Intelligent shearing equipment for producing AKD papermaking surface sizing agent

Abstract

The invention discloses intelligent shearing equipment for producing an AKD (Alkyl Ketene Dimer) papermaking surface sizing agent, and relates to the technical field of papermaking wastewater resource recycling, and the intelligent shearing equipment comprises a shearing device host, a high-rotating-speed shearing module, an intelligent control module, a wastewater treatment module, a closed-loop control module and a heat energy recovery module. The intelligent three-way valve is adopted to dynamically adjust the mixing ratio of the fresh raw materials and the recycled wastewater, and the combined process of the pretreatment unit, the electrocatalytic oxidation reactor and the ultrafiltration membrane assembly is combined, so that suspended solids, organic matters and microorganisms in the wastewater are efficiently removed, the demand of the fresh raw materials and the discharge of the wastewater are remarkably reduced, and the energy consumption is reduced. Meanwhile, the closed-loop control module collects key parameters in real time, the dosage of a wastewater treatment agent is accurately adjusted through a dynamic matching algorithm, the stability and high efficiency of the wastewater treatment process are ensured, and therefore the equipment achieves comprehensive utilization of wastewater and reduces emission and treatment cost.

Description

Technical Field

[0001] The invention relates to the technical field of recycling papermaking wastewater resources, in particular to an intelligent shearing device for producing AKD papermaking surface sizing agent. Background Art

[0002] AKD (Alkyl Ketene Dimer) is a neutral, reactive synthetic sizing agent. Solid wax powder is dispersed in water through an emulsification process to form a stable emulsion. The production process requires thorough mixing and emulsification of the raw materials using equipment such as shear kettles to ensure stable product performance. In traditional production, uneven mixing or inadequate emulsification of the raw materials can easily lead to uneven distribution of AKD particles, affecting sizing effectiveness and paper water resistance.

[0003] The defects of the existing intelligent shearing equipment for sizing agents are:

[0004] 1. Patent document US06494988B1 discloses a process for improving the surface of offset paper. However, the device described in the aforementioned document cannot efficiently and dynamically adjust the mixing ratio of fresh raw materials and recycled wastewater, resulting in low wastewater treatment efficiency and an inability to significantly reduce the demand for fresh raw materials and wastewater discharge.

[0005] 2. Patent document US06753377B1 discloses a polymer dispersion and a method for manufacturing the same. However, the device described in the aforementioned document lacks a risk warning unit to monitor the concentration of heavy metal ions in wastewater in real time, making it impossible to trigger a response mechanism in time to address potential safety risks, thereby affecting the stability and environmental performance of the production process.

[0006] 3. Patent document US4222820A discloses a papermaking agent, but the device described in the above document is unable to optimize the electric field distribution and improve the current efficiency, resulting in a slow degradation rate of organic matter and difficulty in effectively reducing the COD value and toxicity of wastewater;

[0007] 4. Patent document CN111395036A discloses a solid surface sizing agent for papermaking. However, the device in the above document lacks an intelligent control module and an online viscosity sensor to monitor key parameters in real time, resulting in an inability to ensure the stability of the AKD sizing agent product quality. Summary of the Invention

[0008] The object of the present invention is to provide an intelligent shearing device for producing AKD papermaking surface sizing agent to solve the technical problems raised in the above background technology.

[0009] To achieve the above objectives, the present invention provides the following technical solutions: an intelligent shearing device for producing AKD papermaking surface sizing agent, comprising a shearing device main unit, a high-speed shearing module, an intelligent control module, a wastewater treatment module, a closed-loop control module, and a heat recovery module. The shearing device main unit is provided with a shearing chamber, and the feed port of the shearing chamber is installed with an intelligent three-way valve. The other two ends of the intelligent three-way valve are respectively connected to a fresh raw material feed pipeline and a wastewater reuse pipeline. The intelligent three-way valve dynamically adjusts the mixing ratio of fresh raw material and reused wastewater according to the instructions of the closed-loop control module.

[0010] The wastewater treatment module includes a pretreatment unit, a storage tank and a wastewater treatment agent addition unit. The pretreatment unit includes a pretreatment tank, an electrocatalytic oxidation reactor and an ultrafiltration membrane assembly. The top of the pretreatment tank is provided with a negative pressure collection port connected to the wastewater discharge port of the shear cavity, and the pretreatment tank is arranged inside the main body of the shear device. The pretreatment tank is sequentially provided with a metal filter layer with a pore size of 50-200 μm, an electrocatalytic oxidation reactor and an ultrafiltration membrane assembly with a molecular weight cutoff of 5000-10000 Da from top to bottom.

[0011] The input end of the storage tank is connected to the water production end of the ultrafiltration membrane assembly, and the storage tank is arranged at the bottom of the shear device main unit. An agitator is provided in the tank, and a pH monitor, a COD detection probe and a temperature compensation device are integrated in the storage tank.

[0012] The wastewater treatment agent addition unit includes a cationic starch storage tank, an aluminum coagulant metering pump and a mixing spray pipe, all of which are arranged inside the shear device main unit, wherein the output end of the cationic starch storage tank is connected to the upstream pipeline of the pretreatment tank through a Venturi ejector, the output end of the aluminum coagulant metering pump is connected to the premixing chamber of the mixing spray pipe, and the output end of the mixing spray pipe is connected to the upstream pipeline of the pretreatment tank;

[0013] The closed-loop control module collects the turbidity, Zeta potential and COD value of the wastewater in the storage tank in real time, and adjusts the opening of the intelligent three-way valve and the dosage of the wastewater treatment agent through a dynamic ratio algorithm.

