A method of grade control for a mineral concentrate process

Abstract

The present application relates to the technical field of industrial process automatic control, and more specifically, to a kind of ore mixing concentration process grade control method, comprising the steps of: real-time acquisition upstream processing unit's output medium flow signal and current product quality index actual value, extract flow fluctuation characteristic index, calculate quality index deviation;According to flow fluctuation characteristic index and quality index deviation, according to the preset collaborative setting rule, simultaneously generate the correction amount of separation interface liquid level set value and the offset of output medium concentration set value;The correction amount of liquid level set value is output to liquid level controller, drives liquid level adjusting actuator to adjust separation interface liquid level.The present application links and cooperatively controls the liquid level of flotation machine and the concentration of thickener, effectively breaks the vicious cycle of mutual coupling and mutual causality, significantly improves the stability of liquid level and concentrate grade, and realizes synergistic effect.

Description

Technical Field

[0001] This invention relates to the field of industrial process automatic control technology, and more specifically, to a method for grade control in an ore mixing and beneficiation process. Background Technology

[0002] The ore mixing and beneficiation process is a crucial step in mineral processing, typically involving thickening and flotation. Taking the hematite magnetic separation-thickening-flotation mixing and beneficiation process as an example, the ore undergoes magnetic separation before entering a thickener for concentration. The thickener underflow then enters a flotation machine for separation. Concentrate grade and tailings grade are key technological indicators characterizing the product quality and production efficiency of the mixing and beneficiation process.

[0003] The following problems exist in the existing blended selection quality control process:

[0004] 1. The grades of concentrate and tailings exhibit complex characteristics with strong nonlinearity and strong coupling to the slurry level in the flotation machine. The grades of concentrate and tailings vary with production boundary conditions such as feed concentration, feed flow rate, feed particle size, and ore composition, making them difficult to describe with precise mathematical models. The slurry levels in multi-stage series flotation machines exhibit strong coupling characteristics and a nonlinear relationship with the opening of the corresponding flotation machine outlet valves, and are also affected by frequent fluctuations in the slurry flow rate in the first flotation cell.

[0005] 2. The thickening process is difficult to control. The thickening process is a strongly nonlinear cascade process with the bottom flow slurry pump speed as input and slurry concentration as output. It is subject to large and frequent random disturbances from middlings slurry generated by the flotation process. Not only is it required to control the concentration within the target range, but also to control the fluctuations in flow rate and rate of change within the target range.

[0006] 3. Currently, the entire flotation process, including the setting and tracking of slurry level, and the control of feed concentration and flow rate ranges, is entirely manual. When production boundary conditions change frequently, operators find it difficult to accurately and promptly assess the operating conditions and adjust parameters. This often results in the underflow slurry concentration and flow rate exceeding the process specifications during the thickening process, causing malfunctions such as "overflowing" and "failure to scrape bubbles" in the flotation machine. Consequently, valuable metals are lost, metal recovery is reduced, and ultimately, the final concentrate grade is low while the tailings grade is high.

[0007] Therefore, there is an urgent need for a method that can coordinate the control of flotation machine liquid level, thickener underflow concentration and final concentrate grade, so as to improve the control effect of grade stability, liquid level stability and concentration stability with minimal modifications. Summary of the Invention

[0008] The present invention aims to provide a method for controlling the grade in the ore mixing and beneficiation process, so as to solve the problems of insufficient grade stability, liquid level stability and concentration stability caused by the control precision in the prior art;

[0009] To address the aforementioned technical problems, the first aspect of this invention provides a method for grade control in a mixed beneficiation process of ore, particularly applicable to the synergistic optimization control of concentrate and tailings grades in a magnetic separation-thickening-flotation mixed beneficiation process for polymetallic ores such as hematite, magnetite, copper ore, and nickel ore, comprising the following specific steps:

[0010] Step S1: Real-time acquisition of the output medium flow signal from the upstream processing unit. and the actual values ​​of current product quality indicators Furthermore, a sliding window analysis was performed on the flow signal to extract flow fluctuation characteristic indicators. Simultaneously calculate the deviation of quality indicators ;

[0011] Step S2: Based on the flow fluctuation characteristic indicators Deviation of quality indicators According to the preset collaborative setting rules, the correction amount of the liquid level setting value of the sorting interface of the downstream sorting unit is generated simultaneously. offset of the output medium concentration setpoint of the upstream processing unit ;

[0012] Step S3: Adjust the liquid level setpoint. The liquid level controller output to the downstream sorting unit drives the liquid level regulating actuator to adjust the liquid level at the sorting interface;

[0013] Step S4: Offset of concentration setpoint The concentration controller output to the upstream processing unit drives the concentration regulating actuator to adjust the concentration of the output medium.

[0014] Preferably, the flow fluctuation characteristic index in step S1 Calculate using the following formula:

[0015]

[0016] in, This represents the magnitude of the deviation between the output medium flow rate at the current sampling moment and the average output medium flow rate within the sliding window. Output the rate of change of the medium flow rate at the current sampling moment. These are empirical weighting coefficients. The values ​​range from 0.2 to 0.6, and the sum of the weights is 1.

