Continuous automatic carbon black production system

Abstract

The invention relates to the technical field of carbon black treatment, in particular to a continuous automatic carbon black production system which comprises a soaking unit, a forming unit and a drying unit, the soaking unit comprises a soaking channel, a vibration filter is arranged at the top of the soaking channel, a plurality of water spraying ends are arranged on the inner wall of the soaking channel, and the soaking unit is used for allowing carbon black powder to enter; filtering the carbon black powder, enabling the filtered carbon black powder to fall, and starting a water spraying end to spray an aqueous solution in the falling process of the carbon black powder; the forming unit is used for feeding wet carbon black powder, granulating the carbon black powder and outputting formed granular carbon black; the drying unit is used for allowing granular carbon black to enter, drying the granular carbon black and outputting finished carbon black particles. By adopting the scheme, the uniformity of the carbon black soaked aqueous solution in the carbon black granulation process can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of carbon black processing, and in particular to a continuous automated carbon black production system. Background Art

[0002] Carbon black is a kind of material produced by high-temperature cracking of raw materials such as bituminous coal, coke or natural gas. It has excellent electrical and thermal conductivity, wear resistance and UV resistance, and is widely used in rubber, plastic, ink, coating, cosmetics, battery and other industrial fields. Carbon black after production is usually powder, with poor fluidity and high flutteriness. It is very easy to adhere to the surface of other objects during transportation and storage, which makes it difficult to transport and store carbon black. It is also easy to pollute the working environment and endanger the health of workers. In order to facilitate the transportation and use of carbon black and reduce the pollution to transportation tools and working environment, carbon black needs to be granulated.

[0003] The existing carbon black granulation process is mainly divided into wet granulation and dry granulation. At present, most domestic carbon black companies use wet granulation process to produce carbon black. The main process is: input powdered carbon black and an aqueous solution containing a certain amount of binder into a granulator, and the granulated carbon black is formed by the granulator, and then dried to obtain the finished granular carbon black, which can be packaged. However, in the granulation process, the content of the aqueous solution is crucial. If there is too much aqueous solution, the granular carbon black will not be well formed and will be easy to stick together, and the carbon black particle size requirements will not be met. If there is too little aqueous solution, the carbon black powder will not have enough adhesion, and the granular carbon black will be easy to break, resulting in a decrease in the amount of carbon black formed. Therefore, there is an urgent need for a carbon black production system that can improve the uniformity of the carbon black soaking aqueous solution during the carbon black granulation process. Summary of the invention

[0004] The present invention aims to provide a continuous automated carbon black production system, which can improve the uniformity of the carbon black soaking water solution during the carbon black pelletizing process.

[0005] The present invention provides the following basic scheme: A continuous automated carbon black production system comprises a soaking unit, a molding unit and a drying unit. The soaking unit comprises a soaking channel. A vibration filter is arranged on the top of the soaking channel. A plurality of water spray ends are arranged on the inner wall of the soaking channel. The soaking unit is used to allow carbon black powder to enter, filter the carbon black powder, and make the filtered carbon black powder fall. During the falling process of the carbon black powder, the water spray end is started to spray the aqueous solution. The molding unit is used to feed wet carbon black powder, granulate the carbon black powder, and output molded granular carbon black; The drying unit is used to supply granular carbon black, dry the granular carbon black, and output finished carbon black particles.

[0006] Furthermore, a main control unit is included, and the main control unit includes: An image acquisition module, used for acquiring images of granular carbon black and carbon black particles before and after entering the drying unit; The image detection module is used to perform image analysis based on the granular carbon black image and the carbon black particle image to determine whether there is any abnormality in the wetting unit, the molding unit and the drying unit, and to issue an early warning when an abnormality is determined.

[0007] Furthermore, the image detection module is provided with a quantity threshold, and the image detection module is used to identify the average number of particles in the granular carbon black image and the carbon black particle image. When the difference between the average number of particles in the granular carbon black image and the carbon black particle image exceeds the quantity threshold, it is determined that an abnormality occurs.

