A detection system for detecting micro-sand leakage in micro-sand ballast sedimentation process

Abstract

The present application provides a detection system for detecting micro-sand leakage in a micro-sand ballast sedimentation process, including a sound collection component, the sound collection component including a micro-sand impact signal collection piece, a sound sensor, and an acoustic wave analyzer, the micro-sand impact signal collection piece is arranged in a sludge overflow pipe, the sound sensor is used to collect real-time sound signals of micro-sand particles in the sludge overflow pipe hitting the micro-sand impact signal collection piece, the obtained real-time sound signal is converted into a real-time sound spectrum by the acoustic wave analyzer, the real-time sound spectrum is compared with the sound spectrum without micro-sand particles in the sludge overflow pipe, so as to determine the concentration of micro-sand particles in the sludge overflow pipe, and then determine whether the separated micro-sand particles leak from the upper overflow port of the hydrocyclone through the sludge overflow pipe to the outside of the system. The system can monitor the important operating parameters of the process and reduce the labor intensity of manual inspection and sampling.

Description

Technical Field

[0001] The present application relates to the technical field of water treatment, and in particular to a detection system for detecting micro-sand leakage in a micro-sand ballasted sedimentation process. Background Art

[0002] The basic principle of the micro-sand sedimentation tank is to use a physicochemical treatment process that uses continuously circulating micro-sand particles and chemical agents to strengthen flocs and thus improve the settling performance of suspended matter in the water. Coagulants are added to the water to destabilize the suspended matter and colloidal particles in the water, and then polymer coagulants and micro-sand carrier particles with a high density are added, so that the destabilized impurity particles use the carrier as the floc nucleus, and through the bridging adsorption of the polymer chain and the sedimentation and netting effect of the micro-sand particles, alum flocs with a high density are quickly generated, and enter the inclined tube sedimentation tank for efficient separation, which greatly shortens the sedimentation time and improves the treatment effect. The bottom sludge and micro-sand are refluxed and efficiently separated by the hydrocyclone, and the micro-sand is recycled to the system for reuse.

[0003] At present, micro-sand sedimentation tanks are widely used in various application fields of water treatment. Different application conditions are different and relatively rough. Large particles and garbage are often intercepted and not completely enter the system, which has a great impact on the micro-sand sedimentation tank equipment, causing blockage of the circulation system, leakage of micro-sand, and eventually the collapse of the entire treatment process.

[0004] The bottom flow of the cyclone in the circulation system is the component with the smallest channel diameter, usually 1-2 cm, which is easy to be blocked. Moreover, this component is the most critical link in the operation of the system. If it is blocked, the circulation system will fail and the overall process will collapse.

[0005] At present, there is no automatic way to detect blockage during the operation of the micro-sand sedimentation tank. Conventionally, operators conduct inspections, observe the operating status of the cyclone bottom flow and take samples to determine whether the return system is working normally. Even so, it is impossible to determine whether the micro-sand separation efficiency is normal. It is usually necessary to sample the overflow sludge to check whether there is micro-sand overflowing from the top of the cyclone. Long-term micro-sand overflow leads to a decrease in the micro-sand concentration in the tank, a deterioration of the sedimentation effect, and poor effluent quality.

[0006] In the prior art, the main reasons for the loss of micro-sand are the following three: 1) There are large particles in the incoming water, which cause garbage to clog the bottom of the cyclone. The function of the cyclone is mainly to separate micro-sand and sludge. The micro-sand is ejected from the bottom of the cyclone and recovered to the sedimentation tank for recycling. The bottom nozzle of the cyclone is usually very small, and the smallest cyclone is only a few millimeters or a few centimeters. If the incoming water contains large garbage, it is easy to clog the bottom flow port of the cyclone, resulting in failure of cyclone separation. Micro-sand is discharged from the overflow port of the cyclone, causing the loss of micro-sand to outside the system; 2) There are large particles in the incoming water that clog the impeller of the circulation pump. The micro-sand circulation pump usually uses a closed impeller. The flow channel in the pump casing is small, and the rotating parts are easily entangled with ropes and other garbage, resulting in reduced flow and pressure. The cyclone is under low inlet flow and pressure conditions. , the separation efficiency of micro-sand will deteriorate, the cutting particle size will increase sharply, and micro-sand smaller than the cutting particle size will be lost from the overflow port with the sludge in large quantities; 3) The micro-sand concentration is too high, resulting in blockage of the cyclone bottom flow port. In the case of improper design or excessive concentration of micro-sand added in the pool, the micro-sand content at the bottom of the sedimentation tank will greatly exceed the load of the cyclone, resulting in the inability to discharge a large amount of refluxed micro-sand from the bottom of the cyclone in time, exceeding the maximum concentration of micro-sand that can be discharged from the bottom of the cyclone. Micro-sand accumulates in the conical separation chamber at the bottom of the cyclone, causing blockage at the bottom. Since the overflow aperture of the cyclone is larger than the bottom flow aperture, the upper part is not easily blocked, and micro-sand and sludge will be discharged from the overflow port of the cyclone, resulting in the loss of micro-sand to the outside of the system.

[0007] The loss of micro-sand will lead to the following adverse consequences: 1) The concentration of micro-sand in the system decreases sharply, and the flocs formed in the sedimentation tank do not have enough micro-sand ballast for ballasting, resulting in failure to precipitate. The flocs flow out of the sedimentation tank with the effluent, and the effluent of the sedimentation tank becomes worse. The effluent exceeds the standard and the whole equipment cannot operate; 2) Re-adding micro-sand will waste a lot of micro-sand consumables, consume a lot of manpower, and cost carriers. For the micro-sand sedimentation tank process with a processing capacity of 100,000 tons, the system holding amount of micro-sand is about 1.5-4 tons, causing economic losses; 3) The loss of micro-sand with the sludge to the sludge treatment system will increase the burden on the sludge system and cause the sludge treatment system to collapse; and the sludge treatment system equipment cannot withstand the water quality with a high content of quartz sand in the water, which will cause equipment wear or even damage, resulting in serious economic losses; 4) The loss of micro-sand will cause a lot of manual cleaning costs for related systems.

