A method and system for processing waste materials at a concrete batching plant

Abstract

The application discloses a kind of concrete mixing station waste material processing method and system, it is related to waste processing technical field, comprising: the solid content and free moisture data of detection waste slurry;Excess free moisture is removed using targeted solid-liquid separation method, and concentrated waste residue with up-to-standard solid content and uniform distribution is obtained;Pressure regulation and special pressure filtration treatment are carried out based on humidity and agglomeration state data, so that waste residue forms mud cake adapted to subsequent processing;Based on the moisture content, hardness and form data of mud cake, dispersion treatment, powder coating treatment and solidification treatment are sequentially executed, and mud cake is converted into hard particles;Based on the particle size distribution and strength data of hard particles, it is put into concrete mixer according to the preset replacement ratio, replaces part of natural sand and ore powder, and is fully mixed and stirred with concrete raw materials, and finally the concrete product meeting the quality standard is obtained.The application realizes solid-liquid double recovery and efficient conversion of resource of waste material, while reducing the cost and operation difficulty.

Description

Technical Field

[0001] This invention relates to the field of waste treatment technology, specifically to a method and system for treating waste materials from a concrete mixing plant. Background Technology

[0002] With the continuous advancement of urbanization in my country, the demand for concrete, as a core building material in civil engineering, has exploded. During the production process, concrete mixing plants generate a large amount of waste slurry after cleaning concrete equipment and mixer trucks. After the sand and gravel aggregate is recovered by the sand and gravel separator, the remaining waste slurry still contains a large amount of solid waste residue. If not handled properly, it will cause a serious environmental burden.

[0003] Currently, the industry's methods for handling this type of waste material have significant limitations: First, some methods involve landfill disposal, which not only occupies a large amount of land resources but also easily pollutes the soil and groundwater due to waste residue leakage, violating environmental protection requirements; Second, a few have attempted to use the filtered mud cake for making cement bricks, but this requires additional investment in specialized equipment and sites, and the brick-making process is prone to generating new pollution problems, resulting in an imbalance between environmental benefits and economic efficiency; Third, existing treatment processes lack precise parameter linkage control, and solid-liquid separation, filtration, dispersion, and other links rely heavily on experience-based operations, leading to problems such as large fluctuations in the moisture content of the mud cake, uneven particle dispersion, and insufficient stone powder coating, which affect the subsequent recycling effect.

[0004] Furthermore, the existing processes operate independently, lacking a data-closed-loop control mechanism. Deviations in the product state of the previous stage cannot be promptly fed back to subsequent stages for parameter correction, easily leading to unstable quality of the final recycled particles and difficulty in meeting the quality requirements of concrete products. Therefore, there is an urgent need for a waste material treatment technology for concrete mixing plants that combines environmental friendliness, economy, and precision to address many of the pain points of existing technologies. Summary of the Invention

[0005] To solve the above-mentioned technical problems, a method and system for treating waste materials from concrete mixing plants is provided. This technical solution solves the aforementioned problems.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A method and system for treating waste materials from a concrete mixing plant, comprising: The waste slurry generated after the sand and gravel aggregate is recovered by the sand and gravel separation equipment at the concrete mixing plant is obtained, and the solid content and free water content of the waste slurry are tested. Based on the solid content and free water data of the waste slurry, a targeted solid-liquid separation method was used to remove excess free water, resulting in concentrated waste residue with a solid content that meets the standard and is evenly distributed. The humidity and agglomeration status data of the concentrated waste residue are detected, and pressure regulation and special pressure filtration treatment are carried out based on the humidity and agglomeration status data to form a mud cake suitable for subsequent processing. The moisture content, hardness, and morphology of the mud cake are detected. Based on the moisture content, hardness, and morphology data of the mud cake, dispersion treatment, powder coating treatment, and coagulation treatment are performed in sequence to transform the mud cake into hard particles. The particle size distribution and strength data of the hard particles are detected. Based on the particle size distribution and strength data of the hard particles, they are put into a concrete mixer according to a preset substitution ratio to replace part of the natural sand and mineral powder. They are then fully mixed with the concrete raw materials to finally obtain concrete products that meet the quality standards.

[0007] Preferably, the solid-liquid separation process includes: The waste slurry discharged after sand and gravel separation is obtained, and the concentration, flow rate and viscosity data of the waste slurry are detected. Based on the concentration, flow rate and viscosity data of the waste slurry, a suitable solid-liquid separation device is selected. The solid-liquid separation device includes a sedimentation tank and a solid-liquid separation tank. If a sedimentation tank is selected, the waste slurry is introduced into the tank and allowed to settle based on the principle of gravity settling. The settling speed data of the waste residue in the tank is monitored in real time. The sedimentation is accelerated by a stirring device until the waste residue settles to the bottom of the tank. If a solid-liquid separation tank is selected, the waste slurry is pressurized and injected into the tank by a slurry pump. Based on the principle of centrifugal separation, the solid waste residue is deposited under the action of centrifugal force. The clarity data of the supernatant in the tank is monitored in real time, and the upper clear liquid is discharged in real time. The solid waste residue after sedimentation and centrifugation is collected, and its solid content data is tested. Once it is confirmed to meet the standards, it is used as concentrated waste residue. The purity data of the clarified liquid after separation is tested, and after filtration and purification treatment, it is recycled to realize the recycling of water resources.

