CN114410984A - Control method for abnormal working condition in zinc hydrometallurgy leaching process - Google Patents
Control method for abnormal working condition in zinc hydrometallurgy leaching process Download PDFInfo
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- 238000002386 leaching Methods 0.000 title claims abstract description 123
- 238000000034 method Methods 0.000 title claims abstract description 104
- 230000008569 process Effects 0.000 title claims abstract description 69
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 title claims abstract description 61
- 239000011701 zinc Substances 0.000 title claims abstract description 61
- 229910052725 zinc Inorganic materials 0.000 title claims abstract description 61
- 230000002159 abnormal effect Effects 0.000 title claims abstract description 39
- 238000009854 hydrometallurgy Methods 0.000 title claims abstract description 18
- 239000002253 acid Substances 0.000 claims abstract description 128
- 239000002699 waste material Substances 0.000 claims abstract description 77
- 239000000463 material Substances 0.000 claims abstract description 30
- 238000004519 manufacturing process Methods 0.000 claims abstract description 19
- 230000008859 change Effects 0.000 claims abstract description 16
- 238000006243 chemical reaction Methods 0.000 claims abstract description 7
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 claims description 16
- 238000001514 detection method Methods 0.000 claims description 16
- 238000000746 purification Methods 0.000 claims description 14
- XLOMVQKBTHCTTD-UHFFFAOYSA-N zinc oxide Inorganic materials [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 14
- 238000005520 cutting process Methods 0.000 claims description 13
- 238000005868 electrolysis reaction Methods 0.000 claims description 11
- 239000006228 supernatant Substances 0.000 claims description 10
- 238000007599 discharging Methods 0.000 claims description 9
- 239000007788 liquid Substances 0.000 claims description 8
- 239000011787 zinc oxide Substances 0.000 claims description 8
- 230000001174 ascending effect Effects 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 6
- 238000010926 purge Methods 0.000 claims description 6
- 238000007405 data analysis Methods 0.000 claims description 5
- 239000011259 mixed solution Substances 0.000 claims description 5
- 238000005192 partition Methods 0.000 claims description 4
- 238000004886 process control Methods 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 238000005259 measurement Methods 0.000 claims 1
- 230000000630 rising effect Effects 0.000 description 8
- 239000000243 solution Substances 0.000 description 8
- 230000007935 neutral effect Effects 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 230000009467 reduction Effects 0.000 description 6
- 238000003723 Smelting Methods 0.000 description 5
- 230000003044 adaptive effect Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- 238000013528 artificial neural network Methods 0.000 description 3
- 239000012535 impurity Substances 0.000 description 3
- 150000002500 ions Chemical class 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 238000001556 precipitation Methods 0.000 description 3
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- 229910052748 manganese Inorganic materials 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 241000132179 Eurotium medium Species 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 229910001448 ferrous ion Inorganic materials 0.000 description 1
- 229910052598 goethite Inorganic materials 0.000 description 1
- AEIXRCIKZIZYPM-UHFFFAOYSA-M hydroxy(oxo)iron Chemical compound [O][Fe]O AEIXRCIKZIZYPM-UHFFFAOYSA-M 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 229940099596 manganese sulfate Drugs 0.000 description 1
- 239000011702 manganese sulphate Substances 0.000 description 1
- 235000007079 manganese sulphate Nutrition 0.000 description 1
- SQQMAOCOWKFBNP-UHFFFAOYSA-L manganese(II) sulfate Chemical compound [Mn+2].[O-]S([O-])(=O)=O SQQMAOCOWKFBNP-UHFFFAOYSA-L 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 238000006386 neutralization reaction Methods 0.000 description 1
- 230000003472 neutralizing effect Effects 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 150000003752 zinc compounds Chemical class 0.000 description 1
- NWONKYPBYAMBJT-UHFFFAOYSA-L zinc sulfate Chemical compound [Zn+2].[O-]S([O-])(=O)=O NWONKYPBYAMBJT-UHFFFAOYSA-L 0.000 description 1
- 229960001763 zinc sulfate Drugs 0.000 description 1
- 229910000368 zinc sulfate Inorganic materials 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
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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
- C22B19/00—Obtaining zinc or zinc oxide
- C22B19/20—Obtaining zinc otherwise than by distilling
- C22B19/22—Obtaining zinc otherwise than by distilling with leaching with acids
-
- 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
- C22B19/00—Obtaining zinc or zinc oxide
- C22B19/30—Obtaining zinc or zinc oxide from metallic residues or scraps
-
- 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
- C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
- C22B3/04—Extraction of metal compounds from ores or concentrates by wet processes by leaching
- C22B3/06—Extraction of metal compounds from ores or concentrates by wet processes by leaching in inorganic acid solutions, e.g. with acids generated in situ; in inorganic salt solutions other than ammonium salt solutions
- C22B3/08—Sulfuric acid, other sulfurated acids or salts thereof
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
- G05D27/00—Simultaneous control of variables covered by two or more of main groups G05D1/00 - G05D25/00
- G05D27/02—Simultaneous control of variables covered by two or more of main groups G05D1/00 - G05D25/00 characterised by the use of electric means
-
- 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
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
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- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Inorganic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Geology (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
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Abstract
The invention discloses a method for controlling abnormal working conditions in a zinc hydrometallurgy leaching process, which comprises the following steps: s1, obtaining an error value of the current pH value as a first input variable, obtaining a change rate of the error value of the current pH value as a second input variable, and obtaining a preset value of the output variable waste acid adding flow through a fuzzy rule; s2, obtaining a relational expression between the waste acid adding flow and the zinc roasting adding amount in unit time based on material conservation in the zinc dissolving reaction process; s3, defining various abnormal working conditions according to the actual process characteristics of the leaching process, determining a compensation value on the basis of preset values of waste acid flow according to different abnormal working conditions, and finally determining the waste acid adding flow at the current moment. The control method can effectively realize the stable control of the pH value in the leaching process, greatly reduce the labor intensity of workers, provide a waste acid addition amount adjusting scheme aiming at the abnormal working conditions possibly occurring in the leaching process, and greatly improve the control precision when being applied to the abnormal state, thereby improving the production stability.
