A control device for crushing and magnetic separation of heavy nickel-iron slag

Abstract

The utility model relates to a heavy nickel -iron slag processing technical field, and disclose a kind of heavy nickel -iron slag crushing magnetic separation control equipment, and heavy slag is preliminarily broken by jaw crusher, and large block slag is broken to small particle size slag;Two conical crushers are broken to slag;Magnetic separator is used to carry out magnetic separation treatment to the slag after fine crushing, and iron is separated from slag by the magnetic field effect of magnetic separator;Screening machine is used to classify and screen the iron after magnetic separation, and iron is divided into different granularity grades;Iron after slag iron separation by magnetic separator enters screening machine;Controller is used to control the start-stop of motor on jaw crusher and conical crusher, control the magnetic field intensity and magnetic separation time of magnetic separation process of magnetic separator, control the start-stop and screening frequency of screening machine. Through the process of "rough breaking-fine breaking-magnetic separation-classification" and automation control, realize the efficient recovery of metal in heavy nickel-iron slag, the iron recovery rate is high, while reducing manual intervention, reduce cost.

Description

Technical Field

[0001] This utility model belongs to the field of nickel-iron heavy slag treatment technology, specifically relating to a nickel-iron heavy slag crushing and magnetic separation control device. Background Technology

[0002] In the ferronickel smelting process, a large amount of heavy slag containing high metal content is generated during the tapping and slag removal stages, with an average iron content as high as about 15%. With the continuous expansion of ferronickel alloy smelting scale in my country, the discharge of ferronickel slag has also increased year by year. Statistics show that the annual discharge of ferronickel slag has reached approximately 30 million tons, making it the fourth largest smelting slag in my country after iron slag, steel slag, and red mud. However, the overall resource utilization rate of ferronickel slag is only 8% to 15%, with the vast majority being landfilled or open-air dumped. This disposal method not only occupies a large amount of land but also causes serious harm to the surrounding ecological environment, posing a severe challenge to the sustainable development of ferronickel smelting enterprises. At the same time, improper handling of heavy slag increases the difficulty of subsequent processing, especially in the production of manufactured sand and other products. The presence of heavy slag greatly increases the difficulty of crushing and grinding, affecting the quality of the final product and reducing market competitiveness.

[0003] Current technology simply processes heavy slag and water slag together to produce manufactured sand. During production, the mixed slag is crushed and then the iron in the heavy slag is removed using a magnetic separator. However, due to the differences in physical properties and chemical composition between heavy slag and water slag, the magnetic separator struggles to efficiently separate iron. This not only leaves a large amount of iron resources trapped in the slag, preventing effective recycling, but also increases the complexity and cost of subsequent processing, as detailed below:

[0004] Existing iron separators struggle to efficiently separate iron from heavy slag and slag, leaving a large amount of iron trapped in the slag and unable to be effectively recovered. This low separation efficiency increases the complexity of subsequent processing, leading to higher costs. In the production of manufactured sand and other products, the presence of heavy slag increases the difficulty of crushing and grinding, affecting the quality of the final product and reducing market competitiveness. Furthermore, the overall resource utilization rate of nickel-iron slag is low, with the vast majority ending up in landfills or open-air stockpiles, resulting in significant resource waste.

[0005] In view of this, we propose a magnetic separation control device for crushing nickel-iron heavy slag. Utility Model Content

[0006] This invention aims to solve the problem in the existing technology of producing manufactured sand by mixing heavy slag and water slag, and separating iron only through an iron remover. Due to the difference in physicochemical properties between the two, the iron recovery efficiency is low, and a large amount of iron resources are retained in the slag. This method also increases the difficulty of subsequent crushing and grinding, affects product quality, and has a low resource utilization rate for nickel-iron slag, resulting in land occupation and ecological damage from landfilling.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] A magnetic separation control device for crushing nickel-iron heavy slag includes:

[0009] Jaw crushers are used for the initial coarse crushing of heavy slag, breaking large pieces of slag into small particles. The feed inlet A and discharge outlet A of the jaw crusher are respectively equipped with particle size sensors for detecting the feed particle size and discharge particle size of the heavy slag.

