CN115369240A - Automatic control system and method for effectively improving pelletizing efficiency of iron ore powder pellets - Google Patents
Automatic control system and method for effectively improving pelletizing efficiency of iron ore powder pellets Download PDFInfo
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- CN115369240A CN115369240A CN202210943541.2A CN202210943541A CN115369240A CN 115369240 A CN115369240 A CN 115369240A CN 202210943541 A CN202210943541 A CN 202210943541A CN 115369240 A CN115369240 A CN 115369240A
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B1/00—Preliminary treatment of ores or scrap
- C22B1/14—Agglomerating; Briquetting; Binding; Granulating
- C22B1/24—Binding; Briquetting ; Granulating
- C22B1/2406—Binding; Briquetting ; Granulating pelletizing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/04—Sorting according to size
- B07C5/10—Sorting according to size measured by light-responsive means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C5/00—Sorting according to a characteristic or feature of the articles or material being sorted, e.g. by control effected by devices which detect or measure such characteristic or feature; Sorting by manually actuated devices, e.g. switches
- B07C5/36—Sorting apparatus characterised by the means used for distribution
- B07C5/361—Processing or control devices therefor, e.g. escort memory
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Abstract
The invention provides an automatic control system and method for effectively improving pelletizing efficiency of iron ore powder pellets, and belongs to the technical field of iron ore powder pelletizing. This system is including pelletizing disc, arm, camera, conveyer belt, water pipe, loading belt and scraper, and the operation corridor on pelletizing disc next door is close to pelletizing disc department and installs the arm, and camera I aims at the balling area of pelletizing disc, and camera II aims at the conveyer belt in pelletizing disc unloading area, and pelletizing disc top sets up water pipe and loading belt, and pelletizing disc frame inner wall sets up the scraper, and the scraper does not rotate along with the disc. According to the invention, large particles in a balling area are automatically processed by a mechanical arm, the effective volume of the balling area is increased, and the reasonability of balling parameters is determined through the conditions of pellet size distribution and variance evaluation processing in the balling area and the particle size distribution, average particle size and variance of finished pellets. The method effectively improves the pelletizing efficiency of the pellets, reduces the labor intensity and the danger, and realizes cost reduction and efficiency improvement of the pellet process in a pelletizing system.
Description
Technical Field
The invention relates to the technical field of iron ore powder pelletizing, in particular to an automatic control system and method for effectively improving pelletizing efficiency of iron ore powder pellets.
Background
The blast furnace burden structure in China mainly comprises three parts: sinter, pellet and lump ore. The main purposes of the pellet and the lump ore are to improve the charging grade and balance the alkalinity of the blast furnace slag. With the establishment of new standards of energy-saving and environment-friendly pressure of a sintering production system and the emission of gas pollutants, the sintering process is limited to a certain extent, pellets are changed from auxiliary charging materials to main charging materials, and the production of blast furnace high-proportion pellets and alkaline pellets is emphasized, so that the improvement of the yield and the quality of the pellets becomes a new subject of the metallurgical industry. One of the important processes for producing the pellets is to prepare raw pellets with a certain particle size of 10-16mm from mineral powder suitable for pelletizing, and then perform the processes of drying, preheating, roasting, soaking and the like, wherein the properties of the raw pellets mainly comprise falling strength, compressive strength and thermal burst strength. The present invention relates generally to the process of making.
The pelletizing process generally consists of two processes: disk pelletizing and cylinder pelletizing. In China, the disc pelletizing process is adopted for pelletizing, and the rotating speed and the inclination angle in the disc pelletizing process are fixed and are not easy to change. The current research on the pelletizing process is in terms of water content, finished pellet size and composition, types and amounts of added binders and pelletizing time. The research situation of iron ore powder pelletizing in China is mainly as follows:
two pelletizing disks are connected in series in an iron ore pellet pelletizing device, the second pelletizing disk is arranged below the first pelletizing disk, mineral powder which does not become green pellets in the first pelletizing disk and green pellets with the first weight enter the second pelletizing disk, and the second pelletizing disk performs pelletizing again, so that the aims of greatly reducing the ore return rate in the pellet pelletizing process, improving the yield, improving the surface quality and strength of the green pellets and reducing the energy consumption are fulfilled.