Description
Technical Field
The invention belongs to the field of wet leaching, and particularly relates to a control method for abnormal working conditions in a leaching process of zinc hydrometallurgy.
Background
Neutral leaching is a process of dissolving a zinc compound in a zinc-containing material (such as zinc calcine, smoke dust, zinc leaching residue and the like) into a solution as zinc sulfate by using dilute sulfuric acid as a solvent and maintaining proper acidity, temperature, pressure and other conditions, so as to form a residue together with insoluble solids. The technological process diagram of the neutral leaching process of a certain smelting plant is shown in attached figure 1, and mainly comprises 5 cascaded stirred reactors, wherein leaching tanks are arranged in a step mode, the inlet of each leaching tank is positioned at the upper part and has a height difference of about 1 meter with the outlet, and the inlets and the outlets of the leaching tanks are connected through chutes. The waste acid, the acid leaching supernatant, the mixed solution, the manganese ore slurry and other solvents are mixed in the chute and then flow into a No. 1 leaching tank, and the zinc calcine is continuously added into the leaching tank through a belt scale. In order to ensure the leaching temperature in the production process, steam is continuously introduced into the interior of each leaching tank, and in order to further oxidize ferrous ions, excess oxygen is generally introduced into the two latter tanks. In order to achieve corresponding process production indexes, so that impurity ions in the solution have a stable precipitation environment and provide qualified raw materials for subsequent purification procedures, the pH value of the No. 5 leaching tank needs to be controlled within a reasonable range (the No. 5 pH value is set to be 4.8-5.2); according to the actual industrial field investigation, the pH value of the outlet of the tail tank can be ensured to be in a set range as long as the pH value of the outlet of the No. 3 leaching tank can be controlled to be 3-3.5 (the pH value of the No. 3). Therefore, the neutral leaching process can also be said to be a process of controlling the pH value by adjusting the waste acid using calcine as a raw material.
Due to the fact that the fluctuation of the concentration and the flow of the solvent is large, the content of mineral resources is complex, the fluctuation of the blanking is complex and changeable in the actual field, and the fluctuation of the pH value of the outlet of the No. 3 tank is large due to the fact that great uncertainty exists in the field. In the actual production process, an operator usually adjusts the waste acid according to the current pH value of the outlet of the No. 3 tank, the pH set value of the No. 3 tank, the addition amount of the calcine of the No. 1-3 tank, the flow rate of a mixed liquid and the flow rate of the acid leaching supernatant, so that the stability of the pH greatly depends on the subjective factors of the operator; meanwhile, the leaching inlet is a product of roasting, electrolysis and other processes, the outlet is connected with purification, the leaching process is extremely easy to be in an abnormal working condition due to complex and changeable production states, and an operator cannot timely treat the abnormal working condition, so that the fluctuation of pH is caused, and the difficulty of stable control of the pH at the outlet of the No. 3 leaching tank is further aggravated.
In example [1] (why it contributes faithfully, application of adaptation in pH control in zinc smelting [ J ]. university of wuhan theory, 2010, 32 (11): 111- "114), researchers have proposed to use nonlinear PID control based on neural network adaptive PID control in pH process control in zinc hydrometallurgy to improve the control accuracy of pH in the leaching process, in view of the difficulty of high nonlinearity of the pH neutralization process; in example [2] (stable control and application of pH value in the process of precipitating iron by the yanogen goethite method [ D ]. university of south and middle, 2013.), a feed-forward control model of pH value is established by using characteristics such as material balance in the reactor, and the addition amount of calcine is further compensated by fuzzy compensation control, thereby realizing stable control of pH value.
The control method given by the example has certain limitations. The neural network adaptive PID control algorithm proposed by example [1] performs adaptive adjustment on parameters based on a single operation state, but when the process is in an abnormal working condition, the PID value becomes unsuitable. In addition, some theoretical methods such as neural networks require huge computing resources, and are difficult to put into operation in actual industrial fields due to factors such as complex production conditions and the like; the control algorithm provided in example [2] firstly establishes a mechanism model of the iron precipitation process as a feedforward controller to give a preset value of a controlled variable by deeply analyzing the process of the iron leaching precipitation process and combining laws of material conservation, reaction kinetics and the like, and then establishes a compensation value of the controlled variable by a fuzzy compensation controller through expert rules to realize stable control of the pH value. However, the method does not consider analyzing the abnormal working condition, and if the abnormal working condition occurs, the mechanism model becomes not adaptive, so that the control effect is reduced.
