Copper electrolyte composition and volume online control method and device

Abstract

The invention provides a copper electrolyte composition and volume online control method and device, and relates to the technical field of metallurgical engineering. The method comprises the following steps: acquiring ion concentration data of the electrolyte and current volume data of the electrolyte; calculating to obtain a return liquid adjusting amount and calculating to obtain a water supplementing amount; a pneumatic control valve opening degree control instruction is generated and output; the deviation between the real-time flow data and the return liquid adjusting amount or the water supplementing amount is calculated; and judging whether the deviation is within a preset allowable range, and if so, correcting until the deviation is within the allowable range. The regulating quantity is automatically calculated through a data model, the valve is driven to act, closed-loop control is established in combination with a flow feedback and deviation correction mechanism, and online precise regulation and control of electrolyte components and volume are achieved; according to the mode, the hysteresis and errors of manual operation are effectively overcome, the dynamic balance of the system is maintained, the product quality is guaranteed, and meanwhile, the field operation intensity and the safety risk are remarkably reduced.

Description

Technical Field

[0001] This application relates to the field of metallurgical engineering technology, and in particular to a method and apparatus for online control of the composition and volume of copper electrolyte. Background Technology

[0002] Copper electrolytic refining is a core process in hydrometallurgical industry, its main purpose being to purify copper metal through electrochemical reactions. During electrolysis, because the current efficiency of the cathode is typically lower than that of the anode, the rate of copper deposition at the cathode is less than the rate of copper dissolution at the anode, leading to a continuous increase in the copper ion concentration in the electrolyte. To maintain the electrolyte composition within the allowable range, periodic copper removal treatment is necessary. Furthermore, during the dissolution of the anode plate, various impurity ions gradually accumulate in the electrolyte, and to ensure electrolytic efficiency, the electrolyte must be maintained at a specific high-temperature environment, resulting in continuous water evaporation and thus constant fluctuations in electrolyte volume. Therefore, maintaining a dynamic balance between electrolyte composition and volume is crucial for ensuring smooth production.

[0003] Currently, most companies in the industry still employ a relatively traditional semi-manual management model to control fluctuations in electrolyte composition and volume changes. The typical operating procedure involves manually taking samples from the electrolytic cell periodically, sending them to a laboratory for composition analysis, and then manually adjusting the backflow valve or water replenishment valve based on the data feedback to maintain relative stability of the electrolyte within the system. This method relies heavily on manual experience and timed physical operations to cope with continuously changing production environments.

[0004] However, this traditional control method has significant limitations. The main problem lies in the severe lag between detection and adjustment. On the one hand, the testing equipment needs to process a large number of samples, resulting in a long data output cycle; on the other hand, there is a time lag between data reporting and manual valve adjustment. This "double lag" means that the adjustment action often cannot correspond to the actual state of the electrolyte in real time. When the electrolyte composition or volume fluctuates and is not corrected in time, it can easily lead to a deterioration of electrolysis conditions, which in turn affects the crystallization quality of the cathode copper, causing physical defects such as particles and streaks on the product surface, directly reducing the first-pass yield of Grade A copper.

[0005] Furthermore, the existing operating model also brings high labor costs and safety risks. To maintain stable production, operators need to frequently enter and exit the workshop to switch valves, handle short circuits in the tank surface, and clean up substandard electrode plates such as "particle plates" caused by uneven growth. This involves high labor intensity and long-term exposure to the working environment, increasing safety hazards. At the same time, due to the inability to achieve precise control, the resistance and voltage within the system are prone to fluctuations, leading to increased power consumption and reduced current efficiency, which is detrimental to the company's cost control and refined management. Summary of the Invention

[0006] In a first aspect, the present invention provides a method for online control of the composition and volume of a copper electrolyte, comprising: Obtain the ion concentration data and current volume data of the electrolyte; The ion concentration data is input into a preset ion concentration calculation model to calculate the amount of liquid to be returned. The current volume data of the electrolyte is input into a preset volume calculation model, and the amount of water to be replenished is calculated in combination with the preset water evaporation rate. Based on the backflow liquid adjustment amount and the water replenishment amount, corresponding pneumatic regulating valve opening control commands are generated and output; Collect real-time flow data fed back by the flow meter, and calculate the deviation between the real-time flow data and the backflow liquid adjustment amount or the water replenishment amount; Determine whether the deviation is within a preset allowable range. If it exceeds the preset allowable range, generate a corrected pneumatic regulating valve opening control command based on the deviation until the deviation is within the preset allowable range.

[0007] In an optional implementation, the step of inputting the ion concentration data into a preset ion concentration calculation model to calculate the backflow liquid adjustment amount includes: The theoretical yield of cathode copper is calculated based on current density, electrochemical equivalent, and electrolysis time. Calculate the weight of copper dissolved from the anode plate based on the theoretical output of cathode copper and the preset anode copper dissolution rate; Calculate the weight of copper enriched in the electrolyte based on the current copper ion concentration, the target copper ion concentration, and the current volume of the electrolyte. The total weight of copper to be removed is obtained by adding the weight of copper dissolved from the anode plate to the weight of copper enriched in the electrolyte. Based on the total weight of copper to be removed, and combined with the preset copper removal system processing capacity, calculate the processing volume allocated to each copper removal process. The amount of backflow liquid adjustment is calculated based on the processing volume of each copper removal process.

[0008] In an optional embodiment, the electrolyte is distributed in a copper electrolysis system comprising a first electrolysis zone and a second electrolysis zone; The total weight of copper to be removed includes the weight of copper to be removed from the first electrolytic zone and the weight of copper to be removed from the second electrolytic zone; The copper removal process at each stage includes a first-stage copper removal process and a second-stage copper removal process; The backflow liquid adjustment amount includes the backflow liquid amount for the first electrolysis zone and the backflow liquid amount for the second electrolysis zone; The calculation of the processing volume allocated to each copper removal process includes: Calculate the sum of the copper removal weight required for the first electrolytic zone and the copper removal weight required for the second electrolytic zone, and use this as the total copper removal weight required. Based on the proportion of the copper removal weight required in each zone to the total copper removal weight required, the total processing volume of the first-stage copper removal and the total processing volume of the second-stage copper removal are allocated to each zone, resulting in the first-stage copper removal processing volume and the second-stage copper removal processing volume for each zone.

[0009] In an optional implementation, the formula for calculating the amount of backflow liquid adjustment includes: The amount of liquid returned to any zone = the amount of liquid returned from the first stage of copper removal in that zone + the amount of liquid returned from the second stage of copper removal in that zone; where the amount of liquid returned from the first stage of copper removal in that zone = the volume of the first stage of copper removal processing in that zone / 4. The amount of copper stripping liquid returned in the second stage of this partition = the volume of copper stripping treatment in the second stage of this partition / 4.

[0010] In an optional implementation, the calculation step of the backflow liquid adjustment amount is performed by determining the first copper stripping volume of the first electrolytic zone and the second electrolytic zone, and the second copper stripping volume, using the following method: The formula for calculating the theoretical cathode copper yield for each zone is: Q 理论 =I×K×N×C1×η×t×10 -6 ; Among them, Q 理论 η is the theoretical yield of cathode copper; I is the current density; K is the electrochemical equivalent; N is the number of energized groups; C1 is the number of electrolytic cells; η is the expected electrolytic efficiency; t is the electrolysis time. The formula for calculating the weight of copper dissolved from the anode plates in each zone is as follows: ; in, λ represents the weight of copper dissolved from the anode plate; λ is the corresponding copper dissolution rate at the anode. The total processing volume of the first and second stages of copper removal is calculated using the following formula: V 一段总 =(F 循环 -F 二段 )×24; V 二段总 =(F 二段 -C2)×24; Among them, V 一段总 V represents the total volume of copper stripping in one stage. 二段总 This represents the total processing volume of the two-stage copper removal process; F 循环 F is the flow rate of the circulating pump. 二段 C1 is the flow rate for the second-stage copper removal process; C2 is the preset flow rate constant. The calculated weight W of copper dissolved from the anode plates of each zone. 溶出Add the weight of copper enriched in the corresponding electrolyte to obtain the weight of copper to be removed from each zone; Based on the proportion of the copper removal weight required in each zone to the sum of the copper removal weight required in the first electrolytic zone and the second electrolytic zone, the calculated total copper removal processing volume V is calculated for each section. 一段总 and the total processing volume V of the two-stage copper removal process 二段总 The volume of copper stripping in the first stage and the volume of copper stripping in the second stage are allocated to each partition.