[0008] Furthermore, the main control unit also includes a fault location module, which is provided with a volume threshold. The fault location module is used to identify the unit volume of the particulate matter in the granular carbon black image and the carbon black particle image when the image detection module determines that an abnormality occurs. When the difference between the unit volume of the particulate matter in the granular carbon black image and the carbon black particle image exceeds the volume threshold, the drying unit is marked as an abnormal unit, otherwise, the wetting unit is marked as an abnormal unit.

[0009] Furthermore, it also includes an infrared detection unit, which is used to start when the image detection module determines that an abnormality occurs, and collect the wet infrared image and the dry infrared image of the wet unit and the dry unit; The main control unit also includes a fault self-checking module, which is used to perform image analysis based on the wet infrared image and the dry infrared image to generate a self-checking result and output it.

[0010] Furthermore, the fault self-detection module is used to perform image analysis on the drying infrared image to obtain the real-time drying temperature when the drying unit is marked as an abnormal unit, and to determine whether the real-time drying temperature is within a preset drying temperature range. If the real-time drying temperature exceeds the drying temperature range, a self-detection result of temperature control abnormality is generated and output.

[0011] Furthermore, the fault self-detection module is also used to perform image analysis on the wetting infrared image to obtain the real-time wetting temperature when the wetting unit is marked as an abnormal unit, and to determine whether the real-time wetting temperature is lower than a preset wetting temperature threshold. If the real-time wetting temperature is lower than the wetting temperature threshold, a self-detection result of water spray abnormality is generated and output.

[0012] Furthermore, the main control unit further comprises a water spray control module, which is used to control each water spray end to spray the aqueous solution according to a preset average water spray amount; The fault self-check module is also used to obtain the pipeline flow and pipeline pressure connected to each water spray end when the self-check result is abnormal water spraying, and match the corresponding pipeline flow and pipeline pressure according to the average water spraying amount of each water spray end. When there is a mismatch, it is determined that the corresponding water spray end has an abnormality, and the corresponding water spray end is marked and output.

[0013] Furthermore, the fault self-detection module is also used to obtain a real-time wetting image in the wetting channel, which includes the spray status of each water spray end. The spray status of each water spray end is identified based on the real-time wetting image, and the spray information of each water spray end is generated. The corresponding spray information is matched according to the average water spray volume of each water spray end. When there is a mismatch, it is determined that the corresponding water spray end is abnormal, and the corresponding water spray end is marked and output.

[0014] Furthermore, the vibration filter includes a plurality of vibration filter screens, and the carbon black powder passes through the plurality of vibration filter screens in sequence.

[0015] Beneficial effects of the basic program: In the carbon black granulation process, the content of aqueous solution is crucial. If there is too much aqueous solution, the granular carbon black will not be well formed and will be easy to stick together, which will not meet the carbon black particle size requirements. If there is too little aqueous solution, the carbon black powder will not have enough adhesion and the granular carbon black will be easy to break, resulting in a decrease in the carbon black forming amount.

[0016] In this solution, the carbon black powder is filtered through a vibration filter. The setting of multiple vibration filters can, firstly, effectively filter the particulate matter in the carbon black powder to avoid affecting the subsequent carbon black powder's absorption of the aqueous solution; secondly, it can disperse the carbon black powder, increase the degree of dispersion of the subsequent carbon black powder when it falls, and facilitate uniform wetting of the carbon black powder. The water spray end is set to spray water solution to wet the dispersed carbon black powder during the falling process. With this setting, the uniformity of the carbon black wetting aqueous solution during the carbon black granulation process can be effectively improved. The setting of the molding unit and the drying unit can granulate and dry the carbon black powder to obtain finished carbon black particles, which are easy to transport and store.

[0017] In this solution, the image detection module is set up to analyze the images of granular carbon black and carbon black particles before and after drying, automatically determine whether there are abnormal units in the wetting unit, molding unit and drying unit, and issue an early warning when an abnormality occurs. With this setting, the abnormality of the granulation process can be automatically detected and an early warning can be issued for the abnormality, which is convenient for the staff to inspect the production equipment and parameters according to the early warning, find and solve problems in time, and reduce losses.