In the material hanging device of the cylindrical pelletizer, vertical projections of adjacent blades on the front surface of a cross beam are overlapped, the blades form an included angle with a horizontal plane, and the front ends of the blades and the inner wall of a cylinder body form an arc shape. The problem of the unnecessary material adhesion of drum pelletizer influences pelletizing efficiency and quality on the section of thick bamboo wall is solved, production efficiency is improved, the energy consumption is reduced.
The intelligent pelletizing detection system mainly analyzes infrared moisture of mineral powder and balls, detects disc speed and acquires images, judges the working state of a pelletizing machine, adjusts moisture and machine speed, and ensures the quality of green pellets.
The fishing claw is arranged on a support of a sphere in the visual screening equipment of the large-particle robot for the pelletizer, the fishing claw can be opened and closed, the fishing claw and the blocking tooth after closing form a fishing cage, large particles are searched according to a CCD camera, the large particles are found and then are transmitted to a robot controller, the robot moves an arm to a position according to position information, sinks into a material, drags the large particles into the fishing cage, and the fishing claw is opened after the range of a pelletizer is removed, so that the large particles can be removed. This equipment does not consider the actual conditions that the pelletizing disc was administered, 1) the disc pelletization is high-speed operation, and the machine is fished according to the location after the location, unsatisfied actual conditions, and 2) the device design and the action of fishing for will destroy a large amount of normal pelletizing when fishing for the big ball.
Based on the above, the invention divides the balling disk into four areas: 1) a loading area, 2) a water adding area, 3) a nucleation area, and 4) a growing and discharging area. The invention adjusts the volume of the ball area by adding image acquisition in the ball area and the discharging belt, and the judgment and the measure are linked. The system of the invention can run continuously for 24 hours, and only an operator needs to watch the system in an operation room, thereby effectively reducing the working strength of the pellet posts, improving the green pellet production efficiency and stabilizing the green pellet quality.
Disclosure of Invention
The invention aims to provide an automatic control system and method for effectively improving the pelletizing efficiency of iron ore powder pellets.
In the process of iron ore powder pelletizing, the pellet size standard of China is 10-16mm, and in the process of preheating and roasting pellets larger than 16mm, the conditions of sandwich pellets, incomplete burning, low compressive strength, reduced reducibility and the like which deteriorate the metallurgical performance of the pellets can be generated. In the process of pelletizing, due to local accumulation of moisture, powder ore is bonded on a scraper and a disc wall, large balls with the diameter of more than 30mm are inevitably generated, some large balls even exceed 200mm, large balls with the diameter of more than 30mm roll repeatedly in a pelletizing area due to large self-gravity, and almost cannot reach a discharging area. Clearing one balling disk alone needs 10min, and 10 balling disks of a production line use 8 and are equipped with 2, and a cycle needs 80min, because the disc is high-speed moving, can only clear up the pelletizing more than 100mm, clear up the bobble unrealistic. After the cleaning, the super large balls grow in the balling disc repeatedly, and the cleaning is still needed after 1-2 hours and is repeated.
Therefore, based on the actual situation, the invention designs an automatic control system for effectively improving the pelletizing efficiency of the iron ore powder pellets, which comprises a pelletizing disc, a mechanical arm, two cameras, a conveying belt, a water pipe, a feeding belt and a scraper,
a mechanical arm is arranged on an operation gallery beside the pelletizing disc and close to the pelletizing disc,
the camera I is aligned with the balling area of the balling disc, the camera II is aligned with the conveyer belt of the balling disc discharging area,
a water pipe and a feeding belt are arranged above the pelletizing disc, a blanking area is arranged below the feeding belt, a nucleation growing area is arranged behind the blanking area, and a pelletizing area is arranged behind the nucleation growing area according to the clockwise direction;
the inner wall of the pelletizing disc frame is provided with a scraper, the pelletizing disc rotates anticlockwise, and the scraper does not rotate along with the disc.
