A method, system, terminal and medium for producing light aggregate based on hazardous waste

Abstract

This application relates to a method, system, terminal, and medium for producing lightweight aggregates based on hazardous waste, belonging to the field of hazardous waste treatment technology. The method includes: obtaining information on the type of hazardous waste; pre-treating the hazardous waste according to the type information to obtain waste to be processed; collecting the chemical composition and elemental content of the waste to be processed; generating a mixing ratio and an auxiliary material ratio based on the chemical composition and elemental content, using a preset processing standard as a reference; mixing the waste to be processed according to the mixing ratio, and adding auxiliary materials according to the auxiliary material ratio to form a mixed waste; and sintering the mixed waste to obtain lightweight aggregates. This application has the effect of improving the sintering effect of lightweight aggregates.

Description

Technical Field

[0001] This application relates to the field of hazardous waste treatment technology, and in particular to a method, system, terminal and medium for producing lightweight aggregates based on hazardous waste. Background Technology

[0002] Hazardous waste materials such as surface treatment sludge, municipal solid waste incineration fly ash, and secondary aluminum ash slag have similar raw material compositions to those required for the preparation of lightweight aggregates. Through high-temperature sintering, heavy metals in these hazardous wastes can be effectively solidified within the mineral lattice of the ceramsite, while organic pollutants are decomposed at high temperatures.

[0003] The relevant technology mixes various hazardous wastes such as aluminum ash, waste incineration fly ash, and electroplating sludge with solid wastes such as construction waste and river silt in a specific ratio, and then calcines them at 1050-1200℃ after drying, grinding, and pelletizing to obtain lightweight aggregates.

[0004] Regarding the aforementioned technologies, hazardous waste materials have a wide range of sources and complex compositions, with large fluctuations in the content of various elements between different batches, making it difficult to achieve real-time response and precise control to raw material fluctuations, resulting in poor sintering effect of lightweight aggregates. Summary of the Invention

[0005] To improve the sintering effect of lightweight aggregates, this application provides a method, system, terminal and medium for producing lightweight aggregates based on hazardous waste.

[0006] In the first aspect, this application provides a method for producing lightweight aggregates based on hazardous waste, employing the following technical solution: A method for producing lightweight aggregates based on hazardous waste, comprising: Obtain information on the types of hazardous waste; According to the aforementioned type information, the hazardous waste is pretreated to obtain waste to be processed; Collect the chemical composition and elemental content of the waste material to be processed; Based on the preset processing standards, the mixing ratio and the ratio of auxiliary materials are generated according to the chemical composition and the element content. The waste material to be processed is mixed according to the mixing ratio, and auxiliary materials are added according to the auxiliary material ratio to form mixed waste material; The mixed waste material is sintered to obtain lightweight aggregate.

[0007] By adopting the above technical solution, the problem of significant differences in the properties of hazardous waste from different sources is solved through obtaining information on the types of hazardous waste and performing targeted pretreatment. By collecting the chemical composition and elemental content of the waste to be processed and dynamically generating mixing and auxiliary material ratios based on preset processing standards, precise matching of hazardous waste composition with the target product's process requirements is achieved. Finally, lightweight aggregate is formed through sintering. This method, by prioritizing component detection and using it as a basis for proportioning, significantly improves the adaptability of the production formula to different batches of hazardous waste, ensuring sintering effects that control product quality from the source.

[0008] Optionally, the current content of an influencing element is determined from the element content, the influencing element including at least one of chlorine and phosphorus; If the current content exceeds the preset content tolerance range, then the target mixed waste corresponding to the current content is obtained; Calculate the excess amount of the current content compared to the content tolerance range; Adjust the amount of auxiliary materials added according to the above-mentioned excess amount, and adjust the process parameters of sintering treatment; Read the first timestamp of the target mixed waste, where the first timestamp indicates the time when the target mixed waste enters the sintering furnace; According to the first timestamp and the adjusted process parameters, a second timestamp is obtained, which represents the time when the target lightweight aggregate formed by the target mixed waste leaves the sintering furnace; According to the second timestamp, obtain a real-time image of the target lightweight aggregate; Extract the current sintering effect of the target lightweight aggregate from the real-time image; Based on the current sintering effect and the standard sintering effect, adjust the amount of auxiliary materials added and the process parameters.

[0009] By adopting the above technical solution, the current content of influencing elements such as chlorine and phosphorus is identified and compared with the tolerance range. When the levels exceed the limits, the amount of auxiliary materials added and sintering process parameters are adjusted synchronously according to the excess amount, thus achieving a dynamic response to raw material fluctuations. Furthermore, by establishing a spatiotemporal correspondence between the materials entering the kiln and the products exiting the kiln through the first and second timestamps, real-time images of specific batches can be accurately obtained and the sintering effect extracted. Finally, parameters are optimized and adjusted based on the actual results. This method achieves adaptive control and continuous optimization of the production process.

[0010] Optionally, if the influencing element includes chlorine, calculate the first exceedance range of chlorine. Calculate the first increment of alumina based on the first exceedance range; Obtain the alumina content in kaolin; Based on the first increment and the alumina content, calculate the first addition amount of kaolin, and add the kaolin to the target mixed waste according to the first addition amount; Based on the first exceedance range, calculate the reduction in the rotational speed of the sintering furnace; At the first timestamp, the sintering furnace is adjusted according to the decrease in rotation speed, and the peak temperature of the sintering furnace is adjusted according to the first preset temperature.