[0014] Preferably, the closed-loop control module includes a wastewater characteristic database, a dynamic proportioning algorithm, and a risk warning unit. The wastewater characteristic database is used to store historical data on pH value, conductivity, suspended solids concentration, and heavy metal ion content of wastewater from different papermaking process sections. The dynamic proportioning algorithm is based on the real-time COD value and Zeta potential of the storage tank and calculates the maximum allowable wastewater mixing ratio using the following formula:

[0015]

[0016] Among them, P max is the maximum allowable wastewater mixing ratio, CODtarget The maximum COD value allowed for sizing agents, COD fresh COD is the COD value of fresh raw materials, COD reuse COD value of recycled wastewater.

[0017] Preferably, the risk warning unit is used to trigger a three-level response mechanism when it detects that the concentration of heavy metal ions in the wastewater exceeds 0.5 mg / L:

[0018] Primary warning: activate the sound and light alarm and send a text message to the operation terminal;

[0019] Intermediate intervention: Close the wastewater reuse pipeline of the intelligent three-way valve and switch to the fresh raw material feed pipeline;

[0020] Advanced protection: Add disodium EDTA chelating agent into the storage tank at a dosage of 1.2-1.5 times the molar concentration of heavy metal ions.

[0021] Preferably, the high-speed shearing module includes a servo motor, the output shaft of the servo motor is connected to a planetary gear speed increaser, and the planetary gear speed increaser is installed in the middle of the top of the shearing device main body, and the final output speed reaches 8000-12000rpm. A shearing shaft is installed at the output end of the planetary gear speed increaser, and the lower end of the shearing shaft extends to the inside of the shearing cavity, and several shearing disks are provided on the outer wall of the shearing shaft.

[0022] Preferably, the electrocatalytic oxidation reactor comprises a titanium substrate PbO2 coated anode, a carbon fiber felt cathode and a high-frequency pulse power supply. The titanium substrate PbO2 coated anode and the carbon fiber felt cathode are alternately arranged at a spacing of 10-20 mm to form a gradient electrode array. The output parameters of the high-frequency pulse power supply are: pulse frequency 100-500 Hz, duty cycle 30%-70%, peak current density 10-50 mA / cm 2 , the wastewater residence time in the reactor is controlled at 15 to 30 minutes, and the ORP value is maintained at +400mV to +800mV.

[0023] Preferably, the intelligent control module includes an online viscosity sensor, an ultraviolet-visible spectroscopy water quality analyzer and a digital twin module. The online viscosity sensor is used to monitor the viscosity of the emulsion at the outlet of the shear chamber in real time, and the ultraviolet-visible spectroscopy water quality analyzer is used to detect the AKD residue and derivative concentration in the wastewater through multi-wavelength absorbance.

[0024] Preferably, the digital twin module adopts an LSTM neural network, the input parameters include shear rate, wastewater pH value, conductivity, organic matter concentration and recycled water ratio, and the output parameter is the equipment comprehensive operating efficiency index.

[0025] Preferably, the heat energy recovery module includes a plate heat exchanger and a heat storage tank. The plate heat exchanger is used to recover the process waste heat of the shear chamber, and the heat storage tank is used to store heat and supply it to the flushing device of the ultrafiltration membrane assembly, and maintain the backwash water temperature at 45-55°C.

[0026] Preferably, the working steps of the intelligent shearing device for producing AKD papermaking surface sizing agent are as follows:

[0027] S1, the intelligent three-way valve dynamically adjusts the mixing ratio of fresh raw materials and recycled wastewater according to the instructions of the closed-loop control module;

[0028] The S2 high-speed shearing module shears the mixed sizing agent raw materials at high speed, ensuring thorough mixing and achieving the desired particle size distribution. Simultaneously, the intelligent control module's online viscosity sensor monitors the viscosity of the sizing agent at the shear chamber outlet in real time to ensure that the sizing agent meets quality requirements. Furthermore, the UV-Vis spectroscopy water quality analyzer uses multi-wavelength absorbance to detect AKD residues and derivative concentrations in wastewater, providing data support for wastewater treatment.

[0029] S3. The wastewater generated during the shearing process is treated by a pretreatment unit. The wastewater first enters the pretreatment tank and is filtered through a metal filter layer to remove large particles of impurities. The wastewater then enters the electrocatalytic oxidation reactor to remove organic matter and harmful substances in the wastewater through electrocatalytic oxidation. Finally, the wastewater is further filtered through an ultrafiltration membrane assembly to remove small particles and soluble substances, obtaining treated wastewater.

[0030] S4. The treated wastewater is stored in a storage tank, which is equipped with a pH monitor, COD detection probe, and temperature compensation device to monitor various parameters of the wastewater in real time. According to the instructions of the closed-loop control module, part of the wastewater is returned to the shear chamber through the wastewater reuse pipeline for reuse, thus realizing the recycling of wastewater;

[0031] S5. The intelligent control module builds an equipment operation model through the digital twin module based on real-time monitoring data. The model input parameters include shear rate, wastewater pH value, conductivity, organic matter concentration, and recycled water ratio. The output parameters are the equipment's comprehensive operating efficiency index and recommended process parameter adjustments. The closed-loop control module adjusts the opening of the intelligent three-way valve and the amount of wastewater treatment agent added based on this data to ensure that the equipment always operates in the best condition.

[0032] S6. During the operation of the equipment, the heat recovery module recovers the generated heat energy to improve the energy efficiency of the equipment and reduce energy consumption;

[0033] S7. When the equipment completes its production task or requires maintenance, the equipment stops running and the operator performs necessary maintenance and care on the equipment to ensure long-term stable operation of the equipment.

[0034] Preferably, the step S1 further includes the following steps:

[0035] S11. Fresh raw materials enter the shearing chamber through the fresh raw material feeding pipeline. At the same time, part of the treated wastewater also enters the shearing chamber through the wastewater recycling pipeline to achieve wastewater reuse.

