Short-flow heavy medium ore dressing control method, device, system, medium and equipment

Abstract

This application relates to the field of heavy media mineral processing technology, and discloses a short-process heavy media mineral processing control method, device, system, medium, and equipment, including: feeding raw ore into a first-stage mixing tank, supplementing it with concentrated medium through a first medium addition pipeline, feeding the first mixture into a first-stage heavy media hydrocyclone, controlling the overflow to be discarded as tailings after demediuming, and controlling the underflow to be directly transported to a second-stage mixing tank; in the second-stage mixing tank, supplementing it with concentrated medium through a second medium addition pipeline, feeding the second mixture into a second-stage heavy media hydrocyclone, controlling the underflow and overflow to be demediumed to obtain concentrate and middlings respectively; real-time detection of the first deviation between the actual suspension density in the first-stage mixing tank and the first-stage density set value, adjusting the medium replenishment flow rate of the first medium addition pipeline accordingly, and real-time detection of the second deviation between the actual suspension density in the second-stage mixing tank and the second-stage density set value, adjusting the medium replenishment flow rate of the second medium addition pipeline accordingly.

Description

Technical Field

[0001] This application relates to the field of heavy media mineral processing technology, and in particular to a short-process heavy media mineral processing control method, apparatus, system, medium, and equipment. Background Technology

[0002] Heavy media separation is a highly efficient and environmentally friendly physical separation method in the mineral processing field. Its core principle is to use a heavy media suspension with a density between that of the valuable mineral and gangue, separating minerals of different densities based on Archimedes' principle of buoyancy. This technology boasts significant advantages such as high separation accuracy, large processing capacity, and low environmental pollution. It is widely used in the pre-selection and enrichment stages of coal, non-ferrous metals, rare metals, and non-metallic ores, effectively reducing the amount of ore required for subsequent grinding and beneficiation operations, thereby lowering overall beneficiation costs and energy consumption. With the increasing depletion of mineral resources and ever-increasing environmental protection requirements, heavy media separation technology plays an increasingly important role in the green and sustainable development of the mining industry.

[0003] However, existing two-stage heavy medium separation processes typically employ a "full media removal" mode. This means that after separation in the first-stage heavy medium hydrocyclone, the underflow product must be completely destrained by a media removal screen before being transported to the second-stage mixing tank to mix with freshly prepared media before entering the second-stage hydrocyclone for further separation. This process involves numerous steps, leading to an increased number of equipment and significantly higher energy consumption. Furthermore, the media recovery and replenishment systems are relatively decentralized, making centralized and unified management and precise quantitative allocation of the media across the entire system difficult. This can easily cause large density fluctuations in the suspensions separated in the first and second stages, affecting separation efficiency and product quality stability. In addition, the existing systems have limited automation in media replenishment during the first and second stages, relying heavily on manual experience for adjustment. This makes it difficult to adapt to real-time fluctuations in the properties of the raw ore, resulting in poor overall process stability. Summary of the Invention

[0004] In view of this, this application provides a short-process heavy media beneficiation control method, apparatus, system, medium, and equipment. By directly connecting the underflow of the first stage to the second stage without desizing, the process flow is significantly shortened, eliminating intermediate desizing screens, conveying pumps, and other equipment, thus significantly reducing operating energy consumption. Simultaneously, all qualified media are collected in a single collection tank, and concentrated media are independently added to both stages. Combined with closed-loop automatic adjustment based on real-time density deviation, this not only solves the density fluctuation problem caused by media dispersion but also overcomes the interference of the first stage's carried media on the second stage, achieving independent and precise control of the separation density in both stages. The embodiments of this application, while simplifying the process and saving costs, can stably improve concentrate grade and recovery rate and have the ability to adapt to fluctuations in the properties of the raw ore.

[0005] According to one aspect of this application, a short-process heavy media mineral processing control method is provided, comprising: The raw ore is fed into a first-stage mixing tank, and concentrated medium is added to the first-stage mixing tank from the collection tank through the first medium addition pipeline. The resulting first mixture is fed into a first-stage heavy medium hydrocyclone for separation. The overflow of the first-stage heavy medium hydrocyclone is controlled to be discarded as tailings after desliming. The qualified medium produced in the desliming process is collected in the collection tank, and the underflow of the first-stage heavy medium hydrocyclone is controlled to be directly transported to the second-stage mixing tank without desliming treatment. In the two-stage mixing tank, concentrated medium is added from the collecting tank to the two-stage mixing tank through the second medium addition pipeline. The resulting second mixture is fed into the two-stage heavy medium hydrocyclone for separation. The underflow and overflow of the two-stage heavy medium hydrocyclone are controlled to obtain concentrate and middlings after desliming, and the qualified medium generated in the desliming process is collected in the collecting tank. During the operation of the first-stage mixing tank and the second-stage mixing tank, a first deviation between the actual suspension density in the first-stage mixing tank and a preset first-stage density setting value is detected in real time. The flow rate of concentrated medium replenishment in the first medium addition pipeline is dynamically adjusted according to the first deviation. Also, a second deviation between the actual suspension density in the second-stage mixing tank and a preset second-stage density setting value is detected in real time. The flow rate of concentrated medium replenishment in the second medium addition pipeline is dynamically adjusted according to the second deviation. The preset second-stage density setting value is greater than the preset first-stage density setting value.

[0006] According to another aspect of this application, a short-process heavy media mineral processing control device is provided, comprising: A first-stage sorting module is used to feed the raw ore into a first-stage mixing tank, and at the same time, to add concentrated medium from the collection tank to the first-stage mixing tank through the first medium addition pipeline. The resulting first mixture is fed into a first-stage heavy medium hydrocyclone for sorting. The overflow of the first-stage heavy medium hydrocyclone is controlled to be discarded as tailings after desliming. The qualified medium generated in the desliming process is collected into the collection tank, and the underflow of the first-stage heavy medium hydrocyclone is controlled to be directly transported to the second-stage mixing tank without desliming treatment. The two-stage separation module is used to supplement concentrated medium from the collection tank into the two-stage mixing tank through the second medium addition pipeline, and feed the formed second mixture into the two-stage heavy medium hydrocyclone for separation. The underflow and overflow of the two-stage heavy medium hydrocyclone are controlled to obtain concentrate and middlings after desliming, respectively, and the qualified medium generated in the desliming process is collected into the collection tank. The dynamic adjustment module is used to detect, in real time, a first deviation between the actual suspension density in the first mixing tank and a preset first-stage density setting value during the operation of the first mixing tank and the second mixing tank, and dynamically adjust the concentrated medium replenishment flow rate in the first medium addition pipeline according to the first deviation; and to detect, in real time, a second deviation between the actual suspension density in the second mixing tank and a preset second-stage density setting value, and dynamically adjust the concentrated medium replenishment flow rate in the second medium addition pipeline according to the second deviation, wherein the preset second-stage density setting value is greater than the preset first-stage density setting value.

[0007] According to another aspect of this application, a short-process heavy media mineral processing system is provided, comprising: A sorting unit includes a mixing tank and a heavy medium cyclone separator, wherein the outlet of the mixing tank is connected to the inlet of the heavy medium cyclone separator. The two-stage sorting unit includes a two-stage mixing tank and a two-stage heavy medium cyclone separator, wherein the outlet of the two-stage mixing tank is connected to the inlet of the two-stage heavy medium cyclone separator. The media circulation unit includes a media collection tank, a first media addition pipeline, and a second media addition pipeline. The media collection tank is connected to the inlet of the first media addition pipeline and the inlet of the second media addition pipeline, respectively. The outlet of the first media addition pipeline is connected to the media inlet of the first mixing tank, and the outlet of the second media addition pipeline is connected to the media inlet of the second mixing tank. The underflow outlet of the first-stage heavy medium cyclone is directly connected to the inlet of the second-stage mixing tank through the connecting pipe, and no desizing equipment is installed on the connecting pipe. The detection and control unit includes a first density detection device, a second density detection device, and a central control unit. The first density detection device is located at the outlet of the first-stage mixing tank and is used to detect the actual suspension density of the first-stage mixing tank in real time. The second density detection device is located at the outlet of the second-stage mixing tank and is used to detect the actual suspension density of the second-stage mixing tank in real time. The central control unit is electrically connected to the first density detection device, the second density detection device, a first adjustment device on the first medium addition pipeline, and a second adjustment device on the second medium addition pipeline, respectively. It is used to adjust the opening of the first adjustment device according to a first deviation between the actual suspension density in the first-stage mixing tank and a preset first-stage density setting value, and to adjust the opening of the second adjustment device according to a second deviation between the actual suspension density in the second-stage mixing tank and a preset second-stage density setting value.

