Super-aeration air flotation system and implementation method thereof

Abstract

The invention discloses an ultra-aeration air flotation system and an implementation method thereof, and belongs to the technical field of wet-process phosphoric acid production, and the ultra-aeration air flotation system comprises a reaction tank, an inclined guide plate arranged on the inner wall of the reaction tank, a dish-shaped tank which is arranged at the bottom of the reaction tank and is annularly arranged around the center of the reaction tank, and a central island which is formed by protruding the inner ring part of the dish-shaped tank at the bottom of the reaction tank, the aeration mechanism is arranged on the central island and is communicated with the outside through a pipeline; the transmission mechanism is arranged above the reaction tank; the central transmission rod is connected with the output end of the transmission mechanism and is arranged along the axis of the reaction tank; the dynamic settler is arranged at the upper part in the reaction tank and is connected with the central transmission rod; and the overflow port is matched with the dynamic settler. The inclined guide plate, the dish-shaped aeration structure and the dynamic settler are integrally arranged in the reaction tank, so that the super-aeration uniformity, the foam separation capacity, the phosphoric acid purification and the liquid vortex intensity in the wet-process phosphoric acid production process are remarkably enhanced, and the reaction efficiency and the product quality are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of wet-process phosphoric acid production, and more specifically, to an ultra-aeration floating system and a method for realizing the same. Background Art

[0002] The wet-process phosphoric acid process uses sulfuric acid, hydrochloric acid, nitric acid, mainly sulfuric acid to decompose phosphate rock, causing a reaction to generate phosphoric acid and calcium sulfate. Through processes such as acidolysis, filtration, and purification, the separation of phosphoric acid from impurities is achieved. This process is mature and has a large production scale, but there are problems such as the treatment of phosphogypsum waste residue and the improvement of product purity.

[0003] During the production process of wet-process phosphoric acid, the efficiency and stability of the reaction play a crucial role in ensuring product quality and improving production efficiency. With the continuous development of the wet-process phosphoric acid industry, the requirements for output and quality are increasing day by day. Traditional production equipment and processes have gradually shown their limitations and cannot meet the needs of modern industry.

[0004] In the early production of wet-process phosphoric acid, the aeration method in the reaction tank was relatively single, usually using ordinary perforated pipe aeration or single-point aeration heads. This single aeration method caused uneven aeration distribution, seriously affecting the mixing efficiency of the reaction liquid. Since the phosphate rock and sulfuric acid could not fully contact and react, this not only reduced the reaction efficiency, prolonged the production time, but also led to unstable quality of phosphoric acid and phosphogypsum products with a high impurity content. In addition, insufficient aeration made solid particles easy to settle and accumulate in the reaction liquid, interfering with the normal reaction process and possibly causing blockage problems in pipelines and equipment, thus increasing the maintenance cost.

[0005] To solve the problem of uneven aeration, some enterprises tried to increase the aeration volume to optimize the mixing effect of the reaction liquid and adopted the ultra-aeration process. However, although ultra-aeration improved the mixing of the reaction liquid to a certain extent, it also brought new problems. The influx of a large amount of gas caused numerous foams to be generated in the reaction tank. These foams accumulated on the top of the tank, occupying valuable reaction space, thereby affecting the continuity and stability of the reaction. In addition, the presence of foams interfered with the gas-liquid separation process, making it possible for bubbles to be mixed into phosphoric acid and phosphogypsum products, which reduced the product quality.

[0006] To address the problem of foam accumulation, some traditional methods such as adding defoamers were adopted. Although this method solved the foam problem to a certain extent, it also increased the production cost and might have a negative impact on the reaction process, such as changing the chemical properties of the reaction system and affecting the product quality. In addition, the use of defoamers may bring environmental problems because some defoamers are difficult to degrade and will cause potential pollution to the environment.

[0007] In addition, the liquid flow pattern in the traditional reaction tank is relatively single, unable to effectively promote the uniform distribution of materials throughout the reaction space. The serious aggregation of materials in local parts of the reaction tank makes it difficult for the reaction to operate in the best state, thus restricting the further improvement of production efficiency and product quality.

[0008] In view of the many deficiencies in the traditional wet-process phosphoric acid production process in aspects such as aeration, foam treatment, and liquid flow, it has been difficult to meet the current requirements for high-efficiency and high-quality production of wet-process phosphoric acid. Therefore, there is an urgent need for an innovative technical solution that can comprehensively solve the above problems, optimize the wet-process phosphoric acid production process, and meet the growing demand of modern industry for phosphoric acid and phosphogypsum products. Summary of the Invention

[0009] The present invention provides a super-aeration floating system and its implementation method, aiming to solve a series of problems such as uneven aeration, foam accumulation, and unreasonable liquid flow in the traditional wet-process phosphoric acid production process. Through the innovative combination of inclined guide plates, dish-shaped aeration structures, and dynamic settlers and other innovative structures, the comprehensive optimization of the wet-process phosphoric acid production process is achieved.

[0010] To achieve the above object, the technical solution adopted by the present invention is as follows: A super-aeration floating system includes a reaction tank, inclined guide plates arranged on the inner wall of the reaction tank, a dish-shaped tank arranged at the bottom of the reaction tank and arranged in a ring shape with its center, a central island formed by the inner ring part of the dish-shaped tank protruding from the bottom of the reaction tank, an aeration mechanism arranged on the central island and connected to the outside through a pipeline, a transmission mechanism installed above the reaction tank through an external support, a central transmission rod arranged along the axis position of the reaction tank and connected to the output end of the transmission mechanism, a dynamic settler arranged at the upper part inside the reaction tank and connected to the central transmission rod, and an overflow port arranged on the side wall of the reaction tank and matching with the dynamic settler.

[0011] Specifically, the depth of the dish-shaped tank is 0.5 - 2.5 times the installation height of the aeration mechanism, preferably 2 times; the width of the mouth of the dish-shaped tank is 60% - 95% of the inner radius of the reaction tank.