[0036] Compared with the prior art, the present invention has the following beneficial effects:

[0037] 1. This invention uses an intelligent three-way valve to dynamically adjust the mixing ratio of fresh raw materials and recycled wastewater. Combined with a pretreatment unit, an electrocatalytic oxidation reactor, and an ultrafiltration membrane assembly, it efficiently removes suspended solids, organic matter, and microorganisms from wastewater, significantly reducing the demand for fresh raw materials and wastewater discharge. Simultaneously, a closed-loop control module collects key parameters in real time and precisely adjusts the dosage of wastewater treatment agents through a dynamic ratioing algorithm, ensuring the stability and efficiency of the wastewater treatment process. This equipment not only achieves comprehensive wastewater utilization and reduces emissions and treatment costs, but also enhances the company's environmental image and market competitiveness, embodying the multiple values ​​of papermaking companies in terms of clean production, environmental protection, and social responsibility.

[0038] 2. This invention significantly improves the safety and intelligence of the papermaking wastewater treatment process by integrating a wastewater characteristics database, a dynamic proportioning algorithm, and a risk warning unit. The wastewater characteristics database stores key historical data on wastewater from different papermaking process stages, providing a precise calculation basis for the dynamic proportioning algorithm. The algorithm dynamically calculates the maximum allowable wastewater incorporation ratio based on the real-time COD value and Zeta potential of the storage tank, ensuring that the wastewater reuse process is both efficient and safe, and avoiding negative impacts on production. Simultaneously, the risk warning unit monitors the heavy metal ion concentration in the wastewater in real time. If the concentration exceeds the safety threshold of 0.5 mg / L, it immediately triggers a three-level response mechanism, thereby optimizing wastewater treatment efficiency and significantly improving the stability and environmental performance of the production process.

[0039] 3. The present invention achieves efficient oxidation treatment of refractory organic matter in papermaking wastewater through a gradient electrode array consisting of a titanium-based PbO2-coated anode and a carbon fiber felt cathode, combined with precise control of a high-frequency pulse power supply. First, the electrode array design optimizes the electric field distribution, and combined with the pulse characteristics of the high-frequency pulse power supply, significantly improves current efficiency and organic matter degradation rate. Second, by controlling the residence time and ORP value of the wastewater in the reactor, the stability and thoroughness of the wastewater treatment are ensured, and the COD value and toxicity of the wastewater are effectively reduced. The reactor works in conjunction with the overall wastewater reuse system of the equipment, not only improving wastewater treatment efficiency but also promoting the resource utilization of wastewater in papermaking enterprises.

[0040] 4. The present invention uses an intelligent control module and an online viscosity sensor to monitor the viscosity of the emulsion at the outlet of the shear chamber in real time to ensure the stability of the quality of the AKD sizing agent product. The UV-visible spectroscopy water quality analyzer detects the concentration of AKD residues and derivatives in the wastewater through multi-wavelength absorbance, thereby achieving precise control of the wastewater treatment process and reducing raw material waste and pollutant emissions. The digital twin module constructs an equipment operation model based on the LSTM neural network. After inputting the key parameters of shear rate and wastewater pH value, it can predict the emulsion stability index and give process adjustment suggestions. At the same time, it outputs the comprehensive operation efficiency index of the equipment to provide data support for production optimization. In the heat recovery module, the plate heat exchanger efficiently recovers the process waste heat of the shear chamber, and supplies the heat to the flushing device of the ultrafiltration membrane assembly through the heat storage tank, maintaining a backwash water temperature of 45-55°C, which not only reduces energy consumption but also improves the cleaning efficiency and service life of the ultrafiltration membrane. BRIEF DESCRIPTION OF THE DRAWINGS

[0041] Figure 1 It is a schematic diagram of the system flow structure of the present invention;

[0042] Figure 2 This is a schematic diagram of the electrocatalytic oxidation reactor process structure of the present invention;

[0043] Figure 3 This is a schematic diagram of the intelligent control module process structure of the present invention;

[0044] Figure 4 This is a schematic diagram of the heat recovery module process structure of the present invention;

[0045] Figure 5 It is a three-dimensional schematic diagram of the overall structure of the present invention;

[0046] Figure 6 It is a schematic cross-sectional view of the overall structure of the present invention;

[0047] Figure 7 Schematic diagram of the structure of the plate heat exchanger of the present invention;

[0048] Figure 8 This is a schematic diagram of the storage tank structure of the present invention;

[0049] Figure 9 This is a schematic structural diagram of the heat storage tank of the present invention;

[0050] Figure 10 Schematic diagram of the workflow of the present invention.

[0051] Figure: 1. Shearing device host; 2. High-speed shearing module; 3. Intelligent control module; 4. Wastewater treatment module; 5. Closed-loop control module; 6. Heat recovery module; 7. Shearing chamber; 8. Intelligent three-way valve; 9. Fresh raw material feed pipeline; 10. Wastewater reuse pipeline; 11. Pretreatment unit; 12. Storage tank; 13. Wastewater treatment agent addition unit; 14. Pretreatment tank; 15. Electrocatalytic oxidation reactor; 16. Ultrafiltration membrane assembly; 17. Negative pressure collection port; 20. Agitator; 21. pH monitor; 22. COD detection probe; 23. Temperature compensation compensation device; 25. Cationic starch storage tank; 26. Aluminum coagulant metering pump; 27. Mixing spray pipe; 28. Wastewater characteristic database; 29. ​​Dynamic proportioning algorithm; 30. Risk warning unit; 31. Servo motor; 32. Planetary gear speed increaser; 33. Shear shaft; 34. Shear disk; 35. Titanium matrix PbO2 coated anode; 36. Carbon fiber felt cathode; 37. High-frequency pulse power supply; 38. Linear viscosity sensor; 39. UV-visible spectrometer water quality analyzer; 40. Digital twin module; 41. Plate heat exchanger; 42. Heat storage tank; 43. Metal filter layer. DETAILED DESCRIPTION