[0011] In an optional implementation, the expression for the volume calculation model is: V = V0 - q3 × t - V1; Wherein, V represents the water replenishment amount, V0 represents the set standard volume of the electrolyte, q3 represents the preset water evaporation rate, t represents the evaporation time, and V1 represents the current volume of the electrolyte; the preset water evaporation rate is determined based on an electrolyte temperature of 63℃~65℃; and / or, The preset allowable range includes a first preset allowable range for backflow control and a second preset allowable range for water replenishment control: when judging the deviation of the backflow adjustment amount, the first preset allowable range is used; wherein, the first preset allowable range is: the absolute value of the deviation between the real-time flow data and the backflow adjustment amount is less than or equal to 2%; when judging the deviation of the water replenishment amount, the second preset allowable range is used; wherein, the second preset allowable range is: the absolute value of the deviation between the actual volume of the electrolyte after water replenishment confirmed based on the real-time flow data and the set standard volume of the electrolyte is less than or equal to 1%; and / or, The acquisition of electrolyte ion concentration data includes: receiving laboratory data uploaded by the MES system as the ion concentration data through the data interaction interface between the DCS system and the MES system; and / or, The ion concentration data includes copper ion concentration and sulfate ion concentration, wherein the target value for copper ion concentration in the ion concentration calculation model is set to be 40 g / L~50 g / L, and the target value for sulfate ion concentration is 190 g / L~220 g / L.

[0012] In an optional implementation, generating corresponding pneumatic regulating valve opening control commands based on the backflow liquid adjustment amount and the water replenishment amount includes: Compare the calculated backflow adjustment or replenishment volume with the preset high flow rate threshold. If the adjustment amount or water replenishment amount is greater than or equal to the preset high flow threshold, a command is generated to adjust the opening of the pneumatic control valve to the first opening value. If the adjustment amount or water replenishment amount is less than the preset low flow threshold, an instruction is generated to adjust the opening of the pneumatic regulating valve to the second opening value; wherein, the first opening value is greater than the second opening value.

[0013] In a second aspect, the present invention provides an online control device for the composition and volume of a copper electrolyte, comprising: The acquisition module is used to acquire the ion concentration data and current volume data of the electrolyte. The calculation module is used to input the ion concentration data into a preset ion concentration calculation model to calculate the amount of liquid to be returned, and to input the current volume data of the electrolyte into a preset volume calculation model, and to calculate the amount of water to be replenished by combining the preset water evaporation rate. The output module is used to generate and output corresponding pneumatic regulating valve opening control commands based on the backflow liquid adjustment amount and the water replenishment amount, respectively. The calculation module is also used to collect real-time flow data fed back by the flow meter and calculate the deviation between the real-time flow data and the backflow liquid adjustment amount or the water replenishment amount; The judgment module is used to determine whether the deviation is within a preset allowable range. If it exceeds the preset allowable range, a corrected pneumatic regulating valve opening control command is generated based on the deviation until the deviation is within the preset allowable range.

[0014] Thirdly, the present invention provides a computer device, the computer device including a processor and a memory, the memory storing a computer program, and the processor executing the computer program to implement the online control method for the composition and volume of copper electrolyte as described in any of the foregoing embodiments.

[0015] Fourthly, the present invention provides a computer storage medium storing a computer program, which, when executed on a processor, implements the online control method for the composition and volume of copper electrolyte according to any one of the foregoing embodiments.

[0016] The embodiments of this application have the following beneficial effects: This invention acquires electrolyte ion concentration and current volume data, and performs comprehensive calculations using preset ion concentration and volume calculation models. Based on the actual electrochemical consumption and physical evaporation during electrolysis, it scientifically and quantitatively determines the required amount of backflushing liquid and water replenishment. This data model-based calculation method replaces traditional manual estimation, eliminating control inaccuracies caused by manual operation delays or calculation errors. Furthermore, by directly generating opening commands for the pneumatic regulating valve, it achieves automated response and adjustment of the copper electrolyte composition and volume, significantly improving control timeliness.

[0017] Furthermore, this invention introduces a closed-loop control mechanism based on flow feedback. By collecting real-time flow data from the flow meter and calculating the deviation between this data and the theoretical adjustment amount in real time, the opening command of the pneumatic regulating valve can be dynamically corrected automatically when the deviation exceeds the preset allowable range. This mechanism effectively overcomes the influence of factors such as pipeline pressure fluctuations and valve mechanical hysteresis on control accuracy, ensuring that the actual backflow and replenishment volumes closely approximate the calculated theoretical requirements, thereby achieving precise online control of the electrolyte system.

[0018] Ultimately, this precise and automated control mode maintains the electrolyte's composition, concentration, and volume in a relatively balanced and ideal state, effectively avoiding physical defects such as cathode copper particles and streaks caused by increased copper ion concentration or volume fluctuations. This helps improve the first-pass yield of Grade A copper, optimizes current efficiency, and reduces unit power consumption. Simultaneously, the automated closed-loop control significantly reduces the need for frequent manual valve switching by on-site personnel, lowering the frequency of personnel exposure to hazardous environments and reducing labor intensity, thus significantly improving the inherent safety level of the production process. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of this application, the accompanying drawings used in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of this application and therefore should not be considered as a limitation on the scope of protection of this application. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the hardware operating environment involved in an embodiment of the online control method for copper electrolyte composition and volume of the present invention; Figure 2 This is a schematic flowchart of Example 1 of the online control method for copper electrolyte composition and volume of the present invention; Figure 3 This is a detailed flowchart of step S200 in Example 2 of the online control method for copper electrolyte composition and volume of the present invention; Figure 4 This is a detailed flowchart of step S300 in Example 4 of the online control method for copper electrolyte composition and volume of the present invention; Figure 5 This is a schematic diagram of the module connection of the online control device for the composition and volume of copper electrolyte of the present invention. Detailed Implementation

[0021] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0022] The components described in the accompanying drawings can typically be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of this application provided in the drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0023] In the following, the terms “comprising,” “having,” and their cognates, which may be used in various embodiments of this application, are intended only to indicate a particular feature, number, step, operation, element, component, or combination thereof, and should not be construed as excluding, firstly, the presence of one or more other features, numbers, steps, operations, elements, components, or combinations thereof, or adding the possibility of one or more features, numbers, steps, operations, elements, components, or combinations thereof.

[0024] Furthermore, the terms "first," "second," and "third" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.

[0025] Unless otherwise specified, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which the various embodiments of this application pertain. Terms (such as those defined in commonly used dictionaries) shall be interpreted as having the same meaning as in their contextual meaning in the relevant technical field and shall not be construed as having an idealized or overly formal meaning, unless clearly defined in the various embodiments of this application.

[0026] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0027] like Figure 1 The diagram shown is a structural schematic of the hardware operating environment of the terminal involved in an embodiment of the present invention.

[0028] The online control system (device) for copper electrolyte composition and volume in this invention can be a PC, or a mobile terminal device such as a smartphone, tablet, or laptop. This visual navigation optimization system may include: a processor 1001 (e.g., a CPU), a network interface 1004, a user interface 1003, a memory 1005, and a communication bus 1002. The communication bus 1002 is used to establish communication between these components. The user interface 1003 may include a display screen, an input unit such as a keyboard, or a remote control; optionally, the user interface 1003 may also include a standard wired interface or a wireless interface. The network interface 1004 may optionally include a standard wired interface or a wireless interface (e.g., a Wi-Fi interface). The memory 1005 may be a high-speed RAM memory or a stable memory, such as a disk storage device. Optionally, the memory 1005 may also be a storage device independent of the aforementioned processor 1001. Optionally, the online control system for copper electrolyte composition and volume may also include RF (Radio Frequency) circuitry, audio circuitry, a Wi-Fi module, etc. In addition, the visual navigation optimization system can also be equipped with other sensors such as gyroscopes, barometers, hygrometers, thermometers, and infrared sensors, which will not be described in detail here.

