CN114410984B - 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 122
- 238000000034 method Methods 0.000 title claims abstract description 105
- 230000008569 process Effects 0.000 title claims abstract description 69
- 239000011701 zinc Substances 0.000 title claims abstract description 62
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 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 37
- 238000009854 hydrometallurgy Methods 0.000 title claims abstract description 17
- 239000002253 acid Substances 0.000 claims abstract description 120
- 239000002699 waste material Substances 0.000 claims abstract description 68
- 238000004519 manufacturing process Methods 0.000 claims abstract description 26
- 239000000463 material Substances 0.000 claims abstract description 18
- 230000008859 change Effects 0.000 claims abstract description 15
- 238000006243 chemical reaction Methods 0.000 claims abstract description 7
- 238000004090 dissolution Methods 0.000 claims abstract description 4
- 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 16
- 230000001174 ascending effect Effects 0.000 claims description 14
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 12
- 238000007599 discharging Methods 0.000 claims description 11
- 239000006228 supernatant Substances 0.000 claims description 10
- 230000001276 controlling effect Effects 0.000 claims description 9
- 238000005868 electrolysis reaction Methods 0.000 claims description 8
- 239000011259 mixed solution Substances 0.000 claims description 8
- 230000009467 reduction Effects 0.000 claims description 8
- 239000011787 zinc oxide Substances 0.000 claims description 6
- 238000005520 cutting process Methods 0.000 claims description 5
- 238000007405 data analysis Methods 0.000 claims description 5
- 239000007788 liquid Substances 0.000 claims description 5
- 238000004886 process control Methods 0.000 claims description 3
- 238000005259 measurement Methods 0.000 claims description 2
- 230000001105 regulatory effect Effects 0.000 claims description 2
- 230000007935 neutral effect Effects 0.000 description 7
- 239000000243 solution Substances 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 230000000694 effects Effects 0.000 description 6
- 238000003723 Smelting Methods 0.000 description 4
- 230000003044 adaptive effect Effects 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 238000001556 precipitation Methods 0.000 description 4
- 230000000630 rising effect Effects 0.000 description 4
- 239000002904 solvent Substances 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 3
- 238000013528 artificial neural network Methods 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 238000010586 diagram 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
- 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
- 230000006978 adaptation Effects 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
- 238000010926 purge Methods 0.000 description 2
- 239000002994 raw material 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
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000002950 deficient Effects 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
- -1 mixed liquor Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 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
- 239000000047 product Substances 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000126 substance 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
- 239000009111 xianzhong 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
Classifications
-
- 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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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- 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)
- Manufacture And Refinement Of Metals (AREA)
Abstract
The invention discloses a control method for abnormal working conditions in a zinc hydrometallurgy leaching process, which comprises the following steps: s1, acquiring an error value of a current pH value as a first input variable, acquiring a change rate of the error value of the current pH value as a second input variable, and acquiring a pre-adjustment value of the waste acid addition flow of an output variable through a fuzzy rule; s2, conservation of materials in the zinc-based dissolution reaction process, and obtaining a relational expression of the waste acid addition flow and the zinc roasting addition amount in unit time; s3, defining various abnormal working conditions according to the actual process characteristics of the leaching process, determining a compensation value on the basis of a preset value of the waste acid flow aiming at different abnormal working conditions, and finally determining the waste acid addition 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 adjustment scheme aiming at the possible abnormal working condition in the leaching process, and greatly improve the control precision and further improve the production stability when being applied to the abnormal state.
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 zinc hydrometallurgy leaching process.
Background
Neutral leaching refers to a process of dissolving zinc compounds in zinc-containing substances (such as zinc calcine, smoke dust, zinc leaching slag and the like) as zinc sulfate into a solution and forming residues with insoluble solids by using dilute sulfuric acid as a solvent and keeping proper acidity, temperature, pressure and other conditions. A neutral leaching process flow chart of a certain smelting plant is shown in figure 1, and mainly comprises 5 cascaded stirring reactors, leaching tanks are arranged in a step-type manner, an inlet of each leaching tank is positioned at the upper part and has a height difference of about 1 meter with an outlet, and inlets and outlets of the leaching tanks are connected through a chute. The waste acid, acid leaching supernatant, mixed liquor, manganese ore pulp and other solvents are mixed in a chute and then flow into a No. 1 leaching tank, and 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 each leaching tank, and in order to further oxidize ferrous ions, excessive oxygen is usually introduced into the two latter tanks. In order to achieve the corresponding process production index, impurity ions in the solution have a relatively stable precipitation environment, qualified raw materials are provided for the subsequent purification process, and the pH value of a No. 5 leaching tank is required to be controlled within a reasonable range (No. 5 pH set value, 4.8-5.2); according to the actual industrial field investigation, the pH of the outlet of the tail tank can be ensured to be within the set range by controlling the pH of the outlet of the No. 3 leaching tank to be 3-3.5 (the pH set value of No. 3). Thus, the neutral leaching process can also be said to be a process in which calcine is used as a raw material and the pH is controlled by adjusting the spent acid.
