A novel flux feeding control system for a converting furnace

Abstract

The utility model relates to a novel blowing smelting furnace flux feeding control system, including flux material preparation subsystem, flux feeding subsystem, flux control subsystem and blowing slag type control subsystem. Flux material preparation subsystem conveys flux to flux intermediate bin through bin electric vibration, belt conveyor, and the flux intermediate bin is equipped with full material monitoring device to realize stable material preparation and accurate material level control. Flux feeding subsystem connects intermediate bin to kiln discharge opening through belt conveyor, and is equipped with man-machine isolation and weighing device. Flux control subsystem is based on flux calculation module, temperature detection module, flux port blockage detection module, slag discharge state detection module combined with logic controller, drives belt conveyor to run. Blowing slag type subsystem dynamically feedbacks and adjusts feeding through molten slag detection analysis, temperature detection and discharge correction module. The system realizes flux feeding whole process automation control, realizes flux accurate feeding, effectively improves the stability of blowing process and equipment operation reliability.

Description

Technical Field

[0001] This utility model relates to the field of copper pyrometallurgy, and in particular to a novel flux feeding control system for a blowing furnace. Background Technology

[0002] In the pyrometallurgical process of smelting matte into blister copper, the flux charging control in the smelting furnace directly affects the stability of the slag structure and the operating efficiency of the production system. Traditional flux charging systems mostly adopt a segmented mechanized conveying method combined with manual experience-based control, which has shortcomings such as low automation and lagging control parameters. Although existing technologies have made improvements to the charging system in specific aspects such as charging devices, material level monitoring, and batching, they still suffer from insufficient system coordination, the correlation between flux composition and slag shape, and the lack of dynamic correction mechanisms when facing complex operating conditions such as multi-gun top blowing, intermittent melt discharge characteristics, and slag composition sensitivity. These issues make it difficult to meet the high standards required for large-scale continuous smelting processes in terms of operational automation, process intelligence, management visualization, and production safety. Utility Model Content

[0003] To address the problems existing in the background technology, this utility model provides a novel flux charging control system for a blowing furnace, specifically including a flux preparation subsystem, a flux supply subsystem, a flux control subsystem, and a blowing slag type control subsystem. The flux preparation subsystem includes a silo vibrating unit, a belt conveyor, a flux intermediate silo, and an intermediate silo full-load determination control device. The first belt conveyor extends from the discharge end of the silo vibrating unit to the inlet of the flux intermediate silo. The output end of the intermediate silo full-load determination module is communicatively connected to the silo vibrating unit and the first belt conveyor. The flux supply subsystem includes a belt conveyor, a flux discharge port, a human-machine isolation device, a weighing device, and a monitoring device. The input end of the second belt conveyor is connected to the discharge port of the flux intermediate silo, and its output end extends to the flux discharge port. The flux control subsystem includes a flux calculation module, a first temperature detection module, a flux port blockage monitoring module, a slag discharge status detection module, and a first logic controller, all connected in parallel. The input of the first logic controller is communicatively connected to the outputs of the flux calculation module, the first temperature detection module, the flux port blockage monitoring module, and the slag discharge status detection module, respectively. The output of the first logic controller is communicatively connected to a second belt conveyor. The blowing slag control subsystem includes a slag detection and analysis module, a flux feeding correction module, and a second logic controller. The input of the second logic controller is communicatively connected to the output of the slag detection and analysis module, and its output is communicatively connected to the input of the flux feeding correction module. Furthermore, the output of the flux feeding correction module is communicatively connected to the flux calculation module.

[0004] Furthermore, the lower space of the flux intermediate chamber is composed of multiple parallel compartments, which share a top space connected to the feed inlet of the flux intermediate chamber.

[0005] Furthermore, the intermediate silo full determination device includes a material level sensor installed on the upper edge of the inner wall of the flux intermediate silo, a camera device fixed above the flux intermediate silo, and a third logic controller. The output of the third logic controller is communicatively connected to the silo electric vibration unit and the first belt conveyor.

