CN116283225A - Method and system for mixed firing of ceramsite by utilizing fly ash and sludge - Google Patents
Method and system for mixed firing of ceramsite by utilizing fly ash and sludge Download PDFInfo
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Abstract
The invention relates to a method and a system for mixing and burning ceramsite by utilizing fly ash and sludge, belonging to the technical field of artificial intelligence and environmental protection. The method comprises the following steps: uniformly stirring sludge powder, fly ash in a fine powder state and bentonite to obtain a stirring mixture; dynamically correcting the duration of the low-temperature heating treatment based on a visual detection result of the number of air holes of the molded particles of the stirred mixture; each height Wen Shuzhi corresponding to each firing operation in which no firing pop has occurred recently is used as each input data of the convolutional neural network to resolve the height Wen Shuzhi required for the current firing operation. According to the invention, the excessively solidified ceramic grain manufacturing process based on the fly ash and the sludge in the prior art can be upgraded and modified, and the self-adaptive numerical selection of the low-temperature preheating time length and the high-temperature roasting temperature is realized, so that the upgrading and modification of the ceramic grain manufacturing process based on the fly ash and the sludge are completed, and the speed and the efficiency of ceramic grain manufacturing each time are ensured.
Description
Technical Field
The invention relates to the technical field of artificial intelligence and environmental protection, in particular to a method and a system for mixed firing of ceramsite by utilizing fly ash and sludge.
Background
The ceramsite is a lightweight aggregate produced by foaming in a rotary kiln. The material has the characteristics of spherical shape, smooth and hard surface, honeycomb shape inside, small density, low heat conductivity and high strength. In the refractory industry, ceramsite is mainly used as aggregate of heat-insulating refractory materials.
The bulk density of the ceramsite is less than 1100kg/m3, and is generally 300-900 kg/m3. The density of the concrete prepared by taking the ceramsite as the aggregate is 1100-1800 kg/m < 3 >, and the corresponding compressive strength of the concrete is 30.5-40.0 Mpa. The ceramsite is characterized by hard outer surface and a plurality of micropores in the interior. These micropores impart light properties to Tao Lizhi. The ceramic sand is mainly used for petroleum propping agent, and is one of the ceramic sand varieties with the largest demand, and is also called petroleum fracturing propping agent ceramic sand.
The ceramsite has excellent properties such as low density, high cylinder pressure, high porosity, high softening coefficient, good freezing resistance, excellent alkali-resistant aggregate reactivity and the like. Particularly, the ceramsite has the advantages of small density, porous inside, uniform morphology and components, certain strength and firmness, light weight, corrosion resistance, frost resistance, earthquake resistance, good isolation and the like. By utilizing the excellent properties of the ceramic particles, the ceramic particles can be widely applied to the departments of building materials, gardening, food and beverage, fire-resistant heat-insulating materials, chemical industry, petroleum and the like, and the application fields are wider and wider, and the ceramic particles continue to expand.
Fly ash is used as incineration residue of various objects, sludge is used as sediment of municipal refuse, and the disposal has difficulty, time cost and economic cost, and the disposal is easy to accumulate for a long time to pollute the environment. Therefore, if the fly ash and the sludge are used as the manufacturing raw materials of the ceramsite for building and other purposes, on one hand, the reliability and the stability of the building material can be improved, and the resource utilization of the fly ash and the sludge is realized, so that the pollution to the living and production environment of people is reduced.
However, the manufacturing process of the ceramsite based on the fly ash and the sludge in the prior art is too solidified, such as the duration of preheating at low temperature and the fixation of the high temperature of roasting, and cannot be suitable for various complex sources of fly ash materials and sludge materials, so that the manufactured ceramsite finished product is easy to generate phenomena of excessive preheating, insufficient preheating or roasting bursting, and the yield of the ceramsite finished product is greatly reduced.
Disclosure of Invention
In order to solve the problems, the invention provides a method and a system for mixing and burning ceramsite by utilizing fly ash and sludge, which upgrade and reform the manufacturing process of the over-solidified ceramsite based on the fly ash and the sludge in the prior art, introduce a targeted visual recognition mechanism to finish the real-time detection of the number of air hole objects on the surface of uniformly mixed plastic mould particles in low-temperature preheating, provide reference data for the moment of the end of the low-temperature preheating, and simultaneously introduce an artificial intelligent model based on a convolutional neural network to realize the self-adaptive selection of the current high-temperature roasting temperature, thereby enabling the manufacturing process of the ceramsite based on the fly ash and the sludge after upgrade and reform to be more suitable for fly ash materials and sludge materials of various complex sources.