[0029] Those skilled in the art will understand that Figure 1 The system shown is not intended to limit it and may include more or fewer components than illustrated, or combine certain components, or have different component arrangements. Figure 1 As shown, the memory 1005, which is a computer-readable storage medium, may include an operating system, a data interface control program, a network connection program, and a visual navigation optimization program.

[0030] In a specific hardware implementation scenario, to achieve the above control, hardware modifications are required to the existing backflow and replenishment water pipelines in the north and south zones. Specific installation locations include: adding pneumatic regulating valves and flow meters to the pipeline from the south zone circulation tank to the north zone circulation tank; adding pneumatic regulating valves and / or flow meters to the pipelines from the south zone circulation tank to the T1 circulation tank and from the T1 circulation tank to the T1 electrolytic cell; configuring appropriate pneumatic regulating valves and flow meters according to the process flow direction on the branches from the T1 electrolytic cell to the intermediate tank, from the intermediate tank to the T2 electrolytic cell, and connecting to the north and south zone circulation tanks; similarly, control valves also need to be installed on the pipelines connecting the circulation tanks, electrolytic cells, and post-residue tanks related to the arsenic removal system to the north and south zone circulation tanks. These devices require the installation of cables, gas supply pipes, and temperature sensors, and must be connected to the DCS system.

[0031] In summary, the method provided by this invention scientifically and quantitatively calculates the backflow liquid and water replenishment requirements by inputting the acquired electrolyte data into a preset model and automatically generates control commands, thus overcoming the lag and error of manual adjustment from the source. At the same time, by combining the flow meter feedback data to construct a closed-loop correction mechanism, the valve opening can be dynamically adjusted when the actual flow deviation exceeds the standard, eliminating environmental interference and ensuring that the execution process is highly consistent with the theoretical calculation. This online precise control effectively maintains the dynamic balance of the electrolyte system, significantly reducing the intensity of on-site operations and safety risks while improving the quality of cathode copper and current efficiency.

[0032] Example 1 Reference Figure 2 This embodiment provides a method for online control of the composition and volume of copper electrolyte, including: Step S100: Obtain the ion concentration data and current volume data of the electrolyte.

[0033] This step marks the beginning of the control process and aims to monitor the current state of the copper electrolysis system in real time.

[0034] Specifically, the system can read current physicochemical parameters through data interfaces or sensors. This typically involves extracting values ​​for key components such as copper ions and sulfate ions from upstream detection systems or databases, as well as reading the current total electrolyte volume in the tank from the level gauge. This allows the system to obtain a set of digital input values ​​reflecting the current system status (e.g., copper ion concentration 45 g / L, current volume 1980 m³). 3 This provides objective and real-time data support for subsequent accurate calculations, replacing manual estimation or outdated data and solving the problem of information lag.

[0035] For example, laboratory data uploaded by the laboratory can be read through the communication interface between the DCS (Distributed Control System) and MES (Manufacturing Execution System). Concentration data can be directly acquired through online analyzers. Volume data can be calculated using level sensors (radar, ultrasonic) combined with tank dimensions.

[0036] In addition to copper ions and volume, data such as temperature, acidity, and impurity ion concentration can also be obtained as inputs for more complex models.

[0037] Step S200: Input the ion concentration data into a preset ion concentration calculation model to calculate the backflow liquid adjustment amount, and input the current volume data of the electrolyte into a preset volume calculation model, and combine it with a preset water evaporation rate to calculate the water replenishment amount.

[0038] This step is the core decision-making step, which uses a "digital model" to transform the monitored status data into specific process control targets (i.e., how much liquid needs to be drained and how much water needs to be added).

[0039] Specifically, the system runs an internally preset algorithm. First, for the backflow solution, based on the principle of material balance, it calculates the increase in copper ions caused by the electrolysis reaction (the anodic dissolution is greater than the cathode deposition), determining how much volume of high-copper electrolyte needs to be removed (backflowed) to maintain concentration balance. For water replenishment, based on the principle of volume balance, it calculates the volume lost due to water evaporation under high temperature conditions, and combines this with the difference between the current volume and the target standard volume to determine the amount of water to be replenished. The result is two specific control target values, such as "30 m³ of backflow solution needed" and "5 m³ of water replenishment needed." 3 ".

[0040] This step quantifies and standardizes control decisions, avoiding the arbitrariness and errors of manual estimation based on experience, and ensuring the accuracy of material balance.

[0041] The "water evaporation rate" in the model can be a fixed value or a dynamic variable based on the current ambient temperature and electrolyte temperature; the model can also include self-learning correction coefficients based on historical data.

[0042] Step S300: Based on the backflow liquid adjustment amount and the water replenishment amount, generate and output corresponding pneumatic regulating valve opening control commands.

[0043] In this step, the calculated "target processing volume" (business data) is converted into "execution signals" (control signals) that can be recognized by the hardware device.

[0044] Specifically, the system can query the valve's flow characteristic curve (i.e., the correspondence between opening degree and flow rate), and map the required flow rate or total flow to the valve's percentage opening. This generates electronic control commands (such as 4-20mA current signals or digital bus signals), which are then sent to the pneumatic control valve in the field.

[0045] This step automates the decision-making and execution process, offering rapid response and eliminating the need for manual valve operation on-site. For example, it can be executed via the analog output module of a PLC or DCS.

[0046] In addition, safety limits for valve opening can be set (e.g., the valve should not be opened more than 80%); slow start and slow stop logic can be added to prevent water hammer effect.

[0047] Step S400: Collect real-time flow data fed back by the flow meter, and calculate the deviation between the real-time flow data and the backflow liquid adjustment amount or the water replenishment amount.

[0048] This step is the "monitoring" stage in closed-loop control, used to confirm whether the actuator has actually completed the command. Specifically, the system reads the flow counter value installed on the pipeline, adds it up or subtracts the instantaneous value from the target value calculated in step two, thus obtaining a value reflecting the execution error (deviation value).

[0049] The calculations in this step can detect anomalies during the execution process (such as pipe blockage, pressure fluctuations causing insufficient flow at the same opening degree, valve malfunction, etc.), preventing situations where "instructions are issued but not implemented".

[0050] In addition, it can collect cumulative flow (volume) or instantaneous flow (velocity), and select the comparison object according to the control strategy.

[0051] Step S500: Determine whether the deviation is within a preset allowable range. If it exceeds the preset allowable range, generate a corrected pneumatic regulating valve opening control command based on the deviation until the deviation is within the preset allowable range.

[0052] This step is the "correction" stage in closed-loop control, ensuring that the control objective is ultimately achieved.

[0053] Specifically, the deviation calculated in step S400 can be compared with a preset threshold (such as 2% or 1%). If the deviation is too large (indicating insufficient or excessive flow), the system automatically adjusts the valve opening command. For example, if the actual flow is less than the target, the valve opening is increased; otherwise, it is decreased. This process is repeated until the deviation falls within the allowable range.

[0054] The above algorithm can employ a PID (Proportional-Integral-Derivative) control algorithm or an iterative correction algorithm. For example: New opening degree = Original opening degree + (Target value - Actual value) × Adjustment coefficient.

[0055] The calculations in this step allow for a precise approximation of the theoretically calculated backflow and replenishment volumes after dynamic adjustments. This endows the system with anti-interference and self-adaptive capabilities, achieving "precise control" and ensuring that the composition and volume of the electrolyte system strictly meet process requirements.

[0056] For example, PID function blocks or dead-zone control logic can be written in the controller. Additionally, a timeout alarm can be set; if the deviation cannot be eliminated after a prolonged period of correction, an alarm will be triggered to prompt manual inspection of the equipment for faults (such as valve jamming).

[0057] Example 2 Reference Figure 3Based on the foregoing embodiments, this embodiment provides a method for online control of the composition and volume of copper electrolyte. Step S200 involves inputting the ion concentration data into a preset ion concentration calculation model to calculate the backflow adjustment amount, including: Step S210: Calculate the theoretical yield of cathode copper based on current density, electrochemical equivalent, and electrolysis time.

[0058] This step is the starting point for material balance calculations, aiming to calculate the weight of copper that should be deposited on the cathode plate under ideal or pre-defined electrochemical conditions. It should be noted that the parameters used to calculate the theoretical yield of cathode copper may include, but are not limited to, current density, electrochemical equivalent, and electrolysis time. Other indicators and / or parameters may also be included, as long as they are acceptable to the methods provided in the embodiments of this application.