[0006] Furthermore, the first temperature detection module includes a first temperature sensing unit and a second temperature sensing unit, wherein the first temperature sensing unit is located at the flux inlet and the second temperature sensing unit is located at the crude copper discharge outlet of the smelting furnace.

[0007] Furthermore, the flux calculation module includes a first information storage unit and a flux calculation unit. The information storage unit includes a first computer storage medium containing flux composition information, furnace feed amount, smelting process production parameters, cumulative production time, cumulative value of blowing furnace feed amount, and target value of blowing slag structure. The output terminal of the flux calculation unit is connected to the first logic controller.

[0008] Furthermore, the slag detection and analysis module also includes a third temperature sensing unit and a slag temperature logic controller. The third temperature sensing unit is communicatively connected to the input of the slag temperature logic controller at its signal output end, and the output of the slag temperature logic controller is communicatively connected to the second belt conveyor.

[0009] Furthermore, the flux feeding correction module includes a second information storage unit and a difference calculation unit. The input end of the difference calculation unit is interconnected with the slag detection and analysis module and the second information storage unit, and the output end is connected to the flux calculation unit. The second information storage unit includes a computer storage medium with the target value of the blowing slag process control.

[0010] Compared with the prior art, the present invention has the following beneficial effects: the flux charging control system of the blowing furnace realizes intelligent control of feeding and blowing slag by establishing a flux calculation and correction model, logical judgment of each process condition, and equipment action control, which is conducive to stabilizing the quality of blowing products, reducing flux consumption and blowing slag, reducing smelting fuel consumption, improving production safety factor, reducing labor intensity of personnel, and improving the stability of the blowing furnace. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the material carrying structure of the flux charging control system for the blowing furnace of this utility model;

[0012] Figure 2This is a flowchart of the flux charging control system for a blowing furnace according to the first embodiment of this utility model.

[0013] Figure 3 This is a flowchart of the flux feeding control system for a blowing furnace according to the second embodiment of this utility model.

[0014] Explanation of reference numerals in the attached drawings: 1. Flux preparation subsystem; 101. Silo vibratory unit; 102. First belt conveyor; 103. Flux intermediate silo; 104. Intermediate silo fullness judgment and control device; 1041. Level sensor; 1042. Camera device; 2. Flux feeding subsystem; 201. Second belt conveyor; 202. Flux discharge port; 3. Flux control subsystem; 301. Flux calculation module; 302. First temperature detection module; 3021. First temperature sensor; 3022. Second temperature sensor; 303. Flux port blockage monitoring module; 304. Slag discharge status detection module; 305. First logic controller; 4. Blowing slag type control subsystem; 401. Slag detection and analysis module; 402. Flux feeding correction module; 403. Second logic controller. Detailed Implementation

[0015] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The embodiments shown below do not limit the scope of the utility model as described in the claims. Furthermore, the complete contents of the configurations shown in the following embodiments are not limited to those necessary for the solution of the utility model as described in the claims.

[0016] A novel flux charging control system for blowing furnaces, such as Figure 1 and Figure 2 As shown, the system includes a flux preparation subsystem 1, a flux supply subsystem 2, a flux control subsystem 3, and a blowing slag type control subsystem 4. The flux preparation subsystem 1 consists of a silo vibrating unit 101, a first belt conveyor 102, a flux intermediate silo 103, and an intermediate silo full-fill determination control device 104. The intermediate silo full-fill determination control device 104 receives signals from a level sensor 1041 located on the upper edge of the inner wall of the flux intermediate silo 103 and a camera device 1042 fixed above the flux intermediate silo 103 through a third logic controller. It uses "AND" and "OR" relationships to control the start and stop operations of the first belt conveyor and the silo vibrating unit to realize the flux preparation function of the blowing furnace.

