CN113737015B - Intelligent crude tin smelting system and method - Google Patents
Intelligent crude tin smelting system and method Download PDFInfo
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- CN113737015B CN113737015B CN202111130720.6A CN202111130720A CN113737015B CN 113737015 B CN113737015 B CN 113737015B CN 202111130720 A CN202111130720 A CN 202111130720A CN 113737015 B CN113737015 B CN 113737015B
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B25/00—Obtaining tin
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses an intelligent crude tin smelting system and method, wherein the system comprises the following steps: the management layer is used for receiving the management plan and sending management plan data to the execution manufacturing layer; the performing the manufacturing layer includes: the system comprises an MES management system, a smelting expert system and a spray gun expert system; the control layer is used for receiving real-time data and controlling the boiler equipment in the smelting process in real time; the equipment layer collects real-time data of boiler equipment in the smelting process and sends the data to the control layer and the execution manufacturing layer. The method comprises the following steps: collecting real-time data of boiler equipment in the smelting process in real time; and calculating and analyzing the operation plan data, the production management data and the real-time data, so as to realize intelligent analysis, intelligent adjustment, automatic optimization of the operation parameters and automatic deviation correction of main operation parameters, and timely alarm of abnormality. The invention effectively solves the problems of manual intervention, independent control and lack of unified control of each procedure in the original production process.
Description
Technical Field
The invention relates to the technical field of nonferrous metal intelligent roughing, in particular to an intelligent roughing tin smelting system and method.
Background
The tin rough smelting has the characteristics of more links, complex process and facility, etc. In recent years, the tin smelting technology has greatly progressed, and the tin smelting efficiency is greatly improved by adding tin smelting and oxygen enrichment in a Ausmelt top-blown furnace.
Along with the rapid development of modern industry and tin smelting technology, the production scale is increasingly enlarged, the process flow is more and more complex, and the requirements on the intellectualization and the refinement of the control of the tin smelting production process are higher and higher.
The traditional manual control mode and the automatic control mode are combined, so that the fine control requirement of production equipment is difficult to achieve. Although a DCS control system is adopted in part of the tin smelting flow, the control system is relatively independent. In the actual process of smelting crude tin in the top-blown furnace, equipment accidents caused by misoperation are not lacked, and accidents such as accretion and the like caused by operation responsibility and insufficient operation experience are not lacked.
Aiming at the characteristics of more tin smelting production links and complex process and facility, in the process control from the material feeding to the output of crude tin products, the spray gun is corrected and operated by observing the furnace condition and slag by operators; correcting and controlling the feeding quantity of the batching belt through the dispatching telephone feedback of personnel in the main control room; the calculation of the metallurgical ingredients depends on the in-situ decision of the ingredient engineers, and once the metallurgical engineers are inexperienced or the personnel are configured unevenly, the metallurgical ingredients have great influence on the smelting economic and technical indexes of the whole crude smelting.
Therefore, in view of the above, how to provide an intelligent crude tin smelting system and method is a problem that needs to be solved by those skilled in the art.
Disclosure of Invention
In view of the above, the invention provides an intelligent crude tin smelting system and method, which solve the problems of manual intervention, independent control and lack of unified control of each procedure in the original production process.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
an intelligent coarse tin smelting system, comprising: an operation management layer EPR, an execution manufacturing layer MES, a control layer DCS and an equipment layer;
the management layer is used for receiving the management plan and sending management plan data to the execution manufacturing layer;
the executing the manufacturing layer includes: the system comprises an MES management system, a smelting expert system and a spray gun expert system; the MES management system is used for receiving the operation plan sent by the operation management layer and generating production management data according to the operation plan; the smelting expert system is used for comparing smelting data acquired in real time with data in the expert database to realize adjustment and control of a smelting process, and the spray gun expert system is used for comparing smelting data acquired in real time with data in the expert database to realize control of a spray gun and judgment of damage of the spray gun;
the control layer is used for receiving real-time data and controlling boiler equipment in the smelting process in real time;
the equipment layer collects real-time data of boiler equipment in the smelting process and sends the real-time data to the control layer and the execution manufacturing layer.
Preferably, the MES management system comprises an environmental protection management module, a production task management module, a checking management module and a warehouse management module;
the environment-friendly management module is used for managing environment hazard factors generated in the crude tin smelting process;
the production task management is used for executing a month production plan, subdividing the month production plan into daily production and work production tasks, and selecting an optimal production scheme by combining the data of the raw material bin;
the inspection manages the analysis of the composition of the material required for the production of the crude tin and the analysis of the quality of the crude tin produced;
the warehouse management module is used for managing tin-containing raw materials, auxiliary materials and crude tin products and managing the exchange between the raw materials, auxiliary materials and crude tin products and the next working procedure.