[0008] Therefore, there is an urgent need in this field to develop a detection system for detecting micro-sand leakage in the micro-sand ballasted sedimentation process. The system detects the leakage of micro-sand particles through sound to ensure the safe and normal operation of the micro-sand ballasted sedimentation device (micro-sand sedimentation tank). Summary of the invention

[0009] The purpose of the present application is to provide a detection system for detecting micro-sand leakage in a micro-sand ballasted sedimentation process. The system detects the leakage of micro-sand particles through sound to ensure the safe and normal operation of the micro-sand ballasted sedimentation device (micro-sand sedimentation tank).

[0010] The present application provides a detection system for detecting micro-sand leakage in a micro-sand ballast sedimentation process, the detection system comprising a micro-sand ballast sedimentation device and a sound collection component;

[0011] Wherein, the micro-sand ballast sedimentation device comprises a sedimentation tank and a reflux component;

[0012] The return assembly comprises a hydrocyclone, the hydrocyclone is in fluid communication with the bottom of the sedimentation tank, the hydrocyclone comprises an upper overflow port and a lower sand discharge port, the upper overflow port is connected to a sludge overflow pipe, the hydrocyclone is configured to separate mud and sand in the sedimentation tank into micro-sand particles and sludge, the separated sludge flows out of the system through the sludge overflow pipe, and the separated micro-sand particles are discharged from the lower sand discharge port to the micro-sand ballast sedimentation device for reuse;

[0013] The sound collection component includes a micro-sand impact signal collection piece, a sound sensor, and an acoustic wave analyzer. The micro-sand impact signal collection piece is arranged in the sludge overflow pipe. The sound sensor is used to collect real-time sound signals of micro-sand particles in the sludge overflow pipe impacting the micro-sand impact signal collection piece. The obtained real-time sound signal is converted into a real-time sound spectrum by the acoustic wave analyzer. The real-time sound spectrum is compared with the sound spectrum without micro-sand particles in the sludge overflow pipe, so as to determine the concentration of micro-sand particles in the sludge overflow pipe, and then judge whether the separated micro-sand particles leak from the upper overflow port of the hydrocyclone through the sludge overflow pipe to the outside of the system.

[0014] In another preferred example, the real-time sound signal obtained is converted into a real-time sound spectrum by the acoustic wave analyzer, and the real-time sound spectrum is compared with the sound spectrum without micro-sand particles in the sludge overflow pipe, so as to determine the approximate concentration of micro-sand particles in the sludge overflow pipe.

[0015] In another preferred embodiment, the particle size of the micro-sand particles is distributed in the range of 80-250 um.

[0016] In another preferred example, the micro-sand ballasted sedimentation device further includes a coagulation tank, a sand injection tank, and a flocculation tank, and the micro-sand separated by the hydrocyclone is discharged through the sand discharge port to the sand injection tank for reuse.

[0017] In another preferred example, the hydrocyclone further includes a sand-mud separation channel arranged between the upper overflow port and the lower sand discharge port.

[0018] In another preferred example, the diameter of the lower sand discharge port is smaller than the diameter of the upper overflow port.

[0019] In another preferred example, the micro-sand impact signal collection piece is a circular structure, and the area of ​​the micro-sand impact signal collection piece accounts for 10%-50% of the cross-sectional area of ​​the sludge overflow pipe.

[0020] In another preferred example, the micro-sand impact signal collection piece is arranged at the center of the sludge overflow pipe.

[0021] In another preferred example, the sludge overflow pipe includes a vertical section, a curved section, and a horizontal straight pipe section, the horizontal straight pipe section includes a laminar flow section, the vertical section is connected to the upper overflow port of the hydrocyclone, the curved section is located between the vertical section and the horizontal straight pipe section, the micro-sand impact signal collection piece is arranged in the laminar flow section, and the distance between the position of the micro-sand impact signal collection piece and the connection between the curved section and the horizontal straight pipe section is greater than 5 times the diameter of the sludge overflow pipe, so that the sludge in the sludge overflow pipe at the position of the micro-sand impact signal collection piece is in a laminar flow state.

[0022] In another preferred example, the diameter of the sludge overflow pipe is 32 mm, 40 mm, 50 mm, 80 mm and 100 mm.

[0023] In another preferred embodiment, the concentration of the micro-sand particles in the sludge overflow pipe is determined by the following method: the volume of sludge collected per unit time is calculated by the area S (set value) of the micro-sand impact signal collection piece and the pipeline flow rate V (set value), and the number of particles in the corresponding time period is collected by the acoustic wave curve to obtain a change curve of the micro-sand concentration in the sludge;

[0024] In another preferred embodiment, the concentration is indirectly reflected according to the frequency of collisions per unit time.

[0025] In another preferred example, the sound collection component further includes a sound transmission element, one end of the sound transmission element is connected to the micro-sand impact signal collection sheet, and the other end of the sound transmission element is connected to the sound sensor.

[0026] In another preferred example, the sound transmission element is a connecting rod.

[0027] In another preferred example, the sound collection component further includes an interface element, the sludge overflow pipe includes a first pipe and a second pipe, the interface element is arranged between the first pipe and the second pipe, the sound transmission element is connected to the interface element, and the interface element is sealedly connected to the first pipe and the second pipe.

