KR100194163B1 - Method and apparatus for auditing means for measuring bulk material properties and for extracting purified water - Google Patents

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Description

Method and apparatus for auditing means for measuring bulk material properties and for extracting purified water

1 is a schematic diagram of the present invention showing a coal treatment process for receiving coal from a coal mine in a hopper car and transferring it from a storage pile to a burner.

2 is a schematic diagram of the present invention showing coal being moved to a burner through a mechanical sampling system, bunker, online analyzer, metering feeder, grinder.

FIG. 3 is an enlarged detailed view showing the process of coal processing in the typical mechanical sampling system shown in FIGS.

Figure 4 receives, stores and analyzes data from various sensors for systems that signal and record the status of operations, malfunctions, and failures and maintain a database to monitor the status of bulk material, storage and use, and inventory. A schematic diagram showing computer software and its peripheral devices used in the present invention for recording locally and remotely on video monitors and print media, and for interfacing with a main computer.

* Explanation of symbols for main parts of the drawings

10: Hopper 11: Crusher

12,15,21: Belt 13,19,25: Belt Scale

14,27: mechanical sampling system 22: input and output electric channel

28: analyzer 29: weighing feeder

30: grinder 40: first cutter

41: first feeder 42: sample crusher

44: sample receiver 45: second cutter

57: computer 58: disk drive system

62: Modem 17,18,33,35,47,48: Sensor

Bulk materials such as bauxite, sulfur salts, phosphates, gypsum, limestone, cement, feldspar, corn, wheat and other grains, sugar, coal, lignite, peat, anthracite, waste, dirt, wood chips, bark and paper Bulk materials have a variety of properties that are measured, in particular, during processing or processing, either directly or indirectly by extraction of the tablets and by measurement of the properties of the tablets. All variable compositions contained in the tablets are required to be present in the same physicochemical state and proportions as are present in the bulk of the bulk material. The value of these goods in the United States is enormous. For example, forest products in Standard Industrial Class 26 totaled approximately $ 108 billion in shipments in 1986. Among them, $ 4.1 billion for pulp products, $ 42 billion for paper and cardboard products, $ 23 billion for newspaper products, $ 14 billion for corrugated solid fiber boxes, $ 11 billion for sanitary paper products, and $ 3 billion for sanitary food containers.

Coal is another bulk material whose various properties are regularly measured, and the coal mined and processed in the United States in 1986 is estimated to be worth about $ 23 billion.

As another bulk material, nitric acid and phosphate fertilizers are equivalent to about $ 9 billion annually, primary metals are equivalent to $ 50 to $ 60 billion, and inorganic chemicals are equivalent to about $ 12 billion. The cement produced in the United States in 1986 was worth about $ 4 billion. Unfortunately, in the treatment of such bulk material, significant errors occur in the extraction of the tablets in which the properties are measured and in particular in the metering of the bulk material, as well as errors in other properties of the product. It is produced in about 5,000 mines operated by about 3,000 companies. About 85 percent of all coal produced annually in the United States is spent in the electricity industry, or about $ 22.9 billion.

The utility's inventory is currently about 163 million tons, which is nominal at $ 5.5 billion.

The electricity industry is incapable of matching the amount of coal purchased and the amount of coal burned, so it depreciates up to 5 percent of its inventory each year, which is equivalent to $ 137 million annually. Since coal is essentially intact in the usual time frame associated with the transaction, most losses are not physical losses but rather due to inaccuracies in weighing, sampling and analysis. In general, weighing and sampling errors increase with decreasing load. Errors found by experience so far tend to worsen when bulk material handling operations are performed at or below their maximum capacity.

There are significant economic derivatives far beyond just inventory correction. For example, inaccuracies due to overestimation of actual inventory must be compensated for by maintaining extra inventory to avoid risk. Purchasing and stocking costs, interest and insurance premiums cannot be quantitatively calculated correctly but are very realistic. Additional economic derivatives are associated with more accurate and timely quality information. Examples are the forced undervaluation of the unit and the economic impact of the associated extra power purchases, the losses associated with uneconomic transport, and the operation of coal quality better than necessary to meet air quality regulations. Such economic losses cannot be easily measured due to the lack of more accurate and timely information, but are essential. The same problem occurs with other bulk material industries, which far exceed the coal industry in dollar amounts.

