Ceramic spray tower powder cooling and energy consumption reduction fully automatic control device and control method

Abstract

The present invention relates to a fully automatic control device for cooling and reducing energy consumption of powder in a ceramic spray tower and a control method thereof. The fully automatic control device comprises a spray tower lower cone, a cylindrical feeder, and a spray tower hopper, which are connected in sequence. A radially extending flange on the outer wall of the spray tower lower cone is connected to a radially extending flange on the top of the cylindrical feeder via a fixing element. The spray tower hopper is fixed to the bottom of the cylindrical feeder. The device also includes a lifting mechanism disposed at the bottom of the inner cavity of the cylindrical feeder. The cylindrical feeder is equipped with a probe for detecting powder blockage. The lifting mechanism comprises a pair of upper and lower opposing frames, a lifting bracket pivotally mounted between the pair of upper and lower frames, and a cylinder assembly secured by a fixing element within pivot holes at the ends of the lifting brackets of the pair of lower frames.

Description

Technical Field

[0001] The invention belongs to the technical field of ceramics, and in particular relates to a fully automatic control device for cooling and reducing energy consumption of powder in a ceramic spray tower and a control method thereof. Background Art

[0002] The spray powder production process in ceramic companies involves atomizing and dehydrating slurry to form a powder. During this process, temperatures within the spray tower can reach as high as 700°C-1000°C. Consequently, the temperature of the granular powder after the slurry is atomized and dehydrated, resulting in a high temperature upon exiting the tower. This high-temperature powder, in turn, forms a large amount of water vapor when exposed to ambient air. This vapor, when the high-temperature powder enters the powder silo, can cause the powder to clump, leading to the formation of a clumping phenomenon. During the production process, if clumping material mixes with the normal blank, it can cause quality issues such as bulging, impurities, and interlayers. Furthermore, the clumping requires regular manual cleaning, which not only wastes powder but also increases employee labor and production costs. Furthermore, existing ceramic spray tower designs typically direct cold air into the spray tower from the lower hopper and cooling ports on the tower's undercooler, resulting in significant energy loss and high energy consumption, hindering production cost reduction.

[0003] CN202110249051.8 discloses a ceramic spray tower discharge device and a control method thereof, which provides a method for solving the problem of rehumidification and caking of powder when it is transported from the spray tower to the screening process by lowering the temperature of the powder discharged from the spray tower, thereby improving the utilization rate of powder and reducing production costs; and reducing the energy consumption of the cooling equipment for cooling the powder. This technical solution achieves rapid cooling of the powder by adding a ceramic spray tower discharge device below the conical bucket at the bottom of the spray drying tower and adjusting the amount of cold air according to production needs, thereby avoiding the heat dissipation of the freshly prepared powder and the formation of water mist when it meets water molecules in the air. The phenomenon of rehumidification and caking occurs when the powder is transported from the spray tower to the screening process, making the prepared powder quality more ideal and easier to screen and store, thereby improving the utilization rate of the powder. Its shortcomings are: it cannot effectively solve the problems of high temperature and energy loss during the flow of powder.

[0004] Therefore, solving the problems of powder temperature cooling and high energy consumption of spray towers in ceramic enterprises, that is, solving the problem of silo wall formation and reducing the energy consumption of spray towers, will improve the production quality of products, reduce the labor intensity of employees and the production costs of enterprises. Obviously, this is very important for existing ceramic enterprises. Summary of the Invention

[0005] The present invention aims to provide a fully automatic control device and method for cooling and reducing the energy consumption of powder in a ceramic spray tower, which uses a pneumatic cylinder to propel a lifting mechanism up and down, raising the lifting discharge cone into the lower cone of a spray tower until a gap is left between the lower cone and the lifting discharge cone. Powder enters the cylindrical discharge hopper through this gap, thereby preventing large amounts of cold air from entering the spray tower, causing energy loss in the spray tower and buildup of material on the tower walls. Another object of the present invention is to provide a fully automatic control device and method for cooling and reducing the energy consumption of powder in a ceramic spray tower, which, after the powder enters the cylindrical discharge hopper, discharges a mixture of hot air from the powder and cold air entering from cooling holes in the cylindrical discharge hopper and the spray tower lower hopper through a square dehumidification chamber. This allows the powder to be rapidly cooled. A further object of the present invention is to provide a fully automatic control method for cooling and reducing the energy consumption of powder in a ceramic spray tower, which detects and automatically clears the presence of mud and buildup on the tower walls blocking the discharge.

