A nomadic sludge solidification production line apparatus

Abstract

The present application provides a kind of nomadic sludge solidification production line equipment, belong to sludge processing technical field, this nomadic sludge solidification production line equipment includes cutter suction dredging mechanism, pumping transport mechanism, screening reduction mechanism, concentration precipitation mechanism and filter pressing dewatering mechanism;The cutter suction dredging mechanism includes closed cutter head and cutter drive shaft, the cutter drive shaft is fixedly connected with the output shaft of cutter motor;The pumping transport mechanism includes feed pipe, slurry pump body and discharge pipe, one end of the feed pipe is communicated with the closed cutter head, the other end is connected with the feed inlet of the slurry pump body, one end of the discharge pipe is connected with the discharge port of the slurry pump body, one end of the discharge pipe is connected with the discharge port of the slurry pump body, the other end is connected with the feed end of the screening reduction mechanism;The present application can solve the problem of environmental pollution and low processing efficiency in sludge treatment process.

Description

Technical Field

[0001] This invention belongs to the field of sludge treatment technology, and more specifically, relates to a nomadic sludge solidification production line equipment. Background Technology

[0002] Currently, beach silt treatment mainly involves using cutter suction dredgers for dredging and transporting, followed by solidification processes such as thickening and dewatering. Traditional beach silt cutter suction processes suffer from the following problems: First, silt is easily splashed during the suction process, causing secondary pollution and impacting the surrounding environment; second, solid-liquid separation efficiency is low, and the grading effect is poor, making it difficult to meet the classification and disposal requirements of silt with different particle sizes; third, the high moisture content of the silt leads to poor dewatering, increasing the difficulty and cost of subsequent treatment. In engineering practice, mechanical cutter suction dredgers are currently used in conjunction with thickening and dewatering equipment for treatment. However, this method suffers from problems such as large equipment size, large footprint, and high construction difficulty, and the process easily generates large amounts of odor and dust, seriously impacting the surrounding environment.

[0003] Furthermore, due to the lack of effective sealing and protective measures, construction workers are easily exposed to harmful substances, posing significant safety hazards. Although some existing improved technologies have been optimized in certain aspects, such as using closed-loop suction heads and multi-stage screening, they still have not fundamentally solved the problems of environmental pollution and treatment efficiency in the sludge treatment process.

[0004] Therefore, developing a new type of nomadic sludge solidification production line equipment to achieve efficient and environmentally friendly sludge treatment is of great practical significance. Summary of the Invention

[0005] In view of this, the present invention provides a nomadic sludge solidification production line equipment, which can solve the problems of environmental pollution and low treatment efficiency in the sludge treatment process.

[0006] This invention is implemented as follows:

[0007] This invention provides a nomadic sludge solidification production line equipment, comprising a cutter suction dredging mechanism, a pumping and conveying mechanism, a screening and reduction mechanism, a concentration and sedimentation mechanism, and a filter press dewatering mechanism; the cutter suction dredging mechanism includes a closed cutter head and a cutter drive shaft, the cutter drive shaft being fixedly connected to the output shaft of a cutter motor; the pumping and conveying mechanism includes a feed pipe, a slurry pump body, and a discharge pipe, one end of the feed pipe being connected to the closed cutter head, and the other end being connected to the feed inlet of the slurry pump body; one end of the discharge pipe being connected to the discharge outlet of the slurry pump body, and the other end being connected to the feed end of the screening and reduction mechanism; the screening... The volume reduction mechanism includes a three-stage screening box, each stage containing an inclined screen. The screens, from top to bottom, are a first-stage screen, a second-stage screen, and a third-stage screen. The diameter of the sieve openings in the first-stage screen is larger than that in the second-stage screen, and the diameter of the sieve openings in the second-stage screen is larger than that in the third-stage screen. The concentration and sedimentation mechanism includes a conical sedimentation tank with an overflow weir at the top and a conical sludge discharge port at the bottom. The filter press dewatering mechanism includes a filter press housing containing multiple layers of filter plates, with filter chambers formed between adjacent filter plates.

[0008] Based on the above technical solution, the nomadic sludge solidification production line equipment of the present invention can be further improved as follows:

[0009] The enclosed auger head includes an outer shell and an inner auger. The outer shell is cylindrical with a mud inlet at the bottom and a mud outlet at the top. The inner auger is fixedly mounted on the auger drive shaft and consists of multiple spiral cutting blades. A gap is left between the outer edge of the cutting blade and the inner wall of the outer shell.

[0010] Furthermore, the top of the three-stage screening box is provided with a feeding hopper, and the feeding hopper is provided with several spray heads. The spray heads are connected to the clean water tank through water pipes. The bottom of the three-stage screening box is provided with several guide grooves. The guide grooves are arranged along the inclined direction of the screen. One end of the guide groove is connected to the screen, and the other end extends out of the three-stage screening box and is connected to the collection hopper.

[0011] Furthermore, the inner wall of the conical sedimentation tank is provided with multiple annular guide plates, which are arranged in a spiral shape, and sedimentation channels are formed between adjacent annular guide plates; the surface of the annular guide plates is provided with multiple guide holes.

[0012] Furthermore, the filter press housing has a fixed end plate and a movable end plate on both sides, the fixed end plate is fixedly connected to the filter press housing, and the movable end plate is connected to the filter press housing through a hydraulic cylinder; the filter plate is slidably installed in the filter press housing through a guide rod, and the two ends of the guide rod are respectively connected to the fixed end plate and the movable end plate.

[0013] Furthermore, the surface of the filter press plate is provided with a textured grid, and the textured grids of adjacent filter press plates are arranged opposite each other; the edge of the filter press plate is provided with a sealing ring, and the sealing ring is made of elastic rubber material.

[0014] Furthermore, the mud pump body is a twin-screw pump, including a pump housing and a twin-screw rotor disposed within the pump housing. The twin-screw rotor consists of a driving screw and a driven screw. The driving screw is connected to the output shaft of the pump motor, and the driven screw meshes with the driving screw through a gear set for transmission.

[0015] Furthermore, the top of the conical sedimentation tank is provided with multiple return pipes, one end of which is connected to the overflow weir and the other end is connected to the water storage tank; the conical sludge discharge port of the conical sedimentation tank is connected to the feed port of the filter press box through the sludge discharge pipe.