Compared with the prior art, the invention has at least the following outstanding substantial characteristics:
firstly, carrying out low-temperature heating treatment on uniformly mixed plastic mould particles of sludge powder, fly ash bodies in a fine powder state and bentonite bodies which are subjected to extrusion plastic mould treatment until a certain number of air hole objects on the surfaces of the particles are reached, thereby reducing the probability of occurrence of the subsequent high-temperature roasting bursting phenomenon, wherein a targeted visual recognition mechanism is adopted to finish detection of the number of the air hole objects on the surfaces of the particles;
secondly, before the current roasting operation is executed, taking each high Wen Shuzhi corresponding to each roasting operation which does not generate a roasting bursting phenomenon in the past as each input data of a convolutional neural network to run the convolutional neural network to obtain a high Wen Shuzhi required by the current roasting operation, and controlling the high temperature of the current roasting operation based on the obtained high Wen Shuzhi, so that the obtained high temperature roasting temperature is suitable for fly ash materials and sludge materials of various complex sources by adopting an artificial intelligence mode;
finally, the smaller the numerical value of the volume of the cube of the preset three-dimensional size processed by the convolutional neural network is, the smaller the value of the total number of input data of the convolutional neural network is, and before the convolutional neural network is used, the convolutional neural network is subjected to learning actions of preset times, wherein the value of the preset times is in direct proportion to the number of cubes of the preset three-dimensional size required to be subjected to high-temperature roasting operation, and the cubes are subjected to low-temperature heating processing, so that the self-adaptive customization of the used convolutional neural network is completed.
According to a first aspect of the present invention, there is provided a method of co-firing ceramic granules with fly ash and sludge, the method comprising:
mixing sludge powder, fly ash in a fine powder state and bentonite according to a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirring mixture;
performing an extrusion molding process on the obtained stirred mixture to obtain molded particles of each cube of a preset solid size;
performing low-temperature heating treatment on the large-size cubes obtained by bonding the sides of the plastic mold particles of each cube;
after performing the low-temperature heating process, performing an imaging operation on a certain side of the large-sized cube from directly above a central position of the certain side to obtain a corresponding heating monitor pattern;
analyzing image blocks occupied by a certain side face of the large-size cube in the heating monitoring pattern to serve as first image blocks based on the geometric shape of the side face of the cube, and analyzing each image block occupied by each air hole object in the first image block to serve as each second image block based on the preset gray value range of the air holes;
Driving the low-temperature heating apparatus to end the low-temperature heating process performed on the large-size cube when the total number of second image patches in the first image patches exceeds a set number threshold;
taking each height Wen Shuzhi corresponding to each roasting operation which does not generate a roasting bursting phenomenon recently in the past as each input data of a convolutional neural network to run the convolutional neural network to obtain a height Wen Shuzhi required by the current roasting operation;
performing disassembly on the large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing current roasting operation based on the obtained height Wen Shuzhi on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
the smaller the value of the volume of the cube with the preset three-dimensional size is, the smaller the value of the total number of input data of the convolutional neural network is.
According to a second aspect of the present invention there is provided a system for co-firing ceramic granules with fly ash and sludge, the system comprising a memory and one or more processors, the memory storing a computer program configured to be executed by the one or more processors to perform the steps of:
Mixing sludge powder, fly ash in a fine powder state and bentonite according to a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirring mixture;
performing an extrusion molding process on the obtained stirred mixture to obtain molded particles of each cube of a preset solid size;
performing low-temperature heating treatment on the large-size cubes obtained by bonding the sides of the plastic mold particles of each cube;
after performing the low-temperature heating process, performing an imaging operation on a certain side of the large-sized cube from directly above a central position of the certain side to obtain a corresponding heating monitor pattern;
analyzing image blocks occupied by a certain side face of the large-size cube in the heating monitoring pattern to serve as first image blocks based on the geometric shape of the side face of the cube, and analyzing each image block occupied by each air hole object in the first image block to serve as each second image block based on the preset gray value range of the air holes;
driving the low-temperature heating apparatus to end the low-temperature heating process performed on the large-size cube when the total number of second image patches in the first image patches exceeds a set number threshold;
Taking each height Wen Shuzhi corresponding to each roasting operation which does not generate a roasting bursting phenomenon recently in the past as each input data of a convolutional neural network to run the convolutional neural network to obtain a height Wen Shuzhi required by the current roasting operation;
performing disassembly on the large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing current roasting operation based on the obtained height Wen Shuzhi on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
the smaller the value of the volume of the cube with the preset three-dimensional size is, the smaller the value of the total number of input data of the convolutional neural network is.