[0006] The technical solution of the present invention is the fully automatic control device for cooling and reducing energy consumption of powder in the ceramic spray tower, which includes a spray tower lower cone, a cylindrical feeder, and a spray tower hopper connected in sequence. A radially protruding flange on the outer wall of the spray tower lower cone is connected to a radially protruding flange on the top of the cylindrical feeder via a fixing element. The spray tower hopper is fixed to the bottom of the cylindrical feeder. The device is special in that it also includes a lifting mechanism, which is arranged at the bottom of the inner cavity of the cylindrical feeder. The cylindrical feeder is provided with a probe for detecting powder blockage.

[0007] The lifting mechanism consists of a pair of upper frames and a pair of lower frames that are opposed to each other, a lifting bracket pivotally arranged between the pair of upper frames and the pair of lower frames, and a cylinder assembly fixed in the pivot holes at the ends of the lifting brackets of the pair of lower frames through fixing elements.

[0008] Preferably, an upper lifting bracket fixing rod of the lifting mechanism is vertically inserted into a through-hole at one end of a pair of upper frames, a pair of first lifting movable plates are pivotally mounted on the ends of the upper lifting bracket fixing rod located on the upper frames, the ends of the upper movable shafts are vertically embedded in grooves at the other ends of the pair of upper frames, and a pair of second lifting movable plates are pivotally mounted on the ends of the upper movable shafts.

[0009] The lower lifting bracket fixing rod is vertically inserted into the through hole at one end of the pair of lower frames. The lower lifting bracket fixing rod is located at the end of the lower frame and a pair of first lifting movable plates are pivotally installed. The end of the lower movable shaft is vertically embedded in the groove at the other end of the pair of lower frames. The pair of second lifting movable plates are pivotally installed at the end of the lower movable shaft.

[0010] The cylinder assembly connects the piston rod to the pivot hole at the end of the lower frame lifting bracket through a fixing element. The cylinder assembly is fixed on a cylinder fixing plate. The cylinder fixing plate is vertically fixed on the outer wall of the cylindrical feeder. The other end of the piston rod passes through the outer wall of the cylindrical feeder to connect to the cylinder. The cylinder realizes the up and down movement of the lifting mechanism by reciprocating pushing back and forth. During normal feeding, the lifting mechanism rises and raises the lifting and feeding cone covered on a pair of upper frames into the lower cone of the spray tower until a gap is left between the lower cone of the spray tower and the lifting and feeding cone. The powder enters the cylindrical feeder through this gap.

[0011] Preferably, a pair of windows are symmetrically provided on the outer wall of the columnar feeder at the bottom of the flange, and a square dehumidification chamber is installed in each of the windows. The square dehumidification chamber is connected to a dehumidification air duct, and the dehumidification air duct discharges the hot air of the powder out of the columnar feeder through the square dehumidification chamber.

[0012] Preferably, the cylindrical discharger is provided with cooling holes, through which cold air enters the cylindrical discharger to cool the powder. The cold air entering the cooling holes basically blocks the space for entering the spray tower due to the lifting discharge cone, leaving only a gap for discharge, thereby preventing cold air from entering the spray tower, thereby preventing heat loss in the spray tower and reducing energy consumption of the spray tower.

[0013] Preferably, the probe is installed in a cylindrical discharger located above the lifting discharge cone; when mud or tower wall material appears in the spray tower and causes blockage, the probe senses the powder blockage and sends a signal to the controller. The controller instructs the lifting bracket to automatically descend until the lifting discharge cone descends to the lowest position, so that the discharge gap reaches the maximum, which is convenient for cleaning the blockage in the lower cone of the spray tower. When the probe senses that it has returned to normal, it sends a signal to the controller to make the lifting mechanism automatically rise and return to the previous discharge position, thereby realizing automatic control.