[0010] A cone crusher is used to finely crush slag materials to a particle size suitable for magnetic separation. The cone crusher includes cone crusher A and cone crusher B, which are connected in series and perform secondary fine crushing on coarse particles. The slag material after coarse crushing by the jaw crusher enters cone crusher A. Particle size sensors are also installed at the feed inlet and discharge outlet of the cone crusher.

[0011] A magnetic separator is used to perform magnetic separation on finely crushed slag. The magnetic field of the magnetic separator separates iron from the slag. The magnetic separator is equipped with a magnetic field strength sensor to detect the magnetic field strength. The slag after fine crushing by cone crusher B enters the magnetic separator.

[0012] Screening machine is used to classify and screen iron after magnetic separation, separating the iron into different particle size grades; the iron after slag and iron separation by magnetic separator enters the screening machine.

[0013] The controller is used to control the start and stop of the motors on jaw crushers and cone crushers, control the magnetic field strength and magnetic separation time of the magnetic separator, and control the start and stop and screening frequency of the screening machine.

[0014] Preferably, the controller includes a main control unit, a crushing control module, a magnetic separation control module, a screening control module, a human-machine interface, and a data storage and transmission unit.

[0015] The crushing control module connects to the main control unit as well as the jaw crusher and cone crusher; the magnetic separation control module connects to the main control unit as well as the magnetic separator; the screening control module connects to the main control unit as well as the screening machine; and the human-machine interface is connected to the main control unit, used by operators to input control parameters, monitor equipment operating status, and view operating data.

[0016] Preferably, the crushing control module includes a motor controller and a frequency converter. The motor controller controls the start and stop of the motors on the jaw crusher and the cone crusher, and the frequency converter adjusts the speed of the motors on the jaw crusher and the cone crusher to control the crushing force and efficiency.

[0017] Preferably, the magnetic field strength sensor and the particle size sensor are electrically connected to the main control unit, and the particle size sensor is a laser particle size analyzer, while the magnetic field strength sensor is a Hall effect magnetic field sensor.

[0018] As a preferred option, the main control unit adopts Siemens S7-300 PLC.

[0019] As a preferred option, the Siemens 3RW44 soft starter is selected as the motor controller, and the Siemens MM440 frequency converter is selected as the frequency converter.

[0020] Preferably, the magnetic separation control module is equipped with a magnetic field adjustment device that adjusts the magnetic field strength in real time according to the distribution of metals and magnetic differences in the heavy slag to improve the magnetic separation efficiency. The magnetic field adjustment device adopts a thyristor rectifier.

[0021] As a preferred choice, the human-machine interface uses the Siemens TP1200 Comfort touchscreen.

[0022] As a preferred option, the data storage and transmission unit uses a Siemens SM338 positioning module to store operational data and transmit it to the factory management system via industrial Ethernet.

[0023] Preferably, cone crusher A is provided with inlet B and outlet B, cone crusher B is provided with inlet C and outlet C, magnetic separator is provided with inlet D and outlet D, and screening machine is provided with inlet E and outlet E; an automated conveyor A is provided between outlet A and inlet B, an automated conveyor B is provided between outlet B and inlet C, an automated conveyor C is provided between outlet C and inlet D, an automated conveyor D is provided between outlet D and inlet E, and an automated conveyor E arranged in a stepped manner is provided below outlet E.