Disclosure of Invention
The invention aims to provide a method for stably controlling the pH value of the outlet of a No. 3 groove under the abnormal working condition in the leaching process aiming at the problem that the pH value of the outlet of the No. 3 groove is difficult to stabilize because the pH value of the outlet of the No. 3 groove depends on manual control and the fluctuation conditions such as the abnormal working condition and the like are not considered in the manual control in the existing zinc hydrometallurgy leaching process, so as to deal with various working conditions in the leaching production process and ensure the stable production in the leaching process.
In order to achieve the above objects and solve the above technical problems, the present invention adopts the following technical solutions:
a control method for abnormal working conditions in a zinc hydrometallurgy leaching process comprises the following steps:
s1, measuring the pH value of the target detection site, and calculating and acquiring the error value e of the current pH value of the target detection site based on the pH value of the current detection site and the pH set valuetAs a first input variable, calculating the change rate de of the error value for obtaining the current pH valuetAs a second input variable, obtaining a preset value of the output variable waste acid addition flow through a fuzzy rule
S2, obtaining waste acid adding flow based on material conservation in the dissolving reaction process of zinc
Relational expression of zinc roasting addition amount in unit time；
S3, defining various abnormal working conditions according to the actual process characteristics of the leaching process, and determining a compensation value on the basis of a preset value of waste acid flow according to different abnormal working conditions
Then according to the preset value of the waste acid adding flow
Compensation value
And the flow rate of waste acid addition at the last moment
And obtaining the final waste acid adding flow rate, and carrying out process control.
Further, in step S1, the target detection site is an outlet of a third leaching tank; the preset range of the pH value is 3-3.5.
Further, in step S1, obtaining the preset value of the waste acid adding flow rate according to the fuzzy rule
The method comprises the following steps:
s11, determining the error value e of the current pH value of the target detection sitetAs a first input variable, the change rate de of the error value of the current pH valuetAs a second input variable, the first input variable,
as output variable, where et＝Yt-Yt′，det＝et-et-1，YtIs a set value of the current pH value of the target detection site, YtThe actual measured value of the current pH value of the target detection site is obtained;
s12, inputting the first variable etA second input variable detAnd output variables
Dividing the fuzzy sets into a plurality of fuzzy sets, describing each fuzzy set by adopting a proper membership function, and determining parameters in each membership function by combining field experience and data analysis;
s13 based on the first input variable etA second input variable detAnd output variables
The corresponding relation of each fuzzy set function is used for formulating a fuzzy rule, and pre-adjustment values of waste acid adding flow under different conditions are determined according to the fuzzy rule.
Preferably, in step S12, the first input variable e is settThe partition into 5 fuzzy sets: HN, LN, Z, LP, and HP; wherein Z indicates that the current pH is within the process indicator range, LN indicates that the current pH is in a state slightly below the normal range, HN indicates that the current pH is already in a state well below the normal range, LP indicates that the current pH is in a state slightly above the normal range, and HP indicates that the current pH is in a state well above the normal range; wherein HN is described by a Z-type membership function, LN, Z and LP are described by a bell-shaped membership function, and HP is described by an S-type membership function;
second input variable detThe partition into 5 fuzzy sets: HN, LN, Z, LP, and HP; z represents that the pH value is stable and has no change trend, LN represents that the pH value is in a slow descending trend, HN represents that the pH value is in a rapid descending trend, LP represents that the pH value is in a slow ascending trend, and HP represents that the pH value is in a rapid ascending trend; wherein HN is described by a Z-type membership function, LN, Z and LP are described by a bell-type membership function, and HP is described by an S-type membership function;
will output variable
Dividing into 7 fuzzy sets HN, MN, LN, Z, LP, MP and HP, wherein HN represents large reduction of acid (i.e. large reduction of waste acid addition flow), MN represents small reduction of acid (i.e. medium reduction of waste acid addition flow), LN representsThe acid is reduced in small amplitude (namely the reduction amount of the waste acid addition flow is small), Z represents that the acid is not changed (namely the waste acid addition flow is not changed), LP represents that the acid is increased in small amplitude (namely the increase amount of the waste acid addition flow is small), MP represents that the acid is increased in medium amplitude (namely the increase amount of the waste acid addition flow is medium), and HP represents that the acid is increased greatly (namely the increase amount of the waste acid addition flow is large); HN is described by a Z-type membership function, MN, LN, Z, LP and MP are described by a bell-type membership function, and HP is described by an S-type membership function;
and obtaining parameters in each membership function according to field experience and data analysis.