[0008] According to another aspect of this application, a medium is provided having a computer program stored thereon, which, when executed by a processor, implements the above-described short-process heavy media beneficiation control method.

[0009] According to another aspect of this application, an apparatus is provided, including a storage medium, a processor, and a computer program stored on the storage medium and executable on the processor, wherein the processor executes the program to implement the above-described short-process heavy media beneficiation control method.

[0010] By employing the above technical solution, this application provides a short-process heavy media beneficiation control method, apparatus, medium, and equipment. Through a direct flow from the bottom flow stage to the second stage without desizing, the process flow is significantly shortened, eliminating intermediate desizing screens, conveying pumps, and other equipment, thus significantly reducing operating energy consumption. Simultaneously, all qualified media are collected in a single collection tank, and concentrated media are independently added to both stages. Combined with closed-loop automatic adjustment based on real-time density deviation, this not only solves the density fluctuation problem caused by media dispersion but also overcomes the interference of the first stage's carried media on the second stage, achieving independent and precise control of the separation density in both stages. The embodiments of this application, while simplifying the process and saving costs, can stably improve concentrate grade and recovery rate and possess the ability to adapt to fluctuations in the properties of the raw ore.

[0011] The above description is only an overview of the technical solution of this application. In order to better understand the technical means of this application and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this application more obvious and understandable, specific embodiments of this application are given below. Attached Figure Description

[0012] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 A schematic flowchart of a short-process heavy media mineral processing control method provided in an embodiment of this application is shown. Figure 2 This illustration shows a structural schematic diagram of a short-process heavy media mineral processing control device provided in an embodiment of this application; Figure 3 This paper shows a schematic diagram of a short-process heavy media mineral processing system provided in an embodiment of this application. Figure 4 This invention provides a schematic diagram of another short-process heavy media mineral processing system according to an embodiment of the present application. Figure 5 A schematic diagram of the device structure of a computer device provided in an embodiment of this application is shown. Detailed Implementation

[0013] The present application will be described in detail below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present application can be combined with each other.

[0014] This embodiment provides a short-process heavy media beneficiation control method, such as... Figure 1 As shown, the method includes: Step 101: The raw ore is fed into the first mixing tank, and concentrated medium is added to the first mixing tank from the collection tank through the first medium addition pipeline. The resulting first mixture is fed into the first heavy medium hydrocyclone for separation. The overflow of the first heavy medium hydrocyclone is controlled to be discarded as tailings after desliming. The qualified medium generated in the desliming process is collected in the collection tank, and the underflow of the first heavy medium hydrocyclone is controlled to be directly transported to the second mixing tank without desliming treatment.

[0015] Step 102: In the two-stage mixing tank, concentrated medium is added from the collecting tank to the two-stage mixing tank through the second medium addition pipeline. The resulting second mixture is fed into the two-stage heavy medium hydrocyclone for separation. The underflow and overflow of the two-stage heavy medium hydrocyclone are controlled to obtain concentrate and middlings after demediuming, respectively. The qualified medium generated in the demediuming process is collected in the collecting tank.

[0016] Step 103: During the operation of the first-stage mixing tank and the second-stage mixing tank, the first deviation between the actual suspension density in the first-stage mixing tank and the preset first-stage density setting value is detected in real time. The concentrated medium replenishment flow rate in the first medium addition pipeline is dynamically adjusted according to the first deviation. Also, the second deviation between the actual suspension density in the second-stage mixing tank and the preset second-stage density setting value is detected in real time. The concentrated medium replenishment flow rate in the second medium addition pipeline is dynamically adjusted according to the second deviation. The preset second-stage density setting value is greater than the preset first-stage density setting value.

[0017] This application provides a short-process heavy media beneficiation control method. First, the qualified particle size raw ore after crushing and screening is continuously fed into a first-stage mixing tank. Simultaneously, concentrated media is injected into the first-stage mixing tank from the collection tank through a first media addition pipeline. The concentrated media refers to a heavy suspension prepared from high-density solid particles (such as ferrosilicon powder) and water. The raw ore and concentrated media are thoroughly stirred and mixed in the first-stage mixing tank to form a first mixture with uniform density, which is then pumped into a first-stage heavy media hydrocyclone. Here, the density of the suspension in the first mixture is higher than that of water but between that of the useful minerals and gangue. Under the centrifugal force field of the hydrocyclone, the waste rock (gangue) with a density lower than that of the suspension becomes the overflow, which is washed away by a desliming screen to remove the media and discarded as tailings; while the useful minerals and intergrowths with a density higher than that of the suspension become the underflow. It should be noted that the underflow of the first-stage heavy media hydrocyclone does not undergo any desliming treatment and is directly transported to the second-stage mixing tank through the pipeline, eliminating the need for multiple devices for underflow desliming, transportation, and remixing in traditional processes. Meanwhile, the qualified medium removed by the overflow desizing screen of a heavy medium cyclone separator is collected in the collection tank through pipelines for subsequent recycling.

[0018] In the second-stage mixing tank, the underflow from the first-stage heavy media hydrocyclone is mixed again with the concentrated medium added from the same collection tank via the second medium addition pipeline, forming a second mixture with a higher density. This mixture is then pumped into the second-stage heavy media hydrocyclone. At this point, the underflow from the first-stage heavy media hydrocyclone contains ore particles and carried low-density suspensions. Because the second stage needs to separate concentrate, its density setting is higher than that of the first stage, requiring the addition of more concentrated medium to overcome the dilution effect of the first-stage underflow. In the second-stage heavy media hydrocyclone, the densest useful minerals become the underflow, which, after being washed by the desliming screen, yields the concentrate; the slightly lower density intergrowths or middlings become the overflow, which, after desliming, yields the middlings product. The qualified medium removed by the two desliming screens in the second stage is also all returned to the collection tank. In this way, all qualified media generated from all desliming stages in the entire system are collected in the same collection tank, achieving centralized storage and unified management of the media.

[0019] During continuous production, online density meters are installed at the outlets of the first-stage and second-stage mixing tanks to monitor the actual suspension density in each tank in real time. Simultaneously, the actual suspension density in the first-stage mixing tank is compared with a preset density setpoint to determine the first deviation. If the actual suspension density is too low, indicating insufficient medium addition, the opening of the regulating valve on the first medium addition pipeline is automatically increased, or the frequency of the variable frequency pump is increased to increase the concentrated medium replenishment flow rate; conversely, the replenishment amount is reduced. Similarly, the actual suspension density in the second-stage mixing tank is compared with a preset density setpoint to determine the second deviation, and the replenishment flow rate of the second medium addition pipeline is independently adjusted. It is important to note that the second-stage density setpoint must be higher than the first-stage density setpoint because the primary task of the first stage is waste disposal, while the second stage requires a higher density to extract concentrate from the remaining material. The two adjustment loops do not interfere with each other. Even if suspension carried by the underflow from the first stage mixes into the second stage, the interference can be offset by adjusting the concentrated medium replenishment flow rate in the second stage in real time, ensuring that the separation density of each stage remains stable near its respective target value.

[0020] By applying the technical solution of this embodiment, the process flow is significantly shortened by directly connecting the first stage to the second stage without desizing, eliminating intermediate desizing screens, conveying pumps, and other equipment, thus significantly reducing operating energy consumption. Simultaneously, all qualified media are collected in a single collection tank, and concentrated media are independently added to both stages. Combined with closed-loop automatic adjustment based on real-time density deviation, this not only solves the density fluctuation problem caused by media dispersion but also overcomes the interference of the first stage's carrying media on the second stage, achieving independent and precise control of the separation density in both stages. This embodiment, while simplifying the process and saving costs, can stably improve concentrate grade and recovery rate and has the ability to adapt to fluctuations in raw ore properties.

[0021] Optionally, in this embodiment, step 103, "dynamically adjusting the concentrated medium replenishment flow rate in the first medium addition pipeline according to the first deviation," includes: using the first deviation as an input signal to the main controller, and outputting a target set value for the concentrated medium replenishment flow rate in the first medium addition pipeline through the main controller; detecting the actual concentrated medium replenishment flow rate in the first medium addition pipeline in real time, and calculating the flow deviation between the actual concentrated medium replenishment flow rate and the target set value; using the flow deviation as an input signal to the secondary controller, and outputting an adjustment command to a first adjustment device installed on the first medium addition pipeline through the secondary controller, so as to adjust the concentrated medium replenishment flow rate in the first medium addition pipeline through the first adjustment device, wherein the main controller and the secondary controller constitute a density-flow cascade control structure, the main controller uses the density deviation as the control target, and the secondary controller uses the flow deviation as the control target.