Wherein, one end of the mechanical arm cleaning big ball is made of arc sharp stainless steel with the interval of 40mm-50mm.
The application method of the system comprises the following steps:
s1: mineral powder enters a blanking area through a feeding belt;
s2: the pelletizing disc rotates anticlockwise, the mineral powder also rotates anticlockwise, and mist water is added into the pelletizing disc through the water pipe;
s3: the mineral powder is bonded under the action of capillary force and gradually grows into a nucleation growing area;
s4: the nucleated mineral powder grows again and enters a pelletizing area to become finished pellets, and larger pellets which are more than 100mm in the pelletizing area need to be removed;
s5: the finished pellets enter a conveying belt and enter a screening process, pellets smaller than 10mm and larger than 16mm are crushed again and return to a pelletizing system, and qualified pellets of 10-16mm are dried, preheated, roasted, soaked and cooled;
s6: the super-large pellets with the diameter of more than 100mm cannot enter a conveying belt due to the gravity, and continuously roll in a pelletizing area to be large, so that the large pellets are smashed by the operation of the mechanical arm, and the pelletizing efficiency is improved.
The operation control mode of the mechanical arm in the S6 comprises two modes: normal mode operation and energy-saving mode operation.
The conventional operation of the mechanical arm is as follows:
the operation period was set to be one period per hour, 10 times per period, each 30s apart.
The energy-saving mode operation of the mechanical arm is specifically as follows:
observing pellets in a pelletizing area in real time through a camera I, acquiring images of the pellets in the pelletizing area, and controlling a mechanical arm to operate by a control system when the maximum particles of the pellets exceed a preset value of 100 mm; meanwhile, the finished balls on the belt are observed in real time through a camera II, the number of large particles in the finished balls, the size fraction, the average particle size and the variance of the pellets are recorded, the size fraction distribution of the pellets is evaluated, and the reasonability of pelletizing parameters is further judged.
Wherein, the frequency of the image collected by the camera I is 10 s/group.
The technical scheme of the invention has the following beneficial effects:
in the above-mentioned scheme, can effectively get rid of balling-up district large granule through setting up the camera, for balling-up district enlarges effective balling-up space, improves finished product pelletizing degree of consistency, output and quality, saves the labour, effectively avoids the emergence of incident. The terminal system connected with the camera analyzes the acquired images, so that the quality judgment of the pellets has a more real-time basis.
Drawings
FIG. 1 is a schematic structural diagram of an intelligent system for effectively improving the pelletizing efficiency of iron ore powder pellets.
Wherein: 1-pelletizing disc, 2-mechanical arm, 3-pelletizing area, 4-camera I, 5-operation gallery, 6-conveying belt, 7-finished pellet, 8-camera II, 9-nucleation mineral powder, 10-blanking area, 11-nucleation growing area, 12-mineral powder, 13-water pipe, 14-feeding belt and 15-scraper.
Detailed Description
In order to make the technical problems, technical solutions and advantages of the present invention more apparent, the following detailed description is given with reference to the accompanying drawings and specific embodiments.
The invention provides an automatic control system and method for effectively improving pelletizing efficiency of iron ore powder pellets.
