Intelligent control method for whole process of casting coke feeding, batching and mixing and production system thereof

Abstract

The present application relates to a kind of full-process collaborative intelligent control method of casting coke feeding, batching and mixing and production system thereof, including anthracite feeding system, VR hydrocracking residue feeding system, pitch coke feeding system, intelligent batching mixing system and central control system, intelligent batching mixing system includes three-drum weighing vehicle, mixing kneader transition hopper, mixing kneader and press machine transition hopper, coal batching bin of anthracite feeding system, VR hydrocracking concentrated residue batching bin of VR hydrocracking residue feeding system and pitch coke batching bin of pitch coke feeding system are all set above three-drum weighing vehicle, mixing kneader transition hopper, mixing kneader and press machine transition hopper are sequentially set below three-drum weighing vehicle;Anthracite feeding system, VR hydrocracking residue feeding system, pitch coke feeding system and intelligent batching mixing system are connected with central control system electric signal.This application has higher processing efficiency;Weighing precision is higher;Greatly reduce labor cost, improve production efficiency.

Description

Technical Field

[0001] This invention belongs to the field of metallurgical material production technology, specifically relating to a collaborative intelligent control method and production system for the entire process of casting coke feeding, batching and mixing. Background Technology

[0002] As a fuel and reducing agent in the foundry industry, foundry coke's fixed carbon content, mechanical strength, and reactivity directly determine the production efficiency and yield of castings. Traditional foundry coke production processes typically employ a fixed-ratio raw material mixing method, primarily relying on basic raw materials such as anthracite and petroleum coke. However, with increasing environmental requirements and the diversification of raw material resources, VR hydrocracking residue has been introduced as a novel additive to improve the coke's adhesion and thermal stability. Nevertheless, existing technologies still suffer from significant drawbacks in the batching and mixing stages, including manual weighing, inaccurate measurement, high labor intensity for workers, severe dust pollution, and lagging automation, necessitating an urgent upgrade to intelligent systems. Summary of the Invention

[0003] To overcome the shortcomings of existing technologies, this invention provides a collaborative intelligent control method and production system for the entire process of casting coke feeding, batching, and mixing. Its advantages include: using automated equipment for transportation and unpacking, resulting in high processing efficiency; using weighing carts to automatically pick up and weigh different materials, resulting in high weighing accuracy and efficiency; and the overall feeding, batching, and mixing process of this invention has a high degree of automation, which significantly reduces labor costs and improves production efficiency.

[0004] To achieve the above objectives, the present invention employs the following technical solution: A collaborative intelligent control method for the entire process of casting coke feeding, batching, and mixing, specifically including: 1) Anthracite is transported to the coal receiving hopper by a wheel loader, and then to the coal drying cylinder feeding hopper by a vibrating feeder and a bucket conveyor lined with wear-resistant plates. The vibrating feeder then feeds the coal into a counter-current rotary drying cylinder with an inclination angle of 3.5° and a rotation speed of 2.4 r / min. The fuel burns in the combustion chamber of the rotary drying cylinder, generating hot flue gas at 350-400℃. This hot flue gas comes into counter-current contact with the anthracite for heat exchange and drying. After drying, the moisture content of the anthracite is precisely controlled at 2.0%-3.1%. The flue gas after combustion is divided into two parts, with 65%-75% being purified by a high-temperature bag filter. After reaching emission standards, 25%-35% of the exhaust gas is returned to the combustion chamber via a variable frequency induced draft fan for waste heat recycling. The central control system adjusts the flue gas recirculation rate and the fuel supply to the combustion chamber in real time based on the online moisture content of the dried anthracite. When the online moisture content is higher than the target upper limit of 3.1%, the central control system increases the flue gas recirculation ratio to the upper limit of 35% and simultaneously increases the fuel supply. When the online moisture content is lower than the target lower limit of 2.0%, the central control system reduces the flue gas recirculation ratio to the lower limit of 25% and simultaneously reduces the fuel supply, achieving dual closed-loop coordinated control of drying energy consumption and product moisture content.

[0005] In step 1), the rotary drying cylinder is equipped with a guide plate to form a uniform material curtain of anthracite inside the drying cylinder, extending the contact time with the hot flue gas. The guide plate structure includes lifting plates and guide plates arranged alternately along the axis of the drying cylinder. The lifting plates lift the anthracite and allow it to fall freely to form a material curtain. The guide plates control the axial propulsion speed of the anthracite, ensuring that the average residence time of the anthracite in the drying cylinder is not less than 20 minutes.

[0006] 2) The dried anthracite is transported by a bucket conveyor to the feed hopper of the coal crusher, then fed to the crusher by a vibrating feeder, and finally transported by a bucket conveyor to the coal batching silo for temporary storage.

[0007] 3) The ton-bag VR hydrocracking concentration residue is lifted and transported to the automated bag-opening station. After automatic bag opening, it is unloaded into the VR hydrocracking concentration residue transition hopper with an anti-stick inner wall for temporary storage. Then, it is sent to the double-roll crusher for crushing via a vibrating feeder, and then transported to the VR hydrocracking concentration residue batching silo via a bucket conveyor with an anti-stick lining for temporary storage. The anti-stick inner wall and anti-stick layer are made of polytetrafluoroethylene coating or ultra-high molecular weight polyethylene lining to prevent material retention and blockage caused by the strong adhesion of VR hydrocracking concentration residue at room temperature.

[0008] 4) The ton bags of asphalt coke are lifted and transported to the automated bag-opening station for automatic bag opening and unloading into the asphalt coke transition hopper for temporary storage. Then, they are sent to the asphalt coke batching silo for temporary storage through the pneumatic conveying system. The pneumatic conveying system adopts a positive pressure dilute phase conveying method, and the conveying pipeline is equipped with an anti-static grounding device to prevent the risk of combustion and explosion caused by static electricity accumulation in the asphalt coke fine powder during the conveying process.

[0009] 5) The radar level sensors in each batching bin transmit real-time level data and the rate of level change to the central control system. The central control system plans the optimal driving path based on the preset batching formula, the level warning threshold of each batching bin, and the current position of the three-bucket weighing vehicle. It controls the three-bucket weighing vehicle to move precisely to the outlet of the corresponding batching bin in sequence. The optimal driving path planning aims to minimize the total driving distance of the three-bucket weighing vehicle, while also satisfying the batching sequence constraint: anthracite → bituminous coke → VR hydrocracking concentration residue, and the level warning priority constraint: batching bins with levels below the warning threshold are given priority for replenishment.

[0010] 6) After the position sensor of the three-bucket weighing cart returns a precise positioning signal to the central control system, the central control system generates a graded feeding instruction: the raw materials in the batching bin pass through the pneumatic quick-cut valve, the feeder, and the electro-hydraulic flat gate in sequence before entering the corresponding independent weighing hopper of the three-bucket weighing cart; the weighing hopper feeds back the material weight to the central control system in real time. When the material weight reaches 85% of the target amount, the feeder slows down. When it approaches 97% of the target amount, the feeder is shut off in advance. The central control system calculates the compensation amount based on the difference between the material weight and the target amount at the time the feeder is shut off, combined with the average drop statistics of historical batches, and controls the pneumatic quick-cut valve to perform micro-feeding to ensure that the final weighing error of a single material is ≤±0.2%; when the drop compensation amount of 3 consecutive batches exceeds the set threshold, the central control system automatically triggers the feeder speed calibration program.