[0022] In this embodiment, the obtained first deviation is first used as the input signal of the main controller. The main controller can use a PID algorithm to calculate a suitable output value based on the magnitude, accumulation, and trend of the first deviation. This output value is the target setpoint for the concentrated medium replenishment flow rate in the first medium addition pipeline. That is, when the actual suspension density is low, the main controller can increase the target setpoint, and vice versa, thereby macroscopically determining how much concentrated medium needs to be added to correct the density deviation.

[0023] To achieve precise adjustment, a flow meter can be installed on the first medium addition pipeline to monitor the actual concentrated medium replenishment flow rate in the pipeline in real time. This flow rate is then compared with the target setpoint output by the main controller to calculate the flow deviation. If the actual concentrated medium replenishment flow rate is lower than the target setpoint, it indicates insufficient medium replenishment, resulting in a positive deviation; conversely, a negative deviation occurs. This allows for timely detection of discrepancies between the execution parameters (such as valve opening and pump speed) and the commands, providing a basis for fine-tuning.

[0024] The calculated flow deviation is used as the input signal for the secondary controller. The secondary controller also has a built-in control algorithm, which can output specific adjustment commands based on the magnitude and direction of the flow deviation. These commands can include increasing or decreasing the opening of the electric regulating valve, raising or lowering the frequency of the variable frequency pump, and directly controlling the first regulating device installed on the first medium addition pipeline, thereby changing the concentrated medium replenishment flow rate in the first medium addition pipeline. The secondary controller typically responds faster than the primary controller, enabling it to quickly eliminate flow fluctuations.

[0025] It is important to note that the main controller and the secondary controller are connected in series, forming a typical cascade control structure. The main controller uses density deviation as the ultimate control target, and its output serves as the target setpoint for the secondary controller. The secondary controller, on the other hand, uses flow deviation as its direct control target, quickly tracking the main controller's commands. This structure separates density regulation from flow regulation: the main controller focuses on maintaining density stability, while the secondary controller focuses on suppressing internal disturbances such as pipeline pressure fluctuations and valve nonlinearity, ensuring that the actual flow accurately follows the target value. Their collaborative operation guarantees both the accuracy of density control and improves the system's response speed and anti-interference capability.

[0026] Compared to traditional single-loop density control, this embodiment introduces a secondary controller, which can quickly eliminate flow fluctuations in the first medium addition pipeline, avoiding the impact of internal disturbances such as pump pressure changes and valve lag on density regulation. The main controller, on the other hand, does not need to operate frequently, focusing on handling external disturbances such as changes in raw ore properties and interference carried by the first-stage underflow, making density control more stable and precise. This solution is particularly suitable for dynamic disturbance scenarios caused by the lack of media removal in the first-stage underflow in short-process heavy media beneficiation, effectively suppressing density fluctuations in the second stage and improving the stability of concentrate grade and recovery rate.

[0027] Optionally, in this embodiment, step 103, "dynamically adjusting the concentrated medium replenishment flow rate in the second medium addition pipeline according to the second deviation," includes: detecting the actual density of the suspension carried into the second mixing tank by the underflow of the first-stage heavy medium cyclone separator, and recording it as the carried density value; comparing the carried density value with the preset first-stage density setting value, and calculating the carried density deviation; determining the interference amount of the underflow of the first-stage heavy medium cyclone separator on the density of the suspension in the second mixing tank according to the carried density deviation; compensating and correcting the second deviation according to the interference amount to obtain the compensated second deviation; and calculating and adjusting the concentrated medium replenishment flow rate in the second medium addition pipeline according to the compensated second deviation.

[0028] In this embodiment, in the basic control scheme given in steps 101 to 103 above, the concentrated medium replenishment flow rate of the second medium addition pipeline can be directly adjusted by detecting the second deviation between the actual suspension density at the outlet of the second-stage mixing tank and the set value of the second-stage density, thus achieving steady-state density closed-loop control. However, since the underflow of the first-stage heavy medium cyclone in this application enters the second-stage mixing tank directly without demediuming treatment, the fluctuations in the suspension density and flow rate carried by the first-stage underflow itself can directly become a known source of interference for the second-stage mixing tank. This embodiment superimposes a feedforward compensation mechanism on the feedback control of the aforementioned basic control scheme: by detecting the suspension density carried by the first-stage underflow (i.e., the carried density value) and the volumetric flow rate of the first-stage underflow, the actual impact of the interference on the second-stage density (i.e., the interference amount) is calculated, and the interference amount is used to compensate and correct the second deviation, thereby adjusting the replenishment flow rate in advance before the outlet density of the second-stage mixing tank deviates from the set value. This feedforward-feedback composite control can significantly accelerate the system's response speed to a first-stage fluctuation, suppress dynamic overshoot, and improve the stability and control quality of the second-stage sorting density.

[0029] Specifically, a density meter can be installed on the underflow pipe of the first-stage heavy medium hydrocyclone to detect the actual density of the suspension carried by the underflow into the second-stage mixing tank in real time, and record it as the carried density value. Since the underflow from the first stage enters the second stage directly without undergoing demediuming treatment, it itself carries the suspension used in the first-stage separation process. Theoretically, the density of this suspension should be equal to the set density value of the first stage, but in actual production, it may deviate due to fluctuations in the first-stage control. Detecting this carried density value is to obtain the real-time status of the interference source, providing a basis for subsequent compensation.

[0030] Next, the detected carry-over density value is compared with a preset first-stage density setting value to calculate the carry-over density deviation. If the carry-over density value equals the first-stage density setting value, it indicates that the first-stage operation is stable, and the interference from the underflow is zero. If the carry-over density value is higher than the first-stage density setting value, it means that the actual density of the first-stage suspension is too high, and the suspension brought by the underflow is too concentrated, which will increase the overall density of the second-stage mixing tank. Conversely, it will decrease the overall density of the second-stage mixing tank. This carry-over density deviation directly quantifies the degree of interference of the first-stage underflow on the density of the second-stage suspension.

[0031] Furthermore, based on the magnitude and direction of the density deviation carried, the interference of the underflow in the first stage on the suspension density in the second-stage mixing tank is determined using a preset relationship model. Here, the interference can be understood as: without additional compensation, how much the suspension carried by the underflow in the first stage would cause the actual suspension density in the second-stage mixing tank to deviate from the set density value of the second stage. This step converts the density deviation carried into a specific density offset value, providing a quantitative basis for compensation and correction.

[0032] It is important to note that the initially detected second deviation was the difference between the actual suspension density at the outlet of the second-stage mixing tank and the set density value for the second stage. This deviation already included the influence of undercurrent interference from the first stage. By subtracting or adding the interference amount obtained in the previous step to the second deviation, a compensated second deviation can be obtained. The compensated second deviation eliminates known interference components and only reflects density errors caused by factors other than those carried by the undercurrent from the first stage, such as changes in the properties of the raw ore and fluctuations in the added medium, thus making the control target purer.

[0033] Subsequently, the compensated second deviation is used as the input to the controller. Following conventional feedback control logic, the required concentrated medium replenishment flow rate in the second medium addition pipeline is calculated, and a command is output to the regulating device for execution. Since the compensated second deviation has eliminated known interference, the controller only needs to handle the remaining uncertain disturbances, resulting in more precise and stable regulation, avoiding frequent large-scale adjustments due to undercurrent fluctuations.

[0034] This embodiment of the application detects the density of the suspension carried by the underflow in the first stage to obtain information on the source of interference in advance, and subtracts the interference amount from the density deviation, thus achieving a compensation control that combines feedforward and feedback. Compared with the traditional scheme that relies solely on the density feedback at the second-stage outlet, this embodiment of the application can significantly suppress the impact of underflow density fluctuations in the first stage on the second-stage separation, avoid overshoot or oscillation caused by feedback adjustment lag, and thus ensure the rapid response and high stability of the second-stage separation density even in a short-process structure where the underflow in the first stage does not de-separate, ultimately improving the stability of concentrate grade and recovery rate.

[0035] Optionally, in this embodiment of the application, the step of "determining the interference amount of the underflow of the first-stage heavy medium cyclone on the suspension density in the second-stage mixing tank based on the carry-over density deviation" includes: obtaining the volumetric flow rate of the underflow of the first-stage heavy medium cyclone entering the second-stage mixing tank, determining the total material volumetric flow rate in the second-stage mixing tank after the underflow of the first-stage heavy medium cyclone enters the second-stage mixing tank, calculating the proportionality coefficient between the volumetric flow rate and the total material volumetric flow rate; and multiplying the carry-over density deviation by the proportionality coefficient to obtain the interference amount.