[0016] Furthermore, a vibration motor is provided on the outer wall of the three-stage screening box, and the vibration motor is connected to the three-stage screening box through a shock absorption device; the shock absorption device includes a spring support seat and a shock absorption spring, one end of the shock absorption spring is connected to the spring support seat, and the other end is connected to the three-stage screening box.

[0017] Furthermore, the shock-absorbing device also includes a rubber ring.

[0018] Furthermore, the structural dimensional relationships of the enclosed auger head are limited as follows:

[0019]

[0020] In the formula, D o D is the outer diameter of the outer shell (mm); i is the inner diameter of the outer shell (mm); h is the gap between the spiral cutting blade and the inner wall of the outer shell (mm); L is the length of the outer shell (mm).

[0021] Furthermore, the shape of the spiral cutting blade is defined as follows:

[0022]

[0023] In the formula, r is the distance from any point on the helix to the axis (mm); r0 is the distance from the starting point of the helix to the axis (mm); k is the pitch coefficient; and θ is the rotation angle (rad).

[0024] Furthermore, the inclination angle and screen aperture size of the three-stage screening box are limited as follows:

[0025]

[0026] In the formula, α is the screen tilt angle (°); H is the screen height difference (mm); L s d1, d2, and d3 represent the horizontal projection length of the screen (mm); d1, d2, and d3 are the aperture diameters (μm) of the first, second, and third stage screens, respectively.

[0027] Furthermore, the structural parameter relationships of the conical sedimentation tank are defined as follows:

[0028]

[0029] β = 55°~65°;

[0030]

[0031] In the formula, H c D represents the total height of the sedimentation tank (mm). c β is the diameter of the top of the sedimentation tank (mm); β is the angle of the cone base (°); S n The area (mm²) of the nth annular guide vane 2 S0 is the area of ​​the top annular guide vane (mm²). 2 ); λ is the area attenuation coefficient, with a value of 0.1 to 0.2.

[0032] Furthermore, the relationship between the filter plate spacing and pressure distribution is defined as follows:

[0033]

[0034] In the formula, P(x) is the pressure at any position x on the filter press plate (MPa); P0 is the initial pressure (MPa); μ is the pressure decay coefficient; x is the distance from the feed end (mm); L p d represents the total length of the filter press (mm). p This represents the distance between adjacent filter press plates (mm).

[0035] Explanation of the principle:

[0036] 1. The dimensions of the enclosed auger head are based on fluid dynamics principles, ensuring sufficient shearing space while preventing sludge blockage;

[0037] 2. The spiral cutting blade adopts the Archimedes spiral to ensure uniform cutting and efficient conveying.

[0038] 3. The screen tilt angle is based on the principle of gravity screening to ensure uniform material dispersion and automatic conveying; the screen aperture size ratio is optimized based on the grading efficiency.

[0039] 4. The sedimentation tank adopts a multi-layer spiral flow guide, and the area ratio of each layer is controlled by exponential decay to optimize sedimentation efficiency.

[0040] 5. The pressure distribution of the filter press adopts an exponential decay model, which takes into account pressure transmission loss and boundary effects.

[0041] Compared with existing technologies, the nomadic sludge solidification production line equipment provided by this invention has the following advantages: The nomadic sludge solidification production line equipment proposed in this invention successfully solves the environmental pollution problems in traditional sludge treatment processes. Through the design of a closed-loop cutter head, splashing and odor diffusion during sludge suction are effectively prevented. This equipment adopts a process combining multi-stage screening and concentration sedimentation, significantly improving solid-liquid separation efficiency. Sludge of different particle sizes can be effectively separated, facilitating classified disposal. Through the optimized filter press system design, deep dewatering of the sludge is achieved, and the final sludge cake moisture content meets the design requirements, representing a significant improvement over traditional processes.

[0042] In practical applications, this equipment has the following significant advantages: First, the special structural design of the closed-type auger head significantly improves the suction efficiency while completely avoiding the problem of sludge splashing; Second, the twin-screw pump conveying system has good sealing performance, stable conveying pressure, and conveying efficiency that is significantly better than that of traditional single-screw pumps; Third, the three-stage screening system has excellent grading effect, and the particle size distribution range of each product is precisely controlled, far superior to traditional processes; Fourth, the design of the multi-layer guide flow sedimentation tank greatly shortens the sedimentation time and significantly improves the processing efficiency; Fifth, the large-area filter press system has a significant dewatering effect and comprehensively improves the processing capacity.

[0043] Furthermore, the equipment adopts a modular design, making installation and disassembly convenient and highly mobile, allowing for rapid adjustment and optimization according to different project needs. In terms of environmental protection, the entire treatment process is conducted in a closed environment, effectively controlling odor and dust emissions. Environmental monitoring data shows significant environmental advantages compared to traditional equipment, with odor and dust emissions effectively controlled. Simultaneously, the equipment demonstrates excellent adaptability and reliability in practical engineering applications, meeting the sludge treatment needs under various working conditions. Through advanced process design and innovative structural layout, the equipment not only improves the efficiency and quality of sludge treatment but also greatly improves the working environment, providing a novel technical solution for sludge treatment projects. During long-term operation, the equipment exhibits stable performance and reliable operation, with low maintenance costs and high operating efficiency, fully validated by engineering practice. Especially in sludge treatment projects in environmentally sensitive areas, the environmental advantages of this equipment are even more prominent, providing crucial technical support for the implementation of similar projects. Attached Figure Description

[0044] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0045] Figure 1 This is a schematic diagram of a nomadic sludge solidification production line equipment.

[0046] Figure 2 This is a schematic diagram of a closed-loop auger head structure;

[0047] Figure 3 This is a schematic diagram of the screening and volume reduction mechanism.

[0048] Figure 4 This is a schematic diagram of the pumping and conveying mechanism.

