Sludge pyrolysis energy-saving and consumption-reducing device and method based on solid-state microwave energy source

Abstract

The invention relates to a sludge pyrolysis energy-saving and consumption-reducing device and method based on a solid-state microwave energy source, and belongs to the technical field of waste recycling. Comprising a gas outlet, a microwave system, a spiral conveyor and a discharging system, and further comprises a separator, a condenser and a heat preservation layer, the output end of the spiral conveyor is connected with the microwave system, and the microwave system is provided with the heat preservation layer and connected with the discharging system and one end of the separator; and the other end of the separator is connected with the liquid collecting box and the gas outlet through the condenser. The microwave source is high in output power, low in energy consumption, high in processing efficiency, simple and reliable in structure, reasonable in space design and convenient to debug and install.

Description

Technical Field

[0001] The present invention relates to a sludge pyrolysis device and method, belonging to the technical field of waste recycling and utilization. Background Art

[0002] Pyrolysis is considered as a prospective technology for the recycling of organic solid waste at present due to its significant advantages such as low carbon, rapidity, and less secondary pollution, and has achieved engineering applications in the industrial field. Compared with traditional pyrolysis technologies, microwave pyrolysis has more advantages in realizing volume heating from the inside out by emitting electromagnetic waves with the endogenous minerals in organic solid waste as microwave receivers. At present, microwave pyrolysis generally uses a magnetron heat source with a fixed frequency, which easily leads to bottleneck problems such as uneven heating, high energy consumption, and low output power.

[0003] To overcome the above problems, a microwave energy source based on solid state power may be an effective means. At the same time, the solid state energy source can achieve higher output efficiency and save processing costs. The microwave source heating using the solid state power microwave source has a higher integration degree, is easier to realize miniaturized packaging, and the modular design is convenient for expansion and replacement. Moreover, the solid state power source equipment is convenient to control, and the frequency, phase, power, etc. can be real-time feedback and adjusted during operation. For example: the publication number is CN115893786B, and the invention creation name is a microwave pyrolysis sludge drying system and device. In its technical solution, the moisture in the sludge is reduced in the microwave pyrolysis drying device to accelerate the drying efficiency, and the problem of slow evaporation of moisture in the sludge in the related technology is solved. However, it does not effectively separate the water vapor, which is not conducive to recycling and environmental protection; at the same time, the sludge compression area adopts multiple microwave pyrolysis treatments, significantly increasing the energy consumption and being not conducive to energy conservation. In addition, the publication number is CN107200452A, and the invention creation name is microwave pyrolysis - segmented heating condensation strategy for separating and collecting solid-liquid-gas products and in-situ drying of heat energy. This invention has achieved beneficial effects. However, due to the temperature range differences in the generation conditions of solid-liquid-gas products, the gradient temperature rising mechanism of microwave pyrolysis at the present stage can effectively separate and collect, while the segmented heating condensation is prone to increase energy consumption and extend the pyrolysis time due to the temperature rising time and condensation time scheme.

[0004] Therefore, there is an urgent need to propose a sludge pyrolysis energy-saving and consumption-reducing device and method based on a solid state microwave energy source to solve the above technical problems. Summary of the Invention

[0005] To solve the above problems, a sludge pyrolysis energy-saving and consumption-reducing device and method based on a solid state microwave energy source are provided. A brief overview of the present invention is given below to provide a basic understanding of certain aspects of the present invention. It should be understood that this overview is not an exhaustive overview of the present invention. It is not intended to identify the key or important parts of the present invention, nor is it intended to limit the scope of the present invention.

[0006] Technical solution of the present invention:

[0007] A sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source, comprising a gas outlet, a microwave system, a screw conveyor and a discharging system, further comprising a separator, a condenser and a heat-insulating layer. The output end of the screw conveyor is connected to the microwave system, the microwave system is provided with a heat-insulating layer, the microwave system is connected to the discharging system and one end of the separator, and the other end of the separator is connected to a liquid collection tank and the gas outlet through the condenser.