[0018] In this scheme, the abnormal unit is further located for early warning, and the abnormal unit is self-checked to locate the fault. First, based on the granular carbon black image and the carbon black particle image before and after drying, this scheme determines whether an abnormality occurs according to the change in the amount of carbon black, and further locates the abnormal unit as a wetting unit or a drying unit according to the volume change of carbon black. Then, the infrared detection unit is started to collect infrared images, and the real-time temperature conditions of the wetting infrared image and the drying infrared image are compared and analyzed with the temperature conditions required by production to locate abnormal problems, such as problems with the temperature control of the drying unit and the need to adjust the drying temperature. Furthermore, when the wetting unit is abnormal, the water spray end is detected, and the water spray status is detected to determine whether the water spray end is abnormal, such as blockage of the water spray end, substandard water spray end, and other abnormalities. The cause of the fault is located in a timely manner to facilitate timely handling of the fault. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 The present invention is a logic block diagram of a continuous automated carbon black production system embodiment. DETAILED DESCRIPTION

[0020] The following is further described in detail through specific implementation methods: Example A continuous automated carbon black production system, as shown in the attached Figure 1 As shown, it includes a soaking unit, a molding unit, a drying unit, a main control unit, and an infrared detection unit. The soaking unit includes a soaking channel. A vibration filter is provided at the top of the soaking channel. The vibration filter includes a plurality of vibration filters, which are arranged in sequence. The inner wall of the soaking channel is provided with a plurality of water spray ends, which are distributed in a ring shape on the inner wall of the soaking channel. The water spray ends are distributed in multiple layers, and the water spray ends of adjacent layers are staggered. The vibration filter is used to filter the carbon black powder, which passes through multiple vibration filters in sequence and enters the soaking channel. The soaking channel is arranged vertically. After entering the soaking channel, the carbon black powder falls along the soaking channel. The water spray end is used to spray the aqueous solution according to the preset average water spray amount. The filtered carbon black powder falls in the soaking channel. The sprayed aqueous solution soaks the carbon black powder so that the carbon black powder has a certain humidity. The aqueous solution contains a certain amount of binder. The configuration and spray amount of the aqueous solution are configured and set in advance by the technical personnel according to the production process and formula.

[0021] The wetting unit is used to allow carbon black powder to enter, filter the carbon black powder, and make the filtered carbon black powder fall. During the falling process of the carbon black powder, the water spray end is started to spray the aqueous solution. The molding unit is used to allow wet carbon black powder to enter, granulate the carbon black powder, and output the molded granular carbon black. The drying unit is used to allow granular carbon black to enter, dry the granular carbon black, and output the finished carbon black granules. The molding unit and the drying unit can use the granulation equipment and drying equipment in the carbon black granulation production process.

[0022] The main control unit includes an image acquisition module, an image detection module, a fault location module, a fault self-checking module and a water spray control module.

[0023] The water spray control module is used to control each water spray end to spray the aqueous solution according to a preset average water spray volume. The average water spray volume is the dosage of the aqueous solution required for granulation with the carbon black powder.

[0024] The image acquisition module is used to acquire images of granular carbon black and carbon black particles before and after entering the drying unit. Specifically, image acquisition devices are provided at the head and the end of the drying unit, and the images of granular carbon black and carbon black particles are acquired in real time through the image acquisition devices and uploaded.

[0025] The image detection module is used to perform image analysis based on the granular carbon black image and the carbon black particle image, determine whether there is an abnormality in the wetting unit, the molding unit and the drying unit, and issue an early warning when it is determined that an abnormality occurs. Specifically: The image detection module is provided with a quantity threshold, and the image detection module is used to identify the average number of particles in the granular carbon black image and the carbon black particle image. When the difference between the average number of particles in the granular carbon black image and the carbon black particle image exceeds the quantity threshold, it is determined that an abnormality occurs and an early warning is issued. Affected by the drying and image detection accuracy, there is a difference in the number of carbon black before and after drying. The quantity threshold is the maximum value of the granular carbon black crushing during the drying process of the drying unit. When the difference between the average number of particles in the granular carbon black image and the carbon black particle image exceeds the quantity threshold, it means that the carbon black after drying is too crushed, and there may be problems such as abnormal drying temperature and abnormal aqueous solution dosage. At this time, an early warning is issued to remind the staff, and the system performs self-inspection and positioning of the abnormality.