According to a third aspect of the present invention, there is provided a system for co-firing ceramic granules with fly ash and sludge, the system comprising:
the mixing stirring equipment is used for mixing the sludge powder, the fly ash body in a fine powder state and the bentonite body according to a preset mass proportion, and uniformly stirring the obtained mixture to obtain a stirred mixture;
a mold execution device connected with the mixing stirring device for executing extrusion molding treatment on the obtained stirring mixture to obtain mold particles of each cube with preset three-dimensional size;
A low-temperature heating device for performing a low-temperature heating process on the large-sized cubes obtained by bonding the sides of the molded particles of the respective cubes;
the miniature imaging device is used for executing imaging operation on one side surface of the large-size cube right above the central position of the one side surface after the low-temperature heating device is started so as to obtain a corresponding heating monitoring pattern;
the block analysis device is connected with the miniature imaging device and is used for analyzing the image blocks occupied by one side surface of the large-size cube in the heating monitoring pattern based on the geometric shape of the side surface of the cube to serve as a first image block, and simultaneously analyzing each image block occupied by each air hole object in the first image block based on the preset gray value range of the air hole to serve as each second image block;
the dynamic correction device is respectively connected with the low-temperature heating device and the block analysis device and is used for driving the low-temperature heating device to finish the low-temperature heating process of the large-size cube when the total number of the second image blocks in the first image blocks exceeds a set number threshold;
roasting operation equipment for performing disassembly on large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing high-temperature roasting operation on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
A parameter selection device connected to the firing operation device, for taking, as respective input data of the convolutional neural network, respective heights Wen Shuzhi corresponding to respective firing operations for which a firing pop phenomenon has not occurred recently before the firing operation device performs a current firing operation, to run the convolutional neural network to obtain a height Wen Shuzhi required for the current firing operation, and controlling the firing operation device to perform the current firing operation based on the obtained height Wen Shuzhi;
the smaller the value of the volume of the cube with the preset three-dimensional size is, the smaller the value of the total number of input data of the convolutional neural network is.
Drawings
Embodiments of the present invention will be described below with reference to the accompanying drawings, in which:
fig. 1 is a technical flow diagram of a method and system for blending and firing ceramic granules using fly ash and sludge in accordance with the present invention.
Fig. 2 is an internal structural diagram of a convolutional neural network used in the present invention.
Fig. 3 is a block diagram showing a system for mixing and firing ceramic grains using fly ash and sludge according to a sixth embodiment of the present invention.
Fig. 4 is a block diagram showing a system for mixing and firing ceramsite using fly ash and sludge according to a seventh embodiment of the present invention.
Detailed Description
Ceramsite, i.e. ceramic particles. The shape of which varies from process to process. The surface of the ceramic shell is a hard shell which is ceramic or enamel, has the functions of water insulation and air retention, and gives the ceramsite higher strength.
Since the raw materials for producing the ceramsite are many, the variety of the ceramsite is also many, and the color is also many. The color of the baked ceramic particles is mostly dark red and ocher red, and some special varieties are gray yellow, gray black, gray white, gray and the like. The baking-free ceramsite is different in color and generally gray-black due to different solid wastes, and has no glossiness on the surface, which is not as smooth as the baked ceramsite.
Ceramsite is generally used to replace crushed stone and pebbles in concrete. The light weight is the most important point in many excellent performances of the ceramsite, and is also the main reason why the ceramsite can replace heavy sand. The internal structural characteristics of the ceramsite are fine honeycomb micropores. These microwells are closed, not connected. It is formed by the inclusion of a gas into the shell, which is the main reason for the lightweight of the ceramsite.
The fine particle portion of the ceramsite is called ceramic sand. There are many fine particles smaller than 5 mm in the ceramsite, and the fine particles are screened out by a screening machine in production, which is conventionally called ceramic sand. The ceramic sand has slightly high density and good chemical and thermal stability. The ceramic sand is mainly used for preparing light aggregate concrete and light mortar instead of natural river sand or mountain sand, and can also be used as acid-resistant and heat-resistant concrete fine aggregate.
However, the current fly ash and sludge based ceramsite manufacturing process has the following drawbacks: because the sources of the manufacturing raw materials, namely fly ash materials and sludge materials, are complex, the material compositions are quite different, and the contradiction between the difference of the materials and the curing manufacturing process, such as the contradiction between the low-temperature preheating time length and the high-temperature baking temperature of the curing numerical value, ensures that the quality of the produced ceramsite finished product is good and bad, and seriously influences the manufacturing speed and the manufacturing efficiency of the ceramsite.
In order to overcome the defects, the invention discloses a method and a system for mixing and burning ceramsite by utilizing fly ash and sludge, and two different artificial intelligence mechanisms are introduced into a ceramsite manufacturing process to realize real-time control of the technological process, so that the self-adaptive matching of fly ash materials and sludge materials from various complex sources is realized.
As shown in fig. 1, a technical flow diagram of a method and system for co-firing ceramic granules using fly ash and sludge according to the present invention is presented.