[0028] In another preferred example, the interface element is connected to the first pipe and the second pipe by glue or flange.

[0029] In another preferred example, the laminar flow section is arranged on the first pipe and the second pipe, and the first pipe and the second pipe are part of a horizontal straight pipe section in the sludge overflow pipe.

[0030] In another preferred embodiment, the sludge overflow pipe is a soft plastic pipe or a steel pipe lined with soft rubber.

[0031] In another preferred example, the micro-sand impact signal collection piece is a metal collection piece, preferably a metal collection piece with a cavity.

[0032] In another preferred example, the reflux component also includes a circulating reflux pump, which is configured to pump mud and sand in the sedimentation tank into the hydrocyclone, and the cause of the failure of the micro-sand sedimentation device is determined by detecting the sludge flow in the sludge overflow pipe and the concentration of micro-sand particles in the sludge overflow pipe. The cause of the failure includes one of the following: (i) the bottom of the hydrocyclone is partially blocked; (ii) the bottom of the hydrocyclone is completely blocked.

[0033] In another preferred embodiment, the system further comprises a central control device, which is in communication with the sound collection component and controls the operation of the circulation reflux pump and the power component in the micro-sand ballast sedimentation device; wherein

[0034] When it is detected that the sludge flow in the sludge overflow pipe increases and the concentration of the micro-sand particles in the sludge overflow pipe increases slowly, the central control device adjusts the frequency of the circulation return pump and increases the speed of the circulation return pump, thereby increasing the inlet pressure of the hydrocyclone;

[0035] When it is detected that the sludge flow in the sludge overflow pipe suddenly increases and the concentration of the micro-sand particles in the sludge overflow pipe increases sharply, the central control device shuts down the flocculation tank agitator and the scraper in the micro-sand ballast sedimentation device within the set time, and maintains the circulation reflux pump working for a predetermined time. If it is detected that the sludge flow has not decreased, the hydrocyclone is cleaned.

[0036] In another preferred example, the detection system further comprises a flow meter arranged on the sludge overflow pipe, and the flow meter is used to measure the flow of sludge in the sludge overflow pipe.

[0037] In another preferred example, the system further comprises an alarm device, which sends out an alarm signal when the concentration of the micro-sand particles in the sludge overflow pipe exceeds a predetermined threshold value.

[0038] In another preferred example, the micro-sand ballasted sedimentation device further includes a coagulation tank, a sand injection tank, and a flocculation tank, and the micro-sand separated by the hydrocyclone is discharged through the sand discharge port to the sand injection tank for reuse.

[0039] In another preferred example, the reflux component also includes a reflux pipe and a circulating reflux pump, wherein the circulating reflux pump is arranged on the reflux pipe, and the circulating reflux pump is configured to pump the mud and sand in the sedimentation tank, and the mud and sand pass through the circulating reflux pump and enter the hydrocyclone through the reflux pipe.

[0040] The second aspect of the present application also provides a detection device for detecting leakage of micro-sand particles in a micro-sand ballast sedimentation device, the detection device comprising a sound collection component, the micro-sand ballast sedimentation device comprising a sedimentation tank and a reflux component,

[0041] The return assembly comprises a hydrocyclone, the hydrocyclone is in fluid communication with the bottom of the sedimentation tank, the hydrocyclone comprises an upper overflow port and a lower sand discharge port, the upper overflow port is connected to a sludge overflow pipe, the hydrocyclone is configured to separate mud and sand in the sedimentation tank into micro-sand particles and sludge, the separated sludge flows out of the micro-sand ballast sedimentation device through the sludge overflow pipe, and the separated micro-sand particles are discharged from the lower sand discharge port to the micro-sand ballast sedimentation device for reuse;

[0042] The sound collection component includes a micro-sand impact signal collection piece, a sound sensor, and an acoustic wave analyzer. The micro-sand impact signal collection piece is arranged in the sludge overflow pipe. The sound sensor is used to collect real-time sound signals of micro-sand particles in the sludge overflow pipe impacting the micro-sand impact signal collection piece. The obtained real-time sound signal is converted into a real-time sound spectrum by the acoustic wave analyzer. The real-time sound spectrum is compared with the sound spectrum without micro-sand particles in the sludge overflow pipe, so as to determine the concentration of micro-sand particles in the sludge overflow pipe, and then judge whether the separated micro-sand particles leak from the upper overflow port of the hydrocyclone through the sludge overflow pipe to the outside of the micro-sand ballast sedimentation device.

[0043] It should be understood that within the scope of the present invention, the above-mentioned technical features of the present invention and the technical features specifically described below (such as embodiments) can be combined with each other to form a new or preferred technical solution. Due to space limitations, they will not be described one by one here.

[0044] The specification of this application records a large number of technical features, which are distributed in various technical solutions. If all possible combinations of technical features (i.e., technical solutions) of this application are listed, the specification will be too long. In order to avoid this problem, the various technical features disclosed in the above invention content of this application, the various technical features disclosed in the various embodiments and examples below, and the various technical features disclosed in the drawings can be freely combined with each other to form various new technical solutions (these technical solutions are all deemed to have been recorded in this specification), unless such a combination of technical features is technically infeasible. For example, in one example, feature A+B+C is disclosed, and in another example, feature A+B+D+E is disclosed. Features C and D are equivalent technical means that play the same role. Technically, only one of them can be used, and it is impossible to use them at the same time. Feature E can be combined with feature C technically. Then, the solution of A+B+C+D should not be deemed to have been recorded because it is technically infeasible, while the solution of A+B+C+E should be deemed to have been recorded. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. It should be understood that the drawings described below are only some implementation examples of the present invention, and ordinary technicians in this field can also obtain other implementation examples based on these drawings without paying creative work.