[0017] The working principle of the flux preparation subsystem 1 is as follows: When the flux intermediate silo is not full, the first belt conveyor is started. After the belt conveyor is running normally, the silo vibrating unit is started to complete the flux supply from the flux ore bin to the flux intermediate silo. If the flux intermediate silo is full while the system is preparing flux, the vibrating device of the silo vibrating unit must be stopped first. The first belt conveyor is stopped only after the vibrating device is completely shut down. A certain amount of adjustment space should be reserved for the flux intermediate silo during the preparation process. The flux intermediate silo should not be overfilled to avoid equipment damage or increased labor intensity and operational risks. When the system is full, the silo vibrating unit 101 and the first belt conveyor 102 at the upper end should not be started to ensure stable and safe operation of the equipment during this process. The belt conveyor is equipped with isolation nets and guardrails to achieve effective physical isolation between personnel and operating equipment. At the same time, an emergency stop device and interlock function are set up on site to facilitate emergency handling. If the operating equipment malfunctions, it should be stopped for handling to ensure the safety of personnel.

[0018] The flux feeding subsystem 2 consists of a second belt conveyor 201, a flux discharge port 202, a weighing device, and a human-machine isolation device. The input end of the second belt conveyor 201 is connected to the discharge port of the intermediate flux bin 103, and the output end extends to the flux discharge port 202 of the blowing furnace to ensure the stability of the flux feeding state.

[0019] The flux control subsystem 3 consists of a flux calculation module 301, a first temperature detection module 302, a flux inlet blockage monitoring module 303, a slag discharge status detection module 304, and a first logic controller 305. The input terminals of the first logic controller 305 are communicatively connected to the flux calculation module 301, the first temperature detection module 302, the flux inlet blockage monitoring module 303, and the slag discharge status detection module 304, respectively. The output terminal of the first logic controller 305 is communicatively connected to the second belt conveyor 201, using AND and OR relationships to control the start and stop operations of the second belt conveyor 201, ensuring the stability of the blowing process and the safe operation of the equipment. The flux calculation module 301 collects raw material composition information, furnace feed quantity, smelting process production parameters, cumulative production time, and furnace feed quantity during blowing. The required flux dosage for the blowing furnace is calculated by comprehensively considering the cumulative value of the material quantity and the target parameters of the blowing slag structure. Based on the actual production situation, a preliminary flux addition method is determined. The first temperature detection module 302 includes a first temperature sensor 3021 and a second temperature sensor 3022. The first temperature sensor 3021 is located at the flux inlet and is used to detect the melt temperature inside the furnace, which is the first melt temperature. The second temperature sensor 3022 is located at the crude copper discharge outlet of the blowing furnace and is used to detect the melt temperature at the discharge outlet, which is the second melt temperature. The first logic controller 305 determines the next control action of the second belt conveyor 201 based on the supplementary flux dosage, melt temperature, whether slag is being discharged, and whether the blowing flux inlet is unobstructed, as output by the flux calculation module 301. The specific determination process is as follows:

[0020] (1) The replenishment of flux is one of the start-up and shutdown conditions of the second belt conveyor 201. The second belt conveyor 201 can only be started after the replenishment of flux is met. This condition is a "yes (and 1)" relationship for the operation of the second belt conveyor 201. If the replenishment of flux is not met, the second belt conveyor 201 shall not be started. This condition is a "no (or 1)" relationship for the stop operation of the second belt conveyor 201. The judgment standard is mainly based on the comparison between the calculated value of the flux calculation model and the actual amount added. When the calculated value is greater than the actual amount added, the "yes (and 1)" relationship is adopted, and when the calculated value is less than the actual amount added, the "no (or 1)" relationship is adopted. The setting of this condition is based on meeting the flux addition in the blowing process and is highly compatible with other production processes to ensure the safety and stability of the production control of the blowing furnace.

[0021] (2) The melt temperature is one of the start-up and shutdown conditions of the second belt conveyor 201. When the first melt temperature measured at the flux discharge port and the second melt temperature measured at the crude copper discharge port of the blowing furnace both reach the target value, the second belt conveyor is started. This condition is the "meeting the target (and 2)" relationship for the operation of the second belt conveyor 201. If either the first melt temperature or the second melt temperature does not reach the target value, the second belt conveyor 201 shall not be started. This condition is the "not meeting the target (or 2)" relationship for the second belt conveyor 201 to stop operating. The setting of this condition is based on the operating status and stability of the blowing process, ensuring that the blowing melt temperature is controlled within the range required by the process standard, reducing a series of adverse effects caused by abnormal temperature, and further promoting the stability of process production and the safety of equipment operation.