[0036] In this embodiment, firstly, a flow meter, such as an electromagnetic flow meter, is installed on the underflow pipe of a heavy medium cyclone separator to monitor the volumetric flow rate of the underflow entering the second-stage mixing tank in real time. Simultaneously, the total material volumetric flow rate within the second-stage mixing tank after the underflow enters needs to be determined. This total material volumetric flow rate consists of two parts: the volumetric flow rate of the underflow itself plus the volumetric flow rate of the concentrated medium supplied to the second-stage mixing tank via the second medium addition pipe. By acquiring and summing these two flow rates, the total material volumetric flow rate can be obtained. Then, the ratio of the underflow volumetric flow rate to the total material volumetric flow rate is calculated to obtain a proportionality coefficient. The physical meaning of this proportionality coefficient is: the volume fraction of the underflow during the mixing process of the suspension carried by the underflow and the concentrated medium supplied via the second medium addition pipe. This fraction determines the contribution of the underflow's density deviation to the final mixing density.

[0037] Next, the previously calculated carry-over density deviation is multiplied by the proportionality coefficient. The product is the disturbance amount of the underflow on the suspension density in the second-stage mixing tank. This disturbance amount represents the degree to which, without additional compensation measures, the physical mixing of the suspension carried by the underflow with the concentrated medium can cause the actual density at the outlet of the second-stage mixing tank to deviate from the set density value of the second stage. In this way, the abstract carry-over density deviation is transformed into a specific, directly compensable quantitative value for disturbance correction.

[0038] It should be noted that the disturbance quantity is used to characterize the additional impact of the underflow in the first stage on the density of the suspension in the second stage mixing tank due to the deviation of the actual density from the set density value of the first stage, rather than the absolute contribution of the density of the underflow itself. Let ΔD be the difference between the actual density of the suspension carried by the first stage underflow and the set density value of the first stage, and K be the proportion of the underflow volumetric flow rate to the total material volumetric flow rate in the second stage mixing tank. Then, the disturbance quantity caused by the fluctuation of the first stage underflow is ΔD×K. Therefore, by multiplying the density deviation by a proportionality coefficient as the disturbance quantity, the normal component can be accurately eliminated, and only the fluctuating part can be corrected, thereby achieving precise compensation control.

[0039] This application embodiment accurately converts the carried density deviation into the actual interference amount on the second-stage density by real-time detection of the underflow volumetric flow rate and calculation of its proportionality coefficient to the total material volumetric flow rate, thus achieving quantitative and dynamic tracking of the interference. Compared with traditional empirical estimation or fixed coefficient compensation, this method can adapt to operating conditions such as fluctuations in underflow flow rate and changes in the flow rate of the supplementary medium, making the compensation correction more accurate and reliable. This application embodiment makes full use of the measurable flow signal, requires no additional complex equipment, is simple to calculate, and has a fast response, providing a solid quantitative foundation for subsequent effective compensation of the second deviation, thereby significantly improving the stability and control quality of the second-stage sorting density.

[0040] Optionally, in this embodiment of the application, the method further includes: during the process of discarding the overflow of the first-stage heavy medium hydrocyclone after desliming, and during the process of desliming the underflow and overflow of the second-stage heavy medium hydrocyclone, the dilute medium generated by each desliming screen is fed into a common magnetic separator for medium recovery; the concentrated medium recovered by the common magnetic separator is collected in the collection tank; and the tailwater discharged from the common magnetic separator is quantitatively transported to the spraying device of the inspection screening equipment through a first water supply pipeline as spraying water for inspection screening operations. The inspection screening equipment is installed before the raw ore is fed into the first-stage mixing tank and is used for pre-screening the raw ore. The remaining tailwater after distribution through the first water supply pipeline, along with the undersize fine particles produced by the inspection screening equipment, is sent to a fine-particle-level thickening equipment for thickening treatment. The clear water overflowing from the fine-particle-level thickening equipment is collected in an overflow pool. From the overflow pool, multiple independent second water supply pipelines supply water to the spray devices of the waste rock desliming screen, concentrate desliming screen, middlings desliming screen, and the replenishment port of the shared magnetic separator in a quantitative manner. The actual water flow rate in each second water supply pipeline is detected in real time and compared with the preset water flow rate setting value of each pipeline. Based on the deviation obtained from the comparison, the opening of the regulating valve set on each second water supply pipeline is adjusted independently.

[0041] In this embodiment, during the processes of first-stage overflow desliming, second-stage underflow, and overflow desliming, each desliming screen produces two types of materials: oversize product and undersize product. The undersize product mainly consists of diluted media after being sprayed with water, which still contains a large number of recyclable media particles. All of these diluted media are collected and fed into a shared magnetic separator, where the magnetic properties of the media particles are used to separate them from the water. The recovered concentrated media is returned to the collection tank for recycling. The tailwater discharged from the magnetic separator (i.e., the wastewater after removing the media) can be quantitatively delivered to the spray device of the inspection screening equipment through the first water supply pipeline according to a preset flow rate, serving as spray water for the inspection screening operation. The inspection screening equipment is located before the raw ore is fed into the first-stage mixing tank. Its function is to pre-screen the raw ore, separating fine-grained materials in advance to avoid interfering with the heavy media separation. This step achieves the first-stage cascade utilization of wastewater within the system.

[0042] After the primary water supply line supplies water to the inspection screening unit, if the total amount of tailwater discharged from the magnetic separator exceeds the spray water required for inspection screening, the remaining tailwater, along with the undersize fine particles (i.e., -0.5mm mud and fine powder) produced by the inspection screening unit, can be sent to a fine-particle thickener for concentration. In the thickener, solid particles settle to the bottom, forming underflow which serves as feed for the next stage of mineral processing, while the clear water at the top flows out from the overflow outlet. All this overflow water is collected in an overflow pool as a reserve for the system's circulating water. This process separates the fine particles while simultaneously recovering a large amount of clear water.

[0043] The clean water in the overflow pool is delivered to the spray devices of the waste rock desliming screen, concentrate desliming screen, middlings desliming screen, and the makeup water inlet of the shared magnetic separator through multiple independent secondary water supply pipelines. Each water supply pipeline is equipped with a flow regulation device, which can independently set the water supply flow according to the actual needs of each water point. For example, the waste rock desliming screen requires a large amount of water to rinse the surface medium of the tailings, and the magnetic separator needs an appropriate amount of water to adjust the slurry concentration. This multi-point independent supply design ensures that each process stage receives the exact amount of water required, avoiding overall water imbalance.

[0044] To achieve precise water supply, each secondary water supply pipeline can be equipped with a flow meter to monitor the actual water flow rate in real time. Water flow rate settings for each water point can be pre-stored, such as 5 m³ / h for screening and 8 m³ / h for waste rock descaling. The actual water flow rate detected in each pipeline is compared with the corresponding set value to calculate the flow deviation. Based on this deviation, independent adjustment commands are sent to the regulating valves on each pipeline to increase or decrease the valve opening, ensuring the actual water supply precisely follows the set value. In this way, even if the demand at a water point changes or the pipeline pressure fluctuates, balance can be quickly restored, achieving independent closed-loop control of water flow at multiple points.

[0045] This application embodiment utilizes a three-stage cascade system: (1) magnetic separation tailwater is preferentially supplied to inspection and screening equipment; (2) residual tailwater and fine particles are concentrated; (3) overflow clean water is returned to each desliming screen and magnetic separator, which can minimize the amount of fresh water replenishment and realize closed-loop circulation of process water; at the same time, through the closed-loop regulation of the flow of multiple independent water supply pipelines, it is ensured that each water point can obtain accurate and stable water volume, avoiding the impact of local water shortage or overflow on the main process. This application embodiment reduces water consumption and wastewater discharge, and improves the operational stability and automation level of the entire system.

[0046] Optionally, in this embodiment of the application, the method further includes: real-time detection of the liquid level in the collection tank to obtain a first liquid level detection value; when the first liquid level detection value is lower than a first low threshold, automatically initiating the action of replenishing the collection tank with new medium until the first liquid level detection value recovers to a preset first normal liquid level range; when the first liquid level detection value is higher than a first high threshold, issuing an alarm signal; and / or, real-time detection of the liquid level in the overflow tank to obtain a second liquid level detection value; when the second liquid level detection value is lower than a second low threshold, automatically initiating the action of replenishing the overflow tank with new water until the second liquid level detection value recovers to a preset second normal liquid level range; when the second liquid level detection value is higher than a second high threshold, issuing an alarm signal.