As shown in fig. 1, the specific technical process of the present invention is as follows:
firstly, aiming at a low-temperature heating procedure in a manufacturing process of mixed-firing ceramic granules by utilizing fly ash and sludge, adopting an artificial intelligent model based on visual detection, namely a first artificial intelligent model, and executing the quantity detection of air hole objects on the surfaces of uniformly mixed plastic mould particles to be subjected to low-temperature heating;
Secondly, aiming at a high-temperature roasting process in a manufacturing process of mixed-roasting ceramsite by utilizing fly ash and sludge, adopting an artificial intelligence model based on a convolutional neural network, namely a second artificial intelligence model, and executing prediction of the current roasting temperature of uniformly mixed plastic mould particles to be roasted at high temperature, wherein the prediction is based on each high Wen Shuzhi corresponding to each roasting operation which does not generate a roasting bursting phenomenon recently so as to reduce the failure probability of the current roasting operation as much as possible, thereby meeting the high-temperature roasting requirements of fly ash materials and sludge materials from various complex sources;
the convolutional neural network is a customized convolutional neural network after multiple learning, the smaller the numerical value of the volume of the uniformly mixed plastic mould particles processed by the convolutional neural network is, the smaller the value of the total number of input data of the convolutional neural network is, as shown in fig. 1, the value of the total number of input data of the convolutional neural network is M, and M is a natural number greater than or equal to 4;
and wherein the number of times the convolutional neural network learns is proportional to the number of uniformly mixed molded particles required to perform the high temperature firing operation.
The invention has the key points that the fly ash and sludge-based ceramsite manufacturing process with curing parameters and curing procedures in the prior art is upgraded and modified, and two key processes, namely low-temperature preheating and high-temperature baking, are respectively realized by adopting two different artificial intelligent models to realize the self-adaptive selection of preheating duration and baking temperature, so that the flexibility of the fly ash and sludge-based ceramsite manufacturing process is improved, and the quantity of poor-quality ceramsite finished products is reduced.
The method and system for co-firing ceramic granules using fly ash and sludge according to the present invention will be described in detail by way of examples.
First embodiment
The method for mixing and firing the ceramsite by utilizing the fly ash and the sludge provided by the first embodiment of the invention specifically comprises the following steps:
mixing sludge powder, fly ash in a fine powder state and bentonite according to a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirring mixture;
performing an extrusion molding process on the obtained stirred mixture to obtain molded particles of each cube of a preset solid size;
performing low-temperature heating treatment on the large-size cubes obtained by bonding the sides of the plastic mold particles of each cube;
after performing the low-temperature heating process, performing an imaging operation on a certain side of the large-sized cube from directly above a central position of the certain side to obtain a corresponding heating monitor pattern;
analyzing image blocks occupied by a certain side face of the large-size cube in the heating monitoring pattern to serve as first image blocks based on the geometric shape of the side face of the cube, and analyzing each image block occupied by each air hole object in the first image block to serve as each second image block based on the preset gray value range of the air holes;
Driving the low-temperature heating apparatus to end the low-temperature heating process performed on the large-size cube when the total number of second image patches in the first image patches exceeds a set number threshold;
taking each height Wen Shuzhi corresponding to each roasting operation which does not generate a roasting bursting phenomenon recently in the past as each input data of a convolutional neural network to run the convolutional neural network to obtain a height Wen Shuzhi required by the current roasting operation;
performing disassembly on the large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing current roasting operation based on the obtained height Wen Shuzhi on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
the smaller the numerical value of the volume of the cube with the preset three-dimensional size is, the smaller the numerical value of the total number of input data of the convolutional neural network is;
illustratively, the total number of input data of the convolutional neural network is 10 when the volume of the cube of the preset stereoscopic size is 1 cubic centimeter, 30 when the volume of the cube of the preset stereoscopic size is 8 cubic centimeters, and 50 when the volume of the cube of the preset stereoscopic size is 27 cubic centimeters;
As shown in fig. 2, an internal structure of a convolutional neural network is provided, wherein the convolutional neural network comprises a feature input end, a feature extraction end and a feature output end, the feature extraction end comprises a plurality of convolutional layers and a plurality of pooling layers, and the feature output end is connected with the feature extraction end through a full communication layer;
in fig. 2, the feature extraction end includes three convolution layers and two pooling layers, a first convolution layer is connected with the feature input end, a second convolution layer is connected with the first convolution layer, the first pooling layer is connected with the second convolution layer, a third convolution layer is connected with the first pooling layer, the second pooling layer is connected with the third convolution layer, one end of the full communication layer is connected with the second pooling layer, and the other end is connected with the feature output end.
Second embodiment
The second embodiment provided by the invention, unlike the first embodiment of the invention, is a method for mixing and firing ceramic granules by using fly ash and sludge, which further comprises the following steps:
before mixing sludge powder, fly ash in a fine powder state and bentonite in a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirred mixture;
carrying out preset treatment of sequentially drying and crushing the obtained municipal sludge to obtain sludge powder;
Wherein, carrying out the preset treatment of drying and crushing in turn on the obtained municipal sludge to obtain sludge powder comprises: a drying execution device and a crushing execution device are adopted to respectively execute preset treatment of drying and crushing on the obtained municipal sludge;
screening the obtained combustion residual fly ash to remove fly ash powder with a cross section having a maximum radial radius of more than 25 microns, so as to obtain fly ash bodies in a fine powder state;
wherein, the filter screen body with the maximum radial radius of the cross section of the sieve holes equal to 25 microns can be selected to realize that the obtained combustion residual fly ash is subjected to screening treatment so as to remove fly ash powder with the maximum radial radius of the cross section exceeding 25 microns, so that the fly ash body in a fine powder state is obtained.
