Case of integrated production control system in rare earth field
CONTENTS
1. Project background... 2
2. Achievement of objectives... 2
3. Overall framework... 3
4. Centralized control center renovation... 4
5. Workshop retrofit sensors and network modifications... 5
6. Edge process modeling and simulation... 5
7. Basic Industrial Internet Platform... 6
8. Integrated Rare-Earth Production Control Operations... 6
9. Pocket Factory... 6
Note: This document is case advocacy material, omitting confidentiality and program details.
1. Project background
Rare earth is a strategic resource of the country, and the state implements unified planning for the development of the rare earth industry. The state encourages and supports the research, development and application of new technologies, processes, products, materials and equipment in the rare earth industry, continues to improve the level of development and utilization of rare earth resources, and promotes the high-end, intelligent and green development of the rare earth industry.
After 2 months of detailed research, ** Rare Earth currently lacks data synergy interaction between production workshops, lack of complete production process data synergy monitoring and analysis, and is unable to understand the production process and operation in a timely manner, not to mention effective production process optimization.
This project is based on the industrial Internet infrastructure platform to realize equipment interconnection and heterogeneous data integration, and to realize the digitization, informatization and intelligence of the core business of the production process of **rare earths, so that the company's producers, managers and operators can master the production of rare earths at any time, the decision-making of the production process, and optimization of the implementation feedback.
This project promotes the digitalization, informatization and intelligent transformation of **rare earth production links, comprehensively improves the competitiveness of **rare earths from the industry, strategy, technology and market solutions, and creates the intelligent brain of the whole process production of **rare earths roasting, water leaching, extraction, carbon sinking and cauterization.
2. Achievement of objectives
Based on the current situation of ** rare earth production and combined with the current situation of intelligent development of the rare earth industry, through high standard design and high quality completion, to the development of intelligent manufacturing of the entire process of rare earth smelting, to enhance the comprehensive competitiveness of the production and operation of ** rare earth. The entire production line from raw materials to finished products to achieve centralized control, production and operation synergies, real-time monitoring and early warning of key equipment, product tonnes of oxide energy consumption analysis, improve product quality stability, yield stability, equipment operation stability.
The ultimate realization of the production process of the whole process data transparency, data and personnel synergy between production processes, reduce the failure rate of rare earth process key equipment, reduce the overall energy consumption of rare earth products, production process data accumulation and data analysis.
3. Overall framework
** Rare earth production integrated control system construction in line with "both hard and soft, both internal and external", on the one hand, from the hardware level to break the geographical and spatial location limitations, to achieve the centralized control of the production line of each process, on the other hand, from the production process, through the production line of data flow, material flow and energy flow, from the mechanism and big data analysis level to establish the mechanism of modeling On the other hand, from the production process, we can open up the data flow and material flow and energy flow of the production line, establish the mechanism model from the level of mechanism and big data analysis, and build the intelligent application of the unit process and rare earth production line, so as to truly realize the collaborative intelligent control of the whole process of the rare earth production line, and ultimately realize the construction of the rare earth intelligent center.
**Rare earth production integrated management and control system covers the whole process section of continuous production, such as inspection and testing, roasting, water leaching, transformation, extraction, carbon sinking, scorching and environmental protection, etc., and unifies the planning of the edge intelligent model and simulation, industrial Internet basic platform, integrated production and operation monitoring, intelligent decision-making of the whole plant, digital twin, and handheld factory. Simple framework schematic (Note: The detailed framework is confidential and is not intended for public dissemination.), as shown below:
The data framework includes workshop and process (roasting, water leaching, extraction, carbon sinking, scorching, environmental protection and maneuvering), and platform end, which mainly guarantees the real-time, stability, uniqueness and integrity of data transmission. Unified data acquisition, unified data transmission method and communication protocol, unified data processing, unified data storage, unified data modeling and analysis, unified data interface and unified business expansion. The data framework is schematized in the figure below:
4. Centralized control center modifications
Centralized control location:** Rare earth extraction workshop control room.
Existing central control room length 15m * width 6m * height 3m, central control screen installed in the north wall, there are two, respectively, the left side of the security video module and the right side of the centralized control system module. There are five operating stations, and the west side of the center control room is placed in cabinets and desks.
This project replaces the main screen with a large screen of 2.24m high and 8.96m wide, with a display area of 20.07m2, which is arranged on the north wall as the display end of the centralized control system.
The application effect is illustrated in the following figure:
5. Addition of sensors and network modifications in workshops
According to the requirements of the production process in each workshop, the key equipment of the production process in the workshop is installed with sensors to realize the digital monitoring and analysis of the production process, for example, ** the workshop liquid pool is installed with a flow meter; the rotary kiln is installed with a temperature detector; the slurry mixing tanks, neutralization tanks, and slag washing tanks are installed with a level detector and a pH detector, and so on.
The newly added sensors and old sensors are networked and retrofitted with network conversion modules to digitalize production. The network transformation of a workshop is illustrated in the figure below:
6. Edge process modeling and simulation
（1） Roasting process simulation model
The gas phase (natural gas and air) enters the kiln from the kiln head and moves toward the kiln exhaust port, while the solid phase (dried concentrate) and liquid phase (concentrated sulfuric acid) enter the kiln from the kiln tail inlet and move toward the kiln head outlet. In the production process, the solid phase, liquid phase and gas phase carry out complex heat transfer between the kiln for a large number of chemical reactions, and at the same time the material transportation, turning, foaming and other physical reactions. In summary, the establishment of gas-solid-liquid three-phase flow and heat transfer model in the kiln, analyze the three-phase distribution state, movement behavior and temperature distribution comprehensive model. (Note: modeling diagrams are omitted）。
（2） Extraction Material Balance Control and Separation Effect Modeling
Abnormal fluctuations in the distribution of each rare earth element in the extraction tanks at all levels will affect the extraction and separation effect and product purity index.
Real-time monitoring of the organic phase (including saponification solution), material liquid and the flow of each product outlet, sampling results and other parameters, to build the material balance and separation effect model, adjust the water leach solution, organic and residue wash liquid flow ratio, so as to achieve the extraction process optimization and control, and improve the yield and quality of the product. (Note: modeling diagrams are omitted）。
7. Basic industrial Internet platforms
The Industrial Internet is the basic platform for this project, providing the tools to develop the business, while other business functions can be extended in the future.
Industrial Internet platform as the core carrier for the development of industrial intelligence, the platform system provides support for data collection, data modeling, data early warning, data view, data report, data traceability, data physical examination and algorithm analysis.
The industrial Internet platform connects equipment downward and supports application development upward, and gradually establishes the standardization of rare earth smelting and manufacturing capabilities and industrial knowledge through data aggregation, data application and analysis, and builds the core capability of rare earth intelligent manufacturing.
8. Integrated Rare-Earth Production Control Operations
Functional modules of the first phase of the main business include: comprehensive decision-making screen, collaborative monitoring of production processes, key equipment management, energy monitoring, energy early warning, energy analysis, laboratory management, report management and other core business functions. The effect of the decision-making big screen is shown in the following figure:
9. Pocket Factory
The system display layer is displayed through the large screen in the centralized control room, the PC terminal and the mobile terminal. The mobile terminal with the palm mobile application, progress reporting automatically associated with the production data, a key to view the production order all the implementation process, real-time tracking, grasp the production progress of timely adjustments, arrangements for the implementation of production, energy, raw and auxiliary materials consumption and production progress.
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