[0047] In this embodiment, a liquid level sensor can be installed in the collection tank to detect the liquid level of the medium in the tank in real time and obtain a first liquid level detection value. The collection tank is the medium storage and distribution center of the entire system, and its liquid level directly reflects the surplus or deficit of the total amount of medium in the system. A first low threshold (e.g., 20% of the tank volume) and a first high threshold (e.g., 90% of the tank volume) and a first normal liquid level range (e.g., 40% to 80%) can be preset. When the first liquid level detection value is detected to be lower than the first low threshold, it indicates that the system has lost too much medium, such as product carry-over or mechanical leakage. At this time, the action of replenishing new medium to the collection tank is automatically initiated, for example, by opening the medium adding valve or starting the transfer pump, and continuing to replenish until the liquid level is restored to the preset first normal liquid level range before stopping, so as to avoid the sorting density from getting out of control due to insufficient medium. Conversely, when the first liquid level detection value is higher than the first high limit threshold, it indicates that there is an excess of medium in the system, such as excessive recovery or excessive water replenishment. In this case, the system will not be automatically emptied, but will instead issue an alarm signal to remind the operator to check the cause and handle it manually, so as to prevent the medium from overflowing and causing waste and environmental pollution.

[0048] Similarly, a level sensor can be installed in the overflow tank to detect the level of the clean water in the tank in real time and obtain a second level detection value. The overflow tank stores clean water overflowing from the concentration equipment, as well as any other return water, used to supply water to the desliming screens and magnetic separators. A second low threshold (e.g., 30% of the tank volume) and a second high threshold (e.g., 90% of the tank volume), as well as a second normal level range (e.g., 50%–80%) can be preset. When the second level detection value is lower than the second low threshold, it indicates that the circulating water volume may be insufficient due to evaporation, product carry-away, or leakage. At this time, the system can automatically initiate the replenishment of fresh water to the overflow tank, such as by opening the water supply valve, until the level returns to the second normal level range, ensuring that there is no water shortage at any water point. When the second liquid level detection value exceeds the second upper limit threshold, it indicates that there may be excessive water in the system due to high moisture content in the raw ore or excessive external water replenishment. In this case, an alarm signal can be issued to prompt the operator to check and appropriately drain the water or reduce water replenishment to prevent overflow of the pool. The above two control processes are independent and can be implemented separately or simultaneously.

[0049] This embodiment of the application achieves dynamic balance management of media and water through automatic monitoring of the liquid levels in the collection tank and overflow tank: automatic replenishment when the liquid level is low and alarm prompts when the liquid level is high. This avoids production interruptions caused by shortages of key materials and prevents resource waste and safety hazards caused by excessive overflow. Compared with manual inspection and adjustment, this embodiment of the application responds promptly and controls precisely, greatly reducing the labor intensity of operators and ensuring the long-term stable operation of the short-process heavy media mineral processing system.

[0050] Furthermore, as Figure 1 In terms of specific implementation, this application provides a short-process heavy media beneficiation control device, such as... Figure 2 As shown, the device includes: A first-stage sorting module is used to feed the raw ore into a first-stage mixing tank, and at the same time, to add concentrated medium from the collection tank to the first-stage mixing tank through the first medium addition pipeline. The resulting first mixture is fed into a first-stage heavy medium hydrocyclone for sorting. The overflow of the first-stage heavy medium hydrocyclone is controlled to be discarded as tailings after desliming. The qualified medium generated in the desliming process is collected into the collection tank, and the underflow of the first-stage heavy medium hydrocyclone is controlled to be directly transported to the second-stage mixing tank without desliming treatment. The two-stage separation module is used to supplement concentrated medium from the collection tank into the two-stage mixing tank through the second medium addition pipeline, and feed the formed second mixture into the two-stage heavy medium hydrocyclone for separation. The underflow and overflow of the two-stage heavy medium hydrocyclone are controlled to obtain concentrate and middlings after desliming, respectively, and the qualified medium generated in the desliming process is collected into the collection tank. The dynamic adjustment module is used to detect, in real time, a first deviation between the actual suspension density in the first mixing tank and a preset first-stage density setting value during the operation of the first mixing tank and the second mixing tank, and dynamically adjust the concentrated medium replenishment flow rate in the first medium addition pipeline according to the first deviation; and to detect, in real time, a second deviation between the actual suspension density in the second mixing tank and a preset second-stage density setting value, and dynamically adjust the concentrated medium replenishment flow rate in the second medium addition pipeline according to the second deviation, wherein the preset second-stage density setting value is greater than the preset first-stage density setting value.

[0051] Optionally, the dynamic adjustment module is used for: The first deviation is used as the input signal of the main controller, and the main controller outputs the target set value of the concentrated medium replenishment flow rate in the first medium addition pipeline; Real-time detection of the actual concentrated medium replenishment flow rate in the first medium addition pipeline, and calculation of the flow rate deviation between the actual concentrated medium replenishment flow rate and the target set value; The flow deviation is used as the input signal of the secondary controller. The secondary controller outputs an adjustment command to the first adjustment device installed on the first medium addition pipeline, so as to adjust the concentrated medium replenishment flow in the first medium addition pipeline through the first adjustment device. The main controller and the secondary controller form a density-flow cascade control structure. The main controller uses density deviation as the control target, and the secondary controller uses flow deviation as the control target.

[0052] Optionally, the device further includes a water circulation module; the water circulation module is used for: During the process of discarding the overflow of the first-stage heavy medium hydrocyclone after desliming, and the underflow and overflow of the second-stage heavy medium hydrocyclone after desliming, the dilute medium generated by each desliming screen is fed into a common magnetic separator for medium recovery. The concentrated medium recovered by the common magnetic separator is collected in the collection tank, and the tailwater discharged from the common magnetic separator is quantitatively transported to the spraying device of the inspection screening equipment through the first water supply pipeline as spray water for inspection screening operation. The inspection screening equipment is set before the raw ore is fed into the first-stage mixing tank and is used to pre-screen the raw ore. The remaining tailwater after the first water supply pipeline is distributed, along with the undersize fine material produced by the inspection screening equipment, is sent to the fine particle concentration equipment for concentration treatment, and the clear water overflowing from the fine particle concentration equipment is collected into the overflow pool. The overflow pool is supplied with water to the spray devices of the waste rock desliming screen, concentrate desliming screen, middlings desliming screen, and the replenishment port of the common magnetic separator through multiple independent second water supply pipelines. The system monitors the actual water flow in each secondary water supply pipeline in real time and compares it with the preset water flow setting value. Based on the deviation obtained from the comparison, the opening of the regulating valve set on each secondary water supply pipeline is adjusted independently.

[0053] Optionally, the device further includes a liquid level detection module; the liquid level detection module is used for: The liquid level in the collection tank is monitored in real time to obtain a first liquid level detection value; when the first liquid level detection value is lower than a first low threshold, the action of replenishing the collection tank with new medium is automatically initiated until the first liquid level detection value returns to a preset first normal liquid level range; when the first liquid level detection value is higher than a first high threshold, an alarm signal is issued; and / or, The overflow tank level is monitored in real time to obtain a second level detection value. When the second level detection value is lower than the second lower threshold, the overflow tank is automatically replenished with new water until the second level detection value returns to the preset second normal level range. When the second level detection value is higher than the second upper threshold, an alarm signal is issued.

[0054] It should be noted that other corresponding descriptions of the functional units involved in the short-process heavy media mineral processing control device provided in this application embodiment can be found by referring to... Figure 1 The corresponding descriptions in the method will not be repeated here.

[0055] Furthermore, as Figure 1 In terms of specific implementation, this application provides a short-process heavy media mineral processing system, such as... Figure 3 As shown, the system includes: A sorting unit includes a mixing tank and a heavy medium cyclone separator, wherein the outlet of the mixing tank is connected to the inlet of the heavy medium cyclone separator. The two-stage sorting unit includes a two-stage mixing tank and a two-stage heavy medium cyclone separator, wherein the outlet of the two-stage mixing tank is connected to the inlet of the two-stage heavy medium cyclone separator. The media circulation unit includes a media collection tank, a first media addition pipeline, and a second media addition pipeline. The media collection tank is connected to the inlet of the first media addition pipeline and the inlet of the second media addition pipeline, respectively. The outlet of the first media addition pipeline is connected to the media inlet of the first mixing tank, and the outlet of the second media addition pipeline is connected to the media inlet of the second mixing tank. The underflow outlet of the first-stage heavy medium cyclone is directly connected to the inlet of the second-stage mixing tank through the connecting pipe, and no desizing equipment is installed on the connecting pipe. The detection and control unit includes a first density detection device, a second density detection device, and a central control unit. The first density detection device is located at the outlet of the first-stage mixing tank and is used to detect the actual suspension density of the first-stage mixing tank in real time. The second density detection device is located at the outlet of the second-stage mixing tank and is used to detect the actual suspension density of the second-stage mixing tank in real time. The central control unit is electrically connected to the first density detection device, the second density detection device, a first adjustment device on the first medium addition pipeline, and a second adjustment device on the second medium addition pipeline, respectively. It is used to adjust the opening of the first adjustment device according to a first deviation between the actual suspension density in the first-stage mixing tank and a preset first-stage density setting value, and to adjust the opening of the second adjustment device according to a second deviation between the actual suspension density in the second-stage mixing tank and a preset second-stage density setting value.