[0024] Compared with the prior art, the technical effects and advantages of this utility model are:

[0025] This nickel-iron heavy slag crushing and magnetic separation control equipment processes heavy slag through a "coarse crushing—fine crushing—magnetic separation—grading" process: A jaw crusher performs initial coarse crushing, followed by two-stage fine crushing via automated conveyor A into cone crushers A and B. Particle size sensors monitor the feed and discharge particle sizes in real time and provide feedback to the main control unit (PLC). The crushing control module adjusts the motor speed and crushing force. The finely crushed slag is then fed into a magnetic separator via automated conveyor C. A magnetic field strength sensor detects the magnetic field strength, and the magnetic separation control module adjusts the magnetic field strength using a thyristor rectifier based on the characteristics of the heavy slag, achieving slag-iron separation. The separated iron enters a screening machine via automated conveyor D. The screening control module adjusts the screening frequency to grade the iron according to particle size, and the iron is stored via a stepped conveyor. The controller uses a human-machine interface for parameter input and equipment monitoring, while the data storage and transmission unit synchronizes the operating data to the factory management system.

[0026] Existing technologies mix heavy slag with water slag and rely on iron separators to separate iron elements, resulting in low iron recovery rates due to differences in physical properties. This new equipment refines the slag to a magnetically suitable particle size through staged crushing (jaw crusher + two-stage cone crusher), and dynamically adjusts the magnetic field strength using a Hall effect magnetic field sensor and a thyristor rectifier, thereby improving the iron recovery rate and significantly increasing the utilization rate of metal resources.

[0027] In addition, existing technologies require a lot of manual intervention, making it difficult to precisely adjust crushing and magnetic separation parameters. This equipment uses a Siemens PLC main control unit and a sensor network (laser particle size analyzer, magnetic field sensor) to achieve fully automated control of crushing force, magnetic field strength, and screening frequency. For example, the crushing control module precisely adjusts the motor speed through a Siemens frequency converter and soft starter, reducing manual operation errors and lowering costs and risks. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the structure of this utility model;

[0029] Figure 2 This is a schematic diagram of the structure of this utility model;

[0030] Figure 3 This is the wiring diagram for the Siemens S7-300 PLC module of this utility model;

[0031] Figure 4 This is the main circuit diagram of the Siemens 3RW44 soft starter of this utility model;

[0032] Figure 5 This is the control circuit diagram of the Siemens 3RW44 soft starter of this utility model;

[0033] Figure 6 This is the wiring diagram for the Siemens SM338 positioning module of this utility model;

[0034] Figure 7 This is a wiring diagram of the analog control motor circuit of the Siemens MM440 frequency converter.

[0035] In the diagram: 1. Jaw crusher; 2. Cone crusher A; 3. Cone crusher B; 4. Magnetic separator; 5. Screening machine; 6. Controller; 7. Feed inlet A; 8. Discharge outlet A; 9. Feed inlet B; 10. Discharge outlet B; 11. Feed inlet C; 12. Discharge outlet C; 13. Feed inlet E; 14. Discharge outlet E; 15. Automated conveyor A; 16. Automated conveyor B; 17. Automated conveyor C; 18. Automated conveyor D; 19. Automated conveyor E; 20. Feed inlet D; 21. Discharge outlet D. Detailed Implementation

[0036] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0037] The following combination Figures 1 to 7 This application will be described in further detail.

[0038] This application discloses a nickel-iron heavy slag crushing and magnetic separation control device, including a jaw crusher 1, a cone crusher, a magnetic separator 4, a screening machine 5, and a controller 6;

[0039] Jaw crusher 1 is used for preliminary coarse crushing of heavy slag, breaking large pieces of slag into small particles; cone crusher is used for fine crushing of slag, refining it to a particle size suitable for magnetic separation; magnetic separator 4 is used for magnetic separation of the finely crushed slag, separating iron from the slag through the magnetic field of magnetic separator 4; screening machine 5 is used for grading and screening the magnetically separated iron, separating it into different particle size grades; the iron after slag-iron separation by magnetic separator 4 enters screening machine 5; controller 6 is used to control the start and stop of the motors on jaw crusher 1 and cone crusher, control the magnetic field strength and magnetic separation time of magnetic separator 4, and control the start and stop and screening frequency of screening machine 5.

