Comprehensive treatment method and system for scabbing of chemical fertilizer equipment and pipeline

Abstract

The invention relates to the technical field of equipment treatment, in particular to a comprehensive treatment method for scabs of chemical fertilizer equipment and pipelines, which comprises the following steps: S1, surveying and collecting data, and constructing a scabs database; s2, simulation analysis is carried out, and a scabbing area is obtained through calculation; s3, a treatment device is arranged, and a vibration device and an active alternate air inlet temperature control device are arranged in the scabbing area; s4, coating a coating; and S5, designing and implementing a treatment scheme. Through innovative application of a vibration device, an active alternate air inlet temperature control device and a macromolecular nano non-stick coating, adhesion of chemical fertilizer particles and dust on the surface of equipment is effectively reduced, the parking risk of the equipment is reduced, the maintenance cost is reduced, the equipment cleaning times and frequency are reduced, the safety risk caused by manual cleaning is reduced, and the labor and material cost is reduced; the economic benefit is improved.

Description

Technical Field

[0001] The invention relates to the technical field of equipment management, and in particular to a comprehensive management method and system for fertilizer equipment and pipeline scarring. Background Art

[0002] During the fertilizer production process, due to the high temperature, high humidity environment and the physical and chemical properties of the fertilizer itself, fertilizer particles or dust are easily adhered to the granulation tower (granulation tower scraper arm), dryer, various silos, pipelines and other major equipment, forming scarring. This scarring not only affects product quality and restricts the high and stable production of fertilizers, but in severe cases it may even cause equipment shutdown, bringing serious economic losses and safety risks to the fertilizer industry. Traditional cleaning methods are not only inefficient, increase safety hazards during cleaning, but also difficult to fundamentally solve the problem.

[0003] Related technologies are disclosed in the prior art:

[0004] The Chinese patent application with publication number CN102423763A discloses a method and device for preventing scarring of a granulator discharge chute, which uses a compressed air scar blowing system and a heating jacket provided at the bottom of the chute to blow compressed air from the compressed air inlet on the bottom of the chute at a fixed time and quantity to prevent the adhesion, deposition and scarring of granulated materials around the chute, so as to achieve the purpose of timely and convenient removal of scarring and piles. The heating jacket and compressed air scar blowing system can effectively prevent the adhesion and accumulation of solid granulated materials around the chute, and the scarring and piles around the chute can be cleaned in time.

[0005] However, the above prior art still has the following problems:

[0006] (1) It cannot be applied to all scab forming equipment in the entire fertilizer production line. It is not controlled according to the actual scab forming situation, and the energy consumption is large. Maintaining the heating state for a long time consumes a lot of power and is only applicable to specific fertilizer production equipment. It has poor effect on fertilizers with large differences in properties.

[0007] (2) Periodic air cannons require equipment such as compressors, which have poor stability and are expensive. They also generate high noise and energy consumption. Summary of the invention

[0008] In order to solve the above technical problems, the present invention is implemented by the following technical solutions: a comprehensive treatment method for fertilizer equipment and pipeline scarring, comprising the following steps:

[0009] S1. Investigation and data collection: Conduct on-site investigation of fertilizer production equipment, mark the scarring location based on equipment drawings and process design parameters, collect scarring location environmental parameters and scarring parameters, calculate scarring risk level, and build a scarring database;

[0010] S2. Simulation analysis: Establish equipment model in combination with equipment drawings and on-site layout, set simulation variables: fertilizer output, fertilizer particle size and fertilizer type, simulate and obtain the falling material concentration area during equipment operation, and calculate the scarring area based on the falling material concentration area;

[0011] S3. Arrangement of treatment devices: Arrange vibration devices and active alternating air inlet temperature control devices in the scarring area;

[0012] S4, coating; coating the scar area to reduce the adhesion of the scar;

[0013] S5. Design and implementation of governance solutions: Based on historical governance data, build governance solutions and control the operation mode of governance devices in real time through controllers.

[0014] Furthermore, the environmental parameters include temperature, humidity and dust content; the scarring parameters include area, thickness and hardness; and the process design parameters include production capacity, equipment flow rhythm, equipment operation parameters and ancillary facilities.

