FPSH智能煤泥均质机的研制及工业应用

    Development and industrial application of FPSH intelligent coal slime homogenizer

    • 摘要: 在煤泥减量化、去煤泥化政策驱动下,选煤厂高压压滤滤饼普遍存在卸料不连续、掺配不均、商品煤质量周期性波动、下游设备瞬时荷载冲击过载等问题,制约煤泥资源化回掺与企业效益提升。研制了FPSH智能煤泥均质机,整机由滤饼缓冲装置、均质卸料装置、移动支架平台、移动轨道系统、位置感知装置及智能控制装置构成;采用“缓冲储料+往复移动均质卸料+自适应调速+智能闭环控制”工艺,通过PLC采集压滤机工作循环、叶轮电流、行走位置等多源信号,由智能算法协同调速,实现时间、粒度双维度均质化处理。在城塔煤矿1 200万t/a选煤厂工业应用中,高压压滤机滤饼经均质化处理后100~500 mm大块占比下降,50 mm以下占比约85%;压滤系统两班作业循环次数由18次提升至32次,循环效率提升约78%;现场取消了初破破碎机,解决了破碎机过载保护与溜槽堵料问题,末煤产品稳定。FPSH智能煤泥均质机填补了压滤—掺配环节连续均质的空白,为选煤厂智能压滤系统提供了关键装备支撑,对推动煤泥减量化/去煤泥化政策落地、实现降本增效与资源节约具有显著工程价值。

       

      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.

       

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