In today’s era of rapid technological development, coal preparation plant also ushered in a wave of intelligent transformation. As an important part of coal processing, the intelligent system of coal preparation plant is playing a vital role, which greatly improves the efficiency and quality of coal preparation, and is also the key to the sustainable development of the coal industry.
The following gives an introduction to the specific applications brought about by the intelligent system of coal processing plant
一、Intelligent Equipment Monitoring System
Intelligent equipment monitoring system is like the ‘health guard’ of the coal processing plant. By installing various sensors on the equipment, it collects real-time data on the operating status of the equipment, such as vibration, temperature, current, etc. Once abnormal data is detected, the system will immediately and automatically alert the staff to carry out maintenance in time. Once the monitoring data is abnormal, the system will immediately and automatically alarm, reminding the staff to carry out timely maintenance. This can effectively avoid further deterioration of equipment failure and reduce production downtime. For example, in a coal processing plant, the intelligent equipment monitoring system successfully warned of a crusher’s bearing failure in advance. The staff quickly took measures to carry out repairs, avoiding the shutdown of the entire production line due to equipment failure, and saving huge economic losses for the enterprise.
二、Intelligent control system
1.Precise Coal Selection Parameter Adjustment
Intelligent control system can automatically adjust coal selection parameters according to the characteristics and quality requirements of coal. For example, in the flotation process, the system can adjust the adding amount of flotation chemicals and the working parameters of the flotation machine in real time according to the change of coal quality of the incoming material, so as to achieve the best flotation effect. Through this precise parameter adjustment, the output and quality of refined coal are greatly improved.
2.Optimising the production process
The intelligent control system can also optimize the whole coal processing production process. It can automatically arrange the production plan according to the production tasks and equipment status, reasonably allocate equipment resources, and achieve the efficient operation of the production process. For example, when a certain equipment fails, the system can automatically adjust the production process and transfer the materials to other equipment for processing, ensuring the continuity of production.
三、 Intelligent Management Platform
1.Data Integration and Analysis
Intelligent management platform can integrate production data, equipment information, personnel management and other aspects of the coal preparation plant to form a comprehensive database. Through the analysis of these data, managers can understand the production situation, equipment operation status and personnel efficiency and other information in a timely manner, providing a scientific basis for decision-making. For example, by analysing the production data, it is found that the output of fine coal decreases in a certain period of time, and the system can automatically analyse the reasons, which may be the lowering of the working efficiency of a certain equipment or the change of coal quality, and the management personnel can take measures to make adjustments according to this information in a timely manner.
2.Remote monitoring and management
With the help of intelligent management platform, managers can realise remote monitoring and management. No matter where they are, as long as they are connected through the network, they can check the production situation of the coal processing plant in real time and remotely control and debug the equipment. This not only improves management efficiency, but also saves a lot of manpower and time costs for the enterprise. For example, during the epidemic, the management personnel of a coal processing plant realised remote office through the intelligent management platform, which ensured the normal production of the coal processing plant.
In coal beneficiation process, intelligent control system is gradually becoming a key force to realise accurate coal beneficiation.
一、The complexity of coal characteristics and quality requirements
Coal from different origins has different characteristics, such as ash, sulfur, volatile matter and other indicators vary greatly. At the same time, different users also have different requirements on coal quality, some focus on calorific value, some have strict limits on ash. This requires that the coal selection process can be accurately adjusted according to the specific coal characteristics and quality requirements.
二、The precise regulation mechanism of the intelligent control system
1.Real-time monitoring and data analysis
The intelligent control system monitors parameters such as coal flow, particle size, density and the operating status of the equipment in real time through the sensors installed in each link. At the same time, the system carries out rapid analysis of the collected data and establishes a mathematical model between coal characteristics and coal selection parameters. For example, the best sorting parameters are determined by analysing the sorting effect of coal with different particle sizes on specific equipment.
2.Automatic adjustment of coal sorting parameters
According to the data analysis results, the intelligent control system can automatically adjust the coal separation parameters. For example, in the process of heavy media separation, if the density of the incoming coal is detected to change, the system will automatically adjust the density and flow rate of the heavy media to ensure the stability of the sorting effect. For the flotation process, the system can automatically adjust the addition amount of flotation chemicals and the flotation machine’s inflation volume, stirring intensity and other parameters according to the floatability and ash requirements of coal.
3.Dynamic optimisation and feedback adjustment
The intelligent control system is continuously and dynamically optimised during operation. With the change of coal characteristics and the production process, the system will make feedback adjustment according to the actual effect. If it is found that the adjustment of a parameter does not achieve the expected effect, the system will automatically make corrections to achieve the best coal selection effect. For example, after a period of production, it is found that the ash content of the refined coal is on the high side, the system will automatically analyse the reason, which may be the insufficient addition of flotation chemicals or the inappropriate density of heavy media, and then make corresponding adjustments.