[0022] (3) The unobstructed state of the flux discharge port is one of the start-stop conditions of the second belt conveyor 201. The second belt conveyor 201 can only be started when the flux discharge port is unobstructed. This condition is the "yes (and 3)" relationship for the operation of the second belt conveyor 201. When the flux discharge port is not unobstructed, the second belt conveyor 201 must not be started. This condition is the "no (or 3)" relationship for the second belt conveyor 201 to stop operation. The front end of the blowing flux port is connected to the feeding system, and its rear end is connected to the blowing furnace kiln. It plays a role in connecting the upper and lower parts. Only by keeping the blowing furnace flux port 202 unobstructed can the smooth operation of the blowing flux feeding control be met.

[0023] (4) The slag discharge status of the blowing furnace is one of the start-up and shutdown conditions of the second belt conveyor 201. When the blowing furnace has already discharged slag or there is a short-term slag discharge plan, the air quenching pressure, water jacket temperature, and water pump current all increase to the target values ​​of the slag discharge operation parameters, and the second belt conveyor 201 shall not be started. This condition is a "yes (or 4)" relationship for the second belt conveyor 201 to stop running. When the air quenching pressure, water jacket temperature, and water pump current do not reach the target values ​​of the slag discharge operation parameters during the slag discharge process, the second belt conveyor 201 is started. This condition is a "no (and 4)" relationship for the second belt conveyor 201 to run. As an endothermic mineral in the blowing process, flux affects the temperature of the melt in the blowing furnace and the properties of the slag, which may have an adverse effect on the slag discharge process. In order to ensure the smooth operation of the blowing slag discharge process, this control requirement is set.

[0024] The blowing slag shape determination and control system 4 consists of a slag detection and analysis module 401, a flux feeding correction module 402, and a second logic controller 403. The input of the second logic controller 403 is communicatively connected to the output of the slag detection and analysis module 401, and its output is communicatively connected to the input of the flux feeding correction module 402. The output of the flux feeding correction module 402 is communicatively connected to the flux calculation module 301. By comparing the blowing slag detection and analysis results obtained by the slag detection and analysis module 401 with the blowing slag process control target value, the system determines whether the blowing slag shape structure meets the process requirements. If it does, the current flux feeding operation of the blowing furnace is completed; if it does not meet the requirements, the system will execute a correction flux calculation model. The output of the flux feeding correction module 402 is communicatively connected to the flux calculation module 301. Based on the current blowing slag shape structure, slag quantity, actual flux addition, and calculated quantity, the system calculates the flux correction value to further ensure that the blowing slag shape structure meets the process production requirements.

[0025] In the second embodiment of this utility model, the slag detection and analysis module 401 further includes a third temperature sensor and a slag temperature logic controller. The third temperature sensor is set at the slag discharge port of the blowing furnace to collect the slag temperature and is connected to the input terminal of the slag temperature logic controller at the signal output terminal to perform supplementary temperature judgment. The output terminal of the slag temperature logic controller is connected to the second belt conveyor 201 to start the operation. The judgment and control principle is as follows: When the slag temperature exceeds the process control target limit (i.e., "exceeding the limit"), it has seriously affected the service life of the furnace and the safety of production operation. This method is an emergency response measure. The execution of the slag discharge condition "yes (or 4)" is cancelled. At the same time, it is combined with the judgment process of (1), (2), and (3) of the next control action of the second belt conveyor 201. After the start-up conditions of the second belt conveyor 201 are met, the belt conveyor 201 is started to replenish the missing amount of slag at the lower feed port for the cooling operation of the melt inside the blowing furnace. When the slag temperature does not exceed the process control target limit (i.e., "not exceeding the limit"), the execution of the slag discharge condition "yes (or 4)" is executed. It is combined with the judgment process of (1), (2), (3), and (4) of the next control action of the second belt conveyor 201 to stop the operation of the second belt conveyor 201.