[0059] Specifically, the system can substitute the collected current density (reflecting current intensity), the electrochemical equivalent of copper (a physical constant, referring to the mass of copper deposited per unit of charge), the electrolysis time (duration of energization), and possible parameters such as the number of energizing groups and current efficiency into Faraday's law of electrolysis for multiplication. This yields a mass value (e.g., 200 tons), representing the amount of copper metal deposited at the cathode during that time period.

[0060] This step provides a theoretical baseline value, allowing for real-time monitoring of production data without physically weighing each piece of cathode copper, thus laying the foundation for subsequent calculations of anode consumption.

[0061] Step S220: Calculate the weight of copper dissolved from the anode plate based on the theoretical yield of cathode copper and the preset anode copper dissolution rate.

[0062] Since the dissolution efficiency of the anode is usually higher than the deposition efficiency of the cathode in copper electrolytic refining (i.e., the anode dissolves faster and the cathode grows slower), this step aims to quantify the total amount of copper dissolved from the anode into the electrolyte.

[0063] The theoretical cathode yield calculated in step S210 can be used in conjunction with the preset "anode copper dissolution rate" (or anode dissolution efficiency coefficient) to estimate the anode consumption, which represents the weight of copper dissolved into the electrolyte from the anode plate. This quantifies the "source" data of copper ions in the electrolyte and clarifies how much copper is continuously entering the system.

[0064] Step S230: Calculate the weight of copper enriched in the electrolyte based on the current copper ion concentration, the target copper ion concentration, and the current volume of the electrolyte.

[0065] This step aims to calculate the amount of copper metal currently present in the electrolyte that exceeds (or falls below) the process standard. This is a calculation of the "stock" deviation.

[0066] Specifically, the system compares the detected "current concentration" with the "target concentration" required by the process, obtains the concentration difference, and then multiplies the difference by the "current volume".

[0067] For example, it could be: W 富集 =(C 当前 -C 目标 )×V 当前 For example: (45g / L-40g / L)×2000m 3 =10000kg (i.e. 10 tons).

[0068] This yields a mass value, representing the weight of copper that must be removed (or replenished, if negative) from the existing system in order to restore the electrolyte concentration to normal.

[0069] This step transforms the abstract concentration index into a specific quality index, turning the chemical goal of "adjusting the concentration" into the physical goal of "removing how much weight of copper".

[0070] Step S240: Add the weight of copper dissolved from the anode plate to the weight of copper enriched in the electrolyte to obtain the total weight of copper to be removed.

[0071] This step is the summary step of the overall material balance, which determines the overall objective of the copper removal task.

[0072] Specifically, the "incremental source" (the anodic dissolution portion in step 220, usually referring to the excess portion relative to the cathode precipitation or the total dissolution portion, depending on the specific model definition) is summed with the "stock deviation" (the enrichment portion in step S230).

[0073] The formula can be: W 总需脱 =W 溶出 + W 富集 ; In the formula, the two parts can be added directly. However, in the actual model, the part consumed by the cathode may be subtracted, or the "dissolved weight" may specifically refer to the excess dissolved amount.

[0074] The total mass value can be obtained through the above calculations, representing the total amount of copper that the system needs to remove through the copper stripping process within the current time period. By comprehensively considering both the dynamic production volume and historical accumulation during the production process, the adjustment scheme ensures that it can both cope with current production and correct historical deviations.

[0075] Step S250: Based on the total weight of copper to be removed and the preset processing capacity of the copper removal system, calculate the processing volume allocated to each level of the copper removal process.

[0076] In this step, the chemical objective of "weight of copper to be removed" is transformed into the engineering objective of "volume of liquid to be fed into the copper removal equipment," and the task is assigned accordingly.

[0077] Specifically, the total weight can be converted into total volume based on the copper removal efficiency of the copper removal system (such as a single-stage or two-stage electrowinning cell) (i.e., how much copper can be removed per cubic meter of liquid). Then, the total volume is allocated to different processes based on the processing capacity ratio of each stage. This yields the required electrolyte volume (in cubic meters) for each copper removal process.

[0078] This step achieves matching with the capabilities of on-site equipment, avoiding overload operation or resource waste, and realizing refined scheduling.

[0079] Step S260: Calculate the amount of backflow liquid adjustment based on the processing volume of each copper removal process.

[0080] This step is the endpoint of the calculation, converting the processing volume into the direct basis for controlling the valves: the backflow volume. Based on the proportional relationship in the process flow (for example, there is usually a fixed multiple or split relationship between the processing volume and the backflow volume), the "processing volume" is converted into the "backflow volume".

[0081] For example, the calculation method can be: Q 单次倒返 = V 处理体积 / N. Where Q 单次倒返 This indicates the amount or total amount of backflow fluid that needs to be adjusted within a single time period. V 处理体积 This represents the volume of electrolyte to be processed within the entire cycle (e.g., one day), calculated in the previous step. N represents the number of preset time periods divided to complete the reverse operation. For example, if the calculated daily electrolyte volume V is 200m³... 3 Furthermore, the process is set to perform the backtracking operation evenly across four time periods per day (i.e., N=4). Therefore, the backtracking amount Q that needs to be adjusted in each time period is equal to 200m for a single backtracking operation. 3 / 4 = 50m 3 .

[0082] The calculations in this step yield the final backflow adjustment amount (e.g., cubic meters per hour), which will be directly used to generate valve opening commands. This completes the final implementation from "electrochemical principles" to "fluid control parameters," enabling precise control of complex metallurgical processes through the simple physical quantity of flow rate.

[0083] In some embodiments, the electrolyte is distributed in a copper electrolysis system comprising a first electrolysis zone and a second electrolysis zone.

[0084] The above limitation refers to dividing the entire copper electrolysis production system logically or physically into two independent control units (i.e., the first and second partitions, which can usually correspond to physical areas such as the south and north areas).

[0085] Specifically, the system can no longer treat the entire factory as a whole during data acquisition and control, but instead identify and manage the status data of the two partitions separately.

[0086] It enables refined management. Since the operating conditions and temperature distribution of equipment in different areas may vary, zone control can solve the problem of local imbalance and avoid the decrease in control accuracy caused by a "one-size-fits-all" approach.

[0087] The total weight of copper to be removed includes the weight of copper to be removed from the first electrolytic zone and the weight of copper to be removed from the second electrolytic zone.

[0088] The copper removal process at each stage includes a first-stage copper removal process and a second-stage copper removal process.

[0089] This indicates that the copper removal process is not a single step, but rather a staged process (stage one and stage two). The specific control logic can reserve calculation interfaces for the two different stages to calculate the processing volume of each stage separately.

[0090] To adapt to the complex metallurgical process requirements, different stages may undertake different impurity removal or copper recovery tasks, and the graded calculation makes the control more in line with the actual process flow.

[0091] The backflow adjustment amount includes the backflow amount for the first electrolysis zone and the backflow amount for the second electrolysis zone.

[0092] Step S250, calculating the processing volume allocated to each level of copper removal process, includes: Step S251: Calculate the sum of the copper removal weight required for the first electrolytic zone and the copper removal weight required for the second electrolytic zone, as the total copper removal weight required.

[0093] In this step, the system adds the calculated "copper removal weight" (i.e., the excess copper in each partition) for the two partitions. The formula logic may include: W 总 =W 第一分区需脱 +W 第二分区需脱 .

[0094] This step yields the total copper load that the entire system needs to remove at the current moment.

[0095] Understanding the system's total copper removal needs from a holistic perspective provides a basis for allocating limited copper removal capacity subsequently.

[0096] Step S252: Based on the proportion of the copper removal weight required for each partition to the total copper removal weight required, the total processing volume of the first-stage copper removal and the total processing volume of the second-stage copper removal are allocated to each partition, thus obtaining the first-stage copper removal processing volume and the second-stage copper removal processing volume of each partition.

[0097] This step is the core of the "dynamic allocation strategy." The total processing capacity of the copper removal system (total volume of the first stage and total volume of the second stage) is finite and fixed, and needs to be allocated according to the urgency (weight) of the actual needs of the two partitions. Specific algorithms may include, for example: Calculate the weight ratio: Ratio1 = W 第一分区需脱 / W 总 .