[0011] In step 6), an adjustable-speed vibrating feeder is used to supply anthracite and bituminous coke granules, while a variable-frequency screw feeder is used to supply VR hydrocracking concentrate residue powder. An anti-blocking detection device is installed at the feeder outlet. This anti-blocking detection device uses a material flow sensor. If there is no material flow signal for more than 5 seconds, a blockage alarm is sent to the central control system. The central control system automatically triggers the feeder to reverse and clear the blockage. If there is still no material flow signal after three reversals, the central control system switches to the backup feeder channel and issues a manual handling alarm. The central control system collects real-time operating current, vibration, and temperature data from all equipment. The system identifies equipment malfunctions using a pre-defined fault prediction model. This model establishes a baseline of normal operating characteristics based on historical operating data of each device. When the deviation between the real-time collected data and the baseline exceeds a set threshold, an early warning is triggered instead of waiting for an actual equipment failure. When a kneader malfunctions, the central control system automatically assigns its processing tasks to other online kneaders and adjusts the travel path and unloading sequence of the three-hopper weighing cart to ensure production continuity. When all kneaders are at full load, the central control system automatically pauses the material handling action of the three-hopper weighing cart, stops the cart in standby position, and issues a capacity warning to the operator.

[0012] 7) After all the weighing hoppers in the three-hopper weighing cart have completed their material picking and weighing tasks, the central control system collects the material level signals of all online kneader transition hoppers, the working status signals of the kneaders, and the queue of tasks to be processed in real time. The system then uses a load balancing algorithm to match the optimal kneader. The load balancing algorithm takes the current task remaining time of each kneader, the remaining material level in the transition hopper, and the equipment operating status score as inputs, and minimizes the longest waiting time as the optimization objective, and outputs the target kneader number. Subsequently, the central control system issues a discharge task command, controlling the three-hopper weighing cart to travel to the corresponding kneader transition hopper. Once the limit device confirms the position is correct, the discharge valve on the three-hopper weighing cart opens, and the three materials enter the corresponding kneader transition hoppers respectively.

[0013] In step 7), the kneader transition hopper is equipped with an electric heating and insulation device to maintain the material temperature in the kneader transition hopper at 80-100℃; in step 8), the press transition hopper is equipped with a steam jacket insulation device to maintain the mixture temperature at 150-170℃.

[0014] 8) The kneader transmits real-time temperature, stirring current, and main shaft torque signals to the central control system. When it needs to perform a mixing task, it sends a material request signal to the central control system. Anthracite and pitch coke in the kneader's transition hopper first enter the kneader through a pneumatic quick-cut valve for the first stage of premixing and heating. The kneader uses a combined heating method of jacketed electric heating and heating rods built into the stirring paddle, uniformly heating the materials while stirring. The target temperature for the first stage of premixing and heating is 130-150℃, the stirring speed is 15-25 r / min, and the heating time is no less than 8 minutes. The stirring speed is controlled by a program. When the material temperature in the kneader reaches the set temperature and the temperature uniformity is ≤ ± At 5℃, a signal is sent to the central control system allowing the addition of VR hydrocracking concentrate residue. The VR hydrocracking concentrate residue in the kneader transition hopper enters the kneader via a pneumatic quick-cut valve for the second stage of high-temperature kneading. The target temperature for the second stage of high-temperature kneading is 160-185℃, the stirring speed is increased to 30-45 r / min, and the kneading time is no less than 15 min. By increasing the stirring speed and controlling the kneading time, the VR hydrocracking concentrate residue is fully melted and evenly coated on the surface of anthracite and pitch coke particles. After the three materials are fully heated and mixed in the kneader, they fall into the press transition hopper for temporary storage. Subsequently, the materials enter the molding process via a twin-shaft screw conveyor.

[0015] 9) Based on the strength and porosity test results of the previous batch of foundry coke, the central control system automatically fine-tunes the proportions of anthracite, pitch coke, and VR hydrocracking concentrate residue in the next batch. The automatic fine-tuning adopts the following rules: when the strength test result is lower than 3% of the target value, the central control system increases the proportion of VR hydrocracking concentrate residue by 0.5%-1.0% in the next batch, and simultaneously reduces the proportion of anthracite by the same proportion; when the porosity test result is higher than 5% of the target value, the central control system increases the temperature of the second stage of kneading by 5-10℃ and extends the kneading time by 2-3 minutes in the next batch. All formula adjustments are recorded in the batch file, and the single formula adjustment range does not exceed 2%. When it exceeds the safety boundary, it switches to manual confirmation mode.

[0016] Subsequent defective products generated during molding and after firing are manually sorted and collected: Molded defective products are crushed to 8mm and then mixed into the anthracite coal batching bin for reuse at a ratio of 5%-10%; fired defective products are crushed to 8mm and then mixed into the asphalt coke batching bin for reuse at a ratio of 5%-6%. After crushing, the defective products are sent to the corresponding batching bins via a pneumatic conveying system. The central control system automatically adjusts the batching amount of the main raw materials according to the reuse ratio. When adjusting the main raw material batching amount, the central control system simultaneously corrects the batching amount of VR hydrocracking concentrate residue to maintain the mass ratio of the three raw materials. The reuse amount for this batch is recorded in the production batch file for quality traceability.

[0017] The production system used in the whole-process collaborative intelligent control method for casting coke feeding, batching and mixing includes: an anthracite feeding system, a VR hydrocracking residue feeding system, a pitch coke feeding system, an intelligent batching and mixing system and a central control system; The intelligent batching and mixing system includes a three-bucket weighing cart integrating three independent weighing hoppers, a kneader transition hopper, a kneader and a press transition hopper integrating a composite heating device. The coal batching silo of the anthracite feeding system, the VR hydrocracking concentrate residue batching silo of the VR hydrocracking residue feeding system, and the asphalt coke batching silo of the asphalt coke feeding system are arranged sequentially above the three-bucket weighing cart along its travel track. Below the three-bucket weighing cart, multiple sets of parallel kneader transition hoppers, kneaders and press transition hoppers are arranged sequentially in three-dimensional space, forming a vertical material flow of "batching silo → three-bucket weighing cart → kneader transition hopper → kneader". The anthracite feeding system, VR hydrocracking residue feeding system, pitch coke feeding system, and intelligent batching and mixing system are all electrically connected to the central control system. The central control system includes a material level management module, a path planning module, a weighing control module, a kneader scheduling module, and a process parameter closed-loop control module, realizing collaborative intelligent control of the entire process; The closed-loop control module for process parameters stores the baseline values ​​of the physical properties of each raw material, including the target moisture range of anthracite, the softening point range of VR hydrocracking concentrate residue, and the particle size range of pitch coke. It also automatically triggers parameter correction commands for the corresponding process based on the deviation between the online detection data and the baseline values.