[0049] The attached diagram lists the components represented by each number as follows:

[0050] 10. Cutter suction dredging mechanism; 101. Enclosed cutter head; 102. Cutter drive shaft; 103. Cutter motor; 11. Pumping and conveying mechanism; 111. Feed pipe; 112. Slurry pump body; 113. Discharge pipe; 12. Screening and reduction mechanism; 120. Three-stage screening box; 121. Feed hopper; 122. Spray head; 123. Guide trough; 13. Concentration and sedimentation mechanism; 130. Conical sedimentation tank; 131. Overflow weir; 132. Conical sludge discharge port; 133. Annular guide plate; 1331. Guide hole; 14. Filter press dewatering mechanism; 140. Filter press box; 141. Fixed end plate; 142. Movable end plate; 143. Guide rod; 15. Vibration motor; 16. Shock absorption device. Detailed Implementation

[0051] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0052] like Figure 1-4 The diagram illustrates an embodiment of a nomadic sludge solidification production line equipment provided by the present invention. This embodiment includes a sluice suction dredging mechanism 10, a pumping and conveying mechanism 11, a screening and reduction mechanism 12, a concentration and sedimentation mechanism 13, and a filter press dewatering mechanism 14. The sluice suction dredging mechanism 10 includes a closed-type cutter head 101 and a cutter drive shaft 102, with the cutter drive shaft 102 fixedly connected to the output shaft of a cutter motor 103. The pumping and conveying mechanism 11 includes a feed pipe 111, a slurry pump body 112, and a discharge pipe 113. One end of the feed pipe 111 is connected to the closed-type cutter head 101, and the other end is connected to the feed inlet of the slurry pump body 112. One end of the discharge pipe 113 is connected to the discharge outlet of the slurry pump body 112, and the other end is connected to the screen... The feeding end of the separation and reduction mechanism 12 is connected; the screening and reduction mechanism 12 includes a three-stage screening box 120, each screening box is equipped with an inclined screen, the screens from top to bottom are the first-stage screen, the second-stage screen and the third-stage screen, the screen hole diameter of the first-stage screen is larger than the screen hole diameter of the second-stage screen, and the screen hole diameter of the second-stage screen is larger than the screen hole diameter of the third-stage screen; the concentration and sedimentation mechanism 13 includes a conical sedimentation tank 130, the upper part of the conical sedimentation tank 130 is provided with an overflow weir 131, and the bottom of the conical sedimentation tank 130 is provided with a conical sludge discharge port 132; the filter press dewatering mechanism 14 includes a filter press box 140, the filter press box 140 is provided with multiple layers of filter press plates, and a filter press chamber is formed between adjacent filter press plates.

[0053] In the above technical solution, the closed auger head 101 includes an outer shell and an inner auger. The outer shell is cylindrical, with a mud inlet at the bottom and a mud outlet at the top. The inner auger is fixedly installed on the auger drive shaft 102 and is composed of multiple spiral cutting blades. A gap is left between the outer edge of the cutting blade and the inner wall of the outer shell.

[0054] Furthermore, in the above technical solution, the top of the three-stage screening box 120 is provided with a feeding hopper 121, and the feeding hopper 121 is provided with a number of spray heads 122. The spray heads 122 are connected to the clean water tank through water pipes. The bottom of the three-stage screening box 120 is provided with a number of guide grooves 123. The guide grooves 123 are arranged along the inclined direction of the screen. One end of the guide groove 123 is connected to the screen, and the other end extends out of the three-stage screening box 120 and is connected to the collection hopper.

[0055] Furthermore, in the above technical solution, the inner wall of the conical sedimentation tank 130 is provided with multiple annular guide plates 133, the annular guide plates 133 are arranged in a spiral shape, and sedimentation channels are formed between adjacent annular guide plates 133; the surface of the annular guide plates 133 is provided with multiple guide holes 1331.

[0056] Furthermore, in the above technical solution, the filter press housing 140 is provided with a fixed end plate 141 and a movable end plate 142 on both sides. The fixed end plate 141 is fixedly connected to the filter press housing 140, and the movable end plate 142 is connected to the filter press housing 140 through a hydraulic cylinder. The filter plate is slidably installed in the filter press housing 140 through a guide rod 143, and the two ends of the guide rod 143 are connected to the fixed end plate 141 and the movable end plate 142 respectively.

[0057] Furthermore, in the above technical solution, the surface of the filter press plate is provided with a textured grid, and the textured grids of adjacent filter press plates are arranged opposite to each other; the edge of the filter press plate is provided with a sealing ring, which is made of elastic rubber material.

[0058] Furthermore, in the above technical solution, the mud pump body 112 is a twin-screw pump, including a pump housing and a twin-screw rotor disposed in the pump housing. The twin-screw rotor consists of a driving screw and a driven screw. The driving screw is connected to the output shaft of the pump motor, and the driven screw is driven by the driving screw through a gear set.

[0059] Furthermore, in the above technical solution, the top of the conical sedimentation tank 130 is provided with multiple return pipes, one end of which is connected to the overflow weir 131 and the other end is connected to the water storage tank; the conical sludge discharge port 132 of the conical sedimentation tank 130 is connected to the feed port of the filter press box 140 through the sludge discharge pipe.

[0060] Furthermore, in the above technical solution, a vibration motor 15 is provided on the outer wall of the three-stage screening box 120. The vibration motor 15 is connected to the three-stage screening box 120 through a shock absorption device 16. The shock absorption device 16 includes a spring support seat and a shock absorption spring. One end of the shock absorption spring is connected to the spring support seat, and the other end is connected to the three-stage screening box 120.

[0061] Furthermore, in the above technical solution, the shock absorption device 16 also includes a rubber ring.

[0062] The specific implementation of the nomadic sludge solidification production line equipment of the present invention will be described in detail below.

[0063] The nomadic sludge solidification production line equipment of the present invention mainly consists of five parts: a cutter suction dredging mechanism, a pumping and conveying mechanism, a screening and reduction mechanism, a concentration and sedimentation mechanism, and a pressure filtration and dewatering mechanism. The various mechanisms are connected and sealed through pipes and flanges.