[0008] Preferably, the pressure filtration process includes: The flow rate and humidity data of the concentrated waste residue are obtained. Based on the flow rate and humidity data of the concentrated waste residue, it is stably fed into the filter press through the conveying equipment. The filter press is selected from frame filter press, belt filter press and diaphragm filter press according to the processing scale. Obtain the target particle size data for subsequent granulation treatment, and determine the filter press pressure control parameters based on the cake dispersion adaptability requirements; Based on the aforementioned filter press pressure control parameters, the filter press pressure is controlled by the pressure regulation system of the filter press equipment, and the waste residue dewatering rate and sludge cake forming status data are monitored in real time. After the filter press is completed, the resulting mud cake is collected, and the water content, hardness, and morphology of the mud cake are tested to determine whether it meets the dispersion treatment requirements. If the test data does not meet the standards, the filter press pressure parameters are adjusted based on the deviation data and the process is repeated until the mud cake quality meets the standards.

[0009] Preferably, the dispersion process includes: The moisture content, hardness, and morphology data of the mud cake are obtained. Based on this data, the qualified mud cake is fed into the feeding structure of the special cutting device through a conveying device. Based on the moisture content, hardness data of the mud cake and the subsequent target particle size requirements, the configuration parameters of the saw blade group are determined. The configuration parameters include the number of saw blades, the installation spacing, and the arrangement. The saw blade assembly of the cutting device adopts a modular and detachable design. The saw blade assembly is adjusted according to the determined configuration parameters. It is connected to the existing motor of the mixing plant through the adapter interface to drive the saw blade assembly to rotate at high speed to cut the mud cake. The particle size distribution data of the particles is monitored in real time during the cutting process. The feed speed and saw blade speed are adjusted based on the particle size distribution data to ensure particle uniformity. The dispersed fine particles are collected, the particle size distribution data is detected, and after confirmation that the standard is met, they are transported to the powder coating process through a closed conveyor channel.

[0010] Preferably, the powder coating process includes: Obtain the particle size distribution data of the dispersed fine particles. Based on the particle size distribution data, calculate the average particle size using a particle size weighting algorithm. The formula for calculating the average particle size is as follows: in For the first Particle size of the group of particles, For the first The mass of the group of particles, The number of particle size groups was determined, and the appropriate mass ratio of stone powder to granules was established. The initial moisture content of the stone powder is obtained, and the powder is dried based on this data. The dryness of the stone powder is monitored in real time until the moisture content reaches the standard. Based on the determined mass ratio and particle conveying data, the stone powder is added through a conveying structure equipped with a metering device. The formula for calculating the amount of stone powder added is as follows: In the formula, This refers to the amount of stone powder added. For particle size matching coefficient, The average particle size is This refers to the particle delivery rate; Stone powder and fine particles are fed into a mixing device together. Based on the particle flowability and stone powder adhesion data, the two are mixed by stirring and tumbling. The integrity of the coating and the adhesion of the mixed particles are sampled and tested. After confirming that the stone powder is uniformly coated and there is no adhesion, the coated particles are formed and sent to the solidification process.

[0011] Preferably, the solidification process includes: Acquire the initial temperature and humidity data of the encapsulated particles, and based on the initial temperature and humidity data of the encapsulated particles, transfer them to the designated solidification area for layered static stacking, control the stacking height, monitor the environmental temperature and humidity data of the solidification area in real time, and adjust the static solidification time based on the environmental temperature and humidity data of the solidification area. When the environmental temperature and humidity are suitable, use the normal time; when the temperature and humidity deviate from the suitable range, extend the solidification time. Based on solidification time and particle adhesion risk data, the stockpiled particles are turned over according to a preset cycle. The adhesion status data of the particles after turning is monitored in real time. After the particles solidify, their plasticity, strength and particle size distribution data are tested. Based on the plasticity, strength and particle size distribution data, a screening device is used for grading and screening to remove particles with incorrect particle size, adhesion and agglomeration and insufficient strength. The qualified particles after screening are collected and their final strength and uniformity data are tested. After meeting the standards, they are stored in a special storage device for later use.

