CN115268539A - Intelligent granulating control system and method for sintering mixture - Google Patents
Intelligent granulating control system and method for sintering mixture Download PDFInfo
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Abstract
The invention relates to the technical field of sintering, in particular to an intelligent granulating control system and method for a sintering mixture, wherein an intelligent control system is additionally arranged in the whole process of proportioning, mixing and granulating the sintering mixture, relevant links are optimized and improved, an intelligent granulating expert system is utilized to integrate a mixer body and front-end equipment systems, the granulating of the mixture is strengthened, and the aims of high efficiency, high quality, consumption reduction, yield improvement and efficiency improvement of sintering are finally realized; control system includes the automatic module of adding water of intelligence, particle diameter on-line measuring module, atomizing granulation module and intelligent pelletization expert module, intelligence pelletization expert module patrols and examines the formula detection and control adjustment to each control module according to particle diameter analysis result, intelligence is automatic to be added water the module and is combined the realization to water measurement in blendor and the secondary blendor, the water yield with the intelligent control of the mode of adding water, it is showing to practice thrift sintering fuel effect, the wet layer reduces, the gas permeability increases, the pelletization rate promotes by a wide margin, the grain size improves.
Description
Technical Field
The invention relates to the technical field of sintering, in particular to an intelligent granulating control system and method for a sintering mixture.
Background
In China, most of furnace charging materials of blast furnaces are provided by a sintering method, so that sintering plays a significant role in the metallurgical industry of China. Aiming at the national requirements on energy conservation and consumption reduction of the steel industry and the continuous fine development of modern sintering production, the thick material layer sintering is taken as a comprehensive measure for improving the quality of sintered mineral products and saving energy and reducing consumption, and is agreed at home and abroad. The problem of air permeability of the material layer is firstly solved by sintering the thick material layer, so that the granulation of the mixture is the most important link. Many factors influence the pelletization of the sintering mixture, cover the overall process of sintering mixture batching, compounding, pelletization, at this in-process, present corollary equipment is imperfect, and the degree that becomes more meticulous is not enough, and each link equipment can't overall control simultaneously, causes the pelletization rate of sintering mixture lower, the composition is inhomogeneous, the energy consumption is higher.
The existing corollary equipment does not have the change of a self-adaptive process and the change of certain factors in the production process and automatic tracking change, so the defects of the corollary equipment influence the whole sintering line. Due to the many variables of the sintering process. Each link is not controlled finely enough, and a plurality of small changes are accumulated and superposed to cause adverse factors of sintering, thereby influencing the final sintering result. The method has simple response measures for adverse factor change in the sintering process, adopts too many manual intervention means, and does not have a response system for automatic detection and automatic processing.
Disclosure of Invention
In order to solve the technical problems, the invention provides an intelligent granulating control system and method for a sintering mixture, wherein an intelligent control system is additionally arranged in the whole process of proportioning, mixing and granulating the sintering mixture, relevant links are optimized and improved, an intelligent granulating expert system is utilized to integrate a mixer body and equipment systems at the front end, granulating of the mixture is strengthened, and the aims of high efficiency, high quality, consumption reduction, yield improvement and efficiency improvement of sintering are finally fulfilled.
In order to realize the purpose, the invention is realized by adopting the following technical scheme:
the invention provides an intelligent granulating control system for a sintering mixture, which comprises an intelligent automatic water adding module, a particle size online detection module, an atomizing and granulating module and an intelligent granulating expert module in data communication with an upper computer, wherein:
the intelligent automatic water adding module is used for automatically controlling the water adding amount in the primary mixer and comprises a fuzzy feedforward control unit, an expert feedback unit and an intelligent comprehensive control unit, wherein the fuzzy feedforward control unit is used for collecting real-time batching data in the batching process of a sintered mixture, carrying out data preprocessing based on a fuzzy control theory and taking a processing result as feedforward data to participate in final water adding amount calculation, and the batching data comprises the total flow of the mixture, a target moisture value of a sintering process, a moisture measured value at the outlet position of the mixer and the water adding flow calculated in the batching process; the expert feedback unit is used for providing feedback control data for the feedforward data according to actual big data accumulated for many years; the intelligent comprehensive control unit is used for giving the actual water adding amount through comprehensive analysis, reasoning and model operation according to the feedforward data and the feedback control data, and distributing the water adding instruction to the water adding actuator to adjust the water adding amount; the whole closed-loop control system of the intelligent automatic water adding module has a self-learning function;
the online particle size detection module is used for analyzing the particle size of a video image generated by pelletizing and pelletizing the sintering mixture and accurately detecting the proportional quantity of qualified balls;
the atomizing and granulating module comprises an atomizing and granulating control unit and a spraying assembly in electrical signal connection with the atomizing and granulating control unit, the spraying assembly is arranged in the secondary mixer, the atomizing and granulating control unit is used for constructing a mist quantity-moisture control model formed according to a target moisture value, a spraying quantity, a moisture measurement value and a water adding quantity, a mist quantity-weight control model formed according to the weight of materials and the proportion of the materials, a mist diameter-attribute fuzzy control model formed according to different material attributes, the balling speed and the balling cause, and the optimal granulating process control can be realized by combining the particle diameter online detection result;
the intelligent granulating expert module is used for comprehensively and correlatively controlling all equipment and all control modules in the granulating process of the sintering mixture.
In a possible technical scheme, the outlet positions of the primary mixer and the secondary mixer are respectively provided with a first moisture measuring instrument for detecting the moisture measured value.