[0052] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0053] In the description of the present invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," "the other end," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0054] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "provided with," "connected," etc., should be understood in a broad sense. For example, "connected" may refer to a fixed connection, a detachable connection, or an integral connection; it may refer to a mechanical connection or an electrical connection; it may refer to a direct connection or an indirect connection through an intermediate medium; it may refer to internal communication between two components. Those skilled in the art will be able to understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0055] Example 1: Please refer to Figure 1 、 Figure 5 、 Figure 6 and Figure 8 The present invention provides an embodiment of an intelligent shearing device for producing AKD papermaking surface sizing agent, comprising a shearing device main unit 1, a high-speed shearing module 2, an intelligent control module 3, a wastewater treatment module 4, a closed-loop control module 5, and a heat recovery module 6. The device is characterized in that a shearing chamber 7 is provided inside the shearing device main unit 1, an intelligent three-way valve 8 is installed at the feed port of the shearing chamber 7, the other two ends of the intelligent three-way valve 8 are respectively connected to a fresh raw material feed pipeline 9 and a wastewater recycling pipeline 10, and the intelligent three-way valve 8 dynamically adjusts the mixing ratio of fresh raw material and recycled wastewater according to the instructions of the closed-loop control module 5;

[0056] The wastewater treatment module 4 includes a pretreatment unit 11, a storage tank 12 and a wastewater treatment agent addition unit 13. The pretreatment unit 11 includes a pretreatment tank 14, an electrocatalytic oxidation reactor 15 and an ultrafiltration membrane assembly 16. The top of the pretreatment tank 14 is provided with a negative pressure collection port 17 connected to the wastewater discharge port of the shear chamber 7, and the pretreatment tank 14 is arranged inside the shear device main unit 1. The pretreatment tank 14 is sequentially provided with a metal filter layer 43 with a pore size of 50-200 μm, an electrocatalytic oxidation reactor 15 and an ultrafiltration membrane assembly 16 with a molecular weight cutoff of 5000-10000 Da from top to bottom.

[0057] The input end of the storage tank 12 is connected to the water production end of the ultrafiltration membrane assembly 16, and the storage tank 12 is arranged at the bottom of the shearing device main unit 1. The tank is provided with an agitator 20, and the storage tank 12 is integrated with a pH monitor 21, a COD detection probe 22 and a temperature compensation device 23;

[0058] The wastewater treatment agent addition unit 13 includes a cationic starch storage tank 25, an aluminum coagulant metering pump 26 and a mixing spray pipe 27, all of which are arranged inside the shearing device main unit 1, wherein the output end of the cationic starch storage tank 25 is connected to the upstream pipeline of the pretreatment tank 14 through a Venturi ejector, the output end of the aluminum coagulant metering pump 26 is connected to the premixing chamber of the mixing spray pipe 27, and the output end of the mixing spray pipe 27 is connected to the upstream pipeline of the pretreatment tank 14;

[0059] The closed-loop control module 5 collects the turbidity, zeta potential and COD value of the wastewater in the storage tank 12 in real time, and adjusts the opening of the intelligent three-way valve 8 and the amount of wastewater treatment agent added through the dynamic ratio algorithm 29;

[0060] Furthermore, by adopting the intelligent three-way valve 8 to dynamically adjust the mixing ratio of fresh raw materials and recycled wastewater, combined with the combined process of the pretreatment unit 11, the electrocatalytic oxidation reactor 15 and the ultrafiltration membrane assembly 16, the suspended matter, organic matter and microorganisms in the wastewater can be efficiently removed, which significantly reduces the demand for fresh raw materials and the discharge of wastewater. At the same time, the closed-loop control module 5 collects key parameters in real time and accurately adjusts the dosage of the wastewater treatment agent through the dynamic proportioning algorithm 29 to ensure the stability and efficiency of the wastewater treatment process. As a result, the equipment not only realizes the comprehensive utilization of wastewater and reduces emissions and treatment costs, but also improves the company's environmental image, enhances its market competitiveness, and reflects the multiple values ​​of papermaking enterprises in clean production, environmental protection and social responsibility.

[0061] Example 2: Please refer to Figure 1 In one embodiment of the present invention, the closed-loop control module 5 includes a wastewater characteristic database 28, a dynamic proportioning algorithm 29, and a risk warning unit 30. The wastewater characteristic database 28 is used to store historical data on the pH value, conductivity, suspended solids concentration, and heavy metal ion content of wastewater from different papermaking process sections. The dynamic proportioning algorithm 29 calculates the maximum allowable wastewater mixing ratio based on the real-time COD value and Zeta potential of the storage tank 12 using the following formula:

[0062]

[0063] Among them, P max is the maximum allowable wastewater mixing ratio, COD target The maximum COD value allowed for sizing agents, COD fresh COD is the COD value of fresh raw materials, COD reuse COD value of the recycled wastewater;

[0064] The risk warning unit 30 is used to trigger a three-level response mechanism when it detects that the concentration of heavy metal ions in the wastewater exceeds 0.5 mg / L:

[0065] Primary warning: activate the sound and light alarm and send a text message to the operation terminal;

[0066] Intermediate intervention: close the wastewater recycling pipeline 10 of the intelligent three-way valve 8 and switch to the fresh raw material feed pipeline 9;

[0067] Advanced protection: add disodium ethylenediaminetetraacetic acid chelating agent into the storage tank 12, the dosage of which is 1.2-1.5 times the molar concentration of heavy metal ions;

[0068] Furthermore, by integrating the wastewater characteristic database 28, the dynamic proportioning algorithm 29 and the risk warning unit 30, the safety and intelligence level of the papermaking wastewater treatment process are significantly improved. The wastewater characteristic database 28 stores the key historical data of wastewater in different papermaking process sections, providing an accurate calculation basis for the dynamic proportioning algorithm 29. The algorithm dynamically calculates the maximum allowable wastewater mixing ratio based on the real-time COD value and Zeta potential of the storage tank 12, ensuring that the wastewater reuse process is both efficient and safe, and avoiding negative impacts on production. At the same time, the risk warning unit 30 can monitor the concentration of heavy metal ions in the wastewater in real time. If the concentration exceeds the safety threshold of 0.5 mg / L, the three-level response mechanism will be triggered immediately, which not only optimizes the wastewater treatment efficiency, but also greatly improves the stability and environmental protection performance of the production process.