Third embodiment
In a third embodiment of the present invention, unlike the first embodiment of the present invention, the method for mixing and firing ceramic granules using fly ash and sludge further includes:
after dismantling large-size cubes subjected to low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing high-temperature roasting operation on the cubes subjected to low-temperature heating treatment to obtain ceramsite blanks;
The ceramsite blanks are accommodated and cooled to room temperature to obtain ceramsite finished products;
wherein the low temperature is 360-400 ℃ and the high temperature is 1200-1250 ℃;
the specific value of the low temperature can be 380 ℃, and the specific value of the high temperature can be 1220 ℃;
and a cooling tank body is optionally adopted for accommodating each ceramic particle blank and cooling each ceramic particle blank to room temperature to obtain each ceramic particle finished product, and cooling execution equipment is arranged in the cooling tank body.
Fourth embodiment
In a fourth embodiment of the present invention, unlike the first embodiment of the present invention, the method for mixing and firing ceramic grains using fly ash and sludge further includes:
before each corresponding height Wen Shuzhi of each roasting operation which does not generate the roasting explosion phenomenon in the past is used as each input data of a convolutional neural network to run the convolutional neural network to obtain a height Wen Shuzhi required by the current roasting operation, and the roasting operation equipment is controlled to execute the current roasting operation based on the obtained height Wen Shuzhi;
the method comprises the steps of executing a preset number of learning actions on a convolutional neural network, and using the convolutional neural network after the preset number of learning actions are executed to obtain a height Wen Shuzhi required by the current roasting operation;
Wherein, the value of the preset times is in direct proportion to the number of cubes of the preset three-dimensional size, each cube of which the low-temperature heating treatment is performed;
for example, when the number of cubes of the preset three-dimensional size each for which the low-temperature heat treatment is performed is 100, the value of the preset number of times is 50, when the number of cubes of the preset three-dimensional size each for which the low-temperature heat treatment is performed is 200, the value of the preset number of times is 100, when the number of cubes of the preset three-dimensional size each for which the low-temperature heat treatment is performed is 400, the value of the preset number of times is 200, and when the number of cubes of the preset three-dimensional size each for which the low-temperature heat treatment is performed is 800, the value of the preset number of times is 400.
Fifth embodiment
In a fifth embodiment of the present invention, unlike the first embodiment of the present invention, the method for mixing and firing ceramic grains using fly ash and sludge further includes:
continuing the low-temperature heating process performed on the large-size cube when the total number of second image patches in the first image patches does not exceed the set number threshold;
illustratively, the value of the set number threshold is monotonically positively associated with the number of pixels of the first image block.
In any of the above embodiments, optionally, in the method of firing ceramic granules with fly ash and sludge mixing:
performing preset treatments of sequentially drying and pulverizing the obtained municipal sludge to obtain sludge powder comprises: the water content of the obtained municipal sludge is between 78% and 88%, and the water content of the obtained sludge powder is less than or equal to 18%;
for example, the obtained municipal sludge may have a water content of 80% and the obtained sludge powder may have a water content of 14%.
In any of the above embodiments, optionally, in the method of firing ceramic granules with fly ash and sludge mixing:
mixing the sludge powder, fly ash in a fine powder state and bentonite in a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirred mixture, wherein the step of stirring the obtained mixture comprises the following steps of: the preset mass ratio is 40:40:20;
alternatively, mixing the sludge powder, fly ash in a fine state, and bentonite in a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirred mixture includes: the preset mass ratio is 35:35:30;
And alternatively, the sludge powder, the fly ash body in a fine powder state and the bentonite body can be mixed according to a preset volume ratio.
In any of the above embodiments, optionally, in the method of firing ceramic granules with fly ash and sludge mixing:
resolving the image patch occupied by a side of the large-sized cube in the heating monitor pattern based on the geometry of the side of the cube as a first image patch includes: taking the image block with the largest occupied pixel point number in each image block matched with the geometric shape of the side surface of the cube in the heating monitoring pattern as a first image block;
alternatively, resolving the image patch occupied by a certain side of the large-sized cube in the heating monitor pattern based on the geometry of the side of the cube as a first image patch includes: the image block which is matched with the geometric shape of the side face of the cube and is positioned at the central position of the heating monitoring pattern in the heating monitoring pattern is used as a first image block;
wherein resolving each image block occupied by each air hole object in the first image block based on the preset gray value range of the air hole as each second image block includes: taking pixel points with gray values within a preset gray value range of air holes in the first image block as air hole composition pixel points, and fitting each air hole composition pixel point in the first image block to obtain each image block occupied by each air hole object in the first image block;
The preset gray value range of the air hole is defined by an air hole gray upper limit threshold and an air hole gray lower limit threshold, wherein the air hole gray upper limit threshold is larger than the air hole gray lower limit threshold, and the air hole gray upper limit threshold and the air hole gray lower limit threshold are both 0-255.