[0014] Another technical solution of the present invention is the lifting mechanism of the fully automatic control device for cooling and reducing energy consumption of powder in the ceramic spray tower. The special feature of the lifting mechanism is that the lifting mechanism is arranged at the bottom of the inner cavity of the cylindrical feeder of the powder control mechanism. The lifting mechanism is composed of a pair of upper lifting bracket fixing plates and a pair of lower lifting bracket fixing plates opposite each other, a lifting movable plate pivotally arranged between the pair of upper lifting bracket fixing plates and the pair of lower lifting bracket fixing plates, and a cylinder assembly fixed by a fixing element in the end pivot hole of the pair of lower lifting bracket fixing plates.

[0015] Preferably, the upper lifting bracket fixing rod is vertically inserted into the through-hole at one end of a pair of upper lifting bracket fixing plates, the upper lifting bracket fixing rod is located at the end of the upper lifting bracket fixing plate, and a pair of first lifting movable plates are pivotally installed respectively, the end of the upper movable shaft is vertically embedded in the groove at the other end of the pair of upper lifting bracket fixing plates, and the pair of second lifting movable plates are pivotally installed at the end of the upper movable shaft;

[0016] The lower lifting bracket fixing rod is vertically inserted into the through-hole at one end of a pair of lower lifting bracket fixing plates. The lower lifting bracket fixing rod is located at the end of the lower lifting bracket fixing plate, and a pair of first lifting movable plates are pivotally installed. The end heads of the lower movable shafts are respectively vertically embedded in the grooves at the other end of the pair of lower lifting bracket fixing plates, and a pair of second lifting movable plates are respectively pivoted at the ends of the lower movable shafts.

[0017] Preferably: the cylinder assembly connects the piston rod to the pivot hole at the end of the lower lifting bracket fixing plate through a fixing element, the cylinder assembly is fixed on the cylinder fixing plate, the cylinder fixing plate is vertically fixed on the outer wall of the cylindrical feeder, the other end of the piston rod passes through the outer wall of the cylindrical feeder to connect to the cylinder, and the cylinder realizes the up and down movement of the lifting mechanism by reciprocating pushing back and forth. During normal feeding, the lifting mechanism rises and raises the lifting and feeding cone covered on a pair of lifting bracket fixing plates into the lower cone of the spray tower until only a gap is left between the lower cone of the spray tower and the lifting and feeding cone, and the powder enters the cylindrical feeder through this gap.

[0018] Another technical solution of the present invention is the fully automatic control method for cooling powder and reducing energy consumption in the ceramic spray tower, which is special in that it includes the following steps:

[0019] (1) The slurry enters the spray tower and is atomized and dehydrated into powder. The powder falls freely and passes through the lower cone of the spray tower and then enters the cylindrical feeder;

[0020] (2) The cylinder pushes back and forth to realize the up and down movement of the lifting mechanism. Under normal feeding conditions, the lifting mechanism rises and the lifting discharge cone rises into the lower cone of the spray tower until a gap is left between the lower cone of the spray tower and the lifting discharge cone. The powder enters the cylindrical discharger through this gap.

[0021] (3) After the powder enters the cylindrical feeder through the gap between the lower cone of the spray tower and the lifting feeder cone, the dehumidification air duct discharges the hot air of the powder and the mixed air formed by the cold air entering from the cooling hole of the cylindrical feeder and the cold air entering from the lower hopper of the spray tower through the square dehumidification chamber out of the cylindrical feeder, thereby achieving rapid cooling of the powder;

[0022] (4) The cold air entering the spray tower hopper and the cooling hole of the cylindrical discharger is basically blocked by the lifting discharge cone, leaving only a gap for discharge, which prevents the cold air from entering the spray tower, thereby preventing the loss of heat in the spray tower and reducing the energy consumption of the spray tower;

[0023] ⑸ When the spray tower is blocked by mud or wall material, the probe senses the blockage and sends a signal to the controller. The controller instructs the lifting mechanism to automatically descend until the lifting and unloading cone descends to the lowest position, so that the unloading gap reaches the maximum, making it convenient to clean up the blockage in the lower cone of the spray tower. When the probe senses that the powder has returned to normal, it sends a signal to the controller to make the lifting mechanism automatically rise and return to the previous unloading position, realizing automatic control.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] (1) The present invention improves the problem of large water vapor in the powder discharged from the tower due to contact with air at high temperature, improves the problem of powder wall formation, thereby reducing product quality defects, reducing powder waste and reducing the labor intensity of employees, avoiding energy waste in the spray tower, further reducing the production cost of the enterprise, and improving the product competitiveness of the enterprise.

