A multi-stage separation integrated processing method and device

Abstract

The application discloses a kind of multistage separation integrated processing method and device, for the process synergy of existing technology is poor, separation efficiency is low, and secondary emulsification is prone to occur and so on, the application is controlled by PLC system coordination, in turn, filtering, heating, coupling enhanced separation, chaotic electric field dehydration, vacuum circulation separation and multi-gradient fine filter processing are carried out.Coupling enhanced separation unit combines electric field pre-separation and cyclone centrifugal enhanced separation;Chaotic electric field dehydration unit uses pulse position modulation electric field to destroy emulsion interface;Vacuum circulation separation unit realizes depth purification under negative pressure environment.The scheme realizes the step-by-step efficient removal of different particle size impurities in industrial waste oil, and the quality of regenerated oil is significantly improved, and the energy consumption of the system is greatly reduced.The device adopts modular design, and each unit is intelligently coordinated, with high processing efficiency, strong adaptability, stable operation and other advantages, providing reliable technical support for industrial waste oil resource utilization.

Description

Technical Field

[0001] This invention relates to the technical field of treating used lubricants in chemistry to recover useful products, and particularly to a multi-stage separation and integrated processing method and apparatus. Background Technology

[0002] Industrial waste oil refers to discarded greases and lubricants that have lost their usability due to prolonged exposure to high temperatures, high pressures, oxidation, or contamination by external impurities in industrial production, machinery manufacturing, and transportation. Its composition is complex, containing base oils, metal particles, moisture, dissolved gases, and toxic substances such as polycyclic aromatic hydrocarbons, posing a significant environmental hazard.

[0003] Currently, industrial waste oil purification and regeneration technologies mainly employ a "series" process combined treatment mode, which involves simply connecting individual processes such as thermodynamic separation, mechanical filtration, physicochemical dehydration, flocculation sedimentation, and high-speed centrifugation in series. However, this mode has the following drawbacks: the multi-stage combined purification process lacks effective combination methods and operating procedures, the synergy between process units is poor, resulting in difficulty in consistently meeting the quality standards of the regenerated oil; especially when treating micron-sized droplets, secondary emulsification is prone to occur, the removal efficiency of nano-sized water droplets is low, the system pressure drop is large, and the overall purification efficiency is not high. Therefore, there is an urgent need for a highly integrated multi-stage combined purification process method that, through process coupling optimization and intelligent control, can achieve the goal of low-consumption and high-efficiency industrial waste oil regeneration and recycling. Summary of the Invention

[0004] In view of the above-mentioned shortcomings of the existing technology, the purpose of this invention is to solve the technical problems of poor synergy of multi-stage purification processes for industrial waste oil, easy occurrence of secondary emulsification, and low efficiency of impurity removal. The invention provides a multi-stage separation and integrated treatment method and device that can achieve high dehydration and solidification efficiency, stable quality of regenerated oil, and low system energy consumption.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0006] A multi-level separation and integration processing method includes the following steps and is coordinated and controlled by a PLC system;

[0007] 1) The industrial waste oil is passed through a filtration unit to filter out some solid particles;

[0008] 2) The industrial waste oil is passed through a heating unit to reduce its viscosity;

[0009] 3) Industrial waste oil is processed through a coupled and enhanced separation unit to separate some water and solid particles;

[0010] 4) Industrial waste oil is passed through a chaotic electric field dehydration unit to remove micron-sized droplets;

[0011] 5) Industrial waste oil is passed through a vacuum circulation separation unit to remove nano-sized droplets;

[0012] 6) Industrial waste oil is filtered through a multi-gradient fine filtration unit to remove micron-sized solid particles;

[0013] 7) The output is recycled oil.

[0014] Furthermore, in step 2), the heating unit heats the industrial waste oil through an oil bath to reduce the viscosity and flow resistance of the industrial waste oil, thereby improving the efficiency of subsequent separation.

[0015] Furthermore, in step 3), the coupled enhanced separation unit performs electric field pre-separation and cyclone centrifugal enhanced separation on industrial waste oil. Electric field pre-separation promotes droplet aggregation in industrial waste oil through an electric field, while cyclone centrifugal enhanced separation separates droplets and solid particles in industrial waste oil through a centrifugal force field.

[0016] Furthermore, in step 4), the chaotic electric field dehydration unit applies a chaotic pulse-modulated electric field to the industrial waste oil, thereby disrupting the interfacial tension of the emulsion in the industrial waste oil through pulse action, thus removing micron-sized droplets from the industrial waste oil and avoiding secondary emulsification.