[0011] By adopting the above technical solution, for situations where chlorine levels exceed the standard, the required increase in alumina is quantitatively determined by calculating the extent of the exceedance. Combined with the alumina content in the kaolin, the amount of kaolin to be added is precisely calculated, achieving precise control over the chemical solidification of chlorine. Simultaneously, based on the extent of the exceedance, the reduction values ​​for sintering furnace speed and peak temperature are calculated and implemented. By extending the residence time of materials in the high-temperature zone, favorable thermal conditions are created for the reaction between kaolin and chlorides. This method, through coordinated adjustment of batching and sintering, effectively suppresses equipment corrosion and scaling blockage problems caused by chlorine.

[0012] Optionally, if the influencing element also includes phosphorus, the value of the first added amount is increased according to a preset ratio; Calculate the second amount of barium additive based on the first exceedance range; The barium additive is added to the target mixed waste according to the second addition amount; The peak temperature of the sintering furnace is adjusted according to the second preset temperature, which is lower than the first preset temperature.

[0013] By adopting the above technical solution, for the complex condition of simultaneous exceedance of phosphorus and chlorine, the amount of kaolin added is increased in a preset ratio to enhance the solidification of chlorine, while barium additive is introduced to specifically solidify phosphorus, forming a dual chemical stabilization mechanism. Furthermore, a second preset temperature higher than that required for chlorine exceedance is used to lower the peak temperature, accommodating a wider liquid phase formation range induced by phosphorus. This method solves the problem of synergistic treatment under multi-element compound pollution, maintaining production continuity and product stability even under extreme fluctuation conditions.

[0014] Optionally, if the influencing element includes phosphorus, a second exceedance of phosphorus is calculated; Calculate the second increment of silica based on the second exceedance range; Based on the second increment, calculate the third addition amount of the silicon auxiliary material, and add the silicon auxiliary material to the target mixed waste according to the third addition amount; At the first timestamp, the gas extraction system in the sintering furnace is activated, the gas extraction system being used to extract gas from the sintering furnace; The gas extracted by the extraction system is cooled.

[0015] By adopting the above technical solution, for cases of excessive phosphorus levels, the required increase in silica is quantitatively determined by calculating the extent of the exceedance, and silicon additives are added. In-situ solidification is achieved by utilizing the property of silicon and phosphorus to form high-melting-point stable minerals. Simultaneously, the exhaust system is activated to extract and cool the gas inside the kiln, promptly removing phosphorus-containing gaseous substances that volatilize at high temperatures and preventing their accumulation within the system. This method reduces the interference of phosphorus on the sintering process and equipment operating conditions from the source.

[0016] Optionally, an image recognition model is invoked to perform recognition processing on the real-time image to obtain the apparent quality characteristics of the target aggregate. The apparent quality characteristics include at least one of surface vitrification, pore size uniformity coefficient, and surface crack index. The apparent quality characteristics are scored to obtain the apparent quality score of the target aggregate; The classifier is invoked to classify the apparent quality score and obtain the quality level. The quality grade is used as the current sintering effect.

[0017] By employing the above technical solution, real-time images are identified using an image recognition model to quantitatively extract surface quality features such as surface vitrification, pore size uniformity coefficient, and crack index. Furthermore, through scoring and classifier grading, the complex image information is transformed into an intuitive quality grade as a representation of the sintering effect. This method achieves automated and objective evaluation of product appearance quality, avoiding the subjectivity and lag of manual visual inspection, and providing accurate and quantitative decision-making basis for subsequent process adjustments.

[0018] Optionally, real-time images of the target lightweight aggregate at multiple time points are continuously acquired to form a time-series image sequence; Feature extraction is performed on each frame of the time-series image to obtain the trend curve of appearance quality feature parameters changing over time; The rate of change of the trend curve is analyzed to determine whether the sintering effect of the target lightweight aggregate is in a drifting state. If so, then the warning time point at which the sintering effect will exceed the acceptable range within the preset time window is predicted; The current sintering effect is defined as at least one of the trend curve, the stable state judgment result, and the early warning time point.

[0019] By adopting the above technical solution, a time series is formed by continuously acquiring real-time images at multiple time points, and the changing trends of apparent quality characteristic parameters are analyzed, which can identify the drift state of product quality. Furthermore, it can predict the warning time point when the product will exceed the qualified range within a preset time window, enabling operators or control systems to take preventive adjustments before quality deterioration occurs, thereby minimizing the generation of non-conforming products.

[0020] Secondly, this application provides a lightweight aggregate production system based on hazardous waste, employing the following technical solution: A lightweight aggregate production system based on hazardous waste includes: The acquisition module is used to acquire information on the type, chemical composition, and element content. A memory for storing the program of the method for producing lightweight aggregates based on hazardous waste; The processor and the program in the memory can be loaded and executed by the processor to implement the lightweight aggregate production method based on hazardous waste.

[0021] By adopting the above technical solution, the problem of significant differences in the properties of hazardous waste from different sources is solved through obtaining information on the types of hazardous waste and performing targeted pretreatment. By collecting the chemical composition and elemental content of the waste to be processed and dynamically generating mixing and auxiliary material ratios based on preset processing standards, precise matching of hazardous waste composition with the target product's process requirements is achieved. Finally, lightweight aggregate is formed through sintering. This method, by prioritizing component detection and using it as a basis for proportioning, significantly improves the adaptability of the production formula to different batches of hazardous waste, ensuring sintering effects that control product quality from the source.

[0022] Thirdly, this application provides a smart terminal, which adopts the following technical solution: A smart terminal includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and execute the method described in any one of the above.