Sixth embodiment
Fig. 3 is a block diagram showing a system for mixing and firing ceramic grains using fly ash and sludge according to a sixth embodiment of the present invention.
As shown in fig. 3, the system for co-firing ceramic particles with fly ash and sludge includes a memory and N processors, N being a positive integer greater than or equal to 1, the memory storing a computer program configured to be executed by the N processors to perform the steps of:
mixing sludge powder, fly ash in a fine powder state and bentonite according to a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirring mixture;
performing an extrusion molding process on the obtained stirred mixture to obtain molded particles of each cube of a preset solid size;
performing low-temperature heating treatment on the large-size cubes obtained by bonding the sides of the plastic mold particles of each cube;
After performing the low-temperature heating process, performing an imaging operation on a certain side of the large-sized cube from directly above a central position of the certain side to obtain a corresponding heating monitor pattern;
analyzing image blocks occupied by a certain side face of the large-size cube in the heating monitoring pattern to serve as first image blocks based on the geometric shape of the side face of the cube, and analyzing each image block occupied by each air hole object in the first image block to serve as each second image block based on the preset gray value range of the air holes;
driving the low-temperature heating apparatus to end the low-temperature heating process performed on the large-size cube when the total number of second image patches in the first image patches exceeds a set number threshold;
taking each height Wen Shuzhi corresponding to each roasting operation which does not generate a roasting bursting phenomenon recently in the past as each input data of a convolutional neural network to run the convolutional neural network to obtain a height Wen Shuzhi required by the current roasting operation;
performing disassembly on the large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing current roasting operation based on the obtained height Wen Shuzhi on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
The smaller the numerical value of the volume of the cube with the preset three-dimensional size is, the smaller the numerical value of the total number of input data of the convolutional neural network is;
wherein, the system for mixing and firing the ceramsite by utilizing the fly ash and the sludge comprises a storage and N processors, wherein the N processors comprise: each processor may be selected from one of a field programmable gate array, a PAL device, a GAL device, or a DSP processing device;
wherein, the system for mixing and firing the ceramsite by utilizing the fly ash and the sludge comprises a storage and N processors, and the system further comprises: the memory may be selected as a DRAM memory chip.
Seventh embodiment
Fig. 4 is a block diagram showing a system for mixing and firing ceramsite using fly ash and sludge according to a seventh embodiment of the present invention.
As shown in fig. 4, the system for mixing and firing the ceramsite by using the fly ash and the sludge specifically comprises the following components:
the mixing stirring equipment is used for mixing the sludge powder, the fly ash body in a fine powder state and the bentonite body according to a preset mass proportion, and uniformly stirring the obtained mixture to obtain a stirred mixture;
a mold execution device connected with the mixing stirring device for executing extrusion molding treatment on the obtained stirring mixture to obtain mold particles of each cube with preset three-dimensional size;
A low-temperature heating device for performing a low-temperature heating process on the large-sized cubes obtained by bonding the sides of the molded particles of the respective cubes;
the miniature imaging device is used for executing imaging operation on one side surface of the large-size cube right above the central position of the one side surface after the low-temperature heating device is started so as to obtain a corresponding heating monitoring pattern;
the block analysis device is connected with the miniature imaging device and is used for analyzing the image blocks occupied by one side surface of the large-size cube in the heating monitoring pattern based on the geometric shape of the side surface of the cube to serve as a first image block, and simultaneously analyzing each image block occupied by each air hole object in the first image block based on the preset gray value range of the air hole to serve as each second image block;
the dynamic correction device is respectively connected with the low-temperature heating device and the block analysis device and is used for driving the low-temperature heating device to finish the low-temperature heating process of the large-size cube when the total number of the second image blocks in the first image blocks exceeds a set number threshold;
roasting operation equipment for performing disassembly on large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing high-temperature roasting operation on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
A parameter selection device connected to the firing operation device, for taking, as respective input data of the convolutional neural network, respective heights Wen Shuzhi corresponding to respective firing operations for which a firing pop phenomenon has not occurred recently before the firing operation device performs a current firing operation, to run the convolutional neural network to obtain a height Wen Shuzhi required for the current firing operation, and controlling the firing operation device to perform the current firing operation based on the obtained height Wen Shuzhi;
the smaller the numerical value of the volume of the cube with the preset three-dimensional size is, the smaller the numerical value of the total number of input data of the convolutional neural network is;
the system for mixing and firing the ceramsite by utilizing the fly ash and the sludge can further comprise synchronous processing equipment which is respectively connected with the mould executing equipment, the low-temperature heating equipment, the miniature imaging equipment, the block analysis equipment, the dynamic correction equipment, the roasting operation equipment and the parameter selection equipment and is used for realizing the dynamic synchronous control of the mould executing equipment, the low-temperature heating equipment, the miniature imaging equipment, the block analysis equipment, the dynamic correction equipment, the roasting operation equipment and the parameter selection equipment;
and the system for mixing and firing the ceramsite by utilizing the fly ash and the sludge can further comprise an uninterruptible power supply device which is respectively connected with the mould execution device, the low-temperature heating device, the miniature imaging device, the block analysis device, the dynamic correction device, the roasting operation device and the parameter selection device and is used for providing power supply voltages required by the mould execution device, the low-temperature heating device, the miniature imaging device, the block analysis device, the dynamic correction device, the roasting operation device and the parameter selection device.