[0069] Example 3: Please refer to Figure 5 、 Figure 6 、 Figure 7 and Figure 9 The present invention provides an embodiment in which the high-speed shearing module 2 includes a servo motor 31, the output shaft of the servo motor 31 is connected to a planetary gear speed increaser 32, and the planetary gear speed increaser 32 is installed in the middle of the top of the shearing device main body 1, and the final output speed reaches 8000-12000 rpm. The output end of the planetary gear speed increaser 32 is installed with a shearing shaft 33, and the lower end of the shearing shaft 33 extends into the interior of the shearing chamber 7. The outer wall of the shearing shaft 33 is provided with a plurality of shearing discs 34;

[0070] Furthermore, through the synergistic effect of the servo motor 31 and the planetary gear speed increaser 32, a high-speed output of 8000-12000rpm is achieved, providing strong power support for the shearing process. The planetary gear speed increaser 32 is installed in the middle of the top of the shearing device main body 1, ensuring the stability and efficiency of power transmission. The lower end of the shear shaft 33 extends to the inside of the shearing cavity 7. Several shear discs 34 arranged on its outer wall can perform fine shearing of the material under high-speed rotation, significantly improving the shearing efficiency and product quality. This design not only optimizes the shearing effect, but also meets the demand for high-speed and high-efficiency shearing in the production process of AKD papermaking surface sizing agent, providing papermaking enterprises with better quality and more stable sizing agent products.

[0071] Example 4: Please refer to Figure 2 In one embodiment of the present invention, an electrocatalytic oxidation reactor 15 includes a titanium substrate PbO2-coated anode 35, a carbon fiber felt cathode 36, and a high-frequency pulse power supply 37. The titanium substrate PbO2-coated anode 35 and the carbon fiber felt cathode 36 are alternately arranged at a spacing of 10-20 mm to form a gradient electrode array. The output parameters of the high-frequency pulse power supply 37 are: pulse frequency 100-500 Hz, duty cycle 30%-70%, and peak current density 10-50 mA / cm2 , the wastewater residence time in the reactor is controlled at 15 to 30 minutes, and the ORP value is maintained at +400mV to +800mV;

[0072] Furthermore, through the gradient electrode array composed of the titanium matrix PbO2 coated anode 35 and the carbon fiber felt cathode 36, combined with the precise control of the high-frequency pulse power supply 37, efficient oxidation treatment of difficult-to-degrade organic matter in the papermaking wastewater is achieved. First, the electric field distribution is optimized through the electrode array design, and the pulse characteristics of the high-frequency pulse power supply 37 are combined to significantly improve the current efficiency and organic matter degradation rate. Secondly, by controlling the residence time and ORP value of the wastewater in the reactor, the stability and thoroughness of the wastewater treatment are ensured, and the COD value and toxicity of the wastewater are effectively reduced. Finally, the reactor works in coordination with the overall wastewater reuse system of the equipment, which not only improves the wastewater treatment efficiency, but also promotes the resource utilization of wastewater from papermaking enterprises, providing strong support for clean production and sustainable development of the papermaking industry.

[0073] Example 5: Please refer to Figure 3 and Figure 4 In one embodiment of the present invention, the intelligent control module 3 includes an online viscosity sensor 38, an ultraviolet-visible spectrum water quality analyzer 39, and a digital twin module 40. The online viscosity sensor 38 is used to monitor the viscosity of the emulsion at the outlet of the shear chamber 7 in real time. The ultraviolet-visible spectrum water quality analyzer 39 is used to detect the AKD residue and derivative concentration in the wastewater through multi-wavelength absorbance.

[0074] The digital twin module 40 uses an LSTM neural network. The input parameters include shear rate, wastewater pH, conductivity, organic matter concentration, and recycled water ratio. The output parameter is the comprehensive equipment operating efficiency index.

[0075] The heat recovery module 6 includes a plate heat exchanger 41 and a heat storage tank 42. The plate heat exchanger 41 is used to recover the process waste heat of the shear chamber 7. The heat storage tank 42 is used to store heat and supply it to the flushing device of the ultrafiltration membrane assembly 16, and maintain the backwash water temperature at 45-55°C.

[0076] Furthermore, through the intelligent control module 3, the online viscosity sensor 38 monitors the viscosity of the emulsion at the outlet of the shear chamber 7 in real time to ensure the stability of the quality of the AKD sizing agent product. The UV-visible spectroscopy water quality analyzer 39 detects the concentration of AKD residues and derivatives in the wastewater through multi-wavelength absorbance to achieve precise control of the wastewater treatment process and reduce raw material waste and pollutant emissions. The digital twin module 40 builds an equipment operation model based on the LSTM neural network. After inputting the key parameters of shear rate and wastewater pH value, it can predict the emulsion stability index and give process adjustment suggestions. The comprehensive operating efficiency index of the output equipment provides data support for production optimization. In the heat recovery module 6, the plate heat exchanger 41 efficiently recovers the process waste heat of the shear chamber 7, and supplies the heat to the flushing device of the ultrafiltration membrane assembly 16 through the heat storage tank 42, maintaining the backwash water temperature of 45-55°C, which not only reduces energy consumption but also improves the cleaning efficiency and service life of the ultrafiltration membrane. The two modules work together to achieve intelligent closed-loop control of wastewater treatment and cascade utilization of energy while ensuring product quality, providing papermaking enterprises with a comprehensive solution that is efficient, energy-saving and environmentally friendly.