[0012] Specifically, the aeration mechanism includes an aeration support installed at the bottom of the reaction tank, an aeration distribution ring installed on the aeration support and connected to the pipeline for external air supply, and a plurality of aeration nozzles evenly distributed on the aeration distribution ring, and the aeration nozzles are configured downward at the bottom of the aeration distribution ring.

[0013] The present invention forms a disc-shaped aeration structure through the cooperation of an aeration mechanism and a disc-shaped groove, which promotes the smooth circulation of the reaction liquid after aeration, thereby promoting material mixing at a deeper level and enhancing the reaction uniformity. The above aeration mechanism mainly aims at the application conditions of direct gas supply aeration in the wet-process phosphoric acid ultra-aeration floating process. According to the actual application situation of the process, there are also application conditions of pre-aeration (or ultra-aeration) and then feeding. At this time, the structure can be adapted based on the above aeration mechanism. The specific solution is as follows: retain the structures of the above aeration support and aeration distribution ring, connect the pipeline connected to the aeration distribution ring to the external gas-containing material that has been pre-aerated / ultra-aerated, and replace the original aeration nozzle with a more direct aeration outlet structure. The aeration outlet structure is also arranged downward at the bottom of the aeration distribution ring, so as to ensure that the gas-containing material input by this disc-shaped aeration structure can form a smooth circulation flow.

[0014] Specifically, the inclined deflector includes a plurality of downward-turning deflectors arranged in a spiral shape at a position above the inner wall of the reaction tank and a plurality of upward-pressing deflectors arranged in a spiral shape at a position below the inner wall of the reaction tank. The spiral arrangement directions of the downward-turning deflectors and the upward-pressing deflectors are opposite; the downward-turning deflectors and the upward-pressing deflectors are intermittently and pointwise connected to the inner wall of the reaction tank through a plurality of connecting members, so that there is a gap between the inner edge of the deflector and the inner wall of the reaction tank.

[0015] Specifically, the slope inclination angle between the head and tail ends of the downward-turning deflector and the upward-pressing deflector is 15 degrees to 60 degrees, preferably 45 degrees; the downward-turning deflector is inclined 0 degrees to 30 degrees, preferably 15 degrees, relative to the vertical direction of the inner wall towards the stirring direction, and the upward-pressing deflector is inclined 0 degrees to 30 degrees, preferably 15 degrees, relative to the vertical direction of the inner wall towards the stirring direction.

[0016] Specifically, a plurality of deflector through-holes are uniformly formed on the downward-turning deflector and the upward-pressing deflector, and the hole opening rate is 10% to 40%, preferably 35%.

[0017] Through the specific layout design of this inclined deflector, the present invention can effectively guide the reaction liquid to form a three-dimensional circulation path. The downward-turning deflector promotes the downward turning of the upper-layer liquid, while the upward-pressing deflector makes the lower-layer liquid press upward. The two meet, promoting the full mixing of the materials, avoiding local accumulation phenomena, and thus improving the reaction efficiency and product quality.

[0018] Specifically, the dynamic settler includes a first settling mechanism and a second settling mechanism arranged side by side up and down and connected to the central drive rod, and a plurality of positioning connecting members arranged between the first settling mechanism and the second settling mechanism.

[0019] Specifically, the first sedimentation mechanism includes an upper clamping plate and a lower clamping plate arranged in parallel, a plurality of folded connectors densely arranged between the upper clamping plate and the lower clamping plate, a foam sedimentation channel formed between adjacent folded connectors, and sedimentation holes opened on the upper clamping plate and the lower clamping plate and communicating with the foam sedimentation channel; the structure of the second sedimentation mechanism is the same as that of the first sedimentation mechanism, but the opening ratio of the sedimentation holes of the second sedimentation mechanism is smaller than that of the sedimentation holes of the first sedimentation mechanism.

[0020] Specifically, a rotating foam collector corresponding to the overflow port in position and located above the second sedimentation mechanism is provided on the central drive rod. The rotating foam collector includes a plurality of rotating arms circumferentially and evenly distributed around the central drive rod, and scraping heads arranged at the ends of the rotating arms, wherein the length of the rotating arms matches the inner radius of the reaction tank.

[0021] In the present invention, a dynamic sedimenter driven by a transmission mechanism is arranged at the upper part inside the reaction tank to sediment and separate the foam generated by the reaction, effectively solving the problem of foam accumulation at the upper part inside the reaction tank and ensuring sufficient reaction space and stable progress of the reaction.

[0022] Based on the structure of the above ultra-aeration floating system, the present invention also provides an implementation method of the ultra-aeration floating system, including the following steps: S10. Preparation: Ensure that all components of the ultra-aeration floating system are in good condition, the connections are stable, the raw materials are ready and the feeding equipment is normal, the external gas supply system is stable and the pipelines are airtight; S20. Feeding and initial aeration: The material enters the reaction tank through the feeding pipe, and at the same time, the central island aeration mechanism supplies gas, and the dish-shaped tank guides the circulation of the aerated liquid to start the reaction; S30. Mixing and strengthening: The inclined deflector guides the reaction liquid to form a three-dimensional circulation, and with continuous aeration, it promotes the uniform mixing and reaction of the materials; S40. Ultra-aeration and primary foam treatment: Increase the aeration volume to enter ultra-aeration, and the generated foam is initially separated from gas and liquid by the first sedimentation mechanism of the dynamic sedimenter; S50. Secondary foam treatment and discharge: The preliminarily treated foam enters the second sedimentation mechanism for further separation and sedimentation, and then is scraped by the rotating foam collector and discharged through the overflow port; S60. Discharging: After monitoring and judging that the reaction is completed, the product is discharged through the discharging pipe, and the discharging parameters are controlled.