In a possible technical scheme, the system further comprises a fuel dry-basis batching module connected with the intelligent pelletizing expert module in a data communication mode, wherein the fuel dry-basis batching module comprises a second moisture measuring instrument used for measuring the moisture of the fuel in real time and a belt scale used for weighing the dry-basis fuel, and the weight of the fuel batching can be controlled.
In one possible technical scheme, the first moisture meter and/or the second moisture meter is a contact-type moisture meter.
In a possible technical scheme, the intelligent granulation system further comprises a material pre-wetting module in data communication connection with the intelligent granulation expert module, wherein the material pre-wetting module is additionally provided with a spray wetting and stirring device when mineral powder with poor hydrophilic wetting enters a main belt, and can perform automatic closed-loop control on the wetting degree.
In a possible technical scheme, the system also comprises a quicklime slaking module in data communication connection with the intelligent granulation expert module, and the quicklime slaking module is used for realizing closed-loop control on slaking time, water adding amount and lime weight according to a bin number or lime activity degree in the process of adding water to lime in advance.
In a possible technical scheme, the system further comprises a material temperature lifting module in data communication connection with the intelligent pelletizing expert module, and a hot water and/or steam metering and regulating device and a material temperature measuring device are arranged and used for closed-loop management of the temperature of the mixture.
The invention provides a method for controlling intelligent granulation of a sintering mixture, which is realized according to any one of the intelligent granulation control systems of the sintering mixture, and the method comprises the steps of measuring the moisture of fuel in real time through a fuel dry-based batching module, and forming dry-based fuel closed-loop weight control with a belt scale; uniformly adding the calculated water adding amount of the material pre-wetting module into the ore seeds to be pre-wetted in an atomizing form by a spray wetting and stirring device, ensuring that the mineral particles are fully pre-wetted, and mixing and granulating the mineral particles with other ore seeds; the method comprises the steps of adding water into a lime slaker, a spiral feeder and/or a large belt lime batching feeding position to carry out multistage slaking on the quicklime; particle diameter on-line measuring module carries out particle diameter analysis to the video image that sintered mixture pelletization balling generated, and the accurate proportion quantity that detects qualified ball, intelligence pelletization expert module is to intelligent automatic water module of adding according to the particle diameter analysis result, atomizing granulation module, material prewetting module and quick lime digestion module are patrolled and examined the formula and are detected and control the adjustment, intelligence automatic water module that adds combines with atomizing granulation module and realizes measuring the moisture in primary mixer and the secondary mixer, the intelligent control of water yield control and water adding mode, the material prewetting module automatic control is moist the degree of wetness of the mineral powder of wet difference of hydrophilic, quick lime digestion module closed loop control quicklime digestion time, water yield and quick lime weight, in order to satisfy particle diameter optimization.
In the technical scheme, during material preparation, the return fine bin position is controlled to be between one third and one half, the content of the adhesive powder smaller than 0.5 mm in the return fine is 40-50%, the return fine proportion is not more than 3% each time, and the time interval is not less than 1 hour.
In one possible technical scheme, the temperature of the mixture is increased by adopting any one or more of the following methods:
a. the water source in any step or a plurality of steps or all steps of the steps of material pre-wetting, quicklime digestion and mixture water adding is hot water;
b. introducing steam into the secondary mixer, wherein the steam is arranged at the rear end of the atomization granulation, so that the temperature rise granulation is facilitated;
c. a steam pipeline is additionally arranged at the material distribution point to preheat materials, so that the material distribution temperature is increased;
d. the belt is additionally provided with a belt cover to wrap and preserve heat, so that heat loss is reduced, and the environment is improved;
e. on the premise of adding the belt cover, steam is added into the belt cover at the outlet of the secondary mixer;
when the method is used for setting hot water or steam, metering regulation and control devices in communication connection with the material temperature lifting module are arranged.
Compared with the prior art, the invention has the beneficial effects that: a fuzzy feedforward control unit in the intelligent automatic water adding module collects real-time batching data in a batching process of a sintering mixture, data preprocessing is carried out on the basis of a fuzzy control theory, a processing result is used as feedforward data, and an expert feedback unit carries out preprocessing and statistical calculation on a moisture value, a moisture deviation and an interference variable according to actual big data analysis accumulated for many years, so that a feedback control quantity is automatically given; the intelligent comprehensive control unit performs intelligent control on the basis of fuzzy feedforward and expert feedback, gives the actual water adding amount after operation, and distributes a water adding instruction to the water adding regulating valve, so that the intelligent control of three control loops of the mixture water is realized; and the intelligent granulation expert module performs inspection type detection and control adjustment on each control module according to the particle size analysis result, so that the granulation rate is always kept in an optimal state. The intelligent automatic water adding module is combined with the atomizing granulation module to realize intelligent control of water measurement, water adding amount control and water adding modes in the primary mixer and the secondary mixer, and experiments prove that the implementation case can realize control of the real-time water measurement accuracy to +/-0.2 percent, the water adding amount accuracy to +/-0.3 percent, obvious reduction of the water adding amount, obvious sintering fuel saving effect, fuel and electric power saving for each ton of material, reduction of an over-wet layer, increase of air permeability, great improvement of granulation rate, improvement of grain size and obvious effect of increasing yield and efficiency; real-time water measurement value, water adding flow, spraying grain diameter, quicklime digestion time, digestion water flow, pre-wetting water quantity, material temperature, mixture grade real-time data and the like are displayed and recorded on a screen of a middle control room, and multi-node intelligent automatic inspection response control of the sintering and granulating process is realized.