It should be noted that:
the environment protection management module, the production task management module, the inspection management module and the warehouse management module can mutually call data at an MES layer so as to meet the corresponding analysis and statistics functions.
Preferably, the smelting expert system receives and analyzes the environmental management data, the production task management and inspection management data and the real-time data collected by the equipment layer to realize the selection and correction of batching data distribution, material balance, heat balance and slag balance.
Preferably, the control layer includes: and the fuming furnace control module and the top-blowing furnace control module are respectively used for adjusting and correcting control commands of the fuming furnace and the top-blowing furnace according to the real-time data acquired by the equipment layer so as to realize the control of the fuming furnace and the top-blowing furnace.
Preferably, the control layer further includes: the preheating boiler control module and the acid making control module are respectively used for realizing preheating and correcting parameters of an acid making process for the top-blowing furnace according to the real-time data acquired by the equipment layer and further completing acid making.
Preferably, the control layer includes: the equipment layer comprises a boiler cooling system, a coal feeding system, a batching system, a spray gun motion system and a spray gun fluid control system, wherein:
the boiler cooling system collects water consumption and temperature of the top-blown furnace in real time, and collects temperature of a molten pool;
the coal feeding system collects the coal quantity in real time;
the batching system collects the amounts of reducing coal, tin concentrate, returning charge, quartz and limestone generated by the top-blown furnace in real time;
the spray gun motion system collects the real-time position of the spray gun and the up-down operation data of the spray gun in real time;
the spray gun fluid control system collects spray gun wind back pressure, sleeve ventilation back pressure and oxygen back pressure in real time.
An intelligent crude tin smelting method comprises the following steps:
collecting real-time data of boiler equipment in the smelting process in real time;
and calculating and analyzing the operation plan data, the production management data and the real-time data, so as to realize intelligent analysis, intelligent adjustment, automatic optimization of the operation parameters and automatic deviation correction of main operation parameters, and timely alarm of abnormality.
Compared with the prior art, the invention discloses an intelligent crude tin smelting system and method, which have the following technical effects:
(1) Full-process automatic control of production procedures;
(2) The main smelting equipment can be controlled in a refined mode and intelligently;
(3) Realizing unified intelligent control on the whole smelting process;
(4) Providing data support for an ERP system and an upper layer decision;
(5) By introducing an intelligent expert analysis decision system, the method can effectively solve the problems of inconsistent links such as batching, smelting, discharging and the like in rough smelting, and thoroughly overcome the experience sense operation.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required to be used in the embodiments or the description of the prior art will be briefly described below, and it is obvious that the drawings in the following description are only embodiments of the present invention, and that other drawings can be obtained according to the provided drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic structural view of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
The embodiment of the invention discloses an intelligent crude tin smelting system and method, wherein:
an intelligent coarse tin smelting system, comprising: an operation management layer EPR, an execution manufacturing layer MES, a control layer DCS and an equipment layer;
the management layer is used for receiving the management plan and sending management plan data to the execution manufacturing layer;
the performing the manufacturing layer includes: the system comprises an MES management system, a smelting expert system and a spray gun expert system; the MES management system is used for receiving the operation plan sent by the operation management layer and generating production management data according to the operation plan; the smelting expert system is used for comparing smelting data acquired in real time with data in the expert database to realize adjustment and control of smelting process, and the spray gun expert system is used for comparing smelting data acquired in real time with data in the expert database to realize control of the spray gun and judgment of damage of the spray gun;
the control layer is used for receiving real-time data and controlling the boiler equipment in the smelting process in real time;
the equipment layer collects real-time data of boiler equipment in the smelting process and sends the data to the control layer and the execution manufacturing layer.
In order to further realize the technical scheme, the MES management system comprises an environmental protection management module, a production task management module, a checking management module and a warehouse management module;
the environment-friendly management module is used for managing environment hazard factors generated in the crude tin smelting process;
the production task management is used for executing a month production plan, subdividing the month production plan into daily production and class production tasks, and selecting an optimal production scheme by combining the data of the raw material bin;
checking and managing the analysis of the material components required for the production of the crude tin and the analysis of the quality of the produced crude tin;
the warehouse management module is used for managing tin-containing raw materials, auxiliary materials and crude tin products and managing the exchange between the next working procedure.
In order to further realize the technical scheme, the smelting expert system realizes the adjustment of batching data by receiving and analyzing environmental protection management data, production task management and inspection management data and real-time data acquired by an equipment layer and finding out optimal operation parameters through statistical analysis. The heat balance and the slag type selection in the crude tin smelting process are more reasonable.
