Safety automatic feeding device for concentrated sulfuric acid

Abstract

This invention discloses a safe and automatic concentrated sulfuric acid feeding system, belonging to the field of chemical equipment. The invention includes a sulfuric acid storage tank with a discharge port at the bottom of its side wall, where a feeding pump is connected. It also includes: a pH monitoring module installed in the reaction system for online monitoring of the pH values ​​in multiple areas of the reaction system; a liquid level measuring device installed on the top of the sulfuric acid storage tank; and a visual hazard detection device installed above the reaction system. The feeding pump, pH monitoring module, liquid level measuring device, and visual hazard detection device are all connected to a control module. The control module controls the feeding pump to perform safe feeding operations based on the data detected by the pH monitoring module and the liquid level measuring device. This invention can perform risk assessment and coordinate the control of the feeding pump in real time based on the assessed values, thereby controlling the feeding rate of the feeding pump online, effectively improving the safety performance of concentrated sulfuric acid addition, and has the advantages of high safety and intelligence.

Description

Technical Field

[0001] This invention belongs to the field of chemical equipment, specifically, it relates to a safe and automatic concentrated sulfuric acid feeding device. Background Technology

[0002] Concentrated sulfuric acid is a hazardous chemical with wide applications in chemical production. It is highly corrosive. Currently, concentrated sulfuric acid is mainly added manually. In automated operations, a dedicated flow pump is used in conjunction with a concentrated sulfuric acid storage tank for automatic feeding control. The feeding speed and program are set for automated feeding. However, the reaction system changes unevenly during the feeding process, and sudden situations can easily occur. Maintaining the original feeding speed will cause problems in the reaction system. Therefore, the current sulfuric acid addition requires operator supervision, which is not very safe. Summary of the Invention

[0003] In view of the above-mentioned problems in the existing technology, the purpose of the present invention is to provide a safe automatic feeding device for concentrated sulfuric acid.

[0004] To solve the above problems, the technical solution adopted by the present invention is as follows:

[0005] An automatic concentrated sulfuric acid feeding system includes a sulfuric acid storage tank with a discharge port at the bottom of its side wall. A feeding pump is connected to the discharge port to pump concentrated sulfuric acid from the storage tank and meter it into a reaction system. The system further includes: a pH monitoring module installed in the reaction system for online monitoring of pH values ​​in multiple areas; a liquid level measuring device installed on the top of the storage tank, specifically a radar level gauge; and a visual hazard detection device installed above the reaction system. The feeding pump, pH monitoring module, liquid level measuring device, and visual hazard detection device are all connected to a control module. The control module controls the feeding pump to perform safe feeding operations based on data detected by the pH monitoring module and the liquid level measuring device.

[0006] As a preferred embodiment of the present invention, the sulfuric acid storage tank is provided with a float plate, the float plate comprising: a suspended body located below the liquid surface and a floating body located above the liquid surface, the floating body being designed to have the same shape as the cross-section of the sulfuric acid storage tank, the suspended body being located below the floating body and having a slot on the outside of the suspended body corresponding to the position of the discharge port, the inner wall of the sulfuric acid storage tank being provided with a vertically arranged guide rail, and the outer side of the floating body being provided with a guide groove corresponding to the guide rail.

[0007] In a preferred embodiment of the present invention, both the suspended body and the floating body are provided with cavities. The suspended body is provided with a liquid injection port, through which filling liquid is injected into the suspended body. The position of the suspended body relative to the liquid surface is adjusted by the injection volume and density of the filling liquid.

[0008] As a preferred embodiment of the present invention, the radar level gauge calculates the height of the liquid level inside the tank by measuring the height of the upper surface of the floating body.

[0009] As a preferred embodiment of the present invention, the visual hazard detection device is specifically a detection camera installed above the reaction system.

[0010] In a preferred embodiment of the present invention, the control module includes a local controller and a cloud server. The feed pump, pH monitoring module, liquid level measuring device, and detection camera are all connected to the local controller. The local controller is equipped with a wireless signal transmitting module and a wireless signal receiving module. The local controller sends signals to the cloud server through the wireless signal transmitting module. The cloud server stores the received data, calculates the control parameters of the feed pump, and sends the control parameters to the local controller. The local controller controls the feed pump in real time according to the control parameters.