[0008] Preferably: it further comprises a stainless steel barrel and a cooling water system. One outlet of the microwave system is connected to the discharging system through the cooling water system, and a stainless steel barrel is placed below the discharging system.

[0009] Preferably: it further comprises a temperature sensor. The microwave system is provided with a temperature sensor, and a safety valve is installed at the gas outlet.

[0010] Preferably: Another outlet of the microwave system is connected to the inlet of the separator, and the outlet of the separator is connected to the inlet of the condenser through a U-shaped conduit.

[0011] Preferably: The temperature sensor adopts a platinum temperature sensor, the separator is a cyclone dust collector, the microwave system is a gallium nitride microwave conduction system, and the safety valve is a spring-loaded slightly-opening safety valve.

[0012] Preferably: it further comprises a storage hopper, and a storage hopper is arranged at the input end of the screw conveyor.

[0013] A sludge pyrolysis method based on a solid-state microwave energy source, using the sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source, the method comprising the following steps:

[0014] Step 1: Start the device, prepare dehydrated sludge or oily sludge with a moisture content of less than 5% as the pyrolysis raw material, and place it in the storage hopper;

[0015] Step 2: The pyrolysis raw material passes through the screw conveyor system and enters the heat-insulating layer;

[0016] The microwave system operates, and a temperature sensor is configured to accurately extract the temperature during the pyrolysis process;

[0017] Step 3: The sludge or oily sludge raw material treated by the heat-insulating layer generates a biochar product with porous adsorption, is cooled through the cooling water system, and enters the stainless steel barrel from the discharging system;

[0018] Step 4: The non-condensable volatile components released by the biochar during the microwave pyrolysis process contain C1-C4 high-value gases that can be resource-utilized; they are removed through the separator to obtain high-purity value-added gases; finally, they are recovered from the gas outlet through the condenser (cooling and recovery system).

[0019] The present invention has the following beneficial effects:

[0020] By means of the separator and condenser provided at the outlet, the present invention effectively separates gas and liquid, which not only saves energy but also is beneficial to environmental protection and classified recycling and reuse research.

[0021] The microwave source of the present invention has high output power, low energy consumption, high processing efficiency, simple and reliable structure, reasonable space design, and is convenient for debugging and installation. Description of the Drawings

[0022] Figure 1 It is a schematic structural diagram of a sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source.

[0023] Figure 2 It is a structure diagram of a gallium nitride die.

[0024] Figure 3 It is a structure diagram of a gallium nitride transistor.

[0025] Figure 4 It is a schematic diagram of microwave pyrolysis principle.

[0026] In the figure, 1 - gas outlet, 2 - temperature sensor, 3 - condenser, 4 - separator, 5 - microwave system, 6 - thermal insulation layer, 7 - storage hopper, 8 - screw conveyor, 9 - electric control system, 10 - stainless steel barrel, 11 - cooling water system, 12 - discharging system. Detailed Embodiments

[0027] To make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be described below through specific embodiments shown in the drawings. However, it should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the present invention. In addition, in the following description, descriptions of well-known structures and technologies are omitted to avoid unnecessarily confusing the concepts of the present invention.

[0028] Detailed Embodiment 1: In combination with Figures 1-3Description of this embodiment, a sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source in this embodiment, includes a gas outlet 1, a microwave system 5, a screw conveyor 8 and a discharging system 12, and is characterized in that: it further includes a separator 4, a condenser 3 and a heat preservation layer 6. The output end of the screw conveyor 8 is connected to one end of the chamber of the microwave system 5. A heat preservation layer 6 is arranged inside or outside the chamber of the microwave system 5. The microwave system 5 uses a gallium nitride solid-state energy source. The other end of the chamber of the microwave system 5 is connected to the discharging system 12 and one end of the separator 4. The other end of the separator 4 is connected to a liquid collection tank and the gas outlet 1 through the condenser 3. The heat preservation layer 6 or the chamber of the microwave system 5 is filled with inert gas; Representative organic solid wastes such as sludge contain endogenous mineral components such as Si, Fe, Al, etc., which can be used as microwave-absorbing substances to selectively receive the microwaves emitted by the gallium nitride solid-state microwave source, so as to realize the rapid heating of the solid waste from the inside to the outside, and further separate and process the waste liquid and waste gas, improving the separation effect, which is beneficial to environmental protection and classified recycling and re-research and utilization; The microwave source of the present invention has a high output power, low energy consumption, high processing efficiency, a simple and reliable structure, a reasonable space design, and is convenient for debugging and installation;