[0040] The combination of jaw crusher 1, cone crusher, magnetic separator 4, screening machine 5, and controller 6 forms a comprehensive process flow of "coarse crushing—fine crushing—magnetic separation—grading," enabling efficient processing of nickel-iron heavy slag and improving metal recovery rate. The grading crushing technology can process slag lumps of different sizes, providing more suitable slag material for subsequent magnetic separation and improving magnetic separation efficiency. Controller 6 achieves fully automated control from crushing to magnetic separation to grading, effectively reducing manual intervention, lowering labor costs and operational risks.

[0041] The jaw crusher 1 is equipped with particle size sensors at its feed inlet A7 and discharge outlet A8 for detecting the feed particle size and discharge particle size of heavy slag, respectively; the particle size sensors are laser particle size analyzers.

[0042] The cone crusher includes cone crusher A2 and cone crusher B3 connected in series for secondary fine crushing of coarse particles; the slag after coarse crushing by jaw crusher 1 enters cone crusher A2; cone crusher A2 is provided with feed port B9 and discharge port B10, cone crusher B3 is provided with feed port C11 and discharge port C12, an automatic conveyor A15 is provided between discharge port A8 and feed port B9, and an automatic conveyor B16 is provided between discharge port B10 and feed port C11;

[0043] The magnetic separator 4 is equipped with a magnetic field strength sensor for detecting the magnetic field strength. The magnetic field strength sensor adopts the Hall effect magnetic field sensor. The slag after being finely crushed by the cone crusher B3 enters the magnetic separator 4. The magnetic separator 4 is equipped with a feed inlet D20 and a discharge outlet D21. An automatic conveyor C17 is installed between the discharge outlet C12 and the feed inlet D20. The screening machine 5 is equipped with a feed inlet E13 and a discharge outlet E14. An automatic conveyor D18 is installed between the discharge outlet D21 and the feed inlet E13. An automatic conveyor E19 is arranged in a stepped manner below the discharge outlet E14.

[0044] The particle size sensors at the feed inlet A7 and discharge outlet A8 of jaw crusher 1 are laser particle size analyzers, which can accurately detect the feed and discharge particle size of heavy slag, ensuring that the particle size of the slag after preliminary coarse crushing meets the requirements. The cone crusher includes cone crushers A2 and B3 arranged in series. The slag after coarse crushing by jaw crusher 1 sequentially enters cone crushers A2 and B3 for primary and secondary fine crushing, refining the slag to a particle size more suitable for magnetic separation and improving the magnetic separation effect. The crushers are connected by an automated conveyor system, realizing automatic slag transportation, improving production efficiency, and reducing manual handling.

[0045] The magnetic field strength sensor installed inside the magnetic separator 4 is a Hall effect magnetic field sensor, which can accurately detect the magnetic field strength, providing a basis for the magnetic separation control module to adjust the magnetic field strength and ensuring the efficient operation of the magnetic separation process. The cone crusher B3 is connected to the magnetic separator 4 via an automated conveyor C17, enabling the automatic transport of the slag after fine crushing to the magnetic separator 4. The screening machine 5 is used to classify and screen the iron after magnetic separation, separating it into different particle size grades to meet different utilization needs and improve the utilization value of the iron. The magnetic separator 4 and the screening machine 5 are connected via an automated conveyor D18. Below the discharge port E14 of the screening machine 5, a stepped automated conveyor E19 is installed to achieve automatic transport and storage of the classified iron.

[0046] The controller 6 includes a main control unit, a crushing control module, a magnetic separation control module, a screening control module, a human-machine interface, and a data storage and transmission unit. Magnetic field strength sensors and particle size sensors are electrically connected to the main control unit. The main control unit is the core of the controller 6, employing a PLC (Programmable Logic Controller 6) to receive signals from various sensors, process data, and issue control commands. It coordinates the operation of various equipment such as the jaw crusher 1, cone crusher, magnetic separator 4, and screening machine 5, ensuring the orderly progress of the entire crushing and magnetic separation process. The main control unit uses a Siemens S7-300 PLC (e.g.,...). Figure 3 As shown, this is the wiring diagram for CPU315+PS307 (power module)+SM321 (DI module)+SM322 (DO module). The left side is the power module and the right side is the CPU module, which ensures the stability and reliability of the main control unit.