Drawings
FIG. 1 is a schematic diagram of the structure of an intelligent pelletizing control system for sinter mixture according to an embodiment of the present invention;
FIG. 2 is a schematic flow chart of a method for controlling intelligent granulation of a sinter mixture according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a water adding process controlled by the intelligent automatic water adding module;
FIG. 4 is a schematic diagram of a data processing process of the intelligent automatic water adding module;
FIG. 5 is a schematic diagram of the atomization granulation module;
FIG. 6 is a schematic structural diagram of a mixing and pelletizing lining plate inside a secondary mixer.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all embodiments of the present invention.
As shown in fig. 1, the intelligent granulating control system for sinter mixture in the embodiment of the present invention includes an intelligent automatic water adding module 300, a particle size online detection module 400, an atomizing and granulating module 500, and an intelligent granulating expert module 200 in data communication with an upper computer 100, wherein:
the intelligent automatic water adding module 300 is used for automatically controlling the water adding amount in the primary mixer 1 and comprises a fuzzy feedforward control unit 301, an expert feedback unit 302 and an intelligent comprehensive control unit 303, wherein the fuzzy feedforward control unit 301 is used for collecting real-time batching data in the batching process of a sintered mixture, carrying out data preprocessing based on a fuzzy control theory, taking a processing result as feedforward data and participating in final water adding amount calculation, and the batching data comprises total mixture flow, a target moisture value of a sintering process, a moisture measurement value at the outlet position of the mixer and water adding flow calculated in the batching process; the expert feedback unit 302 is used for giving feedback control data to the feedforward data according to actual big data accumulated for many years; the intelligent integrated control unit 303 is used for giving an actual water adding amount through integrated analysis, reasoning and model operation according to the feedforward data and the feedback control data, and distributing a water adding instruction to the water adding actuator to adjust the water adding amount;
the water control of the mixture is important for sintering, the influence on quality, yield and energy consumption is large, the water content of the mixture is directly related to the weight and the water content of sintering raw materials and the water adding flow in the batching process, and the water content of the mixture is suitable for ensuring the important conditions of granulation and improving the air permeability of a material layer.
1) Reflection of suitable moisture during sintering: the sintering material has good air permeability, improves the heat conductivity of the sintering material, enables the heat exchange condition in the material layer to be good, is beneficial to controlling the sintering zone in a narrower range, reduces the resistance of the material layer to air flow in the sintering process, and simultaneously ensures that necessary high temperature is obtained under the condition of less fuel consumption.
2) Influence on sintering production when moisture content is small: firstly, the pellets cannot be formed during the mixing and granulating process, and the particle size composition of the mixture are deteriorated, so that the air permeability of the material layer is deteriorated, the vertical sintering speed is reduced, and the sintering process cannot be performed in severe cases.
3) Influence of excessive moisture content on sintering production: when the moisture of the mixture is too large, a large amount of water vapor evaporated at high temperature enters the airflow in the sintering process, when the temperature of the lower sintering material is lower than the dew point temperature, the water vapor in the airflow can hardly be discharged to the atmosphere along with the airflow, and can be condensed on the cold material with the material layer temperature lower than the dew point temperature, so that the material moisture of the lower sintering material exceeds the original moisture of the lower sintering material, an over-wet layer is formed, the higher the original moisture content is, the more serious the over-wet layer is, and the air permeability of the sintering material can be damaged by the over-wet layer.
In the intelligent automatic water adding module 300 of the present invention, the fuzzy feedforward control unit 301 collects real-time batching data during the batching process of the sintering mixture, and performs data preprocessing based on the fuzzy control theory, and the processing result is used as feedforward data to participate in the final water adding amount calculation, for example, in this embodiment, variables obtained by the fuzzy feedforward control unit 301 from the batching system are shown in table 1:
TABLE 1 variables derived from the batching System by the fuzzy feedforward control Unit
Wherein, W is the weight total flow of the material water adding link. The weight of W is calculated according to the properties of different material temperatures, heat release, incompatibility, material characteristics, chemical reaction and the like. The first 3 measured value Ms of the moisture measuring instrument is a first 3 real-time measured value of the moisture measuring instrument at the mixer 1.
The fuzzy feedforward control unit 301 calculates the real-time material flow of several materials and the corresponding weight coefficients according to the real-time batching data to obtain the weight material flow of various materials; based on a data fuzzy theory, the method comprises the steps of carrying out mean value analysis, error analysis and data sorting on various material flow data, and respectively storing the data in data areas of various material flow rates according to a data stacking technology.
Because the moisture of the sintering material is = (water content/material weight + water content) × 100%, because the original state, high-temperature or water-encountering evaporation characteristics and different water contents of the material cause that if water is added according to the actual material weight control, larger deviation occurs, so that the control is unstable and inaccurate, and therefore, the concept of material weight coefficient is introduced.
Mathematically, the weighting factors are given different scaling factors in order to show how important a number of numbers have in the total. The weight coefficient can be obtained by an empirical method or a multi-factor statistical method, and the obtaining method can be specifically selected according to the prior art, and is not described again here; in the invention, the weight coefficient of the material refers to whether the material generates physical and chemical changes, heat absorption, evaporation and the like after being mixed with water, so that the loss of water content is caused, and the water content of the final sintered material is influenced; according to years of practice of the applicant, the weight coefficients of different materials are determined.