[0026] The fault location module is provided with a volume threshold. The fault location module is used to identify the unit volume of the particles in the granular carbon black image and the carbon black particle image when the image detection module determines that an abnormality occurs. When the difference between the unit volume of the particles in the granular carbon black image and the carbon black particle image exceeds the volume threshold, the drying unit is marked as an abnormal unit. Otherwise, the soaking unit is marked as an abnormal unit. Affected by the drying and image detection accuracy, there is a difference in the volume of carbon black before and after drying. The volume threshold is the maximum value of the volume change of the granular carbon black during the drying process of the drying unit. When the difference between the unit volume of the particles in the granular carbon black image and the carbon black particle image exceeds the volume threshold, it means that the volume change of the carbon black after drying is too large, and there may be a problem of abnormal drying temperature. Otherwise, there may be a problem of abnormal dosage of aqueous solution. The abnormal unit is marked to facilitate the staff to prioritize the abnormal unit and solve the abnormality in time.

[0027] The infrared detection unit is used to start when the image detection module determines that an abnormality occurs, and collects the wet infrared image and dry infrared image of the wet unit and the dry unit. The infrared detection unit is not started in daily production, but only when an abnormality occurs, which reduces the system processing memory occupied by the infrared detection unit, improves the system response efficiency, and improves the system production control accuracy.

[0028] The fault self-check module is used to generate self-check results based on the image analysis of the soaking infrared image and the drying infrared image, and output them. Specifically: When the drying unit is marked as an abnormal unit, the fault self-check module is used to analyze the drying infrared image to obtain the real-time drying temperature, and determine whether the real-time drying temperature is within the preset drying temperature range. If the real-time drying temperature exceeds the drying temperature range, a self-check result of temperature control abnormality is generated and output. The drying temperature range is the temperature range required for drying granular carbon black preset in advance. Combined with the drying infrared image and the drying temperature range, it is further confirmed whether the temperature control of the drying unit is abnormal.

[0029] The fault self-check module is also used to analyze the wetting infrared image to obtain the real-time wetting temperature when the wetting unit is marked as an abnormal unit, and to determine whether the real-time wetting temperature is lower than the preset wetting temperature threshold. If the real-time wetting temperature is lower than the wetting temperature threshold, a self-check result of abnormal water spraying is generated and output. The aqueous solution sprayed by the water spray end has a certain temperature, and the aqueous solution sprayed by the water spray end is greater than 70 degrees Celsius. The aqueous solution with a certain temperature is more likely to enter the carbon black and wet the carbon black powder. The wetting temperature threshold is the preset temperature of the aqueous solution for wetting carbon black. The wetting temperature threshold is less than 65 degrees Celsius. Combined with the wetting infrared image, it is further confirmed whether there is an abnormality in the water spray end of the wetting unit.

[0030] The fault self-check module is also used to obtain the pipeline flow and pipeline pressure connected to each water spray end when the self-check result is abnormal water spray, match the corresponding pipeline flow and pipeline pressure according to the average water spray volume of each water spray end, and when they do not match, it is determined that the corresponding water spray end is abnormal, and the corresponding water spray end is marked and output. The water spray end sprays the aqueous solution through a spray gun, and each spray gun has a unique spray gun identification. Specifically, the fault self-check module is also used to determine whether the average water spray volume is greater than the actual water spray volume corresponding to the pipeline flow and pipeline pressure. If it is greater, it is determined that the corresponding water spray end is blocked, and a self-check result of water spray end blockage is generated at this time, and the spray gun identification of the blocked water spray end is marked. Otherwise, it is determined that the flow control of the water spray end is abnormal, and a self-check result of water spray end flow abnormality is generated at this time, and the spray gun identification of the abnormal water spray end is marked.