[0017] Preferably, the collaborative setting rules in step S2 include:

[0018] Quality deviation priority rule: when > At that time, according to The symbols are adjusted simultaneously. and Prioritize correcting deviations in quality indicators; This refers to the permissible deviation threshold for quality indicators;

[0019] Flow fluctuation feedforward rule: When the flow fluctuation characteristic index Greater than the first threshold At the same time Negative values When it is a positive value; Less than the second threshold At the same time For positive values It is a negative value; when < < and hour, =0, =0.

[0020] Preferably, the flow fluctuation feedforward rule in step S2 is as follows:

[0021] When traffic fluctuation characteristic indicators Greater than the first threshold hour:

[0022]

[0023]

[0024] When traffic fluctuation characteristic indicators Less than the second threshold hour:

[0025]

[0026]

[0027] in, A positive adjustment coefficient. The value range is 0.01 to 0.05. The value range is 0.005 to 0.02. The value range is 0.01 to 0.05. The value range is 0.005 to 0.02.

[0028] Preferably, the priority rule for quality deviation in step S2 is as follows:

[0029] when When the product quality indicators are below the target lower limit, Taking a positive value increases the liquid level at the sorting interface, thereby increasing the yield of the target product. Negative values ​​are used to appropriately reduce the concentration of the output medium and prevent blockage;

[0030] when When the product quality indicators are higher than the target upper limit, maintain and Remain unchanged and observe subsequent changes. If the limits continue to be exceeded, adjust in the opposite direction.

[0031] Preferably, in step S3, the liquid level controller of the downstream sorting unit adopts a PID control algorithm, based on... Compared with the actual liquid level The deviation is used to calculate the liquid level adjustment amount;

[0032] In step S4, the concentration controller of the upstream processing unit adopts a PID control algorithm, based on... Compared with the actual concentration value The deviation is used to calculate the concentration adjustment amount.

[0033] A second aspect of the present invention provides a grade control system for an ore mixing and beneficiation process, which uses the above-described method for control, including:

[0034] The flow detection unit is installed on the connecting pipeline between the upstream processing unit and the downstream sorting unit, and is used to detect the output medium flow signal in real time. ;

[0035] The quality indicator detection unit is installed on the product output pipeline of the downstream sorting unit to detect the actual values ​​of product quality indicators in real time. ;

[0036] The liquid level detection unit is installed on the downstream sorting unit to detect the actual liquid level at the sorting interface in real time. ;

[0037] The concentration detection unit is installed on the output pipeline of the upstream processing unit to detect the actual value of the output medium concentration of the upstream processing unit in real time. ;

[0038] The fluctuation feature extraction module, connected to the flow detection unit and the quality index detection unit, is used to perform sliding window analysis on the flow signal and extract flow fluctuation feature indicators. Simultaneously calculate the deviation of quality indicators ;

[0039] The collaborative setting module is signal-connected to the fluctuation feature extraction module and is used to set the flow fluctuation feature index. Deviation of quality indicators Simultaneously generate correction values ​​for the liquid level setpoint according to preset collaborative setting rules. offset of concentration setpoint ;

[0040] The liquid level control module is connected to the collaborative setting module, the liquid level detection unit, and the liquid level adjustment actuator, respectively, and is used to control the liquid level according to the set value. Compared with the actual liquid level The deviation drives the liquid level regulating actuator to adjust the liquid level at the sorting interface;

[0041] The concentration control module is connected to the collaborative setting module, the concentration detection unit, and the concentration adjustment actuator, respectively, and is used to control the concentration according to the set concentration value. Compared with the actual concentration value The deviation-driven concentration regulating actuator adjusts the output medium concentration;

[0042] The collaborative setting module simultaneously outputs control signals to both the liquid level control module and the concentration control module, achieving coordinated control of liquid level and concentration with the ultimate goal of stabilizing product quality indicators.

[0043] Preferably, the upstream processing unit is a thickener; the downstream separation unit is a flotation machine; the product quality indicator is concentrate grade; the output medium is underflow slurry; the liquid level regulating actuator is the underflow valve of the flotation machine; and the concentration regulating actuator is the underflow pump speed regulating device of the thickener.

[0044] Preferably, the fluctuation feature extraction module includes a sliding window memory, and the time width of the sliding window is 30 to 120 seconds.

[0045] Preferably, the system further includes a human-computer interaction interface for displaying traffic fluctuation characteristic indicators. Quality indicator deviation Liquid level setpoint correction amount Concentration setpoint offset It also includes the operating status of each control loop and provides an online adjustment interface for the thresholds and coefficients in the collaborative setting rules.

[0046] A third aspect of the present invention provides a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps of the above-described method.

[0047] A fourth aspect of the present invention provides a computer device including a memory and a processor, the memory storing a computer program: when the processor executes the computer program, it implements the steps of the above-described ore mixing and beneficiation process grade control method.

[0048] Compared with the prior art, the present invention has the following beneficial effects:

[0049] This invention fully utilizes the existing level gauges, concentration meters, flow meters, online quality index analyzers, and actuators of DCS / PLC systems. It requires no additional hardware and can be implemented solely through modifications to the software logic. The deployment cycle is short, and the return on investment is extremely high.