Taking an automatic water adding system of a 265 sintering machine of a certain company as an example, the weight coefficients of part of materials are shown in table 2:
table 2 265 weight coefficients and weight flow of part of the sintering machine:
from the above table, the original total flow rate is 364 tons/hour, the weighted total flow rate is 351.3 tons/hour, the properties and characteristics of the material are considered in the weighted total flow rate, and the weighted flow rate is used as the material flow rate required by the control system, so that the method is more suitable for practical application.
The weight coefficient of material passes through host computer 100 input, when material attribute takes place great change, can adjust to the system is more stable, and control accuracy is higher, and the response is faster.
Because the distances of various bins relative to the primary mixer 1 are different, the time for various materials to reach the primary mixer 1 needs to be calculated, and the weighted material flow of various materials is extracted in real time at the moment of reaching the primary mixer 1 according to the data of various material flow time periods, and the various material flow is accumulated to form the raw material weighted total material flow.
The fuzzy feedforward calculates the real-time water adding flow according to the real-time data of the material weight material flow, the calculation formula of the water adding flow Ww, the fuzzy control theory and the self-learning technology, evaluates and compares the water adding flow with the data obtained from the expert feedback unit 302, and finely adjusts and controls the real-time water adding flow; meanwhile, the fuzzy feedforward control unit 301 sends the real-time control data to the expert feedback unit 302 for data area storage; the sintering process water distribution control is a system with multiple factors and large lag, the control is difficult to complete by adopting the traditional PID and feedback closed-loop control, once the parameters change, the system can vibrate or overshoot by adopting the traditional control theory, and therefore the steady-state operation problem under the multiple variables and the large lag must be solved by adopting the fuzzy control theory.
The expert feedback unit 302 establishes an expert feedback control model according to the analysis of actual big data accumulated for many years and by combining data such as real-time measurement data, material quantity, change of material types, water adding amount and the like, performs preprocessing and statistical calculation on a water content value, a water content deviation and an interference variable, and automatically gives a feedback correction control quantity.
As shown in fig. 3, the intelligent integrated control unit 303 performs an intelligent control based on fuzzy feedforward and expert feedback, inputs feedforward data and feedback control quantity into the intelligent integrated control model, performs inference and operation, outputs the quantity to the working condition empirical model, gives an actual water adding quantity after operation, distributes a water adding instruction to the water adding regulating valve 5, is provided with a flowmeter 6 and a pressure transmitter 7 on a pipeline, and feeds back a control effect of the water adding instruction on the water adding regulating valve 5, thereby realizing the intelligent control of three control loops of the mixture water content.
Preferably, the whole closed-loop control system of the intelligent automatic water adding module 300 has a self-learning function, and keeps optimized regression under the support of an expert parameter base, wherein the learning and optimizing functions including the manual control parameters are included in the system; as shown in figure 4, three software packages of Fuzzy Feedforward (FF), expert Feedback (EF) and intelligent synthesis (II) are formed by combining ingredient information, associated material attributes, material weights, expert experience data and a self-learning data processing technology according to a moisture measured value, water is stably added under the control of the software packages, so that the moisture of the sintering material is controlled to be a stable moisture content, and the requirements of a sintering process are met.
Preferably, a first moisture measuring instrument 3 for detecting the moisture measured value is arranged at the outlet of the first mixer 1 and the outlet of the second mixer 2, and the first moisture measuring instrument 3 is preferably in a contact type measuring mode that the measuring part is in direct contact with the material, and the measuring mode is superior to point-to-point measurement of infrared rays and microwaves, can measure the average moisture of unit volume and can represent the actual working condition. The measuring method is not influenced by the environment such as dust, steam, high temperature, illumination and the like, and is not influenced by material proportion and material form, so that the moisture value is measured more directly, accurately and stably; for example, a specific application number of the moisture measuring instrument is 201920903573.3, which is named as a moisture sensor disclosed in a contact probe moisture sensor.
The particle size online detection module 400 is used for analyzing the particle size of a video image generated by pelletizing and pelletizing the sintering mixture and accurately detecting the proportional quantity of qualified balls; the online particle size detection module 400 analyzes the particle size of a video image generated by pelletizing and pelletizing a sintering mixture in real time by means of a machine vision technology and a digital image processing technology, accurately detects the proportional quantity of qualified pellets, and outputs a result to the intelligent pelletizing expert module 200, the intelligent pelletizing expert module 200 adjusts the water adding amount, the material adding amount and other elements of a mixer according to the pelletizing particle size distribution condition and trend and the conditions of the incoming material moisture and the incoming material amount, and simultaneously provides adjustment suggestions for a batching process and the like, so that the automatic pelletizing is achieved, and the pelletizing qualified rate is improved.
Preferably, the particle size online detection module 400 has a granulation qualification rate abnormity warning function, so that the production process can be adjusted in time, and the granulation qualification rate and the production efficiency are improved; further, the particle size online detection module 400 sets a history query function, and can query the history change trend of the average particle size and the distribution ratio of the granulation in any time period; a data output port can be further arranged to provide stable real-time data for the subsequent intelligent granulation expert module 200, and images and data are stored for a long time.
The atomizing and granulating module 500 includes an atomizing and granulating control unit 501 and a spraying assembly 502 electrically connected to the atomizing and granulating control unit 501, as shown in fig. 5, the atomizing and granulating control unit 501 is disposed in the granulating host, the spraying assembly 502 can be disposed as a spraying beam laid in the secondary mixer 2, the atomizing and granulating control unit 501 is configured to construct a mist-moisture control model formed according to a target moisture value, a spraying amount, a moisture measurement value and a water addition amount, a mist-weight control model formed according to a material weight and a material proportion, and a mist-diameter-attribute fuzzy control model formed according to different material attributes, a granulating speed and a granulating cause, and can realize an optimal granulating process control by combining particle size online detection results, realize functions of 'dripping granulating and spraying long balls', and improve a granulating rate.