三、The advantages brought by intelligent control system
1.Improve coal selection precision
Precise parameter adjustment can ensure that the coal can be optimally processed in each step of coal beneficiation, so as to improve the quality and recovery rate of refined coal. For example, through the precise regulation of intelligent control system, the recovery rate of fine coal in a coal preparation plant has been increased by more than 5%, and the indexes of ash and sulphur have also been effectively controlled.
2.Reduce production costs
Automatic adjustment of parameters can reduce manual intervention and lower labour costs. At the same time, accurate coal selection can reduce energy consumption and equipment wear and tear, reducing production costs. For example, by optimising the additive amount of flotation chemicals, a coal processing plant can save hundreds of thousands of yuan in chemical costs every year.
3.Enhance production stability
Intelligent control system can quickly respond to changes in coal characteristics and maintain the stability of the coal beneficiation process. This can reduce quality problems and equipment failures caused by production fluctuations and improve production efficiency. For example, in the case of unstable coal sources, the intelligent control system can ensure that the coal processing plant production continues to be stable.
The intelligent management platform of coal preparation plant is playing a great advantage, providing powerful support for the efficient operation and scientific decision-making of coal preparation plant.
一、Integration of multi-faceted data to achieve integrated management
1.Production Data Integration
The intelligent management platform can collect and integrate the production data of the coal preparation plant in real time, including coal production, quality index, process parameters, etc. Through analysing these data, it is possible to achieve the integrated management of coal preparation plant. By analysing these data, the overall situation of production can be clearly understood and problems in the production process can be found in time. For example, by monitoring the production data of different links, it is possible to determine whether there is blockage or failure of a certain equipment, so that timely treatment can be carried out to avoid affecting the operation of the whole production line.
2.Equipment Information Integration
The platform integrates information on the operating status, maintenance records and failure history of equipment. In this way, managers can grasp the health status of equipment at any time, and reasonably arrange the maintenance and overhaul plan of equipment. For example, when the running time of the equipment reaches a certain threshold, the system will automatically remind to carry out maintenance to avoid equipment failure due to overuse. At the same time, when equipment failure occurs, maintenance personnel can query the historical failure records and maintenance records of the equipment to quickly determine the cause of the failure and improve maintenance efficiency.
3.Personnel management integration
The intelligent management platform can manage the information of employees’ attendance, work tasks and performance. By assigning work tasks and tracking task progress, it ensures that each employee can complete his or her work efficiently. At the same time, it evaluates and motivates employees based on their performance data to improve their motivation and sense of responsibility. For example, the system can automatically generate performance reports based on the employee’s work performance, providing a basis for employee promotion and reward.
二、Improve management efficiency
1.Real-time monitoring and remote management
Through the intelligent management platform, managers can monitor the production situation and equipment operation status of the coal preparation plant in real time, and they can understand everything without visiting the site in person. At the same time, the platform supports remote management, and the managers can command and dispatch the coal preparation plant anywhere through the network. This greatly improves management flexibility and efficiency, saving time and costs. For example, during a business trip, managers can check the operation of the coal beneficiation plant and make decisions at any time via mobile phones or tablets.
2.Automate Processes and Reduce Human Errors
The platform can automate some of the management processes, such as the development of production plans and automatic scheduling of equipment. This not only reduces manual intervention and improves work efficiency, but also reduces the probability of human error. For example, the system can automatically formulate production plans based on market demand and equipment conditions to ensure efficient and stable production.
3.Rapid decision support
With the integration of multiple data, the intelligent management platform can provide managers with fast and accurate decision support. Through data analysis and report generation, managers can understand the operation status and problems of the coal processing plant in a short time, and make scientific and reasonable decision-making programmes. For example, when the market demand changes, the managers can quickly adjust the production plan and product structure according to the data analysis results provided by the platform to meet the market demand.
三、Enhance the scientific nature of decision-making
1.Data analysis and prediction
The platform analyses a large amount of production data, equipment information and personnel management data, which can reveal potential patterns and trends. For example, by analysing historical production data, future coal production and quality can be predicted, providing reference for the formulation of production plans. At the same time, by analysing the equipment failure data, the time of equipment failure can be predicted, and maintenance and replacement can be carried out in advance to avoid the impact of equipment failure on production.
2.Risk assessment and early warning
The intelligent management platform can assess and warn the operational risks of the coal preparation plant. For example, when the operating parameters of the equipment are out of the normal range, the system will automatically issue an early warning to remind managers to take timely measures. At the same time, the platform can also assess the market risk, environmental risk, etc., to provide reference for the enterprise’s strategic decision-making.
3.Optimising decision-making scenarios
Through the simulation and evaluation of different decision-making solutions, the intelligent management platform can help managers choose the optimal decision-making solution. For example, when upgrading equipment, the system can simulate the effects and costs of different options to help managers make the most reasonable decisions.
The road to intelligence in coal processing plants is full of challenges, but it is also an inevitable trend for future development. Only through continuous exploration and innovation can we take the lead in the wave of intelligence and inject new vitality into the development of the coal industry.