In addition, in the method and system for mixed firing of the ceramic grains by utilizing the fly ash and the sludge, analyzing each image block occupied by each pore object in the first image block based on the preset gray value range of the pores as each second image block further comprises: taking pixel points with gray values outside a preset gray value range of the air holes in the first image block as other pixel points, wherein each other pixel point in the first image block does not participate in fitting processing;
and in the method and system for co-firing ceramic granules using fly ash and sludge, performing extrusion molding treatment on the obtained stirred mixture to obtain molded granules of each cube of a predetermined solid size, comprising: the side length of the cube of the preset solid size may take a value between 1 cm and 5 cm, and for example, the side length of the cube of the preset solid size may take a value of 3 cm.
Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more of the described features. In the description of the embodiments of the present application, the meaning of "a plurality" is two or more, unless explicitly defined otherwise. In the description of the present specification, reference to the terms "one embodiment," "certain embodiments," "illustrative embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present application. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Although embodiments of the present application have been shown and described above, it will be understood that the above embodiments are illustrative and not to be construed as limiting the application, and that variations, modifications, alternatives, and variations may be made to the above embodiments by one of ordinary skill in the art within the scope of the application.
Claims (10)
1. A method for co-firing ceramic particles by utilizing fly ash and sludge, which is characterized by comprising the following steps:
mixing sludge powder, fly ash in a fine powder state and bentonite according to a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirring mixture;
performing an extrusion molding process on the obtained stirred mixture to obtain molded particles of each cube of a preset solid size;
performing low-temperature heating treatment on the large-size cubes obtained by bonding the sides of the plastic mold particles of each cube;
after performing the low-temperature heating process, performing an imaging operation on a certain side of the large-sized cube from directly above a central position of the certain side to obtain a corresponding heating monitor pattern;
analyzing image blocks occupied by a certain side face of the large-size cube in the heating monitoring pattern to serve as first image blocks based on the geometric shape of the side face of the cube, and analyzing each image block occupied by each air hole object in the first image block to serve as each second image block based on the preset gray value range of the air holes;
driving the low-temperature heating apparatus to end the low-temperature heating process performed on the large-size cube when the total number of second image patches in the first image patches exceeds a set number threshold;
Taking each height Wen Shuzhi corresponding to each roasting operation which does not generate a roasting bursting phenomenon recently in the past as each input data of a convolutional neural network to run the convolutional neural network to obtain a height Wen Shuzhi required by the current roasting operation;
performing disassembly on the large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing current roasting operation based on the obtained height Wen Shuzhi on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
the smaller the value of the volume of the cube with the preset three-dimensional size is, the smaller the value of the total number of input data of the convolutional neural network is.
2. The method of firing ceramic granules with a mixture of fly ash and sludge according to claim 1, further comprising:
carrying out preset treatment of sequentially drying and crushing the obtained municipal sludge to obtain sludge powder;
and screening the obtained combustion residual fly ash to remove fly ash powder with a cross section having a maximum radial radius exceeding 25 microns, so as to obtain fly ash bodies in a fine powder state.
3. The method of firing ceramic granules with a mixture of fly ash and sludge according to claim 1, further comprising:
The ceramsite blanks are accommodated and cooled to room temperature to obtain ceramsite finished products;
wherein, the low temperature is 360-400 ℃ and the high temperature is 1200-1250 ℃.
4. The method of firing ceramic granules with a mixture of fly ash and sludge according to claim 1, further comprising:
before the convolutional neural network is used, a preset number of learning actions are executed on the convolutional neural network, and the convolutional neural network after the preset number of learning actions are executed is used for acquiring a height Wen Shuzhi required by the current roasting operation;
wherein, the value of the preset times is in direct proportion to the number of cubes of the preset three-dimensional size, which are subjected to the low-temperature heating treatment.
5. The method of firing ceramic granules with a mixture of fly ash and sludge according to claim 1, further comprising:
and continuing the low-temperature heating process performed on the large-size cube when the total number of second image patches in the first image patches does not exceed the set number threshold.
6. The method for mixed firing of ceramic particles by utilizing fly ash and sludge according to any one of claims 1 to 5, wherein:
Performing preset treatments of sequentially drying and pulverizing the obtained municipal sludge to obtain sludge powder comprises: the water content of the obtained municipal sludge is between 78% and 88%, and the water content of the obtained sludge powder is less than or equal to 18%.
