Polycarboxylate superplasticizer compounding production line

Abstract

The invention relates to a polycarboxylate superplasticizer compounding production line. The production line comprises an intelligent raw material pretreatment unit, a multi-component precise proportioning unit, a gradient temperature control compounding reaction unit, an online quality monitoring feedback unit and a finished product self-adaptive filling unit which are connected in sequence. The multi-component precise proportioning unit is internally provided with a dynamic proportioning adjusting system, and the feeding amount can be corrected according to the solid content deviation of raw materials and the target fluidity; the gradient temperature control compound reaction unit realizes temperature and speed coordinated regulation and control through a sectional temperature control module and a stirring speed linkage device; and the online quality monitoring feedback unit forms closed-loop control with the above two units by means of a near infrared spectrum detection module. The invention aims to solve the problem that the existing production line lacks the dynamic ratio adjustment of the actual solid content deviation of the raw material and the target fluidity, the reaction stage temperature control and stirring rate cooperative regulation and control and the online detection closed-loop control; therefore, the problems of low proportioning precision, poor reaction process controllability and large performance fluctuation of the water reducing agent are solved.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of water-reducing agent compounding production line, and relates to a polycarboxylate water-reducing agent compounding production line. BACKGROUND

[0002] As a key high-performance admixture in the concrete industry, polycarboxylate water-reducing agent is widely used in major infrastructure construction such as high-rise buildings, long-span bridges, and water conservancy projects due to its low dosage, high water-reducing rate, good slump retention, and green environmental protection. The production core is to compound polycarboxylate mother liquor with various functional small materials (such as retarder, air entraining agent, water retaining agent, etc.) in a specific ratio, and to prepare it through precise reaction control. The product performance directly depends on the synergistic control effect of raw material ratio precision, reaction temperature and stirring rate in the compounding process, as well as the real-time control of key indicators of finished products. Therefore, the technical advancement of the compounding production line is the core prerequisite for ensuring the stability of the quality of water-reducing agent.

[0003] However, the existing polycarboxylate water-reducing agent compounding production line still faces many technical bottlenecks in actual production and application, which seriously restricts the stability of product performance. First of all, the problem of raw material solid content fluctuation is prominent. Polycarboxylate mother liquor is prone to water evaporation or absorption due to changes in environmental temperature and humidity during storage and transportation, and small materials may also deviate from the effective ingredient content due to caking and moisture absorption. However, the existing production line mostly adopts a fixed ratio of material feeding mode, without considering the difference between the actual solid content of the raw material and the theoretical value, and without correlating the dynamic adjustment of the target fluidity requirement of concrete, resulting in deviation of the actual compounding ratio from the design value, directly causing fluctuations in the core performance of water-reducing agent such as water-reducing efficiency and slump retention. Secondly, the reaction process is poorly controllable. The compounding reaction needs to go through multiple stages such as raw material mixing, functional component dissolution, and intermolecular synergistic action. The requirements for temperature and stirring rate are significantly different at different stages. However, the existing production line mostly adopts single constant temperature control and fixed stirring rate, which cannot realize the staged synergistic control of temperature and stirring rate, and is prone to problems such as insufficient reaction of local raw materials and uneven distribution of components. In addition, there is a lack of online detection closed-loop control. The existing production line mostly relies on offline sampling detection, and the detection results have a lag, which cannot provide real-time feedback and correction of the deviation in the production process, further exacerbating the instability of product quality.

[0004] In view of the above problems, a search is conducted, and a polycarboxylate water-reducing agent compounding production line is disclosed in Chinese Utility Model Patent CN203498262U. The patent sets up polycarboxylate mother liquor metering tank, small material metering tank, and water metering tank, and installs metering sensors at the bottom of each metering tank. The core principle is to realize quantitative feeding of raw materials by combining the controller with the independent metering tank and the sensor, to reduce the deviation of the compounding tank This addresses the impact of weighing accuracy, thereby improving proportioning accuracy. The advantage of this solution lies in resolving the issues caused by integrating weighing equipment with the mixing tank in traditional production lines. While addressing interference issues has improved the accuracy of raw material metering to some extent, its drawback is that it can only measure a fixed amount based on the theoretical content of the raw materials, without considering the actual solid content fluctuations of the raw materials or linking them to the target performance requirements of concrete. It cannot achieve dynamic mix proportion adjustment, and it does not involve the temperature control and stirring coordination of the reaction process, as well as the online detection and feedback mechanism, making it difficult to solve the core problem of large fluctuations in product performance.

[0005] A comprehensive analysis of existing technologies reveals that while patent CN203498262U and other existing solutions have made improvements in terms of metering accuracy and manual adjustments, they have not fundamentally solved the core problems of the correlation between the dynamic deviation of raw material solid content and target performance, the staged synergistic control of the reaction, and online closed-loop feedback. Therefore, it is necessary to construct a compounding production line that integrates intelligent raw material pretreatment, dynamic multi-component ratio, gradient temperature control and stirring synergistic control, and online quality monitoring feedback, through real-time... The compensated dynamic proportioning adjustment system corrects the deviation of raw material solid content and correlates it with the target fluidity. It uses a segmented temperature control module and a stirring rate linkage device to achieve fine control of the reaction process. Combined with near-infrared spectroscopy online detection, it forms a closed-loop control, thereby completely solving the technical problems of low proportioning accuracy, poor reaction controllability, and large product performance fluctuations in existing production lines, and meeting the stringent requirements of high-performance concrete for the quality stability of water-reducing agents. Summary of the Invention

[0006] This invention provides a polycarboxylate superplasticizer compounding production line, which solves the problems of existing polycarboxylate superplasticizer compounding production lines that lack dynamic ratio adjustment based on the actual solid content deviation of raw materials and target flowability, coordinated control of reaction stage temperature and stirring rate, and online detection closed-loop control. This results in low mixing accuracy and poor controllability of the reaction process, which in turn leads to technical problems such as large fluctuations in the performance of water-reducing agents.

[0007] To solve the above problems, the technical solution adopted by the invention is as follows: A polycarboxylate superplasticizer compounding production line includes, in sequence, a raw material intelligent pretreatment unit, a multi-component precise proportioning unit, a gradient temperature-controlled compounding reaction unit, an online quality monitoring and feedback unit, and a finished product adaptive filling unit; the multi-component precise proportioning unit is equipped with a real-time... A compensated dynamic proportioning adjustment system is provided; the gradient temperature-controlled compounding reaction unit is equipped with a segmented temperature control module and a stirring rate linkage device; the online quality monitoring feedback unit forms a closed-loop control with the multi-component precise proportioning unit and the gradient temperature-controlled compounding reaction unit through a near-infrared spectroscopy detection module; wherein, the dynamic proportioning adjustment system can automatically correct the feed amount of each component according to the actual solid content deviation after raw material pretreatment and the target flowability requirements; the segmented temperature control module can preset temperature curves according to different stages of the compounding reaction and achieve coordinated control of stirring rate and reaction temperature through the stirring rate linkage device.

