Polycrystalline silicon water quenching system

Abstract

The invention discloses a polycrystalline silicon water quenching system, and particularly relates to the technical field of polycrystalline silicon water quenching, and the water quenching system comprises an integrated control unit, a preheating module, a water quenching module, a temperature adjusting module, an automatic material conveying module, a silicon rod crushing module, a heat energy recovery module and a safety monitoring unit. According to the polycrystalline silicon water quenching system disclosed by the invention, through an intelligent optimization algorithm and real-time data acquisition of the integrated control unit, operation conditions are dynamically adjusted to adapt to different silicon rod characteristics, and the water quenching efficiency and uniformity are improved; the safety monitoring unit monitors temperature, pressure and leakage in real time, abnormal operation is automatically stopped, and the safety accident risk is reduced; the heat energy recovery and water circulation purification assembly effectively reduces energy consumption and resource waste, and the energy management assembly optimizes energy efficiency and reduces cost. The rapid replacement and maintenance design simplifies the maintenance process, reduces the maintenance cost and shortens the downtime; the fault diagnosis system reduces accidental shutdown and guarantees production continuity.

Description

Technical Field

[0001] The invention relates to the technical field of polysilicon water quenching, and in particular to a polysilicon water quenching system. Background Art

[0002] Polycrystalline silicon is a polycrystalline material composed of many small crystals. It is a form of single-element silicon. Under supercooling conditions, when molten single-element silicon solidifies, silicon atoms are arranged into many crystal nuclei in the form of diamond lattices. These crystal nuclei grow into grains with different crystal plane orientations, and combine to form polycrystalline silicon. Polycrystalline silicon is widely used in photovoltaic, integrated circuit and other fields, and is an important basic material for photovoltaic industry and electronic information industry.

[0003] Water quenching is an important step in the production process of polysilicon, and its main purpose is to reduce the breakage loss rate of polysilicon materials. By rapidly cooling the silicon rods after high-temperature calcination, cracks will appear in the silicon rods, so that in the subsequent crushing process, the generation of dust and particles can be reduced, thereby reducing the breakage loss rate. After the silicon rods after water quenching are crushed by the same crusher, the breakage loss of silicon materials can be significantly reduced from the original 3.5% to about 2%. Summary of the invention

[0004] The main purpose of the present invention is to provide a polysilicon water quenching system, which can effectively solve the problems of poor water quenching effect and high breakage loss rate of existing devices.

[0005] To achieve the above object, the technical solution adopted by the present invention is:

[0006] A polysilicon water quenching system, the water quenching system comprising the following modules:

[0007] Integrated control unit for real-time monitoring and adjustment of the entire water quenching process;

[0008] Preheating module, used to preheat the silicon rod to a temperature close to the water quenching temperature to reduce thermal shock and improve water quenching efficiency;

[0009] The water quenching module is equipped with a multi-stage spray system to evenly and quickly cool the preheated silicon rods;

[0010] The temperature regulating module is connected to the water quenching module and is used to maintain a constant temperature of the water quenching liquid to ensure the water quenching effect;

[0011] An automated material conveying module is used to convey silicon rods from the preheating module to the water quenching module, and then from the water quenching module to the subsequent processing area;

[0012] A silicon rod crushing module, located downstream of the water quenching module, is used to crush the water-quenched silicon rods into required sizes, and the silicon rod crushing module has a dust suppression function to reduce dust generation;

[0013] The heat recovery module is used to collect and reuse the heat energy and water resources generated during the water quenching process to improve the utilization efficiency of energy and water resources.

[0014] Preferably, the integrated control unit comprises:

[0015] Data acquisition component, used to collect system operation parameters in real time;

[0016] Intelligent optimization algorithm, which automatically adjusts operating conditions based on collected parameters to optimize water quenching efficiency and quality;

[0017] Human-machine interface, allowing operators to monitor system status and manually intervene in the control process;

[0018] Fault diagnostics systems to detect and predict potential system failures, ensuring continuous production and reducing downtime.