[0011] As a preferred embodiment of the present invention, the safe addition control of concentrated sulfuric acid is achieved by the following method:

[0012] S1. The feed pump is initially started and the speed is gradually increased to collect data. The pH value (pH1, pH2...pHn) of each region and the state diagram of the reaction system are obtained through the pH monitoring module and the detection camera at different feed rates.

[0013] S2. Calculate the uniformity coefficient P by measuring the difference in pH values ​​detected by the pH monitoring module for each region;

[0014] S3. Input the reaction system image into the trained machine recognition model for recognition and output the risk factor Q;

[0015] S5. Calculate the overall risk level R based on the uniformity coefficient P and the risk coefficient Q obtained in real time;

[0016] S6. When the danger level R exceeds the threshold, the power to the feed pump is cut off (at this time, the feed pump's feeding speed is...). Once the overall risk level R is less than the threshold, restart the feed pump and directly adjust the feed rate of the feed pump to... ( If the overall risk level R is still greater than the threshold after restarting the feed pump, repeat the above steps until the overall risk level R is less than the threshold, where K is the correction parameter.

[0017] As a preferred embodiment of the present invention, the uniformity coefficient P is calculated according to the following formula:

[0018] ,

[0019] in: This represents the average pH value.

[0020] As a preferred embodiment of the present invention, the machine recognition model is trained using the following photographs: a photograph of a safe reaction system with label 1, a photograph of a mildly hazardous reaction system with label 2, and a photograph of a severely hazardous reaction system with label 3.

[0021] As a preferred embodiment of the present invention, the degree of danger R is calculated using the following formula:

[0022]

[0023] Wherein: A1 and A2 are obtained by the following method: based on the data set of feeding speed V, uniformity coefficient P, and danger coefficient Q obtained in step S1, the parametric equations of P(V) and Q(V) are obtained by linear fitting of the above data set, respectively. A1 and A2 correspond to the corresponding coefficients in the parametric equations of P(V) and Q(V), respectively, and the threshold is set to 2.

[0024] As a preferred embodiment of the present invention, the correction parameter K=0.9.

[0025] As a preferred embodiment of the present invention, the controller calculates the actual feeding control of the feeding pump using the following formula:

[0026]

[0027] in: This represents the maximum feeding speed of the feed pump.

[0028] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0029] 1. This invention uses a pH monitoring module and a visual hazard detection device in conjunction with a cloud service machine to conduct risk assessment. Based on the assessment values, it coordinates and controls the feeding pump in real time, thereby controlling the feeding rate of the feeding pump online and effectively improving the safety performance of concentrated sulfuric acid addition.

[0030] 2. The present invention provides a float plate inside the sulfuric acid storage tank. The float plate marks the liquid level by a suspended body located below the liquid surface and compresses the liquid surface shape by a floating body located above the liquid surface. When the floating body reaches the bottom, the remaining concentrated sulfuric acid is concentrated at the opening on the side of the floating body, reducing the amount of sulfuric acid residue in the sulfuric acid storage tank and facilitating the measurement of the remaining sulfuric acid level.

[0031] 3. This invention uses machine learning to train a model and output a risk factor Q, thereby enabling intelligent, unattended, and safe addition operations. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of a module for a concentrated sulfuric acid safety feeding device;

[0033] Figure 2 This is a schematic diagram of the structure of a sulfuric acid storage tank;

[0034] Figure 3 This is a control flow diagram for the safe exchange of concentrated sulfuric acid.

[0035] In the diagram: 1-Sulfuric acid storage tank; 101-Discharge port; 102-Air inlet; 103-Guide rail; 201-Floating body; 202-Suspended body; 203-Slot opening. Detailed Implementation

[0036] The present invention will be further described below with reference to specific embodiments.