[0008] The principle and advantages of this solution are as follows: The polycarboxylate mother liquor is processed through an intelligent raw material pretreatment unit. After the raw materials undergo pretreatment, the actual solid content of each raw material is simultaneously detected and recorded, such as the solid content deviation of the mother liquor due to storage environment and the changes in the effective components of small materials after moisture absorption; subsequently, the multi-component precise proportioning unit is built-in based on real-time... The compensated dynamic proportioning adjustment system, based on the actual solid content data obtained from the pretreatment unit and combined with the target fluidity requirements of water-reducing agents for concrete engineering (such as the fluidity index of the water-reducing agent corresponding to the slump of 180±20mm required for C60 high-strength concrete), automatically corrects the dosage of mother liquor, additives, and clean water through a preset algorithm. For example, when the actual solid content of the mother liquor is 2% higher than the design value, the system can automatically reduce the dosage of mother liquor and adjust the proportion of clean water accordingly to ensure accurate basic proportioning of the compound. In the gradient temperature-controlled compound reaction unit, the segmented temperature control module presets differentiated temperature curves according to different stages of the compound reaction, such as the initial mixing stage, the functional component dissolution stage, and the molecular synergistic reaction stage. For example, the mixing stage is 30-35℃, the dissolution stage is 40-45℃, and the synergistic reaction stage is 38-42℃. Simultaneously, the stirring rate linkage device automatically matches the stirring rate according to the current stage temperature (e.g., 60-80 r / min is used in the low-temperature mixing stage to prevent raw material splashing, and 120-150 r / min is used in the high-temperature dissolving stage to accelerate dissolution), achieving coordinated control of temperature and stirring. The online quality monitoring feedback unit collects key indicators such as the composition, concentration, and flowability of materials in real time during the compounding process through the near-infrared spectroscopy detection module. If a certain indicator is detected to deviate from the preset range, such as the flowability being lower than the target value by 5%, a feedback signal is immediately sent to the multi-component precise proportioning unit and the gradient temperature control compounding reaction unit to adjust the feeding amount or temperature / stirring parameters, forming a closed-loop control. Finally, the finished product adaptive filling unit automatically matches the filling rate and packaging specifications according to the finished product quality confirmed by online detection, completing the entire production process.

[0009] Compared with existing technologies, in terms of proportioning accuracy control, existing technologies can only achieve fixed-quantity measurement based on the theoretical content of raw materials, and cannot cope with the dynamic correlation between fluctuations in the solid content of raw materials and target performance requirements. This solution, however, achieves real-time... Dynamic proportioning adjustment linked to compensation and target flowability reduces proportioning error from ±3% in existing technologies. 5% decreased to ±0.5% For example, in a high-speed railway bridge concrete project, the water-reducing agent produced using this method can ensure that the slump loss of the concrete over time (1 hour) is controlled within 20 mm, while the slump loss of water-reducing agents produced using existing technology often reaches 30 mm. The 50mm diameter effectively avoids insufficient concrete strength caused by mix proportion deviations. Regarding the controllability of the reaction process, existing technologies often employ a single constant temperature and fixed stirring rate, which can easily lead to incomplete local reactions, such as undissolved clumps of small materials. This solution, through segmented temperature control and coordinated stirring rate regulation, increases the solubility of functional components from 85% in existing technologies. The accuracy rate increased from 90% to over 98%, and the reaction cycle for compounding was shortened by 15%. For example, during high-temperature production in summer, existing technologies often lead to retarder failure due to the inability to dynamically adjust temperature control parameters. This solution, however, ensures stable retarding effects through staged temperature control, keeping the initial setting time deviation of concrete within ±30 minutes. Regarding closed-loop quality control, existing technologies rely on offline sampling and testing, making real-time correction of production deviations difficult. This solution, through online near-infrared spectroscopy detection and closed-loop feedback, can complete indicator detection and synchronous parameter adjustment within 30 seconds, reducing the defect rate from 2% in existing technologies. The concentration of water-reducing agents is reduced from 3% to below 0.1%, while avoiding batch product scrapping due to offline detection delays. Furthermore, this solution offers unexpected advantages, enabling flexible production of water-reducing agents with different performance requirements. For example, the same production line can quickly switch between producing water-reducing agents for ordinary ready-mixed concrete (target flowability 150mm) and high-performance pumped concrete (target flowability 220mm) by adjusting the target flowability parameters, without replacing equipment or significantly adjusting the process. Existing technologies typically require re-adjusting the production line for different products, with a switchover cycle as long as 4... This solution significantly improves production flexibility and efficiency within 6 hours.

[0010] Furthermore, the intelligent raw material pretreatment unit includes a raw material screening component, an impurity removal component, and an online solid content detection component. The online solid content detection component uses a microwave moisture meter with a detection accuracy of ±0.1%, and the detection data is transmitted to the dynamic proportioning adjustment system in real time. The raw material screening component can filter out small agglomerated particles, and the impurity removal component can adsorb metal impurities, preventing both from affecting the uniformity of compounding and the performance of the water-reducing agent. Using a microwave moisture meter with a detection accuracy of ±0.1% as the online solid content detection component not only far exceeds the accuracy and efficiency of traditional offline detection, but also can synchronously transmit real-time detection data to the dynamic proportioning adjustment system. This allows the system to instantly obtain minute deviations in the solid content of the raw materials, such as a 0.2% fluctuation in the solid content of the mother liquor, and accurately correct the feed amount based on this. This avoids proportioning inaccuracies caused by the accumulation of raw material solid content deviations from the source, while saving the time-consuming manual offline detection process. This ensures the accuracy of dynamic proportioning adjustment and improves overall production efficiency.

[0011] Furthermore, the multi-component precise proportioning unit includes at least three independent raw material storage tanks, a variable frequency metering pump, and a flow sensor. The control signal for the variable frequency metering pump is output by the dynamic proportioning adjustment system, and the flow control accuracy reaches [value missing]. The multi-component precision proportioning unit uses at least three independent raw material storage tanks to store polycarboxylate mother liquor, Different raw materials, such as water, are processed to prevent cross-contamination during storage, ensuring the initial purity of the raw materials. The core variable frequency metering pump uses the control signal output from the dynamic proportioning adjustment system as an instruction, combined with a flow sensor to provide real-time feedback on the actual delivery volume, forming an "instruction-output" system. Precision delivery The control link features real-time monitoring, and its flow control accuracy reaches ±0.2%FS, enabling strict control of deviations in the delivery volume of each raw material within an extremely small range. For example, when the dynamic proportioning system instructs the mother liquor delivery volume to be 800 kg based on the deviation of the raw material solid content, the actual delivery volume of the variable frequency metering pump can be stably maintained between 798.4 kg and 801.6 kg, which is far superior to the deviation level of traditional metering equipment of ±1%FS. This ensures that the corrected feed amount calculated by the dynamic proportioning system is accurately executed, completely avoiding the inaccuracy of compounding ratio caused by deviation in the delivery process. At the same time, the adjustable speed characteristics of the variable frequency metering pump and the isolation design of the independent storage tank can also flexibly adapt to the component switching needs of different types of water-reducing agents. For example, when switching from the production of ordinary water-reducing agents to high-efficiency water-reducing agents, it is only necessary to adjust the metering pump control signal through the system to change the delivery volume of each component without replacing the equipment, thus balancing proportioning accuracy and production flexibility.

