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Automation in mineral processing plants is centred around PLC technology, which is used to build an integrated ‘sensing-control-execution’ system that encompasses the following key subsystems:
- Core Function: Realises coordinated control of ball mills and classifiers to optimise ore grinding fineness and classification efficiency.
- Key Equipment:
- Overflow-type ball mill: Equipped with a servo motor system (power 4,410 kW), the PLC adjusts speed and feed rate, while photoelectric sensors monitor slurry concentration and flow in real time.
- Classifier: Pneumatic actuators control the overflow weir height, combined with fuzzy logic algorithms to dynamically adjust classification particle size, achieving a product particle size of over 95%.
- Real-time Monitoring Network: Pressure, temperature, and flow sensors are deployed, with a set sampling frequency to obtain 20 sets of operational data per second, transmitted to the PLC controller via an analogue-to-digital converter.
- Human-Machine Interface: A touchscreen displays real-time parameters such as ball mill load and slurry temperature, supporting remote debugging by engineers.
- Multi-device interlocking logic: Achieves coordinated operation of ball mills, feeders, and pumps, with flow control accuracy of ±5%.
- Feedback control module: Automatically adjusts feed rate and water flow using the \(u_{ii}(t)=K_{ij}x_i(t)\) algorithm to reduce human intervention errors.
- Servo Motor System: Driven by Mitsubishi FX3U series PLC, with a response time <0.1s, supporting forward/reverse rotation and precise speed adjustment, compatible with wet overflow ball mills (diameter 5.49m, effective volume 206.6m³).
- Pneumatic Actuator Unit: Equipped with built-in displacement sensors in the cylinders, it controls the vertical movement of the robotic arm and the gripper's grasping actions, with positioning accuracy of ±1 mm, suitable for mineral sorting and feeding operations.
- Photoelectric Detection Elements: Infrared through-beam sensors monitor mineral flow blockages, while laser particle size analyzers provide real-time analysis of ground product particle size distribution, with data transmission latency <50 ms.
- Multi-parameter sensors: Integrated pressure (range 0-10 MPa), temperature (-20-120°C), and flow rate (0-500 m³/h) detection functions, supporting 485 bus communication.
- PLC controller: Siemens S7-300 series is selected, equipped with 16 digital input/output modules and 8 analogue modules, with a program scan cycle <10 ms and support for redundant backup.
- Communication module: Connects the host computer and distributed devices via the PROFINET bus to achieve millisecond-level data synchronisation.
This automated system combines ‘intelligent control + precise execution’ to provide a comprehensive solution for the entire process from grinding to classification, catering to the large-scale production needs of various metal and non-metal mines.
© 2021 Yantai KZ Mining Processing Technology & Equipment Inc.