[0023] Fourthly, this application provides a computer storage medium capable of storing corresponding programs, which facilitates improving the sintering effect of lightweight aggregates, and adopts the following technical solution: A computer-readable storage medium storing a computer program that can be loaded by a processor and executed any of the above-described methods for producing lightweight aggregates based on hazardous waste.

[0024] In summary, this application includes at least one of the following beneficial technical effects: 1. By acquiring information on the types of hazardous waste and performing targeted pretreatment, the problem of significant differences in the properties of hazardous waste from different sources was solved. By collecting the chemical composition and elemental content of the waste to be processed and dynamically generating mixing and auxiliary material ratios based on preset processing standards, precise matching of hazardous waste composition with the target product's process requirements was achieved. Finally, lightweight aggregate was formed through sintering. This method, by prioritizing component detection and using it as a basis for proportioning, significantly improved the adaptability of the production formula to different batches of hazardous waste, ensuring sintering effects that control product quality from the source. 2. By identifying the current content of influencing elements such as chlorine and phosphorus and comparing it with the tolerance range, the amount of auxiliary materials added and sintering process parameters are adjusted synchronously according to the excess amount when the limit is exceeded, thus achieving a dynamic response to raw material fluctuations. Furthermore, by establishing the spatiotemporal correspondence between the materials entering the kiln and the products exiting the kiln through the first and second timestamps, real-time images of specific batches can be accurately obtained and the sintering effect extracted. Finally, the parameters are optimized and adjusted in reverse based on the actual effect. This method achieves adaptive control and continuous optimization of the production process. 3. By calling an image recognition model to identify real-time images, quantitative quality features such as surface vitrification, pore size uniformity coefficient, and crack index are extracted. Then, through scoring processing and classifier grading, the complex image information is transformed into an intuitive quality grade as a characterization of the sintering effect. This method achieves automated and objective evaluation of product appearance quality, avoiding the subjectivity and lag of manual visual inspection, and providing accurate and quantitative decision-making basis for subsequent process adjustments. Attached Figure Description

[0025] Figure 1 This is a schematic flowchart of a method for producing lightweight aggregates based on hazardous waste, as disclosed in an embodiment of this application.

[0026] Figure 2 This is a schematic flowchart of an adjustment method for lightweight aggregate production disclosed in an embodiment of this application.

[0027] Figure 3 This is a schematic flowchart of a production adjustment method based on chlorine element disclosed in an embodiment of this application.

[0028] Figure 4 This is a schematic flowchart of a production adjustment method based on chlorine and phosphorus elements disclosed in an embodiment of this application.

[0029] Figure 5 This is a schematic flowchart of a production adjustment method based on phosphorus element disclosed in an embodiment of this application.

[0030] Figure 6 This is a flowchart illustrating one of the methods for generating the current sintering effect disclosed in an embodiment of this application.

[0031] Figure 7 This is a flowchart illustrating a second method for generating the current sintering effect disclosed in an embodiment of this application.

[0032] Figure 8 This is a schematic diagram of a lightweight aggregate production system based on hazardous waste disclosed in an embodiment of this application. Detailed Implementation

[0033] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figures 1 to 8 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0034] This application discloses a method for producing lightweight aggregates based on hazardous waste. (Refer to...) Figure 1 The method includes: Step S101: Obtain information on the type of hazardous waste.

[0035] Hazardous waste refers to waste with hazardous characteristics generated during industrial production or daily life. Optional categories include, but are not limited to, waste mineral oil, mineral oil-containing waste, distillation residues, dye waste, paint waste, organic resin waste, surface treatment waste, incineration residues, non-ferrous metal mining and smelting waste, and spent catalysts.

[0036] For example, the type of hazardous waste can be manually entered by staff. Alternatively, the hazardous waste can be labeled, and the type of hazardous waste can be obtained by scanning the label.

[0037] Step S102: Pre-treat the hazardous waste according to the type information to obtain the waste to be processed.

[0038] In real-world scenarios, different types of hazardous waste have different pretreatment requirements. For example, sludge with high moisture content needs dewatering or drying, large pieces of material need crushing, and materials containing impurities need screening or magnetic separation. Therefore, there is a pre-defined correspondence between different types of hazardous waste and different pretreatment methods. After determining the type of waste, the pretreatment method can be determined from the correspondence for proper pretreatment.

[0039] Step S103: Collect the chemical composition and element content of the waste material to be processed.

[0040] Chemical composition and elemental content can be obtained through online detection or through periodic sampling. For example, the chemical composition and elemental content of the waste to be processed can be collected in real time using a spectrometer. Another example is collecting samples from each batch of waste to be processed and sending them to a laboratory for testing to obtain the chemical composition and elemental content.

[0041] It should be noted that in this application, the main chemical components collected are substances that can be used to produce lightweight aggregates, such as SiO2, Al2O3, Fe2O3, CaO, and MgO. At the same time, the main elements detected are Cl, P, S, F, and heavy metals (such as Pb, Cd, Cr, Ni, Cu, and Zn).

[0042] Step S104: Based on the preset processing standards, generate the mixing ratio and auxiliary material ratio according to the chemical composition and element content.

[0043] Preset processing standards refer to the chemical composition requirements for processing and producing lightweight aggregates. For example, during the sintering of lightweight aggregates, the percentage content of major components such as SiO2, Al2O3, Fe2O3+CaO+MgO, etc., must fall within the preset target range. Simultaneously, for the safety and environmental friendliness of lightweight aggregates, auxiliary materials must be added for chemical consolidation or dilution to prevent corrosion of equipment or impact on product performance during sintering, and to ensure that the content of elements such as Cl, P, S, F, and heavy metals does not exceed the set tolerance limits.