The intelligent granulation expert module 200 is used for overall control of each device and each control module in the process of granulating the sintering mixture in a related manner.
The sintering process has many influencing factors. Where sintering time is an important variable affecting sintering productivity, sintering time depends on the heat front velocity through the bed, and good gas permeability is critical to the heat front velocity. Therefore, the role of permeability in the sintering process is very critical. The original gas permeability is very important during sintering, as is the maintenance of good gas permeability during sintering.
Granulation improves not only the air permeability of the sinter mix, but also the sintering process. The fine material is brought closer together by granulation, so that it adheres to the larger ore fines and return fines particles to form a good liquid phase in which they are bound together or by the liquid phase during sintering. Therefore, the method has good granulation rate and granulation quality, and can effectively improve the sintering yield and quality.
The factors influencing sintering granulation are various, and the specific conditions of various manufacturers are different, but the following problems generally exist:
1) The matched equipment does not have the change of a self-adaptive process and the change of certain factors in the production process and automatic tracking change, so the defect of the matched equipment influences the whole sintering line.
2) Due to the many variables of the sintering process. Each link is not controlled finely enough, and a plurality of small changes are accumulated and superposed to cause adverse factors of sintering, thereby affecting the final sintering result.
3) The method has simple response measures for adverse factor change in the sintering process, adopts too many manual intervention means, and does not have a response system for automatic detection and automatic processing.
According to the invention, the intelligent granulation expert module is adopted to intelligently control and integrate related matched equipment, so that adverse factors to sintering in the processes of material preparation, material mixing and granulation are solved, the granulation rate is improved, the air permeability is increased, the energy consumption is reduced, and the yield and the efficiency are improved; the intelligent automatic water adding device can be formed by hardware such as a programmable controller, an industrial controller and a communication module, sintering batching data, material attributes, sintering data and the like are collected, and control modules such as an intelligent automatic water adding module, a particle size online detection module and an atomization granulation module are subjected to inspection type detection and adjustment, so that particle size optimization is met.
As a preferred embodiment of the present invention, the present invention further includes a dry-based fuel blending module 600 in data communication with the intelligent pelletizing expert module 200, the dry-based fuel blending module 600 includes a second moisture measuring instrument 4 for measuring moisture of the fuel in real time and a belt scale for weighing the dry-based fuel, the dry-based fuel blending module 600 transmits moisture measuring information measured by the second moisture measuring instrument 4 in real time and weighing information of the dry-based fuel by the belt scale to the intelligent pelletizing expert module 200, and the intelligent pelletizing expert module, according to the above information, combines with original moisture data of the raw mineral material, and after removing the moisture corresponding to the moisture, gives a correction value to the fuel blending result, so as to realize dry-based blending, and can control the fuel blending weight, so that the blending ratio of the sintering line fuel is more accurate, effectively control the excess or deficiency of the fuel caused by the change of moisture, and indirectly control the fluctuation of the sintering line carbon; preferably, the second moisture measuring instrument 4 is a contact type measuring mode, and particularly, the moisture sensor disclosed in the patent application No. 201920903573.3 with the patent name of a contact type probe moisture sensor can be selected.
As a preferred embodiment of the present invention, the system further comprises a material pre-wetting module 700 in data communication connection with the intelligent granulation expert module 200, wherein the material pre-wetting module 700 is additionally provided with a spray wetting and stirring device when mineral powder with poor hydrophilic wetting enters a main belt, and can perform automatic closed-loop control on the wetting degree; according to the wettability difference of different mineral powders, mineral powders with poor hydrophilic wettability are selected and added with water in advance before mixing and granulating, so that after the dry materials are wetted, the dry materials can be uniformly mixed with other materials with similar moisture in a mixer, the mineral powder particles can be pre-wetted to improve the surface moisture content of the part of material particles during granulation, and the existence of fine particles of the mixture is reduced, compared with the traditional granulating process, the granulating process of the mixture is strengthened, the granulating effect of the mixture is improved, and the air permeability of a material layer is improved; the water adding amount calculated in advance is uniformly added in an atomizing mode through a spraying wetting and stirring device, so that mineral particles are fully wetted in advance, the granulating effect can be greatly improved under the condition that the production cost is not remarkably increased, and the method is a novel granulating process which can be adopted by sintering production enterprises under the condition of facing complex iron ore powder materials; the material pre-wetting module 700 automatically controls the wetting degree, realizes the local control of the wetting degree or the control of a central control room, can measure the wetting water quantity, transmits data to the intelligent granulation expert module 200, and displays the operation on the upper computer 100.
As a preferred embodiment of the present invention, the system further comprises a quicklime slaking module 800 in data communication with the intelligent granulation expert module 200, and configured to implement closed-loop control on slaking time, water addition amount, and lime weight according to bin number or lime activity during advanced water addition to lime; granulation is the process of the adhesion of the moisture in the mixture and the binder to the coarse particles and grow up. Therefore, the relative ratio of the binder to the core particles, the nature of the binder, the amount and nature of the binder are key factors affecting granulation; the slaking speed of the quicklime can be obviously improved by adding water into the quicklime in advance, slaking time is shortened, the quicklime is enabled to be more easily and uniformly mixed with other raw materials in a uniformly mixing process, the temperature of a mixed material can reach about 65 ℃ after the mixed material is preheated by steam, an over-wet layer in a sintering process can be effectively eliminated, air permeability in the sintering process is improved, and favorable conditions are created for further improving the cloth thickness; the quicklime slaking module 800 is formed by correlating quicklime on the basis of selecting quicklime as a flux and adopting multi-stage slaking in a batching process, wherein the multi-stage slaking can be realized by adding water in a lime slaker, a screw feeder and/or a batching large belt quicklime blanking part, the quicklime slaking module can realize automatic closed-loop control of slaking time, water adding amount and lime weight on different grades of the quicklime according to bin numbers or lime activity degrees, can realize setting slaking time locally and/or remotely (a central control room), transmits data to the intelligent pelletization expert module 200, and displays operation on the upper computer 100.