The fluctuation of the concentration and flow of the solvent in the actual site is large, the content of the mineral source components is complex, the discharging fluctuation condition is complex and changeable, and the site has extremely large uncertainty, so that the fluctuation of the pH of the outlet of the No. 3 tank is large. In the actual production process, the waste acid is usually adjusted by an operator according to the current pH value of the outlet of the No. 3 tank, the pH set value of the No. 3 tank, the calcine addition amount of the No. 1-3 tanks, the flow of the mixed liquor and the flow of the acid leaching supernatant, so that the pH stability greatly depends on subjective factors of the operator; meanwhile, the leached inlet is a product of procedures such as roasting, electrolysis and the like, the outlet is connected with purification, the complicated and changeable production state can lead to the leaching process being extremely easy to be in an abnormal working condition, and operators can not 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] (He Xianzhong. Application of adaptation in pH control of zinc smelting [ J ]. University of marvelin university, 2010, 32 (11): 111-114), researchers have addressed the difficulty of highly non-linear pH neutralization process, and have proposed to use non-linear PID control based on neural network adaptive PID control in pH process control of zinc hydrometallurgy to improve the control accuracy of pH during leaching; in example [2] (Yang Gen. Stable control of pH value in goethite method iron precipitation process and application [ D ]. University of middle and south, 2013.). The feedforward control model of pH value is established by utilizing characteristics of material balance in the reactor and the like, and the addition amount of calcine is further compensated by fuzzy compensation control, so that stable control of pH value is realized.
There are certain limitations to the control methods presented in the examples. The neural network adaptive PID control algorithm of example [1] adaptively adjusts parameters based on a single operating state, but the PID value will become non-adaptive when the process is in an abnormal condition. Moreover, some theoretical methods such as neural networks require huge computing resources, and are difficult to put into operation in actual industrial sites due to factors such as complex production conditions; the control algorithm proposed in the example [2] is that the mechanism model of the iron precipitation process is established as a preset value of the control amount given by the feedforward controller by carrying out deep analysis on the process of the iron precipitation process by combining the laws of conservation of materials, reaction dynamics and the like, and then the compensation value of the control amount given by the fuzzy compensation controller is established by expert rules so as to realize stable control of the pH value. However, the method does not consider the analysis of the abnormal working condition, and if the abnormal working condition occurs, the mechanism model becomes unsuitable, so that the control effect is reduced.
Disclosure of Invention
The invention aims to provide a stable control method for the pH value of a No. 3 tank outlet in the leaching process, aiming at the problem that the pH value of the No. 3 tank outlet is difficult to stabilize due to the fact that the pH value of the No. 3 tank outlet depends on manual control and the fluctuation conditions such as abnormal working conditions are not considered in the manual control in the existing zinc hydrometallurgy leaching process, so as to cope with various working conditions in the leaching production process and ensure stable production in the leaching process.
In order to achieve the above object and solve the above technical problems, the present invention adopts the following technical scheme:
a control method for abnormal working conditions in a zinc hydrometallurgy leaching process comprises the following steps:
s1, measuring the pH value of a target detection site, and calculating and obtaining an error value e of the current pH value of the target detection site based on the pH value and the pH set value of the current detection point t As a first input variable, calculating a change rate de of an error value for obtaining the current pH value t As a second input variable, obtaining a preset adjustment value of the waste acid addition flow of the output variable through fuzzy rules
S2, conservation of materials in the zinc-based dissolution reaction process to obtain the waste acid addition flowA 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 the flow of waste acid aiming at different abnormal working conditionsAnd then according to the pre-adjustment value of the waste acid addition flow>Compensation value->And the waste acid adding flow rate at the last moment>Obtaining the final waste acid adding flowAnd performing 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, the pre-adjustment value of the waste acid addition flow is obtained through fuzzy rulesComprising the following steps:
s11, error value e of current pH value of target detection site t As a first input variable, the change rate de of the error value of the current pH value t As a second input variable,as output variable, where e t ＝Y t -Y t ′，de t ＝e t -e t-1 ，Y t Is the set value of the current pH value of the target detection site, Y t An actual measurement of the current pH of the target detection site;
s12, inputting a first input variable e t Second input variable de t And output variableDividing the fuzzy set 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 e t Second input variable de t And output variableAnd (3) formulating a fuzzy rule according to the corresponding relation of the fuzzy set functions, and determining the pre-adjustment value of the waste acid adding flow under different conditions according to the fuzzy rule.