[0044] The proportion of auxiliary materials refers to the mass percentage of non-hazardous waste materials added to adjust the composition. Optional auxiliary materials include, but are not limited to, clay, kaolin, silica powder, limestone, barium salts, etc.

[0045] For example, the target SiO2 content in the mixture should be 50%-55%, Al2O3 18%-22%, Fe2O3+CaO+MgO ≤ 15%, and Cl ≤ 2%. The mixing ratio and auxiliary material ratio can be set according to the aforementioned standards using a preset proportioning algorithm.

[0046] Step S105: Mix the waste materials to be processed according to the mixing ratio, and add auxiliary materials according to the auxiliary material ratio to form mixed waste materials.

[0047] For example, a conveyor belt is installed below the feeding hopper, which stores waste material or auxiliary material to be processed. The opening of the first feeding hopper is adjusted according to the mixing ratio, and the waste material to be processed is fed onto the conveyor belt. After all the waste material to be processed has been fed, the opening of the second feeding hopper is adjusted according to the auxiliary material ratio, and the auxiliary material is fed onto the conveyor belt. Then, the material mixed with the waste material and auxiliary material is conveyed to a mixing device for thorough mixing, resulting in mixed waste material.

[0048] Step S106: Sinter the mixed waste material to obtain lightweight aggregate.

[0049] Optionally, the equipment used for sintering is a sintering furnace. The sintering furnace can be a rotary kiln, a vertical kiln, or a sintering machine, etc. Taking a rotary kiln as an example, the mixed waste material enters from one end of the rotary kiln. The rotary kiln heats the mixed waste material to a high temperature, and through solid-phase reaction and partial liquid-phase sintering, the particles are bonded and form a stable structure to obtain lightweight aggregate. The lightweight aggregate exits from the other end of the rotary kiln.

[0050] By adopting the above technical solution, the problem of significant differences in the properties of hazardous waste from different sources is solved through obtaining information on the types of hazardous waste and performing targeted pretreatment. By collecting the chemical composition and elemental content of the waste to be processed and dynamically generating mixing and auxiliary material ratios based on preset processing standards, precise matching of hazardous waste composition with the target product's process requirements is achieved. Finally, lightweight aggregate is formed through sintering. This method, by prioritizing component detection and using it as a basis for proportioning, significantly improves the adaptability of the production formula to different batches of hazardous waste, ensuring sintering effects that control product quality from the source.

[0051] During the production process, the content of various chemical components and elements in hazardous waste is constantly changing, necessitating timely adjustments to the mixing ratio and auxiliary material ratio. Therefore, this application discloses an adjustment method for lightweight aggregate production. (Refer to...) Figure 2 The method includes: Step S201: Determine the current content of the influencing element in the element content, the influencing element including at least one of chlorine and phosphorus.

[0052] Chlorine combines with alkali metals (e.g., K, Na) to form alkali metal chlorides (NaCl, KCl). These salts are highly volatile at high temperatures (they begin to volatilize in large quantities above 800°C, and the operating temperature of a rotary kiln can reach 1000°C to 1300°C), and they will circulate and accumulate in the rotary kiln. On the one hand, they corrode refractory bricks, and on the other hand, they condense in low-temperature areas, causing crusting and blockage.

[0053] Phosphorus reacts with calcium and sodium in waste to form a low-melting-point phosphate glass phase. This causes the liquid phase to appear prematurely and the overall viscosity to be too low, leading to ring formation and stickiness of the material, resulting in poor quality of the lightweight aggregate produced.

[0054] Step S202: If the current content exceeds the preset content tolerance range, then obtain the target mixed waste corresponding to the current content.

[0055] The content tolerance range refers to the permissible fluctuation range of an element's content. For example, chlorine content needs to be less than 1%, and phosphorus content needs to be less than 3%. Target mixed waste refers to mixed waste where the current content of the influencing element exceeds its corresponding content tolerance range, essentially identifying which batch of mixed waste has the problem of the influencing element exceeding the standard.

[0056] Step S203: Calculate the excess amount of the current content compared to the content tolerance range.

[0057] For example, the difference between the current content and the upper limit of the content tolerance range is calculated to obtain the excess amount.

[0058] Step S204: Adjust the amount of auxiliary materials added according to the excess amount, and adjust the process parameters of sintering treatment.

[0059] The applicant found that when the levels of influencing elements exceed the limits, simply adjusting the auxiliary materials or the process alone is often insufficient to completely eliminate the impact. Furthermore, adjusting the auxiliary materials can chemically solidify harmful elements, while adjusting the process parameters can adapt to changes in material properties at the physical and thermal levels. Therefore, this application addresses the issue by simultaneously adjusting both the batching and firing processes to achieve synergistic control.

[0060] Step S205: Read the first timestamp of the target mixed waste. The first timestamp indicates the time when the target mixed waste enters the sintering furnace.

[0061] For example, a position sensor is installed at the inlet of the sintering furnace, and when the position sensor detects the target mixed waste, the system time of the position sensor is used as the first timestamp.

[0062] Step S206: According to the first timestamp and the adjusted process parameters, the second timestamp is obtained. The second timestamp represents the time when the target lightweight aggregate formed by the target mixed waste leaves the sintering furnace.

[0063] For example, based on the adjusted process parameters, the residence time of the target mixed waste in the sintering furnace is obtained. The second timestamp is obtained by summing the residence time and the first timestamp.

[0064] Step S207: Obtain a real-time image of the target lightweight aggregate according to the second timestamp.