As a preferred embodiment of the present invention, the system further comprises a material temperature raising module 900 connected to the intelligent granulation expert module 200 in data communication, and a hot water or steam metering and controlling device and a material temperature measuring device 901 are provided for closed-loop management of the mixture temperature.
If the temperature of the mixture reaches above the dew point (for example 65 ℃), the phenomenon of an over-wet layer formed by condensing water vapor in the material layer can be obviously reduced, and in the sintering process, the lower part sintering material can not generate the over-wet phenomenon, but can dry the mixture to reduce the water content of the mixture, effectively reduce the thickness of the over-wet layer and the resistance of the over-wet layer to air flow, improve the air permeability of the material layer, and accelerate the vertical sintering speed to obviously improve the production efficiency of the sintering machine.
The main factors influencing the temperature of the mixture comprise the environmental temperature, the internal self-circulation return-ore temperature, the quality of quicklime and the digestion heat release, the heat efficiency of a steam preheating device, the water temperature during mixing and granulating and the like. In order to increase the temperature of the mixture, any one or more of the following measures can be taken:
a. the water source in any step or a plurality of steps or all steps of the steps of material pre-wetting, quicklime digestion and mixture water adding is hot water;
b. introducing steam into the secondary mixer, wherein the steam is arranged at the rear end of the atomization granulation machine and is beneficial to temperature raising granulation;
c. a steam pipeline is additionally arranged at the material distribution point to preheat materials, so that the material distribution temperature is increased;
d. the belt is additionally provided with a belt cover to wrap and preserve heat, so that heat loss is reduced, and the environment is improved;
e. on the premise of adding the belt cover, steam is added into the belt cover at the outlet of the secondary mixer;
all be provided with when above measure sets up hot water or steam with material temperature lift module 900 communication connection's measurement regulation and control device, add material temperature measuring device 901 simultaneously, all information merge intelligent pelletization expert module unified control, realize closed-loop management.
In the intelligent granulating control method of the sintering mixture of the embodiment of the invention, as shown in fig. 2, during the material mixing, the dry-based material mixing module 600 measures the moisture of the fuel in real time, and forms the closed-loop weight control of the dry-based fuel with the belt scale; uniformly adding the calculated water adding amount of the material pre-wetting module 700 into ore seeds needing to be pre-wetted in an atomizing form through a spraying wetting and stirring device, ensuring that mineral particles are fully pre-wetted, and mixing and granulating the mineral particles with other ore seeds; the method comprises the steps of adding water into a lime slaker, a spiral feeder and/or a large belt lime batching feeding position to carry out multistage slaking on the quicklime; particle size on-line measuring module 400 carries out particle size analysis to the video image of sintering mixture pelletization pelletizing production, and the proportion quantity of qualified ball is detected out accurately, intelligent pelletization expert module 200 is to intelligent automatic water module 300 that adds according to the particle size analysis result, atomizing granulation module 500, material prewetting module 700 and quick lime digestion module 800 carry out patrolling and examining formula detection and control adjustment, intelligent automatic water module 300 that adds combines with atomizing granulation module 500 and realizes measuring the moisture in primary mixer 1 and secondary mixer 2, the intelligent control of water feeding control and water feeding mode, material prewetting module 700 automatic control is wet the degree of wetness of the powdered ore of difference of hydrophilic moisture, quick lime digestion module 800 closed loop control quick lime digestion time, water feeding and quick lime weight, in order to satisfy the particle size optimization.
In an improvement mode of the technical scheme, during batching, the return fine bin position is controlled to be between one third and one half, the content of the adhesive powder smaller than 0.5 mm in the return fine is 40-50%, the return fine proportion is not more than 3% each time, and the time interval is not less than 1 hour; the return ores are used as nuclear particles in the granulating process in the re-proportioning process, the proportioning amount of the return ores plays a relatively important role, the proportioning of the return ores and the position control of the return bin are well controlled in the practical production process, the stability of the quality of the sintered ores is facilitated, the stability of the production process is facilitated, and favorable conditions are created for realizing the operation of low-carbon and thick material layers; through reasonable control and management, the return ore proportioning can be stabilized, more heat is provided for uniformly mixed materials, the quantity of core particles in the granulating process is also stabilized, and the uniformity of the particle size in the granulating process is improved, so that the stability of the sintering process after material distribution and the improvement of the quality of sintered ores are ensured; preferably, the particle size and the proportion of the sintered return ores and the blast furnace return ores are firstly confirmed, and for the shunt technology with the larger proportion of more than 5mm, the coarse-grain return ores do not participate in the granulation, but are added in the later stage of the granulation, so that the granulation of fine particles is not damaged, the granulation effect is improved, and the material layer supporting function can be played during the sintering.