[0050] This invention overcomes the limitations of existing technologies that passively adjust liquid levels based solely on quality indicator deviations. It directly incorporates quality indicator deviations into the collaborative setting rules, achieving a dual collaborative mechanism of quality indicator deviation feedback and flow fluctuation feedforward. When a quality indicator deviation occurs, the system automatically adjusts both the liquid level and concentration setpoints simultaneously, correcting quality indicator fluctuations at their source.

[0051] This invention uses feedforward compensation based on flow fluctuation characteristics to adjust the set values ​​in advance before the actual changes in liquid level, concentration and quality indicators occur, changing "passive response" to "active prevention" and overcoming the shortcomings of traditional feedback control with large lag.

[0052] This invention simultaneously adjusts the liquid level setpoint and concentration setpoint through a collaborative setting module, enabling the two control loops to support each other: concentration adjustment reduces flow and quality index fluctuations entering the downstream sorting unit from the source, providing more stable input conditions for liquid level control; liquid level adjustment enhances the system's tolerance to residual fluctuations, reducing the sources of disturbance for quality index fluctuations. The two form a positive feedback stabilization loop, resulting in an exponential improvement in the overall system quality index stability, rather than a simple linear summation.

[0053] This invention adopts a rule-based reasoning-based collaborative setting strategy, which eliminates the need to establish a complex and precise mathematical model. This avoids the control failure problem caused by the inability of the mathematical model to adapt to complex working conditions in the prior art. It has low engineering implementation difficulty and high reliability.

[0054] The core control logic of this invention is to set a multi-variable collaborative adaptive strategy. Without relying on specific sorting equipment structure, material properties or reagent formulation, it can be extended to similar series sorting / separation processes in industries such as chemical, pharmaceutical, food, and environmental protection, and has broad cross-domain application prospects. Attached Figure Description

[0055] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the drawings without creative effort. In the drawings:

[0056] Figure 1 This is a flowchart of a method for controlling the grade of an ore mixing and beneficiation process according to an embodiment of the present invention.

[0057] Figure 2 This is a system diagram of the grade control system for the ore mixing and beneficiation process according to an embodiment of the present invention. Detailed Implementation

[0058] Hereinafter, exemplary embodiments according to the present invention will be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are merely some embodiments of the present invention, and not all embodiments of the present invention. It should be understood that the present invention is not limited to the exemplary embodiments described herein.

[0059] As stated in the background section above, the present invention aims to overcome the problems of insufficient stability in grade, liquid level, and concentration caused by control precision.

[0060] Example 1

[0061] Figure 1 A flowchart of a method for grade control in an ore blending and beneficiation process according to an embodiment of the present invention is shown, including the following specific steps:

[0062] Step S1: Real-time acquisition of the output medium flow signal from the upstream processing unit. and the actual values ​​of current product quality indicators Furthermore, a sliding window analysis was performed on the flow signal to extract flow fluctuation characteristic indicators. Simultaneously calculate the deviation of quality indicators ;

[0063] Specifically, a flow meter is installed on the connecting pipeline from the upstream processing unit to the downstream sorting unit to monitor the output medium flow rate in real time. An online quality indicator detector is installed on the product output pipeline of the downstream sorting unit to monitor the actual values ​​of product quality indicators in real time. The sliding window time width is set to 30–120 seconds, and the flow data within the window is statistically analyzed.

[0064] Traffic fluctuation characteristic indicators Calculate using the following formula:

[0065]

[0066] in, This represents the magnitude of the deviation between the output medium flow rate at the current sampling moment and the average output medium flow rate within the sliding window. Output the rate of change of the medium flow rate at the current sampling moment. These are empirical weighting coefficients. The values ​​range from 0.2 to 0.6, and the sum of the weights is 1.

[0067] in:

[0068]

[0069]

[0070] In the above formula, This is the arithmetic mean of the output medium flow rate within the sliding window; Set target values ​​for product quality indicators. The specific value is determined on-site based on actual operating conditions; when flow amplitude fluctuation is the main source of interference, a larger value is taken. A larger value should be chosen when the rate of change in flow is the primary source of interference. The larger value is taken when fluctuations in quality indicators are the primary concern. value.

[0071] Step S2: Based on the flow fluctuation characteristic indicators Deviation of quality indicators According to the preset collaborative setting rules, the correction amount of the liquid level setting value of the sorting interface of the downstream sorting unit is generated simultaneously. offset of the output medium concentration setpoint of the upstream processing unit ;

[0072] The collaborative setting rules in step S2 include:

[0073] Quality deviation priority rule: when > At that time, according to The symbols are adjusted simultaneously. and Prioritize correcting deviations in quality indicators; This refers to the permissible deviation threshold for quality indicators;

[0074] The specific rules for prioritizing quality deviations are as follows:

[0075] when When the product quality index is below the target lower limit, indicating a low quality index, it is necessary to increase the yield of the target product. Taking a positive value increases the liquid level at the sorting interface, thereby increasing the yield of the target product. Negative values ​​are used to appropriately reduce the concentration of the output medium and prevent blockage;

[0076] when When the product quality index is higher than the target upper limit, or the quality index is high but does not exceed the equipment upper limit; at this time, maintain and If the indicator remains unchanged, observe subsequent changes and continuously monitor the trend of quality indicator changes. If it continues to exceed the limit, implement reverse fine-tuning.