[0026] ⑵The present invention realizes the up and down movement of the lifting mechanism through the promotion of the cylinder, and raises the lifting discharge cone to the lower cone of the spray tower until a gap is left between the lower cone of the spray tower and the lifting discharge cone. The powder enters the cylindrical discharger through this gap, which greatly reduces the amount of cold air entering the spray tower from the lower hopper of the spray tower and the cooling hole of the cylindrical discharger, prevents the loss of heat in the spray tower, reduces the energy consumption of the spray tower, and also reduces the probability of the lower cone of the spray tower causing material to form on the tower wall due to the entry of cold air, thereby reducing the waste of powder.

[0027] ⑶ The square dehumidification chamber and dehumidification air duct provided in the present invention accelerate the heat exchange between the external cold air and the powder, thereby achieving rapid cooling of the powder.

[0028] (4) The probe of the present invention is installed in the cylindrical discharger and above the lifting discharge cone. When the spray tower is blocked by mud, tower wall material, etc., the probe senses the powder blockage and sends a signal to the controller. The controller issues an instruction to automatically lower the lifting bracket until the lifting discharge cone drops to the lowest position, so that the discharge gap reaches the maximum, which is convenient for cleaning the blockage in the lower cone of the spray tower. When the probe senses that the powder has returned to normal, it sends a signal to the controller to automatically rise the lifting bracket and return to the previous discharge position, thereby realizing automatic control. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a structural schematic diagram of the fully automatic control device of the present invention;

[0030] Figure 2 It is a schematic diagram of the structure decomposition of the fully automatic control device of the present invention;

[0031] Figure 3This is a schematic diagram of the structural coordination between the lower cone of the spray tower and the cylindrical feeder of the fully automatic control device of the present invention;

[0032] Figure 4 It is a schematic diagram of the structural coordination of the spray tower lifting discharge cone and the spray tower discharge hopper of the fully automatic control device of the present invention.

[0033] Description of main component symbols:

[0034] DETAILED DESCRIPTION

[0035] The present invention will be further described below in conjunction with the accompanying drawings:

[0036] See also Figure 1 As shown, the fully automatic control device for cooling and reducing energy consumption of powder in a ceramic spray tower comprises a spray tower 1 and a fully automatic control device 2 for cooling and reducing energy consumption of powder in a spray tower.

[0037] See also Figure 2 、 Figure 3 As shown, the lower cone 101 of the spray tower is fixed together with the cylindrical discharger 201, the square dehumidification chamber 203 is installed on the outside of the upper end of the cylindrical discharger 201, one is installed on each side, the dehumidification air duct 204 is installed on the square dehumidification chamber 203, the lifting bracket 202 is fixed at the lower end inside the cylindrical discharger 201, the lifting discharge cone 207 is fixed on the lifting bracket 202, and moves up and down with the lifting mechanism 202, the spray tower hopper 208 is installed under the cylindrical discharger 201, the cylinder fixing plate 209 is fixed on the outer wall of the cylindrical discharger 201, the cylinder 205 is installed on the cylinder fixing plate 209, the piston rod 2051 is connected to the pivot hole at the end of the descending bracket fixing plate 2022, and the probe 206 is installed on the cylindrical discharger 201.

[0038] See also Figure 4 As shown, the lifting bracket fixing rod 2025 connects the rising bracket fixing plate 2024, the descending bracket fixing plate 2022 and the lifting movable plate 2023 together, the movable shaft 2021 connects the lifting movable plate 2023, and moves back and forth between the rising bracket fixing plate 2024 and the descending bracket fixing plate 2022 to realize the up and down movement of the lifting bracket 202, and the cylinder 205 is fixed together with the lifting movable plate 2023 on the lifting bracket 202, and the cylinder 205 pushes the lifting bracket 202 to move up and down.