[0023] Compared with the prior art, the present invention has the following beneficial effects: (1)The present invention significantly optimizes the uniformity of aeration distribution through the synergistic effect of integrating a reaction tank, an inclined deflector, a dish-shaped tank, an aeration mechanism and a dynamic settler, promotes the full contact between phosphate rock and sulfuric acid, and thus significantly improves the reaction efficiency and product quality. This comprehensive design not only improves the efficiency of chemical reactions, but also ensures a significant improvement in the quality of the final product by optimizing the reaction conditions.

[0024] (2)In the present invention, the annular layout of the dish-shaped tank in combination with the design of the corresponding depth and width, together with the spiral reverse arrangement and through-hole structure of the inclined deflector, jointly form a three-dimensional circulating flow path. Such a design effectively avoids the phenomenon of local accumulation of materials in the reactor and realizes the dynamic mixing enhancement of the reaction liquid. This not only improves the uniformity of the reaction, but also ensures the full contact between the reactants through continuous flow and mixing, thereby further increasing the reaction rate.

[0025] (3)The aeration mechanism in the present invention is arranged based on the position of the central island, and through the cooperation of an aeration distribution ring and an aeration nozzle / aeration outlet facing downward, it ensures that the gas / gas-containing material can be evenly ejected and form a diffused bubble flow. Combined with the configuration of the dish-shaped tank, it enhances the agitation and circulation power of the liquid, thereby improving the aeration efficiency. In this way, the contact area between the gas and the liquid in the stirring and mixing is maximized, making the oxygen transfer efficiency higher, and thus accelerating the process of chemical reactions.

[0026] (4)The dynamic settler in the present invention adopts the cooperation of a two-stage settling mechanism with a decreasing hole opening rate and a rotary foam collector to gradually settle and separate the gas-liquid components in the foam, and discharges them in a timely manner through an overflow port, effectively solving the problem of foam accumulation, ensuring sufficient reaction space, and thus ensuring the smooth progress of the reaction process. Through this efficient foam treatment mechanism, the internal environment of the reaction tank is effectively controlled, providing a guarantee for the smooth progress of chemical reactions.

[0027] (5)The present invention conducts a full-process design for feeding, aeration, mixing enhancement, foam treatment, and discharging, enabling the close connection of each stage of the wet-process phosphoric acid process, optimizing the coherence of system operation, and thus improving the overall production efficiency. Through this comprehensive process control, every link in the production process is optimized, ensuring that every step from raw material input to final product output is efficient and smooth.

[0028] (6)The present invention effectively reduces the risks of equipment wear and scaling through the combined design of structures such as uniform aeration, optimized flow by deflector, and reduction of foam impact by dynamic settler, enhances equipment stability, extends the maintenance cycle and service life, reduces long-term operation costs, and provides higher economic benefits for industrial production. Description of the Drawings

[0029] Figure 1 Schematic diagram of the overall structure of an embodiment of the present invention.

[0030] Figure 2 Schematic diagram of a structure of the inner wall of the reaction tank equipped with an inclined deflector in an embodiment of the present invention.

[0031] Figure 3 Schematic diagram of another structure of the inner wall of the reaction tank equipped with an inclined deflector in an embodiment of the present invention.

[0032] Figure 4 Schematic diagram of yet another structure of the inner wall of the reaction tank equipped with an inclined deflector in an embodiment of the present invention.

[0033] Figure 5 Schematic diagram of the inclined layout structure of the inclined deflector in an embodiment of the present invention, corresponding to Figure 2 the B-B cross-section of area A in

[0034] Figure 6 Schematic diagram of the partial connection structure of a downward-turned deflector in an embodiment of the present invention.

[0035] Figure 7 Schematic diagram of the partial structure of the aeration mechanism (direct supply) in an embodiment of the present invention.

[0036] Figure 8 Schematic diagram of the partial structure of the aeration mechanism (pre-aeration) in an embodiment of the present invention.

[0037] Figure 9 Schematic diagram of the structure of the dynamic settler part in an embodiment of the present invention.

[0038] Figure 10 Top view schematic diagram of the dynamic settler part in an embodiment of the present invention.

[0039] Figure 11 Schematic diagram of the structure where two settling mechanisms are arranged in an embodiment of the present invention.

[0040] Figure 12 Schematic diagram of the structure of the first settling mechanism in an embodiment of the present invention.

[0041] Among them, the components corresponding to the reference numerals are as follows: 1 - Reaction tank, 2 - Inclined deflector, 3 - Dish-shaped tank, 4 - Central island, 5 - Aeration mechanism, 6 - Transmission mechanism, 7 - Central drive rod, 8 - Stirring paddle, 9 - Overflow port, 10 - Dynamic settler, 11 - First sedimentation mechanism, 12 - Second sedimentation mechanism, 13 - Positioning connector, 14 - Upper splint, 15 - Lower splint, 16 - Folded connector, 17 - Foam sedimentation channel, 18 - Rotary foam collector, 21 - Downward-turning deflector, 22 - Upward-pressing deflector, 23 - Deflector through-hole, 24 - Connecting rod member, 25 - Pipeline, 26 - Aeration bracket, 27 - Aeration distribution ring, 28 - Aeration nozzle, 29 - Aeration outlet structure, 31 - Spinning arm, 32 - Foam scraping head. Detailed implementation manners

[0042] The present invention will be further described below in conjunction with the accompanying drawings and embodiments. The implementation manners of the present invention include but are not limited to the following embodiments.

[0043] Embodiment As Figures 1 to 12 shown, the super-aeration floating system includes a reaction tank 1, an inclined deflector 2 arranged on the inner wall of the reaction tank, a dish-shaped tank 3 arranged at the bottom of the reaction tank and arranged in a ring shape centered on its center, a central island 4 formed by the inner ring part of the dish-shaped tank protruding at the bottom of the reaction tank, an aeration mechanism 5 arranged on the central island and communicated with the outside through a pipeline 25, a transmission mechanism 6 installed above the reaction tank through an external bracket, a central drive rod 7 connected to the output end of the transmission mechanism and arranged along the axis position of the reaction tank, a stirring paddle 8 arranged on the central drive rod and located in the reaction tank, a dynamic settler 10 arranged at the upper position in the reaction tank and connected to the central drive rod, and an overflow port 9 arranged on the side wall of the reaction tank and matching the dynamic settler.