[0018] The anthracite feeding system includes a coal receiving hopper, a vibrating feeder, a bucket conveyor, a coal drying cylinder feeding hopper, a rotary drying cylinder, a coal crusher feeding hopper, a crusher, and a coal batching bin. The bottom of the coal receiving hopper is connected to the vibrating feeder. The discharge from the vibrating feeder is fed into the coal drying cylinder feeding hopper via the bucket conveyor. The coal drying cylinder feeding hopper feeds material to the rotary drying cylinder. The discharge from the rotary drying cylinder is then fed to the coal crusher feeding hopper via the bucket conveyor. The coal crusher feeding hopper feeds material to the crusher. The discharge from the crusher is then fed into the coal batching bin via the bucket conveyor. The rotary drying cylinder is equipped with an online moisture detector installed at the discharge end of the drying cylinder. It uses near-infrared or microwave measurement principles, with a detection accuracy of ≤±0.2%. The detection signal is transmitted to the central control system in real time.

[0019] The VR hydrocracking residue feeding system includes an electric hoist, an automated bag-opening station, a VR hydrocracking residue transition hopper, a vibrating feeder, a crusher, a bucket conveyor, and a VR hydrocracking concentrated residue batching silo. The electric hoist delivers bagged VR hydrocracking residue into the automated bag-opening station. Below the automated bag-opening station is a VR hydrocracking residue transition hopper. At the bottom of the VR hydrocracking residue transition hopper is a vibrating feeder that feeds the crusher. The crusher discharges the residue, which is then conveyed to the VR hydrocracking concentrated residue batching silo via the bucket conveyor. The VR hydrocracking concentrated residue batching silo is equipped with an electric heating device on the silo wall to maintain the material temperature inside the silo at 40-60℃, preventing the VR hydrocracking concentrated residue from solidifying at low temperatures during storage, which would affect the flowability of subsequent feeding.

[0020] The asphalt coke feeding system includes an electric hoist, an automated bag-opening station, an asphalt coke transition hopper, a pneumatic conveying system, and an asphalt coke batching silo. The electric hoist transports the asphalt coke to the automated bag-opening station. Below the automated bag-opening station is an asphalt coke transition hopper. The discharge from the asphalt coke transition hopper is sent to the asphalt coke batching silo via the pneumatic conveying system. The conveying pipes, transition hopper, and batching silo of the pneumatic conveying system are all equipped with anti-static grounding devices. The conveying pipes use conductive lining material. The system is equipped with an online dust concentration monitor. When the dust concentration in the pipe exceeds 25% of the lower explosive limit, the central control system automatically triggers the conveying pause and pressure relief protection program.

[0021] Dust removal equipment is installed at every dust-generating point in the production system.

[0022] Compared with the prior art, the beneficial effects of the present invention are: 1. The raw material processing technology is equipped with automated equipment such as automatic bag opening stations, which reduces manual intervention and improves processing efficiency.

[0023] 2. The weighing cart is used to automatically pick up and weigh different materials, which has high weighing accuracy and efficiency.

[0024] 3. Material level sensors are installed in the batching bin and transition hopper, so that the central control system can guide the weighing vehicle to automatically complete the material picking and feeding tasks.

[0025] 4. The silos, transition hoppers, and weighing hoppers are equipped with heat preservation or electric heating devices to ensure a constant material temperature and improve the mixing effect.

[0026] 5. Dust removal equipment is provided at all dust-generating points, which improves the quality of the factory environment.

[0027] 6. The central control system realizes intelligent control of tasks from raw material feeding, weighing cart metering and picking, feeding, mixing in the mixer, and unloading. It has a high degree of automation, which greatly reduces labor costs and improves production efficiency. Attached Figure Description

[0028] Figure 1 This is a diagram of anthracite feeding system; Figure 2 This is a diagram of the VR hydrocracking residue feeding system; Figure 3 This is a diagram of the bituminous coke feeding system; Figure 4 It is an intelligent ingredient mixing system.

[0029] Figure 5 This is a cross-sectional view of a rotary drying cylinder. In the diagram: 1. Coal receiving hopper; 2. Vibrating feeder; 3. Bucket conveyor; 4. Coal drying cylinder feeding hopper; 5. Rotary drying cylinder; 6. Coal crusher feeding hopper; 7. Crusher; 8. Coal batching silo; 9. Electric hoist; 10. Automated bag opening station; 11. VR hydrocracking residue transition hopper; 12. VR hydrocracking concentration residue batching silo; 13. Asphalt coke transition hopper; 14. Pneumatic conveying system; 15. Asphalt coke batching silo; 16. Three-bucket weighing car; 17. Mixer transition hopper; 18. Mixer; 19. Press transition hopper; 20. Twin-shaft screw conveyor; 21. Guide plate; 22. Lifting plate. Detailed Implementation

[0030] The specific embodiments of the present invention will be further described below with reference to the accompanying drawings: like Figures 1-4 As shown in the figure, ↑dust represents dust removal points, which are specifically distributed at equipment locations prone to dust generation, such as receiving hoppers, bag opening stations, bucket conveyors, and batching silos, in order to maintain the environmental quality of the plant area.

[0031] A collaborative intelligent control method for the entire process of casting coke feeding, batching, and mixing, specifically including: 1) Anthracite is transported to the coal receiving hopper 1 by a wheel loader, and then transported to the coal drying cylinder feeding hopper 4 by a vibrating feeder 2 and a bucket conveyor 3 with wear-resistant liners. The vibrating feeder then feeds the coal to the feeding hopper 4 at an inclination angle of 3.5° and a speed of 2.4 r / min. The coal is dried inside a counter-current rotary drying drum 5. Fuel is burned in the combustion chamber of the rotary drying drum 5 to generate hot flue gas at 350-400℃. This hot flue gas comes into counter-current contact with the anthracite for heat exchange and drying. After drying, the moisture content of the anthracite is precisely controlled between 2.0% and 3.1%. The flue gas after combustion is divided into two parts: 65%-75% is purified by a high-temperature bag filter and discharged in compliance with standards, while 25%-35% is returned to the combustion chamber by a variable frequency induced draft fan for waste heat recycling. The central control system adjusts the flue gas return flow and the fuel supply to the combustion chamber in real time based on the online moisture content of the dried anthracite. When the online moisture content is higher than the target upper limit of 3.1%, the central control system increases the flue gas return ratio to the upper limit of 35% and simultaneously increases the fuel supply. When the online moisture content is lower than the target lower limit of 2.0%, the central control system reduces the flue gas return ratio to the lower limit of 25% and simultaneously reduces the fuel supply, achieving dual closed-loop coordinated control of drying energy consumption and product moisture content.

[0032] In step 1), the rotary drying cylinder 5 is equipped with a guide plate inside, see... Figure 5 This allows the anthracite to form a uniform material curtain inside the drying cylinder, extending the contact time with the hot flue gas. The guide plate structure includes lifting plates 22 and guide plates 21 arranged alternately along the axial direction of the drying cylinder. The lifting plates 22 lift the anthracite and allow it to fall freely to form a material curtain. The guide plates 21 control the axial propulsion speed of the anthracite, ensuring that the average residence time of the anthracite in the drying cylinder is not less than 20 minutes.