[0029] It further includes a stainless steel bucket 10 and a cooling water system 11. One outlet of the microwave system 5 is connected to the discharging system 12 through the cooling water system 11. A stainless steel bucket 10 for recovering pyrolysis residues is placed below the discharging system 12. The discharging system 12 is a discharging pipe and a discharging valve installed on the discharging pipe;

[0030] It further includes a temperature sensor 2. A temperature sensor 2 is arranged inside the chamber of the microwave system 5. The gallium nitride solid-state power microwave source generator implements multi-mode microwave frequency conversion heating through an accurate real-time monitoring and rapid feedback mechanism of the microwave pyrolysis temperature of organic solid waste. Based on the endogenic matrix heat absorption and mass transfer characteristics of oily sludge, a real-time switching heating mode of microwaves in different bands is established, ultimately promoting an increase in output power, an improvement in energy conversion efficiency and a significant reduction in energy consumption; At the same time, it solves the problems of poor robustness, slow response speed and excessive overshoot in the traditional microwave pyrolysis temperature control system of organic solid waste; A safety valve is installed at the gas outlet 1;

[0031] Another outlet of the microwave system 5 is connected to the inlet of the separator 4. The outlet of the separator 4 is connected to the inlet of the condenser 3 through a U-shaped upward-bending conduit to prevent backflow;

[0032] The temperature sensor 2 uses a platinum temperature sensor. The separator 4 is a cyclone dust collector. The microwave system 5 uses gallium nitride, the third-generation microwave solid-state energy source, as the solid-state power microwave source generator, which is coupled with the pyrolysis device to complete the research and development of the integrated solid-state gallium nitride microwave pyrolysis device. The pyrolysis coupling technology based on the solid-state microwave energy source has significant advantages over traditional microwave pyrolysis, such as high output power, low energy consumption, and high solid waste treatment efficiency. It provides a new type of green and energy-saving productive technology for the field of organic solid waste resource utilization. Gallium nitride is selected as the raw material, and the double heating method of the solid-state power microwave source is used to design and construct modular units to prepare a small highly integrated microwave solid-state power source device. The safety valve is a spring-loaded slightly opening safety valve;

[0033] It also includes a storage hopper 7. The input end of the screw conveyor 8 is provided with a storage hopper 7, and the electric control system 9 is used for power supply.

[0034] Specific Embodiment 2: Combining Figures 1-4 This embodiment is described. A sludge pyrolysis method based on a solid-state microwave energy source in this embodiment uses a sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source described in Specific Embodiment 1. The assembly process of the device is as follows:

[0035] a. First, install the furnace lining system into the heating section of the furnace body;

[0036] b. Weld the main frame and the auxiliary frame of the rack platform into one body, install the heating section with the installed furnace lining, and then sequentially assemble the storage hopper, screw conveyor, etc. above the heating section, and sequentially assemble the cooling section furnace body, discharge valve, etc. below the heating section;

[0037] c. Then, sequentially assemble the gallium nitride solid-state energy source and the platinum temperature sensor on the heating section. Through precise temperature extraction, efficient and energy-saving microwave heating is realized; at the same time, it overcomes the traditional temperature measurement methods mainly based on external patch infrared temperature sensors and infrared cameras, avoiding errors; then, assemble the cooling water system at the rear position under the rack;

[0038] d. Connect the cables of the gallium nitride microwave conduction system, platinum temperature sensor, screw conveyor, discharge valve, and target flow switch, and connect the PU hose to the microwave conduction system and the water-cooled section furnace body;

[0039] ② The main technical parameters of the whole machine;