[0077] Flow fluctuation feedforward rule: When the flow fluctuation characteristic index Greater than the first threshold At the same time Negative values It is a positive value;

[0078] when Less than the second threshold At the same time For positive values It is a negative value;

[0079] The specific flow fluctuation feedforward rule in step S2 is as follows:

[0080] When traffic fluctuation characteristic indicators Greater than the first threshold hour:

[0081]

[0082]

[0083] At this time, the flow rate fluctuates drastically, posing risks of quality index fluctuations and liquid level overflow. Therefore, we should simultaneously reduce the liquid level setpoint at the sorting interface to reserve buffer space for the upcoming flow rate surge, prevent liquid level overflow from causing quality index deterioration, and increase the output medium concentration setpoint to increase the output medium concentration, making the medium entering the downstream sorting unit more stable, thereby reducing the interference of quality index fluctuations from the source.

[0084] When traffic fluctuation characteristic indicators Less than the second threshold hour:

[0085]

[0086]

[0087] With minimal flow fluctuations and stable operating conditions, the liquid level setpoint at the sorting interface is increased to increase the output of the target product, thereby improving product quality indicators, while the concentration setpoint of the output medium is reduced to prevent blockage of the output pipeline.

[0088] when < < and hour, =0, =0, at this time the flow fluctuation is within the normal range and the quality indicators meet the standards, so keep the existing settings unchanged.

[0089] in, A positive adjustment coefficient. The value range is 0.01 to 0.05. The value range is 0.005 to 0.02. The value range is 0.01 to 0.05. The value range is 0.005 to 0.02.

[0090] The specific values ​​of each threshold and coefficient are determined through on-site testing based on the on-site process conditions and equipment characteristics.

[0091] Step S3: Adjust the liquid level setpoint. The liquid level controller output to the downstream sorting unit drives the liquid level regulating actuator to adjust the liquid level at the sorting interface;

[0092] In step S3, the liquid level controller of the downstream sorting unit adopts a PID control algorithm, based on... Compared with the actual liquid level The deviation is used to calculate the liquid level adjustment amount;

[0093]

[0094] Liquid level controller according to Compared with the actual liquid level The deviation is calculated to determine the liquid level adjustment amount, which is then output to the liquid level adjustment actuator.

[0095] The PID control law for the level controller is:

[0096]

[0097] in:

[0098]

[0099] In the above formula, This is the output control quantity of the liquid level controller. These are all PID parameters for the liquid level control loop; This is the actual liquid level at the current sorting interface.

[0100] Step S4: Offset of concentration setpoint The concentration controller output to the upstream processing unit drives the concentration regulating actuator to adjust the concentration of the output medium.

[0101] Among them, the concentration controller of the upstream and midstream processing units adopts a PID control algorithm, based on... Compared with the actual concentration value The deviation is used to calculate the concentration adjustment amount.

[0102]

[0103] Concentration controller according to Compared with the actual concentration value The deviation is used to calculate the concentration adjustment amount, which is then output to the concentration adjustment actuator.

[0104] The PID control rate of the concentration controller is:

[0105]

[0106] in:

[0107]

[0108] In the above formula, This is the output control quantity of the concentration controller. These are all PID parameters for the liquid level control loop; This is the actual liquid level at the current sorting interface.

[0109] Example 2

[0110] To facilitate a further understanding of the technical solution of this application, a specific case is used for detailed explanation below:

[0111] Application scenario: A magnetic separation-thickening-flotation mixed beneficiation process in a hematite beneficiation plant.

[0112] Process conditions: The plant's mixed beneficiation operation uses four flotation machines connected in series. The underflow slurry from the thickener is transported to the first flotation cell via pipeline. Under the original control method, the flotation machine liquid level was manually adjusted by the operator based on experience, and the underflow concentration of the thickener was manually adjusted by the operator based on the concentration meter reading, thus the concentrate grade control relied entirely on the operator's experience. Due to large fluctuations in the feed grade and flow rate of the upstream magnetic separation operation, the underflow concentration of the thickener frequently exceeded the standard, and the flotation machines frequently experienced overflow and non-scraping malfunctions. The concentrate grade fluctuated within ±1.5 percentage points, and the metal recovery rate was only about 78%.

[0113] In this embodiment, the upstream processing unit is a thickener, the downstream sorting unit is a flotation machine, the product quality index is the concentrate grade, and the output medium is the underflow slurry.

[0114] The implementation method is as follows:

[0115] This embodiment modifies the existing system described above without adding any hardware devices; it only upgrades the software of the original DCS control system.

[0116] Step 1: Add a fluctuation feature extraction module to the DCS system. Set a sliding window (60-second time width) at the existing electromagnetic flowmeter signal access point on the feed pipeline of the first flotation cell to calculate the flow deviation amplitude in real time. and rate of change At the signal access point of the existing online grade analyzer on the overflow product pipeline of the mixed cleaning flotation machine, the actual value of the concentrate grade is read in real time and the grade deviation is calculated. .

