Design And Development Of Computer Control Software For Bauxite Ore Dressing Process

Bayer process and sintering process are mainly applied to the production of bauxite. Sintering process requires high energy consumption and low Al/Si ratio, while the Bayer process requires low energy consumption and high Al/Si ratio. To conserve the energy, Bayer process is always taken as the prior way to produce bauxite in China, but it is confronted with the prerequisite of high Al/Si ratio owing to the condition of the ore in China. Therefore, a series of processes consisting of grinding, floatation and condensation is applied to generate the bauxite concentrate of high Al/Si ratio.This paper is based on the beneficiation process automation project of an alumina company in China, and the control strategy for loop-controlled as well as logic-controlled system is designed initially. Next, the software for the system related above is also designed applied to the beneficiation process automation project of an alumina company in China. The details are revealed as follow:1. Strategy for process loop control and logic interlock control is proposed. Firstly, fuzzy adaptive PID algorithm is proposed to control the loop for the ore feeding process to address the problem of long-term delay and frequent disturbance. At the same time, PI controllers are designed to tune the amount of water supplement to the ball mills’entrance and the level of overflow tank respectively. In addition, a cascade strategy is also put forward to tune the density of grader overflow concentration and thickener underflow concentration. To enhance the safety of the entire system, logic interlock control is also introduced to the equipments such as flat belt、oblique belt、ball mill and grader.2. Control system software the alumina mineral process is designed. It is constituted by process control and process monitoring. The former introduces blocking modeling method to design different control loop to fulfill different purpose, that is, to control different loops including ore-feeding, overflow tank, slurry tank, grader and thickener. The later is consisting of operation and system management, operation management aims to monitor the system, coordinate the equipment, print report forms and show the trend of past data. While the other part is designed to manage the users, log the operation of the engineer and guide the novice.3. Software development is carried out. Based on the ICC platform rendered by I/A Series software, the control software is developed for the mineral process, and monitoring software is designed based on the Foxdraw software. For the process control system software, it completes the configuration of process loop control algorithm, and logic interlock control; while the other part completes the operator management monitor control and system management monitor control.4. Finally, the alumina process control system software has been applied to an alumina processing plant in Chongqing, it turns out to keep the entire process operate stably, and it can meet the production requirements. Overall, it makes it available for automation of the mineral process, which guarantees the system more safe and stable.