[0064] The cutter suction dredging mechanism mainly consists of a closed-type cutter head and a cutter drive shaft. The closed-type cutter head adopts an integral stainless steel structure with a cylindrical outer shell. The outer diameter of the cylinder is between 450 mm and 650 mm, and the length is 1.8 to 2.2 times the outer diameter. The bottom inlet has a conical structure with a cone angle of 75 to 85 degrees. The bottom diameter of the inlet is 0.6 to 0.7 times the outer diameter of the outer shell, and the top outlet has a diameter of 0.4 to 0.5 times the outer diameter of the outer shell. The internal cutter head uses high-strength materials. Made of wear-resistant alloy steel, the cutter head consists of 6 to 8 spiral cutting blades, each with a spiral angle of 38 to 42 degrees and a blade thickness of 12 to 15 millimeters. The gap between the outer edge of the blade and the inner wall of the outer casing is controlled between 28 and 32 millimeters. The auger drive shaft is made of 45# quenched and tempered steel with a shaft diameter of 80 to 100 millimeters. It is connected to the output shaft of the auger motor via a spline. The auger motor has a power of 22 to 30 kilowatts and a speed of 180 to 220 revolutions per minute. The special structural design of the enclosed auger head not only effectively prevents environmental pollution caused by sludge splashing, but also ensures high sludge suction efficiency and conveying capacity through reasonable gap setting and spiral angle design.

[0065] The pumping and conveying mechanism adopts a twin-screw pump structure, including a pump housing, twin-screw rotor, and transmission mechanism. The pump housing is manufactured using an integral casting process, and the material is QT450-10 ductile iron. The inner diameter of the housing is 180 mm to 220 mm, and the length is 4.5 to 5.5 times the inner diameter. The twin-screw rotor consists of a driving screw and a driven screw, which achieve synchronous counter-rotation through precision meshing gears. The screws are made of 42CrMo after quenching and tempering, with a helix angle of 48 degrees to 52 degrees and a pitch of 1.2 to 1.5 times the outer diameter of the screw. The radial clearance between the screw and the inner wall of the pump housing is controlled between 0.15 mm and 0.25 mm. The transmission mechanism includes a pump motor, a reducer, and a coupling. The pump motor power is 37 kW to 45 kW, and the speed is 980 rpm to 1450 rpm. The speed is reduced to 280 rpm to 320 rpm by the reducer. This twin-screw pump has the advantages of stable delivery, good sealing, and low wear, making it particularly suitable for conveying sludge with a high solids content.

[0066] The screening and volume reduction mechanism is the core component of the entire production line. It adopts a three-stage tandem screening structure. Each screening box is a rectangular structure, manufactured using carbon steel welding technology. The box length is 2400 mm to 2800 mm, the width is 1200 mm to 1500 mm, and the height is 800 mm to 1000 mm. The screens are made of stainless steel woven mesh. The screen aperture diameter of the first-stage screen is 70 micrometers to 75 micrometers, and the screen aperture diameter of the second-stage screen is 55 micrometers to 60 micrometers. The third-stage screen has a mesh diameter of 45 to 50 micrometers and an inclination angle of 15 to 20 degrees. A multi-row spray system is installed above the screen, with fan-shaped nozzles at a spray pressure of 0.3 to 0.4 MPa and a nozzle spacing of 200 to 250 millimeters. A V-shaped guide trough at the bottom of the screening chamber has a 60-degree inclination angle and a bottom width of 100 to 120 millimeters, used to collect the oversize material and guide it into the collection hopper. Simultaneously, a 2.2 kW vibrating motor is installed on the outer wall of the screening chamber, with a vibration frequency of 960 to 1440 rpm. This motor is connected to the chamber via a shock-absorbing device consisting of four sets of spring dampers, each with a stiffness coefficient of 60 to 80 kN / m. This multi-stage screening structure design not only improves screening efficiency but also produces a more uniform particle size product.

[0067] The concentration and sedimentation mechanism employs a conical sedimentation tank structure. The tank body is constructed from welded carbon steel, with the inner wall coated with anti-corrosion material. The top diameter of the sedimentation tank is 3000 mm to 3500 mm, and the total height is 2.0 to 2.5 times the top diameter. The cone bottom angle is 55 to 65 degrees. Eight to ten layers of annular baffles are installed on the inner wall of the tank. These baffles are made of stainless steel, with a thickness of 4 mm to 6 mm, and evenly spaced guide holes with a diameter of 30 mm to 40 mm are formed on the surface of the baffles. The vertical spacing between adjacent baffles is 400 mm to 500 mm. An overflow weir is installed at the top of the sedimentation tank, with an adjustable weir height. It is connected to a storage tank via four to six return pipes, with a diameter of 100 mm to 150 mm. A pneumatic butterfly valve is installed at the conical sludge discharge port, enabling automatic sludge discharge via a PLC control system. This multi-layered baffle structure design significantly improves sedimentation efficiency and reduces sedimentation time.

[0068] The filter press dewatering mechanism adopts a plate and frame filter press structure. The filter press housing is welded from carbon steel profiles, with a length of 4000 mm to 4500 mm, a width of 1500 mm to 1800 mm, and a height of 1800 mm to 2000 mm. The filter plates are made of polypropylene, with dimensions of 1250 mm × 1250 mm and a thickness of 45 mm to 50 mm. The surface of each filter plate has a raised grid depth of 2 mm to 3 mm and a grid spacing of 15 mm to 20 mm. The filter plates are slidably installed in the housing by four guide rods made of 45# steel, with a diameter of 60 mm to 80 mm and a chrome-plated surface. The spacing between adjacent filter plates is 25 mm to 30 mm. The extrusion pressure is provided by hydraulic cylinders with a working pressure of 15 MPa to 20 MPa. The sealing rings on the edges of the filter plates are made of nitrile rubber, with a cross-sectional diameter of 20 mm to 25 mm and a hardness of 65 to 70 Shore A. This filter press structure not only has a large filtration area, but also has a good filtration effect and low moisture content in the filter cake.

[0069] During operation, the sludge suction dredging mechanism is first activated, using a closed-loop cutter head to suction the sludge from the bottom of the pool. The shredded sludge is then transported through a closed pipeline to a screening and reduction mechanism by a twin-screw pump. After three-stage screening, solid particles of different sizes are separated. The oversize material is collected via a guide trough and transported off-site in a closed vehicle. The undersize material enters a concentration and sedimentation mechanism for mud-water separation. The supernatant is returned to a storage tank for recycling. The bottom sludge is dewatered by a filter press to obtain sludge cakes with a moisture content of 40% to 50%. The sludge cakes are then stacked, dried, and transported off-site for disposal. The entire process is conducted in a closed environment, effectively preventing the emission of dust and odors, and meeting environmental protection requirements.