[0117] The flow fluctuation characteristic index is calculated according to the following formula. :

[0118]

[0119] Based on on-site testing, determine , , ;

[0120]

[0121] Step 2: Add a collaborative setting module to the DCS system. Based on historical operating data and on-site process requirements, determine the target grade range as 64.0%–65.0%. = 0.5 percentage points, meaning that when the grade exceeds the range of 63.5% to 65.5%, grade priority correction is triggered. = 15, = 5, = 0.03, =0.01, =0.03, =Up 0.01.

[0122] The collaborative setting logic is as follows:

[0123] Grade deviation takes precedence: when the actual grade of the concentrate is < 63.5%, it is considered low grade, and in this case, Used to raise the liquid level and increase bubble removal. Reduce the concentration appropriately to prevent blockage; when the actual concentrate grade is > 65.5%, it is considered that the grade is too high but does not exceed the upper limit. Maintain the current setting and observe subsequent changes.

[0124] Flow fluctuation feedforward:

[0125] when >15:00:

[0126]

[0127]

[0128] when < 5:

[0129]

[0130]

[0131] when And when the grade is in the range of 63.5% to 65.5%:

[0132] =0

[0133] =0

[0134] Step 3: Connect the output signal of the collaborative setting module to the PID control loops for the flotation machine level and the thickener underflow concentration, respectively. Setpoints for the level control loops. The set value of the concentration control loop Two PID control loops drive the electric gate valve of the flotation machine's underflow and the frequency converter of the thickener's underflow pump, respectively.

[0135] Step 4: The system is put into operation and continuously monitors each control indicator.

[0136] Implementation results:

[0137] The following are the statistics after the system has been running continuously for 30 days since its commissioning:

[0138] Concentrate grade fluctuation range ±1.5 percentage points ±0.5 percentage points Shrink by 66.7% Average grade of concentrate 64.2% 64.8% Increased by 0.6 percentage points Average tailings grade 8.5% 6.1% Decrease by 2.4 percentage points Flotation machine liquid level fluctuation range ±8.5 cm ±4.0 cm Reduced by 52.9% Number of times the thickener underflow concentration overshoots (per day) 12.3 times 4.8 times Reduced by 61.0% Metal recovery rate 78.1% 82.6% Increased by 4.5 percentage points

[0139] Effect Analysis:

[0140] In this embodiment, when the collaborative setting module detects a low grade (actual grade < 63.5%), it simultaneously performs two actions: increasing the liquid level setpoint to increase the amount of foam scraping to improve the recovery rate and appropriately decreasing the concentration setpoint to prevent concentration fluctuations caused by underflow blockage. When an increase in flow rate fluctuation is detected... >15. Simultaneously, the system lowers the liquid level setpoint and raises the concentration setpoint. These two actions work synergistically: the increased concentration stabilizes the slurry entering the flotation machine, reducing subsequent flow and grade fluctuations; the liquid level adjustment enhances the system's tolerance to residual fluctuations, reducing sources of grade disturbance. This creates a positive feedback stabilization cycle, significantly improving the overall grade stability of the system. The concentrate grade fluctuation range decreased from ±1.5 percentage points to ±0.5 percentage points, a reduction of 66.7%, achieving a good synergistic grade control effect.

[0141] Example 3

[0142] Application scenario: Mixed flotation process in a copper-nickel sulfide ore beneficiation plant.

[0143] Process conditions: The plant's mixed beneficiation operation uses a configuration of 6 flotation machines in series. The ore properties change frequently, with the copper grade of the raw ore fluctuating between 0.6% and 1.8%, making it difficult to control the concentration of the thickener underflow. Under the original control method, operators needed to adjust the liquid level or concentration parameters on average every 15 minutes, resulting in high labor intensity. Furthermore, the effectiveness of concentrate grade control depended on operator experience, and there were significant differences in indicators between different shifts.

[0144] In this embodiment, the upstream processing unit is a thickener, the downstream sorting unit is a flotation machine, the product quality index is the copper concentrate grade, and the output medium is underflow slurry.

[0145] This embodiment is a modification of an existing PLC control system. Unlike Embodiment 2, the flow fluctuation characteristic index in this embodiment... The calculation used different weighting coefficients. = 0.5, =0.3, = 0.2, to accommodate the more pronounced fluctuations in the plant's flow rate. The sliding window time width is set to 45 seconds.

[0146] Based on the on-site process requirements, the target range for copper concentrate grade was determined to be 22.0%–24.0%. = 0.8 percentage points. =20, =8, =0.02, =0.008, =0.025, =0.012.

[0147] In this embodiment, the level control module and the concentration control module are located in different PLC controllers, which are connected via an industrial Ethernet network. The collaborative setting module is integrated into the central control station and sends setpoint correction commands to both PLC controllers simultaneously via the communication network.