In the import and export markets, there is a fundamental need for sampling and metering bulk goods in bulk goods reservoirs where bulk goods travel through. The United States produced about $ 4 billion worth of cement in 1986 and imported about $ 300 million worth of cement. Metal and ore loads in standard industry classifications 10 and 14, excluding fuel, amounted to $ 23 billion in 1986, and $ 3.2 billion in imports. Coal exported 887 million tons, equivalent to $ 3.5 billion.

The present invention relates to a method and apparatus for auditing and recording operational variables or the results of such variables and the deficiencies obtained in various parts of a facility used to measure one or more properties of a bulk material. According to the invention it is ensured that the accuracy and reliability of the results obtained from the measuring devices are not compromised by variables that can affect the accuracy and reliability of the measuring devices. In practicing the present invention, it is very useful to simultaneously compare properties with measurements of variables that may affect the accuracy of the results obtained by the means used to measure the properties of the bulk material, with appropriate reference criteria. .

The present invention also relates to a method and apparatus for auditing and recording the results of operating and ambient variables or variables that may affect the accuracy and reliability of the means for extracting the bulk material refinement. The tablet is required that all compositions contained therein be present in the same physicochemical state and proportion as present in the mass of bulk material from which the tablet is extracted, and the present invention provides the It is to ensure that the accuracy and reliability of the tablets are not compromised by variables that may affect the accuracy and reliability of the extraction means.

It is also very useful to compare operating variables and surrounding variables with appropriate reference criteria simultaneously.

It is therefore an object of the present invention to provide a method and apparatus for assuring the accuracy and reliability of the purified water extraction means.

It is also an object of the present invention to provide a method and apparatus for ensuring the accuracy and reliability of the results obtained from the measurement of various properties of the bulk material.

It is a further object of the present invention to provide a method and apparatus which enable the simultaneous comparison of the measured operating and peripheral variables with one or more suitable reference criteria.

It is yet another object of the present invention to provide a method and an apparatus which allow to compare simultaneously the results obtained by measuring variables associated with a device for measuring bulk material properties with the measured properties with one or more appropriate reference criteria.

By monitoring the operating variables and comparing them with the appropriate reference criteria, it is possible to improve closed loop control of operation within certain limits exceeded by the reservoir level, inserted chute and flow sensing control, Means are provided for indicating a threshold condition that requires human intervention for correction or adjustment.

It is therefore another object of the present invention to provide means for informing a closed operating condition for improved closed loop control and requiring human intervention for correction or adjustment.

Other objects and advantages of the present invention will become apparent to those of ordinary skill in the art based on the following general description according to the accompanying drawings.

Although the present invention has been described with respect to specific applications for treating coal in electrical installations, it is clear that the same applies to the other bulk materials listed above.

In addition, all components, except software for a particular facility, are now readily available items.

As shown in FIG. 1, item 10 represents a rail slide track hopper unloading facility. Coal is transferred from the track hopper 10 to the crusher 11 and subsequently transferred to the mechanical sampling system 14 via a belt 12 that travels on a belt scale 13. Coal not removed in the mechanical sampling system 14 is transferred onto the belt 15 here and then discharged into a storage Pile: 16. The track hopper 10 has a coarse screen, commonly referred to as a grizzly, with a hole of about 1 ft ² area to ensure that no excessively large coal masses and large freezing coal masses are present in the system. have. Such agglomerates are either crushed manually or by special machines called chackers.

In order to simplify the description of the present invention, the track hopper 10 is shown as directly discharging coal into the crusher 11, but in practice, coal transfer from the track hopper 10 is a feeder conveyor. Is controlled by

In general, the peripheral equipment and devices of a power plant are typically designed to handle coal with a top size of 2 inches. The main purpose of the shredder 11 is to reduce the size of the top of the coal to satisfy the working requirements. The belt scale 13 is a certified commercial scale. The weight measured by the scale is used to pay the coal supplier. Sensor 17 to shredder 11, sensor 18 to belt scale 13, sensor 19 to mechanical sampling system 14, sensor 20 to belt 12, sensor 21 ) Is located on the belt scale 13. These sensors consist of one or more specific sensors, as described below, and are connected to the appropriate recording and monitoring apparatus shown in FIG. 4 by input-output electrical channels 22-22. Coal can be transferred from storage pile 16 by conveyor 23 as desired.