[0044] Specifically, the reaction tank serves as the basic carrier of the entire system and is usually designed as a cylindrical structure to ensure that the materials flow and react evenly in the tank. Its material is selected as a material with good corrosion resistance, such as rubber-lined carbon steel or fiberglass. For large-scale wet-process phosphoric acid production plants, considering the comprehensive requirements of strength and corrosion resistance, rubber-lined carbon steel is a more suitable choice; for some small-scale application scenarios or occasions with requirements for weight, fiberglass material can also be selected. The size of the reaction tank depends on the actual production scale. For example, in large-scale production, the diameter range is usually 5 to 10 meters, and the height is between 6 and 10 meters.

[0045] The inclined baffle plates include two types: the downward - turned baffle plate 21 and the upward - pressed baffle plate 22. The main differences between them lie in the installation positions and forms, while their materials and basic structures can be the same. For example, the material can be selected as corrosion - resistant 316L stainless steel to ensure long - term stable operation in strongly corrosive reaction liquids. The downward - turned baffle plate 21 and the upward - pressed baffle plate 22 are arranged in a reverse spiral form at the upper and lower positions on the inner wall of the reaction tank respectively. Each baffle plate forms a multi - directional inclination. For example, the slope inclination angle (equivalent to the helix angle) between the head and tail ends of the downward - turned baffle plate 21 and the upward - pressed baffle plate 22 is 15° - 60°, preferably 45°, denoted as a in the figure; the inclination angle of the downward - turned baffle plate relative to the vertical direction of the inner wall towards the stirring direction is 0 - 30°, preferably 15°, denoted as b in the figure; the inclination angle of the upward - pressed baffle plate relative to the vertical direction of the inner wall towards the stirring direction is 0 - 30°, preferably 15°. The specific inclination angles of the two can be adjusted according to the actual production process, and they can be the same or different.

[0046] Both the downward - turned baffle plate and the upward - pressed baffle plate are intermittently and point - wise connected to the inner wall of the reaction tank through multiple connecting rods 24, so that there is a gap between the inner edge of the baffle plate and the inner wall of the reaction tank. This gap can be flexibly adjusted according to factors such as actual production requirements and liquid flow rate, and usually remains in the range of 1 to 15 cm. In this embodiment, both the downward - turned baffle plate and the upward - pressed baffle plate are configured as 4. At the same time, there should be an appropriate small gap between the ends of adjacent baffle plates. Therefore, the projected length of each baffle plate in the axial direction of the reaction tank is approximately 1 / 4 of the circumference of the reaction tank. Moreover, a plurality of baffle plate through - holes 23 are evenly opened on the downward - turned baffle plate and the upward - pressed baffle plate, and the opening ratio is 10% - 40%, preferably 35%, to enhance the turbulence when gas - liquid passes through, thereby improving the mixing effect of the reaction system.

[0047] In the dish-shaped aeration structure, the dish-shaped groove is formed by specially processing the bottom of the reaction tank, and a corrosion-resistant material identical or matching to that of the reaction tank is used. During the processing, according to the pre-designed dimensions, a machining pre-forming method or a stacking and filling treatment method is adopted to form a dish-shaped structure arranged in a ring shape centered on the center in the bottom of the reaction tank. The depth of the dish-shaped groove is set according to the installation height of the aeration mechanism, and the installation height of the aeration mechanism also needs to fully consider the overall spatial layout in the reaction tank. Assuming the installation height of the aeration mechanism is 0.5 meters, the depth of the dish-shaped groove is configured to be 1 meter. The width of the groove opening is processed according to 60% - 95% of the inner radius of the reaction tank. If the inner radius of the reaction tank is 3 meters, the width range of the dish-shaped groove is defined between 1.8 and 2.85 meters, and its specific dimensions are determined by calculating the momentum of the materials in the groove during design. After processing, the surface of the dish-shaped groove is polished and anti-corrosion treated to ensure its surface is smooth and has excellent corrosion resistance, thereby reducing the flow resistance of the reaction liquid and effectively avoiding the occurrence of corrosion. The central island is formed by the inner ring part of the dish-shaped groove protruding on the bottom of the reaction tank, and its height and diameter are designed according to the size and stability requirements of the aeration mechanism. Its height is usually slightly higher than that of the aeration mechanism, and the diameter is slightly larger than that of the aeration distribution ring.

[0048] The aeration support 26 is made of 316L stainless steel and is firmly fixed on the central island by welding or bolt connection according to the shape and size of the central island. The aeration distribution ring 27 is also made of 316L stainless steel and is stably installed on the aeration support through welding or auxiliary fixing parts. The configured inlet is connected to the pipeline by welding or flange connection to facilitate the access of external gas supply or gas-containing materials subjected to pre-aeration / super-aeration treatment. For the possible direct gas supply aeration working condition and pre-aeration / super-aeration and then feeding working condition in the wet-process phosphoric acid super-aeration floating process, two corresponding outlet structures are designed on the aeration distribution ring. For the direct gas supply aeration working condition, a plurality of holes are evenly opened at the designed positions on the aeration distribution ring, and the aeration nozzles 28 are installed. In order to make the gas be more evenly distributed, a flow guiding structure or a flow equalizing structure can be added inside the aeration distribution ring; the aeration nozzles 28 are evenly distributed at the bottom of the aeration distribution ring at the designed hole positions and are configured downward, and the number is determined according to the size of the reaction tank and the aeration demand, generally between 10 and 30. Each gas outlet of the aeration nozzle can be in a specific conical shape and size. After the gas is ejected, a uniformly diffused bubble flow can be formed, thereby enhancing the stirring effect and circulation efficiency of the liquid. For the pre-aeration / super-aeration and then feeding working condition, a plurality of holes are also evenly opened at the designed positions on the aeration distribution ring first, and a tubular aeration outlet structure 29 is installed. The size of the holes opened here is usually larger than that of the holes opened in the previous working condition structure, and the inner diameter of the aeration distribution ring and the inner diameter of the corresponding pipeline can be larger, so as to more smoothly access the gas-containing materials that have been pre-aerated / super-aerated in the previous stage.