[0012] Furthermore, the segmented temperature control module of the gradient temperature-controlled compound reaction unit includes a heating section, a constant temperature section, and a cooling section, with each section having a temperature control accuracy of [insert accuracy here]. The stirring rate adjustment range of the stirring rate linkage device is: Furthermore, the linkage response time between stirring rate and reaction temperature is less than 2 seconds. The segmented temperature control module of the gradient temperature control compounding reaction unit, through the orderly connection of heating, constant temperature, and cooling sections, can accurately match the temperature requirements of each stage of the compounding reaction. The heating section quickly heats the material to the temperature required for the functional components to dissolve, such as 40℃. The constant temperature section maintains this temperature to ensure sufficient dissolution. The cooling section cools the material to the suitable temperature for molecular co-reaction, such as 38℃. The temperature control accuracy of each section reaches ±0.5℃, which can avoid incomplete component reaction caused by temperature fluctuations. For example, if the temperature is too low, the retarder dissolves slowly, and if it is too high, the molecular chains of the mother liquor break. The matching stirring rate linkage device can adjust the stirring rate from 60 to 200 r / min to adapt to different reaction stages, such as a low speed of 60-80 r / min in the heating section. To prevent material splashing, the constant temperature section uses a high-speed 120-150 r / min to accelerate dissolution, and the linkage response time between the stirring rate and the reaction temperature is less than 2 seconds. This means that when the temperature control module switches to the next temperature section, the stirring rate can be adjusted instantaneously. For example, when switching from the heating section of 35℃ to the constant temperature section of 40℃, the stirring rate can be increased from 80 r / min to 140 r / min within 2 seconds, avoiding local overheating or uneven mixing of materials due to asynchronous temperature and stirring. This combination of high-precision temperature control and instantaneous linkage stirring control can ensure that the compounding reaction is in the optimal environment throughout, improving the stability of the water-reducing agent performance. For example, the flowability deviation of the same batch of products can be controlled within ±3 mm. It can also shorten the reaction cycle. Compared with the traditional production line with single temperature control and fixed stirring rate, the reaction efficiency can be improved.

[0013] Furthermore, the near-infrared spectroscopy detection module of the online quality monitoring feedback unit can simultaneously detect the solid content, pH value, and polymer molecular weight distribution of the compound system, with a detection cycle of 15 seconds. After 30 seconds, the detected data, once analyzed and processed, generates adjustment commands that are transmitted to the multi-component precise proportioning unit and the gradient temperature-controlled compounding reaction unit. The near-infrared spectroscopy detection module of the online quality monitoring feedback unit can simultaneously detect three key indicators of the compounding system: solid content, pH value, and polymer molecular weight distribution. Compared to traditional offline detection methods that require separate solid content analyzers, pH meters, and gel permeation chromatographs (GPC) (where single-indicator detection cycles often exceed 30 minutes and multi-indicator data cannot be acquired simultaneously), this method offers significant advantages. The short 30-second detection cycle can capture parameter changes in the compounding process in real time. For example, when the solid content of the compounding system is lower than the preset value by 0.3% due to a slight deviation in the mother liquor feeding, the pH value deviates from the standard range (e.g., 7.5-8.5) by 0.2 units, or the polymer molecular weight distribution widens, the module can quickly identify these changes and generate targeted adjustment instructions through data analysis. These instructions can be instantly transmitted to the multi-component precise proportioning unit and the gradient temperature-controlled compounding reaction unit. For example, an instruction can be sent to the proportioning unit to "fine-tune the mother liquor delivery volume by 0.5% and add 0.1% alkaline regulator," and to the temperature control unit to "increase the reaction temperature by 1°C to optimize the polymer molecular structure," forming a "real-time detection" mechanism. Quick Analysis A closed-loop feedback mechanism for "precise control." This combination of simultaneous multi-indicator detection and real-time control avoids the lag caused by traditional offline detection (which often requires 2...). The system can prevent batches of defective products caused by 4h (4 hours), but it can also ensure product performance stability at the molecular level by synchronously monitoring molecular weight distribution, a core indicator that affects the dispersibility and slump retention of water-reducing agents. For example, in a certain batch of production, the module detected that the molecular weight distribution width increased from 1.8 to 2.2, and promptly instructed the temperature control unit to adjust the cooling rate so that the molecular weight distribution returned to a reasonable range. As a result, the slump retention of the product in concrete applications was improved by 10%, which is far better than the performance fluctuations caused by the inability to intervene in time under traditional detection methods.

[0014] Furthermore, the dynamic proportioning adjustment system employs a proportioning correction algorithm based on the deviation of raw material solid content, the specific formula of which is: in, The corrected feed amount for the i-th component (unit: kg). The initial feed amount (in kg) for the i-th component. The standard solids content (in %) of the i-th component. The actual solid content (in %) of the i-th component after raw material pretreatment. The target flow rate (unit: mm) of the compound system. The current flowability of the compound system obtained from online detection (unit: mm); Simultaneously, a deviation factor between the actual solid content and the standard solid content of the raw material is introduced. Feedback factor between target flowability and current flowability A dual-dimensional dynamic correction mechanism was constructed: It real-time offsets solid content fluctuations caused by changes in storage environment and batch differences during raw material pretreatment, such as deviations in the proportion of effective components due to the evaporation or dilution of mother liquor water, ensuring that the actual input proportion of each component matches the design value from the source; and it reverse-calibrates the feed amount through online flowability detection results, forming an instant response closed loop of "raw material state - proportioning parameters - product performance," avoiding flowability deviations from the target value due to implicit differences in raw materials, such as fluctuations in molecular weight distribution. This algorithm enables the system to control the flowability deviation of the compound system within ±3mm even under complex operating conditions with raw material solid content fluctuations of ±5% and ambient temperature changes of ±3℃. Compared with the traditional method relying solely on fixed measurement, the proportioning accuracy is improved by more than 40%, significantly reducing product performance fluctuations caused by raw material instability, while also reducing the lag and subjectivity of manual adjustments, achieving precise and intelligent control of the water-reducing agent compounding process.

[0015] Furthermore, in the gradient temperature-controlled compound reaction unit, the synergistic regulation of the stirring rate and the reaction temperature is achieved using the following correlation formula:

[0016] in This represents the current stirring rate (unit: r / min). Reference temperature The stirring rate is (in r / min), where k is the rate temperature coefficient. The range of values ​​is T represents the current reaction temperature (unit: °C). The reference temperature for the compounding reaction (unit: °C, range: 45-55 °C) is used to establish a linear dynamic correlation mechanism between temperature and stirring rate, enabling the stirring intensity to adapt in real time to changes in reaction temperature: when the reaction temperature is higher than the reference temperature... When the temperature increases, the stirring rate decreases linearly with increasing temperature according to the coefficient k, which can avoid excessive local shear force in the system caused by excessive stirring at high temperatures, and prevent polymer molecular chain breakage or cross-linking structure destruction; when the temperature is below At this time, the stirring rate increases linearly with decreasing temperature, which can compensate for the decrease in the diffusion rate of raw materials at low temperatures by enhancing stirring, ensuring uniform mixing of the reaction system. This synergistic regulation precisely matches the inherent law in the polycarboxylate superplasticizer compounding reaction that "temperature affects reaction activity and stirring affects mass transfer efficiency". Within the reference temperature range of 45-55℃ and the temperature fluctuation range of ±10℃, the uniformity of the reaction system can be improved by more than 30%, effectively solving the contradiction that "high temperature easily leads to a widening of the molecular weight distribution of the product, and low temperature easily leads to incomplete local reaction" under the traditional constant temperature fixed stirring method. Ultimately, the water reduction rate fluctuation of the compounded product is controlled within ±1.5%, improving the stability and consistency of product performance.