Preferably, in step S12, the first input variable e t Divided into 5 fuzzy sets: HN, LN, Z, LP and HP; wherein Z represents the current pThe H value is in the process index range, LN represents that the current pH value is in a state slightly lower than the normal range, HN represents that the current pH value is in a state far lower than the normal range, LP represents that the current pH value is in a state slightly higher than the normal range, and HP represents that the current pH value is in a state far higher than 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;
let the second input variable de t Divided 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 fast descending trend, LP represents that the pH value is in a slow ascending trend, and HP represents that the pH value is in a fast 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;
output variableDividing into 7 fuzzy sets HN, MN, LN, Z, LP, MP and HP, wherein HN represents a large reduction in acid (i.e. large reduction in waste acid addition flow), MN represents a small reduction in acid (i.e. small reduction in waste acid addition flow), Z represents an unchanged acid (i.e. unchanged waste acid addition flow), LP represents a small increase in acid (i.e. small increase in waste acid addition flow), MP represents a large increase in acid (i.e. medium increase in waste acid addition flow), and HP represents a large increase in acid (i.e. large increase in waste acid addition flow); 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;
parameters in each membership function are obtained according to field experience and data analysis.
Further, the Z-membership function is:
the bell-shaped membership function is:
the S-shaped membership function is as follows:
preferably, step S13 includes: the fuzzy rule is as follows:
when the pH value of the No. 3 leaching tank is in a proper range, namely a first input variable e t The fuzzy set Z is taken, and the pH value change trend has slow rise or slow decline or no change trend, namely the second input variable de t Taking fuzzy sets LN, LP or Z, outputting variableTaking a fuzzy set Z;
when the pH value of the No. 3 leaching tank is in a proper range, namely a first input variable e t The fuzzy set Z is taken, and the pH value has a rapid descending trend, namely de t Taking a fuzzy set HN; or the pH value of the No. 3 leaching tank is in a lower state, namely a first input variable e t Taking fuzzy set LN, and the pH value has an ascending trend or is kept unchanged, namely a second input variable de t Taking the fuzzy set HP, LP or ZTaking a fuzzy set LN;
when the pH value of the No. 3 leaching tank is in a lower state, namely a first input variable e t The fuzzy set LN is taken, and the pH value has a descending trend, namely de t Taking a fuzzy set LN or HN; or the pH value of the No. 3 leaching tank is in an extremely low state, namely a first input variable e t Taking the fuzzy set HN and the pH value has an ascending trend, namely taking the fuzzy set HP or LP by the second input variable detTaking a fuzzy set MN;
when the pH value of the No. 3 leaching tank is in an extremely low state, namely a first input variable e t The fuzzy set HN is taken, and the pH value has a decreasing trend or is unchanged, namely de t Taking the fuzzy set Z, HN or HN, thenTaking a fuzzy set HN;
when the pH value of the No. 3 leaching tank is in a proper range, namely a first input variable e t The fuzzy set Z is taken, and the pH value has rapid rising trend, namely de t Taking a fuzzy set HP; or the pH value of the No. 3 leaching tank is in a higher state, namely a first input variable e t Taking the fuzzy set LP and the pH value has an ascending trend, namely taking the fuzzy set HP or LP by the second input variable detTaking a fuzzy set LP;
when the pH value of the No. 3 leaching tank is in a higher state, namely a first input variable e t The fuzzy set LP is taken, and the pH value has an ascending trend, namely de t Taking a fuzzy set LP or HP; or the pH value of the No. 3 leaching tank is in an extremely high state, namely a first input variable e t Taking the fuzzy set HP and the pH value has a descending trend, namely a second input variable de t Taking fuzzy set HN or LN, thenTaking a fuzzy set MP;
when the pH value of the No. 3 leaching tank is in an extremely high state, namely a first input variable e t The fuzzy set HP is taken, and the pH value has an ascending trend or is unchanged, namely de t Taking the fuzzy set LP, HP or ZThe fuzzy set HN is taken.
