Management system based on real-time monitoring and online calculation of activated carbon adsorption capacity

Abstract

The invention discloses a management system based on real-time monitoring and online calculation of activated carbon adsorption capacity, and focuses on the field of VOCs waste gas treatment. The system constructs a five-layer architecture including an acquisition layer, a network layer, a data center layer, an application layer and a display layer, acquires device operation data in real time through multiple sensors, transmits the data to a data center for intelligent analysis, and realizes life prediction and abnormity early warning. Meanwhile, the government can visually supervise the distribution, the operation state and the alarm information of the jurisdiction device through the supervision terminal by means of a 3D map, and automatically generate a statistical report and cost reduction analysis; and the enterprise terminal realizes real-time monitoring of working conditions, activated carbon replacement management and multi-channel alarm pushing. According to the system, through multi-parameter comprehensive evaluation and an intelligent algorithm, the adsorption efficiency calculation error is controlled to be + / -5%, the maintenance cost of an enterprise can be reduced by 35%, the effective operation time of equipment can be prolonged by 28%, meanwhile, the government is assisted in improving the supervision precision and the intelligent level, and optimization of environmental government and economic benefits is achieved.

Description

Technical Field

[0001] This paper deals with a management system based on real-time monitoring and online calculation of the activated carbon adsorption capacity. Background Art

[0002] In today's era of rapid industrialization, emissions of volatile organic compounds (VOCs) have become a key source of air pollution. They not only cause severe damage to the ecological environment, such as the formation of photochemical smog and the exacerbation of the greenhouse effect, but also pose a significant threat to human health, potentially causing respiratory illnesses, neurological disorders, and other conditions. Activated carbon adsorption devices, due to their high treatment efficiency, low energy consumption, and wide applicability, are widely used in VOC treatment in numerous industries, including the petrochemical, chemical, packaging and printing, and industrial coatings industries.

[0003] However, the current traditional activated carbon adsorption device management and monitoring system has exposed many problems that need to be solved urgently. On the one hand, there are obvious defects in the monitoring methods. Most of them only focus on a few key parameters, such as inlet and outlet concentrations, while ignoring factors such as pressure, temperature, humidity, etc. that also have an important impact on the adsorption effect. In addition, the monitoring process is often lagging and intermittent, making it difficult to achieve continuous and accurate monitoring of the adsorption efficiency and real-time operating status of the activated carbon adsorption device. This results in the company being unable to detect and take effective management intervention measures in a timely manner when faced with abnormal operation of the device, which ultimately leads to the risk of unorganized emissions of VOCs or even exceeding emission standards.

[0004] On the other hand, traditional approaches also face difficulties from the perspective of cost control and maintenance management. The operating and maintenance costs of activated carbon adsorption systems are inherently high, covering the procurement of new activated carbon and the disposal of spent activated carbon. Due to a lack of refined management methods, companies struggle to rationally schedule activated carbon replacement cycles based on the actual operating conditions of the system, resulting in frequent over- or under-replacement. The former wastes resources and increases operating costs, while the latter reduces adsorption efficiency, leading to substandard emissions and potential environmental penalties, further burdening the company. Furthermore, manual testing is not only costly, but the accuracy of test results depends heavily on the professionalism and work attitude of the testers, making them prone to errors. The lack of data recording and analysis also means that companies lack scientific and effective data support for operational and management decisions. Furthermore, with increasingly stringent environmental policies and regulations, government regulations are increasingly stringent regarding corporate waste gas treatment data. Traditional data integration methods, with shortcomings in protocol compatibility and other aspects, struggle to meet regulatory requirements. Summary of the Invention

[0005] The purpose of this invention is to provide a management system based on real-time monitoring and online calculation of activated carbon adsorption capacity to address the problems of incomplete monitoring, inaccurate adsorption capacity calculation, and inability to promptly warn of abnormalities during the operation of existing activated carbon adsorption devices. This system effectively monitors the operating conditions of activated carbon adsorption devices, improves their operating efficiency and VOCs control effectiveness, and reduces enterprise operating costs and environmental risks. The following is a specific solution:

[0006] A management system based on real-time monitoring and online calculation of activated carbon adsorption capacity, comprising a collection layer, a network layer, a data center layer, an application layer, and a display layer;

[0007] The application layer includes management-oriented modules for online monitoring, intelligent analysis, forecasting, abnormal alarms, file management, statistical reports, on-site verification, and tracking processing, as well as enterprise-oriented modules for file maintenance, operation analysis, device monitoring, and activated carbon replacement.

