Multi-stage dynamic compensation sulfuric acid dilution cooling control system and method

Abstract

The invention discloses a multistage dynamic compensation sulfuric acid dilution and cooling control system. The system comprises a concentrated acid storage module, a mixing module, a cooling module, a secondary mixing module, a control module and a dilute acid storage module. According to the invention, the mixing module adopts a jet mixer to realize rapid preliminary mixing of concentrated sulfuric acid and clear water, the turbulence degree is enhanced through the mixing strengthening unit, and the mixing uniformity is obviously improved; the cooling module realizes high-efficiency heat transfer through a fractal tree-shaped micro-channel substrate of the phase change micro-channel cooling unit, and forms complete cooling circulation in cooperation with working medium circulation phase change heat absorption of a phase change working medium circulation system and working medium steam liquefaction backflow of a condenser; the second-stage mixing module is used for carrying out accurate concentration correction on dilute acid which does not reach the standard through a stirring device in a second-stage mixing tank, a clear water supplementing pipe and a concentrated acid supplementing pipe; the control module monitors the state of the system in real time through a temperature sensor and a concentration detection device, and a compensation control unit executes a three-level dynamic compensation strategy to ensure stable operation of the system.

Description

Technical Field

[0001] This invention relates to the field of sulfuric acid concentration technology, and in particular to a multi-level dynamic compensation sulfuric acid dilution cooling control system and method. Background Technology

[0002] In the production of silica gel desiccants, the control of the temperature and concentration of dilute sulfuric acid directly affects product quality. Traditional methods of diluting and cooling concentrated sulfuric acid have many serious drawbacks, impacting production efficiency and product quality. Specifically, traditional dilution processes typically rely on simple mixers, which struggle to achieve thorough and uniform mixing of concentrated sulfuric acid and water, leading to uneven concentrations and unstable temperatures. This not only affects product quality but may also cause safety hazards such as localized overheating due to dilution heat. Furthermore, simple mixers cannot effectively control the temperature during dilution, resulting in significant temperature fluctuations in the dilute sulfuric acid, which is detrimental to the stable operation of subsequent processes. Regarding cooling, traditional methods rely primarily on natural cooling, which is slow and cannot meet the demands for rapid temperature regulation in production, leading to extended production cycles. In addition, due to the low efficiency of natural cooling, companies need to equip themselves with numerous dilute sulfuric acid storage tanks to meet storage needs at different stages. This not only increases operating costs and space requirements but also introduces significant storage leakage risks, posing threats to the environment and personnel safety. Simultaneously, the large number of storage tanks complicates management, increasing operational difficulty and the probability of errors. Overall, traditional dilution and cooling methods have significant shortcomings in terms of energy utilization efficiency, production efficiency, product quality stability, and safety, making it difficult to meet the requirements of modern industry for efficient, safe, and stable production. Summary of the Invention

[0003] In view of this, the purpose of this invention is to provide a multi-level dynamic compensation sulfuric acid dilution cooling control system and method.

[0004] To achieve the above-mentioned technical objectives, the technical solution adopted by this invention is as follows:

[0005] A multi-stage dynamically compensated sulfuric acid dilution and cooling control system includes a concentrated acid storage module, a mixing module, a cooling module, a secondary mixing module, a control module, and a dilute acid storage module. The concentrated acid storage module stores concentrated sulfuric acid and includes an insulated storage tank, a liquid level monitoring device, and a flow pipeline. The liquid level monitoring device is located inside the insulated storage tank, and the flow pipeline contains a concentrated acid flow meter and a first liquid pump. The mixing module mixes water and concentrated acid and is connected to the concentrated acid storage module via the flow pipeline. The mixing module includes a jet mixer, a mixing enhancement unit, and a water inlet pipe. The mixing enhancement unit is located downstream of the jet mixer and is coaxially arranged with it. The water inlet pipe communicates with the jet mixer and contains a water flow meter and a second liquid pump. The cooling module performs heat exchange and is connected to the mixing module. At the outlet end of the block, the cooling module includes a phase change microchannel cooling unit, a phase change working fluid circulation system, and a condenser. The phase change microchannel cooling unit has a fractal tree-shaped microchannel substrate. The phase change working fluid circulation system is connected to the microchannel substrate, and the condenser is connected to the phase change working fluid circulation system. The secondary mixing module is used to correct the concentration of fine-grained solutions that do not meet the concentration standard. The secondary mixing module includes a secondary mixing tank, a stirring device, a clean water replenishment pipe, and a concentrated acid replenishment pipe. The secondary mixing tank is located between the cooling module and the dilute acid storage module. A stirring device is installed inside the secondary mixing tank. The secondary mixing tank is connected to both the clean water replenishment pipe and the concentrated acid replenishment pipe. The control module is connected to the concentrated acid storage module, the mixing module, the cooling module, and the secondary mixing module. It includes a temperature sensor, a concentration detection device, and a compensation control unit. The temperature sensor is located at the outlet end of the mixing module. The concentration detection device is located at the outlet end of the cooling module. The dilute acid storage module is connected to the outlet end of the cooling module.