[0148] Implementation results:

[0149] The following are the statistics after the system has been running continuously for 60 days since its commissioning:

[0150] Number of operator interventions (per shift) 32 times 7 times Reduced by 78.1% Copper concentrate grade fluctuation range ±0.8 percentage points ±0.3 percentage points Reduced by 62.5% Average grade of copper concentrate 22.5% 23.2% Increased by 0.7 percentage points Average copper grade of tailings 0.18% 0.12% Decrease by 0.06 percentage points Number of flotation machine overflow failures (times / month) 18 times 2 times Reduced by 88.9%

[0151] Effect Analysis:

[0152] This embodiment further verifies the applicability of the present invention to different ore types and different control hardware platforms. The integrated synergistic control of grade, level, and concentration not only improves the stability of concentrate grade but also significantly reduces the workload of operators, allowing them to devote more energy to other process optimization aspects. Simultaneously, the significant reduction in overflow failures means a substantial decrease in useful metal loss, directly reflected in an improved metal recovery rate.

[0153] Example 4

[0154] Application scenario: A renovation project of a large iron ore beneficiation plant. The plant had previously adopted a DCS control system to achieve automatic liquid level control based on grade feedback, but the control effect was not ideal and the grade fluctuation was still large.

[0155] Process conditions: The plant's mixed cleaning operation uses 8 flotation machines connected in series, with the thickener underflow concentration set at [value missing]. =55%, basic setting value of flotation machine liquid level =35cm. Under the original control method, the liquid level was adjusted only based on the grade deviation, without considering feedforward compensation for flow fluctuations, nor was concentration control incorporated into the collaborative framework. Due to frequent changes in feed conditions, a vicious cycle often occurred: grade fluctuations, the need to adjust the liquid level, liquid level fluctuations leading to concentration fluctuations, and concentration fluctuations leading to further grade fluctuations.

[0156] In this embodiment, the upstream processing unit is a thickener, the downstream sorting unit is a flotation machine, the product quality index is the concentrate grade, and the output medium is the underflow slurry.

[0157] Implementation method:

[0158] The feature of this embodiment is that the plant already has a complete DCS control system and detection instruments, including an online grade analyzer. This invention only needs to add a fluctuation feature extraction module and a collaborative setting module to the original control program, modify the input method of the set value of the original liquid level PID control loop, change the grade deviation single variable feedback setting to the grade deviation feedback + flow fluctuation feedforward dual collaborative setting, and at the same time incorporate the concentration control loop into the collaborative framework.

[0159] Set the sliding window duration width to 90 seconds. =0.35, =0.35, =0.30, the flow rate of this plant changes rapidly, and the grade fluctuates significantly, therefore and The value is relatively large.

[0160] The target grade range is 65.0% to 66.0%. = 0.5 percentage points. =12, = 4, =0.04, =0.015, =0.035, =0.018.

[0161] Implementation results:

[0162] After the system is put into operation, a comparison is made with the original single-variable control method based on grade feedback:

[0163] Concentrate grade fluctuation range ±1.2 percentage points ±0.4 percentage points Shrink by 66.7% Concentrate grade qualification rate (within the target range) 68% 95% Increased by 27 percentage points Number of times the liquid level and concentration interfered with each other (times / hour) 5.8 times 0.6 times Reduced by 89.7% Liquid level stabilization time (after step response) 120 seconds 50 seconds Shortened by 58.3% Concentration stabilization time (after step response) 180 seconds 65 seconds Shortened by 63.9% Drug consumption benchmark 9% reduction Significant savings

[0164] Effect Analysis:

[0165] This embodiment powerfully demonstrates that the present invention also significantly improves conditions where existing automatic grade control is ineffective. By adding a single software modification—a collaborative setting module—the vicious cycle in the original grade control is completely resolved; compared to existing solutions, the number of level-concentration interference events is reduced by 89.7%, from 5.8 times per hour to 0.6 times per hour. The concentrate grade qualification rate increases from 68% to 95%, and the grade fluctuation range narrows from ±1.2 percentage points to ±0.4 percentage points. Reagent consumption is reduced by 9%, resulting in significant overall economic benefits.

[0166] This embodiment also illustrates that the collaborative control of the present invention is not simply superimposing three independent loops of grade deviation feedback, liquid level control and concentration control, but rather transforming the three control variables that originally interfered with each other into mutually supportive ones through structural coupling and reconstruction, so that the performance of the three control loops exceeds the optimal level of their respective independent operation.

[0167] Example 5

[0168] This embodiment provides a grade control system for an ore mixing and beneficiation process, which uses the method in Embodiment 1 for control, including:

[0169] The flow detection unit is installed on the connecting pipeline between the upstream processing unit and the downstream sorting unit, and is used to detect the output medium flow signal in real time. ;

[0170] The quality indicator detection unit is installed on the product output pipeline of the downstream sorting unit to detect the actual values ​​of product quality indicators in real time. ;

[0171] The liquid level detection unit is installed on the downstream sorting unit to detect the actual liquid level at the sorting interface in real time. ;

[0172] The concentration detection unit is installed on the output pipeline of the upstream processing unit to detect the actual value of the output medium concentration of the upstream processing unit in real time. ;

[0173] The fluctuation feature extraction module, connected to the flow detection unit and the quality index detection unit, is used to perform sliding window analysis on the flow signal and extract flow fluctuation feature indicators. Simultaneously calculate the deviation of quality indicators ;