[0047] The crushing control module connects to the main control unit and the jaw crusher 1 and cone crusher; it controls parameters such as start / stop, speed, and crushing force of the jaw crusher 1 and cone crusher; it can flexibly adjust crushing parameters according to different heavy slag characteristics and crushing targets to improve crushing efficiency and quality. The crushing control module includes a motor controller 6 and a frequency converter. The motor controller 6 controls the start / stop of the motors on the jaw crusher 1 and cone crusher, and the frequency converter adjusts the speed of the motors on the jaw crusher 1 and cone crusher to control crushing force and efficiency. The motor controller 6 uses a Siemens 3RW44 soft starter (e.g.,...). Figures 4 to 5 The diagrams shown are the main circuit diagram and control circuit diagram of the Siemens 3RW44 soft starter, respectively. The Siemens MM440 frequency converter is selected. Figure 7 The diagram shown is a wiring schematic of the Siemens MM440 frequency converter analog control motor circuit, which ensures reliable control of the crusher motor and guarantees the accuracy and stability of the control.

[0048] The magnetic separation control module connects to the main control unit and the magnetic separator 4; it is used to control parameters such as magnetic field strength and magnetic separation time during the magnetic separation process. The magnetic separation control module is equipped with a magnetic field adjustment device that adjusts the magnetic field strength in real time based on the distribution of metals and magnetic differences in the heavy slag to improve magnetic separation efficiency. The magnetic field adjustment device uses a silicon controlled rectifier (SCR) rectifier, achieving more efficient slag-iron separation.

[0049] The screening control module connects the main control unit and the screening machine 5; it is used to control parameters such as the start and stop of the screening equipment and the screening frequency; the screening parameters can be flexibly adjusted according to different iron particle size classification requirements to ensure screening effect.

[0050] The human-machine interface (HMI) is connected to the main control unit, allowing operators to input control parameters, monitor equipment operating status, and view operating data. The HMI uses a Siemens TP1200 Comfort touchscreen, enabling convenient operation and real-time monitoring of the entire crushing and magnetic separation control equipment.

[0051] like Figure 6 As shown, the data storage and transmission unit uses a Siemens SM338 positioning module to store operating data and transmit it to the factory management system via industrial Ethernet. Figure 6 In the diagram, ① an error LED (red, fault indicator); ② connected to the CPU grounding point; ③ at the twisted-pair cable connection; these ensure the stability of data transmission.

[0052] During operation, heavy slag enters jaw crusher 1 for preliminary coarse crushing, and then enters cone crusher A2 via automated conveyor A15 for primary fine crushing. The slag after fine crushing in cone crusher A2 enters cone crusher B3 via automated conveyor B16 for secondary fine crushing. Particle size sensors can be installed at the inlet and outlet of jaw crusher 1, or at the inlet and outlet of cone crusher A2 and cone crusher B3. The particle size sensors detect the feed particle size and transmit it to the main control unit. The main control unit adjusts the operating parameters of jaw crusher 1 and cone crusher through the crushing control module according to the set crushing target and feed particle size to perform coarse and fine crushing.

[0053] The crushed slag enters the magnetic separator 4 via automated conveyor C17. A magnetic field strength sensor detects the magnetic field strength, and the magnetic separation control module adjusts the magnetic field strength based on the detection results and the characteristics of the heavy slag, achieving slag-iron separation. The separated iron enters the screening machine 5 via automated conveyor D18. The screening control module controls the operation of the screening machine 5, separating the iron into different particle size grades for storage and recycling. Operators can monitor the operating status of each piece of equipment in real time through a human-machine interface and adjust control parameters as needed. The main control unit stores the operating data through a data storage and transmission unit and transmits it to the plant management system.