[0056] This application provides a short-process heavy media mineral processing system, which may include a primary separation unit, a secondary separation unit, a media circulation unit, connecting pipelines, and a detection and control unit. The primary separation unit consists of a primary mixing tank and a primary heavy media hydrocyclone. The primary mixing tank is used to thoroughly mix the raw ore with concentrated media from the collecting tank to form a first mixture with uniform density. The outlet of the mixing tank is directly connected to the inlet of the primary heavy media hydrocyclone via a pipeline, allowing the mixed slurry to smoothly enter the primary heavy media hydrocyclone for the first separation. Inside the primary heavy media hydrocyclone, a centrifugal force field is used to separate the lower-density waste rock from the higher-density useful minerals and intergrowths, providing feed for the subsequent secondary separation.

[0057] The two-stage separation unit includes a two-stage mixing tank and a two-stage heavy media hydrocyclone. The two-stage mixing tank receives the underflow from the first-stage heavy media hydrocyclone and the concentrated medium added from the collecting tank, mixing the two to form a second mixture with a higher density. The outlet of this mixing tank is also connected to the inlet of the second-stage heavy media hydrocyclone, and the mixed slurry enters the second-stage heavy media hydrocyclone for a second separation. Here, the underflow from the first-stage heavy media hydrocyclone enters the second-stage mixing tank directly without demediuming. In the second-stage heavy media hydrocyclone, the densest useful minerals become the underflow, which, after demediuming, yields concentrate; the slightly lower density intergrowths become the overflow, which, after demediuming, yields middlings, thus achieving the separation of concentrate and middlings.

[0058] The media circulation unit may include a media collection tank, a first media addition pipeline, and a second media addition pipeline. The media collection tank is the media storage and distribution center of the entire system, used to receive qualified media from each desliming screen. Here, qualified media refers to the concentrated suspension of material naturally dripping from each desliming screen without dilution by spray water; its density meets the storage concentration requirements of the media collection tank and can be directly returned to the collection tank for recycling. The outlet of the media collection tank is connected to the inlet of the first media addition pipeline and the inlet of the second media addition pipeline, respectively. The outlet of the first media addition pipeline is connected to the media inlet of a first-stage mixing tank, and the outlet of the second media addition pipeline is connected to the media inlet of a second-stage mixing tank. In this way, the concentrated media in the same media collection tank can be independently and quantitatively supplied to the two sorting units, ensuring both a unified media source and independent control of the supplementary flow rate of the two stages.

[0059] The underflow outlet of the first-stage heavy media hydrocyclone is directly connected to the inlet of the second-stage mixing tank via a connecting pipe, without any desliming equipment installed on this connecting pipe. That is, the underflow from the first-stage heavy media hydrocyclone, containing ore particles and the accompanying suspension, is directly transported to the second-stage mixing tank without any washing, screening, or magnetic separation desliming treatment. This design significantly shortens the process flow, eliminating the desliming screen, conveying pump, and corresponding pipelines located between the first and second stages in traditional processes, thereby significantly reducing equipment investment, operating energy consumption, and the complexity of the mineral processing.

[0060] The detection and control unit may include a first density detection device, a second density detection device, and a central control unit. The first density detection device is installed at the outlet of the first mixing tank to detect the actual density of the suspension in the first mixing tank in real time. The second density detection device is installed at the outlet of the second mixing tank to detect the actual density of the suspension in the second mixing tank in real time. The central control unit is electrically connected to these two density detection devices, a first regulating device on the first medium addition pipeline, and a second regulating device on the second medium addition pipeline. The first and second regulating devices may be electric regulating valves or variable frequency pumps. The central control unit compares the actual suspension density in the first mixing tank with a preset density setpoint for the first stage to obtain a first deviation. Based on this deviation, it automatically adjusts the opening of the first regulating device, thereby changing the concentrated medium replenishment flow rate in the first medium addition pipeline, stabilizing the density in the first stage near the setpoint. Simultaneously, it compares the actual suspension density in the second mixing tank with a preset density setpoint for the second stage to obtain a second deviation. Based on this deviation, it independently adjusts the opening of the second regulating device, stabilizing the density in the second stage near a higher setpoint. This forms two independent, closed-loop automatic density control systems.

[0061] This embodiment of the application constructs a truly short-process system by directly conveying the underflow from the first stage to the mixing tank of the second stage without demediuming, significantly reducing the number of equipment, operating energy consumption, and the complexity of the mineral processing. Simultaneously, it employs a single medium collection tank to independently supply concentrated media to both stages, coupled with online density detection and dual closed-loop regulation by the central control unit, achieving centralized management of the medium and precise independent control of the sorting density. This embodiment not only solves the density fluctuation problems caused by the lengthy process and dispersed medium system in traditional processes, but also overcomes the interference of the medium carried by the first stage underflow on the second stage, offering advantages such as low energy consumption, high control precision, and strong adaptability to fluctuations in raw ore.

[0062] In a specific embodiment, the aforementioned short-process heavy media beneficiation control method can be implemented by the detection and control unit in the short-process heavy media beneficiation system.

[0063] Optionally, in this embodiment of the application, the system further includes: The screening equipment is located upstream of the first mixing tank and is used to pre-screen the raw ore. Its oversize product outlet is connected to the inlet of the first mixing tank. A shared magnetic separator has its inlet connected to the dilute medium outlet of each desliming screen for medium recovery; the concentrated medium outlet of the shared magnetic separator is connected to the collection tank for collecting the recovered concentrated medium; the tailwater outlet of the shared magnetic separator is connected to the spray device of the inspection screening equipment through a first water supply pipeline. The fine-particle concentration equipment has its inlet connected to the residual tailwater outlet of the first water supply pipeline and the undersize fine-particle material outlet of the inspection and screening equipment, respectively, for concentrating the residual tailwater and undersize fine-particle material. An overflow pool, the inlet of which is connected to the overflow outlet of the fine-grained thickening equipment, is used to collect the concentrated water; the outlet of the overflow pool is connected to the water spraying device of the waste rock desliming screen, the water spraying device of the concentrate desliming screen, the water spraying device of the middlings desliming screen, and the water replenishment port of the common magnetic separator through multiple independent second water supply pipelines. Each of the second water supply pipelines is equipped with a water flow detection device and a regulating valve. The water flow detection device and the regulating valve are electrically connected to the central control unit. The central control unit is used to independently adjust the opening of each regulating valve according to the deviation between the actual water flow of each second water supply pipeline and its respective preset water flow setting value.

[0064] Optionally, in this embodiment of the application, the system further includes: A first liquid level detection device is installed in the collection tank to detect the first liquid level in the collection tank in real time. A media replenishment device, connected to the media collection tank, is used to replenish the media collection tank with new media; The second liquid level detection device is installed in the overflow pool to detect the second liquid level of the overflow pool in real time. A water replenishment device, connected to the overflow pool, is used to replenish the overflow pool with new water; The central control unit is electrically connected to the first liquid level detection device, the medium replenishment device, the second liquid level detection device, and the water replenishment device, respectively, and is used for: When the first liquid level is lower than the first low threshold, the medium replenishment device is activated to replenish the medium collection tank with new medium until the first liquid level is restored to the preset first normal liquid level range; when the first liquid level is higher than the first high threshold, an alarm signal is issued. And / or, when the second liquid level is lower than the second lower limit threshold, the water replenishment device is activated to replenish the overflow pool with new water until the second liquid level returns to the preset second normal liquid level range; when the second liquid level is higher than the second upper limit threshold, an alarm signal is issued.