Preferably, in S2, the relation between the flow rate of the waste acid addition and the zinc roasting addition amount per unit time is:
wherein alpha and beta are respectively the soluble zinc coefficient and leaching rate, and respectively 0.58 and 0.9 are taken;and M ZnO The relative molecular masses of sulfuric acid and zinc oxide, respectively; c (C) acid 、C sup And C mix The sulfuric acid concentration in g/L of the waste acid, the acid leaching supernatant and the mixed solution is respectively;And->The waste acid adding flow rates of the No. 1 leaching tank and the No. 2 leaching tank are respectively m 3 /h，F mix The flow rate of the mixed solution is m for the mixed solution of a No. 1 groove 3 /h；F sup The flow of acid leaching supernatant liquid of No. 1 tank is expressed as m 3 /h; m is the sum of zinc calcines entering the No. 1-3 leaching tanks in unit time, and the unit is t/h.
Preferably, in the step S3, the defined abnormal condition includes: zinc calcine discharging fluctuation, zinc calcine breaking, electrolysis slitting and purifying production stopping;
aiming at each abnormal condition, the compensation value for determining each abnormal working condition to compensate on the basis of the preset value of the waste acid flow is as follows: compensation value when zinc roasting blanking fluctuatesIs calculated from formula (5)>
When in a material breaking processIn the condition, if the material breaking time is less than 5min, the compensation value0, if the material breaking time is more than or equal to 5min and less than 8min, the compensation value is ∈10>1/2->If the material breaking time is more than or equal to 8min, compensating valueIs->Wherein the method comprises the steps of
Compensation value of waste acid regulating quantity when in electrolytic cutting working conditionCalculate the value +.>
And recovering the reduced spent acid at the end of the electrolytic slitting process; wherein F is Cutting The flow rate of anode mud sent to the leaching process during electrolytic slitting;
when the purification and production stopping working condition is met, waste acid is not added, and the flow circulates internally;
the addition amount of waste acid in the No. 2 leaching tank is as follows:
when the purification is stopped, the waste acid adding flow of the No. 2 leaching tank is 0;
when the working condition of no production stopping is adopted, the waste acid adding flow of the No. 2 leaching tank is as follows:
wherein,and determining according to the blanking time.
Preferably, the zinc calcine discharging fluctuation means that the discharging amount at the current moment and the discharging amount at the previous moment have deviation of more than 3t/h, namely delta m is more than 3t/h; the zinc calcine breaking refers to the blanking of one of the current No. 1-3 grooves (namely M 1# ，M 2# ，M 3# ) 0t/h and the previous time is greater than 0; the electrolytic slitting refers to that the electrolytic slitting signal F1 is 0 at the current moment and the current moment F1 is set to be 1; the purification stop production means that the purification stop production signal F2 is set to be 1.
Compared with the prior art, the invention has the following beneficial effects:
the invention can effectively realize stable control of the pH value in the leaching process by utilizing fuzzy control, greatly reduce the labor intensity of workers, and simultaneously provide a No. 2 waste acid addition amount adjustment scheme aiming at the possible abnormal working condition 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 that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a process flow diagram of a neutral leaching process of zinc hydrometallurgy calcine;
FIG. 2 is a graph of a membership function of a first input variable;
FIG. 3 is a second input variable membership function;
FIG. 4 is a graph of output variable membership functions;
FIG. 5 is a control surface diagram of the input-output rule generation;
FIG. 6 is a graph showing the comparison of the control effect of the control method of example 1 and the control effect of the manual control;
fig. 7 is a graph showing the comparison of the control effect of the control method of example 1 and the control effect of the manual control on the feeding fluctuation condition.
Detailed Description
The invention will be described more fully hereinafter with reference to the accompanying drawings and preferred embodiments in order to facilitate an understanding of the invention, but the scope of the invention is not limited to the following specific embodiments.
FIG. 1 is a schematic diagram of the neutral leaching process of zinc hydrometallurgy of the invention, wherein:
1#,2#,3#,4#,5# are 5 blanking bins;
zinc calcine: the zinc oxide is also a main dissolved matter from the roasting process, and also comprises sulfate, silicate and ferrite containing impurity ions, wherein the impurity ions are also dissolved into the solution, so that the subsequent process is influenced to a certain extent;
waste acid: the solution produced in the electrolysis process mainly contains sulfuric acid as the solute and is mainly used for neutralizing zinc calcine;
mixing liquid: mixing of post-production liquors from various processes in a smelter;
acid leaching supernatant: the clarified solution after the acid leaching process is filtered by a thickener;
manganese ore pulp: the ore pulp containing solute manganese sulfate is mainly used for oxidizing ferrous elements and sulfur elements in solution.