[0015] Furthermore, the steps of calculating the scar risk level and constructing a scar database include:

[0016] S11. Calculate the risk factor P scab ,as follows:

[0017] P scab =ω1A+ω2d+ω3R-I c

[0018] Among them, A is the scar area, d is the scar thickness, R is the scar hardness, ω1, ω2, ω3 are weight coefficients, I c is the coating coefficient, which is calculated from the coating thickness and type;

[0019] S12, obtaining the scarring risk level from the risk coefficient, the level is determined by a preset threshold or by a directly corresponding coefficient value, the larger the value, the higher the risk level;

[0020] S13, collect environmental parameters to build scar database DB scab ,as follows:

[0021] DB scab ={X temp ,X wetness ,X dust ,P scab ,S P-temp ,S P-wetness ,S P-dust}

[0022] Among them, X temp ,X wetness ,X dustare temperature, humidity and dust quantity, S P-temp ,S P-wetness ,S P-dust The impact of temperature, humidity and dust volume on the risk factor respectively.

[0023] Furthermore, the step of calculating the scarring area based on the falling material concentration area comprises the following steps:

[0024] S21, the obtained multiple blanking concentration areas are combined to obtain the largest area, as follows:

[0025] Q max =(q1∪q2∪…∪q n )

[0026] Among them, Q max is the maximum area, q i , i = 1, 2, ..., n is the material collection area, n is the number of material collection areas;

[0027] S22, the core area is obtained by performing intersection processing on the obtained multiple blanking concentration areas, as follows:

[0028] Q c =(q1∩q2∩…∩q n )

[0029] Among them, Q c For the core area;

[0030] S23, the largest area and the core area constitute the scarring area, as follows:

[0031] Q scab = {Q c ,Q max}

[0032] Among them, Q scab For the scar area.

[0033] Furthermore, the S2 also includes bonding particle force field simulation, establishing a scab model based on simulation software, analyzing the bonding failure area and defining it as a bonding weak area.

[0034] Furthermore, S3 comprises the following steps:

[0035] S31, arrange vibration devices, vibrate generators at the edge of the scar core area and the weak bonding area, and adjust the number and specifications of vibration generators according to the scar risk level;

[0036] S32. Arrange an active alternating air inlet temperature control device. Set up an active alternating air inlet temperature control device in the area with the largest scarring, and equip it with temperature, humidity, and dust sensors to monitor the environmental data in the device in real time, and set two modes of heating or cooling;

[0037] S33, the vibration device and the active alternating air inlet temperature control device are all connected to a controller.

[0038] Furthermore, in step S3, if the scarred area is a rotating component, the conductive slip ring is improved by combining the active alternating air intake temperature control device with the conductive slip ring, so that the conductive slip ring has the dual functions of air intake and conduction.

[0039] Furthermore, the coating is a polymer nano non-stick coating, and the coating structure includes: a strong adhesion performance layer, a high elasticity layer and a smooth outer protective layer; the coating coating steps are:

[0040] S41. Pre-treat the surface of the equipment to increase the friction and adhesion between the coating and the base surface;

[0041] S42, setting a coating thickness gradient distribution according to the maximum area and the core area, wherein the core area is the area with the maximum thickness, and the boundary of the core area is connected with the boundary of the maximum area, and the thickness changes from the inside to the outside in a gradient manner;

[0042] S43, use "M" shaped cross coating method to increase the overall elasticity and surface tension of the coating.

[0043] Furthermore, the construction of a governance solution based on historical governance data includes the following steps:

[0044] S51. Filter the data in the scar database, set the data similarity interval, cluster similar environmental conditions, and set the objective function: P scab <[P], [P] is the permissible risk factor, and the optimal environmental parameters are obtained; based on the real-time environmental parameters, the control parameters of the active alternating air inlet temperature control device are calculated;

[0045] S52. Within a control cycle, if the real-time environmental parameters do not change or the change is less than the set threshold, the current scarring risk level is predicted based on the data in the scarring database, and the number of vibration generators and the vibration frequency are set according to the scarring risk level.

[0046] The present invention also provides a comprehensive treatment system for fertilizer equipment scarring, the comprehensive treatment system comprising a modeling module, a controller, an active alternating air inlet temperature control device, a vibration device, a polymer nano non-stick coating and a sensor;

[0047] The modeling module includes a data acquisition unit, a modeling unit and an analysis unit;

[0048] The active alternating air inlet temperature control device comprises an air inlet unit, a temperature control unit, and an air volume control unit;

[0049] The vibration device includes a wave source detection unit, a vibration generator and a vibration controller; the wave source detection unit is used to detect the scarring condition of the equipment and control the vibration device according to the scarring condition;

[0050] The sensors include temperature, humidity and dust sensors.