[0065] Furthermore, to overcome the shortcomings of traditional heavy media separation processes, such as lengthy flow rates and inefficient control, this application provides an alternative short-flow heavy media beneficiation system and beneficiation control method that features a shorter flow rate, more precise control, and more stable operation. The core of this application lies in achieving a shorter flow rate through process reengineering and intelligent control, allowing the underflow from the first stage of separation to directly enter the second stage of separation without media removal. This is complemented by a centralized, quantitative, closed-loop circulation control system for the media and water, ensuring process stability and efficiency under the short flow rate. The alternative short-flow heavy media beneficiation system and beneficiation control method provided in this application includes, for example… Figure 4 As shown, it includes: 1. Main Process: Raw ore falls from the powder silo 1 and is screened by the inspection and screening equipment 2. The oversize product enters the first-stage mixing tank 3, where it is mixed with concentrated medium from the collecting tank 4, and then pumped into the first-stage heavy medium hydrocyclone 5. The overflow from the first-stage heavy medium hydrocyclone 5 is sent to the waste rock desliming screen 6 for desliming and then discarded as waste; the underflow enters directly into the second-stage mixing tank 7 through a connecting pipe. In the second-stage mixing tank 7, it is mixed with supplemental concentrated medium from the collecting tank 4 and then pumped into the second-stage heavy medium hydrocyclone 8. The underflow from the second-stage heavy medium hydrocyclone 8 is sent to the concentrate desliming screen 9 for desliming to obtain concentrate; the overflow is sent to the middlings desliming screen 10 for desliming to obtain middlings. The undersize product enters the fine particle thickening equipment 11.

[0066] 2. Media Circulation Loop: The qualified media produced by the waste rock desliming screen 6, concentrate desliming screen 9, and middlings desliming screen 10 are collected through pipelines and flow to the collection tank 4. The dilute media produced by these three screens are collected through pipelines and pumped into the shared magnetic separator 12 for recovery. The magnetic concentrate (media) also flows into the collection tank 4. Specifically, the qualified media produced by the waste rock desliming screen 6 first enters the concentrated media tank 30, and then flows to the collection tank 4 through pipelines; the qualified media produced by the concentrate desliming screen 9 first enters the concentrated media tank 31, and then flows to the collection tank 4 through pipelines; the qualified media produced by the middlings desliming screen 10 first enters the concentrated media tank 32, and then flows to the collection tank 4 through pipelines. The dilute media produced by these three screens first enter the dilute media tanks 27, 28, and 29 respectively, and then are collected through their respective pipelines and pumped into the shared magnetic separator 12 for recovery. The collection tank 4 is equipped with a pump, with two outlets: the first media addition pipeline points to the first mixing tank 3, and the second media addition pipeline points to the second mixing tank 7. The diagram shows the access port to the collection tank 4.

[0067] 3. Water Circulation Loop: The tailwater from the shared magnetic separator 12 is first divided into two paths: one path directly supplies water to the inspection and screening equipment 2 via the No. 1 water supply pipeline; the remaining tailwater and the undersize product from the inspection and screening equipment 2 enter the fine particle concentration equipment 11 together. The overflow (filtrate) of this equipment is transported to the overflow pool 13. The overflow pool 13 is equipped with a water supply pump, and its outlet branches into four pipelines: pipeline 2 sprays water to the waste rock desliming screen 6, pipeline 3 sprays water to the concentrate desliming screen 9, pipeline 4 sprays water to the middlings desliming screen 10, and pipeline 5 replenishes water to the shared magnetic separator 12. The diagram also indicates that the water replenishment inlet connects to the overflow pool 13.

[0068] 4. Detection and Control Loop: The outlet pipe of mixing tank 3 is marked with a first density meter 14 and a first flow meter 15; the outlet pipe of mixing tank 7 is marked with a second density meter 16 and a second flow meter 17; the two media addition pipelines of collecting tank 4 are marked with a third density meter 18 and a media flow meter 19, and a fourth density meter 20 and a media flow meter 21; water supply pipelines 1 to 5 are marked with water flow meters 22 to 26. All detection instrument signal lines converge to the central control unit. Control signal lines from the central control unit are connected to the regulating devices on the first and second media addition pipelines, as well as the regulating valves on each water supply pipeline.

[0069] The short-process heavy media beneficiation system in this embodiment employs a dynamic configuration mechanism for a two-stage heavy media separation process. Instead of a fixed two-stage separation pattern (such as a first-stage waste disposal followed by a second-stage cleaning or vice versa), the system dynamically configures the separation process structure in real-time based on the actual properties of the raw ore, including the density of valuable minerals, particle size distribution, and liberation characteristics. The system can combine and adjust various preset process logics according to differences in ore beneficiability, ensuring that the separation process always maintains optimal adaptation to the ore characteristics. Furthermore, the system employs a suspension density setting for the two-stage heavy media separation process: instead of pre-setting fixed density values ​​for the heavy media suspension in the first and second separation stages, the separation density of each stage is set and adjusted based on the compositional characteristics of the current feed ore and the stage separation objectives. The system can continuously optimize and automatically adjust the suspension density of each stage based on raw ore property analysis data, process monitoring feedback, and separation efficiency evaluation, achieving synergistic optimization between density parameters, ore characteristics, and process objectives.

[0070] This application also provides a computer device, which may specifically be a personal computer, a server, a network device, etc. Figure 5 As shown, the computer device includes a bus, a processor, memory, and a communication interface, and may also include an input / output interface and a display device. The processor provides computing and control capabilities. The memory includes a non-volatile storage medium and internal memory. The non-volatile storage medium stores an operating system, computer programs, and a database. The internal memory provides an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The database stores location information. The network interface allows communication with external terminals via a network connection. When the computer program is executed by the processor, it implements the steps in the various method embodiments.

[0071] Those skilled in the art will understand that Figure 5 The structure shown is merely a block diagram of a portion of the structure related to the present application and does not constitute a limitation on the computer device to which the present application is applied. Specific computer devices may include more or fewer components than those shown in the figure, or combine certain components, or have different component arrangements.

[0072] In one embodiment, a computer-readable storage medium is provided, which may be non-volatile or volatile, having stored thereon a computer program that, when executed by a processor, implements the steps in the above method embodiments.

[0073] In one embodiment, a computer program product is provided, including a computer program that, when executed by a processor, implements the steps in the above method embodiments.

[0074] It should be noted that the user information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, data stored, data displayed, etc.) involved in this application are all information and data authorized by the user or fully authorized by all parties.

[0075] Those skilled in the art will understand that all or part of the processes in the above embodiments can be implemented by a computer program instructing related hardware. The computer program can be stored in a non-volatile computer-readable storage medium. When executed, the computer program can include the processes of the embodiments described above. Any references to memory, databases, or other media used in the embodiments provided in this application can include at least one of non-volatile and volatile memory. Non-volatile memory can include read-only memory (ROM), magnetic tape, floppy disk, flash memory, optical memory, high-density embedded non-volatile memory, resistive random access memory (ReRAM), magnetic random access memory (MRAM), ferroelectric random access memory (FRAM), phase change memory (PCM), graphene memory, etc. Volatile memory can include random access memory (RAM) or external cache memory, etc. By way of illustration and not limitation, RAM can take many forms, such as Static Random Access Memory (SRAM) or Dynamic Random Access Memory (DRAM). The databases involved in the embodiments provided in this application may include at least one type of relational database and non-relational database. Non-relational databases may include, but are not limited to, blockchain-based distributed databases. The processors involved in the embodiments provided in this application may be general-purpose processors, central processing units, graphics processing units, digital signal processors, programmable logic devices, quantum computing-based data processing logic devices, etc., and are not limited to these.

[0076] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0077] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of this patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.

Claims

1. A short flow dense medium beneficiation control method, characterized by, include: The raw ore is fed into a first-stage mixing tank, and concentrated medium is added to the first-stage mixing tank from the collection tank through the first medium addition pipeline. The resulting first mixture is fed into a first-stage heavy medium hydrocyclone for separation. The overflow of the first-stage heavy medium hydrocyclone is controlled to be discarded as tailings after desliming. The qualified medium produced in the desliming process is collected in the collection tank, and the underflow of the first-stage heavy medium hydrocyclone is controlled to be directly transported to the second-stage mixing tank without desliming treatment. In the two-stage mixing tank, concentrated medium is added from the collecting tank to the two-stage mixing tank through the second medium addition pipeline. The resulting second mixture is fed into the two-stage heavy medium hydrocyclone for separation. The underflow and overflow of the two-stage heavy medium hydrocyclone are controlled to obtain concentrate and middlings after desliming, and the qualified medium generated in the desliming process is collected in the collecting tank. During the operation of the first-stage mixing tank and the second-stage mixing tank, the first deviation between the actual suspension density in the first-stage mixing tank and the preset first-stage density setting value is detected in real time, and the concentrated medium replenishment flow rate in the first medium addition pipeline is dynamically adjusted according to the first deviation. Also, the second deviation between the actual suspension density in the second-stage mixing tank and the preset second-stage density setting value is detected in real time, and the concentrated medium replenishment flow rate in the second medium addition pipeline is dynamically adjusted according to the second deviation. The preset second-stage density setting value is greater than the preset first-stage density setting value. The step of dynamically adjusting the concentrated medium replenishment flow rate in the first medium addition pipeline according to the first deviation includes: The first deviation is used as the input signal of the main controller, and the main controller outputs the target set value of the concentrated medium replenishment flow rate in the first medium addition pipeline; Real-time detection of the actual concentrated medium replenishment flow rate in the first medium addition pipeline, and calculation of the flow rate deviation between the actual concentrated medium replenishment flow rate and the target set value; The flow deviation is used as the input signal of the secondary controller. The secondary controller outputs an adjustment command to the first adjustment device installed on the first medium addition pipeline, so as to adjust the concentrated medium replenishment flow in the first medium addition pipeline through the first adjustment device. The main controller and the secondary controller form a density-flow cascade control structure. The main controller uses density deviation as the control target, and the secondary controller uses flow deviation as the control target. The method also includes a feedforward compensation mechanism: By detecting the density of the suspension carried by the underflow of the first-stage heavy medium cyclone and the corresponding volumetric flow rate, the interference amount on the suspension density in the second-stage mixing tank is calculated, and the interference amount is used to compensate and correct the second deviation.