[0098] Allocate a volume segment: V 第一分区一段 =V 一段总 ×Ratio1.

[0099] Distribute two volumes: V 第一分区二段 =V 二段总 ×Ratio1.

[0100] (The calculation for the second partition is the same).

[0101] The above calculations determine the specific processing volume quota each partition should receive in the first and second stages of the process. This achieves "on-demand allocation" of resources. If the first partition has more severe copper accumulation, the system will automatically allocate more copper removal processing capacity to it, thereby quickly balancing the status of the two partitions, which is superior to average allocation.

[0102] Furthermore, the formula for calculating the amount of backflow liquid adjustment includes: The single-period backflow volume of any zone = the single-period backflow volume of the first copper removal stage of that zone + the single-period backflow volume of the second copper removal stage of that zone.

[0103] The above formula determines that the required backflow control quantity within any preset time period is the sum of the backflow quantities required at each stage of the process within that time period. Specifically, an addition operation can be performed to obtain a single control variable used to generate valve commands within that time period—the total backflow quantity of that partition in a single time period. This simplifies the complex calculations of multiple processes into a single executable physical quantity, directly guiding the action of the pneumatic control valve.

[0104] The return volume of a single copper removal segment in this zone is equal to the total processing volume of a single copper removal segment in this zone divided by 4.

[0105] The above calculation method defines how to evenly distribute the total processing volume of a complete cycle (e.g., one day) across multiple discrete time periods for execution. The coefficient "4" represents the preset number of time periods divided to complete the return operation.

[0106] This time-sharing execution strategy avoids the impact of a single large flow surge on system stability, achieving the technical effect of breaking down the large flow into smaller, more manageable volumes and ensuring smooth control. The calculated "single-period return volume" is the specific flow control target to be achieved within a single time period. The single-period return volume of the second-stage copper removal in this partition = the total processing volume of the second-stage copper removal in this partition / 4.

[0107] The above formula defines the time-sharing conversion relationship of the two-stage process, and also uses the coefficient "4" (that is, it is divided into 4 time periods for execution), so as to obtain the specific liquid return control target of the two-stage process in a single time period.

[0108] Furthermore, in the calculation step of the backflow liquid adjustment amount, the first-stage copper stripping volume of the first electrolytic zone and the second electrolytic zone and the second-stage copper stripping volume are determined by the following method: (1) Calculate the theoretical cathode copper production of each zone using the following formula: Q 理论 =I×K×N×C1×η×t×10 -6 ; Among them, Q 理论 η is the theoretical yield of cathode copper; I is the current density, a core parameter reflecting the intensity of electrolysis; K is the electrochemical equivalent, a physicochemical constant of copper; N is the number of current-carrying groups, the scale of the electrolytic cells participating in the reaction; C1 is the number of electrolytic cells; η is the expected electroefficiency, the current efficiency, reflecting the effective proportion of electrical energy converted into metal; t is the electrolysis time, the time span of the calculation.

[0109] The theoretical output of cathode copper (Q-theory) is calculated using a formula. Its advantage lies in the fact that it eliminates the need for physical weighing; the output can be calculated in real time based on electrical parameters.

[0110] (2) Calculate the weight of copper dissolved from the anode plates in each zone using the following formula: ; in, λ represents the weight of copper dissolved from the anode plate; λ is the corresponding copper dissolution rate from the anode.

[0111] In this step, the amount of anode dissolution is calculated based on the efficiency difference between the anode and cathode.

[0112] The aforementioned λ (anode copper dissolution rate) reflects the proportion of the difference between the anode dissolution rate and the cathode deposition rate. This formula is used to calculate the excess copper weight (or total dissolution amount, depending on the definition of λ) that enters the electrolyte due to excessive anode dissolution, thus yielding the weight of copper dissolved from the anode plate (W_dissolved). This quantifies the incremental "source" leading to the increased copper ion concentration.

[0113] (3) Calculate the total processing volume of the first and second stages of copper removal, using the following formula: V 一段总=(F 循环 -F 二段 )×24; V 二段总 =(F 二段 -C2)×24; Among them, V 一段总 V represents the total volume of copper stripping in one stage. 二段总 This represents the total processing volume of the two-stage copper removal process; F 循环 F is the flow rate of the circulating pump. 二段 C1 is the flow rate for the second-stage copper removal process; C2 is the preset flow constant, which is the inherent flow loss or baseline deduction value of the system. 24 is the time coefficient, which converts the hourly flow rate into daily processing capacity.

[0114] The above formula calculates the maximum copper removal processing capacity (volume) that the entire system can provide in one day (24 hours). This yields the system's total "first-stage copper removal total processing volume" and "second-stage copper removal total processing volume." This clarifies the system's capacity ceiling, ensuring that subsequent allocations are made within the system's capabilities.

[0115] (4) The calculated weight W of copper dissolved from the anode plates in each zone. 溶出 Add the weight of copper enriched in the corresponding electrolyte to obtain the weight of copper to be removed from each zone.

[0116] (5) Based on the proportion of the copper removal weight required in each zone to the sum of the copper removal weight required in the first electrolytic zone and the second electrolytic zone, the calculated total copper removal volume V of each zone is respectively... 一段总 and the total processing volume V of the two-stage copper removal process 二段总 The volume of copper stripping in the first stage and the volume of copper stripping in the second stage are allocated to each partition.

[0117] For each partition, the total demand = dynamic increment (W dissolution) + static stock deviation (enriched copper weight). Using the previously calculated total demand ratio, the total system capacity (V) calculated above is... 一段总 V 二段总 The data was then divided into a first partition and a second partition. This determined the processing volume that each partition should handle for one and two segments.

[0118] The entire computational logic is closed: from "microscopic electrochemical reaction" (theory) to "macroscopic material balance" (weight of copper to be removed), then to "engineering equipment capacity" (total), and finally to "task allocation for specific zones", forming a complete and logically self-consistent automated control algorithm.

[0119] Example 3 Based on the foregoing embodiments, this embodiment provides a method for online control of the composition and volume of a copper electrolyte, wherein the expression of the volume calculation model is: V = V0 - q3 × t - V1; Wherein, V represents the amount of water replenished, V0 represents the set standard volume of electrolyte, q3 represents the preset water evaporation rate, t represents the evaporation time, and V1 represents the current volume of electrolyte; the preset water evaporation rate is determined based on the electrolyte temperature of 63℃~65℃ (for example, it can be 63℃, 64℃, 65℃, etc.).

[0120] The above formula is a material balance equation, used to quantitatively calculate how much water needs to be added to the system at the current moment in order to maintain a stable liquid level in the electrolyzer.

[0121] Specifically, the system can first determine the set standard volume (V0) of the electrolyte, which is the ideal liquid level state for system operation (e.g., 2000m³ at full load). 3 The system calculates the amount of water evaporation within a specific time period (t) by multiplying the water evaporation rate (q3) by the evaporation time (t). Here, the rate q3 specifically refers to the evaporation rate under the required high-temperature conditions of 63℃~65℃ for the electrolyte. This temperature range is the standard operating temperature for copper electrolytic refining and directly determines the rate of water loss. The system obtains the current actual volume of the electrolyte (V1). The water replenishment amount V is then calculated using a formula.

[0122] The algorithm transforms water replenishment from "checking liquid level and relying on intuition" to "quantitative calculation based on temperature and time." The specifically defined temperature range (63-65℃) ensures that the evaporation rate parameters match the actual production environment, improving the accuracy of the calculations.

[0123] In addition, q3 can be obtained by fitting historical data, or it can be a dynamic function based on a real-time temperature sensor.

[0124] In some embodiments, the preset allowable range includes a first preset allowable range for backflow control and a second preset allowable range for water replenishment control: when judging the deviation of the backflow adjustment amount, the first preset allowable range is used; wherein, the first preset allowable range is: the absolute value of the deviation between the real-time flow data and the backflow adjustment amount is less than or equal to 2%; when judging the deviation of the water replenishment amount, the second preset allowable range is used; wherein, the second preset allowable range is: the absolute value of the deviation between the actual volume of the electrolyte after water replenishment confirmed based on the real-time flow data and the set standard volume of the electrolyte is less than or equal to 1%.