7. The method for mixed firing of ceramic particles by utilizing fly ash and sludge according to any one of claims 1 to 5, wherein:
mixing the sludge powder, fly ash in a fine powder state and bentonite in a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirred mixture, wherein the step of stirring the obtained mixture comprises the following steps of: the preset mass ratio is 40:40:20.
8. The method for mixed firing of ceramic particles by utilizing fly ash and sludge according to any one of claims 1 to 5, wherein:
resolving the image patch occupied by a side of the large-sized cube in the heating monitor pattern based on the geometry of the side of the cube as a first image patch includes: taking the image block with the largest occupied pixel point number in each image block matched with the geometric shape of the side surface of the cube in the heating monitoring pattern as a first image block;
wherein resolving each image block occupied by each air hole object in the first image block based on the preset gray value range of the air hole as each second image block includes: and taking pixel points with gray values within a preset gray value range of air holes in the first image block as air hole composition pixel points, and fitting each air hole composition pixel point in the first image block to obtain each image block occupied by each air hole object in the first image block.
9. A system for co-firing ceramic granules with fly ash and sludge, the system comprising a memory and one or more processors, the memory storing a computer program configured to be executed by the one or more processors to perform the steps of:
mixing sludge powder, fly ash in a fine powder state and bentonite according to a preset mass ratio, and performing uniform stirring treatment on the obtained mixture to obtain a stirring mixture;
performing an extrusion molding process on the obtained stirred mixture to obtain molded particles of each cube of a preset solid size;
performing low-temperature heating treatment on the large-size cubes obtained by bonding the sides of the plastic mold particles of each cube;
after performing the low-temperature heating process, performing an imaging operation on a certain side of the large-sized cube from directly above a central position of the certain side to obtain a corresponding heating monitor pattern;
analyzing image blocks occupied by a certain side face of the large-size cube in the heating monitoring pattern to serve as first image blocks based on the geometric shape of the side face of the cube, and analyzing each image block occupied by each air hole object in the first image block to serve as each second image block based on the preset gray value range of the air holes;
Driving the low-temperature heating apparatus to end the low-temperature heating process performed on the large-size cube when the total number of second image patches in the first image patches exceeds a set number threshold;
taking each height Wen Shuzhi corresponding to each roasting operation which does not generate a roasting bursting phenomenon recently in the past as each input data of a convolutional neural network to run the convolutional neural network to obtain a height Wen Shuzhi required by the current roasting operation;
performing disassembly on the large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing current roasting operation based on the obtained height Wen Shuzhi on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
the smaller the value of the volume of the cube with the preset three-dimensional size is, the smaller the value of the total number of input data of the convolutional neural network is.
10. A system for co-firing ceramic particles with fly ash and sludge, the system comprising:
the mixing stirring equipment is used for mixing the sludge powder, the fly ash body in a fine powder state and the bentonite body according to a preset mass proportion, and uniformly stirring the obtained mixture to obtain a stirred mixture;
A mold execution device connected with the mixing stirring device for executing extrusion molding treatment on the obtained stirring mixture to obtain mold particles of each cube with preset three-dimensional size;
a low-temperature heating device for performing a low-temperature heating process on the large-sized cubes obtained by bonding the sides of the molded particles of the respective cubes;
the miniature imaging device is used for executing imaging operation on one side surface of the large-size cube right above the central position of the one side surface after the low-temperature heating device is started so as to obtain a corresponding heating monitoring pattern;
the block analysis device is connected with the miniature imaging device and is used for analyzing the image blocks occupied by one side surface of the large-size cube in the heating monitoring pattern based on the geometric shape of the side surface of the cube to serve as a first image block, and simultaneously analyzing each image block occupied by each air hole object in the first image block based on the preset gray value range of the air hole to serve as each second image block;
the dynamic correction device is respectively connected with the low-temperature heating device and the block analysis device and is used for driving the low-temperature heating device to finish the low-temperature heating process of the large-size cube when the total number of the second image blocks in the first image blocks exceeds a set number threshold;
Roasting operation equipment for performing disassembly on large-sized cubes subjected to the low-temperature heating treatment to obtain cubes of a preset three-dimensional size, and performing high-temperature roasting operation on the cubes subjected to the low-temperature heating treatment to obtain ceramsite blanks;
a parameter selection device connected to the firing operation device, for taking, as respective input data of the convolutional neural network, respective heights Wen Shuzhi corresponding to respective firing operations for which a firing pop phenomenon has not occurred recently before the firing operation device performs a current firing operation, to run the convolutional neural network to obtain a height Wen Shuzhi required for the current firing operation, and controlling the firing operation device to perform the current firing operation based on the obtained height Wen Shuzhi;
the smaller the value of the volume of the cube with the preset three-dimensional size is, the smaller the value of the total number of input data of the convolutional neural network is.
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