Further, the Z-type membership function is:
the bell-shaped membership function is:
the S-type membership function is:
preferably, step S13 includes: the fuzzy rule is as follows:
when the pH value of No. 3 leaching tank is in a proper range, namely a first input variable etTaking a fuzzy set Z, wherein the pH value change trend has a slow rising trend or a slow falling trend or no change trend, namely a second input variable detTaking fuzzy set LN, LP or Z, then outputting variable
Taking a fuzzy set Z;
when the pH value of No. 3 leaching tank is in a proper range, namely a first input variable etTaking fuzzy set Z and having a rapid pH value decrease trend, i.e. detTaking a fuzzy set HN; or the pH value of the No. 3 leaching tank is in a lower state, namely the first input variable etTaking fuzzy LN and making pH value have ascending trend or be constant, i.e. second input variable detTaking fuzzy sets HP, LP or Z, then
Taking a fuzzy set LN;
when the pH value of No. 3 leaching tank is in a lower state, namely a first input variable etTaking fuzzy LN and having a tendency of pH value to decrease, i.e. detTaking a fuzzy set LN or HN; or the pH value of the No. 3 leaching tank is in an extremely low state, namely the first input variable etTaking fuzzy set HN and pH value with rising trend, i.e. second input variable det takes fuzzy set HP or LP, then
Taking a fuzzy set MN;
when the pH value of No. 3 leaching tank is in an extremely low state, namely a first input variable etTaking a fuzzy set HN, and the pH value is reduced or unchanged, namely detTaking the fuzzy set Z, HN or HN, then
Taking a fuzzy set HN;
when the pH value of the No. 3 leaching tank is in a proper range, namely a first input variable etTaking fuzzy set Z and having rapid rising trend of pH value, i.e. detTaking a fuzzy set HP; or the pH value of the No. 3 leaching tank is in a higher state, namely the first input variable etTaking fuzzy set LP and pH value has rising trend, i.e. second input variable det takes fuzzy set HP or LP, then
Taking a fuzzy set LP;
when the pH value of No. 3 leaching tank is in a higher state, namely a first input variable etTaking fuzzy LP, and the pH value has a rising trend, i.e. detTaking a fuzzy set LP or HP; or the pH value of the No. 3 leaching tank is in an extremely high state, namely the first input variable etTake fuzzy set HP, andthe pH value having a tendency to decrease, i.e. the second input variable detTaking the fuzzy set HN or LN, then
Taking a fuzzy set MP;
when the pH value of No. 3 leaching tank is in an extremely high state, namely a first input variable etTaking fuzzy HP, with rising pH or unchanged, i.e. detTaking fuzzy sets LP, HP or Z, then
And taking a fuzzy set HN.
Preferably, in S2, the relationship between the waste acid addition flow rate and the zinc roasting addition amount per unit time is as follows:
wherein alpha and beta are soluble zinc coefficient and leaching rate respectively, and are 0.58 and 0.9 respectively;
and MZnORelative molecular masses of sulfuric acid and zinc oxide, respectively; cacid、CsupAnd CmixThe sulfuric acid concentration in the waste acid, the acid leaching supernatant and the mixed solution is respectively, and the unit is g/L;
and
the waste acid adding flow rates of the No. 1 leaching tank and the No. 2 leaching tank are respectively, and the unit is m3/h，FmixThe addition flow rate of the mixed liquid in tank No. 1 is m3/h；FsupFlow of acid leaching supernatant in unit of m for tank No. 13H,; m is the total zinc calcine entering the No. 1-3 leaching tank in unit time, and the unit is t/h.
Preferably, in S3, the defined abnormal condition includes: zinc calcine discharging fluctuation, zinc calcine material breaking, electrolysis cut and purification production stopping;
aiming at each abnormal condition, determining the compensation value of each abnormal working condition on the basis of the preset value of the waste acid flow as follows: when the zinc roasting material fluctuates, the compensation value
Is calculated by formula (5)
When the material is in the material breaking working condition, if the material breaking time is less than 5min, the compensation value
Is 0, if the material breaking time is more than or equal to 5min and less than 8min, the compensation value
Is 1/2
If the material breaking time is more than or equal to 8min, the compensation value
Is composed of
Wherein
When the waste acid is in the working condition of electrolytic cutting, the compensation value of the adjustment quantity of the waste acid
Calculated by the following formula
Recovering the reduced waste acid at the end of the electrolytic undercutting process; wherein FCuttingThe flow of anode mud sent to the leaching procedure when the electrolysis is cut;
when the waste acid is in a purification stop working condition, waste acid is not added, and the flow is internally circulated;
the waste acid addition amount of the No. 2 leaching tank is as follows:
when the purification and the production stop are carried out, the adding flow of waste acid in the No. 2 leaching tank is 0;
when the leaching tank is in a working condition of not stopping production, the waste acid adding flow of the No. 2 leaching tank is as follows:
wherein the content of the first and second substances,
determined according to the material breaking time.
Preferably, the discharging fluctuation of the zinc calcine means that the discharging amount at the current moment and the discharging amount at the previous moment have a deviation of more than 3t/h, namely delta m is more than 3 t/h; the zinc calcine broken material refers to the blanking of one groove of No. 1-3 grooves (namely M)1#，M2#，M3#) 0t/h and the previous moment is more than 0; the electrolytic cutting means that an electrolytic cutting signal F1 is 0 at the current moment and F1 is 1 at the current moment; the purge shutdown means that the purge shutdown signal F2 is set to 1.
Compared with the prior art, the invention has the following beneficial effects:
the invention can effectively realize the stable control of the pH value in the leaching process by utilizing the fuzzy control, greatly reduces the labor intensity of workers, and simultaneously provides a No. 2 waste acid addition amount adjusting scheme aiming at the abnormal working conditions possibly occurring in the leaching production process.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to these drawings without creative efforts.