[0065] For example, a camera is installed at the outlet of the sintering furnace, and the camera and position sensor use a synchronized system clock. At the second timestamp, the camera captures a real-time image of the lightweight aggregate. The target lightweight aggregate refers to the lightweight aggregate generated from the target mixed waste.

[0066] Step S208: Extract the current sintering effect of the target lightweight aggregate from the real-time image.

[0067] The current sintering effect refers to a set of indicators that quantitatively characterize the sintering quality of the target lightweight aggregate, obtained through real-time image analysis. Optionally, the current sintering effect includes vitrification, pore size uniformity, crack index, etc.

[0068] Step S209: Based on the current sintering effect and the standard sintering effect, adjust the amount of auxiliary materials added and the process parameters.

[0069] Since the aforementioned steps are based on feedforward control using theoretical models and empirical rules, actual results may deviate. Therefore, by comparing the current sintering effect with the standard sintering effect, the batching and process parameters for subsequent batches are optimized again to form a closed-loop control and continuously improve product quality.

[0070] For example, compare the various indicators in the current sintering effect with the standard ranges of the indicators in the standard sintering effect. Determine if any indicator exceeds the standard range. If so, mark the indicator exceeding the standard range as a problem indicator. Adjust the amount of additives and process parameters according to the problem indicator. If not, there is no need to adjust the amount of additives or process parameters. For example, if the vitrification rate is low, it indicates insufficient sintering, so the sintering temperature can be increased by 5-10°C, and fluxing additives (e.g., Fe2O3, CaO) can be added. If the pore size uniformity coefficient is high, it indicates uneven foaming, so the mixing time can be extended to improve uniformity, and the kiln speed can be adjusted to stabilize the temperature field. If the crack index is high, it indicates rapid cooling or compositional issues, so the cooling rate can be reduced, and the Al2O3 / SiO2 ratio can be adjusted to improve thermal stability.

[0071] By adopting the above technical solution, the current content of influencing elements such as chlorine and phosphorus is identified and compared with the tolerance range. When the levels exceed the limits, the amount of auxiliary materials added and sintering process parameters are adjusted synchronously according to the excess amount, thus achieving a dynamic response to raw material fluctuations. Furthermore, by establishing a spatiotemporal correspondence between the materials entering the kiln and the products exiting the kiln through the first and second timestamps, real-time images of specific batches can be accurately obtained and the sintering effect extracted. Finally, parameters are optimized and adjusted based on the actual results. This method achieves adaptive control and continuous optimization of the production process.

[0072] To address the issue of excessive chlorine levels, it is necessary to adjust the amount of auxiliary materials added and reduce the sintering furnace speed. Therefore, this application discloses a production adjustment method based on chlorine levels. (Refer to...) Figure 3 The method includes: Step S301: Calculate the first exceedance range of chlorine when the influencing elements include chlorine.

[0073] The first exceedance range refers to the degree to which the chlorine content exceeds the standard. It can be expressed as an absolute percentage difference or a relative proportion. In this embodiment, the first exceedance range is expressed as an absolute percentage difference.

[0074] Step S302: Calculate the first increment of alumina based on the first exceedance range.

[0075] One of the solidification mechanisms of chlorine at high temperatures is its reaction with alumina to form stable chloroaluminate minerals. When chlorine levels are excessive, the alumina content in the material system needs to be increased to provide sufficient reactants to fix the excess chlorine.

[0076] For example, let the first exceedance range be A. Cl Then the first increment is ΔAl2O3 = k1 × A Cl ×M. k1 is a dimensionless proportionality value, ranging from 0.8 to 1.2. M is the total mass of the target mixed waste.

[0077] Step S303: Obtain the alumina content in kaolin.

[0078] Alumina content refers to the percentage by mass of alumina in kaolin. Alumina content can be obtained by real-time monitoring of kaolin.

[0079] Step S304: Calculate the first addition amount of kaolin based on the first increment and alumina content, and add the kaolin to the target mixed waste according to the first addition amount.

[0080] For example, the ratio of the first increment to the alumina content is calculated to obtain the first addition amount of kaolin. The first addition amount refers to the additional mass of kaolin.

[0081] Step S305: Calculate the reduction in sintering furnace speed based on the first exceedance range.

[0082] Sufficient time and temperature are required for the solidification of chlorine to proceed fully. When the chlorine content is excessive, in addition to increasing the amount of alumina used for chlorine solidification, it is also necessary to appropriately extend the residence time of the waste in the high-temperature sintering zone to provide more time for the reaction.

[0083] For example, the speed reduction is Δv = k2 × A Cl Where k2 is the speed adjustment coefficient, and its value range is usually 0.05-0.15.

[0084] Step S306: At the first time stamp, adjust the sintering furnace according to the speed reduction value, and adjust the peak temperature of the sintering furnace according to the first preset temperature.

[0085] For example, the first preset temperature is 1150℃-1250℃. This temperature range is just above the formation temperature of low-melting-point phosphates, but below the decomposition temperature of high-melting-point aluminum phosphates. This ensures that the reaction occurs while also preventing the product from being destroyed.

[0086] By adopting the above technical solution, for situations where chlorine levels exceed the standard, the required increase in alumina is quantitatively determined by calculating the extent of the exceedance. Combined with the alumina content in the kaolin, the amount of kaolin to be added is precisely calculated, achieving precise control over the chemical solidification of chlorine. Simultaneously, based on the extent of the exceedance, the reduction values ​​for sintering furnace speed and peak temperature are calculated and implemented. By extending the residence time of materials in the high-temperature zone, favorable thermal conditions are created for the reaction between kaolin and chlorides. This method, through coordinated adjustment of batching and sintering, effectively suppresses equipment corrosion and scaling blockage problems caused by chlorine.

