CN-121988080-A - Intelligent control system and method for phosphogypsum crystal transformation process filter press device

CN121988080ACN 121988080 ACN121988080 ACN 121988080ACN-121988080-A

Abstract

The invention discloses an intelligent control system and method of phosphogypsum crystal transformation process filter press devices, which relate to the technical field of industrial solid-liquid separation and process control and comprise a sensor group, a variable frequency pump, an intelligent regulating valve group and an intelligent control center, wherein the sensor group is used for collecting and forming real-time flow data and batch records, the intelligent control center generates and executes a strategy packet according to batches, the strategy packet is used as unique control output and comprises phase switching and pressure targets, pressure maintaining pressure and pressure maintaining time, pump self-adaptive compensation, valve-pump cooperation, safety interlocking, scale removal linkage and version rollback information, and the whole flow cooperative control of feeding, pressing, pressure maintaining and unloading is realized through candidate strategy sequence generation and rejection, process boundary/safety/real-time verification and rollback, and when scale is triggered, a valve is automatically switched to establish dilute sulfuric acid descaling circulation and suspend model parameter writing, and after verification is recovered, the water content of a filter cake is stable, and the energy consumption is controlled and the equipment is safe.

Inventors

ZHOU LONGHAO
TAO YUNQI
YANG TAO
DAI YONGLIN

Assignees

昆明嘉和科技股份有限公司

Dates

Publication Date: 20260508
Application Date: 20260123

Claims (10)