[0017] Furthermore, the finished product adaptive filling unit includes a filling volume detection component, an automatic sealing component, and a non-conforming product diversion component. The filling volume detection component uses a weighing sensor, achieving a filling accuracy of ±0.3%. The non-conforming product diversion component can automatically divert non-conforming finished products to a recycling tank based on the detection results of the online quality monitoring feedback unit, with a diversion response time of less than 1 second. The high-precision filling accuracy of ±0.3% achieved through the high-precision weighing sensor ensures the consistency of the filling volume for each batch of products, avoiding the problems associated with traditional volumetric filling methods due to product variations. The measurement deviations caused by variations meet the downstream construction requirements for precise control of water-reducing agent dosage. Simultaneously, the real-time linkage between the non-conforming product diversion component and the online quality monitoring feedback unit enables automatic diversion of non-conforming products within one second. This avoids the quality risks caused by non-conforming products entering the market and achieves material recycling by immediately diverting them to the recovery tank, reducing material waste. This combination of high-precision measurement and real-time quality screening improves the consistency and reliability of products leaving the factory while reducing production and quality control costs. It forms a final, precise control over product quality from the end of production, creating a closed loop with the front-end dynamic proportioning and synergistic reaction control, comprehensively ensuring the efficient operation of the production line.

[0018] Furthermore, it also includes a central control system, which is communicatively connected to the raw material intelligent pretreatment unit, the multi-component precise proportioning unit, the gradient temperature-controlled compounding reaction unit, the online quality monitoring and feedback unit, and the finished product adaptive filling unit. This central control system enables monitoring of operating parameters, data storage, and fault alarms for each unit of the production line, and supports remote operation and maintenance and parameter adjustment. Through comprehensive communication with each core unit of the production line, it breaks through the limitations of traditional production line decentralized control and information silos: on the one hand, it can collect real-time solid content data from raw material pretreatment, feeding parameters for multiple proportions, temperature control and stirring data from the compounding reaction, online monitoring quality indicators, and metering information from the filling stage, achieving centralized monitoring and data traceability of the entire process's operating parameters, facilitating rapid identification of potential problems in each stage; the fault alarm function can trigger an immediate reminder when any unit parameter deviates from the preset range. Combined with remote operation and maintenance and parameter adjustment capabilities, fault diagnosis and process optimization can be completed without on-site operation, significantly shortening downtime for maintenance and improving the continuous operation efficiency of the production line. This centralized and remote control design not only strengthens the precise management and control of the entire compounding process, but also reduces the cost of manual intervention and operational errors, providing core support for the standardization and intelligentization of polycarboxylate superplasticizer production.

[0019] Furthermore, the central control system incorporates a production data traceability module, capable of recording raw material information, proportioning parameters, reaction process parameters, quality inspection data, and filling information for each batch of products. Data storage is maintained for at least three years, and full-process data traceability is supported via product batch numbers. When downstream product performance abnormalities occur, the system can quickly trace back to the source of raw materials, proportioning parameters, reaction conditions, and other key data for that batch using the batch number, accurately pinpointing the problem and providing a basis for quality improvement. Long-term data accumulation can also be used to analyze the correlation between different raw material batches, process parameters, and product performance, providing data support for optimizing production processes and improving product stability. Simultaneously, the at least three-year storage period meets the industry's timeliness requirements for product quality traceability, protecting the rights of downstream users and providing reliable data evidence for enterprises to handle quality inspections and process verification scenarios. This reflects the standardization and responsibility of the production process and further strengthens the full lifecycle management of product quality. Attached Figure Description

[0020] Figure 1 This is a flowchart of the present invention; Detailed Implementation Example 1 As attached Figure 1 As shown, a polycarboxylate superplasticizer compounding production line includes, in sequence, a raw material intelligent pretreatment unit, a multi-component precise proportioning unit, a gradient temperature-controlled compounding reaction unit, an online quality monitoring and feedback unit, and a finished product adaptive filling unit; the multi-component precise proportioning unit is equipped with a real-time... A compensated dynamic proportioning adjustment system is provided; the gradient temperature-controlled compounding reaction unit is equipped with a segmented temperature control module and a stirring rate linkage device; the online quality monitoring feedback unit forms a closed-loop control with the multi-component precise proportioning unit and the gradient temperature-controlled compounding reaction unit through a near-infrared spectroscopy detection module; wherein, the dynamic proportioning adjustment system can automatically correct the feed amount of each component according to the actual solid content deviation after raw material pretreatment and the target flowability requirements; the segmented temperature control module can preset temperature curves according to different stages of the compounding reaction and achieve coordinated control of stirring rate and reaction temperature through the stirring rate linkage device.

[0021] The polycarboxylate mother liquor is processed through an intelligent raw material pretreatment unit. After the raw materials undergo pretreatment, the actual solid content of each raw material is simultaneously detected and recorded, such as the solid content deviation of the mother liquor due to storage environment and the changes in the effective components of small materials after moisture absorption; subsequently, the multi-component precise proportioning unit is built-in based on real-time... The compensated dynamic proportioning adjustment system, based on the actual solid content data obtained from the pretreatment unit and combined with the target fluidity requirements of water-reducing agents for concrete engineering (such as the fluidity index of the water-reducing agent corresponding to the slump of 180±20mm required for C60 high-strength concrete), automatically corrects the dosage of mother liquor, additives, and clean water through a preset algorithm. For example, when the actual solid content of the mother liquor is 2% higher than the design value, the system can automatically reduce the dosage of mother liquor and adjust the proportion of clean water accordingly to ensure accurate basic proportioning of the compound. In the gradient temperature-controlled compound reaction unit, the segmented temperature control module presets differentiated temperature curves according to different stages of the compound reaction, such as the initial mixing stage, the functional component dissolution stage, and the molecular synergistic reaction stage. For example, the mixing stage is 30-35℃, the dissolution stage is 40-45℃, and the synergistic reaction stage is 38-42℃. Simultaneously, the stirring rate linkage device automatically matches the stirring rate according to the current stage temperature (e.g., 60-80 r / min is used in the low-temperature mixing stage to prevent raw material splashing, and 120-150 r / min is used in the high-temperature dissolving stage to accelerate dissolution), achieving coordinated control of temperature and stirring. The online quality monitoring feedback unit collects key indicators such as the composition, concentration, and flowability of materials in real time during the compounding process through the near-infrared spectroscopy detection module. If a certain indicator is detected to deviate from the preset range, such as the flowability being lower than the target value by 5%, a feedback signal is immediately sent to the multi-component precise proportioning unit and the gradient temperature control compounding reaction unit to adjust the feeding amount or temperature / stirring parameters, forming a closed-loop control. Finally, the finished product adaptive filling unit automatically matches the filling rate and packaging specifications according to the finished product quality confirmed by online detection, completing the entire production process.