As shown in fig. 1, the system comprises a pelletizing disc 1, a mechanical arm 2, two cameras, a conveying belt 6, a water pipe 13, a feeding belt 14 and a scraper 15,
a mechanical arm 2 is arranged at the position of an operation gallery 5 beside the pelletizing disc 1, which is close to the pelletizing disc 1,
the camera I4 is aligned with the pelletizing area 3 of the pelletizing disc 1, the camera II8 is aligned with the conveying belt 6 beside the pelletizing disc 1,
a water pipe 13 and a feeding belt 14 are arranged above the pelletizing disc 1, a blanking area 10 is arranged below the feeding belt 14, a nucleation growing area 11 is arranged behind the blanking area 10, and a pelletizing area 3 is arranged behind the nucleation growing area 11 in the clockwise direction;
the inner wall of the frame of the pelletizing disc 1 is provided with a scraper 15, the pelletizing disc 1 rotates anticlockwise, and the scraper 15 does not rotate along with the disc.
One end of the mechanical arm cleaning big ball is made of arc sharp stainless steel with the interval of 40mm-50mm.
The application method of the system comprises the following steps:
s1: mineral powder 12 enters the blanking area 10 from a feeding belt 14;
s2: the pelletizing disc 1 rotates anticlockwise, the mineral powder 12 also rotates anticlockwise, and atomized water is added into the pelletizing disc 1 through the water pipe 13;
s3: due to the action of capillary force, mineral powder is bonded and grows into a core in the core growing area 11;
s4: the nucleating mineral powder 9 grows up again and enters the balling area 3 to become finished pellets 7, and larger pellets which are more than 100mm are arranged in the balling area 3;
s5: the finished pellets enter a conveying belt and enter a screening process, the pellets smaller than 10mm and larger than 16mm are crushed again and return to a pelletizing system, and qualified pellets of 10-16mm are dried, preheated, roasted, soaked and cooled;
s6: the super-large pellets with the diameter of more than 100mm cannot enter a conveying belt due to the action of gravity, and continuously roll in a pelletizing area to be large, so that the super-large pellets are smashed through the operation of a mechanical arm, and the pelletizing efficiency is improved.
The operation control mode of the mechanical arm in the S6 comprises two modes: normal mode operation and energy-saving mode operation.
The conventional operation of the mechanical arm is as follows:
the operation period was set to be one period per hour, 10 times per period, each 30s apart.
The energy-saving operation of the mechanical arm is specifically as follows:
observing pellets in a pelletizing area in real time through a camera I, acquiring images of the pellets in the pelletizing area, and controlling a mechanical arm to operate by a control system when the maximum particles of the pellets exceed a preset value of 100 mm;
meanwhile, the finished balls on the belt are observed in real time through a camera II, the number of large particles in the finished balls, the size fraction, the average particle size and the variance of the pellets are recorded, the size fraction distribution of the pellets is evaluated, and the reasonability of pelletizing parameters is further judged.
The frequency of image acquisition by camera I was 10 s/group.
In specific implementation, the intelligent system of the invention is designed into four main parts: 1) a mechanical arm in charge of cleaning large pellets (the diameter is larger than 100 mm), 2) a green pellet grade judging system in a pelletizing area, 3) a belt finished pellet judging system and 4) terminal monitoring. The mechanical arm comprises a mechanical arm body, an automatic control box and a large ball cleaning end.
According to the invention, small mechanical arms are arranged on the periphery of each balling disc according to local conditions, the mechanical arms are arranged according to the rotating speed of the disc to clean the balling disc, meanwhile, cameras are arranged in a balling area of a finished ball belt and the disc, and the mechanical arm cleaning effect is judged in a high-definition high-speed real-time monitoring mode. The main functions of the camera shooting in the balling area of the disk are to judge the cleaning effect and the pellet size fraction composition, the average particle size and the size fraction variance in the balling area of the balling disk. The finished ball belt needs to judge the quality of finished balls, including average particle size, size fraction composition and size fraction variance.
The mechanical arm is characterized by being small, the size of the mechanical arm is 800mm multiplied by 400mm, and the mechanical arm is expanded to the range of 2000mm multiplied by 2000 mm. Because the on-site space is limited, install on the lateral wall of the opposite platform of balling disc, as shown in fig. 1, big ball clearance end is made by the sharp-pointed stainless steel of arcuation of certain size at an interval, the requirement: 1) stainless steel, 2) sharp, and 3) the distance between the two tooth tips is 40mm-50mm, so as to ensure that the small ball is not damaged or is separated from a balling area in advance. The mechanical arm control system determines the field installation environment, and the cleaned big ball can reach the recovery end, is broken and continues to enter the pelletizing system.