[0049] Regarding the dynamic settler, the dynamic settler includes a first settling mechanism 11 and a second settling mechanism 12 arranged side by side vertically and connected to a central drive rod, and a plurality of positioning connectors 13 provided between the first settling mechanism and the second settling mechanism. Specifically, the first settling mechanism 11 includes an upper clamping plate 14 and a lower clamping plate 15 arranged in parallel, a plurality of folded connectors 16 densely arranged between the upper clamping plate and the lower clamping plate, a foam settling channel 17 formed between adjacent folded connectors, and settling holes opened on the upper clamping plate and the lower clamping plate and communicating with the foam settling channel. Among them, the upper clamping plate 14 and the lower clamping plate 15 can be made of 316L stainless steel plates with a thickness of 3 to 5 mm, and are cut into a shape matching the inside of the reaction tank by laser cutting technology. The folded connectors 16 are made of 316L stainless steel and are formed into a specific folded line shape by die stamping. The length and angle are designed to match according to the distance between the upper clamping plate and the lower clamping plate and the expected shape of the foam settling channel. For example, the length is between 5 and 10 cm, and the folded line angle is in the range of 120° to 150°. Using the welding process, the folded connectors are tightly fixed between the upper clamping plate and the lower clamping plate, and the distance between adjacent folded connectors is ensured to be maintained at 2 to 5 cm, thereby constructing the foam settling channel 17. According to the designed foam settling channel, settling holes are pre-opened on the upper clamping plate and the lower clamping plate to ensure that the positions of the settling holes match the foam settling channel formed by the folded connectors. Laser drilling technology can be used to ensure that the accuracy and opening rate of the holes are consistent. The opening rate of the settling holes is controlled between 30% and 40%, preferably 36%. The hole diameter is determined according to the actual situation, generally between 5 and 30 mm. The settling holes are regularly arranged along the position of the foam settling channel to ensure a stable treatment effect on the foam.

[0050] The structure of the second settling mechanism 12 is the same as that of the first settling mechanism, but the opening rate of the settling holes on the second settling mechanism is smaller than that of the settling holes on the first settling mechanism, usually between 25% and 35%, preferably 28%. According to the actual application situation, the aperture of the settling holes on the second settling mechanism can also be appropriately smaller than that of the settling holes on the first settling mechanism. Then, using the positioning connectors 13, such as high-strength bolts, the second settling mechanism is installed side by side above the first settling mechanism, and at the same time, it is ensured that the distance between the two is not less than their respective thicknesses. For example, when the total thickness is 8 to 10 cm, the distance should be set to 10 to 12 cm. During the installation process, ensure that the two settling mechanisms are concentric and the central reference is horizontal.

[0051] The central drive rod 7 can be made of a corrosion-resistant high-strength alloy material, and its diameter is designed according to the size of the reaction tank, the weight of the stirring paddle and related structures such as the dynamic settler, generally between 5 and 20 cm. To further facilitate the collection of foam, a rotating foam collector 18 is also provided on the central drive rod above the second sedimentation mechanism and corresponding to the position of the overflow port. The rotating foam collector includes a plurality of rotating arms 31 evenly distributed in a circle around the central drive rod, and scraping heads 32 arranged at the ends of the rotating arms. The length of the rotating arm matches the inner radius of the reaction tank. The arc-shaped rotating arms 31 of the rotating foam collector 18 can be made of the same material as the central drive rod and formed into an arc by forging. Along the rotation direction on the outer arc side, the chord length of the arc-shaped rotating arm matches the inner radius of the reaction tank, and at the same time, the end should keep a small gap from the inner wall of the reaction tank to avoid direct contact with the tank inner wall. The length of the rotating arm itself can be longer based on the curvature of the arc, ensuring overall full coverage of the area inside the tank during rotation. The rotating arms are evenly distributed in a circle with the central drive rod as the center, and the number is generally 4 to 6. The scraping head 32 is composed of a scraping back plate made of stainless steel, a scraping bottom plate and a scraping baffle made of polytetrafluoroethylene soft board. The scraping back plate can be a plate with a thickness of 5 to 8 mm and is fixedly connected to the end of the rotating arm by welding or bolts to provide sufficient strength support. The scraping bottom plate and the scraping baffle are configured with corresponding thicknesses and are connected to the scraping back plate by bonding or bolts to form a stable L-shaped structure. When the scraping head is installed, it should keep an appropriate distance from the inner wall of the reaction tank, generally 2 to 5 mm, which can effectively scrape the foam without excessive friction damage.

[0052] The drive mechanism 6 can follow the traditional drive structure for stirring the reaction tank, usually in the form of a combination of a motor and a reducer. In the present invention, the drive can be adapted according to the added dynamic settler in the design, improving the efficient collection and treatment of foam on the basis of ensuring the reaction efficiency during stirring.

[0053] The overflow port 9 is arranged on the side wall of the reaction tank and corresponds to the position of the rotating foam collector of the dynamic settler. The size of the overflow port is designed according to the flow rate of the foam scraped by the dynamic settler to ensure that the foam can be discharged in a timely and smooth manner. A baffle to prevent foam overflow can be installed at the edge of the overflow port, and valves and other components can also be equipped to control the foam discharge according to the actual production situation.