[0026] In the third embodiment of this utility model, the lower space of the flux intermediate chamber is composed of multiple parallel compartments. The compartments share the top space and are connected to the feed inlet of the flux intermediate chamber. The discharge outlet of the compartment is connected to the belt conveyor of multiple flux feeding subsystems to ensure uniform material distribution and enable multiple production lines to prepare materials simultaneously.

[0027] The foregoing description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A novel flux charging control system for a blowing furnace, characterized in that, It includes a flux preparation subsystem, a flux supply subsystem, a flux control subsystem, and a blowing slag control subsystem; The flux preparation subsystem includes a hopper vibrating unit, a first belt conveyor, a second belt conveyor, a flux intermediate silo, and an intermediate silo full-fill determination and control device. The first belt conveyor extends from the discharge end of the hopper vibrating unit to the inlet of the flux intermediate silo. The output end of the intermediate silo full-fill determination and control device is communicatively connected to the hopper vibrating unit and the first belt conveyor. The flux feeding subsystem includes a belt conveyor, a flux discharge port, a human-machine isolation device, a weighing device, and a monitoring device. The input end of the second belt conveyor is connected to the discharge port of the intermediate flux bin, and the output end extends to the flux discharge port. The flux control subsystem includes a flux calculation module, a first temperature detection module, a flux port blockage monitoring module, a slag discharge status detection module, and a first logic controller, all arranged in parallel. The input terminal of the first logic controller is communicatively connected to the output terminals of the flux calculation module, the first temperature detection module, the flux port blockage monitoring module, and the slag discharge status detection module, respectively. The output terminal of the first logic controller is communicatively connected to the second belt conveyor. The blowing slag control subsystem includes a slag detection and analysis module, a flux feeding correction module, and a second logic controller. The input terminal of the second logic controller is communicatively connected to the output terminal of the slag detection and analysis module, and its output terminal is communicatively connected to the input terminal of the flux feeding correction module. The output terminal of the flux feeding correction module is communicatively connected to the flux calculation module.

2. The novel flux charging control system for a blowing furnace according to claim 1, characterized in that, The lower space of the flux intermediate chamber is composed of multiple parallel compartments, which share a top space connected to the feed inlet of the flux intermediate chamber.

3. The novel flux charging control system for a blowing furnace according to claim 1, characterized in that, The intermediate silo full-material determination and control device includes a material level sensor installed on the upper edge of the inner wall of the flux intermediate silo, a camera device fixed above the flux intermediate silo, and a third logic controller. The output of the third logic controller is communicatively connected to the silo electric vibration unit and the first belt conveyor.

4. The novel flux charging control system for a blowing furnace according to claim 1, characterized in that, The first temperature detection module includes a first temperature sensing unit and a second temperature sensing unit, wherein the first temperature sensing unit is located at the flux inlet and the second temperature sensing unit is located at the crude copper discharge outlet of the smelting furnace.

5. The novel flux charging control system for a blowing furnace according to claim 1, characterized in that, The flux calculation module includes a first information storage unit and a flux calculation unit. The information storage unit includes a first computer storage medium containing flux composition information, furnace feed amount, smelting process production parameters, cumulative production time, cumulative value of blowing furnace feed amount, and target value of blowing slag structure. The output of the flux calculation unit is connected to the first logic controller.

6. The novel flux charging control system for a blowing furnace according to claim 1, characterized in that, The slag detection and analysis module also includes a third temperature sensing unit and a slag temperature logic controller. The third temperature sensing unit is communicatively connected to the input of the slag temperature logic controller at its signal output end, and the output of the slag temperature logic controller is communicatively connected to the second belt conveyor.

7. The novel flux charging control system for a blowing furnace according to claim 5, characterized in that, The flux feeding correction module includes a second information storage unit and a difference calculation unit. The input end of the difference calculation unit is interconnected with the slag detection and analysis module and the second information storage unit, and the output end is connected to the flux calculation unit. The second information storage unit includes a computer storage medium with the target value of the blowing slag process control.

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