To use the control method, the following definitions are first given: y is the set value of the pH value of the outlet of the No. 3 leaching tank in the leaching process, 3.25, and Y' is the detection value of the pH value of the outlet of the No. 3 leaching tank at present; e isThe 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, de is the change rate of the pH value deviation in the leaching process, and is equal to the difference value between the current time e and the last time e; m is M 1# 、M 2# And M 3# The zinc calcine amount added into the No. 1 leaching tank, the No. 2 leaching tank and the No. 3 leaching tank in unit time is t/h, m is the total amount of the zinc calcine added into the No. 1-3 leaching tank in unit time, t/h is the difference between the current moment and the zinc calcine blanking amount of the No. 1-3 leaching tank in the previous moment, and t/h is the unit;and->The waste acid adding flow rates of the No. 1 leaching tank and the No. 2 leaching tank are respectively m 3 /h；ΔF 2 The unit of the adjustment value of the waste acid adding flow of the No. 2 leaching tank based on pH value feedback at the outlet of the No. 3 leaching tank in the leaching process is m 3 /h；F mix Adding flow for the mixed solution of the No. 1 tank, wherein the unit is m3/h; f (F) sup The flow of acid leaching supernatant liquid of No. 1 tank is expressed as m 3 /h; f1 is a purification stop signal, F2 is an electrolysis slitting signal, and is a boolean value; f (F) Cutting The flow rate of anode mud fed for electrolytic slitting is expressed in m 3 /h; wherein DeltaF 2 The preset value is given first, and then compensation adjustment is carried out 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 pre-adjustment value of the addition amount of the No. 2 waste acid through a fuzzy ruleThe method comprises the following specific steps:
inputting the error value e of the current pH value t As a first input variable, the rate of change de of the error value of the current pH value t As a second variable which is to be taken as a third variable,is the output variable of the fuzzy rule. Wherein e t ＝Y t -Y′ t ，de t ＝e t -e t-1 . E of said first variable t Second variable de t And output variable +.>Divided into a plurality of fuzzy sets.
Wherein error of pH e t The 5 fuzzy sets divided are: HN (negative large), LN (negative small), Z (normal), LP (positive small), HP (positive large). Z represents that the current pH value is in the process index range, LN represents that the current pH value is in a state slightly lower than the normal range, HN represents that the current pH value is already in a state extremely lower than the normal range, LP represents that the current pH value is in a state slightly higher than the normal range, and HP represents that the current pH value is in a state much higher than the normal range.
Rate of change of pH error de t The 5 fuzzy sets divided are: HN (negative large), LN (negative small), Z (normal), LP (positive small), HP (positive large). 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 fast descending trend, LP represents that the pH value is in a slow ascending trend, and HP represents that the pH value is in a fast ascending trend. And is used to describe e t And de t The membership functions of the fuzzy sets are the same as follows:
HN is described by a Z membership function:
LN, Z, LP are described by a bell-shaped membership function:
HP is described by an S-type membership function:
adding amount of waste acidThe fuzzy sets are divided into 7 fuzzy sets: HN (acid greatly reduced), MN (acid greatly reduced), LN (acid greatly reduced), Z (acid unchanged), LP (acid greatly increased), MP (acid greatly increased), HP (acid greatly increased). Wherein the corresponding membership functions used to describe the fuzzy sets are:
HN is described by a Z membership function:
MN, LN, Z, LP, MP is described by a bell-shaped membership function:
HP is described by an S-type membership function:
in the above formulae, x represents a variable, and a and b are parameters of a function.
The parameters of the membership function can be obtained by combining the field expert experience and data analysis as shown in the following 1-2:
TABLE 1
TABLE 2
The membership function images are shown in figures 2-4, respectively.