In more detail with reference to FIG. 2, the coal on conveyor 23 is conveyed to conveyor 24, again passing over an additional belt scale 25. The belt scale 25 is generally not used as a guarantee scale or commercial scale, but instead is used to measure the weight of coal burned. Coal falls into the bunker 26 from the end of the conveyor 24 with the appropriate amount removed by the mechanical sampling system 27, which is typically the same as the mechanical sampling system 14. The coal may then be transferred to the burner 31 via an on-line analyzer 28, metering feeder 29, pulverizer 30. In addition, the sensor 32 on the belt 23, the sensor 33 on the belt scale 25, the sensor 34 on the conveyor 24, the sensor 35 on the mechanical sampling system 27, 36 is located in the bunker 26, sensor 37 in the on-line analyzer 28, sensor 38 in the metering feeder 29, sensor 39 in the grinder 30. These sensors have one or more specific sensors as described below and are connected to the appropriate recording and monitoring apparatus shown in FIG. 4 by input-output electrical channels 22a-22a.

Coal is usually traded in damp conditions, and there is much controversy between buyers and sellers. Moisture is reduced by drainage and evaporation, and increased by rain or snow. In the north, frozen coal is a constant problem. Problems often arise when coal that is not frozen and wet comes into contact with the metal surface below the freezing temperature. Sensors 17, 18, 19, 33, 35, 36, 37, 38 are crushers 11, belt scales 13, mechanical sampling systems 14, belt scales 25, mechanical sampling systems 27. , Ambient and metal temperatures for bunkers 26, online analyzer 28, weighing fader 29, as well as relative humidity for shredder 11 and mechanical sampling system 14, together with date and time It is used to record permanently in real time.

This data ensures temperature and humidity conditions for reliable and accurate operation of the sampling and weighing systems, and can alert you to conditions that may cause device malfunction or malfunction.

Bulk material such as coal is sometimes contaminated with foreign substances that can harm the device. In the case of coal, precautions were required for everything from blasting detonators to crude railway car parts. In coal processing systems, magnetic separators are usually installed as early as possible to protect the machine from floating iron materials. Despite various precautions, mobile machines are sometimes damaged by foreign materials. Sensors 17, 18, 19, 33, 35 and 39 are used for shredder 11, belt scale 13, mechanical sampling cystel 14 to ensure reliable and accurate operating conditions of the sampling and weighing system. It is used to monitor the vibration and sound levels and patterns for the belt scale 25, the mechanical sampling system 27, the grinder 30, and record them permanently in real time with time and date. This additionally provides means for detecting excessive or abnormal conditions that damage the extraction or sampling and metering of the purification, and can also alarm on conditions that indicate operational problems of the device and possible malfunctions. Will be. There is no clear boundary between the audible frequency and the mechanical vibration, but because the mechanical frequency associated with heavy machinery is generally lower than the audible frequency, both frequencies are monitored, recorded clarally and compared with the appropriate reference criteria. This also allows the operator in charge to detect physical abuse when the coal passage is interrupted.

The product by the impact crusher is affected by the tip speed of the hammer. Tip speed is a function of rotational speed, which is affected by load, voltage level, power or current drawn by the crusher motor. Also, the temperature of the motor is affected by load and voltage, and vibration and sound are rotated. It is affected by speed. The sensors 17, 19 and 35 monitor the date and time by monitoring the rotational speed as well as the magnitude and frequency of the vibrations and sounds emitted by the shredder included in the shredder 11 and the mechanical sampling systems 14 and 27. Together it is used to record permanently in real time. These sampling systems will be described later in detail with reference to FIG.

In addition, the sensors 17, 19, 35 record one or more variables, such as voltage, current, power, temperature of the motor, etc. together with time and date in real time to ensure reliable operating conditions of these shredders. This provides a means for detecting excessive or abnormal conditions that may cause damage to sampling and metering, and it is also possible to alert to conditions that indicate operational problems and malfunctions of the device. In addition, there is a diagnostic opportunity for discovery and repair in case of malfunction or failure.

