according to any one of claims 1-4, characterized in that, The salt leaching equipment includes: Salt soaking tank (1), brick frame (2) for supporting bricks, lifting mechanism and conveyor line for raising and lowering brick frame (2); The brine state control system includes a salt replenishment device for adding salt, a stirring mechanism for mixing the brine, a temperature control device for adjusting the brine temperature, and a water replenishment / drainage system for maintaining the liquid level. The multi-parameter sensing system includes a concentration sensor for real-time monitoring of brine concentration, a temperature sensor for monitoring brine temperature, a liquid level sensor for monitoring liquid level height, and a position sensor for monitoring the position of the brick rack (2). The intelligent control cabinet contains a PLC, a human-machine interface, and a data storage unit; the PLC is electrically connected to all sensors and actuators, and is configured to execute the fully automated production process steps as described in any one of claims 1-4, and realize closed-loop control of each parameter and adaptive process calculation.

6. The fully automated salt immersion production process for electrofused reconstituted magnesia-chrome brick products according to claim 5, characterized in that, The concentration sensor is an online conductivity sensor with temperature compensation, which is installed on the side wall of the salt immersion tank (1) through a flange. The probe extends below the liquid surface and avoids the area directly disturbed by stirring. The salt replenishment device includes a sealed salt tank (3) and a shaftless screw conveyor, with the discharge port extending below the liquid surface.

7. The fully automated salt leaching process for electrofused rebonded magnesia-chrome brick products according to claim 5, characterized in that, The PLC is further configured to execute multiple parallel control subroutines, including concentration control, temperature control, liquid level control, lifting control, and fault diagnosis; among which the concentration control subroutine adopts a feedforward-feedback composite control strategy based on deviation and model calculation of salt replenishment amount.

8. The fully automated salt leaching process for electrofused reconstituted magnesia-chrome brick products according to claim 5, characterized in that, The human-machine interface provides a process parameter setting interface, a real-time data display and curve trend interface, a historical data query and report generation interface, a manual operation interface for the equipment, and an alarm and event log interface.

9. The fully automated salt leaching process for electrofused reconstituted magnesia-chrome brick products according to claim 5, characterized in that, The salt leaching equipment also includes a preventive maintenance management module, which issues an early warning message before the preset maintenance threshold is reached based on the cumulative operating time of key components recorded in the data storage unit.

10. The fully automated salt leaching process for electrofused reconstituted magnesia-chrome brick products according to claim 5, characterized in that, The salt immersion tank (1) has an anti-corrosion coating on its inner wall and an insulation layer on its outer side; the tank is equipped with a guide rail for the guide brick frame (2); and the equipment is equipped with an emergency stop device and an audible and visual alarm around its perimeter.

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