The corresponding fuzzy rule is:
rule one: when the pH value of the No. 3 leaching tank is within the process index range, the pH value of the No. 3 leaching tank is in a slow rising trend or a slow falling trend or no change trend. In this case, it is considered that the acid addition amount is reasonable, and the acid addition amount remains unchanged. The rules are:
IF(e t ＝Z and de t ＝LN)or(e t ＝Z andde t ＝Z)or(e t ＝Z andde t ＝LP)，
rule II: when the pH value of the No. 3 leaching tank is in the process index range, the pH value of the No. 3 leaching tank is in a rapid descending trend, which indicates that the pH value is in a low or near-index lower limit state in a short time without intervention. When the current pH is in a state slightly lower than the normal range, but the pH has a rising trend or remains unchanged, it is indicated that the pH will remain in a lower state. Both cases can be categorized as a slight excess of acid, which should be slightly reduced. The rules are:
rule III: when the pH of the 3# leaching tank is slightly lower than the normal range, the pH tends to drop, which indicates that the pH will be lower for a short period of time. Or when the current pH value is in a state far below the normal range, but the pH value has an ascending trend. Both of these conditions can be categorized as acid excess, and the amount of acid added should be moderately reduced. The rules are:
rule IV: when the pH value of the No. 3 leaching tank is far lower than the normal range, the pH value of the No. 3 leaching tank has a descending trend or is unchanged, which indicates that the pH value is in an extremely low state in a short time, and the acid addition and the excessive acid addition are carried out at present, so that the acid is greatly reduced. The rules are:
rule five: when the pH value of the No. 3 leaching tank is in the process index range, the pH value of the No. 3 leaching tank has a rapid rising trend, which indicates that the pH value is too low, and the pH value is in a high or near-to-index upper limit state in a short time without intervention. When the current pH value is in a state slightly higher than the normal range and has no trend of change, or the pH value is in a state slightly higher than the normal range and p has a trend of decrease, the pH value is indicated to be kept in a higher state or close to the index upper limit state. Both cases can be categorized as slightly less acid, and the amount of acid added should be slightly increased. The rule is
Rule six: when the pH value of the No. 3 leaching tank is slightly higher than the normal range, the pH value of the No. 3 leaching tank has an ascending trend, which indicates that the pH value is in a higher state in a short time. Or when the current pH is in a state much higher than the normal range but the pH tends to decrease. Both cases can be classified as acid deficient, and the amount of acid added should be moderately increased. The rules are:
rule seven: when the pH value of the No. 3 leaching tank is far higher than the normal range, the pH value of the leaching tank has an ascending trend or is unchanged, which indicates that the pH value is in a very high state in a short time, and the acid addition amount should be greatly increased. The rules are:
the resulting control surface is as shown in fig. 5:
thus, the pre-adjustment value of the addition amount of the waste acid can be obtained
Step 2: according to the deep analysis of the process technology, the relationship between the addition amount and the blanking amount of the waste acid is established by combining the common conservation of materials and the reaction dynamics, and the method is as follows:
according to the dissolution reaction of zinc, the solvent is assumed to be waste acid, mixed liquor and acid leaching supernatant liquor according to the reaction
ZnO+2H + ＝Zn 2+ H 2 O
From the principle of stoichiometry, the relation between the flow of No. 2 waste acid and the addition amount of calcine is obtained:
wherein alpha and beta are respectively the soluble zinc coefficient and leaching rate, and 0.58 and 0.9 are taken;and M zno The relative molecular masses of sulfuric acid and zinc oxide are 98 and 81, respectively; c (C) acid 、C sup And C mix The sulfuric acid concentration 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 calcine discharging amount entering the No. 1-3 leaching tank in unit time, and the unit is t/h.
Step 3: four abnormal working conditions of zinc calcine discharging fluctuation, zinc calcine breaking, electrolysis slitting and purification production stopping are defined. Zinc calcine blanking fluctuation: namely, the blanking amount at the current moment and the blanking amount at the previous moment have deviation of more than 3t/h; breaking zinc calcine: the blanking of one of the current 1-3 slots is 0t/h and the previous time is not 0; electrolytic slitting: the electrolysis slitting signal F1 at the previous moment is 0 and the current moment F1 is 1, which indicates that the slitting liquid is sent in the electrolysis process, and the slitting working condition is generated; purifying and stopping production: the purge shutdown signal F2 is set to 1, indicating that purge shutdown conditions are present.
Judging that the current leaching process is positioned in abnormal working conditions according to the signals, if the current leaching process is positioned in zinc calcine blanking fluctuation, the compensation value 1 of the waste acid addition amount acts on the pre-adjustment value of the waste acid addition amount, and obtaining according to the expression of the step 2:
if the zinc calcine is in the zinc calcine breaking working condition, the zinc calcine can be obtained according to the expression of the step 2
If the material is interrupted for a short time, namely the material interruption time is less than 5min, thenDoes not act on the pre-tuning value; if the material breaking time is more than or equal to 5min and less than 8min, 1/2 +.>Acting on the waste acid preset value; if the material is cut off for a long time, namely, the time is more than or equal to 8 minutes, 1/2 of the material is added again>Acting on the waste acid preconditioning value, i.e. in this case in common ∈ ->Acting on the waste acid preset value; when the break is recovered, the reduced spent acid is recovered.