[0077] Example 6: Please refer to Figure 10 The present invention provides an embodiment: the working steps of the intelligent shearing device for producing AKD papermaking surface sizing agent are as follows:

[0078] S1, fresh raw materials enter the intelligent three-way valve 8 through the fresh raw material feed pipeline 9, while the wastewater reuse pipeline 10 transports the pre-treated wastewater to the mixing node. The closed-loop control module 5 calculates the optimal mixing ratio based on the real-time water quality data of the storage tank 12 through the dynamic ratio algorithm 29, and adjusts the three-way valve opening to achieve accurate ratio;

[0079] S2. Before the mixed liquid enters the shear chamber 7, the cationic starch storage tank 25 injects the modifier into the pipeline through the Venturi ejector, and the aluminum coagulant metering pump 26 sends the coagulant into the mixing spray pipe 27, forming a micro-turbulent mixing zone in the premixing chamber to complete the initial flocculation reaction;

[0080] S3, the servo motor 31 drives the planetary gear speed increaser 32, increasing the speed to 8000-12000 rpm, driving the shear shaft 33 and the multi-layer shear disk 34 to rotate at high speed. The mixed liquid is subjected to a linear velocity shear force of ≥30 MPa in the gap between the shear disks 34. At the same time, the digital twin module 40 adjusts the shear rate in real time according to the feedback from the online viscosity sensor 38 to ensure that the emulsion particle size is controlled at 0.8-1.2 μm;

[0081] S4, the shear wastewater enters the pretreatment tank 14 through the negative pressure collection port 17 and passes through:

[0082] Metal filter layer 43: intercepts suspended solids with a particle size greater than 50 μm;

[0083] Electrocatalytic oxidation reactor 15: A high-frequency pulse electric field is applied between the titanium substrate PbO2 coated anode 35 and the carbon fiber felt cathode 36 to generate OH free radicals to oxidize and degrade organic matter. The ORP is controlled at +400mV to +800mV.

[0084] Ultrafiltration membrane assembly 16: retains colloidal substances with a molecular weight cutoff of 5000-10000Da;

[0085] The treated water enters the storage tank 12, where the pH monitor 21 and COD detection probe 22 collect water quality data in real time, and the temperature compensation device 23 maintains the water temperature;

[0086] S5, the closed-loop control module 5 obtains the maximum allowable wastewater mixing ratio based on the COD value and Zeta potential of the storage tank 12. When the heavy metal ion concentration exceeds the standard by more than 0.5 mg / L, the risk warning unit 30 initiates a level 3 response;

[0087] S6, the plate heat exchanger 41 recovers the process waste heat generated by the shear chamber 7 and stores the heat in the heat storage tank 42. During backwashing, 45-55°C hot water passes through the ultrafiltration membrane assembly 16, effectively restoring the membrane flux and reducing the frequency of chemical cleaning;

[0088] S7 and the digital twin module 40 use an LSTM neural network to integrate shear rate, wastewater pH, conductivity, and organic matter concentration parameters to build an equipment operation model.