[0019] Preferably, the preheating module comprises:

[0020] Preheating temperature controller, used to accurately control the preheating temperature of silicon rods;

[0021] Hot air circulation components ensure that the silicon rods are heated evenly;

[0022] Preheating time controller adjusts the preheating time according to the size and material properties of the silicon rod.

[0023] Preferably, the water quenching module comprises:

[0024] Pressure controller, used to control the pressure of the spray system to adapt to silicon rods of different sizes and material properties;

[0025] Nozzle cleaning assembly, automatically clears nozzle blockage and maintains spraying efficiency;

[0026] Safety protection components prevent water quenching liquid from splashing and protect the safety of operators.

[0027] Preferably, the temperature adjustment module comprises:

[0028] Temperature sensor, real-time monitoring of the temperature of the water quenching liquid;

[0029] Water quenching temperature controller automatically adjusts the working state of the heat exchanger according to the monitoring results;

[0030] The liquid level control component ensures a constant liquid level of the water quenching liquid in the water tank.

[0031] Preferably, the automated material conveying module comprises:

[0032] A sensor detection component, used to detect the position and state of the silicon rod;

[0033] Automatic fault recovery system, automatically adjusts the conveyor belt speed or stops conveying when abnormal conveying is detected;

[0034] Emergency stop device, used to quickly cut off the power supply of the conveying system in an emergency.

[0035] Preferably, the silicon rod crushing module comprises:

[0036] Vibration frequency controller, which adjusts the crushing vibration frequency according to the hardness and brittleness of the silicon rod;

[0037] Crushing effect monitoring component, which evaluates the size and shape of the silicon rods after crushing and feeds back to the control system to optimize the crushing parameters;

[0038] Dust collection and filtration components to reduce dust emissions during the crushing process.

[0039] Preferably, the heat recovery module comprises:

[0040] Heat recovery components that collect the heat released during the water quenching process and convert it into usable energy;

[0041] Water circulation purification components, filtering and purifying the used water quenching liquid for reuse in the system;

[0042] Energy management components monitor and optimize the energy efficiency of the entire heat recovery module.

[0043] Preferably, the water quenching system further comprises a safety monitoring unit for monitoring potential safety risks in the entire water quenching process and automatically stopping operation when an abnormality is detected. The safety monitoring unit includes but is not limited to temperature monitoring, pressure monitoring and leakage monitoring.

[0044] Preferably, the design of the water quenching system allows for rapid replacement and maintenance of various components to reduce downtime and maintenance costs, and the rapid replacement and maintenance design includes modular components and easily accessible maintenance interfaces.

[0045] Compared with the prior art, the present invention has the following beneficial effects:

[0046] 1. The present invention uses the intelligent optimization algorithm and real-time data acquisition components of the integrated control unit, and the system can dynamically adjust the operating conditions to adapt to the characteristics of different silicon rods, thereby improving the efficiency and uniformity of water quenching. The design of the multi-stage spray system enables the water quenching liquid to be evenly sprayed on the surface of the silicon rod, avoiding the problem of local overheating or underheating, and ensuring the consistency of the water quenching effect.

[0047] 2. The present invention enhances the safety of the system by introducing a safety monitoring unit. By real-time monitoring of temperature, pressure and leakage, the system can automatically stop operation when an abnormality is detected, reducing the probability of safety accidents such as equipment damage, explosion and environmental pollution.

[0048] 3. The present invention enables the system to recycle and reuse the heat energy and water resources generated during the water quenching process through the functions of the heat recovery module and the water circulation purification component, which significantly reduces energy consumption and resource waste; the energy management component further optimizes energy utilization efficiency and reduces energy costs.

[0049] 4. The present invention simplifies the maintenance process of the system and reduces maintenance costs by introducing a quick replacement and maintenance design; modular components and easily accessible maintenance interfaces allow each component to be quickly disassembled and replaced without the need for complex operations and professional technicians, greatly shortening maintenance time.