If electrolytic slitting working conditions occur, according to the flow rate F of anode mud sent to the leaching process during electrolytic slitting Cutting Adaptive process for reduction of spent acid
And recovering the reduced spent acid at the end of the electrolytic slitting process.
If the purification and production stopping process occurs, no waste acid is added in the neutral leaching process, and the flow circulates internally. And the waste acid is recovered to the original waste acid addition amount when the production is recovered in the purification procedure.
Step 4: according to the steps 1,2 and 3, the final addition amount of the waste acid in the No. 2 tank is as follows:
when the purification is stopped, the production is stopped:
when not in the production stopping condition:
wherein the method comprises the steps ofThe compensation value of the waste acid adjustment amount is defined as follows according to the abnormal working condition in the step 3:
and judging the current working condition and combining to obtain the vehicle.
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, the method has the following specific comparison effects:
as can be seen from FIGS. 6-7, the proposed method ensures that the temperature is substantially stable in the interval 3-3.5, while the pH fluctuation is large during manual control. Compared with manual control, the method has smaller fluctuation range and higher qualification rate, and the specific comparison is shown in table 1:
table 1: control performance index comparison at a set point of 3.25
| Controller for controlling a power supply | Yield (%) | Fluctuation range |
| The method | 90.17 | [2.95，3.51] |
| Manual control | 51.44 | [2.26，3.51] |
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.
Claims (8)
1. The control method for the abnormal working condition in the zinc hydrometallurgy leaching process is characterized by comprising the following steps:
s1, measuring the pH value of a target detection site, and calculating and obtaining an error value of the current pH value based on the actually measured pH value and a pH set value of the current detection siteAs the firstAn input variable for calculating the change rate of the error value for obtaining the current pH value>As a second input variable, a pre-adjusted value of the waste acid addition flow of the output variable is obtained by fuzzy rules>；
S2, conservation of materials in the zinc-based dissolution reaction process to obtain the waste acid addition flowA 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 the flow of waste acid aiming at different abnormal working conditionsAnd then according to the pre-adjustment value of the waste acid addition flow>Compensation valueAnd the waste acid adding flow rate at the last moment>Obtaining the final current waste acid adding flow, and performing process control;
in the step S1, the pre-adjustment value of the waste acid addition flow is obtained through fuzzy rulesComprising the following steps:
s11, error value of current pH value of target detection siteAs a first input variable, the rate of change of the error value of the current pH value is +.>As a second input variable, +.>As output variable, wherein-> ，，Setting the current pH value of the target detection site, < + >>An actual measurement of the current pH of the target detection site;
s12, inputting a first input variableSecond input variable->And output variable +.>Dividing the fuzzy set 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 variableFirst, theTwo input variables +.>And output variable +.>Corresponding relation of each fuzzy set function to formulate fuzzy rules and determine pre-adjustment values of waste acid adding flow under different conditions according to the fuzzy rules；
In the step S3, the defined abnormal working conditions include: and (3) zinc calcine discharging fluctuation, zinc calcine breaking, electrolysis slitting and purification stopping production.
2. The method for controlling abnormal conditions in a zinc hydrometallurgy leaching process according to claim 1, wherein in the step S1, the target detection site is an outlet of a third leaching tank; the pH set value ranges from 3 to 3.5.
3. The method for controlling abnormal conditions in a zinc hydrometallurgy leaching process according to claim 1, wherein in step S12, a first input variable is setDivided into 5 fuzzy sets: HN, LN, Z, LP and HP; wherein Z represents that the current pH value is in the process finger range, LN represents that the current pH value is in a state slightly lower than the normal range, HN represents that the current pH value is far lower than the normal range, LP represents that the current pH value is in a state slightly higher than the normal range, and HP represents that the current pH value is far higher than 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 variableDivided 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 fast descending trend, LP represents that the pH value is in a slow ascending trend, and HP represents that the pH value is in a fast 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;
output variableDivided into 7 fuzzy sets HN, MN, LN, Z, LP, MP and HP, wherein HN represents a substantial acid reduction, MN represents an acid medium amplitude reduction, LN represents an acid small amplitude reduction, Z represents an acid invariant, LP represents an acid small amplitude increase, MP represents an acid medium amplitude increase, and HP represents an acid large amplitude increase; 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;
parameters in each membership function are obtained according to field experience and data analysis.