[0051] The beneficial effects of the present invention are:

[0052] 1. Through the innovative application of vibration device, active alternating air inlet temperature control device, and polymer nano non-stick coating, the adhesion of fertilizer particles and dust on the equipment surface is effectively reduced, the risk of equipment shutdown is reduced, and the maintenance cost is reduced: the number and frequency of equipment cleaning are reduced, the safety risks caused by manual cleaning, as well as labor and material costs are reduced, and economic benefits are improved.

[0053] 2. Through modeling and simulation calculations, the key points and areas of treatment can be found more accurately, and the cost of scar treatment can be reduced through reasonable layout.

[0054] 3. Through real-time monitoring data and automatic control of treatment devices, energy consumption is reduced while the treatment effect is improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 It is a schematic diagram of the method flow of the present invention;

[0056] Figure 2 It is a schematic diagram of the system structure of the present invention. DETAILED DESCRIPTION

[0057] In order to deepen the understanding of the present invention, the present invention will be further described in detail below in conjunction with examples. The examples are only used to explain the present invention and do not constitute a limitation on the protection scope of the present invention.

[0058] Embodiment 1

[0059] according to Figure 1 As shown, a comprehensive treatment method for fertilizer equipment and pipeline scarring includes the following steps:

[0060] S1. Investigation and data collection: Conduct on-site investigation of fertilizer production equipment, mark the scarring location based on equipment drawings and process design parameters, collect scarring location environmental parameters and scarring parameters, calculate scarring risk level, and build a scarring database;

[0061] S2. Simulation analysis: Establish equipment model in combination with equipment drawings and on-site layout, set simulation variables: fertilizer output, fertilizer particle size and fertilizer type, simulate and obtain the falling material concentration area during equipment operation, and calculate the scarring area based on the falling material concentration area;

[0062] S3. Arrangement of treatment devices: Arrange vibration devices and active alternating air inlet temperature control devices in the scarring area;

[0063] S4, coating; coating the scar area to reduce the adhesion of the scar;

[0064] S5. Design and implementation of governance solutions: Based on historical governance data, build governance solutions and control the operation mode of governance devices in real time through controllers.

[0065] More specifically, the environmental parameters include temperature, humidity and dust content; the scarring parameters include area, thickness and hardness; the process design parameters include production capacity, equipment flow rhythm, equipment operation parameters and ancillary facilities.

[0066] More specifically, the steps of calculating the scar risk level and constructing a scar database include:

[0067] S11. Calculate the risk factor P scab ,as follows:

[0068] P scab =ω1A+ω2d+ω3R-I c

[0069] Among them, A is the scar area, d is the scar thickness, R is the scar hardness, ω1, ω2, ω3 are weight coefficients, I c is the coating coefficient, which is calculated from the coating thickness and type;

[0070] S12, obtaining the scarring risk level from the risk coefficient, the level is determined by a preset threshold or by a directly corresponding coefficient value, the larger the value, the higher the risk level;

[0071] S13, collect environmental parameters to build scar database DB scab ,as follows:

[0072] DB scab ={X temp ,X wetness ,X dust ,P scab ,S P-temp ,S P-wetness ,S P-dust}

[0073] Among them, X temp ,X wetness ,X dust are temperature, humidity and dust quantity, S P-temp ,S P-wetness ,S P-dust The impact of temperature, humidity and dust volume on the risk factor respectively.

[0074] More specifically, the step of calculating the scarring area based on the falling material concentration area comprises the following steps:

[0075] S21, the obtained multiple blanking concentration areas are combined to obtain the largest area, as follows:

[0076] Q max =(q1∪q2∪…∪q n )

[0077] Among them, Q max is the maximum area, q i , i = 1, 2, ..., n is the material collection area, n is the number of material collection areas;

[0078] S22, the core area is obtained by performing intersection processing on the obtained multiple blanking concentration areas, as follows:

[0079] Q c =(q1∩q2∩…∩q n )

[0080] Among them, Q c For the core area;

[0081] S23, the largest area and the core area constitute the scarring area, as follows:

[0082] Q scab = {Q c ,Q max}

[0083] Among them, Q scab For the scar area.

[0084] More specifically, the S2 also includes bonding particle force field simulation, establishing a scab model based on simulation software, analyzing the bonding failure area and defining it as a bonding weak area.

[0085] More specifically, S3 comprises the following steps:

[0086] S31, arrange vibration devices, vibrate generators at the edge of the scar core area and the weak bonding area, and adjust the number and specifications of vibration generators according to the scar risk level;

[0087] S32. Arrange an active alternating air inlet temperature control device. Set up an active alternating air inlet temperature control device in the area with the largest scarring, and equip it with temperature, humidity, and dust sensors to monitor the environmental data in the device in real time, and set two modes of heating or cooling;

[0088] S33, the vibration device and the active alternating air inlet temperature control device are all connected to a controller.