[0033] 2) The dried anthracite is transported by a bucket conveyor to the coal crusher feed hopper 6, then fed to the crusher 7 by a vibrating feeder, and finally transported to the coal batching bin 8 for temporary storage by a bucket conveyor.

[0034] 3) The ton-bag VR hydrocracking concentration residue is lifted and transported to the automated bag opening station 10. After automatic bag opening, it is unloaded into the VR hydrocracking concentration residue transition hopper 11 with an anti-stick inner wall for temporary storage. Then, it is sent to the double-roll crusher 7 via the vibrating feeder 2 and then to the VR hydrocracking concentration residue batching silo 12 via the bucket conveyor 3 with an anti-stick lining for temporary storage. The anti-stick inner wall and anti-stick layer are made of polytetrafluoroethylene coating or ultra-high molecular weight polyethylene lining to prevent material retention and blockage caused by the strong adhesion of VR hydrocracking concentration residue at room temperature.

[0035] 4) The ton-bag asphalt coke is lifted and transported to the automated bag opening station 10. After automatic bag opening, it is unloaded into the asphalt coke transition hopper 13 for temporary storage. Then, it is sent to the asphalt coke batching silo 13 for temporary storage through the pneumatic conveying system. The pneumatic conveying system adopts a positive pressure dilute phase conveying method. The conveying pipeline is equipped with an anti-static grounding device to prevent the risk of combustion and explosion caused by static electricity accumulation in the asphalt coke fine powder during the conveying process.

[0036] 5) The radar level sensors in each batching bin transmit real-time level data and the rate of change of level to the central control system. The central control system plans the optimal driving path based on the preset batching formula, the level warning threshold of each batching bin, and the current position of the three-bucket weighing cart 16, and controls the three-bucket weighing cart to move precisely to the discharge port of the corresponding batching bin in sequence. The optimal driving path planning takes the shortest total driving distance of the three-bucket weighing cart 16 as the optimization objective, while satisfying the batching sequence constraint: anthracite → bituminous coke → VR hydrocracking concentration residue, and the level warning priority constraint: the batching bin with the level below the warning threshold is given priority for replenishment.

[0037] 6) After the position sensor of the three-bucket weighing cart 16 returns a precise positioning signal to the central control system, the central control system generates a graded feeding instruction: the raw materials in the batching bin pass through the pneumatic quick-cut valve, the feeder, and the electro-hydraulic flat gate in sequence before entering the corresponding independent weighing hopper of the three-bucket weighing cart 16; the weighing hopper feeds back the material weight to the central control system in real time. When the material weight reaches 85% of the target amount, the feeder slows down. When it approaches 97% of the target amount, the feeder is shut off in advance. The central control system calculates the compensation amount based on the difference between the material weight and the target amount at the time the feeder is shut off, combined with the statistical average of the drop difference of historical batches, and controls the pneumatic quick-cut valve to perform micro-feeding to ensure that the final weighing error of a single material is ≤±0.2%; when the drop difference compensation amount of 3 consecutive batches exceeds the set threshold, the central control system automatically triggers the feeder speed calibration program.

[0038] In step 6), an adjustable-speed vibrating feeder is used to supply anthracite and bituminous coke granules, while a variable-frequency screw feeder is used to supply VR hydrocracking concentrate residue powder. An anti-blocking detection device is installed at the feeder outlet. This anti-blocking detection device uses a material flow sensor. If there is no material flow signal for more than 5 seconds, a blockage alarm is sent to the central control system. The central control system automatically triggers the feeder to reverse and clear the blockage. If there is still no material flow signal after three reversals, the central control system switches to the backup feeder channel and issues a manual handling alarm. The central control system collects real-time operating current, vibration, and temperature data from all equipment, and uses preset... The fault prediction model identifies equipment malfunctions. Based on historical operating data of each device, the model establishes a baseline for normal operation characteristics. When the deviation between the real-time collected data and the baseline exceeds a set threshold, an early warning is triggered instead of waiting for an actual equipment failure. When a kneader malfunctions, the central control system automatically assigns its processing tasks to other online kneaders and adjusts the travel path and unloading sequence of the three-hopper weighing cart 16 to ensure production continuity. When all kneaders are at full load, the central control system automatically pauses the material handling action of the three-hopper weighing cart 16, stops it in a standby position, and issues a capacity warning to the operator.

[0039] 7) After all the weighing hoppers in the three-hopper weighing cart 16 have completed the material picking and weighing tasks, the central control system collects the material level signals of all online kneader transition hoppers 17, the working status signals of kneaders 18, and the queue of tasks to be processed in real time. The system then uses a load balancing algorithm to match the optimal kneader. The load balancing algorithm takes the current task remaining time of each kneader 18, the remaining material level in the kneader transition hopper 17, and the equipment operating status score as inputs, and minimizes the longest waiting time as the optimization objective. The algorithm outputs the target kneader number. Subsequently, the central control system issues a discharge task command, controlling the three-hopper weighing cart 16 to travel above the corresponding kneader transition hopper 17. When the limit device confirms the position is correct, the discharge valve of the three-hopper weighing cart 16 opens, and the three materials enter the corresponding kneader transition hopper 17 respectively.

[0040] In step 7), the kneader transition hopper 17 is equipped with an electric heating and insulation device to maintain the material temperature in the kneader transition hopper 17 at 80-100℃; in step 8), the press transition hopper 19 is equipped with a steam jacket insulation device to maintain the temperature of the mixture at 150-170℃.

[0041] 8) The kneader 18 transmits real-time temperature, stirring current, and main shaft torque signals to the central control system. When it needs to perform a mixing task, it sends a material request signal to the central control system. The anthracite and pitch coke in the kneader's transition hopper 17 first enter the kneader through a pneumatic quick-cut valve for the first stage of premixing and heating. The kneader 18 adopts a composite heating method of jacketed electric heating and heating rods built into the stirring paddle, uniformly heating the material while stirring. The target temperature for the first stage of premixing and heating is 130-150℃, the stirring speed is 15-25 r / min, and the heating time is not less than 8 minutes. The stirring speed is controlled by a program. When the material temperature in the kneader reaches the set temperature and the temperature uniformity is achieved... When the temperature is ≤±5℃, a signal is sent to the central control system allowing the addition of VR hydrocracking concentrate residue. The VR hydrocracking concentrate residue in the kneader transition hopper enters the kneader via a pneumatic quick-cut valve for the second stage of high-temperature kneading. The target temperature for the second stage of high-temperature kneading is 160-185℃, the stirring speed is increased to 30-45 r / min, and the kneading time is not less than 15 min. By increasing the stirring speed and controlling the kneading time, the VR hydrocracking concentrate residue is fully melted and evenly coated on the surface of anthracite and pitch coke particles. After the three materials are fully heated and mixed in the kneader 18, they fall into the press transition hopper for temporary storage. Subsequently, the materials enter the molding process via a twin-shaft screw conveyor.