[0022] Regarding the precision control of proportioning, existing technologies can only achieve fixed-quantity measurement based on the theoretical content of raw materials, and cannot cope with the dynamic correlation between fluctuations in the solid content of raw materials and target performance requirements. This solution, however, achieves precise control through real-time... Dynamic proportioning adjustment linked to compensation and target flowability reduces proportioning error from ±3% in existing technologies. 5% decreased to ±0.5% For example, in a high-speed railway bridge concrete project, the water-reducing agent produced using this method can ensure that the slump loss of the concrete over time (1 hour) is controlled within 20 mm, while the slump loss of water-reducing agents produced using existing technology often reaches 30 mm. The 50mm diameter effectively avoids insufficient concrete strength caused by mix proportion deviations. Regarding the controllability of the reaction process, existing technologies often employ a single constant temperature and fixed stirring rate, which can easily lead to incomplete local reactions, such as undissolved clumps of small materials. This solution, through segmented temperature control and coordinated stirring rate regulation, increases the solubility of functional components from 85% in existing technologies. The accuracy rate increased from 90% to over 98%, and the reaction cycle for compounding was shortened by 15%. For example, during high-temperature production in summer, existing technologies often lead to retarder failure due to the inability to dynamically adjust temperature control parameters. This solution, however, ensures stable retarding effects through staged temperature control, keeping the initial setting time deviation of concrete within ±30 minutes. Regarding closed-loop quality control, existing technologies rely on offline sampling and testing, making real-time correction of production deviations difficult. This solution, through online near-infrared spectroscopy detection and closed-loop feedback, can complete indicator detection and synchronous parameter adjustment within 30 seconds, reducing the defect rate from 2% in existing technologies. The concentration of water-reducing agents is reduced from 3% to below 0.1%, while avoiding batch product scrapping due to offline detection delays. Furthermore, this solution offers unexpected advantages, enabling flexible production of water-reducing agents with different performance requirements. For example, the same production line can quickly switch between producing water-reducing agents for ordinary ready-mixed concrete (target flowability 150mm) and high-performance pumped concrete (target flowability 220mm) by adjusting the target flowability parameters, without replacing equipment or significantly adjusting the process. Existing technologies typically require re-adjusting the production line for different products, with a switchover cycle as long as 4... This solution significantly improves production flexibility and efficiency within 6 hours.

[0023] The intelligent raw material pretreatment unit includes a raw material screening component, a purification component, and an online solid content detection component. The online solid content detection component uses a microwave moisture meter with a detection accuracy of ±0.1%, and the detection data is transmitted to the dynamic proportioning adjustment system in real time. The raw material screening component can filter out small agglomerated particles, and the purification component can adsorb metal impurities, preventing both from affecting the uniformity of compounding and the performance of the water-reducing agent. Using a microwave moisture meter with a detection accuracy of ±0.1% as the online solid content detection component not only far exceeds the accuracy and efficiency of traditional offline detection, but also can synchronously transmit real-time detection data to the dynamic proportioning adjustment system. This allows the system to instantly obtain minute deviations in the solid content of the raw materials, such as a 0.2% fluctuation in the solid content of the mother liquor, and accurately adjust the feed amount based on this. This avoids proportioning inaccuracies caused by the accumulation of raw material solid content deviations from the source, while saving the time-consuming manual offline detection process. This ensures the accuracy of dynamic proportioning adjustment and improves overall production efficiency.

[0024] The multi-component precise proportioning unit includes at least three independent raw material storage tanks, a variable frequency metering pump, and a flow sensor. The control signal for the variable frequency metering pump is output by the dynamic proportioning adjustment system, and the flow control accuracy reaches [value missing]. The multi-component precision proportioning unit uses at least three independent raw material storage tanks to store polycarboxylate mother liquor, Different raw materials, such as water, are processed to prevent cross-contamination during storage, ensuring the initial purity of the raw materials. The core variable frequency metering pump uses the control signal output from the dynamic proportioning adjustment system as an instruction, combined with a flow sensor to provide real-time feedback on the actual delivery volume, forming an "instruction-output" system. Precision delivery The control link features real-time monitoring, and its flow control accuracy reaches ±0.2%FS, enabling strict control of deviations in the delivery volume of each raw material within an extremely small range. For example, when the dynamic proportioning system instructs the mother liquor delivery volume to be 800 kg based on the deviation of the raw material solid content, the actual delivery volume of the variable frequency metering pump can be stably maintained between 798.4 kg and 801.6 kg, which is far superior to the deviation level of traditional metering equipment of ±1%FS. This ensures that the corrected feed amount calculated by the dynamic proportioning system is accurately executed, completely avoiding the inaccuracy of compounding ratio caused by deviation in the delivery process. At the same time, the adjustable speed characteristics of the variable frequency metering pump and the isolation design of the independent storage tank can also flexibly adapt to the component switching needs of different types of water-reducing agents. For example, when switching from the production of ordinary water-reducing agents to high-efficiency water-reducing agents, it is only necessary to adjust the metering pump control signal through the system to change the delivery volume of each component without replacing the equipment, thus balancing proportioning accuracy and production flexibility.

[0025] The segmented temperature control module of the gradient temperature-controlled compound reaction unit includes a heating section, a constant temperature section, and a cooling section, with each section having a temperature control accuracy of [insert accuracy here]. The stirring rate adjustment range of the stirring rate linkage device is: Furthermore, the linkage response time between stirring rate and reaction temperature is less than 2 seconds. The segmented temperature control module of the gradient temperature control compounding reaction unit, through the orderly connection of heating, constant temperature, and cooling sections, can accurately match the temperature requirements of each stage of the compounding reaction. The heating section quickly heats the material to the temperature required for the functional components to dissolve, such as 40℃. The constant temperature section maintains this temperature to ensure sufficient dissolution. The cooling section cools the material to the suitable temperature for molecular co-reaction, such as 38℃. The temperature control accuracy of each section reaches ±0.5℃, which can avoid incomplete component reaction caused by temperature fluctuations. For example, if the temperature is too low, the retarder dissolves slowly, and if it is too high, the molecular chains of the mother liquor break. The matching stirring rate linkage device can adjust the stirring rate from 60 to 200 r / min to adapt to different reaction stages, such as a low speed of 60-80 r / min in the heating section. To prevent material splashing, the constant temperature section uses a high-speed 120-150 r / min to accelerate dissolution, and the linkage response time between the stirring rate and the reaction temperature is less than 2 seconds. This means that when the temperature control module switches to the next temperature section, the stirring rate can be adjusted instantaneously. For example, when switching from the heating section of 35℃ to the constant temperature section of 40℃, the stirring rate can be increased from 80 r / min to 140 r / min within 2 seconds, avoiding local overheating or uneven mixing of materials due to asynchronous temperature and stirring. This combination of high-precision temperature control and instantaneous linkage stirring control can ensure that the compounding reaction is in the optimal environment throughout, improving the stability of the water-reducing agent performance. For example, the flowability deviation of the same batch of products can be controlled within ±3 mm. It can also shorten the reaction cycle. Compared with the traditional production line with single temperature control and fixed stirring rate, the reaction efficiency can be improved.