[0031] The pipeline flow and pipeline pressure of each water spray end can reflect the dosage of the aqueous solution sprayed by the water spray end. Therefore, the setting of the fault self-detection module determines whether the water spray end sprays the aqueous solution according to the average water spray amount by matching the average water spray amount, pipeline flow and pipeline pressure, so as to determine whether there is an abnormality in the water spray end.

[0032] In other embodiments, the fault self-checking module is also used to obtain a real-time wetting image in the wetting channel, the real-time wetting image includes the spraying state of each water spray end, the spraying state of each water spray end is identified according to the real-time wetting image, the spraying information of each water spray end is generated, and the corresponding spraying information is matched according to the average spraying amount of each water spray end. When there is no match, it is determined that the corresponding water spray end is abnormal, and the corresponding water spray end is marked and output. The spraying state is the information reflecting the spraying of the aqueous solution, such as the radiation range sprayed by the water spray end and the brightness of the radiation range.

[0033] Specifically, the spraying state includes the radiation range of the water spraying end or the brightness of the radiation range. When the spraying state is the radiation range of the water spraying end, the fault self-detection module is used to perform image recognition based on the real-time wetting image to generate spraying information. At this time, the spraying information is the actual area value of the radiation range of the water spraying end. The corresponding planned area value is generated according to the average water spraying amount of each water spraying end. When the difference between the actual area value and the planned area value is within the preset allowable range, it is determined that there is no abnormality in the water spraying end; otherwise, it is determined that there is an abnormality in the water spraying end. At this time, when the actual area value is greater than the planned area value, a self-detection result of abnormal flow rate of the water spraying end is generated, and the water spraying end identifier of the abnormal water spraying end is marked. When the actual area value is less than the planned area value, a self-detection result of blocked water spraying end is generated, and the water spraying end identifier of the blocked water spraying end is marked.

[0034] When the spraying state is that the radiation range is bright or dark, the fault self-check module is used to generate spraying information by performing image recognition based on the real-time wetting image. At this time, the spraying information is the actual grayscale value of the radiation range of the water spray end. The corresponding planned grayscale value is generated according to the average water spraying amount of each water spray end. When the difference between the actual grayscale value and the planned grayscale value is within the preset allowable range, it is determined that there is no abnormality in the water spray end; otherwise, it is determined that there is an abnormality in the water spray end. At this time, when the actual grayscale value is greater than the planned grayscale value, a self-check result of abnormal flow at the water spray end is generated, and the water spray end identification of the abnormal water spray end is marked. When the actual grayscale value is less than the planned grayscale value, a self-check result of blocked water spray end is generated, and the water spray end identification of the blocked water spray end is marked.

[0035] The present solution can effectively improve the uniformity of the carbon black soaking aqueous solution during the carbon black granulation process, realize the granulation and drying of carbon black powder, obtain finished carbon black particles, and facilitate transportation and storage. At the same time, the faults in the carbon black granulation production process can be located and self-checked in a timely manner, abnormalities can be discovered in a timely manner, and the faults can be handled in a timely manner to reduce production losses.

[0036] The above is only an embodiment of the present invention. The common sense such as the known specific structure and characteristics in the scheme is not described in detail here. The ordinary technicians in the relevant field know all the common technical knowledge in the technical field of the invention before the application date or priority date, can obtain all the existing technologies in the field, and have the ability to apply the conventional experimental means before that date. The ordinary technicians in the relevant field can improve and implement this scheme in combination with their own abilities under the enlightenment given by this application. Some typical known structures or known methods should not become obstacles for ordinary technicians in the relevant field to implement this application. It should be pointed out that for those skilled in the art, without departing from the structure of the present invention, several deformations and improvements can be made, which should also be regarded as the protection scope of the present invention, which will not affect the effect of the implementation of the present invention and the practicality of the patent. The protection scope required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to interpret the content of the claims.