[0037] like Figure 1 As shown, this invention provides a safe automatic concentrated sulfuric acid feeding device, including a sulfuric acid storage tank 1. A discharge port 101 is located at the bottom of the side wall of the sulfuric acid storage tank 1, and a feeding pump is connected to the discharge port 101. The feeding pump draws concentrated sulfuric acid from the sulfuric acid storage tank 1 and meteredly injects it into the reaction system. The device is characterized by further including: a pH monitoring module, installed in the reaction system for online monitoring of the pH value of multiple areas of the reaction system; a liquid level measuring device installed on the top of the sulfuric acid storage tank 1, specifically a radar level gauge installed on the top of the sulfuric acid storage tank 1; a visual hazard detection device installed above the reaction system, specifically a detection camera installed above the reaction system; and a feeding pump. The pH monitoring module, liquid level measuring device, and visual hazard detection device are all connected to the control module. The control module controls the feeding pump to perform safe feeding operations based on the data detected by the pH monitoring module and liquid level measuring device. The control module includes a local controller and a cloud server. The feeding pump, pH monitoring module, liquid level measuring device, and detection camera are all connected to the local controller. The local controller is equipped with a wireless signal transmitting module and a wireless signal receiving module. The local controller sends signals to the cloud server through the wireless signal transmitting module. The cloud server stores the received data, calculates the control parameters of the feeding pump, and sends the control parameters back to the local controller. The local controller controls the feeding pump in real time based on the control parameters.

[0038] like Figure 2As shown, the sulfuric acid storage tank is equipped with a float plate, which includes a suspension body 202 located below the liquid surface and a floating body 201 located above the liquid surface. The floating body 201 is designed to have the same shape as the inner cross section of the sulfuric acid storage tank 1. The suspension body 202 is located below the floating body 201, and the outer side of the suspension body 202 is provided with a groove 203 corresponding to the position of the discharge port 101. The inner wall of the sulfuric acid storage tank 1 is provided with a vertically arranged guide rail 103, and the outer side of the floating body 201 is provided with a guide groove 203 corresponding to the guide rail 103. Both the suspension body 202 and the floating body 201 are provided with cavities. The suspension body 202 is provided with a liquid filling port. Filling liquid is injected into the suspension body 202 through the liquid filling port. The position of the suspension body 202 relative to the liquid surface is adjusted by the injection volume and density of the filling liquid. The radar level gauge calculates the height of the liquid level in the tank by measuring the height of the upper surface of the floating body 201. The radar level gauge is installed at the air inlet 102 at the top of the sulfuric acid storage tank 1.

[0039] Figure 3 As shown, this embodiment uses the following method to control the safe addition of concentrated sulfuric acid:

[0040] S1. The feed pump is initially started and the speed is gradually increased to collect data. The pH value (pH1, pH2...pHn) of each region and the state diagram of the reaction system are obtained through the pH monitoring module and the detection camera at different feed rates.

[0041] S2. The uniformity coefficient P is calculated by differentiating the pH values ​​of each region detected by the pH monitoring module. The uniformity coefficient P is calculated according to the following formula: ,in: Average pH value;

[0042] S3. Input the reaction system image into the trained machine recognition model for recognition and output the hazard factor Q. The machine recognition model is trained using the following photos: a safe reaction system photo with label 1, a slightly hazardous reaction system photo with label 2, and a severely hazardous reaction system photo with label 3.

[0043] S5. Calculate the overall risk level R based on the real-time acquired uniformity coefficient P and risk coefficient Q. The risk level R is calculated using the following formula: Where: A1 and A2 are obtained by the following method: based on the data set of feeding speed V, uniformity coefficient P, and danger coefficient Q obtained in step S1, the parametric equations of P(V) and Q(V) are obtained by linear fitting of the above data set, respectively. A1 and A2 correspond to the corresponding coefficients in the parametric equations of P(V) and Q(V), respectively, and the threshold is set to 2.

[0044] S6. When the danger level R exceeds the threshold, the power to the feed pump is cut off (at this time, the feed pump's feeding speed is...). Once the overall risk level R is less than the threshold, restart the feed pump and directly adjust the feed rate of the feed pump to... ( If the overall risk level R is still greater than the threshold after restarting the feed pump, repeat the above steps until the overall risk level R is less than the threshold, where K is the correction parameter, and the correction parameter K=0.9.