[0017] Furthermore, in step 5), the vacuum circulation separation unit provides a vacuum environment for the industrial waste oil, enabling the nano-sized droplets in the industrial waste oil to vaporize and separate.

[0018] Furthermore, in step 6), the multi-gradient fine filtration unit adopts a gradient filtration method to intercept and filter micron-sized solid particles in industrial waste oil step by step.

[0019] Furthermore, the PLC system coordinates and controls the operating status of the heating unit, the coupling-enhanced separation unit, the chaotic electric field dehydration unit, the vacuum circulation separation unit, and the multi-gradient fine filtration unit according to process parameters.

[0020] Furthermore, the process parameters include the temperature, water content, solids content, pressure, and flow rate of the industrial waste oil.

[0021] The present invention also includes a multi-stage separation integrated processing device for implementing the multi-stage separation integrated processing method described above. The multi-stage separation integrated processing device includes a coarse filter, a heater, a coupling-enhanced separation unit, a chaotic electric field dehydration unit, a vacuum circulation separation unit, a multi-gradient fine filtration unit, and a PLC system. The coarse filter, heater, coupling-enhanced separation unit, chaotic electric field dehydration unit, vacuum circulation separation unit, and multi-gradient fine filtration unit are connected in sequence and are electrically connected to the PLC system respectively.

[0022] Furthermore, the PLC system includes a data acquisition module, a setpoint storage module, a deviation calculation module, an arithmetic module, and an execution control module.

[0023] Compared with the prior art, the present invention has the following advantages:

[0024] 1. This invention, through a seven-step integrated processing flow coordinated and controlled by a PLC system, fundamentally solves the technical bottlenecks of existing industrial waste oil purification technologies, such as isolated operation of process units, poor coordination, and large system pressure drop. This method organically combines processes such as filtration, heating, coupled enhanced separation, chaotic electric field dehydration, vacuum circulation separation, and multi-gradient fine filtration to form a closed-loop controlled full-process treatment system. This not only avoids the efficiency losses caused by poor connections between units in traditional series processes but also improves overall purification efficiency through optimized process sequence design. The quality of the recycled oil consistently meets national standards, while system energy consumption and operating costs are significantly reduced, achieving efficient, stable, and economical recycling of industrial waste oil.

[0025] 2. This invention constructs a three-stage deep purification system consisting of "coupled enhanced separation + chaotic electric field dehydration + vacuum circulation separation," overcoming the limitations of traditional single separation technologies that struggle to remove impurities of different particle sizes. The coupled enhanced separation unit efficiently removes most water and solid particles through the synergistic effect of electric field pre-separation and cyclone centrifugation enhanced separation. The chaotic electric field dehydration unit uses a pulse-modulated electric field to disrupt the interfacial tension of the emulsion, specifically targeting micron-sized droplets for efficient removal and avoiding secondary emulsification. The vacuum circulation separation unit vaporizes and separates nano-sized droplets under negative pressure, achieving deep purification. This three-stage purification system is progressive and complementary, solving the core problems of existing technologies where micron- and nano-sized impurities are difficult to completely remove and prone to secondary emulsification, resulting in a significant improvement in separation efficiency.

[0026] 3. This invention improves the automation level and adaptability of industrial waste oil regeneration treatment by organically combining an intelligent PLC control system with a modular device design. The PLC system coordinates the operating status of each process unit in real time based on key parameters such as temperature, water content, solid content, pressure, and flow rate, realizing dynamic optimization of process parameters and automatic early warning of abnormal conditions. This solution is not only suitable for the treatment of different types and levels of industrial waste oil, but also has advantages such as small footprint, low maintenance cost, and simple operation, resulting in good economic and environmental benefits. Attached Figure Description

[0027] To make the purpose, technical solution, and advantages of the invention clearer, the invention will now be described in further detail with reference to the accompanying drawings:

[0028] Figure 1 This is a connection block diagram of the multi-stage separation and integration processing device described in the embodiment. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to represent selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0031] It should be noted that similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures. In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the figures, or the orientation or positional relationship commonly used when the product is in use. They are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance. In addition, the terms "horizontal," "vertical," etc., do not indicate that the component is required to be absolutely horizontal or suspended, but can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted. In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0032] Example:

[0033] Please see Figure 1 A multi-level separation and integration processing method includes the following steps and is coordinated and controlled by a PLC system;

[0034] 1) The industrial waste oil is passed through a filtration unit to filter out some solid particles;

[0035] 2) The industrial waste oil is passed through a heating unit to reduce its viscosity;

[0036] 3) Industrial waste oil is processed through a coupled and enhanced separation unit to separate some water and solid particles;

[0037] 4) Industrial waste oil is passed through a chaotic electric field dehydration unit to remove micron-sized droplets;

[0038] 5) Industrial waste oil is passed through a vacuum circulation separation unit to remove nano-sized droplets;

[0039] 6) Industrial waste oil is filtered through a multi-gradient fine filtration unit to remove micron-sized solid particles;

[0040] 7) The output is recycled oil.

[0041] The multi-stage separation and integrated processing method of this invention solves the problems of poor synergy and large system pressure drop in existing multi-stage purification processes through a seven-step integrated processing flow coordinated and controlled by a PLC system, and realizes closed-loop control of the entire process of industrial waste oil purification and regeneration. This method organically integrates process units such as filtration, heating, coupled enhanced separation, chaotic electric field dehydration, vacuum circulation separation, and multi-gradient fine filtration. It not only avoids the efficiency loss caused by poor connection between units in traditional series processes, but also improves the overall purification efficiency through optimized design of the process sequence, so that the quality of regenerated oil can stably meet national standards, while reducing system energy consumption and operating costs.

[0042] Please see Figure 1 In step 2), the heating unit heats the industrial waste oil through an oil bath to reduce the viscosity and flow resistance of the industrial waste oil, thereby improving the efficiency of subsequent separation.

[0043] In this way, the viscosity and flow resistance of industrial waste oil are precisely controlled by oil bath heating, creating better physical conditions for subsequent separation processes. Compared with traditional direct heating, this heating method has the advantages of uniform temperature distribution and high thermal efficiency, which can effectively prevent the cracking phenomenon caused by local overheating of waste oil and ensure that the waste oil enters the coupled enhanced separation unit within a suitable viscosity range (usually controlled within 15 cSt - 30 cSt), thereby improving the separation efficiency of water and solid particles and laying the foundation for the stability of the entire purification process.

[0044] Please see Figure 1 In step 3), the coupled enhanced separation unit performs electric field pre-separation and cyclone centrifugation enhanced separation on industrial waste oil. Electric field pre-separation promotes droplet aggregation in industrial waste oil through electric field, while cyclone centrifugation enhanced separation separates droplets and solid particles in industrial waste oil through centrifugal force field.

[0045] In this way, the problem of low efficiency in traditional single centrifugal separation is solved by the dual synergistic mechanism of electric field pre-separation and cyclone centrifugation enhanced separation. In the electric field pre-separation stage, the electric field force is used to promote the aggregation of small droplets into large droplets, which greatly improves the droplet size distribution. In the cyclone centrifugation enhanced separation stage, the centrifugal force field is used to efficiently separate the aggregated large droplets and solid particles. This dual separation mechanism not only improves the one-time removal rate of water and solid particles (up to 90% or more), but also effectively prevents the risk of secondary emulsification caused by excessively high initial water content during subsequent chaotic electric field treatment, providing a key guarantee for the efficient operation of the entire process.

[0046] Please see Figure 1 In step 4), the chaotic electric field dehydration unit applies a chaotic pulse-modulated electric field to the industrial waste oil, thereby disrupting the interfacial tension of the emulsion of the industrial waste oil through pulse action, thus removing micron-sized droplets from the industrial waste oil and avoiding secondary emulsification.

[0047] In this way, the pulsed action of the chaotic pulse-modulated electric field is specifically designed for the efficient removal of micron-sized droplets (1μm-100μm), solving the problem of secondary emulsification that easily occurs in traditional electric field dehydration. This chaotic electric field, through non-periodic, variable-frequency pulsed action, effectively disrupts the stability of the emulsion interface, promoting the rapid aggregation and sedimentation of micron-sized droplets, achieving a dehydration efficiency of over 98%. Simultaneously, the pulsed electric field avoids the interfacial charge saturation phenomenon caused by traditional continuous electric fields, fundamentally preventing secondary emulsification and ensuring the stability and purity of the regenerated oil.

[0048] Please see Figure 1 In step 5), the vacuum circulation separation unit provides a vacuum environment for industrial waste oil, enabling the nano-sized droplets in the industrial waste oil to vaporize and separate.