[0039] See also Figures 1 to 4 As shown, the ceramic spray tower powder material cooling and energy consumption reduction fully automatic control method comprises the following steps:

[0040] 1.1 The slurry enters the spray tower 1 and is atomized and dehydrated into powder. The powder falls freely through the lower cone 101 of the spray tower and then enters the cylindrical feeder 201.

[0041] 1.2 The cylinder 205 pushes the lifting mechanism 202 up and down by pushing it back and forth. Under normal feeding conditions, the lifting mechanism 202 rises and the lifting discharge cone 207 rises into the lower cone 101 of the spray tower until only a gap is left between the lower cone 101 of the spray tower and the lifting discharge cone 207. The powder enters the cylindrical discharger 201 through this gap.

[0042] 1.3 The powder exits the spray tower 1 through the spray tower hopper 208. When the powder enters the cylindrical discharger 201, cold air enters the cooling holes on the cylindrical discharger 201 to cool the powder. At the same time, the dehumidification air duct 204 discharges the hot air of the powder out of the cylindrical discharger 201 through the square dehumidification chamber 203, thereby achieving rapid cooling of the powder. On the other hand, the cold air entering from the spray tower hopper 208 and the cooling holes of the cylindrical discharger is basically blocked by the lifting discharge cone 207, which basically blocks the space for entering the spray tower 1, leaving only a gap for discharge. This prevents cold air from entering the spray tower 1, thereby preventing heat loss in the spray tower and reducing energy consumption of the spray tower.

[0043] 1.4 The probe 206 is installed in the cylindrical discharger 201 and above the lifting discharge cone 207. When mud, tower wall material, etc. appear in the spray tower 1 and cause blockage, the probe 206 senses the powder blockage and sends a signal to the controller. The controller issues an instruction to automatically lower the lifting bracket 202 until the lifting discharge cone 207 drops to the lowest position, so that the discharge gap reaches the maximum, making it convenient to clear the blockage in the lower cone 101 of the spray tower; when the probe 206 senses that the powder has returned to normal, it sends a signal to the controller to automatically rise the lifting bracket 202 and return to the previous discharge position, realizing automatic control.

[0044] The above descriptions are merely preferred embodiments of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention shall fall within the scope of the claims of the present invention.

Claims

1. A fully automatic control device for cooling and reducing energy consumption of powder in a ceramic spray tower, comprising a spray tower lower cone, a cylindrical feeder, and a spray tower lower hopper connected in sequence, characterized in that: The flange protruding radially from the outer wall of the lower cone of the spray tower is connected to the flange protruding radially from the top of the cylindrical discharger through a fixing element. A spray tower discharge hopper is fixedly arranged at the bottom of the cylindrical discharger, and further comprises a lifting mechanism, which is arranged at the bottom of the inner cavity of the cylindrical discharger. The lifting discharge cone is fixedly mounted on the lifting bracket. During normal discharge, the lifting mechanism rises and raises the lifting discharge cone covered on a pair of upper frames into the lower cone of the spray tower until a gap is left between the lower cone of the spray tower and the lifting discharge cone, and the powder enters the column through the gap. shaped discharger to block cold air from entering the spray tower; a probe for detecting powder blockage is provided in the cylindrical discharger, the probe being installed above the lifting discharge cone and connected to the controller signal. When blockage is detected, the lifting mechanism is triggered to descend to expand the discharge gap and clear the blockage; the lifting mechanism is composed of a pair of upper frames and a pair of lower frames arranged opposite each other, a lifting bracket pivotally arranged between the pair of upper frames and the pair of lower frames, and a cylinder assembly fixed by a fixing element in the end pivot hole of the pair of lower frame lifting brackets; The cylindrical feeder is located on the outer wall of the bottom of the flange and a pair of windows are symmetrically opened. A square dehumidification chamber is installed in each of the windows. The square dehumidification chamber is connected to the dehumidification air duct. The dehumidification air duct discharges the hot air of the powder out of the cylindrical feeder through the square dehumidification chamber.