In order to further realize the technical scheme, the control layer comprises: the fuming furnace control module and the top-blowing furnace control module are respectively used for adjusting and correcting control commands of the fuming furnace and the top-blowing furnace according to real-time data acquired by the equipment layer so as to realize control of the fuming furnace and the top-blowing furnace.
In order to further realize the above technical solution, the control layer further includes: the preheating boiler control module and the acid making control module are respectively used for realizing preheating of the top-blowing furnace and correction of parameters of an acid making process according to real-time data acquired by the equipment layer and further completing acid making.
In order to further realize the technical scheme, the control layer comprises: the equipment layer comprises a boiler cooling system, a coal feeding system, a batching system, a spray gun motion system and a spray gun fluid control system, wherein:
the boiler cooling system collects water consumption and temperature of the top-blown furnace in real time, and collects the temperature of a molten pool;
collecting the coal quantity of a coal feeding system in real time;
the batching system collects the amount of the reducing coal, the amount of the tin concentrate, the amount of returned materials, the amount of quartz and limestone generated by the top-blown furnace in real time;
the spray gun motion system collects the real-time position of the spray gun and the up-down operation data of the spray gun in real time;
the spray gun fluid control system collects spray gun wind back pressure, sleeve ventilation back pressure and oxygen back pressure in real time.
It should be noted that:
by utilizing the top-blown furnace roughing technology, intelligent smelting is realized from the links of material storage management, material inspection data in inspection management, material proportioning, smelting, discharge (slag, smoke, metal) and the like, and the main equipment realizes full-flow automatic control. The production management data of the ERP and MES layers and the real-time monitoring feedback data of the equipment layer are introduced to carry out calculation and analysis, so that the functions of intelligent analysis, intelligent adjustment, automatic operation parameter optimization, automatic deviation correction and the like on main operation parameters are realized, and abnormal occurrence is timely alarmed. The batching link can automatically analyze smelting slag to be achieved according to material acceptance conditions, annual production indexes, tin concentrate of various components and returned materials of various components, and analyze impurity elements and main element components to analyze metal balance, heat balance and heavy metal balance. The smelting link can carry out feeding correction according to the ingredients of the materials entering the furnace and the obtained target slag type, carry out the depth operation of the spray gun and the fuel adjustment according to the automatic measured temperature of the molten pool and the slag type, correlate the generated smoke ingredients with dust collection and acid preparation, and carry out parameter correction on the acid preparation process in advance. And the emission link can be used for providing operation guidance and management for subsequent procedures according to the analysis and comparison of the real-time monitoring data and the furnace charging material data.
An intelligent crude tin smelting method comprises the following steps:
collecting real-time data of boiler equipment in the smelting process in real time;
and calculating and analyzing the operation plan data, the production management data and the real-time data, so as to realize intelligent analysis, intelligent adjustment, automatic optimization of the operation parameters and automatic deviation correction of main operation parameters, and timely alarm of abnormality.
The invention integrates analysis, statistics and management, breaks through conventional single-loop control and ratio control, realizes intelligent smelting of tin smelting and rough smelting, and achieves unified coordination control.
As shown in fig. 1, a conventional batching system is automatically controlled and introduced into an expert system. By receiving the operation condition of ERP and the production plan of MES and combining the existing material inventory, main metal and impurity component information, reasonable smelting slag is selected for batching, and batching information is written into a batching system of DCS. And meanwhile, correcting the ingredients according to the analysis result of the smelting slag sample in the process. Big data analysis is introduced to compare slag type batching conditions and economic and technical indexes for many years, so that the most reasonable metallurgical slag type can be optimized.
According to the actual feeding condition in the DCS batching system, the required fuel quantity and the real-time slag pool depth are calculated, and the operation of lifting and descending the spray gun is optimally controlled by performing heat balance calculation. In the metallurgical expert system, the air back pressure, the sleeve ventilation back pressure, the oxygen back pressure, the molten pool temperature, the fuel quantity and the spray gun position information of the spray gun are introduced, and whether the spray gun is damaged or not is judged by combining big data analysis, so that an operator is prompted whether the spray gun needs to be replaced or not.
Through calculating the balance of the materials fed into the furnace and the materials produced, the production economic and technical indexes are related to the operation, and an analysis and optimization expert system is used for providing guidance for the operation of the next stage.
