A detection control device for a flotation separation process

Abstract

This utility model discloses a detection and control device for a flotation process, including a PLC controller and a motor control branch and an instrument detection and feedback branch connected to it. The motor control branch includes: a thickener bottom flow slurry pump circuit, a middlings pump pool slurry pump circuit, a stirring tank circuit, a fine flotation machine circuit, a roughing flotation machine circuit, and a scavenging flotation machine circuit, all connected to the PLC controller. The detection and feedback branch includes several concentration meters, flow meters, level gauges, fine flotation machine valves, roughing flotation machine valves, and scavenging flotation machine valves, all connected to the PLC controller. This utility model, by integrating a phase loss protection circuit and level detection, can significantly optimize the control of flotation process equipment and stabilize equipment operation.

Description

Technical Field

[0001] This utility model relates to the field of mineral processing production monitoring, and in particular to a detection and control device for a flotation process. Background Technology

[0002] Flotation is a crucial production stage in mineral processing. However, existing flotation processes suffer from low production targets and unstable equipment operation. The current direct-start motor circuit structure lacks phase loss protection. When any phase voltage is lost during operation, the motor is forced to operate in an asymmetrical state with one phase missing. The remaining two windings then bear the load originally shared by the three phases, causing a sudden surge in current in the remaining two phases. This enormous current generates heat far exceeding the factory-designed standard. Existing overload protection in the circuit typically uses thermal relays, but their response speed is relatively slow, failing to cut off the power supply before the insulation material is permanently damaged by instantaneous overheating. Utility Model Content

[0003] This application provides a detection and control device for the flotation process. Through a dual design integrating phase loss protection and intelligent liquid level control, it significantly optimizes flotation process parameters, improves system reliability, enhances flotation performance, stabilizes equipment operation, and reduces resource waste. By connecting a 380V relay and a 380V contactor coil in series with each of the three-phase power supplies, the contactor can cut off the motor power supply within less than 100ms when any phase power is lost, preventing overheating of the windings and damage to the insulation material and motor caused by huge currents. This eliminates the need for current transformers or dedicated protection chips, achieving protection through the mechanical linkage of the relay and contactor, reducing hardware costs by more than 40%.

[0004] A detection and control device for a flotation process includes a PLC controller and a motor control branch and an instrument detection and feedback branch connected thereto. The motor control branch includes: a thickener bottom flow slurry pump circuit, a middlings pump pool slurry pump circuit, a stirring tank circuit, a fine flotation machine circuit, a roughing flotation machine circuit, and a scavenging flotation machine circuit, all connected to the PLC controller. The detection and feedback branch includes several concentration meters, flow meters, level gauges, fine flotation machine valves, roughing flotation machine valves, and scavenging flotation machine valves, all connected to the PLC controller.

[0005] The motor control branch includes: AC power supply connected via circuit breaker QF1, fuse FU1, fuse FU2, and fuse FU3 to the thickener underflow slurry pump circuit, middlings ore pump pool slurry pump circuit, agitator circuit, fine flotation machine circuit, rougher flotation machine circuit, and scavenger flotation machine circuit; the thickener underflow slurry pump circuit consists of a first frequency converter VFD1 and a thickener underflow slurry pump motor M1 connected in sequence; the middlings ore pump pool slurry pump circuit consists of a second frequency converter VFD2 and a middlings ore pump pool slurry pump motor M2 connected in sequence; the agitator circuit consists of a first contactor KM1 and a first thermal relay F... R1, stirring tank motor M3; the fine flotation machine circuit consists of the second contactor KM2, the second thermal relay FR2, and the fine flotation machine motor M4 connected in sequence; the roughing flotation machine circuit consists of the third contactor KM3, the third thermal relay FR3, and the roughing flotation machine motor M5 connected in sequence; the scavenging flotation machine circuit consists of the fourth contactor KM4, the fourth thermal relay FR4, and the scavenging flotation machine motor M6 connected in sequence; the PLC controller is connected to the first frequency converter VFD1, the second frequency converter VFD2, the first contactor KM1, the first contactor KM2, the first contactor KM3, and the first contactor KM4 respectively.