[0054] In the present invention, the inclined deflector is arranged in a spiral shape, which, in combination with a specific inclination angle, through-hole design, and connection method with a spacing from the inner wall, jointly constitutes the key factors for optimizing liquid flow and material mixing; the dish-shaped aeration structure formed by the aeration mechanism and the dish-shaped groove, through the design and matching of the depth and width of the dish-shaped groove, in cooperation with the layout design of the aeration mechanism, aeration distribution ring, and aeration nozzle / aeration outlet structure, jointly ensures the uniformity and efficiency of aeration; the design of the folding connectors of the first and second sedimentation mechanisms, the foam sedimentation channel, and the sedimentation hole opening ratio in the dynamic settler, combined with the design of the rotating arms and foam scraping heads of the rotating foam collector, effectively solves the problem of foam accumulation. Through the mutual cooperation of the above-mentioned various structures, an organic whole is formed, comprehensively realizing the optimization of the wet-process phosphoric acid production process.

[0055] Based on the structure of the aforementioned ultra-aeration floating system, the present invention also provides a method for implementing the ultra-aeration floating system, which specifically includes the following processes: 1. Preparation before system startup The equipment inspection link needs to be comprehensive and meticulous, covering all key components such as the reaction tank, inclined deflector, dish-shaped aeration structure, dynamic settler, and overflow port, ensuring that each component is undamaged and firmly connected. In particular, check whether the pipeline connection of the aeration mechanism is sealed and whether the transmission components of the dynamic settler are flexible.

[0056] Material preparation: Prepare raw materials such as phosphate ore pulp and sulfuric acid required for wet-process phosphoric acid production, and ensure that the quality and purity of the raw materials meet the production requirements. At the same time, it is necessary to verify the operating status of the feeding equipment to ensure that it can accurately transport the raw materials to the reaction tank.

[0057] Gas supply preparation: Check the external gas supply system to ensure that it can stably provide gas with the required pressure and flow rate to meet the aeration requirements of the aeration mechanism. To ensure the safety of the gas supply pipeline, strict airtightness tests must be carried out to avoid the risk of gas leakage. When the aeration mechanism corresponds to the application condition of pre-aeration (or ultra-aeration) before feeding, the external gas supply system is connected to the pre-aeration / ultra-aeration equipment in the previous process of the process, and then the pre-treated gas-containing material is input into the corresponding aeration mechanism by the pre-aeration / ultra-aeration equipment in the previous process.

[0058] 2. Feeding of the reaction liquid and initial aeration During feeding under the condition of direct gas supply aeration, the pre-treated reaction materials such as phosphate ore pulp and sulfuric acid are transported into the reaction tank through the feed pipe in a certain proportion. After the materials enter the reaction tank, the drive mechanism drives the stirring blades to stir and mix the materials in the reaction tank. At this time, the inclined deflector arranged on the inner wall of the reaction tank cooperates with the stirring process to enhance the mixing effect.

[0059] At the same time, the aeration mechanism installed on the central island starts to work. The external air supply is smoothly connected to the aeration distribution ring through the pipeline, and then finely sprayed out by the aeration nozzles evenly distributed at the bottom of the distribution ring and facing downward. As the bubbles slowly rise, they effectively disturb the reaction liquid, allowing the reaction liquid to be initially and evenly mixed, thereby smoothly starting the reaction process of phosphate rock and sulfuric acid. The special design of the disc-shaped tank guides the aerated liquid to form a circulating flow pattern, further optimizing the mixing effect of the reaction liquid in the reaction tank.

[0060] On the other hand, when feeding in the pre-aeration / superaeration and re-feeding condition, since the reaction materials such as phosphate ore slurry and sulfuric acid have been processed into gas-containing materials in the previous aeration / superaeration equipment, the gas-containing materials are directly transported by the pipeline connected to the aeration mechanism, enter the reaction tank through the aeration distribution ring and the aeration outlet structure, and guide the liquid to form a circular flow pattern from the disc-shaped groove at the bottom of the reaction tank. When the gas-containing material in the reaction tank reaches a certain level, the transmission mechanism drives the stirring blades to stir and mix the gas-containing material in the reaction tank, thereby comprehensively enhancing the stirring and mixing effect of the materials in the reaction tank.

[0061] 3. Reaction solution circulation and mixing enhancement Guide plate guides circulation: The flow field formed by the stirring of the liquid in the reaction tank forms multiple eddies and turbulences when it contacts the inclined guide plate, constantly changing the flow pattern to promote material mixing and reaction. The downward-turning guide plate turns the upper layer of the reaction liquid down along a spiral trajectory, and the upward-pressing guide plate presses the lower layer of the reaction liquid upward along the opposite spiral trajectory. The intersection of the two forms a three-dimensional circulation path for the reaction liquid in the tank, and the materials are further mixed evenly during the circulation process, avoiding local concentration differences and effectively increasing the reaction rate.

[0062] Continuous aeration and mixing: In the direct air supply aeration condition, the aeration mechanism works continuously. As the reaction liquid circulates, the bubbles are more evenly distributed in the entire reaction tank, continuously providing the required oxygen for the reaction, and promoting more complete contact and reaction between the phosphate ore slurry and sulfuric acid. In the pre-aeration / superaeration and re-feeding condition, the aeration mechanism continuously inputs gas-containing materials. Under the action of the circulating flow of the reaction liquid, the gas in the gas-containing materials can also be mixed and distributed more evenly. Combined with the ingenious cooperation between the disc tank and the aeration mechanism, the circulation power of the reaction liquid is significantly improved, ensuring the uniform distribution of the reaction process in the reaction tank.

[0063] 4. Dealing with over-aeration and foam generation In the direct gas supply aeration mode, according to the production process requirements, the aeration volume is appropriately increased to enter the ultra-aeration stage. At this time, a large amount of gas rapidly surges into the reaction tank, further strengthening the mixing effect of the reaction liquid, but also causing a large amount of foam to be generated in the reaction tank in a short time. In the pre-aeration / ultra-aeration then feeding mode, the processes of aeration and ultra-aeration are carried out by the previous aeration / ultra-aeration equipment, but the processes and the process states formed after the gas-containing materials are input into the reaction tank are similar to those in the direct gas supply aeration mode.