[0046] Figure 1 It is a structural schematic diagram of a detection system for detecting micro-sand leakage in a micro-sand ballasted sedimentation process according to an embodiment of the present application;

[0047] Figure 2 is a schematic diagram of a detection system for detecting micro-sand leakage in a micro-sand ballasted sedimentation process according to an embodiment of the present application;

[0048] Figure 3a is a structural schematic diagram of a portion of a sound collection component according to an embodiment of the present application;

[0049] Figure 3b is a schematic structural diagram of a metal baffle according to an embodiment of the present application;

[0050] Figure 4 It is a sound spectrum in a sludge overflow pipe collected by a sound collection component without micro-sand leakage according to an embodiment of the present application;

[0051] Figure 5 It is a sound spectrum in a sludge overflow pipe collected by a sound collection component with micro-sand leakage according to an embodiment of the present application;

[0052] Figure 6 It is a simulation curve of the change of micro-sand concentration in sludge when the underflow of the cyclone is suddenly blocked according to an embodiment of the present application. DETAILED DESCRIPTION

[0053] After extensive and in-depth research, a detection system for detecting micro-sand leakage in the micro-sand ballasted sedimentation process was developed for the first time. The system collects the sound generated by the micro-sand leakage in the overflow sludge pipe of the hydrocyclone, organizes and analyzes the sound waves, and determines whether the sludge contains micro-sand and its approximate concentration, thereby determining whether there is a micro-sand particle leakage in the micro-sand ballasted sedimentation device. The system controls the operation of the power equipment through communication with the control device of the entire system to achieve the purpose of real-time monitoring, reduce the labor intensity of manual inspection and sampling, avoid the collapse of the process and equipment in unexpected situations, reduce economic losses, and add a safeguard for the stable operation of the process.

[0054] In the following description, many technical details are provided to help readers better understand the present application. However, those skilled in the art can understand that the technical solution claimed in the present application can be implemented even without these technical details and various changes and modifications based on the following embodiments.

[0055] the term

[0056] As used herein, the terms "microsand" and "microsand particles" are used interchangeably.

[0057] As used herein, the terms "micro-sand sedimentation device" and "micro-sand sedimentation tank" are used interchangeably and refer to the same meaning.

[0058] It should be noted that, in the application documents of the present application, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variant thereof are intended to cover non-exclusive inclusion, so that the process, method, article or equipment including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or equipment. In the absence of more restrictions, the elements defined by the sentence "include one" do not exclude the existence of other identical elements in the process, method, article or equipment including the elements. In the application documents of the present application, if it is mentioned that a certain action is performed according to a certain element, it means that at least the action is performed according to the element, which includes two situations: performing the action only according to the element and performing the action according to the element and other elements. Expressions such as multiple, multiple, multiple, etc. include 2, 2 times, 2 kinds and more than 2, more than 2 times, more than 2 kinds.

[0059] In the present invention, all directional indications (such as up, down, left, right, front, back, etc.) are only used to explain the relative position relationship, movement status, etc. between the components in a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0060] This application has at least one of the following advantages

[0061] (a) The detection system for detecting micro-sand leakage in the micro-sand ballast sedimentation process of the present application collects the sound generated by the micro-sand leakage in the overflow sludge pipeline of the hydrocyclone, and analyzes the sound waves to determine whether the sludge contains micro-sand and its approximate concentration, thereby determining whether there is micro-sand particle leakage in the micro-sand ballast sedimentation device;

[0062] (b) The detection system device for detecting micro-sand leakage in the micro-sand ballasted sedimentation process of the present application detects the sludge flow rate and the sound generated by the leakage of micro-sand in the sludge, thereby determining whether the micro-sand particles are leaking and what kind of fault has occurred in the hydrocyclone, thereby promptly resolving the fault, thereby reducing the labor intensity of manual inspection and sampling, avoiding the collapse of the process and equipment in an emergency, reducing economic losses, and adding a safeguard measure for the stable operation of the process;

[0063] (c) The detection system for detecting micro-sand leakage in the micro-sand ballasted sedimentation process of the present application realizes real-time detection of the sound of micro-sand in the sludge hitting the metal sheet by cleverly designing the sound detection component. At the same time, the metal sheet is cleverly arranged in the laminar flow section in the sludge pipeline, so as to more accurately obtain the approximate concentration of micro-sand particles in the sludge pipeline, thereby judging whether the micro-sand particles are leaking;

[0064] (d) The detection system for detecting micro-sand leakage in the micro-sand ballasted sedimentation process of the present application sets a flow meter in the sludge pipeline to detect the flow rate in the sludge flow, and cooperates with the detection of micro-sand concentration to determine the specific fault of the water flow cyclone of the micro-sand ballasted sedimentation device, so as to take corresponding time, which is efficient in troubleshooting and higher in safety of the entire system.

[0065] Hydrocyclone

[0066] In the micro-sand ballast sedimentation device, the bottom flow of the hydrocyclone is the component with the smallest channel diameter, usually 1-2 cm, which is easy to be blocked. Moreover, this component is the most critical link in the operation of the micro-sand ballast sedimentation device. Once blocked, the circulation system will fail and the overall process will collapse.

[0067] The outlet of the hydrocyclone has a high flow rate. The separated sludge overflows from the top of the system. A small amount of micro-sand is also lost with the sludge. The amount of micro-sand loss is controlled to 3-5g / m per ton of water treatment capacity of the entire system. 3 The concentration of fine sand in the normal reflux system pipeline is maintained in the range of 5-15%, which is very high. When the underflow of the cyclone is blocked, a large amount of fine sand will overflow from the top.