[0006] In some embodiments, the phase change microchannel cooling unit includes a microchannel substrate, a sealing cover, and turbulence fins. The surface of the microchannel substrate is etched with fractal tree-like flow channels. The sealing cover is detachably connected to the microchannel substrate via a gasket. The turbulence fins are disposed inside the microchannel.

[0007] In some embodiments, the phase change working fluid circulation system includes a storage tank, a vacuum injection device, and a reflux pipe. The vacuum injection device connects the storage tank to the microchannel substrate, and the reflux pipe connects the condenser to the vacuum injection device. A liquid pump is installed on the reflux pipe.

[0008] In some embodiments, the condenser includes a shell, a cooling water storage tank, a cooling water inlet pipe, a condensation chamber, a dilute acid flow channel, and a cooling water outlet pipe. The shell has a rib structure inside; the cooling water inlet pipe is connected to one end of the chilled water storage tank; the condensation chamber is located inside the shell; the dilute acid flow channel has a condensation chamber outside; and the cooling water outlet pipe connects the condensation chamber and the cooling water storage tank.

[0009] In some embodiments, the secondary mixing module further includes a clean water replenishment valve and a concentrated acid replenishment valve, wherein the clean water replenishment valve is connected to a clean water replenishment pipe; and the concentrated acid replenishment valve is connected to a concentrated acid replenishment pipe.

[0010] In some embodiments, the control module further includes an infrared scanning device, a partition controller, and a safety interlock unit. The infrared scanning device is disposed facing the surface of the microchannel substrate; the partition controller is communicatively connected to the infrared scanning device; and the safety interlock unit is used to respond to a signal from the concentration detection device and is communicatively connected to the concentration detection device signal.

[0011] In a second aspect, the present invention also provides a multi-level dynamic compensation method for sulfuric acid dilution cooling control, comprising the following steps:

[0012] S1. Concentrated acid and water are initially mixed by a jet mixer and then enter the mixing enhancement unit for further mixing.

[0013] S2. The mixture of concentrated acid and water flows through the cooling module for heat exchange;

[0014] S3. The control module monitors the temperature and concentration at the outlet of the cooling module in real time.

[0015] S4. The mixed and cooled dilute acid flows to the dilute acid storage module.

[0016] In some embodiments, step S3 includes three levels of compensation control:

[0017] S31, First-level temperature compensation: When the detected temperature exceeds the set threshold, reduce the concentrated acid feed flow rate;

[0018] S32, Second-level concentration compensation: When the detected concentration deviates from the target value, correction is initiated;

[0019] S33, the third-level cooling power compensation, dynamically adjusts the condensate flow rate based on real-time temperature and concentration.

[0020] In some embodiments, step S32 includes:

[0021] S321. When the concentration sensor detects that the concentration of dilute acid is too high, the clean water replenishment valve is opened through the safety interlock unit.

[0022] S322. When the concentration sensor detects that the concentration of dilute acid is too low, the concentrated acid replenishment valve is opened through the safety interlock unit.

[0023] S323. After adding water or concentrated acid, mix with a stirring device and retest the concentration.

[0024] In some embodiments, step S33 includes:

[0025] S331. Based on the temperature distribution data obtained by the infrared scanning device;

[0026] S332, the zone controller enhances the working fluid circulation intensity in high-temperature areas;

[0027] S333, the zone controller maintains basic cooling power in low-temperature areas.

[0028] By adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0029] Unlike existing technologies, the multi-level dynamic compensation sulfuric acid dilution and cooling control system in the above-mentioned technical solution includes a concentrated acid storage module, a mixing module, a cooling module, a secondary mixing module, a control module, and a dilute acid storage module. This invention ensures the safe storage and accurate metering of concentrated sulfuric acid through an insulated storage tank and a liquid level monitoring device. The mixing module uses a jet mixer to achieve rapid initial mixing of concentrated sulfuric acid and water, and enhances turbulence through a mixing enhancement unit, significantly improving mixing uniformity. The cooling module achieves efficient heat transfer through the fractal tree-shaped microchannel substrate of the phase change microchannel cooling unit, forming a complete cooling cycle in conjunction with the working fluid circulation system's phase change heat absorption and the condenser's working fluid vapor liquefaction and reflux. The secondary mixing module uses a stirring device in the secondary mixing tank, as well as water and concentrated acid replenishment pipes, to accurately correct the concentration of substandard dilute acid. The control module monitors the system status in real time through temperature sensors and concentration detection devices, and the compensation control unit executes a three-level dynamic compensation strategy to ensure stable system operation. The dilute acid storage module reliably stores the final product acid solution. The coordinated operation of these modules achieves efficient, accurate, and stable multi-level dynamic compensation control of the sulfuric acid dilution and cooling process. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1This is an overall schematic diagram of a multi-level dynamic compensation sulfuric acid dilution and cooling control system proposed in this invention;