[0054] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A magnetic separation control device for crushing nickel-iron heavy slag, characterized in that, include: Jaw crusher (1) is used for preliminary coarse crushing of heavy slag, so that large pieces of slag are crushed into small particles. The jaw crusher (1) is equipped with particle size sensors at the feed inlet A (7) and discharge outlet A (8) for detecting the feed particle size and discharge particle size of heavy slag, respectively. A cone crusher is used to finely crush slag materials to refine them to a particle size suitable for magnetic separation. The cone crusher includes a cone crusher A (2) and a cone crusher B (3) that are connected in series and perform secondary fine crushing on coarse particles. The slag material after being coarsely crushed by the jaw crusher (1) enters the cone crusher A (2). The magnetic separator (4) is used to perform magnetic separation on the finely crushed slag. The magnetic field of the magnetic separator (4) separates the iron from the slag. The magnetic separator (4) is equipped with a magnetic field strength sensor for detecting the magnetic field strength. The slag after being finely crushed by the cone crusher B (3) enters the magnetic separator (4). Screening machine (5) is used to classify and screen the iron after magnetic separation, and to separate the iron into different particle size grades; the iron after slag and iron separation by magnetic separator (4) enters screening machine (5); The controller (6) is used to control the start and stop of the motors on the jaw crusher (1) and cone crusher, control the magnetic field strength and magnetic separation time of the magnetic separator (4) during the magnetic separation process, and control the start and stop of the screening machine (5) and the screening frequency.

2. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 1, characterized in that: The controller (6) includes a main control unit, a crushing control module, a magnetic separation control module, a screening control module, a human-machine interface, and a data storage and transmission unit; The crushing control module is connected to the main control unit and the jaw crusher (1) and cone crusher; the magnetic separation control module is connected to the main control unit and the magnetic separator (4); the screening control module is connected to the main control unit and the screening machine (5); the human-machine interface is connected to the main control unit and is used by operators to input control parameters, monitor the operating status of equipment and view operating data.

3. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 2, characterized in that: The crushing control module includes a motor controller (6) and a frequency converter. The motor controller (6) controls the start and stop of the motors on the jaw crusher (1) and the cone crusher, and the frequency converter adjusts the speed of the motors on the jaw crusher (1) and the cone crusher to control the crushing force and efficiency.

4. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 2, characterized in that: The magnetic field strength sensor and particle size sensor are electrically connected to the main control unit. The particle size sensor is a laser particle size analyzer, and the magnetic field strength sensor is a Hall effect magnetic field sensor.

5. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 2, characterized in that: The main control unit uses a Siemens S7-300 PLC.

6. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 3, characterized in that: The motor controller (6) is a Siemens 3RW44 soft starter, and the frequency converter is a Siemens MM440 frequency converter.

7. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 2, characterized in that: The magnetic separation control module is equipped with a magnetic field adjustment device that adjusts the magnetic field strength in real time according to the distribution of metals and magnetic differences in the heavy slag to improve the magnetic separation efficiency. The magnetic field adjustment device adopts a silicon controlled rectifier.

8. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 2, characterized in that: The human-computer interaction interface uses a Siemens TP1200 Comfort touch screen.

9. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 2, characterized in that: The data storage and transmission unit uses a Siemens SM338 positioning module to store operational data and transmit it to the factory management system via industrial Ethernet.

10. The nickel-iron heavy slag crushing and magnetic separation control equipment according to claim 1, characterized in that: The cone crusher A (2) is equipped with a feed inlet B (9) and a discharge outlet B (10), the cone crusher B (3) is equipped with a feed inlet C (11) and a discharge outlet C (12), the magnetic separator (4) is equipped with a feed inlet D (20) and a discharge outlet D (21), and the screening machine (5) is equipped with a feed inlet E (13) and a discharge outlet E (14). An automated conveyor A (15) is provided between the discharge outlet A (8) and the feed inlet B (9), an automated conveyor B (16) is provided between the discharge outlet B (10) and the feed inlet C (11), an automated conveyor C (17) is provided between the discharge outlet C (12) and the feed inlet D (20), an automated conveyor D (18) is provided between the discharge outlet D (21) and the feed inlet E (13), and an automated conveyor E (19) is arranged in a stepped manner below the discharge outlet E (14).

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