[0089] More specifically, in step S3, if the scarred area is a rotating component, the conductive slip ring is improved, and the active alternating air intake temperature control device is combined with the conductive slip ring, so that the conductive slip ring has the dual functions of air intake and conduction; when the implementation object is a rotating device, it is ensured that there is no contact between the rotating component and the fixed component, and reliable gas medium and electrical signal synchronous operation and synchronous transmission functions are achieved, and single use or combined use can be selected according to actual conditions.

[0090] More specifically, the coating is a polymer nano non-stick coating, and the coating structure includes: a strong adhesion performance layer, a high elasticity layer and a smooth outer protective layer; the coating coating steps are:

[0091] S41. Pre-treat the surface of the equipment to increase the friction and adhesion between the coating and the base surface;

[0092] S42, setting a coating thickness gradient distribution according to the maximum area and the core area, wherein the core area is the area with the maximum thickness, and the boundary of the core area is connected with the boundary of the maximum area, and the thickness changes from the inside to the outside in a gradient manner;

[0093] S43, use "M" shaped cross coating method to increase the overall elasticity and surface tension of the coating.

[0094] More specifically, building a governance solution based on historical governance data includes the following steps:

[0095] S51. Filter the data in the scar database, set the data similarity interval, cluster similar environmental conditions, and set the objective function: P scab <[P], [P] is the permissible risk factor, and the optimal environmental parameters are obtained; based on the real-time environmental parameters, the control parameters of the active alternating air inlet temperature control device are calculated;

[0096] S52. Within a control cycle, if the real-time environmental parameters do not change or the change is less than the set threshold, the current scarring risk level is predicted based on the data in the scarring database, and the number of vibration generators and the vibration frequency are set according to the scarring risk level.

[0097] Embodiment 2

[0098] like Figure 2 As shown, this embodiment also provides a comprehensive management system for fertilizer equipment scarring, the comprehensive management system includes a modeling module, a controller, an active alternating air inlet temperature control device, a vibration device, a polymer nano non-stick coating and a sensor;

[0099] The modeling module includes a data acquisition unit, a modeling unit and an analysis unit;

[0100] The active alternating air inlet temperature control device comprises an air inlet unit, a temperature control unit, and an air volume control unit;

[0101] The vibration device includes a wave source detection unit, a vibration generator and a vibration controller; the wave source detection unit is used to detect the scarring condition of the equipment and control the vibration device according to the scarring condition;

[0102] The sensors include temperature, humidity and dust sensors.

[0103] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and 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, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. A comprehensive treatment method for fertilizer equipment and pipeline scarring, characterized in that: The following steps are involved: S1. Investigation and data collection: Conduct on-site investigation of fertilizer production equipment, mark the scarring location based on equipment drawings and process design parameters, collect scarring location environmental parameters and scarring parameters, calculate scarring risk level, and build a scarring database; S2. Simulation analysis: Establish equipment model in combination with equipment drawings and on-site layout, set simulation variables: fertilizer output, fertilizer particle size and fertilizer type, simulate and obtain the falling material concentration area during equipment operation, and calculate the scarring area based on the falling material concentration area; S3. Arrangement of treatment devices: Arrange vibration devices and active alternating air inlet temperature control devices in the scarring area; S4, coating; coating the scar area to reduce the adhesion of the scar; S5. Design and implementation of governance solutions: Based on historical governance data, build governance solutions and control the operation mode of governance devices in real time through controllers.

2. A comprehensive treatment method for fertilizer equipment and pipeline scarring according to claim 1, characterized in that: The environmental parameters include temperature, humidity and dust content; the scarring parameters include area, thickness and hardness; the process design parameters include production capacity, equipment flow rhythm, equipment operation parameters and ancillary facilities.

3. A comprehensive treatment method for fertilizer equipment and pipeline scarring according to claim 2, characterized in that: The steps of calculating the scar risk level and constructing a scar database include: S11. Calculate the risk factor P scab ,as follows: P scab =ω1A+ω2d+ω3R-I c Among them, A is the scar area, d is the scar thickness, R is the scar hardness, ω1, ω2, ω3 are weight coefficients, I c is the coating coefficient, which is calculated from the coating thickness and type; S12, obtaining the scarring risk level from the risk coefficient, the level is determined by a preset threshold or by a directly corresponding coefficient value, the larger the value, the higher the risk level; S13, collect environmental parameters to build scar database DB scab ,as follows: DB scab ={X temp ,X wetness ,X dust ,P scab ,S P-temp ,S P-wetness ,S P-dust } Among them, X temp ,X wetness ,X dust are temperature, humidity and dust quantity, S P-temp ,S P-wetness ,S P-dust The impact of temperature, humidity and dust volume on the risk factor respectively.