[0174] The collaborative setting module is signal-connected to the fluctuation feature extraction module and is used to set the flow fluctuation feature index. Deviation of quality indicators Simultaneously generate correction values ​​for the liquid level setpoint according to preset collaborative setting rules. offset of concentration setpoint ;

[0175] The liquid level control module is connected to the collaborative setting module, the liquid level detection unit, and the liquid level adjustment actuator, respectively, and is used to control the liquid level according to the set value. Compared with the actual liquid level The deviation drives the liquid level regulating actuator to adjust the liquid level at the sorting interface;

[0176] The concentration control module is connected to the collaborative setting module, the concentration detection unit, and the concentration adjustment actuator, respectively, and is used to control the concentration according to the set concentration value. Compared with the actual concentration value The deviation-driven concentration regulating actuator adjusts the output medium concentration;

[0177] The collaborative setting module simultaneously outputs control signals to both the liquid level control module and the concentration control module, achieving coordinated control of liquid level and concentration with the ultimate goal of stabilizing product quality indicators.

[0178] In this embodiment, the upstream processing unit is a thickener; the downstream sorting unit is a flotation machine; the product quality indicator is concentrate grade; the output medium is underflow slurry; the liquid level regulating actuator is the underflow valve of the flotation machine; and the concentration regulating actuator is the underflow pump speed regulating device of the thickener.

[0179] In this embodiment, the fluctuation feature extraction module includes a sliding window memory, and the time width of the sliding window is 30 to 120 seconds.

[0180] In this embodiment, the system further includes a human-computer interaction interface for displaying traffic fluctuation characteristic indicators. Quality indicator deviation Liquid level setpoint correction amount Concentration setpoint offset It also includes the operating status of each control loop and provides an online adjustment interface for the thresholds and coefficients in the collaborative setting rules.

[0181] This embodiment, through a single software logic modification, couples the originally independent flotation machine level control and thickener underflow concentration control into a collaborative control loop with the ultimate goal of grade stability, without increasing hardware investment.

[0182] In addition, this embodiment utilizes a dual synergistic control strategy based on flow fluctuation feedforward and grade deviation feedback, so that level control and concentration control support and reinforce each other, reducing grade fluctuation interference from the source, and improving the control effect in three dimensions: level stability, concentration stability and final concentrate grade stability.

[0183] Example 6

[0184] According to one aspect of the present invention, a computer program product or computer program is provided, the computer program product or computer program including computer instructions stored in a computer-readable storage medium. A processor of a computer device reads the computer instructions from the computer-readable storage medium, and executes the computer instructions, causing the computer device to perform the methods provided in the various alternative implementations described above.

[0185] In another aspect, the present invention also provides a computer-readable medium, which may be included in the electronic device described in the above embodiments; or it may exist independently and not assembled into the electronic device. The computer-readable medium carries one or more programs, which, when executed by the electronic device, cause the electronic device to implement the ore mixing and beneficiation process grade control method described in the above embodiments.

[0186] It should be noted that although several modules or units of the device for performing actions have been mentioned in the detailed description above, this division is not mandatory. In fact, according to embodiments of the present invention, the features and functions of two or more modules or units described above can be embodied in one module or unit. Conversely, the features and functions of one module or unit described above can be further divided and embodied by multiple modules or units.

[0187] Through the above description of the embodiments, those skilled in the art will readily understand that the exemplary embodiments described herein can be implemented by software or by combining software with necessary hardware. Therefore, the technical solutions according to the embodiments of the present invention can be embodied in the form of a software product, which can be stored in a non-volatile storage medium (such as a CD-ROM, USB flash drive, portable hard drive, etc.) or on a network, including several instructions to cause a computing device (such as a personal computer, server, touch terminal, or network device, etc.) to execute the method according to the embodiments of the present invention.

[0188] Those skilled in the art will readily conceive of embodiments of the invention upon consideration of the specification and practice of the methods disclosed herein. The invention is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein.

[0189] It should be understood that the present invention is not limited to the precise structure described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A method for grade control in an ore mixing and beneficiation process, characterized in that, The specific steps include the following: Step S1: Real-time acquisition of the output medium flow signal from the upstream processing unit. and the actual values ​​of current product quality indicators Furthermore, a sliding window analysis was performed on the flow signal to extract flow fluctuation characteristic indicators. Simultaneously calculate the deviation of quality indicators ; Step S2: Based on the flow fluctuation characteristic indicators Deviation of quality indicators According to the preset collaborative setting rules, the correction amount of the liquid level setting value of the sorting interface of the downstream sorting unit is generated simultaneously. offset of the output medium concentration setpoint of the upstream processing unit ; Step S3: Adjust the liquid level setpoint. The liquid level controller output to the downstream sorting unit drives the liquid level regulating actuator to adjust the liquid level at the sorting interface; Step S4: Offset of concentration setpoint The concentration controller output to the upstream processing unit drives the concentration regulating actuator to adjust the concentration of the output medium.

