无人值守智能加介系统设计与应用

    Design and application of the intelligent unattended medium adding system

    • 摘要: 目前很多选煤厂在介质制备与添加环节完全依赖人工操作,这种方式会造成介质堆高低不平、合格介质桶液位控制不准确及操作不及时引起的介质沉淀,且工人劳动强度大、工作环境恶劣。为解决上述问题,设计了一套基于3D激光扫描技术的无人值守智能加介系统;同时对受限于场地规模,无法满足土建和钢结构要求的选煤厂,针对两段两产品重介质旋流器分选工艺设计了一套内循环无人值守智能加介系统。基于3D激光扫描技术的无人值守智能加介系统主要包括无人值守介质制备单元和浓介质添加控制单元,系统通过3D激光雷达识别、自动冲水控制和智能加介控制,实现介质的自动制备和精确添加;内循环无人值守智能加介系统主要包括浓介质桶液位识别、自动补介和浓介质的精准添加,系统通过自动引入高密度悬浮液至浓介质桶,来满足主选系统介质添加的需求。应用结果表明,补连塔选煤厂投入运行基于3D激光扫描技术的无人值守智能加介系统后,介耗较改造前平均降低0.51 kg/t,一年节约介质约7 140 t,实现了介质的自动制备和精确添加,降低了介耗;沙曲选煤厂投入运行内循环无人值守智能加介系统后,当密度偏差≥0.02 g/cm3时,加介时长仅需150 s,在降低了土建和钢结构工程需求、减少了维护工作量的同时,实现了悬浮液密度的快速提升。无人值守智能加介系统在补连塔选煤厂和沙曲选煤厂的应用提升了生产效率和产品质量,降低了能耗成本,为选煤行业智能化转型提供了支持。

       

      Abstract: The medium preparation and addition processes are currently carried out in a manual mode in coal preparation plants. The troubles with the manual operation include uneven height of medium pile in medium tank, inaccurate control of liquid level in correct medium tank, deposition of medium solids caused by delay in operation, high labor intensity and harsh working environment. To deal with this situation, an intelligent unattended medium adding system based on 3D laser-scanning technologies is developed. Besides, a similar system of the closed-circuit type is specifically developed for a plant which uses two-stage two-product heavy medium cyclone as primary washing equipment, and has difficulties in making civil work and erecting steel structures because of space limitations. The former system consists of the medium preparation and thick medium adding and control subsystems, which can perform automatic medium preparation and accurate adding function through 3D LiDAR recognition, automatic control of flushing of water and intelligent addition of medium. The intelligent closed-circuit system mentioned above can carry out recognition of liquid level in thick medium tank, automatic replenishment of medium and accurate addition of thick medium. Through the system, high-density medium suspension can be automatically led into thick medium tank to cater to the needs of the primary washing process for addition of medium. Application of the 3D LiDAR system at Bulianta Plant has led to a cut of medium consumption by 0.51 kg/t on average, a save of 7 140 tons of medium a year, and realization of automatic preparation and addition of medium. With the use of the intelligent closed-circuit system at Shaqu Plant, the medium is added at the time when deviation of medium density is greater than or equal to 0.02 g/cm3, with a duration of only 150 s. Other attractions include less requirements for civil work and erection of steel structures, reduced maintenance work, and rapid increase of medium suspension density to required level. Field application of the two systems has made it possible to improve coal washing efficiency and quality of product, reduce energy consumption and operating costs. The development of the two intelligent medium adding system provides a technical support for intelligent transformation of coal preparation plants.

       

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