3 is a detailed view of the samplers 14 and 27, which will be described in more detail as follows. 3 is a schematic of a typical two-stage mechanical sampling system, the first cutter 40, the first feeder 41, the sample shredder 42, the second cutter 43, and the sample receiver 44. , Sample carousal 45, and sample balance 46. The various components are connected by a suitable chute, by which coal is transported through the sampling system. A three stage system with additional separation by a third cutter is common.

The treatment properties of the bulk material change with particle size distribution, moisture content and impurity ratio. Coal is one of the most difficult of all bulk materials. This situation is exacerbated by on-line crushing and separation in the sampling system, which changes the processing characteristics of the bulk material and changes the flow rate of the separated sample to the friction, adhesion and cohesion of coal. It is reduced to such an extent that it has a value greater than the inertia force and gravity that maintains its movement.

Potentially significant causes of errors that occur in retained samples are containment, obstructions, irregularities and discontinuous flow. Physical overuse of sampling systems frequently occurs in this situation. Operators resume the flow by tapping dropping devices, cutters and shredders with heavy pipes and large hammers. Such overuse can permanently impair the performance of the sampling system.

The sensors 47, 48, 49, 50, 51, 52, 53 and 54 are connected to the drop-down device, component, seal and sample route to ensure reliable and accurate sampling operation. 45) and metal temperature, vibration and vibration patterns, sound and acoustic patterns in the sample balance 46 are used to permanently record in real time with date and time. Such monitoring enables the alarm to be alerted to problems in the operation of the device and to conditions that indicate possible malfunction or overuse. You also have diagnostic opportunities to detect and repair malfunctions and failures. These sensors consist of one or more specific sensors described below and are connected to the appropriate recording and monitoring device shown in FIG. 4 by input-output electrical channels 55-55.

There are two basic methods commonly used in refining extraction sampling of bulk materials: time basis and mass basis. For both types of sampling, national and international standards specify the minimum number and minimum weight of increments required for the weight of the cargo represented by the purified sample.

Time-based sampling extracts sample increments at regular time intervals. In order to keep the proportion of the variable composition in the sample the same as present throughout, the sample cutters that extract or convert the increments must move at the same fixed speed for all increments.

Gravimetric sampling extracts sample increments at regular weight intervals, and in order to keep the proportion of variable composition in the sample the same as present throughout, the speed of the sample cutters must vary in direct proportion to the change in flow rate.

For both time-based and weight-based sampling, if cutter crossing occurs in line with a linear change in quality over time or weight, or if crossing of a second or third cutter occurs in line with the preceding cutters in the system Serious errors may occur.

The linear change in quality over time or weight is closely related to the change in flow rate, and the change in flow rate may indicate the capacity limitations of the bulk material handling system related to the change in the treatment properties of the bulk material. Crushers also cause a linear change in quality over time or weight, which is due to making bulk material easier to break.

Thus, in order to ensure accurate and reliable operating conditions of time- and weight-based sampling, the sensors 47, 52 and 56 count the number of crossings of the first cutter 40 and the second cutter 43. Then measure the speed of the first fader 41, measure the time at which the crossing took place, the length of the crossing cycle, the speed of the sample cutters in real time and record in real time with the date and time, which cutters are operated simultaneously It is used to determine if there is. Such monitoring additionally makes it possible to issue alarms indicating operational problems of the device and possible malfunctions and to provide diagnostic opportunities for detecting and repairing the malfunctions that have occurred.

The sensors 18 and 33 monitor the flow rate of the belt scales 13 and 25, the voltage and frequency of the power supply, the ambient temperature, the vibrations, the operating time and record them permanently in real time with the date and time, and the sampling system 14 And 27) to ensure the flow rate to and to check the flow change and the synchronism of the cutter crossings mutually.

The sensors 20, 21 of FIG. 1, the sensors 32, 34 of FIG. 2, and the genser 56 of FIG. 3 are used to detect fault conditions on the conveyors 12, 15, 23, 24 and 41. It is used to monitor the voltage, current (or power) to the conveyor drive motor or hydraulic power pack motor, and to record permanently with date and time in real time. All the conveyors of the bulk material handling system currently in use are interconnected, preventing them from preceding other conveyors in the system that are not operating. For this reason, sensors that monitor existing control states can be usefully substituted for the above sensors for recording information on conveyor speed, voltage, and the like.

