本文選題：赤鐵礦磨礦過程　切入點(diǎn)：磨礦粒度　出處：《東北大學(xué)》2015年博士論文

【摘要】：我國(guó)赤鐵礦資源豐富,但大部分赤鐵礦存在品位低、礦物組成復(fù)雜、鐵礦物比磁化系數(shù)低、有用礦物嵌布粒度粗細(xì)不均、礦物之間共生緊密的特點(diǎn),普遍采用一段球磨機(jī)與螺旋分級(jí)機(jī)、二段球磨機(jī)與旋流器構(gòu)成的兩段閉路磨礦過程,其首要任務(wù)是將磨礦產(chǎn)品粒度指標(biāo)(常以-200目百分含量表示,%200mesh)控制在工藝規(guī)定的目標(biāo)值范圍內(nèi),使得有用礦物與脈石單體充分解離,為后續(xù)選別工序提供粒度合格的礦漿；同時(shí)應(yīng)將球磨機(jī)負(fù)荷控制在最佳點(diǎn)附近,提高球磨機(jī)處理量,提高磨礦效率。因此,實(shí)現(xiàn)磨礦過程全流程的控制對(duì)于選礦生產(chǎn)指標(biāo)的提高、降低能源消耗都具有重要的現(xiàn)實(shí)意義。由于我國(guó)赤鐵礦磨礦工藝流程不同于國(guó)外普遍采用的一段棒磨機(jī)開路磨礦、二段球磨機(jī)與水力旋流器閉路磨礦流程,是一個(gè)具有綜合復(fù)雜性的冶金工業(yè)過程,主要表現(xiàn)在：1、赤鐵礦磨礦過程由兩段連續(xù)閉路磨礦組成,工藝流程較長(zhǎng),影響磨礦產(chǎn)品粒度指標(biāo)的操作因素較多,如球磨機(jī)的給礦量、球磨機(jī)入口加水量、螺旋分級(jí)機(jī)溢流濃度、旋流器給礦濃度等工藝參數(shù),并且赤鐵礦中的強(qiáng)磁性顆粒存在“磁團(tuán)聚”現(xiàn)象,使得在線粒度檢測(cè)儀表難以真實(shí)測(cè)量磨礦粒度指標(biāo),因此難以采用常規(guī)控制方法實(shí)現(xiàn)該過程的運(yùn)行反饋控制,在實(shí)際生產(chǎn)過程中廣泛采用人工手動(dòng)控制方式根據(jù)磨礦粒度的化驗(yàn)值憑經(jīng)驗(yàn)調(diào)整基礎(chǔ)控制回路的設(shè)定值,然而由于人工化驗(yàn)周期較長(zhǎng),無法實(shí)時(shí)對(duì)磨礦生產(chǎn)過程進(jìn)行指導(dǎo),導(dǎo)致磨礦粒度波動(dòng)范圍大,無法為選別工序提高粒度合格的礦漿；2、赤鐵礦原礦性質(zhì)頻繁波動(dòng)使得一段磨礦過程存在較大的不確定性,易造成球磨機(jī)負(fù)荷工作點(diǎn)發(fā)生漂移,使其工作在“欠負(fù)荷”或“過負(fù)荷”故障工況,嚴(yán)重時(shí)發(fā)生球磨機(jī)“漲肚”或“空砸”等事故,影響磨礦過程的安全穩(wěn)定運(yùn)行；3、國(guó)外普遍采用定量給礦、配比給水的棒磨機(jī)開路磨礦為再磨過程提供粒度合格的礦漿,由于礦漿流量穩(wěn)定,采用閉環(huán)定值控制方法即可實(shí)現(xiàn)對(duì)再磨過程泵池液位的控制,而不會(huì)造成旋流器給礦壓力的較大波動(dòng)；而赤鐵礦一段球磨機(jī)與螺旋分級(jí)機(jī)的閉路磨礦過程礦漿流量波動(dòng)較大,并且泵池液位受到污水、沖洗水等隨機(jī)干擾的影響,導(dǎo)致再磨過程泵池液位發(fā)生頻繁較大波動(dòng),如果采用常規(guī)設(shè)定值閉環(huán)控制方式則需要較大改變礦漿泵轉(zhuǎn)速,導(dǎo)致旋流器給礦壓力發(fā)生較大波動(dòng),影響旋流器分級(jí)效率,因此常規(guī)閉環(huán)定值控制方法難以應(yīng)用于赤鐵礦再磨過程。綜上所述,必須結(jié)合我國(guó)赤鐵礦磨礦過程的生產(chǎn)實(shí)際,開發(fā)出適應(yīng)我國(guó)赤鐵礦磨礦過程的基礎(chǔ)回路控制方法和全流程運(yùn)行反饋控制方法,對(duì)于提高磨礦產(chǎn)品質(zhì)量、提高磨礦效率、降低能源消耗都有著重要的現(xiàn)實(shí)意義。本文依托國(guó)家重點(diǎn)基礎(chǔ)研究發(fā)展計(jì)劃(973)重點(diǎn)課題“復(fù)雜生產(chǎn)制造全流程一體化控制系統(tǒng)整體控制策略與運(yùn)行控制方法”(編號(hào)：2009CB320601),提出了在以磨礦粒度指標(biāo)和球磨機(jī)負(fù)荷為控制目標(biāo)的赤鐵礦磨礦全流程控制策略,開展了赤鐵礦磨礦全流程運(yùn)行反饋控制與再磨過程基礎(chǔ)回路控制方法的研究,并在此基礎(chǔ)上設(shè)計(jì)和開發(fā)了赤鐵礦磨礦過程智能控制軟件,同時(shí)結(jié)合“酒鋼選礦廠綜合自動(dòng)化系統(tǒng)”改造項(xiàng)目,進(jìn)行了赤鐵礦磨礦全流程智能控制系統(tǒng)軟、硬件結(jié)構(gòu)設(shè)計(jì)、安裝、調(diào)試、工業(yè)實(shí)驗(yàn)并投入運(yùn)行,取得如下成果：1、針對(duì)赤鐵礦磨礦過程生產(chǎn)工藝特點(diǎn)和具有的綜合復(fù)雜特性,提出了將兩段連續(xù)閉路磨礦流程作為一個(gè)整體來考慮的赤鐵礦磨礦全流程運(yùn)行反饋控制方法,實(shí)現(xiàn)球磨機(jī)給礦量、球磨機(jī)入口礦漿水礦比、螺旋分級(jí)機(jī)溢流濃度、旋流器給礦濃度四個(gè)基礎(chǔ)回路的設(shè)定控制與設(shè)定值跟蹤控制。該方法具有智能設(shè)定控制層和基礎(chǔ)回路控制層兩層結(jié)構(gòu),其中智能設(shè)定控制層建立了基于案例推理基礎(chǔ)回路預(yù)設(shè)定模塊、基于RBF人工神經(jīng)網(wǎng)絡(luò)的磨礦粒度軟測(cè)模型、基于規(guī)則推理的磨礦粒度反饋調(diào)節(jié)器和球磨機(jī)負(fù)荷故障診斷與自愈控制器；基礎(chǔ)回路控制層則設(shè)計(jì)了球磨機(jī)給礦環(huán)節(jié)增益自適應(yīng)內(nèi)模控制器、基于物料平衡模型的前饋控制與Fuzzy-PI串級(jí)控制相結(jié)合的分級(jí)機(jī)溢流濃度復(fù)合控制器。通過對(duì)基礎(chǔ)回路的設(shè)定控制與設(shè)定值跟蹤控制,從而保證磨礦粒度指標(biāo)的實(shí)際值處于其目標(biāo)值范圍內(nèi),并使球磨機(jī)工作在最佳負(fù)荷工作點(diǎn)附近。2、針對(duì)二段再磨過程泵池液位受到大的隨機(jī)干擾的影響,造成泵池液位波動(dòng)大,使旋流器給礦壓力頻繁波動(dòng)在工藝規(guī)定范圍外的狀況,提出了由泵池液位區(qū)間控制和旋流器給礦壓力回路控制組成的模糊切換控制方法,泵池液位區(qū)間控制通過對(duì)給礦壓力設(shè)定值保持器和模糊補(bǔ)償器的切換,將給礦壓力設(shè)定值控制在所允許的波動(dòng)范圍內(nèi)；通過給礦壓力PI回路控制器跟蹤其設(shè)定值,從而將泵池液位控制在目標(biāo)值范圍內(nèi),并將給礦壓力的波動(dòng)控制在允許的范圍內(nèi),保證再磨過程安全運(yùn)行,提高旋流器分級(jí)效率。3、在上述智能運(yùn)行反饋控制方法和再磨過程基礎(chǔ)回路控制方法的基礎(chǔ)上,設(shè)計(jì)了赤鐵礦磨礦全流程智能控制系統(tǒng)�？刂葡到y(tǒng)硬件包括皮帶秤、流量計(jì)、液位計(jì)、壓力傳感器等檢測(cè)儀表,電動(dòng)調(diào)節(jié)閥、變頻器等執(zhí)行機(jī)構(gòu),以及PLC控制系統(tǒng)、監(jiān)控計(jì)算機(jī)、計(jì)算機(jī)網(wǎng)絡(luò)等。