[0045] The following is a sample control code:

[0046] import numpy as np

[0047] # Step S1: Data collection

[0048] def collect_data():

[0049] data = []

[0050] for speed in range(0, 100, 10):

[0051] # Start pump with initial speed

[0052] set_pump_speed(speed)

[0053] # Monitor and record PH values ​​from PH monitoring module

[0054] ph_values ​​= monitor_ph()

[0055] data.append(ph_values)

[0056] return data

[0057] # Step S2: Calculate uniformity coefficient (P)

[0058] def calculate_uniformity_coefficient(ph_values):

[0059] n = len(ph_values)

[0060] ph_avg = np.mean(ph_values)

[0061] ph_max = np.max(ph_values)

[0062] ph_min = np.min(ph_values)

[0063] p = 1 - np.sum(ph_values - ph_avg) / (n * (ph_max - ph_min))

[0064] return p

[0065] # Step S3: Machine recognition model for danger coefficient (Q)

[0066] def machine_recognition(image):

[0067] # Use trained machine learning model to recognize and calculatedanger coefficient

[0068] q = trained_model.predict(image)

[0069] return q

[0070] # Step S5: Calculate comprehensive danger coefficient (R)

[0071] def calculate_comprehensive_danger(p, q):

[0072] a1 = get_parameter_a1()

[0073] a2 = get_parameter_a2()

[0074] r = (a1 / (a1+a2)) * p + (a2 / (a1+a2)) * q

[0075] return r

[0076] # Step S6: Control pump and adjust speed

[0077] def control_pump(pump_speed):

[0078] set_pump_speed(pump_speed)

[0079] # Main control loop

[0080] def main_control_loop():

[0081] while 1:

[0082] # Step S1: Data collection

[0083] data = collect_data()

[0084] # Step S2: Calculate uniformity coefficient

[0085] p = calculate_uniformity_coefficient(data)

[0086] # Step S3: Machine recognition model for danger coefficient

[0087] image = capture_reaction_system_image()

[0088] q = machine_recognition(image)

[0089] # Step S5: Calculate comprehensive danger coefficient

[0090] r = calculate_comprehensive_danger(p, q)

[0091] # Step S6: Pump control and adjustment

[0092] if r>threshold:

[0093] # Step S6 - Part 1: Pump power off

[0094] control_pump(0)

[0095] while r>threshold:

[0096] # Step S6 - Part 2: Pump power on with adjusted speed

[0097] pump_speed *= 0.9

[0098] control_pump(pump_speed)

[0099] # Step S2: Calculate uniformity coefficient again

[0100] p = calculate_uniformity_coefficient(data)

[0101] # Step S3: Machine recognition model for danger coefficient again

[0102] image = capture_reaction_system_image()

[0103] q = machine_recognition(image)

[0104] # Step S5: Calculate comprehensive danger coefficient again

[0105] r = calculate_comprehensive_danger(p, q)

[0106] else:

[0107] # Resume normal operation

[0108] control_pump(normal_speed)

[0109] In actual operation, to prevent the sulfuric acid storage tank 1 from bottoming out and causing the sulfuric acid flow to stop, thus increasing the time for operators to replenish sulfuric acid, the controller calculates the actual feeding control of the feed pump using the following formula: ,in: This represents the maximum feeding speed of the feed pump.

[0110] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the invention.