[0006] The circuit for the thickener bottom flow slurry pump and the circuit for the middlings pump pool slurry pump also include a phase loss protection circuit.

[0007] The direct-start motor control box is equipped with a three-position knob, a motor running indicator light, a start button, and a stop button. The power supply for phase L1 is connected to the upper end of the three-position knob via fuse FU1. The local terminals of the three-position knob are connected in sequence to the stop button and the start button, and then to the normally closed fault contact of the FR1 thermal relay and one end of the KA1 relay coil. The other end of the KA1 relay coil is connected to phase L3 via fuse FU3, and also to phase L2 via contactor KM1, the second normally open contact of the KA1 relay, and fuse FU2. The start button SB2 is connected in parallel with the first normally open contact of the KA1 relay, and the start button SB2 is also connected in parallel with the normally open contact circuit of the KA4 relay via the remote terminal of the three-position knob.

[0008] The remote terminal of the three-position knob is connected to the KA3 relay coil and then grounded; phase L1 is connected to the motor running indicator light via fuse FU1 and the first normally open contact of the KA2 relay and then grounded; phase L1 is also connected to the KA3 relay coil via fuse FU1 and the normally open contact of the KM1 contactor.

[0009] The second normally open contact of relay KA2 is connected to the PLC DI run signal, the second normally open contact of relay KA3 is connected to the PLC DI remote signal, and the PLC DO start / stop signal is connected to the coil of relay KA4.

[0010] The detection feedback branch includes: the control cabinet's single-phase power (L, N, PE) is output as a total power supply via circuit breaker QF1; the total power supply is also connected to a DC24V switching power supply via a second circuit breaker QF2, and then connected to a fourth circuit breaker QF4 before being connected to a PLC controller; the PLC controller is connected to several concentration meters, flow meters, and level gauges on-site to collect signals, and is also connected to the valves of the fine flotation machine, roughing flotation machine, and scavenging flotation machine on-site to control valve opening and pipeline flow; the PLC controller is also connected to a host computer for communication; the +220V power supply is connected to various sensors and valves via a third circuit breaker QF3.

[0011] The level gauges include a stirred tank level gauge, a concentrate pump pool level gauge, a middlings pump pool level gauge, a fine flotation machine level gauge, a roughing flotation machine level gauge, and a scavenging flotation machine level gauge; the concentration gauge is a thickener underflow concentration gauge; the flow meters include a thickener underflow flow meter and a flotation machine blower flow meter.

[0012] The motor control branch also includes a blower circuit and a dosing tank metering pump circuit;

[0013] The blower circuit includes: +380V power supply connected to the fifth contactor, the fifth thermal relay, and the blower motor via short circuit QF1, fuse FU1, fuse FU2, and fuse FU3; the dosing tank metering pump circuit includes: +380V power supply connected to the sixth contactor, the sixth thermal relay, and the dosing tank metering pump motor via circuit breaker QF1.

[0014] The PLC controller is also connected to the current sensor of the stirring tank, the current sensor of the fine flotation machine, the current sensor of the roughing flotation machine, the current sensor of the scavenging flotation machine, the current sensor of the blower, and the current sensor of the metering pump of the dosing tank.

[0015] This utility model has the following beneficial effects and advantages:

[0016] 1. Reliable power cut-off: By connecting a 380V relay and a 380V contactor coil in series with the three-phase power supply, the contactor can cut off the motor power supply within less than 100ms when any phase power is lost, avoiding the damage to the insulation material and the motor caused by huge current overheating of the winding.

[0017] 2. Low-cost burnout prevention eliminates the need for current transformers or dedicated protection chips. Protection is achieved through mechanical linkage of relays and contactors, reducing hardware costs by more than 40%. Attached Figure Description

[0018] Figure 1 This is a schematic diagram illustrating the application scenario of the detection and control device of this utility model.

[0019] Figure 2 This is a schematic diagram of the detection and control device of this utility model.

[0020] Figure 3 This is an electrical schematic diagram of the motor control branch in an embodiment of this application.

[0021] Figure 4 This is a circuit diagram for motor phase loss protection in an embodiment of this application.