[0089] Working principle: by adopting the intelligent three-way valve 8 to dynamically adjust the mixing ratio of fresh raw materials and recycled wastewater, combined with the combined process of the pretreatment unit 11, the electrocatalytic oxidation reactor 15 and the ultrafiltration membrane assembly 16, the suspended solids, organic matter and microorganisms in the wastewater are efficiently removed, and the demand for fresh raw materials and the discharge of wastewater are significantly reduced. At the same time, the closed-loop control module 5 collects key parameters in real time, and accurately adjusts the dosage of the wastewater treatment agent through the dynamic ratio algorithm 29 to ensure the stability and efficiency of the wastewater treatment process. As a result, the equipment not only realizes the comprehensive utilization of wastewater, reduces emissions and treatment costs, but also improves the environmental image of the enterprise, enhances market competitiveness, and reflects the papermaking enterprise's clean production. The system significantly enhances the safety and intelligence of the papermaking wastewater treatment process by integrating a wastewater characteristics database 28, a dynamic proportioning algorithm 29, and a risk warning unit 30. The wastewater characteristics database 28 stores key historical data on wastewater from different papermaking process stages, providing a precise calculation basis for the dynamic proportioning algorithm 29. The algorithm dynamically calculates the maximum allowable wastewater mixing ratio based on the real-time COD value and Zeta potential of the storage tank 12, ensuring that the wastewater reuse process is both efficient and safe, and avoiding negative impacts on production. At the same time, the risk warning unit 30 can monitor the concentration of heavy metal ions in the wastewater in real time and detect if the concentration exceeds 0.The safety threshold of 5mg / L will immediately trigger the three-level response mechanism, which not only optimizes the wastewater treatment efficiency, but also greatly improves the stability and environmental performance of the production process. Through the synergistic effect of the servo motor 31 and the planetary gear speed increaser 32, a high-speed output of 8000-12000rpm is achieved, which provides strong power support for the shearing process. The planetary gear speed increaser 32 is installed in the middle of the top of the shearing device main body 1 to ensure the stability and efficiency of power transmission. The lower end of the shear shaft 33 extends to the inside of the shear cavity 7. Several shear discs 34 arranged on its outer wall can perform fine shearing on the material under high-speed rotation, which significantly improves the shearing efficiency and product quality. This design is not It not only optimizes the shearing effect, but also meets the demand for high-speed and high-efficiency shearing in the production process of AKD papermaking surface sizing agent, providing papermaking enterprises with better quality and more stable sizing agent products. The gradient electrode array composed of titanium matrix PbO2 coating anode 35 and carbon fiber felt cathode 36, combined with the precise control of high-frequency pulse power supply 37, realizes the efficient oxidation treatment of difficult-to-degrade organic matter in papermaking wastewater. First, the electric field distribution is optimized by the electrode array design, and the pulse characteristics of the high-frequency pulse power supply 37 are combined to significantly improve the current efficiency and organic matter degradation rate. Secondly, by controlling the residence time and ORP value of the wastewater in the reactor, the stability and thoroughness of the wastewater treatment are ensured, effectively reducing The COD value and toxicity of the wastewater are determined. Finally, the reactor works in conjunction with the overall wastewater reuse system of the equipment, which not only improves the wastewater treatment efficiency, but also promotes the resource utilization of wastewater in papermaking enterprises, providing strong support for the clean production and sustainable development of the papermaking industry. Through the intelligent control module 3, the online viscosity sensor 38 monitors the viscosity of the emulsion at the outlet of the shear chamber 7 in real time to ensure the stability of the quality of the AKD sizing agent product. The UV-visible spectroscopy water quality analyzer 39 detects the concentration of AKD residues and derivatives in the wastewater through multi-wavelength absorbance, thereby achieving precise control of the wastewater treatment process and reducing raw material waste and pollutant emissions. The digital twin module 40 builds an equipment operation model based on the LSTM neural network. By inputting key parameters such as shear rate and wastewater pH, the system can predict the emulsion stability index and provide process adjustment suggestions. It also outputs the equipment's comprehensive operating efficiency index, providing data support for production optimization. In the heat recovery module 6, the plate heat exchanger 41 efficiently recovers process waste heat from the shear chamber 7 and supplies this heat to the flushing device of the ultrafiltration membrane assembly 16 via the heat storage tank 42, maintaining a backwash water temperature of 45-55°C. This reduces energy consumption and improves the cleaning efficiency and service life of the ultrafiltration membrane. The two modules work together to achieve intelligent closed-loop control of wastewater treatment and cascade energy utilization while ensuring product quality, providing papermaking companies with a comprehensive, efficient, energy-saving, and environmentally friendly solution.

[0090] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. An intelligent shearing device for producing AKD papermaking surface sizing agent, comprising a shearing device main unit (1), a high-speed shearing module (2), an intelligent control module (3), a wastewater treatment module (4), a closed-loop control module (5) and a heat recovery module (6), characterized in that: A shearing chamber (7) is provided inside the shearing device main unit (1), and an intelligent three-way valve (8) is installed at the feed port of the shearing chamber (7). The other two ends of the intelligent three-way valve (8) are respectively connected to a fresh raw material feed pipeline (9) and a wastewater recycling pipeline (10). The intelligent three-way valve (8) dynamically adjusts the mixing ratio of fresh raw material and recycled wastewater according to the instructions of the closed-loop control module (5); The wastewater treatment module (4) comprises a pretreatment unit (11), a storage tank (12) and a wastewater treatment agent addition unit (13); the pretreatment unit (11) comprises a pretreatment tank (14), an electrocatalytic oxidation reactor (15) and an ultrafiltration membrane assembly (16); wherein a negative pressure collection port (17) is provided on the top of the pretreatment tank (14) to connect to the wastewater discharge port of the shearing chamber (7); and the pretreatment tank (14) is arranged inside the shearing device main unit (1); and a metal filter layer (43) with a pore size of 50-200 μm, an electrocatalytic oxidation reactor (15) and an ultrafiltration membrane assembly (16) with a molecular weight cutoff of 5000-10000 Da are sequentially arranged in the pretreatment tank (14) from top to bottom; The input end of the storage tank (12) is connected to the water production end of the ultrafiltration membrane assembly (16), and the storage tank (12) is arranged at the bottom inside the shearing device main unit (1), and an agitator (20) is provided in the tank. The storage tank (12) is also integrated with a pH monitor (21), a COD detection probe (22) and a temperature compensation device (23); The wastewater treatment agent addition unit (13) includes a cationic starch storage tank (25), an aluminum coagulant metering pump (26) and a mixing spray pipe (27), all of which are arranged inside the shearing device main unit (1), wherein the output end of the cationic starch storage tank (25) is connected to the upstream pipeline of the pretreatment tank (14) through a Venturi ejector, the output end of the aluminum coagulant metering pump (26) is connected to the premixing chamber of the mixing spray pipe (27), and the output end of the mixing spray pipe (27) is connected to the upstream pipeline of the pretreatment tank (14); The closed-loop control module (5) collects the turbidity, zeta potential and COD value of the wastewater in the storage tank (12) in real time, and adjusts the opening of the intelligent three-way valve (8) and the amount of wastewater treatment agent added through a dynamic ratio algorithm (29).

2. The intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 1, characterized in that: The closed-loop control module (5) includes a wastewater characteristic database (28), a dynamic proportioning algorithm (29) and a risk warning unit (30). The wastewater characteristic database (28) is used to store historical data on pH value, conductivity, suspended solids concentration and heavy metal ion content of wastewater from different papermaking process sections. The dynamic proportioning algorithm (29) calculates the maximum allowable wastewater mixing ratio based on the real-time COD value and Zeta potential of the storage tank (12) using the following formula: Among them, P max is the maximum allowable wastewater mixing ratio, COD target The maximum COD value allowed for sizing agents, COD fresh COD is the COD value of fresh raw materials, COD reuse COD value of recycled wastewater.