4. A comprehensive treatment method for fertilizer equipment and pipeline scarring according to claim 3, characterized in that: The method of calculating the scarring area based on the falling material concentration area comprises the following steps: S21, the obtained multiple blanking concentration areas are combined to obtain the largest area, as follows: Q max =(q1∪q2∪…∪q n ) Among them, Q max is the maximum area, q i , i = 1, 2, ..., n is the material collection area, n is the number of material collection areas; S22, the core area is obtained by performing intersection processing on the obtained multiple blanking concentration areas, as follows: Q c =(q1∩q2∩…∩q n ) Among them, Q c For the core area; S23, the largest area and the core area constitute the scarring area, as follows: Q scab ={Q c ,Q max } Among them, Q scab For the scar area.

5. A comprehensive treatment method for fertilizer equipment and pipeline scarring according to claim 4, characterized in that: The S2 also includes bonding particle force field simulation, establishing a scab model based on simulation software, analyzing the bonding failure area and defining it as a bonding weak area.

6. A comprehensive treatment method for fertilizer equipment and pipeline scarring according to claim 5, characterized in that: The S3 comprises the following steps: S31, arrange vibration devices, vibrate generators at the edge of the scar core area and the weak bonding area, and adjust the number and specifications of vibration generators according to the scar risk level; S32. Arrange an active alternating air inlet temperature control device. Set up an active alternating air inlet temperature control device in the area with the largest scarring, and equip it with temperature, humidity, and dust sensors to monitor the environmental data in the device in real time, and set two modes of heating or cooling; S33, the vibration device and the active alternating air inlet temperature control device are all connected to a controller.

7. A comprehensive treatment method for fertilizer equipment and pipeline scarring according to claim 1, characterized in that: In step S3, if the scarred area is a rotating component, the conductive slip ring is improved by combining the active alternating air intake temperature control device with the conductive slip ring, so that the conductive slip ring has the dual functions of air intake and conduction.

8. A comprehensive treatment method for fertilizer equipment and pipeline scarring according to claim 6, characterized in that: The coating is a polymer nano non-stick coating, and the coating structure includes: a strong adhesion performance layer, a high elasticity layer and a smooth outer protective layer; the coating coating steps are: S41. Pre-treat the surface of the equipment to increase the friction and adhesion between the coating and the base surface; S42, setting a coating thickness gradient distribution according to the maximum area and the core area, wherein the core area is the area with the maximum thickness, and the boundary of the core area is connected with the boundary of the maximum area, and the thickness changes from the inside to the outside in a gradient manner; S43, adopt "M" shaped cross coating method to increase the overall elasticity and surface tension of the coating.

9. A comprehensive treatment method for fertilizer equipment and pipeline scarring according to claim 8, characterized in that: The construction of a governance solution based on historical governance data includes the following steps: S51. Filter the data in the scar database, set the data similarity interval, cluster similar environmental conditions, and set the objective function: P scab <[P], [P] is the permissible risk factor, and the optimal environmental parameters are obtained; based on the real-time environmental parameters, the control parameters of the active alternating air inlet temperature control device are calculated; S52. Within a control cycle, if the real-time environmental parameters do not change or the change is less than the set threshold, the current scarring risk level is predicted based on the data in the scarring database, and the number of vibration generators and the vibration frequency are set according to the scarring risk level.

10. A comprehensive treatment system for fertilizer equipment scarring, characterized in that: A comprehensive treatment method for fertilizer equipment and pipeline scarring as described in any one of claims 1 to 9, wherein the comprehensive treatment system comprises a modeling module, a controller, an active alternating air inlet temperature control device, a vibration device, a polymer nano non-stick coating and a sensor; The modeling module includes a data acquisition unit, a modeling unit and an analysis unit; The active alternating air inlet temperature control device comprises an air inlet unit, a temperature control unit, and an air volume control unit; The vibration device includes a wave source detection unit, a vibration generator and a vibration controller; the wave source detection unit is used to detect the scarring condition of the equipment and control the vibration device according to the scarring condition; The sensors include temperature, humidity and dust sensors.

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