FIG. 1 is a process flow diagram of a neutral leaching process of zinc calcine produced by zinc hydrometallurgy;
FIG. 2 is a graph of membership functions for a first input variable;
FIG. 3 is a second input variable membership function;
FIG. 4 is a membership function of an output variable;
FIG. 5 is a diagram of a control surface generated by the input-output rules;
FIG. 6 is a comparison graph of the control effect of the control method of embodiment 1 on the material breakage condition of manual control;
fig. 7 is a comparison graph of the control effect of the blanking fluctuation situation of the control method and the manual control in the embodiment 1.
Detailed Description
In order to facilitate an understanding of the invention, the invention will be described more fully and in detail below with reference to the accompanying drawings and preferred embodiments, but the scope of the invention is not limited to the specific embodiments below.
Fig. 1 is a schematic structural diagram of a neutral leaching process of zinc hydrometallurgy, wherein:
1#, 2#, 3#, 4#, 5# are 5 blanking bins;
zinc calcine: from the roasting process, zinc oxide is also a main dissolved substance, and simultaneously, the zinc oxide also comprises sulfate, silicate and ferrite containing impurity ions, and the impurity ions are also dissolved into the solution to have certain influence on the subsequent process;
waste acid: the solute of the solution generated in the electrolysis process is mainly sulfuric acid and is mainly used for neutralizing zinc calcine;
mixing liquid: mixing produced liquid from each process of a smelting plant;
acid leaching supernatant liquid: the acid leaching process is carried out on the clear solution after being filtered by a thickener;
manganese ore slurry: the ore pulp containing solute manganese sulfate is mainly used for oxidizing ferrous element and sulfur element in solution.
To use this control method, the following definitions are first given: y is the set value of pH value at the outlet of the No. 3 leaching tank in the leaching process of 3.25, and Y' is the detection value of the pH value at the outlet of the No. 3 leaching tank at present; e is the deviation value of the pH value detection value of the outlet of the leaching tank No. 3 in the leaching process and a set value, and de is the change rate of the pH value deviation in the leaching process and is equal to the difference value of the current time e and the last time e; m1#、M2#And M3#The zinc calcine adding amount of the leaching tank No. 1, the leaching tank No. 2 and the leaching tank No. 3 in unit time is t/h, m is the total amount of the zinc calcine added into the leaching tank No. 1-3 in unit time and is t/h, and deltam is the difference value of the zinc calcine discharging amount of the leaching tank No. 1-3 at the current moment and the last moment and is t/h;
and
the waste acid adding flow rates of the No. 1 leaching tank and the No. 2 leaching tank are respectively, and the unit is m3/h；ΔF2The adjustment value of the waste acid adding flow of the No. 2 leaching tank based on the pH value feedback of the No. 3 leaching tank outlet in the leaching process is m3/h；FmixThe addition flow rate of the mixed liquid in tank No. 1 is m3/h；FsupFlow of acid leaching supernatant in unit of m for tank No. 13H; f1 is a purification production stop signal, F2 is an electrolysis cutting signal and is a Boolean value; fCuttingFor electrolysis ofAnode mud flow rate in m3H; wherein Δ F2A preset value is given, and compensation adjustment is performed according to the working condition.
Step 1: obtaining the pH value of the outlet of the No. 3 tank according to the pH detection device; if the pH value is not within the preset range of 3-3.5, obtaining a preset adjustment value of the addition amount of No. 2 waste acid through a fuzzy rule
The method comprises the following specific steps:
inputting error value e of current pH valuetAs a first input variable, the rate of change de of the error value of the current pH valuetAs a second variable, the number of bits in the first variable,
is the output variable of the fuzzy rule. Wherein et＝Yt-Y′t，det＝et-et-1. E of said first variabletSecond variable detAnd output variables
Into a plurality of fuzzy sets.
Wherein the error of the pH value etThe divided 5 fuzzy sets are: HN (negative large), LN (negative small), Z (normal), LP (positive small), HP (positive large). Z indicates that the current pH is within the process index range, LN indicates that the current pH is in a state slightly lower than the normal range, HN indicates that the current pH is already in a state that is extremely low far below the normal range, LP indicates that the current pH is in a state slightly higher than the normal range, and HP indicates that the current pH is in a state far higher than the normal range.
Rate of change of pH error detThe divided 5 fuzzy sets are: HN (negative large), LN (negative small), Z (normal), LP (positive small), HP (positive large). Z represents the pH value to be stable and not change, LN represents the pH value to be in a slow descending trend, HN represents the pH value to be in a rapid descending trend, LP represents the pH value to be in a slow ascending trend, and HP represents the pH value to be in a rapid ascending trend. And is used to describe etAnd detThe membership functions of the fuzzy sets are all the same as follows:
HN is described by a type Z membership function:
LN, Z, LP are described by a bell-shaped membership function:
HP is described by a type S membership function:
adding waste acid
The fuzzy sets are divided into 7 fuzzy sets: HN (acid decrease), MN (acid decrease), LN (acid decrease), Z (acid does not change), LP (acid increase), MP (acid increase), HP (acid increase). Wherein the corresponding membership functions used to describe the fuzzy sets are:
HN is described by a type Z membership function:
MN, LN, Z, LP, MP are described by a bell-shaped membership function:
HP is described by a type S membership function:
in the above formulas, x represents a variable, and a and b are parameters of a function.