2. The ceramic spray tower powder cooling and energy consumption reduction automatic control device according to claim 1, characterized in that: The upper lifting bracket fixing rod of the lifting mechanism is vertically inserted into the through-hole at one end of the pair of upper frames. The upper lifting bracket fixing rod is located at the end of the upper frame and a pair of first lifting movable plates are pivotally installed. The ends of the upper movable shafts are vertically embedded in the grooves at the other ends of the pair of upper frames. A pair of second lifting movable plates are pivotally installed at the ends of the upper movable shafts. The lower lifting bracket fixing rod is vertically inserted into the through hole at one end of the pair of lower frames. The lower lifting bracket fixing rod is located at the end of the lower frame and a pair of first lifting movable plates are pivotally installed. The end of the lower movable shaft is vertically embedded in the groove at the other end of the pair of lower frames. The pair of second lifting movable plates are pivotally installed at the end of the lower movable shaft. The cylinder assembly connects the piston rod to the pivot hole at the end of the lower frame lifting bracket through a fixing element. The cylinder assembly is fixed on a cylinder fixing plate, and the cylinder fixing plate is vertically fixed on the outer wall of the cylindrical feeder. The other end of the piston rod passes through the outer wall of the cylindrical feeder and connects to the cylinder. The cylinder realizes the up and down movement of the lifting mechanism by reciprocating pushing back and forth.

3. The ceramic spray tower powder material cooling and energy consumption reduction automatic control device according to claim 1, characterized in that: The cylindrical feeder is provided with cooling holes, through which cold air enters the cylindrical feeder to cool the powder. The gap prevents cold air from entering the spray tower, thereby preventing heat loss in the spray tower and reducing energy consumption of the spray tower.

4. The ceramic spray tower powder cooling and energy consumption reduction automatic control device according to claim 1, characterized in that: The probe is installed in a cylindrical discharger located above the lifting discharge cone; when mud or tower wall material appears in the spray tower and causes blockage, the probe senses the powder blockage and sends a signal to the controller. The controller instructs the lifting bracket to automatically descend until the lifting discharge cone descends to the lowest position, so that the discharge gap reaches the maximum, which is convenient for cleaning the blockage in the lower cone of the spray tower. When the probe senses that the powder has returned to normal, it sends a signal to the controller to automatically rise the lifting mechanism and return to the previous discharge position, thereby realizing automatic control.

5. A fully automatic control method for cooling and reducing energy consumption of powder in a ceramic spray tower, the method being based on the fully automatic control device for cooling and reducing energy consumption of powder in a ceramic spray tower according to claim 1, characterized in that: The following steps are involved: (1) The slurry enters the spray tower and is atomized and dehydrated into powder. The powder falls freely and passes through the lower cone of the spray tower and then enters the cylindrical feeder; (2) The cylinder pushes back and forth to realize the up and down movement of the lifting mechanism. Under normal feeding conditions, the lifting mechanism rises and the lifting discharge cone rises into the lower cone of the spray tower until a gap is left between the lower cone of the spray tower and the lifting discharge cone. The powder enters the cylindrical discharger through this gap. (3) After the powder enters the cylindrical feeder through the gap between the lower cone of the spray tower and the lifting feeder cone, the dehumidification air duct discharges the hot air of the powder and the mixed air formed by the cold air entering from the cooling hole of the cylindrical feeder and the cold air entering from the lower hopper of the spray tower through the square dehumidification chamber out of the cylindrical feeder, thereby achieving rapid cooling of the powder; (4) The cold air entering the spray tower hopper and the cooling hole of the cylindrical discharger is basically blocked by the lifting discharge cone, leaving only a gap for discharge, which prevents the cold air from entering the spray tower, thereby preventing the loss of heat in the spray tower and reducing the energy consumption of the spray tower; ⑸ When the spray tower is blocked by mud or wall material, the probe senses the blockage and sends a signal to the controller. The controller instructs the lifting mechanism to automatically descend until the lifting and unloading cone descends to the lowest position, so that the unloading gap reaches the maximum, making it convenient to clean up the blockage in the lower cone of the spray tower. When the probe senses that the powder has returned to normal, it sends a signal to the controller to make the lifting mechanism automatically rise and return to the previous unloading position, realizing automatic control.

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