[0050] 5. The present invention predicts and diagnoses potential system failures through the fault diagnosis system provided in the integrated control unit, thereby reducing unexpected shutdowns and ensuring the continuity of production; at the same time, the automatic fault recovery system and emergency stop device of the automated material conveying module not only ensure the safe transportation of materials, but also improve the reliability of the system.

[0051] 6. The present invention effectively reduces dust emission during the crushing process through the dust collection and filtering components in the silicon rod crushing module, thereby reducing the impact on the working environment and the health of operators. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 It is a block diagram of the system composition of the present invention;

[0053] Figure 2 It is a schematic diagram of the operation process of the present invention;

[0054] Figure 3 It is a schematic diagram of the data flow communication process of the present invention. DETAILED DESCRIPTION

[0055] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0056] like Figure 1 , Figure 2 and Figure 3 As shown, a polysilicon water quenching system comprises the following modules:

[0057] The integrated control unit is the brain of the system, which is used to monitor and adjust the entire water quenching process in real time. It monitors the operating status of each module and adjusts the operating parameters according to the feedback data to ensure the efficiency and stability of the water quenching process.

[0058] Preheating module, used to preheat the silicon rod to a temperature close to the water quenching temperature to reduce thermal shock and improve water quenching efficiency;

[0059] The water quenching module is equipped with a multi-stage spray system to evenly and quickly cool the preheated silicon rods;

[0060] The temperature regulating module is connected to the water quenching module and is used to maintain a constant temperature of the water quenching liquid to ensure the water quenching effect;

[0061] The automated material conveying module is used to convey the silicon rods from the preheating module to the water quenching module, and then from the water quenching module to the subsequent processing area, achieving seamless connection between the silicon rods in various modules and improving production efficiency;

[0062] The silicon rod crushing module is located downstream of the water quenching module and is used to crush the water-quenched silicon rods into required sizes. The silicon rod crushing module has a dust suppression function to reduce dust generation and environmental pollution.

[0063] The heat energy recovery module is used to collect and reuse the heat energy and water resources generated during the water quenching process to improve the utilization efficiency of energy and water resources, improve the utilization efficiency of energy and water resources, reduce production costs, and achieve green production.

[0064] Furthermore, the integrated control unit comprises:

[0065] Data acquisition component, used to collect system operation parameters in real time;

[0066] High-precision sensors are used to collect key system operation parameters in real time, including but not limited to temperature, pressure, and flow, to provide data support for intelligent optimization of the system;

[0067] Intelligent optimization algorithm automatically adjusts operating conditions according to the collected parameters to optimize water quenching efficiency and quality. It dynamically adjusts operating conditions, including the preheating temperature of the preheating module and the spraying pressure of the water quenching module, to improve the water quenching effect and energy efficiency ratio, and reduce the large difference in finished product quality caused by slight differences in raw materials.

[0068] Human-machine interface, providing an intuitive operating platform, allowing operators to monitor system status and manually intervene in the control process when necessary, improving system flexibility and reliability;

[0069] The fault diagnosis system is used to detect and predict potential system failures by continuously monitoring system performance, ensuring continuous production and reducing downtime, ensuring production continuity and reducing maintenance costs.

[0070] Furthermore, the preheating module comprises:

[0071] The preheating temperature controller uses advanced temperature control technology to accurately control the preheating temperature of the silicon rods, ensuring that the silicon rods reach a suitable temperature before entering the water quenching process, reducing thermal shock and improving water quenching efficiency;

[0072] The hot air circulation component ensures that the silicon rods are evenly heated through evenly distributed hot air, avoiding local overheating or underheating, and improving the uniformity and efficiency of preheating;

[0073] The preheating time controller adjusts the preheating time according to the size and material properties of the silicon rod to ensure uniform preheating of the silicon rod, laying a good foundation for the subsequent water quenching process.