[0125] In this embodiment, different judgment criteria (first preset allowable range vs. second preset allowable range) are set for "return fluid" and "water replenishment". This defines when the automatic control system considers the adjustment to have met the standard and when further correction is needed. This is the "stop condition" of the closed-loop control system.

[0126] Specifically, for backflow control: a first preset allowable range is adopted. The system compares the real-time flow rate fed back by the flow meter with the target flow rate calculated by the model, requiring the absolute value of the deviation between the two to be ≤2%. For example, the target is 100m³ / h. 3 / h, as long as the actual flow rate is between 98-102m 3 The system considers the control to be qualified within a certain time frame ( / h) and will no longer adjust the valve.

[0127] For water replenishment (total volume control): a second preset allowable range is used. Since water replenishment focuses on the final liquid level (volume), the system calculates the amount of water added by integrating flow meter data, adds it to the original volume, and judges the deviation between the actual total volume after water replenishment and the set standard volume (V0). The absolute value of the deviation is required to be ≤1%. This achieves differentiated and precise control. Backflow prevention focuses on the relative accuracy of the process flow rate, while water replenishment focuses on the absolute accuracy of the final total volume.

[0128] This avoids the inadequacy of using a single standard. A 1% volume deviation control ensures the stability of the total system volume, preventing overflow or cavitation; a 2% flow deviation control takes into account fluid fluctuations, avoiding frequent valve oscillations and adjustments, and extending equipment life.

[0129] In some embodiments, step S100, obtaining the ion concentration data of the electrolyte, includes: step S110, receiving the test data uploaded by the MES system as the ion concentration data through the data interaction interface between the DCS system and the MES system.

[0130] In this step, laboratory data is received through the data exchange interface between the DCS system and the MES system. The digitization source path for the "ion concentration data" is specified.

[0131] The above-mentioned MES (Manufacturing Execution System) stores the electrolyte sampling and analysis results uploaded by the laboratory.

[0132] The aforementioned DCS (Distributed Control System) serves as the executing entity of this control method.

[0133] The aforementioned interactive interface allows DCS to automatically retrieve the latest laboratory report data from MES via communication protocols (such as OPC, Modbus, etc.) as input variables for subsequent models.

[0134] This step breaks down "information silos." It eliminates the input errors and time delays that may occur when manually entering test data on the DCS screen, automates the data flow, and ensures that the model calculations use the latest and most accurate test results.

[0135] In some embodiments, the ion concentration data includes copper ion concentration and sulfate ion concentration, wherein the target value for copper ion concentration set in the ion concentration calculation model is 40 g / L to 50 g / L (e.g., 40 g / L, 42 g / L, 44 g / L, 45 g / L, 46 g / L, 48 g / L, 50 g / L, etc.), and the target value for sulfate ion concentration is 190 g / L to 220 g / L (e.g., 190 g / L, 200 g / L, 210 g / L, 220 g / L, etc.).

[0136] This implementation defines the "baseline" or "ideal state" of the control system, which is the specific numerical range of the "target copper ion concentration." Specifically, in the ion concentration calculation model, these values ​​are used as constants or setpoints in the calculation. For example, when calculating the weight of enriched copper, C in the formula... 目标 This means taking the value from this range (e.g., the median value of 45 g / L). This ensures that the control system's adjustment direction is to bring the electrolyte composition back to the optimal chemical environment for the deposition of high-quality cathode copper.

[0137] The process window was clarified. The vague concept of "compositional stability" was concretized into an executable numerical range: a copper concentration of 40-50 g / L and an acid concentration of 190-220 g / L represent the optimal balance between ensuring current efficiency and suppressing impurity precipitation.

[0138] Example 4 Reference Figure 4 Based on the foregoing embodiments, this embodiment provides a method for online control of the composition and volume of copper electrolyte. Step S300 involves generating corresponding pneumatic regulating valve opening control commands based on the backflow adjustment amount and the water replenishment amount, including: Step S310: Compare the calculated backflow adjustment amount or water replenishment amount with the preset high flow rate threshold.

[0139] This step marks a turning point in the control strategy. The system not only focuses on the fact that "adjustment is needed," but also assesses the magnitude of "how much adjustment is needed" (i.e., the scale of the adjustment demand).

[0140] Specifically, the system reads the calculated values ​​of "return fluid adjustment amount" (usually flow rate or volume) and "water replenishment amount". These values ​​are compared with the "high flow rate threshold" and "low flow rate threshold" preset in the controller to obtain a logical judgment result, such as "the current demand is a high flow rate demand", "the current demand is a low flow rate demand", or "the current demand is in an intermediate state".

[0141] This step differentiates the control strategy. Different levels of adjustment requirements dictate different levels of response speed and control precision. By determining the magnitude of these requirements, we can lay the foundation for subsequently matching the most suitable execution strategy.

[0142] For example, comparison instructions (greater than, less than) can be used in the logic blocks of a DCS or PLC.

[0143] In step S320, if the adjustment amount or water replenishment amount is greater than or equal to the preset high flow rate threshold, an instruction is generated to adjust the opening of the pneumatic regulating valve to the first opening value.

[0144] This step is a rapid response strategy for "high load" operating conditions.

[0145] When the system determines that the calculated adjustment value exceeds (or equals) the "high flow threshold," it directly calls the preset "first opening value" (a large percentage value, such as 50% or higher). A corresponding electrical signal is generated and sent to the pneumatic control valve. The valve quickly opens to a large angle, and the pipeline flow rate increases significantly.

[0146] This step enables faster material conveying and quickly eliminates system deviations in cases of severe backlog (e.g., large-scale liquid return) or severe water shortage. It also prevents excessively long adjustment times due to insufficient opening, which could disrupt production cycles.

[0147] For example, the algorithm could be: IF (Target_Volume >= Threshold_High) THEN Valve_Opening = Open_Value_1.

[0148] Step S330: If the adjustment amount or water replenishment amount is less than the preset low flow threshold, an instruction is generated to adjust the opening of the pneumatic regulating valve to the second opening value; wherein, the first opening value is greater than the second opening value.

[0149] This step is a fine-grained control strategy for "low load" or "fine-tuning" operating conditions.

[0150] Specifically, when the system determines that the calculated adjustment value is lower than the "low flow threshold," the system calls the preset "second opening value" (a small percentage value, such as 10% or 20%). A corresponding electrical signal is generated to drive the valve. The valve maintains a small opening angle, and the fluid in the pipeline flows through at a low velocity.

[0151] This step avoids overkill when demand is low, preventing instantaneous flow overshoot caused by excessive valve opening. It reduces frequent, large-amplitude valve opening and closing oscillations under low-flow conditions, extending the lifespan of the pneumatic control valve. Small-aperture water replenishment or liquid emptying causes less disturbance to the liquid in the tank, helping to maintain a stable electrolysis process.

[0152] For example, the algorithm could be: IF (Target_Volume <Threshold_Low) THEN Valve_Opening =Open_Value_2。

[0153] The aforementioned "first opening value is greater than second opening value" defines the logical relationship between two preset opening values, ensuring that the control logic conforms to physical laws. This is a constraint condition for parameter setting. During system initialization or parameter setting, it must be ensured that the first opening value (e.g., 50%) used for high flow rates is numerically greater than the second opening value (e.g., 10%) used for low flow rates. This ensures the logical consistency of "high demand matches high channel, low demand matches low channel," ensuring that the control system can correctly adjust the conveying capacity according to the load size.

[0154] Furthermore, although the aforementioned implementation only mentions two levels (greater than the high threshold and less than the low threshold), in actual implementation, more levels can be added between the high and low thresholds, or a segmented control strategy can be adopted, using continuous PID regulation in the middle region and fixed-value regulation at both ends. Hysteresis comparison logic can be introduced when judging the threshold to prevent the valve from frequently jumping between the first and second opening degrees when the adjustment amount fluctuates slightly near the threshold.

[0155] Example 5 To verify the effectiveness of the method described in this application, we will take the actual work tasks of a copper electrolysis company on a certain day as an example.

[0156] 1. Basic parameter settings: The current density is set at 32000A, the electrochemical equivalent is 1.1852 g / (A·h), the expected electroefficiency is 98.5% (0.985), the electrolysis time is 24 hours, and C1 is set to 38. In the copper electrolysis process scenario described in this embodiment, this constant represents the number of electrolytic cells contained in each energized group (N).