[0022] Figure 5 This is the electrical schematic diagram of the detection feedback branch in the embodiments of this application. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0024] An embodiment of this utility model provides a detection and control device for a flotation process, used as field equipment in the flotation process.

[0025] like Figure 1 As shown, the on-site equipment includes a thickener, a thickener underflow slurry pump, a mixing tank, a dosing tank, a dosing tank metering pump, a roughing flotation machine, a cleaning flotation machine, a concentrate pump tank, a scavenging flotation machine, a middlings pump tank, a middlings pump tank slurry pump, and a blower. The thickener is connected to the thickener underflow slurry pump via metal pipes. The thickener underflow slurry pump is connected to the mixing tank via metal pipes. Underflow concentration meters and flow meters are installed on the pipes. The dosing tank is connected to the dosing tank metering pump via metal pipes. The dosing tank metering pump is connected to the mixing tank via metal pipes. The mixing tank is connected to the roughing flotation machine via metal pipes. The roughing flotation machine transports concentrate to the cleaning flotation machine via metal pipes. The roughing flotation machine transports coarse tailings to the scavenging flotation machine via metal pipes. The cleaning flotation machine… The concentrate is transported to the concentrate pump pool via metal pipelines. The tailings are transported to the roughing flotation machine via metal pipelines. The concentrate and tailings are transported to the middlings pump pool via metal pipelines. The rough and concentrate tailings are transported to the tailings area via metal pipelines. The middlings pump pool is connected to the middlings pump pool slurry pump via metal pipelines. The middlings pump pool slurry pump is connected to the thickener via metal pipelines. Blowers are connected to the concentrate flotation machine, roughing flotation machine, and scavenging flotation machine via metal pipelines. A flotation machine air flow meter is installed at the blower outlet.

[0026] The mixing tank is equipped with a level gauge to detect the level of the slurry and reagent mixture inside; the concentrate pump tank is equipped with a level gauge to detect the level of the slurry and reagent mixture inside; the fine flotation machine is equipped with a level gauge to detect the level of the slurry and reagent mixture inside; the roughing flotation machine is equipped with a level gauge to detect the level of the slurry and reagent mixture inside; the scavenging flotation machine is equipped with a level gauge to detect the level of the slurry and reagent mixture inside; and the middlings pump tank is equipped with a level gauge to detect the level of the slurry and reagent mixture inside.

[0027] like Figure 2 As shown, a level detection and control device for a flotation process according to this utility model includes: a PLC controller and a motor control branch and an instrument detection feedback branch connected to it respectively; the motor control branch includes: a thickener underflow slurry pump circuit, a middlings pump pool slurry pump circuit, a stirring tank circuit, a fine flotation machine circuit, a roughing flotation machine circuit, a scavenging flotation machine circuit, a blower circuit, and a reagent tank metering pump circuit, all connected to the PLC controller respectively; the detection feedback branch includes a thickener underflow concentration meter, a thickener underflow flow meter, a flotation machine blower flow meter, a stirring tank level gauge, a concentrate pump pool level gauge, a middlings pump pool level gauge, a fine flotation machine level gauge, a roughing flotation machine level gauge, a scavenging flotation machine level gauge, a fine flotation machine valve, a roughing flotation machine valve, and a scavenging flotation machine valve, all connected to the PLC controller respectively.

[0028] like Figure 3As shown, the motor control branch includes a first frequency converter VFD1, a thickener underflow slurry pump motor M1, a second frequency converter VFD2, a middlings pump pool slurry pump motor M2, a first contactor KM1, a first thermal relay FR1, a stirring tank motor M3, a second contactor KM2, a second thermal relay FR2, a fine flotation machine motor M4, a third contactor KM3, a third thermal relay FR3, a roughing flotation machine motor M5, and a fourth contactor KM4, a fourth thermal relay FR4, a scavenging flotation machine motor M6. Furthermore, the current in the motor control branch flows through the first frequency converter VFD1 into the thickener underflow slurry pump motor M1, through the second frequency converter VFD2 into the middlings pump pool slurry pump motor M2, through the first contactor KM1 and the first thermal relay FR1 into the stirring tank motor M3, through the second contactor KM2 and the second thermal relay FR2 into the fine flotation machine motor M4, through the third contactor KM3 and the third thermal relay FR3 into the roughing flotation machine motor M5, and through the fourth contactor KM4 and the fourth thermal relay FR4 into the scavenging flotation machine motor M6. The above circuit structure enables the following: the power supply from the distribution cabinet enters through circuit breaker QF1, fuse FU1, fuse FU2, and fuse FU3, and then distributes the power to frequency converters VFD1 and VFD2, contactor KM1 and thermal relays FR1, KM2 and FR2, contactor KM3 and FR3, and contactor KM4 and FR4, thereby controlling the thickener underflow slurry pump motor M1, the middlings pump pool slurry pump motor M2, the mixing tank motor M3, the fine flotation machine motor M4, the roughing flotation machine motor M5, and the scavenging flotation machine motor M6.