[0064] During the process of foam treatment, as the foam in the reaction tank is generated and increases, the role of the dynamic settler gradually becomes prominent, and a large amount of foam gradually rises to the top of the reaction tank. The foam first surges into the first settling mechanism. This mechanism relies on the parallel upper clamping plate and lower clamping plate, as well as the settling holes on it and the foam settling channels constructed by the folded connectors between them to initially break and settle the foam, thus realizing the initial separation of gas and liquid.

[0065] 5. Further treatment and discharge of foam Secondary settling stage: The foam that has been initially treated by the first settling mechanism continues to rise and enters the second settling mechanism for treatment. The opening rate of the settling holes of the second settling mechanism is smaller than that of the first settling mechanism, further separating and settling the foam to improve the gas-liquid separation effect.

[0066] Foam collection and discharge: The remaining foam after two-stage settling is collected by the rotating foam collector located at the upper part of the second settling mechanism. The rotating foam collector is driven by the central drive rod, and its circumferentially distributed arc-shaped rotating arms and the scraping foam heads at their ends in an L shape rotate synchronously, effectively scraping the remaining foam and discharging it out of the reaction tank through the overflow port matching the dynamic settler, ensuring that the foam in the reaction tank is effectively controlled and maintaining the sufficiency of the reaction space and the stable progress of the reaction.

[0067] 6. Discharge of reaction products Judgment of reaction completion: Continuously monitor the reaction process in the reaction tank, and judge whether the reaction is completed by detecting parameters such as the composition, temperature, and pressure of the reaction liquid. When all parameters meet the preset reaction termination conditions, it indicates that the production reaction of wet-process phosphoric acid has been completed.

[0068] Discharge: After the reaction is completed, the generated phosphoric acid, phosphogypsum, and the remaining reaction liquid are discharged from the reaction tank through the discharge pipe and then enter a series of subsequent treatment processes such as separation and purification.

[0069] 7. System maintenance and cleaning Regular inspection: During the operation of the system, it is necessary to regularly check the states of various components, including but not limited to the connection firmness of the inclined deflector, the efficiency of the dish-shaped aeration structure, and the smooth operation condition of the dynamic settler. At the same time, check whether the overflow port is unobstructed to prevent blockage.

[0070] Cleaning and maintenance: According to the production situation and the operating condition of the equipment, regularly clean the reaction tank, remove impurities and scale adhering to components such as the tank wall, baffle plate, and aeration mechanism, and ensure the performance of each component and the operating efficiency of the system. Replace worn or damaged components in a timely manner to ensure the long-term stable operation of the system.

[0071] Through the above structural design in cooperation with the wet-process phosphoric acid process, the present invention presents the following technical advantages in multiple aspects: I. Optimize aeration and mixing effects: The design of the dish-shaped aeration structure makes aeration more uniform and efficient. The aeration mechanism is located on the central island and aerates downward through aeration nozzles. Combining with the shape of the dish-shaped tank, it guides the reacted liquid after aeration to form a good circulating flow. This circulation mode makes the oxygen distribution in the reacted liquid more uniform, promotes the full contact between phosphate rock and sulfuric acid, and greatly improves the reaction efficiency. At the same time, the inclined baffle plate further strengthens the mixing of the liquid. The downward-turning and upward-pressing baffle plates work together to form a three-dimensional circulation path, ensuring the comprehensive mixing of materials in the reaction tank, thereby eliminating local concentration unevenness and further enhancing the uniformity of the reaction. Through actual tests, compared with the traditional reaction system, the reaction efficiency of this system is increased by 20% - 40%, and the uniformity of the reaction system is increased by 25% - 35%.

[0072] II. Effectively separate the foam problem: The setting of the dynamic settler effectively solves the problem of foam accumulation in the upper part of the reaction tank during the over-aeration process. The first settling mechanism and the second settling mechanism form a foam settling channel through settling holes with different opening ratios and folded connectors, gradually separating and settling the foam, and fully separating the gas and liquid in the foam. The rotating foam collector further scrapes off the residual foam and discharges it through the overflow port, ensuring that there is enough effective space in the reaction tank for the reaction. Practical applications have proved that after the introduction of this system, the problem of foam accumulation has been significantly curbed, and the effective utilization rate of the reaction space can be increased to between 20% - 30%, thereby ensuring the efficiency and stability of the reaction process.

[0073] III. Improve product quality and output: Due to the uniform aeration, sufficient mixing, and effective solution of the foam problem, the production quality and output of phosphoric acid and phosphogypsum are significantly improved. The reaction is more sufficient, which significantly reduces the impurities in phosphoric acid and phosphogypsum products and makes the composition tend to be stable, and thus the application performance in multiple fields such as construction and chemical industry is improved. At the same time, the increase in reaction efficiency directly leads to an increase in output. Within the same production time, the output of phosphoric acid and phosphogypsum can be increased by 25% - 35%, bringing higher economic benefits to the enterprise.

[0074] IV. Enhancing equipment stability and lifespan: The reasonable design and collaborative operation of the inclined deflector, dish-shaped aeration structure, and dynamic settler reduce the impact and wear on the equipment during the reaction process. For example, uniform aeration and liquid flow reduce the erosion of the reaction liquid on the inner wall of the reaction tank, and the dynamic settler effectively prevents damage to the equipment caused by foam. This enhances the stability of the equipment and extends its service life.

[0075] V. Environmental protection and sustainability: This system avoids the use of traditional antifoaming agents, reduces potential environmental pollution, and meets environmental protection requirements. At the same time, by improving production efficiency and product quality, it realizes more efficient utilization of resources and has good sustainability.

[0076] In summary, the present invention demonstrates significant advantages in the production of phosphogypsum, can comprehensively improve production efficiency, product quality, equipment stability, and environmental protection performance, and provides an innovative solution for the wet-process phosphoric acid production industry.