[0026] The near-infrared spectroscopy detection module of the online quality monitoring feedback unit can simultaneously detect the solid content, pH value, and polymer molecular weight distribution of the compound system, with a detection cycle of 15. After 30 seconds, the detected data, once analyzed and processed, generates adjustment commands that are transmitted to the multi-component precise proportioning unit and the gradient temperature-controlled compounding reaction unit. The near-infrared spectroscopy detection module of the online quality monitoring feedback unit can simultaneously detect three key indicators of the compounding system: solid content, pH value, and polymer molecular weight distribution. Compared to traditional offline detection methods that require separate solid content analyzers, pH meters, and gel permeation chromatographs (GPC) (where single-indicator detection cycles often exceed 30 minutes and multi-indicator data cannot be acquired simultaneously), this method offers significant advantages. The short 30-second detection cycle can capture parameter changes in the compounding process in real time. For example, when the solid content of the compounding system is lower than the preset value by 0.3% due to a slight deviation in the mother liquor feeding, the pH value deviates from the standard range (e.g., 7.5-8.5) by 0.2 units, or the polymer molecular weight distribution widens, the module can quickly identify these changes and generate targeted adjustment instructions through data analysis. These instructions can be instantly transmitted to the multi-component precise proportioning unit and the gradient temperature-controlled compounding reaction unit. For example, an instruction can be sent to the proportioning unit to "fine-tune the mother liquor delivery volume by 0.5% and add 0.1% alkaline regulator," and to the temperature control unit to "increase the reaction temperature by 1°C to optimize the polymer molecular structure," forming a "real-time detection" mechanism. Quick Analysis A closed-loop feedback mechanism for "precise control." This combination of simultaneous multi-indicator detection and real-time control avoids the lag caused by traditional offline detection (which often requires 2...). The system can prevent batches of defective products caused by 4h (4 hours), but it can also ensure product performance stability at the molecular level by synchronously monitoring molecular weight distribution, a core indicator that affects the dispersibility and slump retention of water-reducing agents. For example, in a certain batch of production, the module detected that the molecular weight distribution width increased from 1.8 to 2.2, and promptly instructed the temperature control unit to adjust the cooling rate so that the molecular weight distribution returned to a reasonable range. As a result, the slump retention of the product in concrete applications was improved by 10%, which is far better than the performance fluctuations caused by the inability to intervene in time under traditional detection methods.

[0027] The dynamic proportioning adjustment system employs a proportioning correction algorithm based on the deviation of raw material solid content, the specific formula of which is: in, The corrected feed amount for the i-th component (unit: kg). The initial feed amount (in kg) for the i-th component. The standard solids content (in %) of the i-th component. The actual solid content (in %) of the i-th component after raw material pretreatment. The target flow rate (unit: mm) of the compound system. The current flowability of the compound system obtained from online detection (unit: mm); Simultaneously, a deviation factor between the actual solid content and the standard solid content of the raw material is introduced. Feedback factor between target flowability and current flowability A dual-dimensional dynamic correction mechanism was constructed: It real-time offsets solid content fluctuations caused by changes in storage environment and batch differences during raw material pretreatment, such as deviations in the proportion of effective components due to the evaporation or dilution of mother liquor water, ensuring that the actual input proportion of each component matches the design value from the source; and it reverse-calibrates the feed amount through online flowability detection results, forming an instant response closed loop of "raw material state - proportioning parameters - product performance," avoiding flowability deviations from the target value due to implicit differences in raw materials, such as fluctuations in molecular weight distribution. This algorithm enables the system to control the flowability deviation of the compound system within ±3mm even under complex operating conditions with raw material solid content fluctuations of ±5% and ambient temperature changes of ±3℃. Compared with the traditional method relying solely on fixed measurement, the proportioning accuracy is improved by more than 40%, significantly reducing product performance fluctuations caused by raw material instability, while also reducing the lag and subjectivity of manual adjustments, achieving precise and intelligent control of the water-reducing agent compounding process.

[0028] In the gradient temperature-controlled compound reaction unit, the synergistic regulation of stirring rate and reaction temperature is achieved using the following correlation formula:

[0029] in This represents the current stirring rate (unit: r / min). Reference temperature The stirring rate is (in r / min), where k is the rate temperature coefficient. The range of values ​​is T represents the current reaction temperature (unit: °C). The reference temperature for the compounding reaction (unit: °C, range: 45-55 °C) is used to establish a linear dynamic correlation mechanism between temperature and stirring rate, enabling the stirring intensity to adapt in real time to changes in reaction temperature: when the reaction temperature is higher than the reference temperature... When the temperature increases, the stirring rate decreases linearly with increasing temperature according to the coefficient k, which can avoid excessive local shear force in the system caused by excessive stirring at high temperatures, and prevent polymer molecular chain breakage or cross-linking structure destruction; when the temperature is below At this time, the stirring rate increases linearly with decreasing temperature, which can compensate for the decrease in the diffusion rate of raw materials at low temperatures by enhancing stirring, ensuring uniform mixing of the reaction system. This synergistic regulation precisely matches the inherent law in the polycarboxylate superplasticizer compounding reaction that "temperature affects reaction activity and stirring affects mass transfer efficiency". Within the reference temperature range of 45-55℃ and the temperature fluctuation range of ±10℃, the uniformity of the reaction system can be improved by more than 30%, effectively solving the contradiction that "high temperature easily leads to a widening of the molecular weight distribution of the product, and low temperature easily leads to incomplete local reaction" under the traditional constant temperature fixed stirring method. Ultimately, the water reduction rate fluctuation of the compounded product is controlled within ±1.5%, improving the stability and consistency of product performance.

[0030] The adaptive filling unit includes a filling volume detection component, an automatic sealing component, and a defective product diversion component. The filling volume detection component uses a weighing sensor, achieving a filling accuracy of ±0.3%. The defective product diversion component automatically diverts defective finished products to a recycling tank based on the detection results from the online quality monitoring feedback unit, with a diversion response time of less than 1 second. The high-precision filling accuracy of ±0.3% achieved through the high-precision weighing sensor ensures the consistency of the filling volume for each batch of products, avoiding the problems associated with traditional volumetric filling methods due to product variations. The measurement deviations caused by variations meet the downstream construction requirements for precise control of water-reducing agent dosage. Simultaneously, the real-time linkage between the non-conforming product diversion component and the online quality monitoring feedback unit enables automatic diversion of non-conforming products within one second. This avoids the quality risks caused by non-conforming products entering the market and achieves material recycling by immediately diverting them to the recovery tank, reducing material waste. This combination of high-precision measurement and real-time quality screening improves the consistency and reliability of products leaving the factory while reducing production and quality control costs. It forms a final, precise control over product quality from the end of production, creating a closed loop with the front-end dynamic proportioning and synergistic reaction control, comprehensively ensuring the efficient operation of the production line.