[0008] The display layer includes WeChat mini-programs, large detection screens, platform portals, enterprise dashboards, and 3D maps;

[0009] The network layer is based on 4G, WiFi, industrial Internet dedicated lines and other communication methods, and encrypts and transmits the data of the collection layer to the data center to ensure data security and real-time performance;

[0010] The data center layer uses cloud computing and big data technologies to clean, store and process raw data, and provide computing power, algorithms and data support.

[0011] The collection layer is used to collect real-time operating data of the activated carbon adsorption device. The network layer transmits the collected data to the application layer, and the application layer analyzes the activity evaluation index A of the activated carbon using the following formula;

[0012]

[0013] Among them, σ is the adsorption capacity influence coefficient, and the value range is between 0.8-1.2; γ is the temperature influence coefficient, and the value range is between 0.01-0.1; δ is the temperature correction coefficient, and the value range is between 0.9-1.1.

[0014] q e Indicates the actual adsorption capacity of activated carbon (mg / g), which can be obtained through actual online measurement values;

[0015] q m Indicates the theoretical saturated adsorption capacity of activated carbon (mg / g). This data can be obtained based on the type of activated carbon and the parameters provided by the supplier;

[0016] T represents the actual temperature at this time, which is measured by a temperature sensor, and T0 is the optimal adsorption temperature of this type of activated carbon;

[0017] P i This is the real-time pressure at this time, measured by the pressure sensor, and P0 is the standard atmospheric pressure;

[0018] k j is the inhibition coefficient of the jth component on the adsorption activity of activated carbon, which is predetermined according to the interaction characteristics between each component and activated carbon, C j is the concentration of the jth component in the exhaust gas (mg / m 3 ), collected by VOCs concentration sensors and other gas component detection equipment, n is the number of components in the exhaust gas;

[0019] ω is the humidity influence coefficient, which ranges from 0.01 to 0.1 and reflects the inhibitory effect of humidity on the adsorption activity of activated carbon; H is the relative humidity of the exhaust gas, which is collected by the humidity sensor.

[0020] In order to obtain real-time data, so as to display the real-time adsorption capacity of activated carbon from multiple angles, the sensor group of the collection layer includes a weighing sensor for collecting actual adsorption amount related data, a temperature sensor for collecting temperature data, a pressure sensor for collecting pressure data, a VOCs concentration sensor for collecting gas component concentration data and a specific component gas composition detection device, and a humidity sensor for collecting humidity data.

[0021] This system utilizes a multi-parameter comprehensive evaluation mechanism to construct an activated carbon activity evaluation formula. Key indicators, such as adsorption capacity, temperature, pressure, gas composition, and humidity, are integrated into a dynamic quantitative model. This overcomes the ambiguity inherent in traditional empirical judgments and enables real-time, millisecond-level assessment of activated carbon adsorption performance. Compared to traditional methods that rely on manual observation of pressure gauges and empirical estimation of replacement cycles, the adsorption efficiency calculation error is as low as ±5%, providing a scientific basis for precise control of the adsorption process.

[0022] Through the display layer, managers can access the A-value dynamic curve, VOCs concentration heat map, and multi-parameter trend analysis for all devices in real time to develop predictive maintenance strategies. This strategy abandons the traditional extensive model of "periodic replacement + emergency repair" and automatically generates maintenance work orders that include optimal replacement time windows and parameter adjustment priorities by analyzing data characteristics such as the A-value decay rate, pressure difference mutation frequency, and humidity-adsorption capacity correlation. Adopting this model can reduce enterprise maintenance costs by 35%, increase equipment effective operating time by 28%, and maintain a stable average VOCs removal rate above 92%, achieving dual optimization of economic and environmental benefits.

[0023] In order to issue a warning to the display layer in a timely manner and prevent the problem of VOCs gas emission caused by insufficient activation capacity of activated carbon, the application layer evaluates the adsorption efficiency of the activated carbon adsorption device based on the activated carbon activity evaluation index A. When A is lower than 120% of the preset threshold, the temperature, humidity or pressure value is adjusted until A reaches 120% of the preset threshold. If the real-time data of A cannot be improved by adjusting the temperature, humidity or pressure value, an alarm of insufficient activated carbon activity is issued to the display layer.

[0024] At the same time, in order to further improve the life of the activated carbon adsorption device, the activated carbon is operated at the optimal activity temperature as much as possible. When A exceeds the preset health value, it is determined whether the difference between the real-time temperature T and T0 is too large. If the difference is too large, the T value is adjusted.