Dynamic weighing of moving bulk material during transfer results in a number of variables that can affect weighing accuracy. Belt flexibility and belt tension are examples of these variables. Temperature is a factor influencing the flexibility of the belt. Temperature is also a factor influencing analog and digital devices. Many existing belt scales employ mechanical means to measure belt movement (speed), load, and the combination of belt speed and load. Newer technologies employ electromechanical and electronic means for measuring belt speed, scale, and the combination of belt speed and load. The latter accuracy is sensitive to the effects of radio frequency interference (RFI) and electromagnetic interference, as well as voltage and frequency variations in power. Both mechanical and electronic balances are affected by deflection between adjacent idlers and by vibrations that can be caused by belt connections and adjacent moving machines such as sampling systems and shredders.

The accuracy of the belt scale is also affected by the load level. For commercial scales the load level is limited in the range of 35% to 100% of the rated capacity by the National Bureau of Standards Handbook 44. In case of operation outside these limits an alarm signal is provided.

Sensors 18 and 33 are used to monitor the operating time, flow rate, voltage and frequency of the power source, ambient temperature, vibration of the belt scales 13 and 25 and record them permanently with date and time in real time. This information with comparative information on the relevant conveyors 12 and 24 is essential to ensure the effectiveness of weighing without adversely affecting the measurement factors.

Numerical values consist of two dimensions: quantity (weight or number) and quality (beneficial property, property or component). Socially, laws and regulations require that weighing for payment be done on an authorized scale.

Bulk material sampling is a complex task and the need for accuracy, precision and reliability is not widely recognized socially. As a result, in sampling, no similar legal or regulatory guarantee requirements are set. However, nationally and internationally, there are sampling standards of voluntary implications, which are widely used in trading as reference standards in contracts and arrangements.

With the advent of on-line analyzers, a new era of bulk material processing is achieved, and the status of receipt, inventory and use can be maintained in real time in terms of valuable compositions and accessories as well as conventional weight units such as tonnes or pounds.

For example, an electrical installation typically records a record of the receipt, inventory and use of coal, which is ultimately related to the coal's valuable properties, due to the lack of timely information on heating values. value).

The problem is solved with the advent of online analyzers that can provide the information in real time. Available online analyzers use X-ray fluorescence, microwave moisture analyzers, nuclear magnetic resonance, gamma ray and prompt gamma ray neutron activity assays and continuous calorimeters. Therefore, the heating value of the combustible composition of coal can be obtained in real time.

Depending on where the online analyzer is in the bulk ash flow, the sensor 37 on the online analyzer 28 receives in real time analytical data relating to the bulk material that has been received, recorded and used in inventory, and then The data is shown in FIG. 4 and becomes part of the database maintained by the computer and associated software, which will be discussed in more detail below.

Factors discussed herein may damage the accuracy and reliability of accredited balances, sampling systems, and on-line analyzers, which are outside the scope of the laws and regulations.

In real time, by measuring and permanently recording these factors, the accuracy of weighing can be assured beyond what has been possible so far. By similar monitoring by mechanical sampling and on-line analyzers, compliance with applicable sampling and test standards, accuracy, precision and reliability of bulk material sampling and analysis can be guaranteed to essentially the same level as the official weighing. In combination with accredited weighing, such sampling can effectively provide timely measurement of the total value with an accredited status.

In more detail with respect to FIG. 4, FIG. 4 includes a disk drive system 58, a video terminal 59, one or more printers 60, and is shown in FIG. 1 by an input-output electrical channel 61. A computer 57 is shown connected to the corresponding conductors from the sensors shown in FIGS. Also shown is modem 62, telephone connection 63 to main office 64, and microwave connection 65 to central repair shop 66. Computer 57 is controlled by proprietary software, which acquires the signals of the various sensors in the system through analog and digital input-output channels that regulate the received signals. The computer 57 has an electronic clock calendar, a disk drive for permanently recording data from the sensor, an interface for a modem and a printer, and a video terminal keyboard.

