基于多变量耦合技术的浮选过程控制自主调节系统研究与应用

    Study and application of autonomous adjustment system for flotation process control based on multivariable coupling technology

    • 摘要: 针对田陈煤矿选煤厂浮选过程控制中药剂用量调整手段单一、指标不稳定、药剂浪费、人工劳动强度大等问题,研究开发了一套基于多变量耦合技术的浮选过程控制自主调节系统。基于田陈煤矿选煤厂浮选系统生产现状,分析了煤泥浮选多变量耦合关系,明确入浮特性、药剂制度等因素的相互作用;研制矿浆液位与泡沫层限位一体化检测装置,实现对矿浆液位和泡沫层厚度的实时采集与监测;对矿浆液位调节机构进行自动化升级,实现浮选槽内矿浆液位的稳定控制;增设充气量测控装置,实现对充气量的在线调节;整合多系统构建浮选过程控制自主调节系统,并开发基于B/S架构的软件平台,实现集中监控和数据互联互通;构建产品指标预测模型,用于预测尾煤灰分,尾煤灰分预测均方误差为1.56%。应用结果表明:浮选过程控制自主调节系统投用前后,整体浮选效果得到了改善,精煤产率由76.36%提升至77.42%,年创经济效益 128.5 万元。田陈煤矿选煤厂通过实施基于多变量耦合技术的浮选过程控制自主调节系统,有效优化了浮选效果,在入选煤质变差的情况下,仍有效提升了产品质量稳定性,降低了药剂消耗并提高了精煤产率,带来了显著的经济、社会及环境效益。未来随着灰分数据可靠性的进一步提升,系统预测模型精度有望持续增强,为浮选过程智能化升级提供有力支撑。

       

      Abstract: With an aim to tackle the problems faced by Tianchen Coal Mine's coal preparation plant in operation of its flotation process control — including limited diversity in agent adjustment, unstable indicators, agent waste and high manual labor intensity — an autonomous adjustment system based on multivariable coupling technology is developed. Based on the production status of the flotation system at Tianchen coal preparation plant, the multivariable coupling relationships in coal slime flotation are analyzed, clarifying the interactions among factors such as feed characteristics and agent regime. An integrated measuring device for pulp level and froth layer limit is developed to achieve real-time collection and monitoring of pulp level and froth thickness. The automation upgrade of the pulp level adjustment mechanism is carried out to stabilize pulp level control in flotation cells. An aeration rate measurement and control device is added to enable online regulation of aeration volume. Multiple systems are integrated to establish an autonomous adjustment system for flotation process control, with a B/S architecture-based software platform developed for centralized monitoring and data interoperability. A product index prediction model is constructed to forecast tailings ash content, achieving a mean square error of 1.56% in tailings ash prediction. Application results demonstrate that the overall flotation performance improved significantly after implementing the autonomous adjustment system for flotation process control. The clean coal yield increased from 76.36% to 77.42%, generating an annual economic benefit of 1.285 million yuan. Through the implementation of this adjustment system, Tianchen coal preparation plant effectively optimizes flotation performance. Despite deteriorating feed coal quality, the system enhances product stability, reduces reagent consumption, and increases clean coal yield, delivering tangible economic, social, and environmental benefits. With future improvements in ash data reliability, the predictive model precision is projected to advance continuously, providing robust support for intelligent flotation process upgrades.

       

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