[0042] 9) Based on the strength and porosity test results of the previous batch of foundry coke, the central control system automatically fine-tunes the proportions of anthracite, pitch coke, and VR hydrocracking concentrate residue in the next batch. The automatic fine-tuning adopts the following rules: when the strength test result is lower than 3% of the target value, the central control system increases the proportion of VR hydrocracking concentrate residue by 0.5%-1.0% in the next batch, and simultaneously reduces the proportion of anthracite by the same proportion; when the porosity test result is higher than 5% of the target value, the central control system increases the temperature of the second stage of kneading by 5-10℃ and extends the kneading time by 2-3 minutes in the next batch. All formula adjustments are recorded in the batch file, and the single formula adjustment range does not exceed 2%. When it exceeds the safety boundary, it switches to manual confirmation mode.

[0043] Subsequent defective products generated during molding and after firing are manually sorted and collected: Molded defective products are crushed to 8mm and then mixed into the anthracite coal batching bin for reuse at a ratio of 5%-10%; fired defective products are crushed to 8mm and then mixed into the asphalt coke batching bin for reuse at a ratio of 5%-6%. After crushing, the defective products are sent to the corresponding batching bins via a pneumatic conveying system. The central control system automatically adjusts the batching amount of the main raw materials according to the reuse ratio. When adjusting the main raw material batching amount, the central control system simultaneously corrects the batching amount of VR hydrocracking concentrate residue to maintain the mass ratio of the three raw materials. The reuse amount for this batch is recorded in the production batch file for quality traceability.

[0044] The production system employed in the fully collaborative intelligent control method for the entire process of foundry coke feeding, batching, and mixing includes: an anthracite feeding system ( Figure 1 , Figure 5 VR hydrocracking residue feeding system ( Figure 2 ), Pitch coke feeding system ( Figure 3 Intelligent ingredient mixing system Figure 4 ), central control system and dust removal system; The intelligent batching and mixing system includes a three-bucket weighing cart 16 integrating three independent weighing hoppers, a kneader transition hopper 17, a kneader 18 integrating a composite heating device, and a press transition hopper 19. The coal batching bin 8 of the anthracite feeding system, the VR hydrocracking concentrate residue batching bin 12 of the VR hydrocracking residue feeding system, and the asphalt coke batching bin 15 of the asphalt coke feeding system are arranged sequentially above the three-bucket weighing cart 16 along its travel track. Below the three-bucket weighing cart 16, multiple sets of parallel kneader transition hoppers 17, kneaders 18, and press transition hoppers 19 are arranged sequentially in three-dimensional space, forming a vertical material flow of "batching bin → three-bucket weighing cart → kneader transition hopper → kneader". The anthracite feeding system, VR hydrocracking residue feeding system, pitch coke feeding system, and intelligent batching and mixing system are all electrically connected to the central control system. The central control system includes a material level management module, a path planning module, a weighing control module, a kneader scheduling module, and a process parameter closed-loop control module, realizing collaborative intelligent control of the entire process; The closed-loop control module for process parameters stores the baseline values ​​of the physical properties of each raw material, including the target moisture range of anthracite, the softening point range of VR hydrocracking concentrate residue, and the particle size range of pitch coke. It also automatically triggers parameter correction commands for the corresponding process based on the deviation between the online detection data and the baseline values.

[0045] The three-hopper weighing cart 16 is used to intelligently select the material hopper according to the demand, and weigh the anthracite, VR hydrocracking residue and pitch coke respectively. After transmitting the signal from the central control system, the material in the hopper is unloaded into the corresponding kneader transition hopper 17. The kneader transition hopper 17 is used to temporarily store the raw materials and heat the VR hydrocracking residue to ensure the correct mixing process. The kneader 18 is used to fully heat and mix the three raw materials.

[0046] See Figure 1The anthracite feeding system includes a coal receiving hopper 1, a vibrating feeder 2, a bucket conveyor 3, a coal drying cylinder feeding hopper 4, a rotary drying cylinder 5, a coal crusher feeding hopper 6, a crusher 7, and a coal batching bin 8. The bottom of the coal receiving hopper 1 is connected to the vibrating feeder 2. The discharge from the vibrating feeder 2 is fed into the coal drying cylinder feeding hopper 4 via the bucket conveyor 3. The coal drying cylinder feeding hopper 4 feeds material to the rotary drying cylinder 5. The discharge from the rotary drying cylinder 5 is then fed to the coal crusher feeding hopper 6 via the bucket conveyor 3. The coal crusher feeding hopper 6 feeds material to the crusher 7. The discharge from the crusher 7 is then fed into the coal batching bin 8 via the bucket conveyor 3. The rotary drying cylinder is equipped with an online moisture detector installed at the discharge end of the drying cylinder. It uses near-infrared or microwave measurement principles, with a detection accuracy of ≤±0.2%. The detection signal is transmitted to the central control system in real time.

[0047] Coal receiving hopper 1 is used to store anthracite raw materials transported by wheel loaders; vibrating feeder 2 and bucket conveyor 3 are used to transport the anthracite raw materials to coal drying cylinder feeding hopper 4, and then to rotary drying cylinder 5 via vibrating feeder; rotary drying cylinder 5 is used to dry anthracite, and it is equipped with a combustion chamber for fuel combustion to generate flue gas. After the hot flue gas exchanges heat with the anthracite, part of it is purified by the drying cylinder dust collector and discharged into the atmosphere, and part of the flue gas is returned to the combustion chamber of rotary drying cylinder 5 for waste heat utilization. The dust collected is returned to the anthracite batching bin; coal crusher feeding hopper 6 is used to temporarily store the dried anthracite raw materials; crusher 7 is used to crush the anthracite raw materials; anthracite batching bin 8 is used to temporarily store the crushed anthracite raw materials, and is also equipped with a heat preservation function to keep the raw materials at a predetermined temperature.

[0048] See Figure 2 The VR hydrocracking residue feeding system includes an electric hoist 9, an automated bag-opening station 10, a VR hydrocracking residue transition hopper 11, a vibrating feeder 2, a crusher 7, a bucket conveyor 3, and a VR hydrocracking concentrated residue batching bin 12. The electric hoist 9 feeds bagged VR hydrocracking residue into the automated bag-opening station 10. The VR hydrocracking residue transition hopper 11 is located below the automated bag-opening station 10. The bottom of the VR hydrocracking residue transition hopper 11 is equipped with a vibrating feeder 2, which feeds material to the crusher 7. The material discharged from the crusher 7 is sent to the VR hydrocracking concentrated residue batching bin 12 via the bucket conveyor 3. The VR hydrocracking concentrated residue batching bin is equipped with an electric heating device for the bin wall to maintain the material temperature in the bin at 40-60℃, preventing the VR hydrocracking concentrated residue from solidifying at low temperatures during storage and affecting the flowability of subsequent feeding.

[0049] Electric hoist 9 is used to transport bagged VR hydrocracking residue to automated bag opening station 10, which is used to remove the packaging bag and transport the raw material to VR hydrocracking residue transition hopper 11; vibrating feeder 2 is used to transport the raw material to crusher 7; crusher 7 and bucket conveyor 3 are used to crush VR hydrocracking residue and transport it to VR hydrocracking concentration residue batching silo 12.