[0040] a. Power supply: 380 + 10V, 50Hz, installed power: 12Kw;

[0041] b. Processed sludge: sludge or oily sludge with a water content of less than 5%;

[0042] c. Output: 10kg / h;

[0043] e. Inlet and outlet speed: frequency conversion adjustable (manual), temperature control: automatically controlled by adjusting the microwave output power;

[0044] f. Circulating cooling water system: outlet pressure ≥ 0.15 MPa, circulating cooling water flow ≥ 3 m 2 / h;

[0045] g. Total equipment weight is about 2000 kg, and the ground bearing capacity of the rack platform column foundation ≥ 10000 kg / m 2 ;

[0046] The present invention sets operating parameters such as the operating frequency and output power of the microwave source, combines the operating effect and stability evaluation, and optimizes the operating mode of the microwave source; develops a self - protection mechanism and function for the microwave source in an overloaded environment to improve the operating stability and high - power output of the equipment; couples with the pyrolysis system to complete the research and development of an integrated device;

[0047] ③ The whole machine assembly first undergoes cold commissioning, and then hot commissioning after the cold commissioning is qualified;

[0048] The method includes the following steps:

[0049] Combined with the device structure and technical operating parameters, taking oily sludge as the raw material, the operating process of the device is described in detail;

[0050] Step 1: Start the device, prepare dehydrated sludge or oily sludge with a moisture content lower than 5% as the pyrolysis raw material, and place it in the storage hopper 7;

[0051] Step 2: The pyrolysis raw material passes through the screw conveyor system 8 and enters the insulation layer 6. To ensure a strict anaerobic pyrolysis environment, the inside of the insulation layer is an inert environment of high - purity nitrogen or argon;

[0052] At this time, the microwave system 5 (gallium nitride solid-state energy source device) operates in an inside-out heating mode and is equipped with a temperature sensor 2, which can overcome the problem of large errors in the temperature measurement results caused by the traditional external patch infrared temperature sensor and the temperature measurement method mainly based on infrared cameras, and achieve accurate extraction of the temperature during the pyrolysis process; the microwave-absorbing components in the sludge or oily sludge, such as oxygen and inorganic minerals, quickly absorb microwaves, and can effectively achieve rapid frequency conversion heating of the pyrolysis raw materials compared with the traditional silicon thermocouple heating method. At the same time, overload protection and dual-mode heating are implemented, which can solve the phenomenon that the microwave generator stops working due to excessive load, and save energy and increase efficiency; a continuous and pulsed dual-mode heating method of gallium nitride solid-state power microwave source is proposed, an integrated miniaturized modular solid-state power source device is developed, a real-time feedback and adjustment mechanism for the frequency and power of the organic solid waste microwave solid-state energy source during operation is established, and a protection function for the microwave solid-state energy source in an overload environment such as over-power, over-voltage, and over-temperature is designed to realize the technology and product development of an organic solid waste microwave solid-state energy source with high output power, low energy consumption, and multiple operating modes; the solid-state power source uses semiconductor devices to ensure the long-term effective operation of the equipment, extend the service life by dozens of times, have no attenuation during long-term operation, and be durable; the solid-state power source is convenient to adopt the Internet of Things remote monitoring mode, has multiple detection functions and a perfect protection circuit, and can predict equipment failures and abnormal alarms in advance; the solid-state power source is dual-mode integrated, has two working modes of continuous wave and pulsed wave, is internally powered by low-voltage direct current, the power supply system is simple, can be started with a wide range, and can maintain stable output under the conditions of unstable AC output voltage or too low or too high input voltage, with high reliability and high stability; the microwave leakage is small and it is safe to use; gallium nitride is connected to a platinum temperature sensor, and the temperature is accurately extracted for monitoring the reliability of the bare chip; the gallium nitride microwave solid energy source can emit a frequency of 2.45 GHz; based on the real-time monitoring results of the beam emitted by gallium nitride, the radio frequency performance is evaluated, and further feedback to the system for information on whether the performance has declined, and the system can perform automatic correction; this system can avoid redundant equipment measurement links to reduce measurement and maintenance costs;