[0049] In this way, a cyclic separation mechanism under vacuum conditions is used to specifically remove nano-sized droplets (less than 1 μm), filling the gap in traditional purification processes for handling nano-sized impurities. Under vacuum conditions (typically controlled between -0.08 MPa and -0.095 MPa), the boiling point of nano-sized water droplets decreases, and they are rapidly vaporized and separated through cyclic heating. This unit can reduce the water content of waste oil from 0.5% after micron-level treatment to below 0.05%, meeting the stringent quality standards for recycled oil. Simultaneously, the vacuum environment also has the additional effect of removing dissolved gases, further improving the overall quality of the recycled oil.

[0050] Please see Figure 1 In step 6), the multi-gradient fine filtration unit uses a gradient filtration method to intercept and filter micron-sized solid particles in industrial waste oil step by step.

[0051] In this way, by intercepting solid particles of different sizes step by step through gradient filtration, precise removal of micron-sized solid impurities is achieved. This multi-gradient fine filtration unit adopts a three-stage filtration accuracy configuration of 5μm-10μm, 1μm-5μm, and 0.5μm-1μm. By filtering step by step, the problem of easy clogging of single-precision filters is avoided, and the service life of the filter element is extended. At the same time, the gradient filtration design ensures the thoroughness of solid particle removal, keeping the solid particle content of the recycled oil below NAS 6 level, meeting the strict cleanliness requirements of high-end mechanical equipment for lubricating oil, and extending the service life of the recycled oil.

[0052] Please see Figure 1 The PLC system coordinates and controls the operation of the heating unit, the coupling-enhanced separation unit, the chaotic electric field dehydration unit, the vacuum circulation separation unit, and the multi-gradient fine filtration unit according to the process parameters.

[0053] In this way, the PLC system enables real-time coordinated control of each process unit, achieving intelligent and adaptive adjustment of the entire purification process. Based on the process parameters monitored online, the PLC system dynamically adjusts the operating parameters of each unit (such as heating temperature, electric field strength, vacuum degree, filtration pressure, etc.) to ensure that each process unit operates collaboratively under optimal conditions. This intelligent coordinated control not only improves the automation level of the system and reduces manual intervention, but also automatically adjusts the process parameters according to changes in waste oil characteristics, ensuring the stability and consistency of recycled oil quality and improving the reliability and adaptability of the system.

[0054] Please see Figure 1 The process parameters include the temperature, water content, solids content, pressure, and flow rate of the industrial waste oil.

[0055] In this way, by accurately monitoring and controlling key process parameters such as temperature, moisture content, solids content, pressure, and flow rate, precise data support and control basis are provided for the entire purification process. Real-time monitoring and feedback control of these parameters enable the system to accurately identify abnormal states in the process (such as sudden changes in moisture content, abnormal increases in pressure, etc.) and make timely parameter adjustments or fault warnings. In particular, online monitoring of moisture content and solids content provides a direct basis for judging the separation effect of each process unit, ensuring the controllability and traceability of the quality of recycled oil, and providing a scientific basis for process optimization and quality control.

[0056] Please see Figure 1The present invention also includes a multi-stage separation integrated processing device for implementing the multi-stage separation integrated processing method described above. The multi-stage separation integrated processing device includes a coarse filter, a heater, a coupling enhanced separation unit, a chaotic electric field dehydration unit, a vacuum circulation separation unit, a multi-gradient fine filtration unit, and a PLC system. The coarse filter, heater, coupling enhanced separation unit, chaotic electric field dehydration unit, vacuum circulation separation unit, and multi-gradient fine filtration unit are connected in sequence and are electrically connected to the PLC system respectively.

[0057] The multi-stage separation integrated processing device of this invention connects the coarse filter, heater, coupled enhanced separation unit, chaotic electric field dehydration unit, vacuum circulation separation unit, and multi-gradient fine filtration unit in sequence according to the process flow, and realizes unified control through a PLC system. This solves the problems of traditional equipment being scattered, having complex pipeline connections, and having large energy losses. This integrated device has the advantages of high energy utilization and simple operation and maintenance. The tight connection between each unit reduces intermediate transmission links, reduces system pressure drop and heat loss, and improves the overall energy efficiency ratio. At the same time, the modular design facilitates the installation, commissioning, and subsequent maintenance and upgrades of the equipment.