[0068] The hydrocyclone comprises an upper overflow port, a lower sand discharge port and a sand-mud separation channel arranged between the upper overflow port and the lower sand discharge port, the upper overflow port is connected to a sludge overflow pipe, and the mud and sand in the sedimentation tank are pumped into the hydrocyclone by a circulating reflux pump, and the hydrocyclone is configured to separate the mud and sand in the sedimentation tank into micro-sand particles and sludge, the separated sludge flows out of the system through the sludge overflow pipe, and the separated micro-sand particles are discharged from the lower sand discharge port to the micro-sand ballast sedimentation device for reuse; the caliber of the lower sand discharge port of the hydrocyclone is smaller than the caliber of the upper overflow port.

[0069] Micro sand ballast sedimentation device

[0070] The micro-sand ballast sedimentation device is used to remove suspended matter and other pollutants in water, and the micro-sand ballast sedimentation device includes a sedimentation tank, a coagulation tank, a sand injection tank, a flocculation tank, and a reflux component; the reflux component includes a hydrocyclone, a reflux pipeline and a circulating reflux pump, and the hydrocyclone is in fluid communication with the bottom of the sedimentation tank;

[0071] The hydrocyclone comprises an upper overflow port, a lower sand discharge port and a sand-mud separation channel arranged between the upper overflow port and the lower sand discharge port. The micro-sand particles separated by the hydrocyclone are discharged to the sand injection pool through the sand discharge port for reuse.

[0072] The circulation return pump is arranged on the return pipe, and the circulation return pump is configured to pump the mud and sand in the sedimentation tank, and the mud and sand pass through the circulation return pump and enter the hydrocyclone through the return pipe.

[0073] The micro-sand ballast sedimentation device also includes a power component, such as a flocculation tank agitator and a mud scraper.

[0074] The micro-sand sedimentation tank is a ballast sedimentation process. The concentration of ballast in the system is crucial to the normal operation of the system. The main problem with the current application of this process is the serious loss of ballast micro-sand. The main reasons for the loss of micro-sand are (1) the influent particles such as grass sticks, leaves, steel wire and other debris block the bottom flow of the cyclone, which will cause a large amount of micro-sand loss; (2) the micro-sand addition ratio is not appropriate, the concentration is too high and exceeds the cyclone's bearing capacity, a large amount of micro-sand accumulates inside, causing the bottom flow to be blocked, and the micro-sand is lost from the overflow port with the sludge; (3) the unreasonable design leads to the wrong selection of the cyclone, resulting in the blockage of the bottom flow, and the micro-sand is lost from the overflow port with the sludge.

[0075] In a normally operating micro-sand ballast sedimentation tank, the normal loss rate of micro-sand is 1-5g / ton of processing volume, 80% of which is lost outside the system with sludge, and 20% is lost with effluent. Micro-sand should be maintained in the pool within the designed concentration range. Currently, there is no effective means to monitor the micro-sand concentration in the pool in real time. Operators usually judge the micro-sand concentration in the pool by sampling and detecting the bottom flow of the cyclone at irregular intervals. The present invention provides a basic method for directly detecting the loss of micro-sand, so that the micro-sand concentration in the pool can be indirectly known based on the accumulated empirical data under long-term operation, providing a reference for operators to replenish the total amount of micro-sand on a daily basis.

[0076] The present application provides a system for real-time detection of micro-sand loss, which can avoid a large amount of micro-sand loss in the system and provide an additional guarantee measure for the smooth operation of the process.

[0077] A detection system for detecting micro-sand leakage in micro-sand ballast sedimentation process

[0078] See also Figure 1 and Figure 2The detection system of the present application collects the sound generated by the leakage of micro-sand in the overflow sludge pipeline of the hydrocyclone, organizes and analyzes the sound waves, determines whether the sludge contains micro-sand and its approximate concentration, and guides the operation of the equipment through communication with the entire system to achieve the purpose of real-time monitoring. Preferably, the system can monitor important operating parameters of the process (concentration of micro-sand). For example, the system can compare the daily cumulative operating data to find the high and low trends of micro-sand loss; at the same time, it can monitor the occurrence of sudden large-scale losses in real time, and promptly alarm and take action to avoid the expansion of losses. Preferably, the system reduces the labor intensity of manual inspections and sampling, avoids the collapse of processes and equipment in sudden situations, reduces economic losses, and adds a safeguard for the stable operation of the process.

[0079] The present application provides a detection system for detecting micro-sand leakage in a micro-sand ballast sedimentation process, the detection system comprising a micro-sand ballast sedimentation device and a sound collection component; wherein the micro-sand ballast sedimentation device is used to remove suspended matter and other pollutants in water, and the micro-sand ballast sedimentation device comprises a sedimentation tank and a reflux component;

[0080] The return assembly comprises a hydrocyclone, the hydrocyclone is in fluid communication with the bottom of the sedimentation tank, the hydrocyclone comprises an upper overflow port and a lower sand discharge port, the upper overflow port is connected to a sludge overflow pipe, the hydrocyclone is configured to separate mud and sand in the sedimentation tank into micro-sand particles and sludge, the separated sludge flows out of the system through the sludge overflow pipe, and the separated micro-sand particles are discharged from the lower sand discharge port to the micro-sand ballast sedimentation device for reuse;

[0081] The sound collection component includes a micro-sand impact signal collection piece, a sound sensor, and an acoustic wave analyzer. The micro-sand impact signal collection piece is arranged in the sludge overflow pipe. The sound sensor is used to collect real-time sound signals of micro-sand particles in the sludge overflow pipe hitting the micro-sand impact signal collection piece. The real-time sound signal obtained is converted into a real-time sound spectrum by the acoustic wave analyzer. The real-time sound spectrum is compared with the sound spectrum without micro-sand particles in the sludge overflow pipe, so as to determine the concentration of micro-sand particles in the sludge overflow pipe, and then determine whether the separated micro-sand particles leak from the upper overflow port of the hydrocyclone through the sludge overflow pipe to the outside of the system. Preferably, in the present application, the sound sensor is a vibration-based sound sensor.