[0157] The volume of both the south and north areas is set at 2000m³. 3 (Full load).

[0158] The number of power-connected groups in the South Zone is set at 5.9, and in the North Zone at 6.

[0159] The copper leaching rate of the anode in the south area was set at 0.75% (0.0075), and in the north area it was set at 1% (0.01).

[0160] Set the circulation pump flow rate to 25m³ / h 3 / h, the second-stage copper removal flow rate is 7.8m³ / h. 3 / h, with the preset flow constant C2 set to 0.8.

[0161] 2. Real-time monitoring data: South system: Current copper concentration 45.64 g / L, target concentration 43 g / L.

[0162] North system: Current copper concentration 46.06 g / L, target concentration 41.5 g / L.

[0163] 3. Model calculation process: (1) Calculate the theoretical yield of cathode copper (Q-theory): The Q-theory for the Southern Region = 32000 × 1.1852 × 5.9 × 38 × 0.985 × 24 × 10 -6 ≈ 201.01 tons; The Q-theory for the North Zone = 32000 × 1.1852 × 6 × 38 × 0.985 × 24 × 10 -6 ≈ 204.42 tons.

[0164] (2) Calculate the weight of copper dissolved from the anode plate (W_dissolved): Leaching from the South Zone W = 201.01 / (1-0.0075) × 0.0075 ≈ 1.519 tons; Leaching from the North Zone W = 204.42 / (1-0.01) × 0.01 ≈ 2.065 tons.

[0165] (3) Calculate the weight of copper enriched in the electrolyte (W enrichment): W enrichment in the southern region = (45.64 - 43) × 2000 / 1000 = 5.280 tons; North W enrichment = (46.06 - 41.5) × 2000 / 1000 = 9.120 tons.

[0166] (4) Calculate the total weight of copper to be removed: The amount of copper to be removed in the southern area is 1.519 + 5.280 = 6.799 tons; The amount of copper to be removed in the North Zone is 2.065 + 9.120 = 11.185 tons. Total copper removal weight required = 17.984 tons.

[0167] (5) Calculate the total processing volume: Total copper stripping volume (Vsection total) = (25 - 7.8) × 24 = 412.8 m2 3 ; Total processing volume for the two-stage copper removal process (Vtwo-stage total) = (7.8 - 0.8) × 24 = 168 m2 3 .

[0168] (6) Calculate the return volume of each time period and generate control targets: According to the method in this application, in order to achieve stable control, the total processing volume calculated in the previous step needs to be evenly distributed into 4 time periods (i.e., N=4).

[0169] First, based on the allocated processing volume, calculate the amount of liquid to be returned to each process within a single time period: The single-period return volume in the southern area is 156.06m³. 3 / 4≈39.02m 3 ; The single-period return volume of the second section in the South Zone is 63.51m³. 3 / 4≈15.88m 3 ; The single-period return volume in the North Zone is 256.74 m³. 3 / 4≈64.19m 3 ; The single-period return volume of the second section in the North Zone is 104.49 m³. 3 / 4≈26.12m 3 ; Then, the return liquid volume of each zone in the first and second time periods is added together to obtain the total control target of each zone in a single time period: Total return volume in the South Zone during a single time period = (Return volume of South Zone Section 1 during a single time period) + (Return volume of South Zone Section 2 during a single time period) = 39.02m 3 +15.88m 3 =54.90m 3 ; Total return volume in the North Zone during a single time period = (Return volume of North Zone Section 1 during a single time period) + (Return volume of North Zone Section 2 during a single time period) = 64.19m 3 +26.12m 3 =90.31m 3 ; The system calculates the total return volume of the South Zone in a single time period (54.90m³) based on the above calculations. 3 ")" and "Total return volume in the North District in a single time period (90.31m)" 3As a result, within each time period, control commands are automatically generated to drive the corresponding valves to adjust the flow rate. By breaking down the process into smaller, time-sharing actions, the impact of a single large flow rate surge on system stability is effectively avoided, achieving stable and precise control over the electrolyte composition and volume.

[0170] Implementation effect verification After the online control method and device described in this application were put into operation in actual production, significant technical effects were achieved compared with the traditional semi-manual control mode. Specific data comparison is shown in the table below: Table 1. Comparison Data Results

[0171] Furthermore, implementing this method effectively avoids abnormal system resistance and voltage caused by a decrease in sulfate ions or an increase in copper ions, significantly reduces the labor intensity of on-site personnel in handling short circuits and particle boards, and improves the intrinsic safety level.

[0172] refer to Figure 5 This application also provides an online control device for the composition and volume of copper electrolyte, comprising: The acquisition module 10 is used to acquire the ion concentration data and current volume data of the electrolyte; The calculation module 20 is used to input the ion concentration data into a preset ion concentration calculation model to calculate the amount of liquid to be returned, and to input the current volume data of the electrolyte into a preset volume calculation model, and to calculate the amount of water to be replenished by combining the preset water evaporation rate. Output module 30 is used to generate and output corresponding pneumatic regulating valve opening control commands based on the backflow liquid adjustment amount and the water replenishment amount, respectively. The calculation module 20 is also used to collect real-time flow data fed back by the flow meter and calculate the deviation between the real-time flow data and the backflow liquid adjustment amount or the water replenishment amount; The judgment module 40 is used to determine whether the deviation is within a preset allowable range. If it exceeds the preset allowable range, a corrected pneumatic regulating valve opening control command is generated based on the deviation until the deviation is within the preset allowable range.

[0173] It is understood that the device in this embodiment corresponds to the online control method of copper electrolyte composition and volume in the above embodiment. The options in the above embodiment are also applicable to this embodiment, so they will not be described again here.

[0174] This application also provides a computer device, which includes a processor and a memory. The memory stores a computer program, and the processor is used to execute the computer program to implement the online control method for the composition and volume of copper electrolyte as described in any of the foregoing embodiments.

[0175] The processor can be an integrated circuit chip with signal processing capabilities. The processor can be a general-purpose processor, including at least one of a Central Processing Unit (CPU), Graphics Processing Unit (GPU), Network Processor (NP), Digital Signal Processor (DSP), Application-Specific Integrated Circuit (ASIC), Field-Programmable Gate Array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. The general-purpose processor can be a microprocessor or any conventional processor, capable of implementing or executing the methods, steps, and logic block diagrams disclosed in the embodiments of this application.

[0176] The memory can be, but is not limited to, Random Access Memory (RAM), Read Only Memory (ROM), Programmable Read-Only Memory (PROM), Erasable Programmable Read-Only Memory (EPROM), Electrically Erasable Programmable Read-Only Memory (EEPROM), etc. The memory is used to store computer programs, and the processor can execute the computer programs accordingly after receiving execution instructions.

[0177] This application embodiment also provides a computer storage medium storing a computer program, which, when executed on a processor, implements the online control method for the composition and volume of copper electrolyte according to any one of the foregoing embodiments.

[0178] The computer storage medium can be a readable storage medium, a non-volatile storage medium, or a volatile storage medium. For example, the computer storage medium may include, but is not limited to, various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0179] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can also be implemented in other ways. The apparatus embodiments described above are merely illustrative. For example, the flowcharts and block diagrams in the accompanying drawings show the architecture, functionality, and operation of possible implementations of apparatus, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that, in alternative implementations, the functions marked in the blocks may occur in a different order than those marked in the drawings. For example, two consecutive blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagram and / or flowchart, and combinations of blocks in the block diagram and / or flowchart, can be implemented using a dedicated hardware-based system that performs the specified function or action, or using a combination of dedicated hardware and computer instructions.

[0180] In addition, the functional modules or units in the various embodiments of this application can be integrated together to form an independent part, or each module can exist independently, or two or more modules can be integrated to form an independent part.

[0181] If the aforementioned functions are implemented as software functional modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a smartphone, personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application.

[0182] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application.