[0070] In practical applications, the nomadic sludge solidification production line equipment of this invention has the following advantages: The closed-loop cutter head design avoids the splashing problem encountered in traditional sludge dredging processes; the use of twin-screw pumps ensures the stability and reliability of sludge transport; the three-stage screening structure improves grading efficiency, resulting in products with uniform particle size; the multi-layer flow-guided sedimentation tank shortens sedimentation time and improves processing efficiency; and the filter press system employs a large-area filter plate design, significantly improving dewatering performance. Furthermore, the entire system adopts a modular design, allowing each processing unit to be adjusted and optimized according to actual needs, demonstrating strong adaptability and widespread application value.

[0071] Based on the above-described specific embodiments, this invention further optimizes and limits the structural parameters of each key component and their interrelationships to improve the overall performance and working efficiency of the equipment.

[0072] In the structural design of a closed-type auger head, to ensure suction efficiency and prevent clogging, the structural relationship between the outer shell and the internal auger was studied in depth. Through fluid dynamics analysis and verification with a large amount of experimental data, the optimal structural parameter relationship was determined: the ratio of the outer diameter to the inner diameter of the outer shell satisfies... The gap h between the spiral cutting blade and the inner wall of the outer shell needs to be dynamically adjusted according to the viscosity of the sludge. A larger value is used when the sludge has a low water content, and a smaller value is used when the water content is high. The ratio of the outer shell length to the outer diameter meets the following requirements. This structural proportion ensures sufficient suction space while avoiding excessive equipment weight. Simultaneously, the shape of the spiral cutting blade needs to satisfy Archimedes' spiral equation r = r0 + kθ, and its derivative equation... This indicates that the pitch coefficient k is a constant, and this design ensures that the cutting blade can cut and transport the silt evenly.

[0073] For the structural optimization of the three-stage screening box, the relationship between the screen inclination angle and screening efficiency was the primary consideration. By establishing a dynamic model of the screen inclination angle and material movement, the optimal inclination angle relationship was determined.

[0074] This angle range ensures that the material slides down evenly under gravity while also allowing sufficient time for thorough screening. The screen mesh size is designed using a geometric progression. This progressive aperture design not only improves classification efficiency but also avoids clogging problems caused by fine particles in single-stage screening.

[0075] The key to a thickening and sedimentation mechanism lies in the structural design of the conical sedimentation tank and the arrangement of the annular baffle. Through fluid dynamics analysis, the optimal structural proportions of the sedimentation tank were determined: the ratio of total height to top diameter satisfies... The cone bottom angle β is controlled between 55 and 65 degrees. To optimize the arrangement of the annular guide vanes, an area reduction coefficient is introduced to ensure that the area ratio of adjacent guide vanes meets the following requirements. Where λ is the area decay coefficient, with a value ranging from 0.1 to 0.2. This gradual change in area ensures sufficient settling area while avoiding secondary suspension of the bottom sludge.

[0076] The core of a filter press mechanism lies in the pressure distribution and spacing control between the filter plates. By establishing a pressure transmission model, the pressure distribution equation at any position on the filter plate is obtained:

[0077] The pressure attenuation coefficient μ needs to be adjusted according to the moisture content of the sludge; at the same time, the ratio of the filter press plate spacing to the total length needs to meet the following requirements. This structural design ensures sufficient filtration area while avoiding seal failure caused by excessive local pressure.

[0078] In the overall production line layout, a complete spatial layout model was established by optimizing the positional relationships between various processing units. The height difference between the centerlines of each processing unit satisfies an arithmetic sequence relationship, and the connecting pipes between adjacent units follow the shortest path principle, with pipe turning angles not exceeding 45 degrees. This layout not only reduces conveying losses but also facilitates equipment maintenance and repair. Simultaneously, the distance between each processing unit also needs to consider process requirements and equipment maintenance space, generally controlled between 1.5 and 2.0 times the maximum size of the equipment.

[0079] The innovations in these optimized designs and parameter constraints are mainly reflected in the following aspects: First, the structural relationships of each key component are described through rigorous mathematical models, making the design and manufacturing of the equipment more precise and controllable. Second, continuously differentiable mathematical functions are introduced to describe the shape and positional relationships of the components, facilitating parameter optimization and adjustment. Third, exponential relationships are used to describe pressure distribution and area changes, which better reflects actual engineering characteristics. Finally, the determination of the range of each parameter is based on a large amount of experimental data and engineering practice experience, demonstrating strong practicality and reliability. Through these optimized designs, the processing efficiency and operational stability of the equipment are significantly improved, providing a new technical solution for sludge treatment engineering.

[0080] Specifically, the principle of this invention is as follows: The nomadic sludge solidification production line equipment of this invention is based on fluid mechanics, solid-liquid separation, and pressure filtration theories. Through system structural optimization and process innovation, it achieves efficient and environmentally friendly sludge treatment. First, in the design of the closed-type cutter head, the shape and gap of the cutter are optimized using fluid mechanics principles, creating a special flow field structure between the cutting blade and the outer shell. This ensures sufficient shearing action while avoiding splashing caused by eddies. The rational design of the spiral cutting blades, utilizing the spiral propulsion principle, improves the sludge conveying efficiency. Second, in the pumping system, a twin-screw pump structure is adopted. Through the synchronous counter-rotation of the two screws, a closed conveying cavity is formed. Utilizing the volumetric conveying principle, stable sludge conveying is achieved. The special surface design of the screws ensures good sealing while reducing power consumption. In the screening system, based on particle classification theory, through multi-stage series connection and a reasonable screen inclination design, the synergistic effect of gravity and vibration is utilized to improve screening efficiency. Simultaneously, the screen adopts a special weaving structure, ensuring sufficient passing area while avoiding clogging. In the sedimentation system, laminar flow sedimentation theory is utilized, and the multi-layered guide plates extend the water flow path, increase sedimentation time, and improve sludge-water separation. The spiral arrangement of the guide plates creates a stable flow field structure, preventing short-circuiting. In the filter press system, based on capillary action and mechanical filtration principles, the structure and arrangement of the filter plates are optimized to increase the effective filtration area and improve dewatering efficiency. The rational design of the pressure distribution avoids seal failure caused by excessive local pressure. All processing units in the entire system are arranged according to material flow patterns, utilizing gravity transport to reduce energy consumption and improve operating efficiency. Through the application of these innovative technological principles, the environmental pollution problems inherent in traditional sludge treatment equipment have been successfully solved, achieving efficient and environmentally friendly sludge treatment.