The software provides a variety of services. The software converts the sensor signals into realistic units and, if necessary, permanently records the sensor data in a database maintained on the disk driver system 58 along with the date and time from the internal electronic clock calendar, Analyze sensor data against benchmark-related conditions, check synchronization of sampling system operation, and provide visual and audio alarm signals for any situation that exceeds certain limits or requires human attention or adjustment. Cause it to occur.

In comparing the data obtained from the device for measuring the properties of the bulk material with the data obtained from the variables measured simultaneously with the measurement of the properties of the bulk material, appropriate benchmarks can be selected as reference criteria.

For example, such benchmarks include contracts, equipment and process specifications, operating and material standards, purchasing and receiving specifications, regulatory and legal limits, and limits established by experience and experience.

The software also checks bulk goods receipts for preset quality and quantity limits and records conversions in receipt, inventory and use in realistic weight, valuable composition, valuable properties and monetary terms. The software provides the necessary services for interactive keyboard input of biographical dada, and access security to various levels of software and data by predetermined priority levels. Keep it. The software provides stop, failure, status, operation and diagnostic reports locally and at remote terminals in state offices and repair shops. The software also provides inputs and outputs for the main computer.

In addition to being performed at a particular location, the present invention should be able to be tailored to the specific needs of any given facility. The computer program instruction code is preferably modular re-entrant code to facilitate this kind of customization. Such computer programs can be easily written by qualified programmers who are familiar with structural assembly or higher level computer languages.

While the invention has been described in terms of preferred embodiments, it is clear that modifications can be made readily by one of ordinary skill in the art without departing from the scope and spirit of the invention.

Claims (9)

A method of auditing means for measuring one or more properties of a bulk material to improve accuracy or reliability of bulk material measurements, comprising: measuring at least one property of the bulk material with the means; One or more variables independent of the means for measuring properties, affecting the normal operation of the means directly or indirectly, thereby affecting the accuracy or reliability of the results obtained by the means for measuring the bulk material. And means for simultaneously measuring the bulk material properties, wherein the means audit method for measuring the bulk material properties. The method of claim 1, wherein the one or more measurements obtained by measuring the one or more variables affecting the accuracy of the results obtained by the means for measuring the bulk material properties are determined by the reference criteria required to ensure the validity of the property measurements. A means audit method for measuring bulk material characteristics, characterized in that the comparison is performed at the same time. CLAIMS 1. A method of auditing means for extracting a purified product from a defined mass of bulk material to improve the accuracy or reliability of the refined product, the method comprising: physically extracting an increment from the defined mass of bulk material; One or more indirectly affecting the normal operation of the refinery extraction means, thereby affecting the reliability or accuracy of the refinement obtained by the means used to extract the refinery from the defined mass of bulk material. Measuring peripheral shift or operating shift simultaneously with said incremental extraction. 4. A method as claimed in claim 3, wherein said increment is extracted as said small stream from said bulk material. CLAIMS 1. An apparatus for auditing means for measuring one or more properties of a bulk material to improve accuracy or reliability of bulk material measurements, comprising: first means for measuring one or more properties of the bulk material; One or more affecting the normal operation of the first means directly or indirectly, thereby affecting the accuracy or reliability of the results obtained by the first means and independent of the first means for measuring bulk material properties. And a second means for measuring a variable simultaneously with the measurement of said bulk material property. 6. A bulk material according to claim 5, further comprising a third means for comparing the measurements obtained by said second means with a reference criterion required to ensure the validity of the characteristic measurements by said first means. Apparatus auditor for measuring properties. An apparatus for auditing a means for extracting a refined from a bulk material for improving the accuracy or reliability of extracting the refined product, comprising: a first means for extracting a refined product from the bulk material, and the normal operation of the first means Affects directly or indirectly to, thereby affecting the accuracy or reliability of the refinement extraction by the first means, independent of the first means for extracting the refinery from the bulk material And a second means for measuring the above parameters simultaneously with the extraction of the purified product. 8. Apparatus audit device according to claim 7, characterized in that it comprises a third means for comparing the measurements obtained by said second means with a reference criterion required to ensure the validity of said tablet extraction. . 6. Apparatus as claimed in claim 5, comprising a fourth means for displaying the current state of all threshold monitored parameters and measurements.

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