[0012] Preferably, the mixing and stirring includes: Obtain data on the design strength and workability requirements of concrete, and combine this data with the particle size distribution and strength of hard particles to establish a corresponding relationship between the substitution ratios of hard particles and natural sand and mineral powder, forming an intuitive conversion table. Based on the aforementioned alternative proportions and the required feed volume data of the concrete mixer, the feed volume data for hard particles, natural sand, and mineral powder are determined. The hard particles are precisely fed into the concrete mixer in the determined amount using a feeding device, while the feed volume of natural sand and mineral powder is adjusted simultaneously. The proportions are then integrated with the mixer control system for automated feeding. During the mixing process, the slump, spread, and homogeneity of the concrete mixture are monitored in real time, and the proportions or mixing parameters are fine-tuned based on this data. Finally, the compressive strength, durability, and other quality data of the final concrete product are tested, and preparation is completed after confirming compliance with relevant standards.

[0013] Preferably, the dispersion process of the cutting device includes: Obtain data on the moisture content, hardness, and target particle size range of the mud cake. Select multiple high-strength wear-resistant saw blades and install them on a dedicated rotating shaft. Based on the moisture content and hardness data of the mud cake, adjust the number of saw blades through a detachable fixing structure and adjust the saw blade spacing through adjusting shims or a dedicated adjustment mechanism to form a cutting combination suitable for the working conditions. For mud cakes with high moisture content and strong viscosity, increase the number of saw blades and reduce the spacing. For mud cakes with low moisture content and hard texture, reduce the number of saw blades and increase the spacing. Drive the rotating shaft to drive the saw blade group to rotate synchronously at high speed. Based on the coordinated control data of feed speed and saw blade speed, the mud cake is gradually cut and decomposed. Real-time monitoring of particle size distribution data after cutting is performed. Based on the particle size distribution data after cutting, the saw blade configuration and operating parameters are iteratively optimized.

[0014] Preferably, the method further includes: setting up data acquisition nodes in the processing stage to collect key parameter data of waste slurry, concentrated waste residue, mud cake, intermediate particles and final products in real time; establishing a correlation database of parameters in each stage, optimizing the processing parameters of the next stage based on the detection data of the previous stage, forming a closed-loop control logic; and correcting deviations in the processing process based on the correlation database and the closed-loop control logic.

[0015] A waste material treatment system for a concrete mixing plant includes: The data acquisition module is used to collect key parameter data of waste slurry, concentrated waste residue, mud cake, intermediate particles and final products; The solid-liquid separation module is used to receive waste slurry, select the separation method based on the key parameter data of the data acquisition module, perform solid-liquid separation and output concentrated waste residue, and recycle the clarified liquid. The filter press module is used to receive concentrated waste residue, adjust the filter press pressure based on key parameter data, make the concentrated waste residue into a suitable sludge cake, and obtain sludge cake quality data. The granulation module is used to perform dispersion, powder coating and coagulation processes based on key parameter data, and output qualified hard granules. The mixing module is used to retrieve key parameter data and preset proportions, control the amount of hard particles fed, and work in conjunction with the concrete mixer to complete the mixing process. The control module automatically adjusts the operating parameters of each module based on preset logic.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. This invention transforms waste slurry from concrete mixing plants into hard particles that can replace natural sand and mineral powder, successfully turning waste into treasure. It not only solves the problems of landfill pollution from waste materials and secondary pollution from brick making, but also reduces reliance on the mining of natural sand and gravel resources, which is in line with the concept of green development. At the same time, the clarified liquid after solid-liquid separation can be recycled for concrete mixing or equipment cleaning after purification, realizing the recycling of water resources and further improving resource utilization.

[0017] 2. Each processing step of this invention optimizes parameter settings based on the detection data of the previous step. For example, it selects the solid-liquid separation method according to the concentration and flow rate of the waste slurry, adjusts the saw blade configuration according to the moisture content of the mud cake, and determines the stone powder ratio based on the particle size. This effectively avoids the quality fluctuations caused by the reliance on experience in traditional processes. Through quantitative tools such as particle size weighting algorithms and stone powder dosage calculation formulas, as well as real-time monitoring and deviation correction mechanisms, it ensures that the final recycled particles have uniform particle size and meet the strength standards, thus guaranteeing the quality stability of concrete products.

[0018] 3. The dispersion device in this invention adopts a modular and detachable saw blade assembly design, which does not require a special drive equipment and can be directly connected to the existing motor of the batching plant. The mixing equipment adopts a miniaturized design and can be linked with ordinary concrete mixers, which greatly reduces the size of the equipment and the investment cost. It provides a lightweight basic configuration combination for small batching plants and supports the equipment rental mode, which effectively solves the problem that small batching plants cannot carry out waste material recycling due to capital and site limitations, and improves the popularization of the technology.

