Rapid quantitative analysis of three elements (Al, Mg and Fe) in molten zinc based on laser-induced breakdown spectroscopy combined with machine learning algorithm

Hot-dip galvanizing represents one of the most cost-effective methods for the prevention of metal corrosion, and is therefore employed extensively across a range of fields. Carrying out the research and development of technology and devices for quantitative analysis of chemical elements in hot-dip galvanising process can provide theoretical basis and technical support for the efficiency of hot-dip galvanising process and reduction of energy consumption. A machine learning-assisted LIBS combined with a programmable logic controller (PLC) for simultaneous on-line/in-site monitoring of multiple elements in hot-dip galvanising solution (molten zinc) was developed in the current study. The LIBS spectral data of the on-site hot-dip galvanising solution was collected under optimised experimental conditions. In order to further reduce the influence of experimental noise on the analysis performance, the on-site LIBS spectral data were preprocessed and anomalous spectral data were screened based on normalisation and principal component analysis-Mahalanobis distance (PCA-MD). On the basis of the optimised data, component prediction models for three key elements of on-site hot-dip galvanising solution were constructed. The storage and re-call of the model was achieved based on Python combined with LabVIEW, thus real-time prediction of the on-site component content of hot-dip galvanising solution was achieved. The results show that the random forest model presents the best prediction results, in which the R² is 0.9978 and the RMSE is 0.0013% for Al, the R² is 0.9984 and the RMSE is 0.0011% for Mg, and the R² is 0.9932 and the RMSE is 0.0001% for Fe. From the on-site analysis results of the constructed model, its MRE of Al, Mg and Fe is 0.0098, 0.0236, and 0.2102, respectively. In summary, the in-situ/on-line analysis system of hot-dip galvanising solution combined with machine learning constructed in this study shows excellent performance, which can satisfy the needs of hot-dip galvanising solution production site. This study is expected to provide theoretical basis and technical reference for quality control and process optimisation in other production sites in the metallurgical field.