Claims

1. A method for online control of the composition and volume of a copper electrolyte, characterized in that, include: Obtain the ion concentration data and current volume data of the electrolyte; The ion concentration data is input into a preset ion concentration calculation model to calculate the amount of liquid to be returned. The current volume data of the electrolyte is input into a preset volume calculation model, and the amount of water to be replenished is calculated in combination with the preset water evaporation rate. Based on the backflow liquid adjustment amount and the water replenishment amount, corresponding pneumatic regulating valve opening control commands are generated and output; Collect real-time flow data fed back by the flow meter, and calculate the deviation between the real-time flow data and the backflow liquid adjustment amount or the water replenishment amount; Determine whether the deviation is within a preset allowable range. If it exceeds the preset allowable range, generate a corrected pneumatic regulating valve opening control command based on the deviation until the deviation is within the preset allowable range.

2. The method for online control of copper electrolyte composition and volume as described in claim 1, characterized in that, The step of inputting the ion concentration data into a preset ion concentration calculation model to calculate the backflow adjustment amount includes: The theoretical yield of cathode copper is calculated based on current density, electrochemical equivalent, and electrolysis time. Calculate the weight of copper dissolved from the anode plate based on the theoretical output of cathode copper and the preset anode copper dissolution rate; Calculate the weight of copper enriched in the electrolyte based on the current copper ion concentration, the target copper ion concentration, and the current volume of the electrolyte. The total weight of copper to be removed is obtained by adding the weight of copper dissolved from the anode plate to the weight of copper enriched in the electrolyte. Based on the total weight of copper to be removed, and combined with the preset copper removal system processing capacity, calculate the processing volume allocated to each copper removal process. The amount of backflow liquid adjustment is calculated based on the processing volume of each copper removal process.

3. The method for online control of copper electrolyte composition and volume as described in claim 2, characterized in that, The electrolyte is distributed in a copper electrolysis system comprising a first electrolysis zone and a second electrolysis zone; The total weight of copper to be removed includes the weight of copper to be removed from the first electrolytic zone and the weight of copper to be removed from the second electrolytic zone; The copper removal process at each stage includes a first-stage copper removal process and a second-stage copper removal process; The backflow liquid adjustment amount includes the backflow liquid amount for the first electrolysis zone and the backflow liquid amount for the second electrolysis zone; The calculation of the processing volume allocated to each copper removal process includes: Calculate the sum of the copper removal weight required for the first electrolytic zone and the copper removal weight required for the second electrolytic zone, and use this as the total copper removal weight required. Based on the proportion of the copper removal weight required in each zone to the total copper removal weight required, the total processing volume of the first-stage copper removal and the total processing volume of the second-stage copper removal are allocated to each zone, resulting in the first-stage copper removal processing volume and the second-stage copper removal processing volume for each zone.

4. The method for online control of copper electrolyte composition and volume as described in claim 3, characterized in that, The formula for calculating the amount of backflow liquid adjustment includes: The backflow volume of any zone = the backflow volume of the first stage of copper removal in that zone + the backflow volume of the second stage of copper removal in that zone; where, The amount of copper stripping liquid returned in one section of this partition = the volume of copper stripping treatment in one section of this partition / 4; The amount of copper stripping liquid returned in the second stage of this partition = the volume of copper stripping treatment in the second stage of this partition / 4.

5. The method for online control of copper electrolyte composition and volume as described in claim 3, characterized in that, In the calculation step of the backflow liquid adjustment amount, the first-stage copper removal processing volume of the first electrolysis zone and the second electrolysis zone and the second-stage copper removal processing volume are determined by the following method: The formula for calculating the theoretical cathode copper yield for each zone is: Q 理论 =I×K×N×C1×η×t×10 -6 ; Among them, Q 理论 η is the theoretical yield of cathode copper; I is the current density; K is the electrochemical equivalent; N is the number of energized groups; C1 is the number of electrolytic cells; η is the expected electrolytic efficiency; t is the electrolysis time. The formula for calculating the weight of copper dissolved from the anode plates in each zone is as follows: ； in, λ represents the weight of copper dissolved from the anode plate; λ is the corresponding copper dissolution rate at the anode. The total processing volume of the first and second stages of copper removal is calculated using the following formula: V 一段总 =(F 循环 -F 二段 )×24; V 二段总 =(F 二段 -C2)×24; Among them, V 一段总 V represents the total volume of copper stripping in one stage. 二段总 This represents the total processing volume of the two-stage copper removal process; F 循环 F is the flow rate of the circulating pump. 二段 C1 is the flow rate for the second-stage copper removal process; C2 is the preset flow rate constant. The calculated weight W of copper dissolved from the anode plates of each zone. 溶出 Add the weight of copper enriched in the corresponding electrolyte to obtain the weight of copper to be removed from each zone; Based on the proportion of the copper removal weight required in each zone to the sum of the copper removal weight required in the first electrolytic zone and the second electrolytic zone, the calculated total copper removal processing volume V is calculated for each section. 一段总 and the total processing volume V of the two-stage copper removal process 二段总 The volume of copper stripping in the first stage and the volume of copper stripping in the second stage are allocated to each partition.

6. The method for online control of copper electrolyte composition and volume as described in claim 1, characterized in that, The expression for the volume calculation model is: V = V0 - q3 × t - V1; Wherein, V represents the water replenishment amount, V0 represents the set standard volume of the electrolyte, q3 represents the preset water evaporation rate, t represents the evaporation time, and V1 represents the current volume of the electrolyte; the preset water evaporation rate is determined based on an electrolyte temperature of 63℃~65℃; and / or, The preset allowable range includes a first preset allowable range for backflow control and a second preset allowable range for water replenishment control: when judging the deviation of the backflow adjustment amount, the first preset allowable range is used; wherein, the first preset allowable range is: the absolute value of the deviation between the real-time flow data and the backflow adjustment amount is less than or equal to 2%; when judging the deviation of the water replenishment amount, the second preset allowable range is used; wherein, the second preset allowable range is: the absolute value of the deviation between the actual volume of the electrolyte after water replenishment confirmed based on the real-time flow data and the set standard volume of the electrolyte is less than or equal to 1%; and / or, The acquisition of electrolyte ion concentration data includes: receiving laboratory data uploaded by the MES system as the ion concentration data through the data interaction interface between the DCS system and the MES system; and / or, The ion concentration data includes copper ion concentration and sulfate ion concentration, wherein the target value for copper ion concentration in the ion concentration calculation model is set to be 40 g / L~50 g / L, and the target value for sulfate ion concentration is 190 g / L~220 g / L.

7. The method for online control of copper electrolyte composition and volume as described in claim 1, characterized in that, The step of generating corresponding pneumatic regulating valve opening control commands based on the backflow liquid adjustment amount and the water replenishment amount includes: Compare the calculated backflow adjustment or replenishment volume with the preset high flow rate threshold. If the adjustment amount or water replenishment amount is greater than or equal to the preset high flow threshold, a command is generated to adjust the opening of the pneumatic control valve to the first opening value. If the adjustment amount or water replenishment amount is less than the preset low flow threshold, an instruction is generated to adjust the opening of the pneumatic regulating valve to the second opening value; wherein, the first opening value is greater than the second opening value.

8. A device for online control of copper electrolyte composition and volume, characterized in that, include: The acquisition module is used to acquire the ion concentration data and current volume data of the electrolyte. The calculation module is used to input the ion concentration data into a preset ion concentration calculation model to calculate the amount of liquid to be returned, and to input the current volume data of the electrolyte into a preset volume calculation model, and to calculate the amount of water to be replenished by combining the preset water evaporation rate. The output module is used to generate and output corresponding pneumatic regulating valve opening control commands based on the backflow liquid adjustment amount and the water replenishment amount, respectively. The calculation module is also used to collect real-time flow data fed back by the flow meter and calculate the deviation between the real-time flow data and the backflow liquid adjustment amount or the water replenishment amount; The judgment module is used to determine whether the deviation is within a preset allowable range. If it exceeds the preset allowable range, a corrected pneumatic regulating valve opening control command is generated based on the deviation until the deviation is within the preset allowable range.

9. A computer device, characterized in that, The computer device includes a processor and a memory, the memory storing a computer program, and the processor executing the computer program to implement the online control method for the composition and volume of copper electrolyte as described in any one of claims 1-7.

10. A computer storage medium, characterized in that, It stores a computer program, which, when executed on a processor, implements the online control method for the composition and volume of copper electrolyte according to any one of claims 1-7.

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