[0053] Among them, the comparison between the gallium nitride microwave solid-state energy source product and similar products is as follows:

[0054]

[0055] Step 3: The sludge or oily sludge raw materials treated by the heat preservation layer 6 generate a biochar product with porous adsorption, are cooled by the cooling water system 11, and enter the stainless steel barrel from the discharging system 12. The obtained biochar product can be used as a pollutant adsorbent, a soil remediation agent, or a garden soil fertilizer;

[0056] Step 4: The non-condensable volatile components released by the biochar during the microwave pyrolysis process contain high-value gases of C1-C4, which can be utilized as resources. In addition, gases such as H2S, HCN, and NH3 are harmful to the human body and are further removed through the separator 4 to obtain high-purity value-added gases. Finally, after passing through the condenser 3 (cooling and recovery system), they are recovered from the gas outlet 1.

[0057] It should be noted that in the above embodiments, as long as the technical solutions do not conflict, they can be arranged and combined. Those skilled in the art can exhaust all possibilities based on the mathematical knowledge of permutations and combinations. Therefore, the present invention will no longer describe the technical solutions after permutation and combination one by one, but it should be understood that the technical solutions after permutation and combination have been disclosed by the present invention.

[0058] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. For those skilled in the art, the present invention can have various modifications and changes. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source, comprising a gas outlet (1), a microwave system (5), a screw conveyor (8) and a discharging system (12), characterized in that: It also includes a separator (4), a condenser (3) and a heat insulation layer (6). The output end of the screw conveyor (8) is connected to the microwave system (5). The microwave system (5) is provided with a heat insulation layer (6). The microwave system (5) is connected to the discharging system (12) and one end of the separator (4). The other end of the separator (4) is connected to a liquid collection tank and a gas outlet (1) through the condenser (3).

2. The sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source according to claim 1, characterized in that: It also includes a stainless steel bucket (10) and a cooling water system (11). One outlet of the microwave system (5) is connected to the discharging system (12) through the cooling water system (11). The stainless steel bucket (10) is placed below the discharging system (12).

3. The sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source according to claim 1 or 2, characterized in that: It also includes a temperature sensor (2). The microwave system (5) is provided with a temperature sensor (2). A safety valve is installed at the gas outlet (1).

4. The sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source according to claim 3, characterized in that: Another outlet of the microwave system (5) is connected to the inlet of the separator (4). The outlet of the separator (4) is connected to the inlet of the condenser (3) through a U-shaped conduit.

5. The sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source according to claim 3, characterized in that: The temperature sensor (2) is a platinum temperature sensor. The separator (4) is a cyclone dust collector. The microwave system (5) is a gallium nitride microwave conduction system. The safety valve is a spring-loaded slightly-opening safety valve.

6. The sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source according to claim 1, characterized in that: It also includes a storage hopper (7). The input end of the screw conveyor (8) is provided with a storage hopper (7).

7. A sludge pyrolysis method based on a solid-state microwave energy source, characterized in that: Using the sludge pyrolysis energy-saving and consumption-reducing device based on a solid-state microwave energy source according to any one of claims 1-6, the method includes the following steps: Step 1: Start the device, prepare dehydrated sludge or oily sludge with a moisture content lower than 5% as the pyrolysis raw material, and place it in the storage hopper (7); Step 2: The pyrolysis raw material passes through the screw conveyor system (8) and enters the heat insulation layer (6); The microwave system (5) operates, and is equipped with a temperature sensor (2) to accurately extract the temperature during the pyrolysis process; Step 3: The sludge or oily sludge raw material after being treated by the heat insulation layer (6) generates a biochar product with porous adsorption, is cooled through the cooling water system (11), and enters the stainless steel bucket from the discharging system (12); Step 4: The non-condensable volatile components released by the biochar during the microwave pyrolysis process contain high-value gases of C1-C4 and can be resource-utilized; they are removed through the separator (4) to obtain high-purity value-added gases; finally, they are recovered from the gas outlet (1) through the condenser (3) (cooling recovery system).

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