Abstract:
Driven by the implementation of slime reduction and slime-free operation policies, coal preparation plants commonly encounter several challenges associated with high-pressure filter cakes, including intermittent discharge, inadequate mixing uniformity, periodic fluctuations in product coal quality, and instantaneous overload impacts on downstream equipment. These issues restrict the resource utilization of coal slime through blending and hinder further improvements in operational efficiency and economic benefits. An FPSH intelligent coal slime homogenizer was developed to address these challenges. The complete system consists of a filter cake buffering unit, a homogenizing discharge unit, a mobile support platform, a traveling rail system, a position sensing device, and an intelligent control system. A novel process integrating buffered storage, reciprocating mobile homogenized discharge, adaptive speed regulation, and intelligent closed-loop control was adopted. The programmable logic controller (PLC) collects multiple signals, including filter press cycle counts, impeller current, and travel position. An intelligent control algorithm coordinates the operating parameters and performs adaptive speed adjustment, enabling two-dimensional homogenization based on both residence time and particle size distribution. The FPSH intelligent coal slime homogenizer was applied in a 12 Mt/a coal preparation plant of Chengta Coal Mine. After homogenization treatment of the high-pressure filter cake, the proportion of large particles (100~500 mm) was significantly decreased, with particles smaller than 50 mm accounting for approximately 85%. The number of operating cycles of the filter press system increased from 18 to 32 cycles per two-shift operation, representing an improvement in cycle efficiency of approximately 78%. Furthermore, the primary crusher was eliminated from the process, effectively resolving problems associated with crusher overload protection and chute blockage, while ensuring stable production of the fine coal product. The FPSH intelligent coal slime homogenizer fills the technological gap in continuous homogenization between filter pressing and coal blending processes, providing critical equipment for the development of intelligent filter press systems in coal preparation plants. The proposed technology demonstrates significant engineering value in promoting slime reduction and slime-free operation, improving resource utilization efficiency, and achieving cost reduction and productivity enhancement.