[0087] This application discloses a production adjustment method based on chlorine and phosphorus elements. (Refer to...) Figure 4 The method includes: Step S401: If the influencing elements also include phosphorus, increase the value of the first addition amount according to the preset ratio.

[0088] When both chlorine and phosphorus are present in excessive amounts in the waste material, the presence of phosphorus expands the liquid phase formation temperature range during sintering, causing the waste material to remain in a molten or semi-molten state over a wider temperature range. This leads to increased chlorine volatilization and changes in the dispersion and reaction behavior of kaolin in the liquid phase. Therefore, separate adjustments are required.

[0089] The preset ratio is a fixed value that is set in advance. Technicians can set the specific value of the preset ratio according to actual needs. For example, the preset ratio is 1.2.

[0090] Step S402: Calculate the second amount of barium additive based on the first exceedance range.

[0091] The barium ions provided by the barium additive can react with phosphate ions to form a very insoluble barium phosphate precipitate, which fixes the phosphorus in the ceramsite mineral phase.

[0092] For example, let the first exceedance range be A. Cl Then the second addition amount is Δm = k3 × A Cl ×M. k3 is a dimensionless proportionality value, ranging from 0.2 to 0.5. M is the total mass of the target mixed waste.

[0093] Step S403: Add the barium additive to the target mixed waste according to the second addition amount.

[0094] Barium carbonate can be used as the barium auxiliary material.

[0095] Step S404: Adjust the peak temperature of the sintering furnace according to the second preset temperature, where the second preset temperature is lower than the first preset temperature.

[0096] For example, the second preset temperature is 1135℃-1240℃. Phosphate compounds typically have low melting points, causing the waste to begin forming a liquid phase at lower temperatures, and the amount of liquid phase increases rapidly with increasing temperature. In this case, if the first preset temperature for chlorine exceeding the limit is still applied, it may not be sufficient to suppress the risk of over-melting exacerbated by the presence of phosphorus. Over-melting can lead to adhesion, collapse, and damage to the pore structure of lightweight aggregates. Therefore, when both chlorine and phosphorus exceed the limit simultaneously, the peak sintering temperature needs to be reduced to a greater extent.

[0097] By adopting the above technical solution, for the complex condition of simultaneous exceedance of phosphorus and chlorine, the amount of kaolin added is increased in a preset ratio to enhance the solidification of chlorine, while barium additive is introduced to specifically solidify phosphorus, forming a dual chemical stabilization mechanism. Furthermore, a second preset temperature higher than that required for chlorine exceedance is used to reduce the peak temperature, accommodating a wider liquid phase formation range induced by phosphorus. This method solves the problem of synergistic treatment under multi-element compound pollution, maintaining production continuity and product stability even under extreme fluctuation conditions.

[0098] To address the issue of excessive chlorine levels, it is necessary to update the amount of auxiliary materials added and change the operating mode of the sintering furnace. Therefore, this application discloses a production adjustment method based on phosphorus levels. (Refer to...) Figure 5 The method includes: Step S501: If the influencing element includes phosphorus, calculate the second exceedance range of phosphorus.

[0099] The second exceedance range refers to the degree of exceedance of the phosphorus standard. It can be expressed as an absolute percentage difference or a relative proportion. In this embodiment, the second exceedance range is expressed as an absolute percentage difference.

[0100] Step S502: Calculate the second increment of silicon dioxide based on the second exceedance range.

[0101] Silica can increase the degree of polymerization and viscosity of waste melt, thereby offsetting the viscosity-reducing effect of phosphorus and preventing excessive material flow. Furthermore, silica and phosphorus pentoxide can form high-melting-point compounds such as silicon phosphate (SiP2O7), achieving the chemical solidification of phosphorus.

[0102] For example, let the first exceedance range be A. Si Then the second increment is ΔSiO2 = k4 × A Si ×M. K4 is a dimensionless proportionality value, ranging from 1.5 to 3.0. M is the total mass of the target mixed waste.

[0103] Step S503: Calculate the third addition amount of silicon auxiliary material based on the second increment, and add the silicon auxiliary material to the target mixed waste according to the third addition amount.

[0104] For example, the ratio of the second increment to the silica content in the silicon additive is calculated to obtain the third addition amount of the silicon additive. The third addition amount refers to the additional mass of the silicon additive.

[0105] Step S504: At the first time stamp, the gas extraction system in the sintering furnace is turned on. The gas extraction system is used to extract gas from the sintering furnace.

[0106] Besides reacting with silicates to form solid products at high temperatures, some phosphorus compounds have high vapor pressures and easily volatilize into flue gas. If these phosphorus-containing gaseous substances condense in the furnace or flue, they form viscous deposits, leading to a series of problems such as flue blockage, reduced heat exchanger efficiency, and bag filter clogging. Furthermore, phosphorus-containing gas emissions also cause environmental pollution.

[0107] Step S505: Cool the gas extracted by the extraction system.

[0108] Cooling can condense gaseous phosphorus compounds into solid particles, making them easier for subsequent dust removal equipment to capture, thereby completely separating phosphorus from the system.