控制系統(tǒng)軟件包括過程監(jiān)控軟件、磨礦全流程智能運(yùn)行反饋控制軟件和再磨過程控制軟件,其中過程監(jiān)控軟件實(shí)現(xiàn)了球磨機(jī)給礦量、各處加水流量、礦漿濃度、給礦壓力、泵池液位等工藝參數(shù)的監(jiān)控以及生產(chǎn)設(shè)備的程序啟停功能；智能運(yùn)行反饋軟件實(shí)現(xiàn)了磨礦粒度指標(biāo)、球磨機(jī)負(fù)荷為目標(biāo)的基礎(chǔ)回路設(shè)定與跟蹤控制；再磨過程控制軟件實(shí)現(xiàn)泵池液位區(qū)間與旋流器給礦壓力的模糊切換控制。4、將上述研制的赤鐵礦磨礦全流程智能控制系統(tǒng)應(yīng)用于酒鋼選礦廠赤鐵礦磨礦生產(chǎn)過程,實(shí)現(xiàn)了以磨礦粒度和球磨機(jī)負(fù)荷為目標(biāo)的磨礦過程智能回路設(shè)定與跟蹤控制,并將二段再磨泵池液位和旋流器給礦壓力的波動(dòng)控制在工藝規(guī)定的范圍內(nèi)。磨礦全流程智能控制系統(tǒng)的長(zhǎng)期運(yùn)行表明,磨礦粒度指標(biāo)從72.96%提高到76.72%,提高了3.76個(gè)百分點(diǎn),球磨機(jī)臺(tái)時(shí)處理量提高了2.65%,磨礦產(chǎn)品單噸電耗降低2%以上,同時(shí)杜絕了球磨機(jī)“過負(fù)荷”和“欠負(fù)荷”故障工況的發(fā)生,取得了顯著應(yīng)用成效。磨礦全流程智能控制系統(tǒng)的成功應(yīng)用,驗(yàn)證了本文所提方法的有效性和實(shí)用性。
[Abstract]:China is rich in hematite resources, but most are low grade hematite, complex mineral composition, iron ore is magnetized low coefficient of useful mineral qianbulidu uneven thickness, the characteristics of close symbiosis between minerals, a ball mill with spiral classifier is widely used, two milling machine and cyclone composed of two stage closed circuit grinding the process of drawing, the main task will be to the particle size of the grinding product index (often with -200 mesh% said,%200mesh) in the process control provisions within the range of the target value, the useful minerals and gangue monomer dissociation, the procedure provides qualified size for subsequent separation pulp industry; at the same time the ball mill load control in the optimal point, improve the mill capacity, to improve the grinding efficiency. Therefore, to achieve control of the whole process of grinding process to improve the flotation production targets, reduce all has the important practical significance because of my energy consumption. A rod mill in hematite ore grinding process is different from the foreign commonly used open grinding, two ball mill closed and hydrocyclone grinding process is a complex metallurgical process, mainly in: 1, hematite ore grinding process is composed of two sections of continuous closed circuit grinding composition that process is longer, more operational factors affecting the grinding particle size index, such as the volume of ore mill, ball mill entrance water, spiral classifier overflow concentration, cyclone feed concentration and other technological parameters, and hematite magnetic particles are "magnetic reunion" phenomenon, the online detecting instrument to size the true measure of grinding size index, so it is difficult to use conventional control method to realize the operation of the feedback control in the actual production process is widely used in manual control mode according to the grinding size test value Based on the set value control loop to adjust, but because of a manual test cycle is longer, not in real time on the grinding process guidance, resulting in a large size range of grinding, unable to choose don't process increasing the particle size of qualified pulp; 2, hematite ore properties makes frequent fluctuations in a grinding process is not the uncertainty caused by the ball mill load operating point drift, to make it work in the "low load" or "overload" fault conditions, the ball mill "Rose belly" or "empty hit" the accident is serious, the impact of safe and stable operation of the grinding