Dynamic Threshold Adjustment in X-Ray Ore Sorting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing beneficiation methods for phosphate ores, particularly in China, face challenges with high energy and chemical consumption, environmental unfriendliness, and fluctuating ore grades due to the use of conventional flotation methods, which are not effectively managed by X-ray sorting technology as ore grades vary significantly.
Innovation Solution
An intelligent sorting method based on dynamic adjustment of a threshold, utilizing an X-ray intelligent sorting system that initially treats ores to a predetermined granularity, performs grade detection, and dynamically adjusts the sorting threshold based on error rates to maintain consistent ore grades entering the flotation system, thereby optimizing the beneficiation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional flotation methods are used for phosphate ore beneficiation, then ore processing is achieved, but energy consumption and chemical consumption increase significantly
Solution Approach 1:
The patent applies preliminary action by implementing X-ray intelligent sorting before flotation to pre-separate high-grade ores from low-grade ores. This preliminary classification ensures that only high-grade ores enter the flotation process, reducing the volume of material requiring energy-intensive flotation treatment and thereby lowering overall energy consumption while maintaining processing efficiency
Solution Approach 2:
The patent applies local quality by creating different processing paths for different ore grades. High-grade ores are directly selected and sent to flotation, while low-grade ores are discarded. This localized quality-based separation optimizes resource allocation and reduces unnecessary energy expenditure on low-grade material
2Productivity
If conventional flotation methods are used for phosphate ore beneficiation, then ore processing is achieved, but environmental pollution increases due to tailing water treatment requirements
Solution Approach 1:
The patent applies preliminary action by implementing X-ray intelligent sorting before flotation to pre-separate high-grade ores from low-grade ores. This preliminary classification ensures that only high-grade ores enter the flotation process, reducing the volume of material requiring treatment and thereby lowering tailing water generation and associated environmental pollution
Solution Approach 2:
The patent applies discarding and recovering by systematically discarding low-grade ores that do not meet the threshold criteria through X-ray sorting. This selective discarding prevents low-grade material from entering the flotation process, reducing the amount of tailing water generated and the environmental burden of water treatment
3Ease of operation
If a fixed threshold is used in X-ray sorting, then sorting operation is simple, but the grade of ores entering flotation fluctuates significantly due to varying raw ore grades
Solution Approach 1:
The patent applies dynamics by implementing a dynamic threshold adjustment mechanism in the X-ray sorting system. The threshold is no longer fixed but automatically adapts based on real-time feedback from ore grade detection devices. This dynamic adjustment ensures that the sorting system maintains stable ore grade output despite variations in raw ore quality, while remaining operationally simple through automated control
Solution Approach 2:
The patent applies feedback by establishing a closed-loop control system where ore grade detection devices continuously monitor the grade of ores entering flotation. This detection information is fed back to the X-ray sorting system, which automatically adjusts the sorting threshold to maintain consistent ore grade. The feedback mechanism ensures stability without requiring manual intervention
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach stabilizes the grade of phosphate ores entering the flotation system, reduces energy and chemical consumption, and enhances environmental sustainability by dynamically adjusting the sorting threshold to maintain consistent ore quality, improving the overall efficiency and cost-effectiveness of the beneficiation process.
Implementation Method 1
ore blocks are irradiated by X-rays, and data information of the attenuation intensity of X-rays after X-rays after passing through the are blocks is detected by a detector
Data Source
AI summary
The present application relates to a method and system for performing intelligent sorting based on dynamic adjustment of a threshold. The method includes: sorting ores with a predetermined granularity by an intelligent sorting system according to a current grade threshold to output the sorted ores; performing grade detection on the fine ores to obtain a current state parameter of the fine ores; calculating a first error rate of a current comprehensive grade based on the current comprehensive grade and a target comprehensive grade, and in a case that the first error rate is not within a set range of a comprehensive error rate, calculating a dynamic adjustment step length for a grade threshold according to the current state parameter of the fine ores; and performing dynamic adjustment according to the dynamic adjustment step length and the current grade threshold to obtain the adjusted current grade threshold.