[0019] 4. This invention breaks down complex processes into standardized steps by establishing a relational database of parameters for each stage and an intuitive ratio conversion table. This eliminates the need for complex calculations by operators and allows direct integration with the concrete mixer control system for automated material feeding and mixing. The entire process only requires the collection of key data through the detection module, while the control module automatically adjusts parameters, reducing manual intervention, operational difficulty, and human error, thus improving processing efficiency. Attached Figure Description

[0020] Figure 1 This is a flowchart of the method steps of the present invention; Figure 2 This is a system framework diagram of the present invention. Detailed Implementation

[0021] The following description is intended to disclose the invention and enable those skilled in the art to implement it. The preferred embodiments described below are merely examples, and other obvious variations will occur to those skilled in the art.

[0022] Reference Figure 1 As shown, a method for treating waste materials from a concrete mixing plant includes: The waste slurry generated after the sand and gravel aggregate is recovered by the sand and gravel separation equipment at the concrete mixing plant is obtained, and the solid content and free water content of the waste slurry are tested. Based on the solid content and free water data of the waste slurry, a targeted solid-liquid separation method was used to remove excess free water, resulting in concentrated waste residue with a solid content that meets the standard and is evenly distributed. The humidity and agglomeration status data of the concentrated waste residue are detected, and pressure regulation and special pressure filtration treatment are carried out based on the humidity and agglomeration status data to form a mud cake suitable for subsequent processing. The moisture content, hardness, and morphology of the mud cake are detected. Based on the moisture content, hardness, and morphology data of the mud cake, dispersion treatment, powder coating treatment, and coagulation treatment are performed in sequence to transform the mud cake into hard particles. The particle size distribution and strength data of the hard particles are detected. Based on the particle size distribution and strength data of the hard particles, they are put into a concrete mixer according to a preset substitution ratio to replace part of the natural sand and mineral powder. They are then fully mixed with the concrete raw materials to finally obtain concrete products that meet the quality standards.

[0023] The solid-liquid separation process includes: The waste slurry discharged after sand and gravel separation is obtained, and the concentration, flow rate and viscosity data of the waste slurry are detected. Based on the concentration, flow rate and viscosity data of the waste slurry, a suitable solid-liquid separation device is selected. The solid-liquid separation device includes a sedimentation tank and a solid-liquid separation tank. If a sedimentation tank is selected, the waste slurry is introduced into the tank and allowed to settle based on the principle of gravity settling. The settling speed data of the waste residue in the tank is monitored in real time. The sedimentation is accelerated by a stirring device until the waste residue settles to the bottom of the tank. If a solid-liquid separation tank is selected, the waste slurry is pressurized and injected into the tank by a slurry pump. Based on the principle of centrifugal separation, the solid waste residue is deposited under the action of centrifugal force. The clarity data of the supernatant in the tank is monitored in real time, and the upper clear liquid is discharged in real time. The solid waste residue after sedimentation and centrifugation is collected, and its solid content data is tested. After confirming that it meets the standards, it is used as concentrated waste residue. The purity data of the clarified liquid after separation is tested, and after filtration and purification treatment, it is recycled to realize the recycling of water resources. Based on the actual working conditions of the waste slurry, the separation equipment is adaptively selected to solve the problem of poor adaptability of a single separation method. Real-time monitoring of settling velocity and clarity is introduced to ensure separation efficiency and the quality of concentrated waste residue. Simultaneously, liquid recovery is realized to avoid water waste and form a closed loop of solid-liquid dual recovery.

[0024] The pressure filtration process includes: The flow rate and humidity data of the concentrated waste residue are obtained. Based on the flow rate and humidity data of the concentrated waste residue, it is stably fed into the filter press through the conveying equipment. The filter press is selected from frame filter press, belt filter press and diaphragm filter press according to the processing scale. Obtain the target particle size data for subsequent granulation treatment, and determine the filter press pressure control parameters based on the cake dispersion adaptability requirements; Based on the aforementioned filter press pressure control parameters, the filter press pressure is controlled by the pressure regulation system of the filter press equipment, and the waste residue dewatering rate and sludge cake forming status data are monitored in real time. After the filter press is completed, the resulting mud cake is collected, and the water content, hardness and morphology of the mud cake are tested to determine whether it meets the dispersion treatment requirements. If the test data does not meet the standards, the filter press pressure parameters are adjusted based on the deviation data and the process is repeated until the mud cake quality meets the standards. Establish the correlation logic of the filter press parameters for the target particle size to ensure that the characteristics of the filter cake are accurately adapted to the subsequent dispersion treatment, and avoid the inefficiency of subsequent processes due to filter cake quality problems; set up a filter cake quality inspection and rework mechanism to break the traditional extensive mode of one-time filter press molding and ensure the quality stability of intermediate products.