In an improved mode of the above technical scheme, as shown in fig. 6, a spiral guide plate with a certain width is gradually laid on the inner wall of the secondary mixer from the feeding end to the discharging end, the rotation direction of the spiral is the opposite direction of the rotation of the mixer, so as to form an inverse spiral, so as to change the stress state of the mixture, and the thickness of the guide plate is gradually increased, the final purpose is to allow the materials to be more fully mixed in the mixer, the automatic classification of the granularity of the mixture is realized, the purpose that large-particle materials go outwards first and small-particle materials return to the pelletizing is achieved, the effective mixing and pelletizing time is prolonged, the effective rolling path of the materials is increased, and the pelletizing effect is improved.
Verification of comparative experiments
Now, the data comparison with the practical case of a 265 sintering project is described as follows: the project intelligent granulating control system comprises an intelligent automatic water adding module 300, a particle size online detection module 400, an atomizing and granulating module 500, a fuel dry-basis batching module 600, a pre-wetting module 700, a quicklime digesting module 800, a material temperature increasing module 900 and an intelligent granulating expert module 200 which is in data communication with an upper computer 100 according to the technical concept of the invention, wherein the intelligent granulating expert module 200 is used for overall and associated control of all devices and all control modules in the granulating process of sintering mixture.
Tests prove that the granulation rate can be effectively improved, the grain size can be improved, the strength can be enhanced under the comprehensive action of each module in the embodiment of the invention, and the data is shown in table 3:
TABLE 3 comparison of granulation before and after modification according to the present invention
Under the comprehensive action of each module in the embodiment of the invention, the water stability rate of the mixture can be effectively improved, the water addition amount and the fuel consumption are reduced, the ferrous oxide (FeO) is improved, the return mine is reduced, the utilization coefficient of the sintering machine is improved, and the data is shown in Table 4:
TABLE 4 comparison of stability Effect before and after reforming according to the present inventive concept
The fuel dry-based batching module 600 deducts the weight of the moisture of the material mainly through moisture detection to obtain the instantaneous dry material amount of the material, and dry-based batching is performed on the materials such as the fuel, so that the defect that the proportioning error is large due to the influence of rainwater, raw material original moisture and the like in the prior art is overcome, and the fluctuation problem of blending ore components, moisture and the like is reduced. Practice proves that the iron stability rate of the blended ore is improved to 88.68% from the original 85.62%, the water content stability rate of the blended ore is improved to 95.63% from 90.22%, the quality stability rates of the blended ore and the sintered ore are further improved, and powerful conditions are created for quality improvement and consumption reduction of sintering.
The prewetting module 700 is mainly used for prewetting materials such as return ores, coke powder, dedusting ash and part of mineral powder in advance by adding water, and simultaneously, the wetting water consumption is deducted from the total water addition amount, so that the granulating effect of the mixture is improved on the premise of ensuring the stability of the total water addition amount, and the prewetting module has obvious effect through practical observation, and the specific comparison method is as follows:
1) Adding water to the materials to be moistened in advance to moisten the materials to the same degree;
2) The granulation data (based on the particle size content of more than 3 mm) at the primary and secondary mixing outlets were measured under the same conditions.
The front and back data pairs are as in table 5:
table 5 comparison of the results of the prewetting module on the granulation effect
The quicklime digestion module 800 adopts a mode of adding water in a lime slaker, a spiral feeder and a batching large belt quicklime blanking position to carry out multistage digestion on quicklime, the quicklime digestion process can release heat to a mixture, the material temperature can be effectively improved, the fuel consumption in the sintering process is reduced, meanwhile, an over-wet layer is reduced, the air permeability is improved, and the sintering utilization coefficient is improved.
The material temperature raising module 900 raises the temperature of the mixture by the following method:
(1) The water sources of all the steps of material pre-wetting, quicklime digestion and mixture water adding are hot water;
(2) Steam is introduced into the secondary mixer 2 and is arranged at the rear end of the atomizing granulation, so that the temperature rise granulation is facilitated;
(3) A steam pipeline is additionally arranged at the material distribution point to preheat materials, so that the material distribution temperature is increased;
(4) The belt is additionally provided with a belt cover to wrap and preserve heat, so that heat loss is reduced, and the environment is improved;
(5) On the premise of adding the belt cover, steam is added into the belt cover at the outlet of the secondary mixer 2;
in the method, when hot water or steam is set, metering regulation and control devices in communication connection with the material temperature lifting module 900 are arranged, and the material temperature can be effectively lifted by a material temperature lifting system, so that the material temperature can be lifted to be more than 65 ℃, and the requirements of a sintering process are met.
The above description is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.