[0025] This device can also be further developed into an activated carbon life prediction system, that is, the application layer combines the activated carbon activity evaluation index A with the device operation time. When the activity evaluation index A steadily decreases, a function fitting is performed, and the estimated time for the activated carbon to reach a preset threshold is obtained based on the fitted function. By outputting the estimated time, the service life of the activated carbon adsorption system is obtained, and a replacement recommendation is issued to the display layer.

[0026] At the same time, a yellow warning is issued when the activated carbon activity evaluation index A reaches 150% of the preset threshold, and a red warning is issued when A is lower than 120% of the preset threshold and the VOCs emission concentration at the outlet is close to the emission standard.

[0027] For the convenience of management, the display layer has a report generation function, which regularly generates information including activated carbon activity evaluation index A, device operation time, VOCs emission concentration, and activated carbon adsorption capacity.

[0028] Beneficial effects:

[0029] By leveraging the Internet of Things and big data technologies, we can improve regulatory accuracy and transparency, achieving the integration of "digital government" and "green governance." This reduces the frequency of manual inspections and lowers the human and financial costs of daily monitoring, effectively helping regulatory authorities gain real-time insights into VOC emissions within their jurisdictions and enabling more scientific and effective oversight.

[0030] Through a multi-level architecture and multi-dimensional functional integration, this system addresses the limitations of traditional activated carbon adsorption devices, often characterized by limited monitoring and extensive management. It achieves a closed-loop process from data collection and intelligent analysis to early warning and disposal. Compared to existing technologies, this innovative system integrates the dual needs of government regulation and enterprise operations. Through dynamic threshold management, lifespan prediction models, and visual monitoring tools, it significantly enhances the scientific and economic efficiency of VOCs management, promising broad industry applications. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a schematic diagram of the architecture of the intelligent monitoring cloud service platform for activated carbon adsorption devices;

[0032] Figure 2 This is the change diagram of the activated carbon activity index A when the adjustment mechanism is not introduced;

[0033] Figure 3 This is a graph showing changes in the activated carbon activity index A when the adjustment mechanism is introduced. DETAILED DESCRIPTION

[0034] In order to deepen the understanding of the present invention, the present invention will be further described in detail below with reference to embodiments and drawings. The embodiments are only used to explain the present invention and do not constitute a limitation on the scope of protection of the present invention.

[0035] Example 1:

[0036] A management system based on real-time monitoring and online calculation of activated carbon adsorption capacity. The system constructs a five-layer architecture consisting of collection layer, network layer, data center layer, application layer and display layer, and collects device operation data in real time through multiple sensors.

[0037] The collection layer is used to collect real-time operating data of the activated carbon adsorption device. The network layer transmits the collected data to the application layer. The application layer transmits the calculation results to the display layer in real time and gives corresponding suggestions.

[0038] Among them, in the application layer, the A value is used to represent the activated carbon activity evaluation index. The larger the value, the higher the activated carbon adsorption activity. The calculation formula of the A value is as follows:

[0039]

[0040] Among them, σ is the adsorption capacity influence coefficient, and its value range is 0.9; γ is the temperature influence coefficient, and its value range is 0.06; δ is the temperature correction coefficient, and its value range is 1.

[0041] like Figure 1 As shown in the figure, when no adjustment mechanism is introduced, the activated carbon activity index A value changes with usage time, showing a trend of first rising and then falling. This overall decline is subject to slight changes as the adsorption capacity and temperature change. Through real-time function fitting, the service life of the activated carbon can be easily predicted.

[0042] Figure 2After the adjustment mechanism is introduced, when A is lower than 120% of the preset threshold, the temperature, humidity or pressure value is adjusted until A reaches 120% of the preset threshold. It can be seen from the figure that after the adjustment mechanism is introduced, the service life of the activated carbon can be effectively extended until the adsorption capacity can no longer be improved by adjusting the parameters. The activated carbon activity index A will further decrease. At this time, the life prediction system will also issue a warning signal in time to prompt relevant users to replace the activated carbon in time.

[0043] Since the system was put into operation, precise control of the activated carbon replacement cycle has effectively avoided excessive VOC emissions due to activated carbon saturation. For example, in a chemical industrial park, the system's implementation has boosted the average VOC emission reduction rate for enterprises within the park to over 90%. VOC concentrations in the regional atmosphere have been significantly reduced, effectively curbing the formation of ozone pollution and playing a significant role in improving regional air quality and protecting the health of residents.