[0082] To make the purpose, technical solution and advantages of the present invention clearer, the embodiments of the present invention will be further described in detail below in conjunction with the accompanying drawings. It should be understood that these are only some examples that the present invention may take for the reader, but are not intended to limit the scope of the present invention.

[0083] Sound collection component

[0084] See also Figure 1-Figure 3b , the present application provides an embodiment of a sound collection component, specifically,

[0085] A small steel sheet is set in the top overflow pipe (sludge overflow pipe of the hydrocyclone), and the sound sensor is connected to the steel sheet. When the micro-sand content in the water is high, a large amount of micro-sand will hit the steel sheet. The sound produced by the impact is completely different from the noise produced by normal water flow. The sound wave analyzer is used to count the frequencies and amplitudes of different bands, and judge the concentration of micro-sand in the water, so as to determine whether there is a micro-sand leakage.

[0086] The acoustic wave analyzer outputs a 4-20ma signal, or sets a threshold value, outputs a switch signal, and communicates with the micro-sand sedimentation tank control system (for example, a central control device). When it is determined that there is a large amount of micro-sand loss, it guides the sedimentation tank operation to avoid causing greater economic losses.

[0087] Preferably, a metal baffle is provided in the sludge overflow pipe of the hydrocyclone, and the material is selected to be hard steel. Carbon steel, stainless steel, duplex stainless steel or titanium alloy and other materials can be selected according to different water qualities.

[0088] Preferably, the baffle should adopt a circular structure rather than a square or other angular structure to ensure that the tangential flow velocity of the sludge at the edge of the metal baffle is uniform and reduce background noise.

[0089] Preferably, the sludge pipe should be made of soft plastic pipe or steel lined with soft rubber and other materials to ensure that the vibration caused by the collision between the micro-sand and the pipe can be effectively blocked.

[0090] Preferably, the area of ​​the metal baffle should be 10-50% of the cross-sectional area of ​​the pipeline.

[0091] Preferably, the metal baffle is set at the center of the pipeline and in the center of the straight pipeline. The length of the straight pipe section before the metal baffle should be greater than 5 times the pipe diameter; the length of the straight pipe section before the metal baffle should be greater than 5 times the pipe diameter to ensure that the sludge in the pipeline is in a laminar state. Laminar flow refers to a water flow state in which the flow velocity and direction at each point of the pipeline cross section are the same; a straight pipe section refers to a straight pipeline, and there should be no elbows, tees, etc. within a distance of five times the pipe diameter before and after that change the direction of the water flow or affect the uniform flow of the water flow in the pipe cross section.

[0092] Preferably, the metal baffle and the connecting rod are rigidly connected to ensure effective transmission of vibration.

[0093] Preferably, the metal baffle is a hollow structure with a convex surface, and the convex surface is the surface for the micro-sand particles to hit, which is more convenient for sound collection because the metal cavity can amplify the sound of the micro-sand hitting the metal (see Figure 3b ).

[0094] Preferably, the connecting rod and the pipeline are flexibly connected, and flexible materials such as rubber and polyurethane are used to avoid the transmission of sound and vibration in the sludge pipeline and reduce the interference of background noise.

[0095] Preferably, the flow rate in the sludge pipeline is usually 0.8-4m / s. Under high sludge flow rate conditions, a smaller metal baffle should be used, and under low sludge flow rate conditions, a larger metal baffle should be used.

[0096] In one embodiment, for a specific working condition, two basic parameters, the area S of the metal baffle and the flow rate V of the sludge in the sludge overflow pipe, are set in the program to calculate the total amount of sludge collected by the metal baffle per unit time. In other embodiments, a flow meter is provided on the sludge overflow pipe to detect the flow of sludge.

[0097] In other embodiments, for a specific selected hydrocyclone, its pressure and flow are fixed values. The system can calculate the sludge overflow pipe flow rate through the pressure transmitter value at the cyclone inlet, and then calculate the sludge flow in the sludge overflow pipe in combination with the set metal baffle area S.

[0098] In other embodiments, the cyclone is a static component, and all flow size bands are fixed. Each cyclone has a corresponding flow-pressure curve. The flow rate can be known by reading the pressure gauge at the front end of the cyclone, and the flow rate in the sludge overflow pipe can be obtained by converting it with the pipe diameter of the sludge overflow pipe, so as to calculate the sludge flow in the sludge overflow pipe in combination with the area S of the set metal baffle.

[0099] Sound signal analysis

[0100] The solid content of sludge in the sludge overflow pipe of the micro-sand ballast sedimentation device does not exceed 2%. The density of sludge is less than that of water, and the sludge hitting the metal baffle will not produce sound. The particle size of micro-sand is distributed in 80-250um, and the actual density is 2.65g / cm. The sound is only generated when the micro-sand leaks, and for the micro-sand sedimentation tank system, the particles that can produce sound must be micro-sand particles.

[0101] The loss of micro-sand occurs only when the cyclone bottom flow is blocked, and at the same time the flow in the sludge pipeline will increase by 11%-42%.

[0102] The sound sensor is used to collect the real-time sound signal of the micro-sand particles in the sludge overflow pipe hitting the micro-sand impact signal collection piece, and convert the obtained real-time sound signal into a real-time sound spectrum through the acoustic wave analyzer. The real-time sound spectrum is compared with the sound spectrum without micro-sand particles in the sludge overflow pipe, so as to determine the approximate concentration of the micro-sand particles in the sludge overflow pipe, and then judge whether the separated micro-sand particles leak from the upper overflow port of the hydrocyclone through the sludge overflow pipe to the outside of the system.