[0025] The dispersion process includes: The moisture content, hardness, and morphology data of the mud cake are obtained. Based on this data, the qualified mud cake is fed into the feeding structure of the special cutting device through a conveying device. Based on the moisture content, hardness data of the mud cake and the subsequent target particle size requirements, the configuration parameters of the saw blade group are determined. The configuration parameters include the number of saw blades, the installation spacing, and the arrangement. The saw blade assembly of the cutting device adopts a modular and detachable design. The saw blade assembly is adjusted according to the determined configuration parameters. It is connected to the existing motor of the mixing plant through the adapter interface to drive the saw blade assembly to rotate at high speed to cut the mud cake. The particle size distribution data of the particles is monitored in real time during the cutting process. The feeding speed and saw blade speed are adjusted based on the particle size distribution data to ensure particle uniformity. The dispersed fine particles are collected, the particle size distribution data is detected, and after confirmation that the standard is met, they are transported to the powder coating process through a closed conveyor channel. The design incorporates modular, detachable saw blades to precisely match the saw blade configuration with the characteristics of the mud cake and the target particle size, solving the problems of fixed parameters, easy saw blade sticking, and uneven particle size in traditional cutting devices. It reuses existing motors in the mixing plant, eliminating the need for dedicated drive equipment and reducing equipment investment costs. Real-time control and particle detection during the cutting process are introduced to ensure the uniformity of the dispersed products.

[0026] The powder coating process includes: Obtain the particle size distribution data of the dispersed fine particles. Based on the particle size distribution data, calculate the average particle size using a particle size weighting algorithm. The formula for calculating the average particle size is as follows: in For the first Particle size of the group of particles, For the first The mass of the group of particles, The number of particle size groups was determined, and the appropriate mass ratio of stone powder to granules was established. The initial moisture content of the stone powder is obtained, and the powder is dried based on this data. The dryness of the stone powder is monitored in real time until the moisture content reaches the standard. Based on the determined mass ratio and particle conveying data, the stone powder is added through a conveying structure equipped with a metering device. The formula for calculating the amount of stone powder added is as follows: In the formula, This refers to the amount of stone powder added. For particle size matching coefficient, The average particle size is This refers to the particle delivery rate; Stone powder and fine particles are fed into a mixing device together. Based on the particle flowability and stone powder adhesion data, the two are mixed by stirring and tumbling. The integrity of the coating and the adhesion of the mixed particles are sampled and tested. After confirming that the stone powder is uniformly coated and there is no adhesion, the coated particles are formed and sent to the coagulation treatment stage. The average particle size is calculated by a quantitative algorithm, and the amount of stone powder added is precisely controlled by a special formula, replacing the traditional speed estimation method and ensuring the accuracy of the proportion. The addition of stone powder drying pretreatment and coating status detection solves the problem of particle adhesion caused by stone powder clumping due to moisture and uneven coating, thereby improving the stability of the powder coating process and the quality of the product.

[0027] The solidification process includes: Acquire the initial temperature and humidity data of the encapsulated particles, and based on the initial temperature and humidity data of the encapsulated particles, transfer them to the designated solidification area for layered static stacking, control the stacking height, monitor the environmental temperature and humidity data of the solidification area in real time, and adjust the static solidification time based on the environmental temperature and humidity data of the solidification area. When the environmental temperature and humidity are suitable, use the normal time; when the temperature and humidity deviate from the suitable range, extend the solidification time. Based on solidification time and particle adhesion risk data, the stockpiled particles are turned over according to a preset cycle. The adhesion status data of the particles after turning is monitored in real time. After the particles solidify, their plasticity, strength and particle size distribution data are tested. Based on the plasticity, strength and particle size distribution data, a screening device is used for grading and screening to remove particles with incorrect particle size, adhesion and agglomeration and insufficient strength. The qualified particles after screening are collected and their final strength and uniformity data are tested. After meeting the standards, they are stored in a special storage device for later use. Establish a dynamic adaptation mechanism between ambient temperature and humidity and solidification time to solve the problems of fixed solidification time and great influence from the environment in traditional methods; set up regular turning and adhesion monitoring to prevent particle adhesion from the source; add graded screening and final quality testing to ensure that the strength and particle size of hard particles meet the standards, and provide quality assurance for subsequent replacement of natural sand and gravel.