1. The intelligent control system of the phosphogypsum crystal transformation process filter press device is characterized by comprising a sensor group, a variable frequency pump, an intelligent regulating valve group and an intelligent control center; The sensor group collects pump flow, pump lift, pump vibration, pump temperature, filter chamber pressure, valve opening and filter cake water content, outputs real-time flow data, and outputs batch records when the filter pressing batch is finished; The intelligent regulating valve group comprises a crystal transformation reaction tank outlet valve, a filter press feed inlet valve, a pump outlet main pipe valve, a dilute sulfuric acid tank valve and a circulating tank front end valve; The intelligent control center presses the filter batch to generate and issue a strategy packet, and the strategy packet is used as a control instruction carrier for the variable frequency pump and the intelligent regulating valve group; The strategy package comprises a stage switching and pressure target parameter, a pressure maintaining pressure set value and a pressure maintaining time set value, a pump self-adaptive pressure compensation parameter, a valve and pump cooperative control curve parameter, a safety interlocking threshold and action parameter, a scaling triggering threshold and a recovery threshold, a scaling linkage action parameter, a strategy package version number and a rollback pointer; The intelligent control center comprises a strategy sequence generation and rejection module, a strategy package feasibility verification module, a strategy package release and rollback module, a pressure maintaining pressure and pressure maintaining time optimization module, a scaling discrimination and descaling linkage module and a safety interlocking module; The strategy sequence generation and elimination module generates a candidate strategy sequence based on the batch record and eliminates the candidate strategy sequence which does not meet the water content threshold of the filter cake, the pressure safety upper limit threshold of the filter chamber, the pressure change rate threshold, the batch energy consumption budget threshold and the strategy calculation time delay threshold, so as to output candidate control parameters, and the strategy package is generated according to the candidate control parameters; The strategy package feasibility checking module performs process boundary checking, safety interlocking reachability checking and real-time checking on the strategy package, prohibits issuing the strategy package when checking fails and triggers the strategy package issuing and rollback module to recover the last stable strategy package according to the rollback pointer; the strategy packet issuing and rollback module is used for issuing the strategy packet and recording the strategy packet version number when the strategy packet feasibility verification module passes the verification, and recovering the last stable strategy packet according to the rollback pointer when rollback is triggered; The pressure maintaining pressure and pressure maintaining time optimizing module updates a historical data training model based on the batch record and outputs the pressure maintaining pressure set value and the pressure maintaining time set value of the next filter pressing batch; The scale judging and descaling linkage module calculates scale risk based on pump design flow deviation, pump energy consumption drift and pump lift and pump flow consistency deviation value determined based on pump calibration characteristic relation, controls the outlet valve of the crystal transition reaction tank and the feed inlet valve of the filter press to be closed when the scale risk reaches the scale triggering threshold, and controls the dilute sulfuric acid tank valve and the front end valve of the circulating tank to be opened to establish scale removal circulation after confirming that a feed link is physically isolated; The safety interlocking module is used for controlling the pump outlet main pipe valve to release pressure to the circulating pool and controlling the variable frequency pump to stop pumping when the pressure of the filter chamber exceeds the upper safety limit threshold value of the pressure of the filter chamber.
2. The intelligent control system of phosphogypsum crystal transformation process filter press device according to claim 1, wherein the process boundary check comprises a step sequence check of a feeding step, a pressing step, a pressure maintaining step and a discharging step, and a pressure boundary check of a feeding step, a pressure of a filter chamber is 0.2MPa to 0.6MPa, a pressure of a pressing step, a pressure of a filter chamber is 1.5MPa to 2.5MPa, a pressure maintaining step maintains the pressure maintaining pressure set value, and a pressure of a discharging step, the pressure of the filter chamber is released to normal pressure.
3. The intelligent control system of phosphogypsum crystal transformation process filter press device according to claim 1, wherein the strategy sequence generation and rejection module checks the interlocking condition that the filter press feed inlet valve is in the closed state in the pressure maintaining stage when rejecting the candidate strategy sequence, and the interlocking condition that the crystal transformation reaction tank outlet valve and the filter press feed inlet valve are in the closed state during the descaling cycle establishment and operation, and rejects the candidate strategy sequence violating the interlocking condition.
4. The intelligent control system of phosphogypsum crystal transformation process filter press device according to claim 1, wherein the valve and pump cooperative control curve parameter is used for controlling the filter press feed inlet valve to be in a full-open state and controlling the filter chamber pressure to be in a range of 0.2MPa to 0.6MPa in a feed stage, and limiting the target opening of the filter press feed inlet valve to be in a range of 50 percent to 80 percent in a press stage and cooperatively regulating the rotation speed of the variable frequency pump to increase the filter chamber pressure to be in a range of 1.5MPa to 2.5MPa and restricting the pressure change rate not to exceed the pressure change rate threshold.
5. The phosphogypsum crystal process press filter device intelligent control system of claim 1, wherein the pump adaptive pressure compensation parameter is used for executing micro-drop rotation speed compensation to restrain overpressure in an approximate bandwidth of 0.3MPa where the pressure of the filter chamber is close to the pressure maintaining pressure set value, and executing speed-down unloading when the pressure of the filter chamber exceeds the pressure maintaining pressure set value.
6. The phosphogypsum crystal process filter press device intelligent control system of claim 1, wherein the scale discrimination and scale removal linkage module performs clean water replacement after the scale removal cycle is completed and recalculates the scale risk after the clean water replacement is completed, and resumes parameter writing and feeding when the scale risk is below the recovery threshold.
7. The phosphogypsum crystal process filter press device intelligent control system of claim 1, wherein the intelligent control center comprises an execution plan selection module and a degradation control module, the execution plan selection module is used for predicting policy calculation time delay and outputting degradation instructions when the policy calculation time delay exceeds the policy calculation time delay threshold, and the degradation control module is used for maintaining the last stable policy package and prohibiting issuing of new policy packages when receiving the degradation instructions.
8. The phosphogypsum crystal process filter press device intelligent control system of claim 7, wherein the safety interlock module outputs an early warning signal and triggers the degradation control module to maintain the last stability strategy package when the pump vibration exceeds a pump vibration threshold or the pump temperature exceeds a pump temperature threshold.
9. An intelligent control method of a phosphogypsum crystal transformation process filter press device is characterized by comprising the following steps: S1, collecting pump flow, pump lift, pump vibration, pump temperature, filter chamber pressure, valve opening and filter cake water content, and forming real-time flow data, and forming a batch record containing stage duration, dwell time timing value, filter chamber pressure fluctuation, batch energy consumption and filter cake water content at the end of a filter pressing batch; S2, generating a candidate strategy sequence based on the batch record, and eliminating the candidate strategy sequence which does not meet the filter cake water content threshold, the filter chamber pressure safety upper limit threshold, the pressure change rate threshold, the batch energy consumption budget threshold and the strategy calculation time delay threshold to output candidate control parameters, and generating a strategy packet based on the candidate control parameters, wherein the strategy packet comprises a pressure maintaining pressure set value and a pressure maintaining time set value; S3, performing process boundary verification, safety interlocking accessibility verification and real-time verification on the strategy packet, releasing the strategy packet when verification passes, and prohibiting releasing the strategy packet and rolling back to the last stable strategy packet when verification fails; s4, controlling a feed inlet valve of the filter press to be in a full-open state in a feed stage, and controlling the pressure of the filter chamber to be in a range of 0.2MPa to 0.6 MPa; S5, limiting the target opening of the filter press feed inlet valve to be in a range of 50-80 percent in a squeezing stage, and cooperatively adjusting the rotating speed of the variable frequency pump to enable the pressure of the filter chamber to be increased to be in a range of 1.5-2.5 MPa, wherein the constraint pressure change rate does not exceed the pressure change rate threshold; s6, closing a feed inlet valve of the filter press in a pressure maintaining stage and executing micro-reduction rotating speed compensation within an approximate bandwidth of 0.3MPa, which is close to the pressure maintaining pressure set value, of the filter chamber to inhibit overpressure and maintain the pressure maintaining pressure set value to the pressure maintaining time set value; s7, controlling the pressure of the filter chamber to be relieved to normal pressure in the unloading stage, and forming the batch record; S8, updating a historical data training model after the batch is finished, and outputting the pressure maintaining pressure set value and the pressure maintaining time set value of the next filter pressing batch; And S9, controlling the pump outlet main pipe valve to release pressure to the circulating pool and stopping the pump when the pressure of the filter chamber exceeds the safety upper limit threshold of the pressure of the filter chamber.
10. The intelligent control method of phosphogypsum crystal transformation process filter press device according to claim 9, further comprising the steps of: S10, judging the scaling risk based on the pump design flow deviation, the pump energy consumption drift and the pump lift and pump flow consistency deviation value, closing the crystal transformation reaction tank outlet valve and the filter press feed inlet valve when the scaling risk reaches the scaling trigger threshold, opening the dilute sulfuric acid tank valve and the circulating tank front end valve after confirming that the physical isolation of a feed link is established, establishing a descaling cycle, executing clear water replacement and recalculating the scaling risk after the descaling cycle is finished, suspending parameter writing of the historical data training model before the scaling risk is lower than the recovery threshold, and recovering parameter writing and feeding after the scaling risk is lower than the recovery threshold.