[0050] See Figure 3 The asphalt coke feeding system includes an electric hoist 9, an automated bag-opening station 10, an asphalt coke transition hopper 13, a pneumatic conveying system 14, and an asphalt coke batching silo 15. The electric hoist 9 transports the asphalt coke to the automated bag-opening station 10. Below the automated bag-opening station 10 is the asphalt coke transition hopper 13. The discharge from the asphalt coke transition hopper 13 is sent to the asphalt coke batching silo 15 via the pneumatic conveying system 14. The conveying pipes, transition hopper, and batching silo of the pneumatic conveying system are all equipped with anti-static grounding devices. The conveying pipes use conductive lining material. The system is equipped with an online dust concentration monitor. When the dust concentration in the pipe exceeds 25% of the lower explosive limit, the central control system automatically triggers the conveying pause and pressure relief protection program.

[0051] Electric hoist 9 is used to transport asphalt coke to automated bag opening station 10, which is used to remove packaging bags and transport raw materials to asphalt coke transition hopper 13; pneumatic conveying system 14 is used to transport asphalt coke raw materials to asphalt coke batching silo 15.

[0052] The batching bins (coal batching bin 8, VR hydrocracking concentration residue batching bin 12, and pitch coke batching bin 15) are used to temporarily store the processed raw materials for the next mixing process; the batching bins are equipped with automatic weighing function to transmit the weight of the raw materials in the bins to the server in real time.

[0053] The central control system includes components such as an industrial computer server, a system control power distribution cabinet, and a wireless communication device. The industrial computer server can simultaneously receive, store, process, and send commands to multiple devices. The industrial computer server is connected to a mobile terminal via a wireless communication device, and the mobile terminal can remotely synchronize server information and send commands to the server from the terminal.

[0054] Dust removal equipment is installed at every dust-generating point in the production system.

[0055] The feeding process of this invention is as follows: 1) See Figure 1Anthracite is transported to the coal receiving hopper 1 by a wheel loader, and then to the coal drying cylinder feeding hopper 4 by a vibrating feeder 2 and a bucket conveyor 3. It is then fed into the rotary drying cylinder 5 by the vibrating feeder and dried. The anthracite forms a uniform material curtain under the action of the guide plate 21. The hot flue gas generated after the fuel is burned in the combustion chamber of the rotary drying cylinder 5 enters the rotary drying cylinder 5 to dry the anthracite. The flue gas after combustion is divided into two parts. One part is purified by the dust collector of the drying cylinder and discharged into the atmosphere. The other part is returned to the combustion chamber of the rotary drying cylinder 5 for waste heat utilization.

[0056] 2) The dried anthracite is transported by the bucket conveyor 3 to the coal crusher feed hopper 6, then fed to the crusher 7 by the vibrating feeder, and then transported to the anthracite batching bin 8 by the bucket conveyor 3 for temporary storage.

[0057] 3) See Figure 2 The ton-bag VR hydrocracking concentration residue is lifted by an electric hoist 9 and transported to the automated bag opening station 10. After automatic bag opening, it is unloaded into the VR hydrocracking concentration residue transition hopper 11 for temporary storage. Then, it is sent to the crusher 7 for crushing by the vibrating feeder 2 and then transported to the VR hydrocracking concentration residue batching silo 12 for temporary storage by the bucket conveyor 3.

[0058] 4) See Figure 3 The electric hoist 9 lifts the ton bags of asphalt coke and transports them to the automated bag opening station. After automatic bag opening, the bags are unloaded into the asphalt coke transfer hopper for temporary storage. Then, they are sent to the asphalt coke batching silo for temporary storage via a pneumatic conveying system.

[0059] 5) See Figure 4 The material level sensor in the batching silo transmits the material level information in the silo to the central control system in real time. The central control system then instructs the three-hopper weighing cart 16 to move to the discharge position of the batching silo based on the material level information.

[0060] 6) When the arrival signal of the three-bucket weighing cart 16 returns to the central control system, the central control system issues a feeding command. The raw materials in the batching bin pass through the pneumatic quick-cut valve, the feeder, and the electro-hydraulic flat gate in sequence before entering the weighing hopper of the three-bucket weighing cart 16. To improve weighing accuracy, a speed-regulating motor vibrating feeder is used to supply granular materials between the batching bin and the three-bucket weighing cart 16, and a variable feeder unit is used to supply fine powder. The weighing hopper transmits the weight of the material to the central control system in real time. When it approaches the batching amount (such as 85-90% of the target amount), the central control system issues a signal, and the feeder switches from fast feeding to slow feeding. To ensure accurate batching, a pneumatic quick-cut valve that can be quickly closed is selected in the process flow.

[0061] 7) The feeding process of asphalt coke and VR hydrocracking concentration residue can be completed according to step 6). After all the weighing hoppers in the three-hopper weighing car 16 have completed the feeding and weighing tasks, the central control room determines the kneader transition hopper 17 paired with the three-hopper weighing car 16 based on the material level signal in the kneader transition hopper 17. Then, the central control system issues a discharge task command to control the three-hopper weighing car 16 to travel above the corresponding kneader transition hopper 17. When the limit device confirms the position is corresponding, the discharge valve of the three-hopper weighing car 16 is opened, and the three materials enter the corresponding kneader transition hopper 17 respectively. The kneader transition hopper 17 is equipped with a heat preservation device to maintain the material temperature.

[0062] 8) The kneader 18 transmits its working status signal to the central control system in real time. When it needs to perform a mixing task, it sends a material request signal to the central control system. The anthracite and pitch coke in the kneader transition hopper 17 first enter the kneader 18 for premixing through the pneumatic quick-cut valve. The kneader 18 is equipped with an electric heating device, which heats the material while mixing. When the material temperature in the kneader 18 reaches the preset temperature, it sends a signal to the central control system to allow the addition of VR hydrocracking concentrate residue. The VR hydrocracking concentrate residue in the kneader transition hopper 17 enters the kneader 18 through the pneumatic quick-cut valve. After the three materials are fully heated and mixed in the kneader 18, they fall into the press transition hopper 19 for temporary storage. The press transition hopper 19 is equipped with a heat preservation device. Then the material enters the molding process through the twin-shaft screw conveyor 20.

[0063] 9) Non-conforming products generated during subsequent molding and after firing are manually collected and stored in the raw material plant. They are then periodically transported to the non-conforming product crusher's feed hopper using a wheel loader. The material in the non-conforming product crusher's feed hopper is fed to the crusher by a vibrating feeder, and then sent to the non-conforming product batching hopper via a pneumatic conveying system, thus achieving rational utilization of raw materials.

[0064] The intelligent feeding and mixing process for foundry coke of this invention is equipped with automated equipment such as an automatic bag-opening station, resulting in high processing efficiency. A weighing cart is used for automatic weighing of different materials, achieving high weighing accuracy and efficiency. The central control system intelligently controls tasks from raw material feeding, weighing cart metering, feeding, mixing in the mixer, and unloading. Insulation or electric heating devices are installed in the silos, mixer transition hopper, and weighing hopper to ensure constant material temperature and improve mixing efficiency. Dust removal equipment is provided at all dust-generating points, improving the plant environment quality. The high degree of automation significantly reduces labor costs and improves production efficiency.