Claims (10)
1. Sinter mixture intelligence pelletization control system, its characterized in that, including intelligent automatic water module (300), particle diameter on-line measuring module (400), atomizing granulation module (500) and with host computer (100) data communication's intelligent pelletization expert module (200), wherein:
the intelligent automatic water adding module (300) is used for automatically controlling the water adding amount in the primary mixer (1) and comprises a fuzzy feedforward control unit (301), an expert feedback unit (302) and an intelligent comprehensive control unit (303), wherein the fuzzy feedforward control unit (301) is used for collecting real-time batching data in the batching process of a sintering mixture, carrying out data preprocessing based on a fuzzy control theory, taking a processing result as feedforward data to participate in final water adding amount calculation, and the batching data comprises total mixture flow, a target moisture value of a sintering process, a moisture measurement value at an outlet position of the mixer and water adding flow calculated in the batching process; the expert feedback unit (302) is used for giving feedback control data to the feedforward data according to actual big data accumulated for many years; the intelligent integrated control unit (303) is used for giving the actual water adding amount through integrated analysis, reasoning and model operation according to the feedforward data and the feedback control data, and distributing the water adding instruction to the water adding actuator to adjust the water adding amount; the whole closed-loop control system of the intelligent automatic water adding module (300) has a self-learning function;
the online particle size detection module (400) is used for carrying out particle size analysis on a video image generated by pelletizing and pelletizing the sintering mixture and accurately detecting the proportional quantity of qualified balls;
the atomizing and granulating module (500) comprises an atomizing and granulating control unit (501) and a spraying assembly (502) in electrical signal connection with the atomizing and granulating control unit, wherein the spraying assembly (502) is arranged in the secondary mixer (2), the atomizing and granulating control unit (501) is used for constructing a mist quantity-moisture control model formed according to a target moisture value, a spraying quantity, a moisture measurement value and a water adding amount, a mist quantity-weight control model formed according to the weight of materials and the proportion of the materials, a mist diameter-attribute fuzzy control model formed according to different material attributes, the balling speed and the balling cause, and the optimal granulating process control can be realized by combining the online detection result of the particle diameter;
the intelligent granulating expert module (200) is used for overall and associated control of all equipment and all control modules in the granulating process of the sintering mixture.
2. The intelligent pelletizing control system for sinter mix according to claim 1, characterized in that the outlet positions of the primary mixer (1) and the secondary mixer (2) are provided with a first moisture meter (3) for detecting the moisture measurement value.
3. The intelligent sinter mix granulation control system as claimed in claim 2, further comprising a dry fuel base blending module (600) in data communication with said intelligent granulation expert module (200), wherein said dry fuel base blending module (600) comprises a second moisture meter (4) for real-time moisture measurement of fuel and a belt scale for weighing dry fuel, and is capable of controlling fuel blending weight.
4. The intelligent sinter mix granulation control system as claimed in claim 3, wherein the first moisture meter (3) and/or the second moisture meter (4) is a contact moisture meter.
5. The intelligent sinter mix granulation control system as claimed in claim 1, further comprising a material pre-wetting module (700) in data communication with the intelligent granulation expert module (200), wherein the material pre-wetting module (700) is provided with a spray wetting and stirring device when mineral powder with poor hydrophilic wetting enters the main belt, and can perform automatic closed-loop control on the wetting degree.
6. The intelligent sinter mix granulation control system as claimed in claim 1, further comprising a quicklime slaking module (800) in data communication with the intelligent granulation expert module (200) for performing closed-loop control on slaking time, water addition amount, and lime weight according to bin number or lime activity during advanced lime water addition.
7. The intelligent sinter mix granulation control system as claimed in claim 1, further comprising a material temperature raising module (900) in data communication with the intelligent granulation expert module (200), wherein a hot water and/or steam metering control device and a material temperature measuring device (901) are provided for closed-loop management of the mix temperature.
8. An intelligent pelletizing control method for a sinter mixture is realized according to the intelligent pelletizing control system for the sinter mixture of any one of claims 1 to 7, and is characterized in that real-time moisture measurement is performed on fuel through a fuel dry-based batching module (600) to form dry-based fuel closed-loop weight control with a belt scale; uniformly adding the calculated water adding amount of the material pre-wetting module (700) into ore seeds needing to be pre-wetted in an atomizing form by a spraying wetting and stirring device to ensure that mineral particles are fully wetted in advance, and mixing and granulating the ore seeds with other ore seeds; the method comprises the steps of adding water into a lime slaker, a spiral feeder and/or a large belt lime batching feeding position to carry out multistage slaking on the quicklime; particle size on-line measuring module (400) carries out particle size analysis to the video image that sintered mixture pelletization generated, and the proportion quantity of accurate detection qualified ball, intelligence pelletization expert module (200) is to intelligent automatic water module (300) that adds according to the particle size analysis result, atomizing granulation module (500), material prewetting module (700) and quick lime digestion module (800) carry out patrolling and examining formula detection and control adjustment, intelligence automatic water module (300) combines with atomizing granulation module (500) to realize measuring the moisture in primary mixer (1) and secondary mixer (2), the intelligent control of water feeding control and water feeding mode, material prewetting module (700) automatic control is moist the degree of wetness of the poor powdered ore of hydrophilic moist, quick lime digestion module (800) closed loop control quick lime digestion time, water feeding and quick lime weight, in order to satisfy particle size optimization.
9. The intelligent pelletizing control method for sinter mixture as claimed in claim 8, wherein during batching, the return ore bin is controlled between one third and one half, the content of adherent powder smaller than 0.5 mm in the return ore is 40% -50%, the return ore ratio is not more than 3% each time, and the time interval is not less than 1 hour.
10. The intelligent sinter mix granulation control method of claim 8, wherein the mix temperature is raised by any one or more of the following methods:
a. the water source in any step or a plurality of steps or all steps of the steps of material pre-wetting, quicklime digestion and mixture water adding is hot water;
b. steam is introduced into the secondary mixer (2) and is arranged at the rear end of the atomizing granulation, so that the temperature raising granulation is facilitated;
c. a steam pipeline is additionally arranged at the material distribution point to preheat materials, so that the material distribution temperature is increased;
d. the belt is additionally provided with a belt cover, and the belt cover is wrapped for heat preservation, so that heat loss is reduced, and the environment is improved;
e. on the premise of adding the belt cover, steam is added into the belt cover from the outlet of the secondary mixer;
when the hot water or the steam is set, the metering regulation and control device communicated with the material temperature lifting module (900) is arranged.
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