process; 3, foreign commonly used quantitative feeding, ratio of rod mill the water supply and open circuit grinding provide ore granularity qualified for the grinding process, the slurry flow stability, the closed-loop constant control method can control the regrinding process pump pool level, and will not cause the cyclone Large fluctuations to the mine pressure; and a hematite ball mill with spiral classifier closed circuit grinding process of slurry flow fluctuation, and sump level by sewage, water flushing effect of random interference, resulting in re grinding process of the sump level frequent fluctuations, if the conventional closed-loop control mode is set value need to change large slurry pump speed, leading to the cyclone feeding pressure fluctuation, influence the classification efficiency of hydrocyclone, so the conventional closed-loop constant control method is difficult to be applied to hematite regrinding process. To sum up, the actual production of hematite in China must be combined with the grinding process, to adapt to the development of China's hematite ore grinding process the basic loop control method and the whole process of operation of the feedback control method, to improve the quality of grinding products, improve grinding efficiency, reduce energy consumption has important practical significance. This paper relies on the national key basic research and development program (973) "as the important project of complex manufacturing process integration control system overall control strategy and operation control method" (number: 2009CB320601), put forward the control strategy in the whole process of grinding the grinding granularity index and load control target of hematite, the Hematite the grinding process and grinding operation feedback control loop control method based on process, and on the basis of the design and development of intelligent control software of hematite ore grinding process, combined with the "transformation project of Jiuquan beneficiation plant integrated automation system, the hematite grinding process intelligent control system software and hardware. The structure design, installation, commissioning, and operation of the industrial experiment, the achievements are as follows: 1, according to the characteristics of production technology of hematite ore grinding process and has integrated complex characteristics, put forward The two section of continuous closed circuit grinding process as a whole to consider the whole process of hematite ore grinding operation feedback control method, realize the volume of ore mill, pulp mill entrance water ratio, spiral classifier overflow concentration, cyclone feed concentration of four basic loop set control tracking control and the method setting. With intelligent setting control loop control layer and the base layer two layer structure, the intelligent control setting establishes case based reasoning based loop pre setting module based on the particle size of RBF artificial neural network soft sensor model based on rule reasoning grind size feedback regulator and load fault diagnosis and self-healing controller based on the basic loop; the control layer is designed for ball mill feeding link gain adaptive internal model controller, feedforward control and Fuzzy-PI mass balance model for cascade control based on the