2. The method according to claim 1, characterized in that, The method further includes: During the process of discarding the overflow of the first-stage heavy medium hydrocyclone after desliming, and the underflow and overflow of the second-stage heavy medium hydrocyclone after desliming, the dilute medium generated by each desliming screen is fed into a common magnetic separator for medium recovery. The concentrated medium recovered by the common magnetic separator is collected in the collection tank, and the tailwater discharged from the common magnetic separator is quantitatively transported to the spraying device of the inspection screening equipment through the first water supply pipeline as spray water for inspection screening operation. The inspection screening equipment is set before the raw ore is fed into the first-stage mixing tank and is used to pre-screen the raw ore. The remaining tailwater after the first water supply pipeline is distributed, along with the undersize fine material produced by the inspection screening equipment, is sent to the fine particle concentration equipment for concentration treatment, and the clear water overflowing from the fine particle concentration equipment is collected into the overflow pool. The overflow pool is supplied with water to the spray devices of the waste rock desliming screen, concentrate desliming screen, middlings desliming screen, and the replenishment port of the common magnetic separator through multiple independent second water supply pipelines. The system monitors the actual water flow in each secondary water supply pipeline in real time and compares it with the preset water flow setting value. Based on the deviation obtained from the comparison, the opening of the regulating valve set on each secondary water supply pipeline is adjusted independently.

3. The method according to claim 2, characterized in that, The method further includes: The liquid level in the collection tank is monitored in real time to obtain a first liquid level detection value; when the first liquid level detection value is lower than a first low threshold, the action of replenishing the collection tank with new medium is automatically initiated until the first liquid level detection value returns to a preset first normal liquid level range; when the first liquid level detection value is higher than a first high threshold, an alarm signal is issued; and / or, The overflow tank level is monitored in real time to obtain a second level detection value. When the second level detection value is lower than the second lower threshold, the overflow tank is automatically replenished with new water until the second level detection value returns to the preset second normal level range. When the second level detection value is higher than the second upper threshold, an alarm signal is issued.

4. A short-process heavy media mineral processing control device, characterized in that, include: A first-stage sorting module is used to feed the raw ore into a first-stage mixing tank, and at the same time, to add concentrated medium from the collection tank to the first-stage mixing tank through the first medium addition pipeline. The resulting first mixture is fed into a first-stage heavy medium hydrocyclone for sorting. The overflow of the first-stage heavy medium hydrocyclone is controlled to be discarded as tailings after desliming. The qualified medium generated in the desliming process is collected into the collection tank, and the underflow of the first-stage heavy medium hydrocyclone is controlled to be directly transported to the second-stage mixing tank without desliming treatment. The two-stage separation module is used to supplement concentrated medium from the collection tank into the two-stage mixing tank through the second medium addition pipeline, and feed the formed second mixture into the two-stage heavy medium hydrocyclone for separation. The underflow and overflow of the two-stage heavy medium hydrocyclone are controlled to obtain concentrate and middlings after desliming, respectively, and the qualified medium generated in the desliming process is collected into the collection tank. A dynamic adjustment module is used to detect, in real time, a first deviation between the actual suspension density in the first mixing tank and a preset first-stage density setting value during the operation of the first mixing tank and the second mixing tank, and dynamically adjust the concentrated medium replenishment flow rate in the first medium addition pipeline according to the first deviation; and to detect, in real time, a second deviation between the actual suspension density in the second mixing tank and a preset second-stage density setting value, and dynamically adjust the concentrated medium replenishment flow rate in the second medium addition pipeline according to the second deviation, wherein the preset second-stage density setting value is greater than the preset first-stage density setting value; The dynamic adjustment module is further configured to use the first deviation as an input signal to the main controller, and output a target set value for the concentrated medium replenishment flow rate in the first medium addition pipeline through the main controller; detect the actual concentrated medium replenishment flow rate in the first medium addition pipeline in real time, and calculate the flow deviation between the actual concentrated medium replenishment flow rate and the target set value; use the flow deviation as an input signal to the secondary controller, and output an adjustment command to the first adjustment device installed on the first medium addition pipeline through the secondary controller, so as to adjust the concentrated medium replenishment flow rate in the first medium addition pipeline through the first adjustment device. The main controller and the secondary controller constitute a density-flow cascade control structure, with the main controller using density deviation as the control target and the secondary controller using flow deviation as the control target. The dynamic adjustment module is also used to calculate the amount of interference to the density of the suspension in the second mixing tank by detecting the density of the suspension carried by the underflow of the first-stage heavy medium cyclone and the corresponding volumetric flow rate, and to use the amount of interference to compensate and correct the second deviation.

5. A short-process heavy media mineral separation system, characterized in that, include: A sorting unit includes a mixing tank and a heavy medium cyclone separator, wherein the outlet of the mixing tank is connected to the inlet of the heavy medium cyclone separator. The two-stage sorting unit includes a two-stage mixing tank and a two-stage heavy medium cyclone separator, wherein the outlet of the two-stage mixing tank is connected to the inlet of the two-stage heavy medium cyclone separator. The media circulation unit includes a media collection tank, a first media addition pipeline, and a second media addition pipeline. The media collection tank is connected to the inlet of the first media addition pipeline and the inlet of the second media addition pipeline, respectively. The outlet of the first media addition pipeline is connected to the media inlet of the first mixing tank, and the outlet of the second media addition pipeline is connected to the media inlet of the second mixing tank. The underflow outlet of the first-stage heavy medium cyclone is directly connected to the inlet of the second-stage mixing tank through the connecting pipe, and no desizing equipment is installed on the connecting pipe. The detection and control unit includes a first density detection device, a second density detection device, and a central control unit. The first density detection device is located at the outlet of the first-stage mixing tank and is used to detect the actual suspension density of the first-stage mixing tank in real time. The second density detection device is located at the outlet of the second-stage mixing tank and is used to detect the actual suspension density of the second-stage mixing tank in real time. The central control unit is electrically connected to the first density detection device, the second density detection device, a first adjustment device on the first medium addition pipeline, and a second adjustment device on the second medium addition pipeline, respectively. It is used to adjust the opening of the first adjustment device according to a first deviation between the actual suspension density in the first-stage mixing tank and a preset first-stage density setting value, and to adjust the opening of the second adjustment device according to a second deviation between the actual suspension density in the second-stage mixing tank and a preset second-stage density setting value. The detection and control unit is further configured to use the first deviation as an input signal to the main controller, and output a target set value for the concentrated medium replenishment flow rate in the first medium addition pipeline through the main controller; detect the actual concentrated medium replenishment flow rate in the first medium addition pipeline in real time, and calculate the flow deviation between the actual concentrated medium replenishment flow rate and the target set value; use the flow deviation as an input signal to the secondary controller, and output an adjustment command to the first adjustment device installed on the first medium addition pipeline through the secondary controller, so as to adjust the concentrated medium replenishment flow rate in the first medium addition pipeline through the first adjustment device, wherein the main controller and the secondary controller constitute a density-flow cascade control structure, the main controller uses density deviation as the control target, and the secondary controller uses flow deviation as the control target; The detection and control unit is also used to calculate the amount of interference to the density of the suspension in the second mixing tank by detecting the density of the suspension carried by the underflow of the first-stage heavy medium cyclone and the corresponding volumetric flow rate, and to use the amount of interference to compensate and correct the second deviation.

6. A computer-readable storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the method of any one of claims 1 to 3.

7. A computer device, comprising a storage medium, a processor, and a computer program stored on the storage medium and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method of any one of claims 1 to 3.

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