Combining with the field expert experience and data analysis, the parameter table of the membership function can be obtained as shown in the following 1-2:
TABLE 1
TABLE 2
The membership function images are shown in fig. 2-4, respectively.
The corresponding fuzzy rule is:
rule one is as follows: when the pH value of the 3# leaching tank is in the process index range, the pH value shows a slow rising trend or a slow falling trend or no change trend. In this case, it is considered that the amount of the acid added is reasonable and the amount of the acid added is kept constant. The rule is as follows:
IF(et＝Z and det＝LN)or(et＝Z anddet＝Z)or(et＝Z anddet＝LP)，
rule two: when the pH value of the 3# leaching tank is in the process index range, the pH value is in a rapid descending trend, the condition indicates that the acid is excessive, and the pH value is in a lower or close to the lower index limit state in a short time without intervention. When the pH value is slightly lower than the normal range, but the pH value is inclined upward or remains unchanged, the pH value is kept at a lower state. Both of these cases can be classified as a slight excess of acid, and the amount of acid added should be slightly reduced. The rule is as follows:
rule three: when the pH value of the 3# leaching tank is slightly lower than the normal range and the pH value tends to decrease, the situation shows that the pH value is in a lower state in a short time. Or when the current pH is in a state far below the normal range but the pH tends to rise. Both of these cases can be attributed to excess acid, and the acid addition should be moderately reduced. The rule is as follows:
rule four: when the pH value of the 3# leaching tank is far lower than the normal range and the pH value is in a descending trend or unchanged, the situation shows that the pH value is in an extremely low state in a short time, and the acid is greatly reduced when the acid is added and is excessive. The rule is as follows:
rule five: when the pH value of the 3# leaching tank is in the process index range, the pH value of the leaching tank has a rapid rising trend, which indicates that the acid is too little, and the pH value is in a higher state or is close to the upper limit of the index in a short time without intervention. And when the current pH value is in a state slightly higher than the normal range and has no change trend, or the pH value is in a state slightly higher than the normal range and p has a downward trend, the pH value is indicated to be kept in a higher state or close to an index upper limit state. Both of these cases can be classified as slightly low acid, and the acid addition should be slightly increased. Rule is that
Rule six: when the pH value of the 3# leaching tank is slightly higher than the normal range and the pH value tends to rise, the situation shows that the pH value is in a higher state in a short time. Or when the current pH is in a state far higher than the normal range but the pH tends to decrease. Both of these cases can be classified as acid deficiency and should be moderately increased. The rule is as follows:
rule seven: when the pH value of the 3# leaching tank is far higher than the normal range and the pH value is in an increasing trend or unchanged, the situation shows that the pH value is in an extremely high state in a short time, and the addition amount of the acid should be greatly increased. The rule is as follows:
the resulting control surface is shown in FIG. 5:
from this, a pre-adjusted value for the addition of waste acid can be obtained
Step 2: according to the deep analysis of the process technology, the relationship between the waste acid addition amount and the blanking amount is established by combining the common material conservation and the reaction kinetics, and the method specifically comprises the following steps:
according to the dissolution reaction of zinc, assuming that the solvent has waste acid, mixed solution and acid leaching supernatant, according to the reaction
ZnO+2H+＝Zn2+H2O
The relationship between the flow of No. 2 waste acid and the addition amount of calcine is obtained through stoichiometric theory:
wherein alpha and beta are soluble zinc coefficient and leaching rate respectivelyTaking 0.58 and 0.9;
and MznoRelative molecular masses of sulfuric acid and zinc oxide, 98 and 81, respectively; cacid、CsupAnd CmixThe sulfuric acid concentrations of the waste acid, the acid leaching supernatant and the mixed solution are 169g/L, 23g/L and 3g/L respectively; m is the sum of the blanking amount of the calcine entering the No. 1-3 leaching tanks in unit time, and the unit is t/h.
And step 3: defining four abnormal working conditions of zinc calcine blanking fluctuation, zinc calcine material break, electrolysis cut and purification production stop. Zinc calcine blanking fluctuation: namely, the feeding amount at the current moment and the feeding amount at the previous moment have deviation of more than 3 t/h; breaking zinc calcine: the blanking of one of the current No. 1-No. 3 slots is 0t/h, but the blanking of the previous time is not 0; electrolytic slitting: when the current electrolysis cutting signal F1 is 0 and the current time F1 is 1, the situation that cutting liquid is fed in the electrolysis process and a cutting working condition occurs is shown; purification and production halt: the purge shutdown signal F2 is set to 1, indicating the presence of a purge shutdown condition.
Judging whether the current leaching process is in abnormal working conditions according to the signals, and if the current leaching process is in zinc calcine feeding fluctuation, obtaining a preset adjustment value of the waste acid addition amount by applying a compensation value 1 of the waste acid addition amount to the waste acid addition amount according to an expression in the step 2:
if the zinc calcine is in the material breaking working condition, the expression of the step 2 can be used for obtaining
If the material is cut off in a short time, namely the material cutting time is less than 5min, then
Do not act on the pre-adjustment value; if the material breaking time is more than or equal to 5min and less than 8min, 1/2 is added
Acting on a waste acid pre-adjustment value; if the material is cut off for a long time, namely the time is more than or equal to 8min, 1/2 is added
Acting on waste acid pre-adjustment values, i.e. when total
Acting on a waste acid pre-adjustment value; when the material is broken and recovered, recovering the reduced waste acid.