3. The intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 2, characterized in that: The risk warning unit (30) is used to trigger a three-level response mechanism when detecting that the concentration of heavy metal ions in the wastewater exceeds 0.5 mg / L: Primary warning: activate the sound and light alarm and send a text message to the operation terminal; Intermediate intervention: close the wastewater recycling pipeline (10) of the intelligent three-way valve (8) and switch to the fresh raw material feeding pipeline (9); Advanced protection: adding disodium ethylenediaminetetraacetic acid chelating agent into the storage tank (12), the dosage of which is 1.2-1.5 times the molar concentration of heavy metal ions.

4. The intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 1, characterized in that: The high-speed shearing module (2) includes a servo motor (31), the output shaft of the servo motor (31) is connected to a planetary gear speed increaser (32), and the planetary gear speed increaser (32) is installed in the middle of the top of the shearing device main unit (1), and the final output speed reaches 8000-12000 rpm. The output end of the planetary gear speed increaser (32) is installed with a shearing shaft (33), and the lower end of the shearing shaft (33) extends into the interior of the shearing cavity (7), and the outer wall of the shearing shaft (33) is provided with a plurality of shearing discs (34).

5. The intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 1, characterized in that: The electrocatalytic oxidation reactor (15) comprises a titanium substrate PbO2 coated anode (35), a carbon fiber felt cathode (36) and a high-frequency pulse power supply (37). The titanium substrate PbO2 coated anode (35) and the carbon fiber felt cathode (36) are alternately arranged at a spacing of 10-20 mm to form a gradient electrode array. The output parameters of the high-frequency pulse power supply (37) are: pulse frequency 100-500 Hz, duty cycle 30%-70%, peak current density 10-50 mA / cm 2 , the wastewater residence time in the reactor is controlled at 15 to 30 minutes, and the ORP value is maintained at +400mV to +800mV.

6. The intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 1, characterized in that: The intelligent control module (3) includes an online viscosity sensor (38), an ultraviolet-visible spectrum water quality analyzer (39) and a digital twin module (40), wherein the online viscosity sensor (38) is used to monitor the viscosity of the emulsion at the outlet of the shear chamber (7) in real time, and the ultraviolet-visible spectrum water quality analyzer (39) is used to detect the AKD residue and derivative concentration in the wastewater through multi-wavelength absorbance.

7. The intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 6, characterized in that: The digital twin module (40) adopts an LSTM neural network, and the input parameters include shear rate, wastewater pH value, conductivity, organic matter concentration and recycled water ratio, and the output parameter is the equipment comprehensive operation efficiency index.

8. The intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 1, characterized in that: The heat energy recovery module (6) includes a plate heat exchanger (41) and a heat storage tank (42). The plate heat exchanger (41) is used to recover the process waste heat of the shear chamber (7). The heat storage tank (42) is used to store heat and supply it to the flushing device of the ultrafiltration membrane assembly (16), and maintain the backwash water temperature at 45-55°C.

9. The method for using the intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 7, characterized in that: The working steps of the intelligent shearing equipment for producing AKD papermaking surface sizing agent are as follows: S1, the intelligent three-way valve (8) dynamically adjusts the mixing ratio of fresh raw materials and recycled wastewater according to the instructions of the closed-loop control module (5); S2, the high-speed shearing module (2) performs high-speed shearing on the mixed sizing agent raw materials to fully mix the raw materials and achieve the required particle size distribution. At the same time, the online viscosity sensor (38) of the intelligent control module (3) monitors the viscosity of the sizing agent at the outlet of the shearing chamber (7) in real time to ensure that the quality of the sizing agent meets the requirements. In addition, the UV-visible spectroscopy water quality analyzer (39) detects the AKD residue and derivative concentration in the wastewater through multi-wavelength absorbance, providing data support for wastewater treatment; S3. The wastewater generated during the shearing process is treated by a pretreatment unit (11). The wastewater first enters a pretreatment tank (14), passes through a metal filter layer (43) to filter out large particles of impurities, and then enters an electrocatalytic oxidation reactor (15). Organic matter and harmful substances in the wastewater are removed by electrocatalytic oxidation. Finally, the wastewater is further filtered through an ultrafiltration membrane assembly (16) to remove small particles and soluble substances, thereby obtaining treated wastewater. S4. The treated wastewater is stored in a storage tank (12). The storage tank (12) is integrated with a pH monitor (21), a COD detection probe (22), and a temperature compensation device (23) to monitor various parameters of the wastewater in real time. According to the instructions of the closed-loop control module (5), part of the wastewater is returned to the shear chamber (7) through the wastewater recycling pipeline (10) for reuse, thereby realizing the recycling of the wastewater. S5, the intelligent control module (3) constructs an equipment operation model through the digital twin module (40) based on the real-time monitoring data. The input parameters of the model include shear rate, wastewater pH value, conductivity, organic matter concentration and recycled water ratio. The output parameters are the equipment comprehensive operation efficiency index and the recommended process parameter adjustment amount. The closed-loop control module (5) adjusts the opening of the intelligent three-way valve (8) and the amount of wastewater treatment agent added based on these data to ensure that the equipment always operates in the best state; S6. During the operation of the equipment, the heat recovery module (6) recovers the generated heat energy to improve the energy efficiency of the equipment and reduce energy consumption; S7. When the equipment completes its production task or requires maintenance, the equipment stops running and the operator performs necessary maintenance and care on the equipment to ensure long-term stable operation of the equipment.

10. The method for using the intelligent shearing device for producing AKD papermaking surface sizing agent according to claim 9, characterized in that: The S1 also includes the following steps: S11. Fresh raw materials enter the shearing chamber (7) through the fresh raw material feeding pipeline (9). At the same time, part of the treated wastewater also enters the shearing chamber (7) through the wastewater recycling pipeline (10), thereby realizing the reuse of wastewater.

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