[0103] In one embodiment, a sound acquisition card is further included, and the sound sensor is connected to the sound acquisition card. The sound sensor acquires real-time sound signals and transmits analog sound signals to the sound acquisition card, which converts the analog signals into digital signals and then transmits them to a connected computer. The sound wave analyzer software on the computer receives digital audio input and performs mathematical operations such as Fourier transform to convert time domain signals into frequency domain representations to generate sound spectrums.

[0104] Optionally, the analysis software calculates the sludge volume collected per unit time through the area S (set value) of the baffle and the pipeline flow rate V (set value), and collects the number of particles in the corresponding time period through the acoustic wave curve to obtain a curve of the change of micro-sand concentration in the sludge, and sets a threshold for signal output.

[0105] Optionally, the concentration is indirectly reflected by the frequency of the micro-sand particles hitting the metal baffle in a unit time. Optionally, the sound frequencies generated by the collision of micro-sand of different particle sizes with metal baffles of different area masses are different. Through software analysis and processing, the frequency of the effective frequency is captured to determine the approximate concentration or content of the micro-sand particles.

[0106] This application provides the sound spectrum records collected when there are no micro-sand particles in the sludge pipeline. Figure 4 When there are micro sand particles in the overflow pipe, the collected sound spectrum records are as follows Figure 5 , Figure 5 The sound spectrum of the micro-sand particles hitting the baffle can be identified at the red arrow in the figure. And when the cyclone underflow is suddenly blocked, the simulated micro-sand concentration change curve in the sludge is Figure 6 The sudden blockage at the bottom of the cyclone will cause the concentration of micro-sand in the sludge pipe to suddenly increase, and maintain at a higher range for a period of time until the concentration of micro-sand in the sedimentation tank decreases, and the concentration of micro-sand in the sludge pipe also decreases slowly. There are concentration fluctuations in the sludge pipe in a short period of time, and the overall trend in the sludge pipe is still normal concentration-sudden increase-slow decrease.

[0107] Central control unit

[0108] In the detection system of the present application, a central control device is provided, and the central control device includes a processor.

[0109] The central control device is in communication connection with the sound collection component, and the central control device controls the operation of the circulation reflux pump and the power component in the micro-sand ballast sedimentation device;

[0110] The cause of the failure of the micro-sand ballast sedimentation device is determined by detecting the sludge flow in the sludge overflow pipe and the concentration of the micro-sand particles in the sludge overflow pipe. The cause of the failure includes one of the following: (i) the bottom of the hydrocyclone is partially blocked; (ii) the bottom of the hydrocyclone is completely blocked.

[0111] When it is detected that the sludge flow in the sludge overflow pipe increases and the concentration of the micro-sand particles in the sludge overflow pipe increases slowly, the hydrocyclone underflow is partially blocked, and the central control device adjusts the frequency of the circulation return pump and increases the speed of the circulation return pump, thereby increasing the inlet pressure of the hydrocyclone;

[0112] When it is detected that the sludge flow in the sludge overflow pipe suddenly increases (increase range 11-42%), and the concentration of micro-sand particles in the sludge overflow pipe increases sharply, at this time, the bottom of the cyclone is completely blocked. When the situation does not change within the set time (such as 10 seconds), the processor of the central control device performs the following operations to immediately shut down the flocculation tank agitator and the scraper, and maintain the circulation pump for a specific time (such as 60 seconds) (the cessation of the flocculation tank agitator causes the stirring in the tank to lose power, and the micro-sand is deposited at the bottom of the flocculation tank for temporary storage; the cessation of the scraper causes the micro-sand deposited in the sedimentation tank to be dispersed on the entire bottom surface of the sedimentation tank and cannot be gathered to the central mud bucket, thereby causing the concentration of sand in the micro-sand circulation pipe to drop sharply, reducing the micro-sand content entering the cyclone to achieve the purpose of flushing the cyclone).

[0113] When the sludge flow is restored - the central control unit starts the flocculation tank agitator and scraper and resumes operation.

[0114] When the sludge flow rate does not recover, the blockage at the bottom of the cyclone is not caused by a large amount of micro-sand accumulation, but by large particles. The central control device executes a shutdown operation and manual cleaning.

[0115] All documents mentioned in this application are considered to be included in the disclosure of this application as a whole, so that they can be used as the basis for modification when necessary. In addition, it should be understood that after reading the above disclosure of this application, those skilled in the art can make various changes or modifications to this application, and these equivalent forms also fall within the scope of protection claimed in this application.

Claims

1. A detection system for detecting micro-sand leakage in a micro-sand ballast sedimentation process, characterized in that: The detection system includes a micro-sand ballast sedimentation device and a sound collection component; Wherein, the micro-sand ballast sedimentation device comprises a sedimentation tank and a reflux component; The return assembly comprises a hydrocyclone, the hydrocyclone is in fluid communication with the bottom of the sedimentation tank, the hydrocyclone comprises an upper overflow port and a lower sand discharge port, the upper overflow port is connected to a sludge overflow pipe, the hydrocyclone is configured to separate mud and sand in the sedimentation tank into micro-sand particles and sludge, the separated sludge flows out of the system through the sludge overflow pipe, and the separated micro-sand particles are discharged from the lower sand discharge port to the micro-sand ballast sedimentation device for reuse; The sound collection component includes a micro-sand impact signal collection piece, a sound sensor, and an acoustic wave analyzer. The micro-sand impact signal collection piece is arranged in the sludge overflow pipe. The sound sensor is used to collect real-time sound signals of micro-sand particles in the sludge overflow pipe impacting the micro-sand impact signal collection piece. The obtained real-time sound signal is converted into a real-time sound spectrum by the acoustic wave analyzer. The real-time sound spectrum is compared with a sound spectrum without micro-sand particles in the sludge overflow pipe, so as to determine the concentration of micro-sand particles in the sludge overflow pipe, and then determine whether the separated micro-sand particles leak from the upper overflow port of the hydrocyclone through the sludge overflow pipe to the outside of the system; The sludge overflow pipe includes a vertical section, a curved section, and a horizontal straight pipe section, the horizontal straight pipe section includes a laminar flow section, the vertical section is connected to the upper overflow port of the hydrocyclone, the curved section is located between the vertical section and the horizontal straight pipe section, the micro-sand impact signal collection piece is arranged in the laminar flow section, and the distance between the position where the micro-sand impact signal collection piece is located and the connection between the curved section and the horizontal straight pipe section is greater than 5 times the diameter of the sludge overflow pipe, so that the sludge in the sludge overflow pipe at the position where the micro-sand impact signal collection piece is located is in a laminar flow state.