[0028] The mixing and stirring includes: Obtain data on the design strength and workability requirements of concrete, and combine this data with the particle size distribution and strength of hard particles to establish a corresponding relationship between the substitution ratios of hard particles and natural sand and mineral powder, forming an intuitive conversion table. Based on the aforementioned alternative proportions and the required feed volume data of the concrete mixer, the feed volume data for hard particles, natural sand, and mineral powder are determined. The hard particles are precisely fed into the concrete mixer in the determined amount using a feeding device, while the feed volume of natural sand and mineral powder is adjusted simultaneously. The proportions are then integrated with the mixer control system for automated feeding. During the mixing process, the slump, spread, and homogeneity of the concrete mixture are monitored in real time, and the proportions or mixing parameters are fine-tuned based on this data. Finally, the compressive strength, durability, and other quality data of the final concrete product are tested, and preparation is completed after confirming compliance with relevant standards. An intuitive alternative mix conversion table is developed, eliminating the need for complex calculations and reducing operational difficulty; the mix ratio is integrated with the existing mixer control system, automating material feeding and reducing human error; performance monitoring and dynamic fine-tuning during the mixing process are introduced to ensure that the final concrete product quality meets standards, solving the problems of ambiguous mix ratios and the potential impact on product performance caused by traditional alternative material feeding.

[0029] The dispersion process of the cutting device includes: Obtain data on the moisture content, hardness, and target particle size range of the mud cake. Select multiple high-strength wear-resistant saw blades and install them on a dedicated rotating shaft. Based on the moisture content and hardness data of the mud cake, adjust the number of saw blades through a detachable fixing structure and adjust the saw blade spacing through adjusting shims or a dedicated adjustment mechanism to form a cutting combination suitable for the working conditions. For mud cakes with high moisture content and strong viscosity, increase the number of saw blades and reduce the spacing. For mud cakes with low moisture content and hard texture, reduce the number of saw blades and increase the spacing. Drive the rotating shaft to drive the saw blade group to rotate synchronously at high speed. Based on the coordinated control data of feed speed and saw blade speed, the mud cake is gradually cut and decomposed. Real-time monitoring of particle size distribution data after cutting is performed. Based on the particle size distribution data after cutting, the saw blade configuration and operating parameters are iteratively optimized. The logic for adapting saw blade configuration to mud cake characteristics is refined, and differentiated cutting schemes are developed for mud cakes with different moisture content and hardness to further improve dispersion efficiency and particle uniformity. An iterative optimization mechanism for cutting parameters is introduced to adjust saw blade configuration and operating parameters in reverse based on cutting product data to continuously improve dispersion effect.

[0030] It also includes: setting up data acquisition nodes in the processing stage to collect key parameter data of waste slurry, concentrated waste residue, mud cake, intermediate particles and final products in real time; establishing a correlation database of parameters in each stage, optimizing the processing parameters of the next stage based on the detection data of the previous stage, forming a closed-loop control logic; and correcting deviations in the processing process based on the correlation database and the closed-loop control logic. By constructing a comprehensive data acquisition and correlation database, clarifying the linkage relationship between parameters in each stage, and breaking the limitations of independent operation of each stage in traditional processes, deviations are corrected in real time through closed-loop control logic, ensuring the stability of the entire processing flow and the consistency of product quality, and providing technical support for the large-scale promotion of the process.

[0031] Reference Figure 2 As shown, a waste material treatment system for a concrete mixing plant includes: The data acquisition module is used to collect key parameter data of waste slurry, concentrated waste residue, mud cake, intermediate particles and final products; The solid-liquid separation module is used to receive waste slurry, select the separation method based on the key parameter data of the data acquisition module, perform solid-liquid separation and output concentrated waste residue, and recycle the clarified liquid. The filter press module is used to receive concentrated waste residue, adjust the filter press pressure based on key parameter data, make the concentrated waste residue into a suitable sludge cake, and obtain sludge cake quality data. The granulation module is used to perform dispersion, powder coating and coagulation processes based on key parameter data, and output qualified hard granules. The mixing module is used to retrieve key parameter data and preset proportions, control the amount of hard particles fed, and work in conjunction with the concrete mixer to complete the mixing process. The control module automatically adjusts the operating parameters of each module based on preset logic; Each module functions independently but collaborates deeply with the data acquisition and control modules to adapt to the processing needs of mixing plants of different sizes. The control module enables automatic adjustment of parameters in each stage without manual intervention, reducing the operational threshold. It simultaneously integrates the entire process of solid-liquid separation, pressure filtration, granulation, and mixing, and supports liquid recovery, realizing one-stop waste material treatment and resource utilization. The system has a high degree of integration and strong practicality.

[0032] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention. The scope of protection claimed by the appended claims and their equivalents is defined.

Claims

1. A method for treating waste materials from a concrete mixing plant, characterized in that, include: The waste slurry generated after the sand and gravel aggregate is recovered by the sand and gravel separation equipment at the concrete mixing plant is obtained, and the solid content and free water content of the waste slurry are tested. Based on the solid content and free water data of the waste slurry, a targeted solid-liquid separation method was used to remove excess free water, resulting in concentrated waste residue with a solid content that meets the standard and is evenly distributed. The humidity and agglomeration status data of the concentrated waste residue are detected, and pressure regulation and special pressure filtration treatment are carried out based on the humidity and agglomeration status data to form a mud cake suitable for subsequent processing. The moisture content, hardness, and morphology of the mud cake are detected. Based on the moisture content, hardness, and morphology data of the mud cake, dispersion treatment, powder coating treatment, and coagulation treatment are performed sequentially to transform the mud cake into hard particles. The particle size distribution and strength data of the hard particles are detected. Based on the particle size distribution and strength data of the hard particles, they are put into a concrete mixer according to a preset substitution ratio to replace part of the natural sand and mineral powder. They are then fully mixed with the concrete raw materials to finally obtain concrete products that meet the quality standards.