[0065] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for coordinated intelligent control of the entire process of casting coke feeding, batching, and mixing, characterized in that, Specifically, it includes: 1) Anthracite is transported to the coal receiving hopper by a wheel loader, and then to the coal drying cylinder feeding hopper via a vibrating feeder and a bucket conveyor lined with wear-resistant plates. The vibrating feeder then feeds the coal into a counter-current rotary drying cylinder for drying. The fuel burns in the combustion chamber of the rotary drying cylinder, generating hot flue gas at 350-400℃. This hot flue gas comes into counter-current contact with the anthracite for heat exchange and drying. After drying, the moisture content of the anthracite is precisely controlled at 2.0%-3.1%. The flue gas after combustion is divided into two parts: 65%-75% is purified by a high-temperature bag filter before being discharged in compliance with standards, and the remaining 25% is discharged separately. -35% of the waste heat is recycled back to the combustion chamber via a variable frequency induced draft fan. The central control system adjusts the flue gas recirculation rate and the fuel supply to the combustion chamber in real time based on the online moisture detection value of the dried anthracite. When the online moisture detection value is higher than the target upper limit of 3.1%, the central control system increases the flue gas recirculation ratio to the upper limit of 35% and simultaneously increases the fuel supply. When the online moisture detection value is lower than the target lower limit of 2.0%, the central control system reduces the flue gas recirculation ratio to the lower limit of 25% and simultaneously reduces the fuel supply, thus achieving dual closed-loop coordinated control of drying energy consumption and product moisture content. 2) The dried anthracite is transported by a bucket conveyor to the feed hopper of the coal crusher, then fed to the crusher by a vibrating feeder, and finally transported by a bucket conveyor to the coal batching silo for temporary storage. 3) The ton-bag VR hydrocracking concentrated residue is lifted and transported to the automated bag-opening station. After automatic bag opening, it is unloaded into the VR hydrocracking concentrated residue transition hopper with an anti-stick inner wall for temporary storage. Then, it is sent to the crusher for crushing via a vibrating feeder and transported to the VR hydrocracking concentrated residue batching silo via a bucket conveyor with an anti-stick lining for temporary storage. The anti-stick inner wall and anti-stick layer are made of polytetrafluoroethylene coating or ultra-high molecular weight polyethylene lining to prevent material retention and blockage caused by the strong adhesion of VR hydrocracking concentrated residue at room temperature. 4) The ton bags of asphalt coke are lifted and transported to the automated bag-opening station for automatic bag opening and unloading into the asphalt coke transition hopper for temporary storage. Then, they are sent to the asphalt coke batching silo for temporary storage through the pneumatic conveying system. The pneumatic conveying system adopts a positive pressure dilute phase conveying method, and the conveying pipeline is equipped with an anti-static grounding device. 5) The radar level sensors in each batching bin transmit real-time level data and the rate of change of level to the central control system. The central control system plans the optimal driving path based on the preset batching formula, the level warning threshold of each batching bin, and the current position of the three-bucket weighing cart. It controls the three-bucket weighing cart to move precisely to the discharge port of the corresponding batching bin in sequence. The optimal driving path planning aims to minimize the total driving distance of the three-bucket weighing cart, while also satisfying the batching sequence constraint: anthracite → bituminous coke → VR hydrocracking concentration residue, and the level warning priority constraint: batching bins with levels below the warning threshold are given priority for replenishment. 6) After the position sensor of the three-bucket weighing cart returns a precise positioning signal to the central control system, the central control system generates a graded feeding instruction: the raw materials in the batching bin pass through the pneumatic quick-cut valve, the feeder, and the electro-hydraulic flat gate in sequence before entering the corresponding independent weighing hopper of the three-bucket weighing cart; the weighing hopper feeds back the material weight to the central control system in real time. When the material weight reaches 85% of the target amount, the feeder slows down. When it approaches 97% of the target amount, the feeder is shut off in advance. The central control system calculates the compensation amount based on the difference between the material weight and the target amount at the time the feeder is shut off, combined with the average drop statistics of historical batches, and controls the pneumatic quick-cut valve to perform micro-feeding to ensure that the final weighing error of a single material is ≤±0.2%; when the drop compensation amount of 3 consecutive batches exceeds the set threshold, the central control system automatically triggers the feeder speed calibration program; 7) After all the weighing hoppers in the three-hopper weighing cart have completed their material picking and weighing tasks, the central control system collects the material level signals of all online kneader transition hoppers, the working status signals of the kneaders, and the queue of tasks to be processed in real time. The system then uses a load balancing algorithm to match the optimal kneader. The load balancing algorithm takes the current task remaining time of each kneader, the remaining material level in the transition hopper, and the equipment operating status score as inputs, and minimizes the longest waiting time as the optimization objective. The system then outputs the target kneader number. Subsequently, the central control system issues a discharge task command, controlling the three-hopper weighing cart to travel to the top of the corresponding kneader transition hopper. Once the limit device confirms the position is correct, the discharge valve on the three-hopper weighing cart opens, and the three materials enter the corresponding kneader transition hoppers respectively. 8) The kneader transmits real-time temperature, stirring current, and main shaft torque signals to the central control system. When it needs to perform a mixing task, it sends a material request signal to the central control system. The anthracite and pitch coke in the kneader's transition hopper first enter the kneader through a pneumatic quick-cut valve for the first stage of premixing and heating. The kneader uses a combined heating method of jacketed electric heating and heating rods built into the stirring paddle, uniformly heating the materials while stirring. The target temperature for the first stage of premixing and heating is 130-150℃, the stirring speed is 15-25 r / min, and the heating time is no less than 8 minutes. The stirring speed is controlled by a program. When the material temperature in the kneader reaches the set temperature... When the temperature uniformity is ≤±5℃, a signal is sent to the central control system allowing the addition of VR hydrocracking concentrate residue. The VR hydrocracking concentrate residue in the transition hopper of the kneader enters the kneader through the pneumatic quick-cut valve for the second stage of high-temperature kneading. The target temperature for the second stage of high-temperature kneading is 160-185℃, the stirring speed is increased to 30-45r / min, and the kneading time is not less than 15min, so that the VR hydrocracking concentrate residue is fully melted and evenly coated on the surface of anthracite and pitch coke particles. After the three materials are fully heated and mixed in the kneader, they fall into the transition hopper of the press for temporary storage. Then the materials enter the molding process through the twin-shaft screw conveyor.

2. The intelligent control method for the entire process of casting coke feeding, batching, and mixing according to claim 1, characterized in that, In step 1), the rotary drying cylinder is equipped with a guide plate to form a uniform material curtain of anthracite inside the drying cylinder, extending the contact time with the hot flue gas. The guide plate structure includes lifting plates and guide plates arranged alternately along the axis of the drying cylinder. The lifting plates lift the anthracite and allow it to fall freely to form a material curtain. The guide plates control the axial propulsion speed of the anthracite, ensuring that the average residence time of the anthracite in the drying cylinder is not less than 20 minutes.