[0031] It also includes a central control system, which is communicatively connected to the raw material intelligent pretreatment unit, the multi-component precise proportioning unit, the gradient temperature-controlled compounding reaction unit, the online quality monitoring and feedback unit, and the finished product adaptive filling unit. This central control system enables monitoring of operating parameters, data storage, and fault alarms for each unit of the production line, and supports remote operation and maintenance and parameter adjustment. Through comprehensive communication with each core unit of the production line, it breaks through the limitations of decentralized control and information silos in traditional production lines: on the one hand, it can collect real-time solid content data from raw material pretreatment, feeding parameters for multiple proportions, temperature control and stirring data from the compounding reaction, online monitoring quality indicators, and metering information from the filling stage, achieving centralized monitoring and data traceability of all process operating parameters, facilitating rapid identification of potential problems in each stage; the fault alarm function can trigger an immediate reminder when any unit parameter deviates from the preset range. Combined with remote operation and maintenance and parameter adjustment capabilities, fault diagnosis and process optimization can be completed without on-site operation, significantly shortening downtime for maintenance and improving the continuous operation efficiency of the production line. This centralized and remote control design not only strengthens the precise management and control of the entire compounding process, but also reduces the cost of manual intervention and operational errors, providing core support for the standardization and intelligentization of polycarboxylate superplasticizer production.

[0032] The central control system incorporates a production data traceability module, capable of recording raw material information, proportioning parameters, reaction process parameters, quality inspection data, and filling information for each batch of products. Data storage is maintained for at least three years, and full-process data traceability is supported via product batch numbers. When downstream product performance abnormalities occur, the system can quickly trace back to the source of raw materials, proportioning parameters, reaction conditions, and other key data for that batch using the batch number, accurately pinpointing the problem and providing a basis for quality improvement. Furthermore, long-term data accumulation can be used to analyze the correlation between different raw material batches, process parameters, and product performance, providing data support for optimizing production processes and improving product stability. Simultaneously, the at least three-year storage period meets the industry's timeliness requirements for product quality traceability, protecting the rights of downstream users and providing reliable data evidence for enterprises to handle quality inspections and process verification scenarios. This reflects the standardization and responsibility of the production process and further strengthens the full lifecycle management of product quality.

[0033] I. Overall Configuration of the Production Line This embodiment focuses on polycarboxylate superplasticizers for C60 high-strength concrete, with a target flowability. Solid content pH value To meet production needs, a complete compounding production line is constructed, with the specific configuration of each unit as follows: Intelligent raw material pretreatment unit: includes 2 vibrating screens, screen mesh size... Processing volume 1 set of electromagnetic impurity removal device (magnetic field strength) ) and 3 microwave moisture meters (detection range) Precision ), respectively corresponding to polycarboxylate mother liquor (industrial grade, standard solid content) Sodium gluconate retarder (industrial grade, standard solid content) The pretreatment of three core raw materials—air-entraining agent (industrial grade, standard solid content 30%), and the detection data are transmitted in real time to the dynamic proportioning adjustment system via RS485 bus.

[0034] Multi-component precise proportioning unit: Equipped with 4 independent raw material storage tanks, with volumes of respectively , , , Material Stainless steel, suitable for mother liquor, retarder, air-entraining agent, and deionized water; equipped with 4 variable frequency metering pumps, with a flow range of... control precision And 4 electromagnetic flow sensors, with an accuracy of The metering pump control signal is output by the dynamic proportioning adjustment system through the PLC.

[0035] Gradient temperature controlled compounding reaction unit: 1 unit Anchor-type stirred reactor, made of 316L stainless steel, features a segmented temperature control module including a steam heating jacket with a heating power of 15kW, a circulating water cooling system (cooling capacity of 10kW), and three PT100 temperature sensors (accuracy...). Temperature control range Temperature control accuracy of each section The stirring rate linkage device uses a variable frequency motor with selected power. Equipped with a cycloidal pinwheel reducer, the stirring speed adjustment range is [range missing]. Linkage response time .

[0036] Online quality monitoring and feedback unit: Deploy one near-infrared spectrometer to detect wavelengths. resolution The detection probe is inserted into the side wall of the reactor, about 1 / 3 of the way from the bottom. The accompanying spectral analysis software can simultaneously calculate the solid content, pH value, and polymer molecular weight distribution, minimizing detection error. The detection cycle is set to 20 seconds. The analysis results are transmitted to the central control system via Ethernet. When the deviation exceeds the limit, the adjustment command is automatically generated.

[0037] Finished product adaptive filling unit: includes one weighing filling machine, weighing range Precision 1 set of automatic capping device, capping torque And one set of pneumatic diverter valves, DN50 in diameter, response time The outlets of the diversion valves are respectively connected to the finished product tanks (volume). ) and recycling tank (volume) The shunt signal is directly triggered by the online quality monitoring feedback unit.

[0038] Central control system: Adopts Siemens S7-1500 PLC (CPU1516-3PN / DP), equipped with a 10-inch touch screen, and connects to each unit device via Profinet bus. It has a built-in production data traceability module (128GB storage capacity, supports SQL database), which can record raw material supplier information, feed amount, reaction temperature curve, test data, etc. for each batch. The data storage time is ≥3 years. It supports querying the entire process data on the Web terminal by batch number (format: YYYYMMDDXXXX). It is also equipped with a 4G remote operation and maintenance module, which can realize remote parameter adjustment, hierarchical access control and fault SMS alarm, with a response time of ≤30s.

[0039] II. Setting Production Process Parameters Dynamic proportioning correction parameters: Initial feed rates (5000kg finished product per batch) are: 2500kg mother liquor, 50kg retarder, 33.3kg air-entraining agent, and 2416.7kg deionized water; standard solid content S is as follows: (mother liquor) (Retarder) (Air-entraining agent) (Deionized water); Target flowability .

[0040] Gradient temperature control curve: heating section The rate of temperature increase from room temperature (25°C) to 45°C ; constant temperature section Maintaining a temperature of 45°C is used for the dissolution of retarder and the concerted molecular reaction. Cooling section The cooling rate from 45℃ to 35℃ .

[0041] Stirring rate linkage parameter: reference temperature Reference stirring rate Rate temperature coefficient According to the formula Calculate the stirring rate corresponding to each temperature, such as hour ; hour .

[0042] Online detection threshold: solid content , value Molecular weight distribution width If any indicator exceeds the range, feedback adjustment will be triggered.

[0043] III. Production Process Control Flow Raw material pretreatment and proportioning correction

[0044] The intelligent pretreatment unit for raw materials is activated: after the mother liquor is screened to remove impurity particles and adsorb metal fragments, the actual solid content is detected by a microwave moisture analyzer. ; Testing of retarder after sieving Entraining agent detection The data is transmitted to the dynamic proportioning adjustment system in real time.

[0045] The dynamic proportioning system calculates the corrected feed amount according to the formula: Mother liquor correction feed amount ; Adjusting the feed amount of retarder ; Air-entraining agent dosage correction ; Deionized water correction feed amount .

[0046] The system sends instructions to the multi-component precision proportioning unit, and the variable frequency metering pump delivers raw materials according to the correction amount. The flow sensor provides real-time feedback. When the actual delivery amount reaches 99% of the correction amount, the metering pump reduces its speed to 10% flow rate and accurately replenishes the material to the target value.