[0081] Example 1:

[0082] Taking a city beach silt treatment project as an example, the treated river section is 2800 meters long, the beach width varies from 25 to 45 meters, the silt thickness ranges from 0.8 to 2.5 meters, and the silt moisture content ranges from 125% to 165%. Both sides of the beach are residential areas, with strict environmental protection requirements and limited construction space. The nomadic silt solidification production line equipment used in this embodiment is installed on a flatbed boat 28.5 meters long and 12.5 meters wide, with a total power of 185 kilowatts.

[0083] The enclosed auger head's outer casing is made of 316L stainless steel, with an outer diameter of 580 mm, an inner diameter of 520 mm, and a total length of 1160 mm. The bottom inlet has a conical structure with a cone angle of 82 degrees, a bottom diameter of 380 mm, and a top outlet diameter of 265 mm. The internal auger is made of high-chromium alloy steel and consists of 8 spiral cutting blades, each with a helix angle of 40 degrees, a blade thickness of 14 mm, and a 30 mm gap between the outer edge and the inner wall of the casing. The auger drive shaft is made of 45# quenched and tempered steel with a shaft diameter of 92 mm. It is connected to the output shaft of a 26 kW auger motor via a spline, operating at a speed of 200 rpm.

[0084] The pumping and conveying mechanism uses a QT450-10 ductile iron pump housing with an inner diameter of 205 mm and a length of 985 mm. The twin-screw rotor is made of 42CrMo heat-treated steel with a helix angle of 50 degrees, a pitch of 282 mm, and a radial clearance of 0.2 mm between it and the inner wall of the pump housing. The transmission mechanism uses a 42 kW pump motor with a speed of 1420 rpm, which is reduced to 295 rpm by a reducer with a reduction ratio of 4.8. The pumping pipeline uses stainless steel pipe with an outer diameter of 219 mm and a wall thickness of 8 mm, and the pipeline connection uses DN200 flange connections.

[0085] The three-stage screening chamber of the screening and volume reduction mechanism is made of Q345B carbon steel, with a length of 2650 mm, a width of 1350 mm, and a height of 920 mm. The screens are woven from 904L stainless steel wire, with the first-stage screen having an aperture of 72 microns, the second-stage screen 58 microns, and the third-stage screen 46 microns, and the screen tilt angle is 18 degrees. The spray device uses fan-shaped nozzles with a spray pressure of 0.35 MPa and a nozzle spacing of 220 mm. The guide trough has a V-shaped structure with a wall inclination angle of 60 degrees and a bottom width of 110 mm. The vibrating motor has a power of 2.2 kW and a vibration frequency of 1150 rpm. The shock absorption device uses four sets of spring shock absorbers, each with a spring stiffness coefficient of 72 kN / m.

[0086] The conical sedimentation tank of the concentration and sedimentation mechanism is made of Q345B carbon steel with an epoxy resin anti-corrosion coating on the inner wall. The tank has a top diameter of 3200 mm, a total height of 7360 mm, and a cone base angle of 62 degrees. Nine layers of annular baffles, made of 316L stainless steel (5 mm thick), are installed on the inner wall, with 35 mm diameter baffle holes and a vertical spacing of 460 mm between adjacent baffles. The overflow weir has an adjustable structure and is connected to an 85 cubic meter water storage tank via six 125 mm diameter return pipes. Bottom sludge discharge is controlled by a DN150 pneumatic butterfly valve.

[0087] The filter press dewatering mechanism features a welded housing made of carbon steel profiles, measuring 4250 mm in length, 1650 mm in width, and 1920 mm in height. The filter plates are made of polypropylene, measuring 1250 mm × 1250 mm, with a thickness of 48 mm, a 2.5 mm deep textured grid, and a grid spacing of 18 mm. Four guide rods are made of 45# steel, with a diameter of 72 mm and a 0.05 mm thick hard chrome plating. The spacing between adjacent filter plates is 28 mm, and the hydraulic cylinder operates at a pressure of 18 MPa. The sealing rings are made of nitrile rubber, with a cross-sectional diameter of 22 mm and a hardness of 68 Shore A.

[0088] The equipment demonstrated excellent performance during actual operation. Statistical analysis of operating data under different working conditions led to the development of a detailed operating parameter table, as follows.

[0089] Table 1. Operating parameters of cutter heads for sludge with different moisture contents:

[0090]

[0091] Table 2 Screening parameters for sludge of different particle sizes:

[0092] Table 3 Filtration parameters for sludge with different solid contents:

[0093]

[0094]

[0095] During actual operation, key process parameters are dynamically adjusted based on on-site monitoring data. During the sludge suction operation, the cutter head burial depth is controlled between 75% and 85% of the sludge layer thickness, and the cutter rotation speed is adjusted between 185 and 205 revolutions per minute depending on the sludge moisture content. The pumping system's working pressure is consistently maintained between 0.8 and 1.2 MPa, with the motor speed adjusted via a frequency converter to adapt to different operating conditions. The screening system maintains optimal grading results by adjusting the vibration frequency and spray pressure, keeping the moisture content of the oversize material below 85%. The sludge interface height in the sedimentation tank is controlled between 2.5 and 3.2 meters via an online monitoring system; the sludge discharge frequency is automatically increased when the interface rises. The filter press system uses a segmented pressurization method, with an initial pressure of 8 MPa, increasing by 2 MPa every 10 minutes until the set pressure is reached.