Claims

1. A continuous automated carbon black production system, characterized in that: It includes a soaking unit, a molding unit and a drying unit. The soaking unit includes a soaking channel. A vibration filter is provided at the top of the soaking channel. A plurality of water spray ends are provided on the inner wall of the soaking channel. The soaking unit is used to allow carbon black powder to enter, filter the carbon black powder, and make the filtered carbon black powder fall. When the carbon black powder falls, the water spray end is started to spray the aqueous solution. The molding unit is used to feed wet carbon black powder, granulate the carbon black powder, and output molded granular carbon black; The drying unit is used to supply granular carbon black, dry the granular carbon black, and output finished carbon black particles.

2. A continuous automated carbon black production system according to claim 1, characterized in that: It also includes a main control unit, which includes: An image acquisition module, used for acquiring images of granular carbon black and carbon black particles before and after entering the drying unit; The image detection module is used to perform image analysis based on the granular carbon black image and the carbon black particle image to determine whether there is any abnormality in the wetting unit, the molding unit and the drying unit, and to issue an early warning when an abnormality is determined.

3. A continuous automated carbon black production system according to claim 2, characterized in that: The image detection module is provided with a quantity threshold, and is used to identify the average quantity of particles in the granular carbon black image and the carbon black particle image. When the difference between the average quantity of particles in the granular carbon black image and the carbon black particle image exceeds the quantity threshold, it is determined that an abnormality occurs.

4. A continuous automated carbon black production system according to claim 2 or 3, characterized in that: The main control unit also includes a fault location module, which is provided with a volume threshold. The fault location module is used to identify the unit volume of the particulate matter in the granular carbon black image and the carbon black particle image when the image detection module determines that an abnormality occurs. When the difference between the unit volume of the particulate matter in the granular carbon black image and the carbon black particle image exceeds the volume threshold, the drying unit is marked as an abnormal unit, otherwise, the wetting unit is marked as an abnormal unit.

5. A continuous automated carbon black production system according to claim 4, characterized in that: It also includes an infrared detection unit, which is used to start when the image detection module determines that an abnormality occurs, and collect the soaking infrared image and the drying infrared image of the soaking unit and the drying unit; The main control unit also includes a fault self-checking module, which is used to perform image analysis based on the wet infrared image and the dry infrared image to generate a self-checking result and output it.

6. A continuous automated carbon black production system according to claim 5, characterized in that: The fault self-check module is used to perform image analysis on the drying infrared image to obtain the real-time drying temperature when the drying unit is marked as an abnormal unit, and to determine whether the real-time drying temperature is within the preset drying temperature range. If the real-time drying temperature exceeds the drying temperature range, a self-check result of temperature control abnormality is generated and output.

7. A continuous automated carbon black production system according to claim 6, characterized in that: The fault self-detection module is also used to perform image analysis on the wetting infrared image to obtain the real-time wetting temperature when the wetting unit is marked as an abnormal unit, and to determine whether the real-time wetting temperature is lower than the preset wetting temperature threshold. If the real-time wetting temperature is lower than the wetting temperature threshold, a self-detection result of water spray abnormality is generated and output.

8. A continuous automated carbon black production system according to claim 7, characterized in that: The main control unit also includes a water spray control module, which is used to control each water spray end to spray the aqueous solution according to a preset average water spray amount; The fault self-check module is also used to obtain the pipeline flow and pipeline pressure connected to each water spray end when the self-check result is abnormal water spraying, and match the corresponding pipeline flow and pipeline pressure according to the average water spraying amount of each water spray end. When there is a mismatch, it is determined that the corresponding water spray end has an abnormality, and the corresponding water spray end is marked and output.

9. A continuous automated carbon black production system according to claim 8, characterized in that: The fault self-detection module is also used to obtain a real-time wetting image in the wetting channel. The real-time wetting image includes the spray status of each water spray end. The spray status of each water spray end is identified according to the real-time wetting image, and the spray information of each water spray end is generated. The corresponding spray information is matched according to the average water spray volume of each water spray end. When there is a mismatch, it is determined that the corresponding water spray end is abnormal, and the corresponding water spray end is marked and output.

10. A continuous automated carbon black production system according to claim 1, characterized in that: The vibration filter includes a plurality of vibration filter screens, and the carbon black powder passes through the plurality of vibration filter screens in sequence.

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