2. The method for grade control in the ore mixing and beneficiation process according to claim 1, characterized in that, Flow fluctuation characteristic indicators in step S1 Calculate using the following formula: in, This represents the magnitude of the deviation between the output medium flow rate at the current sampling moment and the average output medium flow rate within the sliding window. Output the rate of change of the medium flow rate at the current sampling moment. These are empirical weighting coefficients. The values ​​range from 0.2 to 0.6, and the sum of the weights is 1.

3. The method for grade control in the ore mixing and beneficiation process according to claim 1, characterized in that, The collaborative setting rules in step S2 include: Quality deviation priority rule: when > At that time, according to The symbols are adjusted simultaneously. and Prioritize correcting deviations in quality indicators; This refers to the permissible deviation threshold for quality indicators; Flow fluctuation feedforward rule: When the flow fluctuation characteristic index Greater than the first threshold At the same time Negative values When it is a positive value; Less than the second threshold At the same time For positive values It is a negative value; when < < and hour, =0, =0.

4. The method for grade control in the ore blending and beneficiation process according to claim 3, characterized in that, The specific flow fluctuation feedforward rule in step S2 is as follows: When traffic fluctuation characteristic indicators Greater than the first threshold hour: When traffic fluctuation characteristic indicators Less than the second threshold hour: in, A positive adjustment coefficient. The value range is 0.01 to 0.

05. The value range is 0.005 to 0.

02. The value range is 0.01 to 0.

05. The value range is 0.005 to 0.

02.

5. The method for grade control in the ore mixing and beneficiation process according to claim 3, characterized in that, The quality deviation priority rule in step S2 is as follows: when When the product quality indicators are below the target lower limit, Taking a positive value increases the liquid level at the sorting interface, thereby increasing the yield of the target product. Negative values ​​are used to appropriately reduce the concentration of the output medium and prevent blockage; when When the product quality indicators are higher than the target upper limit, maintain and Remain unchanged and observe subsequent changes. If the limits continue to be exceeded, adjust in the opposite direction.

6. The method for grade control in the ore mixing and beneficiation process according to claim 1, characterized in that, In step S3, the liquid level controller of the downstream sorting unit adopts a PID control algorithm, based on... Compared with the actual liquid level The deviation is used to calculate the liquid level adjustment amount; In step S4, the concentration controller of the upstream processing unit adopts a PID control algorithm, based on... Compared with the actual concentration value The deviation is used to calculate the concentration adjustment amount.

7. A grade control system for an ore mixing and beneficiation process, characterized in that, the control is performed using the method described in any one of claims 1-6, and that, include: The flow detection unit is installed on the connecting pipeline between the upstream processing unit and the downstream sorting unit, and is used to detect the output medium flow signal in real time. ; The quality indicator detection unit is installed on the product output pipeline of the downstream sorting unit to detect the actual values ​​of product quality indicators in real time. ; The liquid level detection unit is installed on the downstream sorting unit to detect the actual liquid level at the sorting interface in real time. ; The concentration detection unit is installed on the output pipeline of the upstream processing unit to detect the actual value of the output medium concentration of the upstream processing unit in real time. ; The fluctuation feature extraction module, connected to the flow detection unit and the quality index detection unit, is used to perform sliding window analysis on the flow signal and extract flow fluctuation feature indicators. Simultaneously calculate the deviation of quality indicators ; The collaborative setting module is signal-connected to the fluctuation feature extraction module and is used to set the flow fluctuation feature index. Deviation of quality indicators Simultaneously generate correction values ​​for the liquid level setpoint according to preset collaborative setting rules. offset from concentration setpoint ; The liquid level control module is connected to the collaborative setting module, the liquid level detection unit, and the liquid level adjustment actuator, respectively, and is used to control the liquid level according to the set value. Compared with the actual liquid level The deviation drives the liquid level regulating actuator to adjust the liquid level at the sorting interface; The concentration control module is connected to the collaborative setting module, the concentration detection unit, and the concentration adjustment actuator, respectively, and is used to control the concentration according to the set concentration value. Compared with the actual concentration value The deviation-driven concentration regulating actuator adjusts the output medium concentration; The collaborative setting module simultaneously outputs control signals to both the liquid level control module and the concentration control module, achieving coordinated control of liquid level and concentration with the ultimate goal of stabilizing product quality indicators.

8. The ore mixing and beneficiation process grade control system according to claim 7, characterized in that, The upstream processing unit is a thickener; the downstream separation unit is a flotation machine; the product quality indicator is concentrate grade; the output medium is underflow slurry; the liquid level regulating actuator is the underflow valve of the flotation machine; and the concentration regulating actuator is the speed regulating device of the underflow pump of the thickener.

9. The ore mixing and beneficiation process grade control system according to claim 7, characterized in that, The fluctuation feature extraction module includes a sliding window memory, with a sliding window time width of 30 to 120 seconds.

10. The ore mixing and beneficiation process grade control system according to claim 7, characterized in that, The system also includes a human-computer interaction interface for displaying traffic fluctuation characteristic indicators. Quality indicator deviation Liquid level setpoint correction amount Concentration setpoint offset It also includes the operating status of each control loop and provides an online adjustment interface for the thresholds and coefficients in the collaborative setting rules.

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