combination of Machine level overflow concentration composite controller. Based on the basic loop set control tracking control with the set value, so as to ensure the grinding size index of the actual value in the target range, and make the mill work in the vicinity of the optimal load operating point of.2, because of the influence of the two stage grinding process of the sump level by random disturbance of cause, sump level fluctuations, the cyclone feed pressure fluctuation in the process outside the scope of the situation, put forward by the pump pool level interval control and cyclone feed pressure loop fuzzy control switch control method is composed of the sump level by controlling the interval to the mine pressure setting switch holder and fuzzy the compensator, feeding pressure setpoint control fluctuations in the allowable range; through the feeding pressure PI loop controller to track its set value, thus the sump level control in the target range And, to mine the fluctuation of pressure control in the allowed range, to ensure the safe operation of grinding process, improve the classification efficiency of hydrocyclone in the intelligent operation of.3, feedback control method and regrinding basic loop control method on the process of the design of the hematite grinding process intelligent control system hardware of the control system. Including belt scale, flow meter, level meter, pressure sensor and detection instrument, electric control valve, actuator and inverter, PLC control system, computer monitoring, computer network and so on. The control system software including process monitoring software, the whole process of the grinding operation intelligent feedback control software and regrinding process control software, including process monitoring software implementation of the volume of ore mill, all water flow, slurry concentration, feeding pressure, monitor the pump tank level and other parameters of the production equipment and the program start stop function; intelligent operation Fed software of grinding size index, set the basis for the target and the ball mill load loop tracking control; regrinding fuzzy switching control.4 process control software to realize the sump level interval and cyclone feeding pressure, the development of hematite ore grinding process intelligent control system used in Jiuquan beneficiation plant hematite grinding process, the grinding and tracking control of intelligent circuit to process ore grinding size and load as the goal, and the two section grinding pump pool level and cyclone feed pressure fluctuation is controlled in the range of technology within the prescribed that the long term operation of grinding process intelligent control system. The grinding granularity index increased from 72.96% to 76.72%, an increase of 3.76 percentage points, the ball milling increases 2.65%, grinding products to reduce power consumption more than 2% tons, and eliminate the "overload" and the ball mill The application of "under load" fault condition has achieved remarkable results. The successful application of the intelligent control system of grinding process proves the effectiveness and practicability of the proposed method.

【學(xué)位授予單位】：東北大學(xué)
【學(xué)位級(jí)別】：博士
【學(xué)位授予年份】：2015
【分類號(hào)】：TD951;TD67
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本文編號(hào)：1716405