2. The method for treating waste materials from a concrete mixing plant according to claim 1, characterized in that, The solid-liquid separation process includes: The waste slurry discharged after sand and gravel separation is obtained, and the concentration, flow rate and viscosity data of the waste slurry are detected. Based on the concentration, flow rate and viscosity data of the waste slurry, a suitable solid-liquid separation device is selected. The solid-liquid separation device includes a sedimentation tank and a solid-liquid separation tank. If a sedimentation tank is selected, the waste slurry is introduced into the tank and allowed to settle based on the principle of gravity settling. The settling speed data of the waste residue in the tank is monitored in real time, and the sedimentation is accelerated by a stirring device until the waste residue settles to the bottom of the tank. If a solid-liquid separation tank is selected, the waste slurry is pressurized and injected into the tank by a slurry pump. Based on the principle of centrifugal separation, the solid waste residue is deposited under the action of centrifugal force. The clarity data of the supernatant in the tank is monitored in real time, and the upper clear liquid is discharged in real time. The solid waste residue after sedimentation and centrifugation is collected, and its solid content data is tested. Once it is confirmed to meet the standards, it is used as concentrated waste residue. The purity data of the clarified liquid after separation is tested, and after filtration and purification treatment, it is recycled to realize the recycling of water resources.

3. The method for treating waste materials from a concrete mixing plant according to claim 1, characterized in that, The pressure filtration process includes: The flow rate and humidity data of the concentrated waste residue are obtained. Based on the flow rate and humidity data of the concentrated waste residue, it is stably fed into the filter press through the conveying equipment. The filter press is selected from frame filter press, belt filter press and diaphragm filter press according to the processing scale. Obtain the target particle size data for subsequent granulation treatment, and determine the filter press pressure control parameters based on the cake dispersion adaptability requirements; Based on the aforementioned filter press pressure control parameters, the filter press pressure is controlled by the pressure regulation system of the filter press equipment, and the waste residue dewatering rate and sludge cake forming status data are monitored in real time. After the filter press is completed, the resulting mud cake is collected, and the water content, hardness, and morphology of the mud cake are tested to determine whether it meets the dispersion treatment requirements. If the test data does not meet the standards, the filter press pressure parameters are adjusted based on the deviation data and the process is repeated until the mud cake quality meets the standards.

4. The method for treating waste materials from a concrete mixing plant according to claim 1, characterized in that, The dispersion process includes: The moisture content, hardness, and morphology data of the mud cake are obtained. Based on this data, the qualified mud cake is fed into the feeding structure of the special cutting device through a conveying device. Based on the moisture content, hardness data of the mud cake and the subsequent target particle size requirements, the configuration parameters of the saw blade group are determined. The configuration parameters include the number of saw blades, the installation spacing, and the arrangement. The saw blade assembly of the cutting device adopts a modular and detachable design. The saw blade assembly is adjusted according to the determined configuration parameters. It is connected to the existing motor of the mixing plant through the adapter interface to drive the saw blade assembly to rotate at high speed to cut the mud cake. The particle size distribution data of the particles is monitored in real time during the cutting process. The feed speed and saw blade speed are adjusted based on the particle size distribution data to ensure particle uniformity. The dispersed fine particles are collected, the particle size distribution data is detected, and after confirmation that the standard is met, they are transported to the powder coating process through a closed conveyor channel.

5. The method for treating waste materials from a concrete mixing plant according to claim 1, characterized in that, The powder coating process includes: Obtain the particle size distribution data of the dispersed fine particles. Based on the particle size distribution data, calculate the average particle size using a particle size weighting algorithm. The formula for calculating the average particle size is as follows: ， in For the first Particle size of the group of particles, For the first The mass of the group of particles, The number of particle size groups was determined, and the appropriate mass ratio of stone powder to granules was established. The initial moisture content of the stone powder is obtained, and the powder is dried based on this data. The dryness of the stone powder is monitored in real time until the moisture content reaches the standard. Based on the determined mass ratio and particle conveying data, the stone powder is added through a conveying structure equipped with a metering device. The formula for calculating the amount of stone powder added is as follows: ， In the formula, This refers to the amount of stone powder added. For particle size matching coefficient, The average particle size is This refers to the particle delivery rate; Stone powder and fine particles are fed into a mixing device together. Based on the particle flowability and stone powder adhesion data, the two are mixed by stirring and tumbling. The integrity of the coating and the adhesion of the mixed particles are sampled and tested. After confirming that the stone powder is uniformly coated and there is no adhesion, the coated particles are formed and sent to the solidification process.