2. The detection system according to claim 1, characterized in that: The micro-sand impact signal collection piece is a circular structure, and the area of ​​the micro-sand impact signal collection piece accounts for 10%-50% of the cross-sectional area of ​​the sludge overflow pipe.

3. The detection system according to claim 2, characterized in that: The micro-sand impact signal collection piece is arranged at the center of the sludge overflow pipe.

4. The detection system according to claim 3, characterized in that: The particle size of the micro sand particles is distributed in the range of 80-250 um.

5. The detection system according to claim 4, characterized in that: The sound collection component also includes a sound transmission element, one end of which is connected to the micro-sand impact signal collection sheet, and the other end of which is connected to the sound sensor.

6. The detection system according to claim 5, characterized in that: The sound collection assembly also includes an interface element, the sludge overflow pipe includes a first pipe and a second pipe, the interface element is arranged between the first pipe and the second pipe, the sound transmission element is connected to the interface element, and the interface element is sealedly connected to the first pipe and the second pipe.

7. The detection system according to claim 1, characterized in that: The micro-sand impact signal collection piece is a metal collection piece.

8. The detection system according to claim 1, wherein: The reflux component also includes a circulating reflux pump, which is configured to pump mud and sand in the sedimentation tank into the hydrocyclone. The cause of the failure of the micro-sand ballast sedimentation device is determined by detecting the sludge flow in the sludge overflow pipe and the concentration of micro-sand particles in the sludge overflow pipe. The cause of the failure includes one of the following: (i) the bottom of the hydrocyclone is partially blocked; (ii) the bottom of the hydrocyclone is completely blocked.

9. The detection system according to claim 8, characterized in that: The system further comprises a central control device, which is in communication with the sound collection component and controls the operation of the circulation reflux pump and the power component in the micro-sand ballast sedimentation device; in When it is detected that the sludge flow in the sludge overflow pipe increases and the concentration of the micro-sand particles in the sludge overflow pipe increases slowly, the central control device adjusts the frequency of the circulation return pump and increases the speed of the circulation return pump, thereby increasing the inlet pressure of the hydrocyclone; When it is detected that the sludge flow in the sludge overflow pipe suddenly increases and the concentration of the micro-sand particles in the sludge overflow pipe increases sharply, the central control device shuts down the flocculation tank agitator and the scraper in the micro-sand ballast sedimentation device within the set time, and maintains the circulation reflux pump working for a predetermined time. If it is detected that the sludge flow has not decreased, the hydrocyclone is cleaned.

10. A detection device for detecting leakage of micro-sand particles in a micro-sand ballast sedimentation device, characterized in that: The detection equipment includes a sound collection component, and the micro-sand ballast sedimentation device includes a sedimentation tank and a reflux component. The return assembly comprises a hydrocyclone, the hydrocyclone is in fluid communication with the bottom of the sedimentation tank, the hydrocyclone comprises an upper overflow port and a lower sand discharge port, the upper overflow port is connected to a sludge overflow pipe, the hydrocyclone is configured to separate mud and sand in the sedimentation tank into micro-sand particles and sludge, the separated sludge flows out of the micro-sand ballast sedimentation device through the sludge overflow pipe, and the separated micro-sand particles are discharged from the lower sand discharge port to the micro-sand ballast sedimentation device for reuse; The sound collection component includes a micro-sand impact signal collection piece, a sound sensor, and an acoustic wave analyzer. The micro-sand impact signal collection piece is arranged in the sludge overflow pipe. The sound sensor is used to collect real-time sound signals of micro-sand particles in the sludge overflow pipe impacting the micro-sand impact signal collection piece. The obtained real-time sound signal is converted into a real-time sound spectrum by the acoustic wave analyzer. The real-time sound spectrum is compared with a sound spectrum without micro-sand particles in the sludge overflow pipe, so as to determine the concentration of micro-sand particles in the sludge overflow pipe, and further determine whether the separated micro-sand particles leak from the upper overflow port of the hydrocyclone through the sludge overflow pipe to the outside of the micro-sand ballast sedimentation device; The sludge overflow pipe includes a vertical section, a curved section, and a horizontal straight pipe section, the horizontal straight pipe section includes a laminar flow section, the vertical section is connected to the upper overflow port of the hydrocyclone, the curved section is located between the vertical section and the horizontal straight pipe section, the micro-sand impact signal collection piece is arranged in the laminar flow section, and the distance between the position where the micro-sand impact signal collection piece is located and the connection between the curved section and the horizontal straight pipe section is greater than 5 times the diameter of the sludge overflow pipe, so that the sludge in the sludge overflow pipe at the position where the micro-sand impact signal collection piece is located is in a laminar flow state.

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