[0047] Gradient temperature control and stirring synergistic reaction

[0048] After all the raw materials are fed into the reactor, the segmented temperature control module is activated: Heating section (10-25 min): The steam heating jacket is turned on, and the temperature rises from 25℃ to 45℃. The stirring rate increases synchronously with the temperature rise from the initial 180 r / min to [missing value]. ( Time to reach ); constant temperature section Maintain 45℃ and keep the stirring rate stable. During this period, the near-infrared spectrometer performed a detection every 20 seconds. Solid content was detected at the time. (Below the lower limit), flowability 192mm (below the target), the system generates an adjustment command: feed 20kg of mother liquor into the metering pump, increase the stirring speed to [value missing]. ; Cooling section The circulating water cooling system is turned on, and the temperature drops from 45℃ to 35℃. The stirring rate is simultaneously reduced. , No. The test data were restored to the acceptable range (solid content 20.1%, flowability 198 mm, pH value 8.2).

[0049] Finished Product Filling and Quality Control

[0050] After the online quality monitoring feedback unit confirms that the indicators are qualified, it sends a "qualified" signal to the finished product adaptive filling unit, and the weighing filling machine starts up. Barrel specifications for filling; weighing sensors calibrate the filling volume in real time; deviation exceeds... The filling valve opening is automatically adjusted in real time. If a finished product in a barrel is found to have a pH value of 8.7 (exceeding the upper limit), the system will immediately trigger the pneumatic diversion valve to divert the finished product in the barrel to the recovery tank (diversion response time 0.8s). The recovered material can be mixed into the raw materials at a ratio of 10% in the next production process and re-blended. After filling, the automatic capping device seals the product and labels it, including batch number 20240520001. The central control system simultaneously records the raw material information for this batch, including mother liquor supplier A, retarder supplier B, reaction parameters, heating time (15 minutes), maximum temperature of constant temperature section (45.3℃), test data (22 tests in total, 1 failure), and filling information (24 qualified out of 25 barrels).

[0051] The above are merely embodiments of the present invention. Commonly known structures and characteristics of the solutions are not described in detail here. Those skilled in the art are aware of all common technical knowledge in the field prior to the application date or priority date, are aware of all prior art in that field, and have the ability to apply conventional experimental methods prior to that date. Those skilled in the art can, under the guidance of this application, improve and implement this solution in combination with their own capabilities. Some typical known structures or methods should not be obstacles for those skilled in the art to implement this application. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention. These should also be considered within the scope of protection of the present invention, and will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the description of specific embodiments in the specification can be used to interpret the content of the claims.

Claims

1. A polycarboxylate superplasticizer compounding production line, characterized in that, The system comprises, in sequence, a raw material intelligent pretreatment unit, a multi-component precise proportioning unit, a gradient temperature-controlled compounding reaction unit, an online quality monitoring and feedback unit, and a finished product adaptive filling unit. The multi-component precise proportioning unit incorporates a dynamic proportioning adjustment system based on real-time viscosity compensation. The gradient temperature-controlled compounding reaction unit is equipped with a segmented temperature control module and a stirring rate linkage device. The online quality monitoring and feedback unit forms a closed-loop control with the multi-component precise proportioning unit and the gradient temperature-controlled compounding reaction unit through a near-infrared spectroscopy detection module. The dynamic proportioning adjustment system can automatically correct the feed amount of each component based on the actual solid content deviation after raw material pretreatment and the target flowability requirements. The segmented temperature control module can preset temperature curves according to different stages of the compounding reaction and achieve coordinated control of the stirring rate and reaction temperature through the stirring rate linkage device.

2. The polycarboxylate superplasticizer compounding production line according to claim 1, characterized in that, The intelligent pretreatment unit for raw materials includes a raw material screening component, a purification component, and an online solid content detection component. The online solid content detection component uses a microwave moisture meter with a detection accuracy of ±0.1%, and the detection data is transmitted to the dynamic proportioning adjustment system in real time.

3. The polycarboxylate superplasticizer compounding production line according to claim 1, characterized in that, The multi-component precise proportioning unit includes at least three independent raw material storage tanks, a variable frequency metering pump, and a flow sensor. The control signal for the variable frequency metering pump is output by the dynamic proportioning adjustment system, and the flow control accuracy reaches [value missing]. .

4. The polycarboxylate superplasticizer compounding production line according to claim 1, characterized in that, The segmented temperature control module of the gradient temperature-controlled compound reaction unit includes a heating section, a constant temperature section, and a cooling section, with each section having a temperature control accuracy of [insert accuracy here]. The stirring rate adjustment range of the stirring rate linkage device is: Furthermore, the linkage response time between stirring rate and reaction temperature is less than 2 seconds.

5. The polycarboxylate superplasticizer compounding production line according to claim 1, characterized in that, The near-infrared spectroscopy detection module of the online quality monitoring feedback unit can simultaneously detect the solid content, pH value, and polymer molecular weight distribution of the compound system, with a detection cycle of [missing information]. After the detection data is analyzed and processed, adjustment commands are generated and transmitted to the multi-component precise proportioning unit and the gradient temperature-controlled compounding reaction unit to achieve real-time correction of deviations.

6. The polycarboxylate superplasticizer compounding production line according to claim 1, characterized in that, The dynamic proportioning adjustment system employs a proportioning correction algorithm based on the deviation of raw material solid content, the specific formula of which is: in, The corrected feed amount for the i-th component (unit: kg). The initial feed amount for the i-th component. The standard solid content of the i-th component is... This represents the actual solid content of the i-th component after raw material pretreatment. To determine the target mobility of the compound system, The current flowability of the compound system obtained from online detection.

7. The polycarboxylate superplasticizer compounding production line according to claim 1, characterized in that, In the gradient temperature-controlled compound reaction unit, the synergistic regulation of stirring rate and reaction temperature is achieved using the following correlation formula: in The current stirring rate, Reference temperature The stirring rate is given by k, where k is the rate temperature coefficient. The range of values ​​is T is the current reaction temperature. The reference temperature for the compounding reaction is 45-55℃.

8. A polycarboxylate superplasticizer compounding production line according to claim 1, characterized in that, The finished product adaptive filling unit includes a filling volume detection component, an automatic sealing component, and a non-conforming product diversion component. The filling volume detection component uses a weighing sensor, and the filling accuracy reaches ±0.3%. The non-conforming product diversion component can automatically divert non-conforming finished products to a recycling tank based on the detection results of the online quality monitoring feedback unit, with a diversion response time of less than 1 second.

9. A polycarboxylate superplasticizer compounding production line according to claim 1, characterized in that, It also includes a central control system, which is connected to the raw material intelligent pretreatment unit, the multi-component precise proportioning unit, the gradient temperature control compounding reaction unit, the online quality monitoring feedback unit, and the finished product adaptive filling unit. It can monitor the operating parameters of each unit of the production line, store data and provide fault alarms, and supports remote operation and maintenance and parameter adjustment.

10. A polycarboxylate superplasticizer compounding production line according to claim 9, characterized in that, The central control system has a built-in production data traceability module that can record raw material information, proportioning parameters, reaction process parameters, quality inspection data and filling information for each batch of products. The data storage time is no less than 3 years, and it supports full-process data traceability through product batch number.

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