Description

Intelligent control system and method for phosphogypsum crystal transformation process filter press device Technical Field The invention relates to the technical field of industrial solid-liquid separation and process control, in particular to an intelligent control system and method for a phosphogypsum crystal transformation process filter press device. Background In the phosphogypsum crystal transformation process, slurry enters a filter press to carry out solid-liquid separation after crystal transformation reaction, the filter pressing process generally comprises the stages of feeding, squeezing, pressure maintaining, discharging and the like, the pressure in a filter chamber is obviously changed along with gradual formation and thickening of a filter cake, the viscosity, solid content, crystal form and particle size distribution of the phosphogypsum slurry are easily influenced by reaction conditions, circulating water fluctuation and equipment states, so that the filter pressing resistance and dehydration characteristics of the same production line in different batches are different, meanwhile, phosphogypsum is easily adhered to and scaled at a pipeline and a valve part, filter cloth blockage and pump working condition drift are superposed, so that pressure response lag, energy consumption rise and operation risk increase, and continuous cooperative adjustment is required for pump rotating speed, valve opening, filter chamber pressure and pressure maintaining time, and control output stability and controllability are maintained under abnormal working conditions. In the prior art, a PLC sequential control mode or a single parameter-based experience control mode is adopted, press filtration operation is realized by setting feeding pressure, squeezing pressure and fixed pressure maintaining time, or filtrate flow and pressure change are manually observed to regulate, certain limitations exist, such as pressure regulation lag caused by stage switching depending on a fixed threshold value or manual judgment, pressure boost overshoot and pressure impact are easy to occur to damage a filter cake structure and increase water content batch fluctuation, valves and variable frequency pumps are often regulated respectively, cooperative control under unified constraint is not available, water content targets and energy consumption budgets are difficult to meet, pressure maintaining pressure and pressure maintaining time are often taken according to experience, an adaptive optimization mechanism based on batch data is not formed, energy consumption rise caused by excessive pressure maintaining or insufficient pressure maintaining causes insufficient dehydration, in addition, pump flow reduction caused by scaling and energy consumption drift are often subjected to maintenance after-the fact, on-line discrimination and descaling are not available, abnormal working condition data are easy to pollute control parameter setting or model updating to cause subsequent batch control strategy distortion, and when calculation resources or communication state fluctuation is difficult to release, the existing control scheme lacks strategy verification, version rollback and maintenance is difficult to guarantee continuous stable operation. Therefore, there is a need for an intelligent control system and method for a filter press device for phosphogypsum crystal transformation process, which can generate and verify an executable control strategy based on real-time flow data and batch record, realize closed loop collaborative optimization of pump-valve-pressure maintaining time, and realize interlocking protection, automatic descaling and strategy degradation maintenance under the conditions of overpressure, scaling, abnormal equipment state and the like, so as to stabilize the water content of a filter cake, control energy consumption and improve the safety and reliability of the system. Disclosure of Invention The invention aims to overcome the defects of the prior art and provides an intelligent control system and an intelligent control method for a phosphogypsum crystal transformation process filter press device, so as to solve the problems. The invention aims at realizing the technical scheme that the intelligent control system of the phosphogypsum crystal transformation process filter press device comprises a sensor group, a variable frequency pump, an intelligent regulating valve group and an intelligent control center; The sensor group collects pump flow, pump lift, pump vibration, pump temperature, filter chamber pressure, valve opening and filter cake water content, and outputs real-time flow data, and outputs batch record when the press filtration batch is finished; The intelligent regulating valve group comprises a crystal transformation reaction tank outlet valve, a filter press feed inlet valve, a pump outlet main pipe valve, a dilute sulfuric acid tank valve and a circulating tank front end valve; The intelligent con