[0032] Figure 2 This is a partial structural schematic diagram of a multi-level dynamic compensation sulfuric acid dilution cooling control system proposed in a specific embodiment of the present invention;

[0033] Figure 3 This is a schematic diagram of the specific structure of the cooling module proposed in a specific embodiment of the present invention;

[0034] Figure 4 This is a schematic diagram of the control module structure proposed in a specific embodiment of the present invention;

[0035] Figure 5 This is an example diagram illustrating the method applicable to a multi-level dynamic compensation sulfuric acid dilution cooling control system according to the present invention;

[0036] Figure 6 This is an example diagram of the three-level compensation steps proposed in a specific embodiment of the present invention;

[0037] Figure 7 This is an example diagram of the second-level concentration compensation step proposed in a specific embodiment of the present invention;

[0038] Figure 8 This is an example diagram of the third-level cooling power compensation step proposed in a specific embodiment of the present invention.

[0039] Figure label:

[0040] 1. Concentrated acid storage module; 11. Insulated storage tank; 12. Liquid level monitoring device; 13. Flow pipeline; 131. Concentrated acid flow meter; 132. First liquid pump; 2. Mixing module; 21. Jet mixer; 22. Mixing enhancement unit; 23. Clean water inlet pipeline; 231. Clean water flow meter; 232. Second liquid pump; 3. Cooling module; 31. Phase change microchannel cooling unit; 311. Microchannel substrate; 312. Sealing cover plate; 313. Turbulence fins; 32. Phase change working fluid circulation system; 321. Storage tank; 322. Vacuum filling device; 323. Return pipe; 324. Pumping unit. 33. Pump; 334. Condenser; 335. Shell; 336. Cooling water storage tank; 337. Cooling water inlet pipe; 338. Condensation chamber; 339. Dilute acid flow channel; 330. Cooling water outlet pipe; 4. Secondary mixing module; 41. Secondary mixing tank; 42. Stirring device; 43. Clean water replenishment pipe; 44. Concentrated acid replenishment pipe; 45. Clean water replenishment valve; 46. Concentrated acid replenishment valve; 5. Control module; 51. Temperature sensor; 52. Concentration detection device; 53. Compensation control unit; 54. Infrared scanning device; 55. Zone controller; 56. Safety interlock unit; 6. Dilute acid storage module. Detailed Implementation

[0041] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be particularly noted that the following embodiments are for illustrative purposes only and do not limit the scope of the invention. Similarly, the following embodiments are only some, not all, embodiments of the present invention, and all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] Please see Figure 1-4 A multi-stage dynamically compensated sulfuric acid dilution and cooling control system includes a concentrated acid storage module 1, a mixing module 2, a cooling module 3, a secondary mixing module 4, a control module 5, and a dilute acid storage module 6. The concentrated acid storage module 1 stores concentrated sulfuric acid and includes an insulated storage tank 11, a liquid level monitoring device 12, and a flow pipe 13. The liquid level monitoring device 12 is located inside the insulated storage tank 11. The flow pipe 13 is equipped with a concentrated acid flow meter 131 and a first liquid pump 132. The mixing module 2 is used to mix water and concentrated acid. 2. The mixing module 2 is connected to the concentrated acid storage module 1 via a flow pipe. The mixing module 2 includes a jet mixer 21, a mixing enhancement unit 22, and a clean water inlet pipe 23. The mixing enhancement unit 22 is located downstream of the jet mixer 21 and is coaxially arranged with the jet mixer 21. The clean water inlet pipe 23 communicates with the jet mixer 21 and contains a clean water flow meter 231 and a second liquid pump 232. The cooling module 3 is used for heat exchange and is connected to the outlet end of the mixing module 2. Module 3 includes a phase change microchannel cooling unit 31, a phase change working fluid circulation system 32, and a condenser 33. The phase change microchannel cooling unit 31 has a fractal tree-shaped microchannel substrate 311. The phase change working fluid circulation system 32 is connected to the microchannel substrate 311, and the condenser 33 is connected to the phase change working fluid circulation system 32. The secondary mixing module 4 is used to correct the concentration of fine-grained solutions that do not meet the concentration standards. The secondary mixing module 4 includes a secondary mixing tank 41, a stirring device 42, a clean water replenishment pipe 43, and a concentrated acid replenishment pipe 44. The secondary mixing tank 41 is located in the cooling module. Between the secondary mixing tank 41 and the dilute acid storage module 6, a stirring device 42 is installed inside the secondary mixing tank 41. The secondary mixing tank 41 is connected to a clean water replenishment pipe 43 and a concentrated acid replenishment pipe 44. The control module 5 is connected to the concentrated acid storage module 1, the mixing module 2, the cooling module 3 and the secondary mixing module 4. It includes a temperature sensor 51, a concentration detection device 52 and a compensation control unit 53. The temperature sensor 51 is located at the outlet end of the mixing module 2. The concentration detection device 52 is located at the outlet end of the cooling module 3. The dilute acid storage module 6 is connected to the outlet end of the cooling module 3.