[0109] By adopting the above technical solution, for cases of excessive phosphorus levels, the required increase in silica is quantitatively determined by calculating the extent of the exceedance, and silicon additives are added. In-situ solidification is achieved by utilizing the property of silicon and phosphorus to form high-melting-point stable minerals. Simultaneously, the exhaust system is activated to extract and cool the gas inside the kiln, promptly removing phosphorus-containing gaseous substances that volatilize at high temperatures and preventing their accumulation within the system. This method reduces the interference of phosphorus on the sintering process and equipment operating conditions from the source.

[0110] This application discloses a method for generating the current sintering effect. (Refer to...) Figure 6 The method includes: Step S601: Call the image recognition model to perform recognition processing on the real-time image to obtain the apparent quality characteristics of the target aggregate. The apparent quality characteristics include at least one of surface vitrification, pore size uniformity coefficient and surface crack index.

[0111] For example, the image recognition model processes real-time images as follows: It performs grayscale processing and denoising on the real-time image to obtain a processed image. It identifies and separates lightweight aggregate regions in the processed image. Based on the grayscale distribution and texture characteristics of the lightweight aggregate regions, it calculates the area ratio of the vitrified layer to obtain the surface vitrification rate. It statistically analyzes the pore size of each pore within the lightweight aggregate region and calculates the ratio of the standard deviation of the pore size to the average pore size to obtain the pore size uniformity coefficient. Finally, it statistically analyzes the total length, maximum width, and density of cracks on each lightweight aggregate within the lightweight aggregate region to obtain the surface crack index.

[0112] Step S602: The apparent quality characteristics are scored to obtain the apparent quality score of the target aggregate.

[0113] Optionally, the surface vitrification rate, pore size uniformity coefficient, and surface crack index in the appearance quality characteristics can be normalized and weighted to obtain the appearance quality score.

[0114] Optionally, a scoring model can be invoked to score the appearance quality features and obtain an appearance quality score.

[0115] Step S603: Call the classifier to classify the apparent quality score and obtain the quality level.

[0116] For example, the classifier has a built-in scoring threshold. If the apparent quality score is greater than the scoring threshold, the quality level is set to acceptable. If the apparent quality score is less than the scoring threshold, the quality level is set to unacceptable.

[0117] Step S604: Use the quality grade as the current sintering effect.

[0118] By employing the aforementioned technical solution, real-time images are identified using an image recognition model, and apparent quality features such as surface vitrification, pore size uniformity coefficient, and crack index are quantitatively extracted. Furthermore, through scoring processing and classifier grading, the complex image information is transformed into an intuitive quality grade as a characterization of the sintering effect. This method achieves automated and objective evaluation of product appearance quality, avoiding the subjectivity and lag of manual visual inspection, and providing accurate and quantitative decision-making basis for subsequent process adjustments.

[0119] This application discloses a second method for generating the current sintering effect. (Refer to...) Figure 7 The method includes: Step S701: Continuously acquire real-time images of the target lightweight aggregate at multiple time points to form a time-series image sequence.

[0120] For example, real-time images of the target lightweight aggregate at multiple time points are acquired according to a preset acquisition frequency to form a time-series image sequence.

[0121] Step S702: Extract features from each frame of the time-series image sequence to obtain the trend curve of the appearance quality feature parameters changing over time.

[0122] The feature extraction process can be referred to Figure 6 The embodiments shown are not described in detail here.

[0123] Step S703: Perform a rate of change analysis on the trend curve to determine whether the sintering effect of the target lightweight aggregate is in a drifting state.

[0124] It should be noted that the fluctuations on the trend curve are of two types: one is normal random fluctuation, which is an inherent variability in the production process; the other is systematic drift, which indicates that the quality of lightweight aggregate is undergoing a unidirectional and continuous change.

[0125] For example, linear regression is performed on the feature values ​​of the most recent N time points to obtain the fitted slope and its confidence interval. If the fitted slope is not zero and the confidence interval is less than a preset limit value, it is in a drift state.

[0126] Step S704: If so, predict the warning time point when the sintering effect will exceed the acceptable range within the preset time window.

[0127] The warning time point refers to the specific time predicted based on the current drift trend when the product quality is about to exceed the acceptable range.

[0128] After identifying the drift state, it is necessary to predict how long it will take for the product quality to exceed the acceptable range based on the current trend, and use the time point when the product quality exceeds the acceptable range as the warning time point.

[0129] Step S705: Take at least one of the trend curve, the stable state judgment result, and the warning time point as the current sintering effect.

[0130] By employing the above technical solution, and continuously acquiring real-time images from multiple time points to form a time series, and analyzing the changing trends of apparent quality characteristic parameters, the drift state of product quality can be identified. Furthermore, it can predict the warning time point within a preset time window when the product is about to exceed the acceptable range, enabling operators or control systems to take preventative adjustments before quality deterioration occurs, thus minimizing the generation of defective products.

[0131] Based on the same inventive concept, embodiments of this application provide a lightweight aggregate production system based on hazardous waste. Please refer to... Figure 8 ,include: The acquisition module 801 is used to acquire type information, chemical composition, and element content; The memory 802 is used to store the program for the above-described method for producing lightweight aggregates based on hazardous waste; The processor 803 can load and execute the program in the memory to implement the above-mentioned lightweight aggregate production method based on hazardous waste.

[0132] By adopting the above technical solution, the problem of significant differences in the properties of hazardous waste from different sources is solved through obtaining information on the types of hazardous waste and performing targeted pretreatment. By collecting the chemical composition and elemental content of the waste to be processed and dynamically generating mixing and auxiliary material ratios based on preset processing standards, precise matching of hazardous waste composition with the target product's process requirements is achieved. Finally, lightweight aggregate is formed through sintering. This method, by prioritizing component detection and using it as a basis for proportioning, significantly improves the adaptability of the production formula to different batches of hazardous waste, ensuring sintering effects that control product quality from the source.