[0044] At the same time, this system promotes innovation in environmental supervision models, enhances the credibility and authority of government environmental law enforcement, helps companies improve their environmental compliance, reduces the negative social impact caused by environmental violations, and promotes harmonious development between companies and surrounding communities.

[0045] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. A management system based on real-time monitoring and online calculation of activated carbon adsorption capacity, characterized in that: Includes collection layer, network layer, data center layer, application layer and presentation layer; The application layer includes management-oriented modules for online monitoring, intelligent analysis, forecasting, abnormal alarms, file management, statistical reports, on-site verification, and tracking processing, as well as enterprise-oriented modules for file maintenance, operation analysis, device monitoring, and activated carbon replacement. The display layer includes WeChat mini-programs, large detection screens, platform portals, enterprise dashboards, and 3D maps; The network layer is based on 4G, WiFi, industrial Internet dedicated lines and other communication methods, and encrypts and transmits the data of the collection layer to the data center to ensure data security and real-time performance; The data center layer uses cloud computing and big data technologies to clean, store and process raw data, and provide computing power, algorithms and data support.

2. The management system based on real-time monitoring and online calculation of activated carbon adsorption capacity according to claim 1, characterized in that: The sensor group of the collection layer includes a weighing sensor for collecting actual adsorption data, a temperature sensor for collecting temperature data, a pressure sensor for collecting pressure data, a VOCs concentration sensor for collecting gas component concentration data and a specific component gas composition detection device, and a humidity sensor for collecting humidity data; The collection layer is used to collect real-time operating data of the activated carbon adsorption device. The network layer transmits the collected data to the application layer, and the application layer analyzes the activity evaluation index A of the activated carbon using the following formula; Among them, σ is the adsorption capacity influence coefficient, γ is the temperature influence coefficient, δ is the temperature correction coefficient, and ω is the humidity influence coefficient; q e Indicates the actual adsorption capacity of activated carbon, q m represents the theoretical saturated adsorption capacity of activated carbon, T represents the actual temperature at this time, which is measured by a temperature sensor, T0 is the optimal adsorption temperature of this type of activated carbon, P i is the real-time pressure at this time, P0 is the standard atmospheric pressure, k j is the inhibition coefficient of the jth component on the adsorption activity of activated carbon, C j is the concentration of the jth component in the exhaust gas, n is the number of components in the exhaust gas, and H is the relative humidity of the exhaust gas.

3. The management system based on real-time monitoring and online calculation of activated carbon adsorption capacity according to claim 2, characterized in that: The application layer evaluates the adsorption efficiency of the activated carbon adsorption device based on the activated carbon activity evaluation index A. When A is lower than a preset threshold of 120%, the temperature, humidity or pressure value is adjusted until A reaches 120% of the preset threshold. If the real-time data of A cannot be improved by adjusting the temperature, humidity or pressure value, an alarm of insufficient activated carbon activity is issued to the display layer.

4. The management system based on real-time monitoring and online calculation of activated carbon adsorption capacity according to claim 3 is characterized in that: When A exceeds the preset health value, it is determined whether the difference between the real-time temperature T and T0 is too large. If the difference is too large, the T value is adjusted.

5. The management system based on real-time monitoring and online calculation of activated carbon adsorption capacity according to claim 3, characterized in that: The application layer combines the activated carbon activity evaluation index A with the device operation time. When the activity evaluation index A steadily decreases, a function fitting is performed, and the estimated time for the activated carbon to reach the preset threshold is obtained based on the fitted function. By outputting the estimated time, the service life of the activated carbon adsorption system is obtained, and a replacement recommendation is issued to the display layer.

6. The management system based on real-time monitoring and online calculation of activated carbon adsorption capacity according to claim 3, characterized in that: When the activated carbon activity evaluation index A reaches 150% of the preset threshold, a yellow warning is issued.

7. The management system based on real-time monitoring and online calculation of activated carbon adsorption capacity according to claim 6, characterized in that: When A is lower than 120% of the preset threshold and the VOCs emission concentration at the outlet is close to the emission standard, a red warning is issued.

8. The management system based on real-time monitoring and online calculation of activated carbon adsorption capacity according to any one of claims 3 to 7, characterized in that: The display layer has the function of generating reports, which regularly generates information including activated carbon activity evaluation index A, device operation time, VOCs emission concentration, and activated carbon adsorption capacity.

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