[0029] The motor control branch also includes a fifth contactor KM5, a fifth thermal relay FR5, a blower motor M7, a sixth contactor KM6, a sixth thermal relay FR6, and a dosing tank metering pump motor M8. Furthermore, the main circuit current flows through the fifth contactor KM5 and the fifth thermal relay FR5 into the blower motor M7, and through the sixth contactor KM6 and the sixth thermal relay FR6 into the dosing tank metering pump motor M8.

[0030] like Figure 4As shown, a phase loss protection circuit is added to the direct-start motor control. A direct-start motor control box is installed on-site, equipped with a three-position knob, motor running indicator light, start button, and stop button. The L1 phase power supply is connected to the upper end of the three-position knob. The local terminal of the three-position knob is connected to the stop button and start button (the start button is connected in parallel with the first normally open contact of the KA1 relay). This is then connected in parallel with the remote terminal of the three-position knob to the normally open contact circuit of the KA4 relay, and further connected to the normally closed fault contact of the FR thermal relay and the KA1 relay coil. One path returns to the L3 phase, and the other path connects to the second normally open contact of the KA1 relay and the KM1 contactor, returning to the L2 phase (for phase loss protection; the KM1 contactor will not close if any phase voltage is missing). Simultaneously, the remote terminal of the three-position knob is connected to the KA3 relay coil. The motor running indicator light is connected to the first normally open contact of the KA2 relay. The second normally open contact of the KA2 relay is connected to the PLC DI running signal. The second normally open contact of the KA3 relay is connected to the PLC DI remote signal. The DO start / stop signal is connected to the KA4 relay coil.

[0031] like Figure 5 The diagram shows the electrical schematic of the detection feedback branch. The detection feedback branch includes: the control cabinet's single-phase power (L, N, PE) is output as a main power supply via fuse QF1. This main power supply is then connected to a DC 24V switching power supply via a second circuit breaker QF2, and then to a fourth circuit breaker QF4 before connecting to the PLC controller. The PLC controller connects to several field sensors to collect signals and also connects to the valves of the fine flotation machine, roughing flotation machine, and scavenging flotation machine to control pipeline opening. The PLC controller also connects to a host computer for communication. A +220V power supply is connected to each sensor and valve via a third circuit breaker QF3. Through this circuit structure, the control cabinet power supply enters the main power switch via fuse QF1. The main power switch then supplies power to circuit breakers QF2 and QF3. Circuit breaker QF2 connects to the DC 24V switching power supply, converting the 220V power to 24V to provide 24V voltage to the programmable logic controller (PLC).

[0032] The detection feedback branch also includes a programmable logic controller (PLC), a switch, DI modules, DO modules, AI modules, AO modules, a host industrial computer, and relays KA1, KA2, KA3, KA4, KA5, KA6, KA7, and KA8. The PLC is used to collect field data and control various field devices. The PLC is connected via relay KA1 to the first frequency converter VFD1 of the thickener underflow slurry pump motor M1; via relay KA2 to the second frequency converter VFD2 of the middlings pump pool slurry pump motor M2; via relay KA3 to the first contactor KM1 of the mixing tank motor M3; via relay KA4 to the second contactor KM2 of the fine flotation machine motor M4; via relay KA5 to the third contactor KM3 of the roughing flotation machine motor M5; and via relay KA6 to the fourth contactor KM4 of the scavenging flotation machine motor M6. The control circuit also includes relays KA7 and KA8. Furthermore, the programmable logic controller (PLC) is connected to the fifth contactor KM5 of the blower motor via the seventh relay KA7, and to the sixth contactor KM6 of the metering pump motor via the eighth relay KA8. The digital output modules of the PLC, Q0.0 to Q0.7, are sequentially connected to relays KA1 to KA8, which in turn control the start and stop of the thickener underflow slurry pump, the middlings pump pool slurry pump, the mixing tank, the cleaning flotation machine, the roughing flotation machine, the scavenging flotation machine, the blower, and the metering pump.