If the electrolytic undercutting working condition occurs, the flow F of the anode mud sent to the leaching procedure during the electrolytic undercutting is determinedCuttingSelf-adaptive waste acid reduction
And recovering the reduced spent acid at the end of the electrolytic slitting process.
If the purification production stopping process occurs, no waste acid is added in the neutral leaching process, and the flow is internally circulated. And the original waste acid addition amount is recovered when the purification process is recovered.
And 4, step 4: according to the steps 1, 2 and 3, the final waste acid additive amount of the No. 2 tank is obtained as follows:
when the purification is stopped:
when not in the production stop condition:
wherein
Is made wasteThe compensation value of the acid adjustment amount is as follows according to the abnormal working condition defined in the step 3:
and judging the current working condition and combining to obtain the working condition.
Example 1
In order to prove the effectiveness of the method, the method is applied to the neutral leaching process of zinc smelting zinc calcine of a certain smelting plant and compared with manual control, and the specific comparison effect is as follows:
as can be seen from FIGS. 6-7, the proposed method can ensure that the temperature is substantially stabilized within the interval 3-3.5, while the pH value fluctuates considerably during manual control. Compared with manual control, the method has a smaller fluctuation range and higher yield, and the specific comparison is shown in table 1:
table 1: comparison of control Performance indicators at a set value of 3.25
| Controller | Percent pass (%) | Range of fluctuation |
| The method mentioned | 90.17 | [2.95，3.51] |
| Manual control | 51.44 | [2.26，3.51] |
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (9)
1. A control method for abnormal working conditions in a zinc hydrometallurgy leaching process is characterized by comprising the following steps:
s1, measuring the pH value of the target detection site, and calculating and acquiring an error value e of the current pH value based on the actually measured pH value and the pH set value of the current detection sitetAs a first input variable, calculating the change rate de of the error value for obtaining the current pH valuetAs a second input variable, obtaining a preset value of the output variable waste acid addition flow through a fuzzy rule
S2, obtaining waste acid adding flow based on material conservation in the dissolving reaction process of zinc
A relational expression of the zinc roasting addition amount in unit time;
s3, defining various abnormal working conditions according to the actual process characteristics of the leaching process, and determining a compensation value on the basis of a preset value of waste acid flow according to different abnormal working conditions
Then according to the preset value of the waste acid adding flow
Compensation value
And the flow rate of waste acid addition at the last moment
And finally obtaining the waste acid adding flow at the current moment, and carrying out process control.
2. The method for controlling abnormal conditions in the zinc hydrometallurgy leaching process according to claim 1, wherein in step S1, the target detection site is an outlet of a third leaching tank; the range of the pH set value is 3-3.5.
3. The method for controlling abnormal conditions in the zinc hydrometallurgy leaching process according to claim 1, wherein in step S1, the preset value of the waste acid adding flow is obtained through fuzzy rules
The method comprises the following steps:
s11, determining the error value e of the current pH value of the target detection sitetAs a first input variable, the change rate de of the error value of the current pH valuetAs a second input variable, the first input variable,
as output variable, where et＝Yt-Yt，det＝et-et-1，YtIs a set value of the current pH value of the target detection site, Yt' is the actual measurement value of the current pH value of the target detection site;
s12, inputting a first input variable et and a second input variable detAnd output variables
Dividing the fuzzy sets into a plurality of fuzzy sets, describing each fuzzy set by adopting a proper membership function, and determining parameters in each membership function by combining field experience and data analysis;
s13 based on the first input variable etA second input variable detAnd output variables
The corresponding relation of each fuzzy set function is used for formulating a fuzzy rule, and the preset value of the waste acid adding flow under different conditions is determined according to the fuzzy rule
4. The method for controlling abnormal conditions in the zinc hydrometallurgy leaching process of claim 3, wherein in step S12, the first input variable e is settThe partition into 5 fuzzy sets: HN, LN, Z, LP, and HP; wherein Z indicates that the current pH is within the process range, LN indicates that the current pH is in a state slightly below the normal range, HN indicates that the current pH is far below the normal range, LP indicates that the current pH is in a state slightly above the normal range, and HP indicates that the current pH is far above the normal range; wherein HN is described by a Z-type membership function, LN, Z and LP are described by a bell-shaped membership function, and HP is described by an S-type membership function;
second input variable detThe partition into 5 fuzzy sets: HN, LN, Z, LP, and HP; z represents that the pH value is stable and has no change trend, LN represents that the pH value is in a slow descending trend, HN represents that the pH value is in a rapid descending trend, LP represents that the pH value is in a slow ascending trend, and HP represents that the pH value is in a rapid ascending trend; wherein HN is described by a Z-type membership function, LN, Z and LP are described by a bell-type membership function, and HP is described by an S-type membership function;
will output variable
Dividing the fuzzy sets into 7 fuzzy sets HN, MN, LN, Z, LP, MP and HP, wherein HN represents that acid is greatly reduced, MN represents that acid is reduced in amplitude, LN represents that acid is reduced in small amplitude, Z represents that acid is unchanged, LP represents that acid is increased in small amplitude, MP represents that acid is increased in small amplitude, and HP represents that acid is greatly increased; HN by Z-type membership functions, MN, LN, Z, LP and MP by bell-type membership functions, and HP is described by an S-type membership function;
and obtaining parameters in each membership function according to field experience and data analysis.