[0133] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0134] This application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed as a method for producing lightweight aggregates based on hazardous waste.

[0135] Computer storage media include, for example, USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, optical disks, and other media that can store program code.

[0136] Based on the same inventive concept, embodiments of this application provide a smart terminal, including a memory and a processor, wherein the memory stores a computer program that can be loaded and executed by the processor for a method of producing lightweight aggregates based on hazardous waste.

[0137] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0138] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. A method for producing lightweight aggregates based on hazardous waste, characterized in that, include: Obtain information on the types of hazardous waste; According to the aforementioned type information, the hazardous waste is pretreated to obtain waste to be processed; Collect the chemical composition and elemental content of the waste material to be processed; Based on the preset processing standards, the mixing ratio and the ratio of auxiliary materials are generated according to the chemical composition and the element content. The waste material to be processed is mixed according to the mixing ratio, and auxiliary materials are added according to the auxiliary material ratio to form mixed waste material; The mixed waste material is sintered to obtain lightweight aggregate.

2. The method for producing lightweight aggregates based on hazardous waste according to claim 1, characterized in that, The method further includes: The current content of the influencing element is determined from the element content, and the influencing element includes at least one of chlorine and phosphorus. If the current content exceeds the preset content tolerance range, then the target mixed waste corresponding to the current content is obtained; Calculate the excess amount of the current content compared to the content tolerance range; Adjust the amount of auxiliary materials added according to the above-mentioned excess amount, and adjust the process parameters of sintering treatment; Read the first timestamp of the target mixed waste, where the first timestamp indicates the time when the target mixed waste enters the sintering furnace; According to the first timestamp and the adjusted process parameters, a second timestamp is obtained, which represents the time when the target lightweight aggregate formed by the target mixed waste leaves the sintering furnace; According to the second timestamp, obtain a real-time image of the target lightweight aggregate; Extract the current sintering effect of the target lightweight aggregate from the real-time image; Based on the current sintering effect and the standard sintering effect, adjust the amount of auxiliary materials added and the process parameters.

3. The method for producing lightweight aggregates based on hazardous waste according to claim 2, characterized in that, The method further includes: If the influencing element includes chlorine, calculate the first exceedance range of chlorine. Calculate the first increment of alumina based on the first exceedance range; Obtain the alumina content in kaolin; Based on the first increment and the alumina content, calculate the first addition amount of kaolin, and add the kaolin to the target mixed waste according to the first addition amount; Based on the first exceedance range, calculate the reduction in the rotational speed of the sintering furnace; At the first timestamp, the sintering furnace is adjusted according to the decrease in rotation speed, and the peak temperature of the sintering furnace is adjusted according to the first preset temperature.

4. The method for producing lightweight aggregates based on hazardous waste according to claim 3, characterized in that, The method further includes: If the influencing elements also include phosphorus, the value of the first added amount is increased according to a preset ratio; Calculate the second amount of barium additive based on the first exceedance range; The barium additive is added to the target mixed waste according to the second addition amount; The peak temperature of the sintering furnace is adjusted according to the second preset temperature, which is lower than the first preset temperature.

5. The method for producing lightweight aggregates based on hazardous waste according to claim 2, characterized in that, The method further includes: When the influencing element includes phosphorus, calculate the second exceedance range of phosphorus. Calculate the second increment of silica based on the second exceedance range; Based on the second increment, calculate the third addition amount of the silicon auxiliary material, and add the silicon auxiliary material to the target mixed waste according to the third addition amount; At the first timestamp, the gas extraction system in the sintering furnace is activated, the gas extraction system being used to extract gas from the sintering furnace; The gas extracted by the extraction system is cooled.

6. The method for producing lightweight aggregates based on hazardous waste according to claim 2, characterized in that, The step of extracting the current sintering effect of the target lightweight aggregate from the real-time image includes: An image recognition model is invoked to perform recognition processing on the real-time image to obtain the apparent quality characteristics of the target aggregate. The apparent quality characteristics include at least one of surface vitrification, pore size uniformity coefficient, and surface crack index. The apparent quality characteristics are scored to obtain the apparent quality score of the target aggregate; The classifier is invoked to classify the apparent quality score and obtain the quality level. The quality grade is used as the current sintering effect.

7. The method for producing lightweight aggregates based on hazardous waste according to claim 6, characterized in that, The method further includes: Real-time images of the target lightweight aggregate at multiple time points are continuously acquired to form a time-series image sequence; Feature extraction is performed on each frame of the time-series image to obtain the trend curve of appearance quality feature parameters changing over time; The rate of change of the trend curve is analyzed to determine whether the sintering effect of the target lightweight aggregate is in a drifting state. If so, then the warning time point at which the sintering effect will exceed the acceptable range within the preset time window is predicted; The current sintering effect is defined as at least one of the trend curve, the stable state judgment result, and the early warning time point.

8. A lightweight aggregate production system based on hazardous waste, characterized in that, The system is used to perform the method for producing lightweight aggregates based on hazardous waste as described in any one of claims 1 to 7, comprising: The acquisition module is used to acquire information on the type, chemical composition, and element content. A memory for storing the program of the method for producing lightweight aggregates based on hazardous waste; The processor and the program in the memory can be loaded and executed by the processor to implement the lightweight aggregate production method based on hazardous waste.

9. A smart terminal, characterized in that, It includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer program is stored that can be loaded by a processor and execute the method as described in any one of claims 1 to 7.

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