[0058] Please see Figure 1 The PLC system includes a data acquisition module, a setpoint storage module, a deviation calculation module, an arithmetic module, and an execution control module.

[0059] In this way, a complete intelligent control closed-loop system is constructed through the collaborative work of the data acquisition module, setpoint storage module, deviation calculation module, calculation module, and execution control module. The data acquisition module acquires the operating status of each process unit in real time; the setpoint storage module saves the optimal process parameters; the deviation calculation module analyzes the difference between the actual value and the setpoint; the calculation module calculates the control quantity through PID algorithms; and the execution control module precisely adjusts the operating parameters of each unit. This modular PLC system architecture not only improves control accuracy and response speed but also has self-learning and adaptive capabilities, enabling continuous optimization of control strategies based on historical operating data, achieving dynamic optimization of process parameters, and ensuring long-term stable and efficient operation of the system.

[0060] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit the technical solutions. Those skilled in the art should understand that any modifications or equivalent substitutions to the technical solutions of the present invention without departing from the spirit and scope of the present invention should be covered within the scope of the claims of the present invention.

Claims

1. A multi-level separation and integration processing method, characterized in that: This includes the following steps and is coordinated and controlled via a PLC system; 1) The industrial waste oil is passed through a filtration unit to filter out some solid particles; 2) The industrial waste oil is passed through a heating unit to reduce its viscosity; 3) Industrial waste oil is processed through a coupled and enhanced separation unit to separate some water and solid particles; 4) Industrial waste oil is passed through a chaotic electric field dehydration unit to remove micron-sized droplets; 5) Industrial waste oil is passed through a vacuum circulation separation unit to remove nano-sized droplets; 6) Industrial waste oil is filtered through a multi-gradient fine filtration unit to remove micron-sized solid particles; 7) The output is recycled oil.

2. The multi-level separation and integration processing method according to claim 1, characterized in that: In step 2), the heating unit heats the industrial waste oil through an oil bath to reduce its viscosity and flow resistance, thereby improving the efficiency of subsequent separation.

3. The multi-level separation and integration processing method according to claim 2, characterized in that: In step 3), the coupled enhanced separation unit performs electric field pre-separation and cyclone centrifugation enhanced separation on industrial waste oil. Electric field pre-separation promotes droplet aggregation in industrial waste oil through an electric field, while cyclone centrifugation enhanced separation separates droplets and solid particles in industrial waste oil through a centrifugal force field.

4. The multi-level separation and integration processing method according to claim 3, characterized in that: In step 4), the chaotic electric field dehydration unit applies a chaotic pulse-modulated electric field to the industrial waste oil. The pulse action disrupts the interfacial tension of the industrial waste oil emulsion, thereby removing micron-sized droplets from the industrial waste oil and preventing secondary emulsification.

5. The multi-level separation and integration processing method according to claim 4, characterized in that: In step 5), the vacuum circulation separation unit provides a vacuum environment for industrial waste oil, enabling the nano-sized droplets in the industrial waste oil to vaporize and separate.

6. The multi-level separation and integration processing method according to claim 5, characterized in that: In step 6), the multi-gradient fine filtration unit uses a gradient filtration method to intercept and filter micron-sized solid particles in industrial waste oil step by step.

7. The multi-level separation and integration processing method according to claim 6, characterized in that: The PLC system coordinates and controls the operation of the heating unit, the coupling-enhanced separation unit, the chaotic electric field dehydration unit, the vacuum circulation separation unit, and the multi-gradient fine filtration unit according to process parameters.

8. The multi-level separation and integration processing method according to claim 7, characterized in that: Process parameters include the temperature, water content, solids content, pressure, and flow rate of industrial waste oil.

9. A multi-stage separation and integrated processing device, characterized in that: To implement the multi-stage separation and integrated processing method as described in claim 8, the multi-stage separation and integrated processing device includes a coarse filter, a heater, a coupling-enhanced separation unit, a chaotic electric field dehydration unit, a vacuum circulation separation unit, a multi-gradient fine filtration unit, and a PLC system; the coarse filter, heater, coupling-enhanced separation unit, chaotic electric field dehydration unit, vacuum circulation separation unit, and multi-gradient fine filtration unit are connected in sequence and are electrically connected to the PLC system respectively.

10. The multi-stage separation and integrated processing device according to claim 9, characterized in that: A PLC system includes a data acquisition module, a setpoint storage module, a deviation calculation module, an arithmetic module, and an execution control module.

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