[0033] The programmable logic controller (PLC) used is a Siemens S7-1500. The PLC's CPU and the host industrial control computer (HPC) are connected via fiber optic cable through a switch for data exchange. Production operators control the field equipment through the HPC to ensure smooth production. The PLC and related electrical components are installed in a control cabinet, which is then installed in the field. Concentration meters, flow meters, level gauges, and current sensors are all connected to the PLC in the control cabinet via shielded signal cables to collect field data and control the field equipment. The thickener underflow concentration meter collects the thickener underflow concentration, and the mixing tank level gauge collects the mixing tank level. The PLC adjusts the frequency of the thickener underflow slurry pump based on the collected data, thereby controlling the thickener underflow concentration. The PLC output module is connected to the frequency setpoint signal of the slurry pump M2 in the ore pumping station via shielded signal cables. The PLC controls the frequency of the slurry pump M2 in the ore pumping station to regulate the ore pumping station level. The system controls the underflow concentration of the thickener, the liquid level in the mixing tank, and the liquid level in the middlings pump tank to ensure that each flotation unit operates stably under optimal conditions. The programmable logic controller's analog output (AO) module connects to: the VFD1 frequency converter for the thickener underflow slurry pump; the VFD2 frequency converter for the middlings pump tank slurry pump; the valves for the cleaning flotation unit; the valves for the roughing flotation unit; and the valves for the scavenging flotation unit.

[0034] With the above setup, the power supply for the motor control branch enters the main power switch, passes through the power protection device fuse QF1, and then supplies power to the thickener underflow slurry pump M1, middlings pump pool slurry pump M2, mixing tank M3, fine flotation machine M4, roughing flotation machine M5, and scavenging flotation machine M6 respectively. The circuit is connected to the main power switch. The control circuit connects to the operation, fault, and remote feedback signals of each field device through the programmable logic controller (PLC) digital input (DI) module. It connects to each relay through the PLC digital output (DO) module, thereby controlling the start and stop of each device. The PLC analog input (AI) module connects to the concentration meter, flow meter, level gauge, current sensor, and frequency and current feedback of the frequency converter in the field. The PLC analog output (AO) module connects to the frequency converters of each device, providing the set frequency.

[0035] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A detection and control device for a flotation process, characterized in that, It includes a PLC controller and motor control branches and instrumentation detection feedback branches connected to it respectively; the motor control branches include: a thickener bottom flow slurry pump circuit, a middlings pump pool slurry pump circuit, a stirring tank circuit, a fine flotation machine circuit, a roughing flotation machine circuit, and a scavenging flotation machine circuit, all connected to the PLC controller respectively; the detection feedback branches include several concentration meters, flow meters, level gauges, fine flotation machine valves, roughing flotation machine valves, and scavenging flotation machine valves, all connected to the PLC controller respectively.