The action of the mechanical arm is a standard action set after debugging and acts on the balling area. There are two types of automatic control, 1) the standard actions set are operated according to the frequency, such as period, frequency, etc., such as: the mechanical arm runs for a period of 10 times every hour, the interval is 30s every time, 2) the energy-saving mode of the mechanical arm, large particles larger than 100mm appear in the green ball granularity judgment system in the balling area, the mechanical arm runs for 10 times, the mechanical arm stops running below an early warning value, and if the large particles are higher than the early warning value (larger than 100 mm), the mechanical arm runs for a period again.
The green ball granularity judging system in the balling area consists of mainly video camera, image acquiring system, memory system and corresponding algorithm judging system.
The belt finished ball detection system consists of a camera, an image acquisition system, a storage system and a corresponding algorithm identification system.
The algorithm and the terminal mainly have the following functions: 1) The method is convenient for an operator to switch the general mode and the energy-saving mode of the mechanical arm at the terminal, and 2) analysis results such as finished ball granularity composition, average particle size, variance and the like are presented to provide judgment basis for the pelletizing result for the operator.
In a specific application, the following process is carried out:
(1) The debugged mechanical arm, the green ball balling area image acquisition and analysis system and the finished product ball belt image acquisition and analysis system ensure that the image of the operation terminal is clear and the acquisition and analysis system is normal;
(2) The mechanical arm enters a normal operation mode:
(1) set up the arm operating cycle at the platform switch board, this sets up to: operating a cycle every hour, operating the mechanical arm 10 times every hour, setting the interval for 30s every time, and removing large balls which roll repeatedly and are larger than 100 mm; (2) and a camera I of the balling area image acquisition and analysis system continuously acquires balling area pictures of the disc balling machine, the acquisition frequency is 10 s/piece, the frame frequency is 400 frames/s, the balling area large ball diameter, green ball granularity composition, average particle size and variance are analyzed, and the operation effect of the mechanical arm at this time is judged by judging the large ball diameter.
(3) And (3) continuously acquiring finished ball images on a belt before sieving by using a camera II of an image acquisition and analysis system of a finished ball belt, wherein the frame frequency is 400 frames/s, and analyzing the average particle size, the particle size distribution and the maximum particle size:
1) The finished product ratio of 10-16mm pellets is obtained through the average grain diameter composition,
2) The pelletizing time and the water quantity adjusting direction are analyzed according to the proportion of the pellet size fraction less than 10mm and more than 16mm,
3) The variance is the sign of the uniformity of the particle size distribution of the pellets in the area, and if the variance is larger, the water flow, the using amount of the binder bentonite and the feeding amount of the mineral powder are adjusted.
(3) When the system enters an energy-saving mode, setting and debugging standard actions of the mechanical arm:
(1) setting a maximum particle diameter early warning value (the maximum value is 100 mm) in a balling area;
(2) judging the granularity composition, the average particle size and the variance of the green balls in the balling area through a balling area camera and a storage analysis system, and if the judgment value exceeds the early warning value;
(3) starting a mechanical arm terminal, and cleaning for one period;
(4) after cleaning, judging the cleaning effect by the balling area camera and the storage analysis system, and if the cleaning effect exceeds the early warning value, automatically starting the mechanical arm terminal and repeating the steps;
(4) Evaluating the granularity composition, the average particle size and the variance of the finished belt balls in real time;
(5) An operator watches a real-time picture at a terminal, and according to the judgment results of green balls and belt finished balls in a balling area, the balling parameters, the moisture, the water flow and the material speed of the green balls and the belt finished balls are judged, and if the green balls and the belt finished balls have problems, the balling parameters, the moisture, the water flow and the material speed are adjusted on site at any time.
