五举煤业智能洗选综合管控平台设计与应用

    Design and application of the integrated intelligent coal washing management and control platform at Wuju Coal Company′s coal preparation plant

    • 摘要: 选煤厂智能化建设在系统集成与扩展、数据采集与分析、智能化建设与生产实践结合等方面面临诸多挑战。在此背景下,针对五举煤业选煤厂人工操作依赖度高、设备故障频发、工艺参数调节滞后、产品质量稳定性差等问题,开发了一套智能洗选综合管控平台。该平台包括数据接入层、基础设施层、综合管控层和决策应用层,具备标准化数据管理、重介质分选全流程闭环控制、煤泥浓缩压滤联动控制、设备全生命周期管理、作业环境安全智能防控和选煤生产智能集控等核心功能。应用表明:智能洗选综合管控平台的投用取消了选煤厂的固定岗位,实现了全厂设备的远程集控,大大提高了生产效率,每班作业人员由15人减少至6人,全员效率提升至139 t/工;设备故障率大幅降低,平均每天非计划停机时间由55 min降至10 min以内,连续带料生产时间比例由65%提高至90%以上;有效降低了介质及药剂的消耗,每月节省电、介、药成本约12.5万元;稳定了产品质量,重介质悬浮液密度波动控制在0.005 g/cm3以内,洗选精煤灰分波动范围为±0.5个百分点;同时通过引入环境监测传感器、AI识别装置等,实现了对生产过程中环境危险因素的智能感知。五举煤业智能洗选综合管控平台的投用显著提高了选煤厂生产系统的运行效率,大幅度降低了智能化系统的管理难度,为同行业智能化选煤厂建设提供了参考借鉴。

       

      Abstract: The intelligent construction of coal preparation plants faces multiple challenges in areas such as system integration and expansion, data acquisition and analysis, and combination of intelligent systems with production practice. Against this backdrop, in order to address the problems of Wuju Plant, such as over-reliance on manual operations, frequent equipment failures, delayed adjustment of process parameters, and inconsistency of product quality, an integrated intelligent coal washing management and control platform has been developed. The platform comprises four layers: a data access layer, an infrastructure layer, a comprehensive management and control layer, and a decision-making application layer. Its core functions include: standardized data governance, closed-loop control of the dense medium separation process, coordinated control of coal slime thickening and press filtration, full lifecycle equipment management, intelligent prevention and control of workplace environment for safety, centralized intelligent control of coal washing operation. Practice shows that the application of the platform has led to elimination of fixed posts, realization of remote centralized control of all equipment of the plant, and noticeable improvement of washing efficiency; the number of operators per shift has been reduced from 15 to 6, and the overall productivity efficiency has increased to 139 tons per worker; the equipment failure rate has been significantly reduced. The average unplanned shutdown time per day has been reduced from 55 minutes to less than 10 minutes, and the proportion of continuous coal washing time has increased from 65% to more than 90%; the consumption of medium and reagents is effectively reduced, saving 125,000 yuan in electricity, medium, and reagent costs per month; the product quality is stabilized; the density fluctuation of the medium suspension can be controlled within 0.005 g/cm3; the fluctuation of ash of clean coal can be controlled within a range of ±0.5 percentage points; and by introducing environmental monitoring sensors, AI recognition devices, etc., the intelligent perception of environmental risk factors in the coal washing process is made possible. Application of the intelligent platform makes it possible for the plant to significantly improve washing efficiency and great ease the management of the intelligent coal washing system. The study provides a reference for the development of intelligent coal washing plants.

       

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