[0096] During a complete work cycle, the equipment has a processing capacity of 75 to 95 cubic meters of undisturbed sludge per hour. After treatment, the oversize material is divided into three grades according to particle size: the first grade has a particle size greater than 72 micrometers, accounting for 15% of the total; the second grade has a particle size between 58 and 72 micrometers, accounting for 25% of the total; and the third grade has a particle size between 46 and 58 micrometers, accounting for 30% of the total. After sedimentation and pressure filtration, the undersize material has a moisture content reduced to between 42% and 48%, and the sludge cake strength meets the requirements for stockpiling. The residual water generated by the system is treated and reused in the spray system, with the makeup water volume being only 8% to 12% of the total system water volume.

[0097] In terms of environmental protection, strict sealing and deodorization measures are implemented during equipment operation. Air curtains are installed in the suction operation area to prevent the spread of odors. The pumping pipeline adopts a double-layer structure with insulation material filling the middle, providing both thermal insulation and soundproofing. Both the screening and filtration systems are located in sealed chambers, which maintain a slight negative pressure. Exhaust gases are treated by activated carbon adsorption before being discharged in compliance with standards. System operating noise measured at 1 meter from the equipment does not exceed 85 decibels, and vibration levels meet environmental protection requirements.

[0098] The entire treatment project lasted 85 days, treating a total of 138,500 cubic meters of beach silt, with an average daily treatment capacity of 1,629 cubic meters. The equipment operated stably, with a mechanical reliability rate exceeding 98%, requiring only two planned maintenance checks. After treatment, the depth of the beach silt decreased by 0.8 meters to 2.5 meters, and the water quality significantly improved, with transparency increasing 2.5 times. Environmental monitoring showed no secondary pollution during the treatment process, and the air quality in the residential area met standards at 100%, earning praise from surrounding residents.

[0099] The project implementation process accumulated a wealth of practical experience. First, the modular design of the equipment demonstrated significant advantages, facilitating transportation and installation. The weight of a single module was kept below 8 tons, and the maximum size did not exceed 6 meters, making road transport convenient. Second, the application of the automated control system greatly reduced manual operation, with key process parameters automatically adjusted, improving operational efficiency and safety. Third, the equipment's corrosion protection measures were effective; key components used corrosion-resistant materials, and the outer wall was coated with a special anti-corrosion coating, ensuring long-term stable operation. Finally, the equipment was easy to maintain; major wear parts used standard parts, and spare parts were readily available, reducing maintenance costs.

[0100] Example 2:

[0101] Taking a silt treatment project at a coastal city's bathing beach as an example, the total treatment area reached 82,000 square meters. The silt thickness was unevenly distributed, with the deepest point at 4.2 meters, the shallowest at 0.6 meters, and an average thickness of 2.1 meters. The silt contained a large amount of shell fragments and sea sand. Because the treatment area was adjacent to a tourist resort, strict requirements were placed on environmental protection and operating hours, and the impact of sea tides needed to be considered. In this embodiment, the nomadic silt solidification production line equipment was built on two parallel-operating flatbed boats. The main boat was 32.5 meters long and 15.8 meters wide, and the auxiliary boat was 22.5 meters long and 12.5 meters wide, with a total equipment power of 265 kilowatts.

[0102] Considering the unique characteristics of coastal silt, the structural parameters of the enclosed cutter head were optimized. The outer shell adopts a double-layer structure, with an inner layer made of wear-resistant alloy steel and an outer layer made of 316L stainless steel. The outer diameter is 620 mm, the inner diameter is 542 mm, and the total length is 1285 mm. Based on fluid dynamics analysis, the outer shell structure must satisfy the following relationships:

[0103] Where h is the gap between the helical cutting blade and the inner wall of the outer casing, and is taken as 39 mm. The ratio of the outer casing length to its outer diameter satisfies: Sufficient mixing space was ensured.

[0104] The built-in reamer is made of high-chromium tungsten alloy steel and consists of 8 spiral cutting blades. The spiral equation satisfies:

[0105] r = 85 + 26θ, where r is the distance from any point on the helix to the axis (in millimeters), θ is the rotation angle (in radians), the initial radius r0 is 85 mm, and the pitch coefficient k is 26. The blade thickness is 16 mm, and the hardness reaches HRC62. The auger drive shaft is made of 42CrMo material, with a shaft diameter of 108 mm, and is connected to a 38 kW auger motor via a coupling, with an operating speed of 185 rpm.

[0106] The screening and volume reduction system employs a special screen arrangement scheme, with the inclination angles of the three-stage screens meeting the following requirements:

[0107] In the formula, H represents the screen height difference of 580 mm, and L... s The horizontal projected length of the screen is 2636 mm. The ratio of the screen aperture diameters of the three-stage screen meets the following requirements: Where d1 is taken as 75 micrometers, d2 is calculated to be 45.5 micrometers and d3 is 27.6 micrometers. The screening box is made of Q345B carbon steel, with a length of 3200 mm, a width of 1850 mm and a height of 1150 mm.

[0108] The structural parameters of the conical sedimentation tank satisfy the following relationship:

[0109] In the formula H c The total height of the sedimentation tank is 8460 mm, D c The top diameter is 3600 mm, and the cone base angle β is 62 degrees. The area distribution of the annular guide vane satisfies: In the formula S n Let Sn be the area of ​​the nth layer of guide vanes, and S0 be the area of ​​the top layer guide vane, which is 10.18 square meters. A total of 12 layers of guide vanes are installed. The guide vanes are made of 2205 duplex stainless steel, with a thickness of 6 mm and a guide hole diameter of 42 mm.

[0110] The pressure distribution of the filter press system satisfies:

[0111] In the formula, P0 is the feed end pressure (22 MPa), x is the distance from the feed end, and L... p The total length of the filter press plates is 4850 mm. The ratio of the filter press plate spacing to the total length is: Therefore, the spacing between the filter press plates was determined to be 121 mm. The filter press plates are made of modified polypropylene, with dimensions of 1500 mm × 1500 mm and a thickness of 52 mm.

[0112] The equipment demonstrated excellent adaptability during actual operation, especially in treating coastal silt containing shell fragments. The processing data is summarized below.