And through analysis and calculation of harmful impurities in input and output, production guidance is provided for the next process. Such as: providing reference for boiler feed water for waste heat power generation through heat balance calculation; providing a reference for an acid making system through the SO2 content and the oxygen amount (air amount) in the material; and by collecting the distribution of heavy metal components in each link, decision basis is provided for environmental protection management.
In this embodiment:
1. in the equipment layer, the system is required to be provided with a batching system, a furnace cooling water system, a coal (fuel) feeding system, a spray gun control system, a fluid control system and a batching system, and each system realizes automatic control and uploads analysis data required by an expert system.
2. The control layer needs to establish a stable and reliable DCS system, and can realize data interaction with the MES.
3. The MES layer needs to integrate various data of the whole crude tin production for an expert system to use, needs to analyze production data of each period and each time period, builds an expert model and sends analysis results to the DCS.
4. The operation management layer needs to establish an ERP system for operation decision.
5. And establishing a big data analysis model. And collecting and arranging data in a certain period of time, comparing and optimizing each control index.
In the present specification, each embodiment is described in a progressive manner, and each embodiment is mainly described in a different point from other embodiments, and identical and similar parts between the embodiments are all enough to refer to each other. For the device disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant points refer to the description of the method section.
The previous description of the disclosed embodiments is provided to enable any person 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 generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended 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 (5)
1. An intelligent coarse tin smelting system, comprising: an operation management layer EPR, an execution manufacturing layer MES, a control layer DCS and an equipment layer;
the management layer is used for receiving the management plan and sending management plan data to the execution manufacturing layer;
the executing the manufacturing layer includes: the system comprises an MES management system, a smelting expert system and a spray gun expert system; the MES management system is used for receiving the operation plan sent by the operation management layer and generating production management data according to the operation plan; the smelting expert system is used for comparing smelting data acquired in real time with data in the expert database to realize adjustment and control of a smelting process, and the spray gun expert system is used for comparing smelting data acquired in real time with data in the expert database to realize control of a spray gun and judgment of damage of the spray gun;
the MES management system comprises an environmental protection management module, a production task management module, a checking management module and a warehouse management module;
the environment-friendly management module is used for managing environment hazard factors generated in the crude tin smelting process; the production task management is used for executing a month production plan, subdividing the month production plan into daily production and work production tasks, and selecting an optimal production scheme by combining the data of the raw material bin; the inspection manages the analysis of the composition of the material required for the production of the crude tin and the analysis of the quality of the crude tin produced; the warehouse management module is used for managing tin-containing raw materials, auxiliary materials and crude tin products and managing the exchange between the warehouse management module and the next working procedure;
the control layer is used for receiving real-time data and controlling boiler equipment in the smelting process in real time;
the equipment layer collects real-time data of boiler equipment in the smelting process and sends the real-time data to the control layer and the execution manufacturing layer;
the equipment layer comprises a boiler cooling system, a coal feeding system, a batching system, a spray gun motion system and a spray gun fluid control system, wherein:
the boiler cooling system collects water consumption and temperature of the top-blown furnace in real time, and collects temperature of a molten pool; the coal feeding system collects the coal quantity in real time; the batching system collects the amounts of reducing coal, tin concentrate, returning charge, quartz and limestone generated by the top-blown furnace in real time; the spray gun motion system collects the real-time position of the spray gun and the up-down operation data of the spray gun in real time; the spray gun fluid control system collects spray gun wind back pressure, sleeve ventilation back pressure and oxygen back pressure in real time.
2. The intelligent coarse tin smelting system according to claim 1, wherein the smelting expert system receives and analyzes environmental management data, production task management and inspection management data, and real-time data collected by the equipment layer to realize distribution of batching data, material balance, heat balance and slag type selection and correction.
3. An intelligent coarse tin smelting system according to claim 1, wherein the control layer comprises: and the fuming furnace control module and the top-blowing furnace control module are respectively used for adjusting and correcting control commands of the fuming furnace and the top-blowing furnace according to the real-time data acquired by the equipment layer so as to realize the control of the fuming furnace and the top-blowing furnace.
4. The intelligent coarse tin smelting system of claim 1, wherein the control layer further comprises: the preheating boiler control module and the acid making control module are respectively used for realizing preheating and correcting parameters of an acid making process for the top-blowing furnace according to the real-time data acquired by the equipment layer and further completing acid making.
5. An intelligent crude tin smelting method is characterized by comprising the following steps:
collecting real-time data of boiler equipment in the smelting process in real time;
and calculating and analyzing the operation plan data, the production management data and the real-time data, so as to realize intelligent analysis, intelligent adjustment, automatic optimization of the operation parameters and automatic deviation correction of main operation parameters, and timely alarm of abnormality.
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