5. The method for controlling abnormal conditions in the zinc hydrometallurgy leaching process according to claim 4, wherein the Z-type membership function is:
the bell-shaped membership function is:
the S-type membership function is:
6. the method for controlling abnormal conditions in the zinc hydrometallurgy leaching process according to claim 3, wherein the step S13 includes: the fuzzy rule is as follows:
when the first input variable etTake fuzzy set Z, and second input variable detTaking fuzzy set LN, LP or Z, then outputting variable
Taking a fuzzy set Z;
when the first input variable etTaking a fuzzy set Z, and detTaking a fuzzy set HN; or a first input variable etTake the fuzzy set LN and the second input variable detTaking fuzzy sets HP, LP or Z, then
Mould taking outA fuzzy LN;
when the first input variable etTake fuzzy set LN, and detTaking a fuzzy set LN or HN; or a first input variable etTake the fuzzy set HN, and the second input variable detTaking the fuzzy set HP or LP, then
Taking a fuzzy set MN;
when the first input variable etTaking the fuzzy set HN, and detTaking the fuzzy set Z, HN or HN, then
Taking a fuzzy set HN;
when the first input variable etTaking a fuzzy set Z, and detTaking a fuzzy set HP; or a first input variable etTake the fuzzy set LP, and the second input variable detTaking fuzzy set Z, HN or LN, then
Taking a fuzzy set LP;
when the first input variable etTake fuzzy sets LP, and detTaking a fuzzy set LP or HP; or a first input variable etTake the fuzzy set HP, and the second input variable detTaking the fuzzy set HN or LN, then
Taking a fuzzy set MP;
when the first input variable etTaking the fuzzy set HP, and detTaking fuzzy sets LP, HP or Z, then
And taking a fuzzy set HN.
7. The method for controlling abnormal conditions in the zinc hydrometallurgy leaching process according to any one of claims 1 to 6, wherein in S2, the relation between the waste acid adding flow and the zinc roasting adding amount in unit time is as follows:
wherein alpha and beta are soluble zinc coefficient and leaching rate respectively, and are 0.58 and 0.9 respectively;
and MZnORelative molecular masses of sulfuric acid and zinc oxide, respectively; cacid、CsupAnd CmixThe sulfuric acid concentration in the waste acid, the acid leaching supernatant and the mixed solution is respectively, and the unit is g/L;
and
the waste acid adding flow rates of the No. 1 leaching tank and the No. 2 leaching tank are respectively, and the unit is m3/h，FmixThe addition flow rate of the mixed liquid in tank No. 1 is m3/h；FsupFlow of acid leaching supernatant in unit of m for tank No. 13And m is the sum of zinc calcine entering a No. 1-3 leaching tank in unit time, and the unit is t/h.
8. The method for controlling abnormal conditions in the zinc hydrometallurgy leaching process according to any one of claims 1 to 6, wherein in S3, the defined abnormal conditions include: zinc calcine discharging fluctuation, zinc calcine material breaking, electrolysis cut and purification production stopping;
aiming at each abnormal condition, determining the compensation value of each abnormal working condition on the basis of the preset value of the waste acid flow as follows:
when the zinc roasting material fluctuates, the compensation value
Is calculated by formula (5)
If the material breaking time is less than 5min, the compensation value
Is 0, if the material breaking time is more than or equal to 5min and less than 8min, the compensation value
Is composed of
If the material breaking time is more than or equal to 8min, the compensation value
Is composed of
Wherein
When the waste acid is in the working condition of electrolytic cutting, the compensation value of the adjustment quantity of the waste acid
Calculated by the following formula
Recovering the reduced waste acid at the end of the electrolytic undercutting process; wherein FCuttingThe flow of anode mud sent to the leaching procedure when the electrolysis is cut;
when the waste acid is in a purification stop working condition, waste acid is not added, and the flow is internally circulated;
therefore, the addition amount of waste acid in the leaching tank No. 2 is as follows:
therefore, when the purification and the stopping are performed, the adding flow of the waste acid in the No. 2 leaching tank is 0;
when the leaching tank is in a working condition of not stopping production, the waste acid adding flow of the No. 2 leaching tank is as follows:
wherein the content of the first and second substances,
9. the method for controlling abnormal conditions in the leaching process of zinc hydrometallurgy according to claim 8, wherein the zinc calcine discharging fluctuation means a deviation of more than 3t/h between the total discharging amount of the leaching tank No. 1-3 at the current moment and the total discharging amount of the leaching tank No. 1-3 at the previous moment; the zinc calcine material breakage means that the blanking of a certain leaching tank in the current No. 1-3 leaching tank is 0t/h and is more than 0 at the previous moment; the electrolytic cutting means that an electrolytic cutting signal F1 is 0 at the current moment and F1 is 1 at the current moment; the purge shutdown means that the purge shutdown signal F2 is set to 1.
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