3. The intelligent control method for the entire process of casting coke feeding, batching, and mixing according to claim 1, characterized in that, In step 6), an adjustable-speed vibrating feeder is used to supply anthracite and bituminous coke granules, while a variable-frequency screw feeder is used to supply VR hydrocracking concentrate residue powder. An anti-blocking detection device is installed at the feeder outlet. The anti-blocking detection device uses a material flow detection sensor. When there is no material flow signal for more than 5 seconds of continuous detection, a blockage alarm is sent to the central control system. The central control system automatically triggers the feeder to reverse and clear the blockage. If there is still no material flow signal after 3 reversals and clearing, the central control system switches to the backup feeder channel and issues a manual handling alarm. The central control system collects real-time data on the operating current, vibration, and temperature of all equipment and identifies equipment anomalies through a preset fault prediction model. The fault prediction model establishes a normal operating characteristic baseline based on the historical operating data of each device. When the deviation between the real-time collected data and the baseline exceeds a set threshold, an early warning is triggered instead of waiting for an actual equipment failure. When a kneader malfunctions, the central control system automatically assigns its processing tasks to other online kneaders and adjusts the travel path and unloading sequence of the three-hopper weighing cart to ensure production continuity. When all kneaders are at full load, the central control system automatically pauses the material handling action of the three-hopper weighing cart, stops the three-hopper weighing cart in the standby position, and issues a capacity warning to the operator.

4. The intelligent control method for the entire process of casting coke feeding, batching, and mixing according to claim 1, characterized in that, In step 7), the kneader transition hopper is equipped with an electric heating and insulation device to maintain the material temperature in the kneader transition hopper at 80-100℃; in step 8), the press transition hopper is equipped with a steam jacket insulation device to maintain the mixture temperature at 150-170℃.

5. The intelligent control method for the entire process of casting coke feeding, batching, and mixing according to claim 1, characterized in that, Subsequent defective products generated during the molding process and after firing are manually sorted and collected: after being crushed to 8mm, the molded defective products are mixed into the anthracite coal batching bin at a ratio of 5%-10% for reuse; after being crushed to 8mm, the fired defective products are mixed into the asphalt coke batching bin at a ratio of 5%-6% for reuse.

6. The intelligent control method for the entire process of casting coke feeding, batching, and mixing according to claim 1, characterized in that, Based on the strength and porosity test results of the previous batch of foundry coke, the central control system automatically fine-tunes the proportions of anthracite, pitch coke, and VR hydrocracking concentrate residue in the next batch. This automatic fine-tuning follows these rules: when the strength test result is 3% lower than the target value, the central control system increases the proportion of VR hydrocracking concentrate residue by 0.5%-1.0% in the next batch, while simultaneously reducing the proportion of anthracite proportionally; when the porosity test result is 5% higher than the target value, the central control system increases the second-stage mixing temperature by 5-10°C and extends the mixing time by 2-3 minutes in the next batch. All formula adjustments are recorded in the batch file, and the magnitude of a single formula adjustment does not exceed 2%. If the adjustment exceeds the safety boundary, it switches to manual confirmation mode.

7. The production system employed in the fully collaborative intelligent control method for the entire process of casting coke feeding, batching, and mixing as described in any one of claims 1-6, is characterized in that... include: Anthracite feeding system, VR hydrocracking residue feeding system, pitch coke feeding system, intelligent batching and mixing system, and central control system; The intelligent batching and mixing system includes a three-bucket weighing cart integrating three independent weighing hoppers, a kneader transition hopper, a kneader and a press transition hopper integrating a composite heating device, and the coal batching hopper of the anthracite feeding system, the VR hydrocracking concentrate residue batching hopper of the VR hydrocracking residue feeding system, and the asphalt coke batching hopper of the asphalt coke feeding system are arranged sequentially above the three-bucket weighing cart along its travel track. Below the three-bucket weighing cart, multiple sets of parallel kneader transition hoppers, kneader and press transition hoppers are arranged in three-dimensional space to form a vertical material flow of "batching bin → three-bucket weighing cart → kneader transition hopper → kneader". The anthracite feeding system, VR hydrocracking residue feeding system, pitch coke feeding system, and intelligent batching and mixing system are all electrically connected to the central control system. The central control system includes a material level management module, a path planning module, a weighing control module, a kneader scheduling module, and a process parameter closed-loop control module, realizing collaborative intelligent control of the entire process; The closed-loop control module for process parameters stores the baseline values ​​of the physical properties of each raw material, including the target moisture range of anthracite, the softening point range of VR hydrocracking concentrate residue, and the particle size range of pitch coke. It also automatically triggers parameter correction commands for the corresponding process based on the deviation between the online detection data and the baseline values.

8. The production system employed in the fully collaborative intelligent control method for the entire process of casting coke feeding, batching, and mixing according to claim 7, is characterized in that... The anthracite feeding system includes a coal receiving hopper, a vibrating feeder, a bucket conveyor, a coal drying cylinder feeding hopper, a rotary drying cylinder, a coal crusher feeding hopper, a crusher, and a coal batching bin. The bottom of the coal receiving hopper is connected to the vibrating feeder. The discharge from the vibrating feeder is fed into the coal drying cylinder feeding hopper via the bucket conveyor. The coal drying cylinder feeding hopper feeds material to the rotary drying cylinder. The discharge from the rotary drying cylinder is then fed to the coal crusher feeding hopper via the bucket conveyor. The coal crusher feeding hopper feeds material to the crusher. The discharge from the crusher is then fed into the coal batching bin via the bucket conveyor. The rotary drying cylinder is equipped with an online moisture detector installed at the discharge end of the drying cylinder. It uses near-infrared or microwave measurement principles, with a detection accuracy of ≤±0.2%. The detection signal is transmitted to the central control system in real time.

9. The production system employed in the fully collaborative intelligent control method for the entire process of casting coke feeding, batching, and mixing according to claim 7, is characterized in that, The VR hydrocracking residue feeding system includes an electric hoist, an automated bag-opening station, a VR hydrocracking residue transition hopper, a vibrating feeder, a crusher, a bucket conveyor, and a VR hydrocracking concentrated residue batching silo. The electric hoist delivers bagged VR hydrocracking residue into the automated bag-opening station. Below the automated bag-opening station is a VR hydrocracking residue transition hopper. At the bottom of the VR hydrocracking residue transition hopper is a vibrating feeder that feeds material to the crusher. The crusher discharges material into the VR hydrocracking concentrated residue batching silo via the bucket conveyor. The VR hydrocracking concentrated residue batching silo is equipped with an electric heating device for the silo wall to maintain the material temperature inside the silo at 40-60℃.

10. The production system employed in the fully collaborative intelligent control method for the entire process of casting coke feeding, batching, and mixing according to claim 7, is characterized in that... The asphalt coke feeding system includes an electric hoist, an automated bag-opening station, an asphalt coke transition hopper, a pneumatic conveying system, and an asphalt coke batching bin. The electric hoist transports the asphalt coke to the automated bag-opening station. The asphalt coke transition hopper is located below the automated bag-opening station. The discharge from the asphalt coke transition hopper is sent to the asphalt coke batching bin via the pneumatic conveying system.

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