[0074] Preferably, the water quenching module comprises:

[0075] The pressure controller is used to control the pressure of the spray system to adapt to silicon rods of different sizes and material properties, ensuring that the water quenching liquid is evenly sprayed on the surface of the silicon rod to achieve rapid and uniform cooling;

[0076] Nozzle cleaning assembly, automatically clears nozzle blockage, maintains spraying efficiency, and avoids uneven water quenching caused by nozzle blockage;

[0077] Safety protection components prevent water quenching liquid from splashing and protect the safety of operators, protecting the safety of operators and reducing safety hazards in the working environment.

[0078] Furthermore, the temperature adjustment module includes:

[0079] Temperature sensor, real-time monitoring of the temperature of the water quenching liquid to ensure the accuracy of temperature control;

[0080] The water quenching temperature controller automatically adjusts the working state of the heat exchanger according to the monitoring results of the temperature sensor, maintains a constant temperature of the water quenching liquid, and ensures the consistency of the water quenching effect;

[0081] The liquid level control component ensures a constant liquid level of the water quenching liquid in the water tank, avoids the liquid level fluctuation caused by evaporation and extraction of the water quenching liquid affecting the water quenching effect, and ensures the stable operation of the system.

[0082] Furthermore, the automated material conveying module includes: a sensor detection component for detecting the position and state of the silicon rods to ensure that the silicon rods are accurately conveyed to the next processing stage;

[0083] Automatic fault recovery system, which automatically adjusts the conveyor belt speed or stops conveying when abnormal conveying is detected, thus reducing production interruption and material loss caused by conveying failure;

[0084] The emergency stop device is used to quickly cut off the power supply of the conveying system in an emergency, ensure the safety of personnel and equipment, and reduce the risk of accidents.

[0085] Furthermore, the silicon rod crushing module comprises:

[0086] Vibration frequency controller adjusts the crushing vibration frequency according to the hardness and brittleness of the silicon rod to improve crushing efficiency and output;

[0087] Crushing effect monitoring component, which evaluates the size and shape of the silicon rods after crushing and feeds back to the control system to optimize the crushing parameters and ensure product quality;

[0088] Dust collection and filtration components reduce dust emissions during the crushing process, reducing the impact on the working environment and operator health.

[0089] Furthermore, the heat recovery module comprises:

[0090] Heat recovery components collect the heat released during the water quenching process and convert it into usable energy, and use the heat energy or converted electrical energy for other parts of the system;

[0091] Water circulation purification components filter and purify the used water quenching liquid to make it meet the standards for reuse so that it can be reused by the system, reducing the consumption of water resources;

[0092] The energy management component monitors and optimizes the energy utilization efficiency of the entire heat recovery module to ensure efficient use of energy and reduce energy waste.

[0093] Furthermore, the water quenching system also includes a safety monitoring unit for monitoring potential safety risks in the entire water quenching process and automatically stopping operation when an abnormality is detected. The safety monitoring unit includes but is not limited to temperature monitoring, pressure monitoring and leakage monitoring.

[0094] Temperature monitoring monitors the temperature of each part of the system in real time to prevent equipment damage and safety accidents caused by overheating; pressure monitoring monitors system pressure to prevent safety accidents such as explosions caused by excessive pressure; leakage monitoring monitors system leakage and responds in time to prevent environmental pollution and equipment damage, thereby ensuring the safety of the production environment.

[0095] Furthermore, the design of the water quenching system allows for rapid replacement and maintenance of individual components to reduce downtime and maintenance costs, and the rapid replacement and maintenance design includes modular components and easily accessible maintenance interfaces.

[0096] The system maintenance time and cost are significantly reduced through modular components and easily accessible maintenance interfaces. At the same time, the modular design allows each component to be quickly disassembled and replaced without the need for complex operations and professional technicians, greatly shortening maintenance time.

[0097] The easily accessible maintenance interface design allows maintenance personnel to easily reach key components for maintenance and replacement, improving maintenance efficiency; this design not only reduces maintenance costs, but also improves system reliability and stability, ensuring production continuity.