2. The detection and control device for a flotation process according to claim 1, characterized in that, The motor control branch includes: AC power supply connected via circuit breaker QF1, fuse FU1, fuse FU2, and fuse FU3 to the thickener underflow slurry pump circuit, middlings ore pump pool slurry pump circuit, agitator circuit, fine flotation machine circuit, rougher flotation machine circuit, and scavenger flotation machine circuit; the thickener underflow slurry pump circuit consists of a first frequency converter VFD1 and a thickener underflow slurry pump motor M1 connected in sequence; the middlings ore pump pool slurry pump circuit consists of a second frequency converter VFD2 and a middlings ore pump pool slurry pump motor M2 connected in sequence; the agitator circuit consists of a first contactor KM1 and a first thermal relay F... R1, stirring tank motor M3; the fine flotation machine circuit consists of the second contactor KM2, the second thermal relay FR2, and the fine flotation machine motor M4 connected in sequence; the roughing flotation machine circuit consists of the third contactor KM3, the third thermal relay FR3, and the roughing flotation machine motor M5 connected in sequence; the scavenging flotation machine circuit consists of the fourth contactor KM4, the fourth thermal relay FR4, and the scavenging flotation machine motor M6 connected in sequence; the PLC controller is connected to the first frequency converter VFD1, the second frequency converter VFD2, the first contactor KM1, the first contactor KM2, the first contactor KM3, and the first contactor KM4 respectively.

3. The detection and control device for a flotation process according to claim 2, characterized in that, The circuit for the thickener bottom flow slurry pump and the circuit for the middlings pump pool slurry pump also include a phase loss protection circuit. The direct-start motor control box is equipped with a three-position knob, a motor running indicator light, a start button, and a stop button. The power supply for phase L1 is connected to the upper end of the three-position knob via fuse FU1. The local terminals of the three-position knob are connected in sequence to the stop button and the start button, and then to the normally closed fault contact of the FR1 thermal relay and one end of the KA1 relay coil. The other end of the KA1 relay coil is connected to phase L3 via fuse FU3, and also to phase L2 via contactor KM1, the second normally open contact of the KA1 relay, and fuse FU2. The start button SB2 is connected in parallel with the first normally open contact of the KA1 relay, and the start button SB2 is also connected in parallel with the normally open contact circuit of the KA4 relay via the remote terminal of the three-position knob. The remote terminal of the three-position knob is connected to the KA3 relay coil and then grounded; phase L1 is connected to the motor running indicator light via fuse FU1 and the first normally open contact of the KA2 relay and then grounded; phase L1 is also connected to the KA3 relay coil via fuse FU1 and the normally open contact of the KM1 contactor. The second normally open contact of relay KA2 is connected to the PLC DI run signal, the second normally open contact of relay KA3 is connected to the PLC DI remote signal, and the PLC DO start / stop signal is connected to the coil of relay KA4.

4. The detection and control device for a flotation process according to claim 1, characterized in that, The detection feedback branch includes: the control cabinet's single-phase power (L, N, PE) is output as a total power supply via circuit breaker QF1; the total power supply is also connected to a DC24V switching power supply via a second circuit breaker QF2, and then connected to a fourth circuit breaker QF4 before being connected to a PLC controller; the PLC controller is connected to several concentration meters, flow meters, and level gauges on-site to collect signals, and is also connected to the valves of the fine flotation machine, roughing flotation machine, and scavenging flotation machine on-site to control valve opening and pipeline flow; the PLC controller is also connected to a host computer for communication; the +220V power supply is connected to various sensors and valves via a third circuit breaker QF3.

5. A detection and control device for a flotation process according to claim 1 or 4, characterized in that, The level gauges include a stirred tank level gauge, a concentrate pump pool level gauge, a middlings pump pool level gauge, a fine flotation machine level gauge, a roughing flotation machine level gauge, and a scavenging flotation machine level gauge; the concentration gauge is a thickener underflow concentration gauge; the flow meters include a thickener underflow flow meter and a flotation machine blower flow meter.

6. The detection and control device for a flotation process according to claim 1, characterized in that, The motor control branch also includes a blower circuit and a dosing tank metering pump circuit; The blower circuit includes: +380V power supply connected to the fifth contactor, the fifth thermal relay, and the blower motor via short circuit QF1, fuse FU1, fuse FU2, and fuse FU3; the dosing tank metering pump circuit includes: +380V power supply connected to the sixth contactor, the sixth thermal relay, and the dosing tank metering pump motor via circuit breaker QF1.

7. The detection and control device for a flotation process as described in claim 3, characterized in that, The PLC controller is also connected to the current sensor of the stirring tank, the current sensor of the fine flotation machine, the current sensor of the roughing flotation machine, the current sensor of the scavenging flotation machine, the current sensor of the blower, and the current sensor of the metering pump of the dosing tank.

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