Claims

1. A concentrated sulfuric acid safety automatic feeding system, comprising a sulfuric acid storage tank (1), a discharge port (101) is arranged at the bottom of the side wall of the sulfuric acid storage tank (1), a feeding pump is connected to the position of the discharge port (101), and the concentrated sulfuric acid in the sulfuric acid storage tank (1) is extracted outward and metered and injected into a reaction system through the feeding pump, characterized in that, Further comprising: a PH monitoring module arranged in the reaction system for online monitoring of the PH values of multiple regions of the reaction system; a liquid level measuring device arranged on the top of the sulfuric acid storage tank (1), which is specifically a radar level meter arranged on the top of the sulfuric acid storage tank (1); a visual danger detection device arranged above the reaction system, wherein the feeding pump, the PH monitoring module, the liquid level measuring device and the visual danger detection device are all connected to the control module, and the control module controls the feeding pump to perform safe feeding operation according to the data detected by the PH monitoring module and the liquid level measuring device; The visual danger detection device is specifically a detection camera arranged above the reaction system; The safe feeding control of concentrated sulfuric acid is performed by the following method: S1, the feeding pump is initially started and gradually accelerated to collect data, and the PH values of each region at different feeding speeds are obtained by the PH monitoring module and the detection camera, PH1, PH2…PHn, and a reaction system state diagram; S2, the PH values of each region detected by the PH monitoring module are calculated by difference to obtain an uniformity coefficient P; S3, the reaction system picture is input into the trained machine recognition model for recognition and output of a danger coefficient Q; S5, the comprehensive danger degree R is calculated according to the real-time obtained uniformity coefficient P and danger coefficient Q; S6, when the comprehensive risk degree R exceeds the threshold value, the feeding pump is powered off, at this time the feeding speed of the feeding pump is , after the comprehensive risk degree R is less than the threshold value, the feeding pump is restarted and the feeding speed of the feeding pump is directly adjusted to , , after the feeding pump is restarted, if the comprehensive risk degree R is still greater than the threshold value, the step of powering off the feeding pump is repeated until the comprehensive risk degree R is less than the threshold value, wherein K is a correction parameter.

2. The automatic concentrated sulfuric acid feeding system according to claim 1, characterized in that, The sulfuric acid storage tank is provided with a floating plate, which comprises: a suspended body (202) located below the liquid surface, and a floating body (201) located above the liquid surface, wherein the floating body (201) is designed to have a shape consistent with the cross section of the sulfuric acid storage tank (1), the suspended body (202) is arranged below the floating body (201), and the outer side of the suspended body (202) is provided with a slot (203) corresponding to the position of the discharge port (101), and the inner wall of the sulfuric acid storage tank (1) is provided with a vertical guide rail (103), and the outer side of the floating body (201) is provided with a slot (203) corresponding to the guide rail (103).

3. The automatic concentrated sulfuric acid feeding system according to claim 2, characterized in that, The suspended body (202) and the floating body (201) are both provided with cavities, and the suspended body (202) is provided with a liquid filling port, and the position of the suspended body (202) relative to the liquid surface is adjusted by the injection amount and density of the filling liquid.

4. The automatic concentrated sulfuric acid feeding system according to claim 3, characterized in that, The radar level meter calculates the height of the liquid surface in the tank by measuring the height of the upper surface of the floating body (201).

5. The automatic concentrated sulfuric acid feeding system according to claim 4, characterized in that, The control module comprises a local controller and a cloud server, and the feeding pump, the PH monitoring module, the liquid level measuring device and the detection camera are all connected to the local controller, the local controller is provided with a wireless signal sending module and a wireless signal receiving module, the local controller sends signals to the cloud server through the wireless signal sending module, the cloud server stores and calculates the received data to obtain the control parameters of the feeding pump and sends the control parameters to the local controller, and the local controller controls the feeding pump in real time according to the control parameters.

6. The automatic concentrated sulfuric acid feeding system according to claim 5, wherein The uniformity coefficient P is calculated according to the following formula: ， wherein: is the average pH value.

7. The automatic concentrated sulfuric acid feeding system according to claim 6, characterized in that, The machine recognition model is trained by the following photos: a safe reaction system photo with label 1, a mild danger reaction system photo with label 2, and a serious danger reaction system photo with label 3.

8. The automatic concentrated sulfuric acid feeding system according to claim 7, characterized in that, The danger degree R is calculated by the following formula: Wherein: A1, A2 are obtained by the following method: according to the data group of the feeding speed V obtained in step S1 and the uniformity coefficient P and the danger coefficient Q, the data group is linearly fitted to obtain the parameter equation of P(V) and Q(V), A1 and A2 correspond to the corresponding coefficients in the parameter equation of P(V) and Q(V) respectively, and the threshold is set to 2.

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