While the foregoing is directed to the preferred embodiment of the present invention, it will be appreciated by those skilled in the art that various changes and modifications may be made therein without departing from the principles of the invention as set forth in the appended claims.
Claims (7)
1. An automatic control system for effectively improving pelletizing efficiency of iron ore powder pellets is characterized by comprising a pelletizing disc, a mechanical arm, two cameras, a conveying belt, a water pipe, a feeding belt and a scraper,
a mechanical arm is arranged on an operation gallery beside the pelletizing disc and close to the pelletizing disc,
the camera I is aligned with the balling area of the balling disc, the camera II is aligned with the conveyer belt of the balling disc discharging area,
a water pipe and a feeding belt are arranged above the pelletizing disc, a blanking area is arranged below the feeding belt, a nucleation growing area is arranged behind the blanking area, and a pelletizing area is arranged behind the nucleation growing area according to the clockwise direction;
the inner wall of the pelletizing disc frame is provided with a scraper, the pelletizing disc rotates anticlockwise, and the scraper does not rotate along with the disc.
2. The automatic control system for effectively improving the pelletizing efficiency of the iron ore powder pellets as claimed in claim 1, wherein one end of the mechanical arm for cleaning the large pellets is made of arc-shaped sharp stainless steel with the interval of 40mm-50mm.
3. The application method of the automatic control system for effectively improving the pelletizing efficiency of the iron ore powder pellets according to claim 1 is characterized by comprising the following steps:
s1: mineral powder enters a blanking area through a feeding belt;
s2: the pelletizing disc rotates anticlockwise, the mineral powder also rotates anticlockwise, and mist water is added into the pelletizing disc through the water pipe;
s3: the mineral powder is bonded under the action of capillary force, and grows into a nucleation area;
s4: the nucleated mineral powder grows again and enters a pelletizing area to become finished pellets, and larger pellets with the diameter of more than 100mm exist in the pelletizing area;
s5: the finished pellets enter a conveying belt and enter a screening process, pellets smaller than 10mm and larger than 16mm are crushed again and return to a pelletizing system, and qualified pellets of 10-16mm are dried, preheated, roasted, soaked and cooled;
s6: the super-large pellets with the diameter of more than 100mm cannot enter a conveying belt due to the action of gravity, and continuously roll in a pelletizing area to be large, so that the super-large pellets are smashed through the operation of a mechanical arm, and the pelletizing efficiency is improved.
4. The application method of the automatic control system for effectively improving the pelletizing efficiency of the iron ore powder pellets according to claim 3, wherein the operation control modes of the mechanical arm in the S6 are two types: normal mode operation and energy-saving mode operation.
5. The application method of the automatic control system for effectively improving the pelletizing efficiency of the iron ore powder pellets, which is claimed in claim 4, is characterized in that the conventional operation of the mechanical arm is specifically as follows:
the operation period was set to be one period per hour, 10 times per period, each 30s apart.
6. The application method of the automatic control system for effectively improving the pelletizing efficiency of the iron ore powder pellets, according to claim 4, is characterized in that the energy-saving operation of the mechanical arm is specifically as follows:
the camera I is used for observing the pellets in the pelletizing area in real time, images of the pellets in the pelletizing area are collected, and when the maximum particles of the pellets exceed a preset value of 100mm, the control system controls the mechanical arm to operate;
meanwhile, the finished pellets on the belt are observed in real time through a camera II, the number of large particles in the finished pellets, the size fraction of the pellets, the average particle size and the variance are recorded, the size fraction distribution of the pellets is evaluated, and the reasonability of pelletizing parameters is further judged.
7. The application method of the automatic control system for effectively improving the pelletizing efficiency of the iron ore powder pellets, which is claimed in claim 6, is characterized in that the frequency of the image collected by the camera I is 10 s/group.
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