[0077] The above embodiments are only the preferred embodiments of the present invention and do not limit the protection scope of the present invention. Any changes made by adopting the design principle of the present invention and non-creative labor on this basis shall fall within the protection scope of the present invention.

Claims

1. A super-aeration floating system, characterized in that It includes a reaction tank (1), an inclined deflector (2) arranged on the inner wall of the reaction tank (1), a dish-shaped tank (3) arranged at the bottom of the reaction tank (1) and arranged in a ring shape with its center, a central island (4) formed by the inner ring part of the dish-shaped tank (3) protruding from the bottom of the reaction tank (1), an aeration mechanism (5) arranged on the central island (4) and connected to the outside through a pipeline, a transmission mechanism (6) installed above the reaction tank (1) through an external support, a central transmission rod (7) connected to the output end of the transmission mechanism (6) and arranged along the axis position of the reaction tank (1), a dynamic settler (10) arranged at the upper part inside the reaction tank (1) and connected to the central transmission rod (7), and an overflow port (9) arranged on the side wall of the reaction tank (1) and matching the dynamic settler (10).

2. The super-aeration floating system according to claim 1, wherein The depth of the dish-shaped tank (3) is 0.5 - 2.5 times the installation height of the aeration mechanism (5); the width of the notch of the dish-shaped tank (3) is 60% - 95% of the inner radius of the reaction tank (1).

3. The super-aeration floating system according to claim 1, wherein The aeration mechanism (5) includes an aeration support (26) installed at the bottom of the reaction tank (1), an aeration distribution ring (27) installed on the aeration support (26) and connected to the pipeline for external air supply, and a plurality of aeration nozzles (28) evenly distributed on the aeration distribution ring (27), and the aeration nozzles (28) are configured downward at the bottom of the aeration distribution ring (27).

4. The super-aeration floating system according to claim 1, characterized in that The inclined deflector (2) includes a plurality of downward-turning deflectors (21) arranged in a spiral shape at the upper position along the inner wall of the reaction tank (1) and a plurality of upward-pressing deflectors (22) arranged in a spiral shape at the lower position along the inner wall of the reaction tank (1), and the spiral arrangement directions of the downward-turning deflectors (21) and the upward-pressing deflectors (22) are opposite; the downward-turning deflectors (21) and the upward-pressing deflectors (22) are intermittently connected to the inner wall of the reaction tank (1) at multiple points through a plurality of connecting members, so that there is a gap between the inner edge of the deflector and the inner wall of the reaction tank (1).

5. The super-aeration floating system according to claim 4, wherein The slope inclination angle between the head and tail ends of the downward-turning deflectors (21) and the upward-pressing deflectors (22) is 15 degrees - 60 degrees; the downward-turning deflectors (21) are inclined 0 degrees - 30 degrees in the stirring direction relative to the vertical direction of the inner wall, and the upward-pressing deflectors (22) are inclined 0 degrees - 30 degrees in the stirring direction relative to the vertical direction of the inner wall.

6. The super-aeration floating system according to claim 4, wherein A plurality of deflector through holes (23) are evenly formed on the downward-turning deflectors (21) and the upward-pressing deflectors (22), and the opening ratio is 10% - 40%.

7. The super-aeration floating system according to any one of claims 1 to 6, characterized in that, The dynamic settler (10) includes a first settling mechanism (11) and a second settling mechanism (12) arranged side by side up and down and connected to the central transmission rod (7), and a plurality of positioning connectors (13) arranged between the first settling mechanism (11) and the second settling mechanism (12).

8. The super-aeration floating system according to claim 7, characterized in that, The first sedimentation mechanism (11) includes an upper clamping plate (14) and a lower clamping plate (15) arranged in parallel, a plurality of folded connectors (16) densely arranged between the upper clamping plate (14) and the lower clamping plate (15), a foam sedimentation channel (17) formed between adjacent folded connectors (16), and sedimentation holes opened on the upper clamping plate (14) and the lower clamping plate (15) and communicating with the foam sedimentation channel (17); the structure of the second sedimentation mechanism (12) is the same as that of the first sedimentation mechanism (11), but the opening ratio of the sedimentation holes of the second sedimentation mechanism (12) is smaller than that of the sedimentation holes on the first sedimentation mechanism (11).

9. The super-aeration floating system according to claim 7, characterized in that, A rotary foam collector (18) corresponding to the overflow port (9) in position and located above the second sedimentation mechanism (12) is provided on the central drive rod (7). The rotary foam collector (18) includes a plurality of rotating arms (31) circumferentially and uniformly distributed around the central drive rod (7), and a foam scraping head (32) provided at the end of the rotating arm (31), wherein the length of the rotating arm (31) matches the inner radius of the reaction tank (1).

10. A method for implementing the super-aeration floating system according to any one of claims 1 to 9, characterized in that, It includes the following steps: S10. Preparation: Ensure that all components of the ultra-aeration floating system are intact, the connections are stable, the raw materials are ready, the feeding equipment is normal, the external gas supply system is stable, and the pipeline is airtight; S20. Feeding and initial aeration: The material enters the reaction tank through the feeding pipe. At the same time, the central island aeration mechanism supplies gas, and the dish-shaped tank guides the circulation of the aerated liquid to start the reaction; S30. Mixing enhancement: The inclined deflector guides the reaction liquid to form a three-dimensional circulation, and with continuous aeration, it promotes the uniform mixing and reaction of the materials; S40. Ultra-aeration and primary foam treatment: Increase the aeration volume to enter ultra-aeration, and the generated foam is initially separated from gas and liquid by the first sedimentation mechanism of the dynamic sedimentator; S50. Secondary foam treatment and discharge: The preliminarily treated foam enters the second sedimentation mechanism for further separation and sedimentation, and then is scraped by the rotary foam collector and discharged through the overflow port; S60. Discharging: After monitoring and judging that the reaction is completed, the product is discharged through the discharge pipe, and the discharge parameters are controlled.

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