4. The method for controlling abnormal conditions in a zinc hydrometallurgy leaching process according to claim 3, wherein the Z-type membership function is:
（1）；
the bell-shaped membership function is:
（2）；
the S-shaped membership function is as follows:
（3）。
5. a method for controlling abnormal conditions in a zinc hydrometallurgy leaching process according to claim 3, wherein step S13 comprises: the fuzzy rule is as follows:
when the first input variableTaking the fuzzy set Z and the second input variable +.>Taking fuzzy sets LN, LP or Z, outputting variableTaking a fuzzy set Z;
when the first input variableGet fuzzy set Z, and->Taking a fuzzy set HN; or the first input variable +>Taking the fuzzy set LN and the second input variable +.>Taking the fuzzy set HP, LP or Z, +.>Taking a fuzzy set LN;
when the first input variableTaking fuzzy set LN, and +.>Taking a fuzzy set LN or HN; or the first input variable +>The fuzzy set HN is taken and the second input variable +.>Taking the fuzzy set HP or LP, then +.>Taking a fuzzy set MN;
when the first input variableFuzzy set HN is taken and +.>Taking fuzzy set Z, HN or HN, then +.>Taking a fuzzy set HN;
when the first input variableGet fuzzy set Z, and->Taking a fuzzy set HP; or the first input variable +>Taking the fuzzy set LP and the second input variable +.>Taking fuzzy set Z, HN or LN, then +.>Taking a fuzzy set LP;
when the first input variableGet fuzzy set LP, and +.>Taking a fuzzy set LP or HP;or the first input variable +>Taking the fuzzy set HP and the second input variable +.>Taking fuzzy set HN or LN, then +.>Taking a fuzzy set MP;
when the first input variableGet fuzzy set HP, and->Taking the fuzzy set LP, HP or Z, +.>The fuzzy set HN is taken.
6. The method for controlling abnormal conditions in a zinc hydrometallurgy leaching process according to any one of claims 1 to 5, wherein in S2, the relation between the waste acid addition flow and the zinc roasting addition amount in unit time is:
（4）；
wherein the method comprises the steps ofAnd->The soluble zinc coefficient and the leaching rate are respectively 0.58 and 0.9;And->The relative molecular masses of sulfuric acid and zinc oxide, respectively;、And->The sulfuric acid concentration in g/L of the waste acid, the acid leaching supernatant and the mixed solution is respectively;And->The waste acid adding flow rates of the No. 1 leaching tank and the No. 2 leaching tank are respectively m 3 /h，The flow rate of the mixed solution is m for the mixed solution of a No. 1 groove 3 /h；The flow of acid leaching supernatant liquid of No. 1 tank is expressed as m 3 And (3) per hour, wherein m is the sum of zinc calcines entering the No. 1-3 leaching tank in unit time, and the unit is t/hour.
7. The method for controlling abnormal conditions in a zinc hydrometallurgy leaching process according to any one of claims 1 to 5, wherein for each abnormal condition, a compensation value for each abnormal condition, which compensates on the basis of a preset value of the flow rate of the waste acid, is determined as follows:
compensation value when zinc roasting blanking fluctuatesIs calculated from formula (5)>：
（5）；
If the material breaking time is less than 5min, compensating value0, if the material breaking time is more than or equal to 5min and less than 8min, the compensation value1/2->If the material breaking time is more than or equal to 8min, the compensation value is +.>Is->；
Wherein the method comprises the steps of
（6）；
Compensation value of waste acid regulating quantity when in electrolytic cutting working conditionCalculate the value +.>：
（7）；
And recovering the reduced spent acid at the end of the electrolytic slitting process; wherein the method comprises the steps ofThe flow rate of anode mud sent to the leaching process during electrolytic slitting;
when the purification and production stopping working condition is met, waste acid is not added, and the flow circulates internally;
therefore, the waste acid addition amount of the No. 2 leaching tank is as follows:
therefore, when the purification is stopped, the waste acid adding flow of the No. 2 leaching tank is 0;
when the working condition of no production stopping is adopted, the waste acid adding flow of the No. 2 leaching tank is as follows:；
wherein,。
8. the method for controlling abnormal conditions in a zinc hydrometallurgy leaching process according to claim 7, wherein the zinc calcine discharging fluctuation refers to a deviation of more than 3t/h between the total discharging amount of a No. 1-3 leaching tank at the current moment and the total discharging amount of a No. 1-3 leaching tank at the previous moment; the zinc calcine breaking means that the blanking of a certain tank in the leaching tanks 1-3 is 0t/h and the previous moment is more than 0; the electrolytic slitting refers to that the electrolytic slitting signal F1 is 0 at the current moment and the current moment F1 is set to be 1; the purification stop production means that the purification stop production signal F2 is set to be 1.
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