[0113] Table 4. Operating parameters corresponding to tidal conditions:

[0114]

[0115] Table 5. Screening parameters for different shell contents:

[0116]

[0117] Table 6. Filtration parameters under different salinity conditions:

[0118] salinity(‰) Filtration time (min) Final pressure (MPa) Moisture content (%) 20 to 25 62 18 46 25 to 30 68 19 48 30 to 35 75 20 50 35 and above 82 21 52

[0119] In actual operation, the equipment effectively copes with the challenges brought by tidal changes. During high tide, a stable feed rate is maintained by adjusting the cutter head depth and rotation speed; during low tide, a movable guide channel ensures continuous operation. The system is equipped with automated salinity compensation control, automatically extending the filtration time and increasing the filtration pressure when the feed salinity increases. For areas with high shell fragment content, screen clogging is avoided by increasing the vibration frequency and washing pressure.

[0120] The entire treatment project lasted 125 days, treating a total of 186,500 cubic meters of coastal silt, with an average daily treatment capacity of 1,492 cubic meters. The equipment demonstrated high reliability, with a mechanical integrity rate of 96.5%. The treated coastal area showed a significant reduction in silt depth, a marked improvement in water quality, and has been restored to its scenic function, reopening to tourists. The project accumulated valuable experience in coastal silt treatment, providing important technical references for similar projects.

Claims

1. A nomadic-style sludge solidification production line equipment, characterized in that, The system includes a sluice suction dredging mechanism (10), a pumping and conveying mechanism (11), a screening and reduction mechanism (12), a concentration and sedimentation mechanism (13), and a filter press dewatering mechanism (14). The sluice suction dredging mechanism (10) includes a closed sluice head (101) and a sluice drive shaft (102), which is fixedly connected to the output shaft of a sluice motor (103). The pumping and conveying mechanism (11) includes a feed pipe (111), a mud pump body (112), and a discharge pipe (113). One end of the feed pipe (111) is connected to the closed sluice head (101), and the other end is connected to the mud pump body (113). The feed inlet of the 12) is connected, one end of the discharge pipe (113) is connected to the discharge port of the mud pump body (112), and the other end is connected to the feed end of the screening and reduction mechanism (12); the screening and reduction mechanism (12) includes a three-stage screening box (120), each stage of the screening box is provided with an inclined screen, the screens are arranged from top to bottom as a first-stage screen, a second-stage screen and a third-stage screen, the screen hole diameter of the first-stage screen is larger than the screen hole diameter of the second-stage screen, and the screen hole diameter of the second-stage screen is larger than the screen hole diameter of the third-stage screen; the concentration and sedimentation mechanism (13) includes a conical sedimentation tank. The conical sedimentation tank body (130) has an overflow weir (131) at its upper part and a conical sludge discharge port (132) at its bottom. The filter press dewatering mechanism (14) includes a filter press housing (140), which has multiple layers of filter plates inside, forming a filter press chamber between adjacent filter plates. The inner wall of the conical sedimentation tank body (130) is provided with multiple layers of annular guide plates (133), which are arranged in a spiral shape, forming a sedimentation channel between adjacent annular guide plates (133). The surface of the annular guide plates (133) is provided with... Multiple guide holes (1331); the top of the conical sedimentation tank (130) is provided with multiple return pipes, one end of which is connected to the overflow weir (131) and the other end is connected to the water storage tank; the conical sludge discharge port (132) of the conical sedimentation tank (130) is connected to the feed port of the filter press box (140) through the sludge discharge pipe; after three-stage screening, solid particles of different sizes are separated, the oversize material is collected through the guide trough and transported out by a closed vehicle, the undersize material enters the thickening sedimentation mechanism for mud-water separation, the supernatant is returned to the water storage tank for recycling, and the bottom sludge is dewatered through the filter press dewatering mechanism.

2. The nomadic sludge solidification production line equipment according to claim 1, characterized in that, The enclosed auger head (101) includes an outer shell and an inner auger. The outer shell is cylindrical with a mud inlet at the bottom and a mud outlet at the top. The inner auger is fixedly installed on the auger drive shaft (102). The inner auger is composed of multiple spiral cutting blades, and there is a gap between the outer edge of the cutting blade and the inner wall of the outer shell.

3. The nomadic sludge solidification production line equipment according to claim 2, characterized in that, The top of the three-stage screening box (120) is provided with a feeding hopper (121), and the feeding hopper (121) is provided with a plurality of spray heads (122). The spray heads (122) are connected to the clean water tank through water pipes. The bottom of the three-stage screening box (120) is provided with a plurality of guide grooves (123). The guide grooves (123) are arranged along the inclined direction of the screen. One end of the guide groove (123) is connected to the screen, and the other end extends out of the three-stage screening box (120) and is connected to the collection hopper.

4. The nomadic sludge solidification production line equipment according to claim 3, characterized in that, The filter press housing (140) has a fixed end plate (141) and a movable end plate (142) on both sides. The fixed end plate (141) is fixedly connected to the filter press housing (140), and the movable end plate (142) is connected to the filter press housing (140) through a hydraulic cylinder. The filter plate is slidably installed in the filter press housing (140) through a guide rod (143), and the two ends of the guide rod (143) are connected to the fixed end plate (141) and the movable end plate (142) respectively.

5. The nomadic sludge solidification production line equipment according to claim 4, characterized in that, The surface of the filter press plate is provided with a textured grid, and the textured grids of adjacent filter press plates are arranged opposite each other; the edge of the filter press plate is provided with a sealing ring, which is made of elastic rubber material.

6. The nomadic sludge solidification production line equipment according to claim 5, characterized in that, The mud pump body (112) is a twin-screw pump, including a pump housing and a twin-screw rotor disposed in the pump housing. The twin-screw rotor consists of a driving screw and a driven screw. The driving screw is connected to the output shaft of the pump motor, and the driven screw is driven by the driving screw through a gear set.

7. The nomadic sludge solidification production line equipment according to claim 6, characterized in that, A vibration motor (15) is provided on the outer wall of the three-stage screening box (120). The vibration motor (15) is connected to the three-stage screening box (120) through a shock-absorbing device (16). The shock-absorbing device (16) includes a spring support seat and a shock-absorbing spring. One end of the shock-absorbing spring is connected to the spring support seat, and the other end is connected to the three-stage screening box (120).

8. The nomadic sludge solidification production line equipment according to claim 7, characterized in that, The shock absorption device (16) also includes a rubber ring.

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