[0098] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A polysilicon water quenching system, characterized in that: The water quenching system includes the following modules: Integrated control unit for real-time monitoring and adjustment of the entire water quenching process; Preheating module, used to preheat the silicon rod to a temperature close to the water quenching temperature to reduce thermal shock and improve water quenching efficiency; The water quenching module is equipped with a multi-stage spray system to evenly and quickly cool the preheated silicon rods; The temperature regulating module is connected to the water quenching module and is used to maintain a constant temperature of the water quenching liquid to ensure the water quenching effect; An automated material conveying module is used to convey silicon rods from the preheating module to the water quenching module, and then from the water quenching module to the subsequent processing area; A silicon rod crushing module, located downstream of the water quenching module, is used to crush the water-quenched silicon rods into required sizes, and the silicon rod crushing module has a dust suppression function to reduce dust generation; The heat recovery module is used to collect and reuse the heat energy and water resources generated during the water quenching process to improve the utilization efficiency of energy and water resources.

2. A polysilicon water quenching system according to claim 1, characterized in that: The integrated control unit comprises: Data acquisition component, used to collect system operation parameters in real time; Intelligent optimization algorithm, which automatically adjusts operating conditions based on collected parameters to optimize water quenching efficiency and quality; Human-machine interface, allowing operators to monitor system status and manually intervene in the control process; Fault diagnostics systems to detect and predict potential system failures, ensuring continuous production and reducing downtime.

3. The polysilicon water quenching system according to claim 1, characterized in that: The preheating module comprises: Preheating temperature controller, used to accurately control the preheating temperature of silicon rods; Hot air circulation components ensure that the silicon rods are heated evenly; Preheating time controller adjusts the preheating time according to the size and material properties of the silicon rod.

4. The polysilicon water quenching system according to claim 1, characterized in that: The water quenching module comprises: Pressure controller, used to control the pressure of the spray system to adapt to silicon rods of different sizes and material properties; Nozzle cleaning assembly, automatically clears nozzle blockage and maintains spraying efficiency; Safety protection components prevent water quenching liquid from splashing and protect the safety of operators.

5. The polysilicon water quenching system according to claim 1, characterized in that: The temperature regulating module comprises: Temperature sensor, real-time monitoring of the temperature of the water quenching liquid; Water quenching temperature controller automatically adjusts the working state of the heat exchanger according to the monitoring results; The liquid level control component ensures a constant liquid level of the water quenching liquid in the water tank.

6. The polysilicon water quenching system according to claim 1, characterized in that: The automated material conveying module comprises: A sensor detection component, used to detect the position and state of the silicon rod; Automatic fault recovery system, automatically adjusts the conveyor belt speed or stops conveying when abnormal conveying is detected; Emergency stop device, used to quickly cut off the power supply of the conveying system in an emergency.

7. The polysilicon water quenching system according to claim 1, characterized in that: The silicon rod crushing module comprises: Vibration frequency controller, which adjusts the crushing vibration frequency according to the hardness and brittleness of the silicon rod; Crushing effect monitoring component, which evaluates the size and shape of the silicon rods after crushing and feeds back to the control system to optimize the crushing parameters; Dust collection and filtration components to reduce dust emissions during the crushing process.

8. The polysilicon water quenching system according to claim 1, characterized in that: The heat recovery module comprises: Heat recovery components that collect the heat released during the water quenching process and convert it into usable energy; Water circulation purification components, filtering and purifying the used water quenching liquid for reuse in the system; Energy management components monitor and optimize the energy efficiency of the entire heat recovery module.

9. The polysilicon water quenching system according to claim 1, characterized in that: The water quenching system also includes a safety monitoring unit for monitoring potential safety risks in the entire water quenching process and automatically stopping operation when an abnormality is detected. The safety monitoring unit includes but is not limited to temperature monitoring, pressure monitoring and leakage monitoring.

10. The polysilicon water quenching system according to claim 1, characterized in that: The design of the water quench system allows for quick replacement and maintenance of individual components to reduce downtime and maintenance costs, and the quick replacement and maintenance design includes modular components and easily accessible maintenance interfaces.

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