6. The method for treating waste materials from a concrete mixing plant according to claim 1, characterized in that, The solidification process includes: Acquire the initial temperature and humidity data of the encapsulated particles, and based on the initial temperature and humidity data of the encapsulated particles, transfer them to the designated solidification area for layered static stacking, control the stacking height, monitor the environmental temperature and humidity data of the solidification area in real time, and adjust the static solidification time based on the environmental temperature and humidity data of the solidification area. When the environmental temperature and humidity are suitable, use the normal time; when the temperature and humidity deviate from the suitable range, extend the solidification time. Based on solidification time and particle adhesion risk data, the stockpiled particles are turned over according to a preset cycle. The adhesion status data of the particles after turning is monitored in real time. After the particles solidify, their plasticity, strength and particle size distribution data are tested. Based on the plasticity, strength and particle size distribution data, a screening device is used for grading and screening to remove particles with incorrect particle size, adhesion and agglomeration and insufficient strength. The qualified particles after screening are collected and their final strength and uniformity data are tested. After meeting the standards, they are stored in a special storage device for later use.

7. The method for treating waste materials from a concrete mixing plant according to claim 1, characterized in that, The mixing and stirring includes: Obtain data on the design strength and workability requirements of concrete, and combine this data with the particle size distribution and strength of hard particles to establish a corresponding relationship between the substitution ratios of hard particles and natural sand and mineral powder, forming an intuitive conversion table. Based on the aforementioned alternative proportions and the required feed volume data of the concrete mixer, the feed volume data for hard particles, natural sand, and mineral powder are determined. The hard particles are precisely fed into the concrete mixer in the determined amount using a feeding device, while the feed volume of natural sand and mineral powder is adjusted simultaneously. The proportions are then integrated with the mixer control system for automated feeding. During the mixing process, the slump, spread, and homogeneity of the concrete mixture are monitored in real time, and the proportions or mixing parameters are fine-tuned based on this data. Finally, the compressive strength, durability, and other quality data of the final concrete product are tested, and preparation is completed after confirming compliance with relevant standards.

8. The method for treating waste materials from a concrete mixing plant according to claim 4, characterized in that, The dispersion process of the cutting device includes: Obtain data on the moisture content, hardness, and target particle size range of the mud cake. Select multiple high-strength wear-resistant saw blades and install them on a dedicated rotating shaft. Based on the moisture content and hardness data of the mud cake, adjust the number of saw blades through a detachable fixing structure and adjust the saw blade spacing through adjusting shims or a dedicated adjustment mechanism to form a cutting combination suitable for the working conditions. For mud cakes with high moisture content and strong viscosity, increase the number of saw blades and reduce the spacing. For mud cakes with low moisture content and hard texture, reduce the number of saw blades and increase the spacing. Drive the rotating shaft to drive the saw blade group to rotate synchronously at high speed. Based on the coordinated control data of feed speed and saw blade speed, the mud cake is gradually cut and decomposed. Real-time monitoring of particle size distribution data after cutting is performed. Based on the particle size distribution data after cutting, the saw blade configuration and operating parameters are iteratively optimized.

9. The method for treating waste materials from a concrete mixing plant according to claim 1, characterized in that, Also includes: Data acquisition nodes are set up in the processing stage to collect key parameter data of waste slurry, concentrated waste residue, mud cake, intermediate particles and final products in real time; Establish a database linking parameters for each stage, optimize the processing parameters for the next stage based on the detection data from the previous stage, and form a closed-loop control logic. Based on the aforementioned associated database and closed-loop control logic, deviations in the processing are corrected.

10. A waste material treatment system for a concrete mixing plant, characterized in that, include: The data acquisition module is used to collect key parameter data of waste slurry, concentrated waste residue, mud cake, intermediate particles and final products; The solid-liquid separation module is used to receive waste slurry, select the separation method based on the key parameter data of the data acquisition module, perform solid-liquid separation and output concentrated waste residue, and recycle the clarified liquid. The filter press module is used to receive concentrated waste residue, adjust the filter press pressure based on key parameter data, make the concentrated waste residue into a suitable sludge cake, and obtain sludge cake quality data. The granulation module is used to perform dispersion, powder coating and coagulation processes based on key parameter data, and output qualified hard granules. The mixing module is used to retrieve preset proportions based on key parameter data, control the amount of hard particles to be fed, and work in conjunction with the concrete mixer to complete the mixing process. The control module automatically adjusts the operating parameters of each module based on preset logic.

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