[0043] In this embodiment, the concentrated acid storage module 1 refers to an acid storage unit equipped with an insulated storage tank 11. The tank is equipped with a liquid level monitoring device 12 for real-time monitoring of the concentrated sulfuric acid storage. The mixing module 2 is connected to the concentrated acid storage module 1 through a flow pipe and includes a jet mixer 21 and a mixing enhancement unit 22. The jet mixer 21 is a device that uses a high-speed jet to achieve liquid-liquid mixing and is used to initially mix concentrated sulfuric acid with water. The mixing enhancement unit 22 is coaxially arranged downstream of the jet mixer 21 to enhance the fluid turbulence and improve the mixing uniformity. The cooling module 3 is connected to the outlet of the mixing module 2 and includes a phase change microchannel cooling unit 31, a phase change working fluid circulation system 32, and a condenser 33. The phase change microchannel cooling unit 31 refers to a heat exchange structure with a fractal tree-shaped microchannel substrate 311 for achieving efficient heat transfer. The phase change working fluid circulation system 32 is connected to the microchannel substrate 311 for working fluid circulation phase change heat absorption. The condenser 33 is connected to the working fluid circulation system for working fluid vapor liquefaction and reflux. The secondary mixing module 4 includes a secondary mixing tank 41 and its internal stirring device 42. This module is located between the cooling module 3 and the dilute acid storage module 6. It achieves fine-tuning of concentration through a clean water replenishment pipe 43 and a concentrated acid replenishment pipe 44, and is used to correct the concentration of dilute acid that does not meet the standards. The control module 5 is connected to each functional module. Its temperature sensor 51 is located at the outlet of the mixing module 2, and its concentration detection device 52 is located at the outlet of the cooling module 3. The compensation control unit 53 is used to execute a three-level dynamic compensation strategy. The dilute acid storage module 6 is connected to the outlet of the cooling module 3 and is used to store the final product acid solution. This system achieves multi-level dynamic compensation control of the dilution and cooling process through modular collaborative operation.

[0044] In this embodiment, the concentrated acid storage module 1 ensures the safe storage and accurate metering of concentrated sulfuric acid through the insulated storage tank 11 and the liquid level monitoring device 12; the mixing module 2 uses a jet mixer 21 to achieve rapid initial mixing of concentrated sulfuric acid and water, and enhances the turbulence through the mixing enhancement unit 22, significantly improving the mixing uniformity; the cooling module 3 achieves efficient heat transfer through the fractal tree-shaped microchannel substrate 311 of the phase change microchannel cooling unit 31, and forms a complete cooling cycle in conjunction with the working fluid circulation system 32 for working fluid circulation phase change heat absorption and the working fluid vapor liquefaction and reflux of the condenser 33; the secondary mixing module 4 performs accurate concentration correction of substandard dilute acid through the stirring device 42 in the secondary mixing tank 41 and the water replenishment pipe 43 and concentrated acid replenishment pipe 44; the control module 5 monitors the system status in real time through the temperature sensor 51 and the concentration detection device 52, and the compensation control unit 53 executes a three-level dynamic compensation strategy to ensure stable system operation; the dilute acid storage module 6 reliably stores the final finished acid solution. The coordinated operation of each module realizes efficient, accurate and stable multi-level dynamic compensation control of the sulfuric acid dilution and cooling process.

[0045] Furthermore, in some embodiments, the phase change microchannel cooling unit 31 includes a microchannel substrate 311, a sealing cover plate 312, and turbulence fins 313. The surface of the microchannel substrate 311 is etched with fractal tree-like flow channels; the sealing cover plate 312 is detachably connected to the microchannel substrate 311 via a gasket; and the turbulence fins 313 are disposed inside the microchannel.

[0046] In this embodiment, the phase change microchannel cooling unit 31 refers to a device for achieving efficient heat exchange, comprising three main components: a microchannel substrate 311, a sealing cover 312, and turbulence fins 313. The microchannel substrate 311 is a metal substrate with fractal tree-like flow channels etched on its surface. These fractal tree-like flow channels are microchannel networks with multi-level branching structures designed using biomimetic principles, used to increase the heat exchange area and optimize the fluid flow path. The sealing cover 312 is a metal cover plate used in conjunction with the microchannel substrate 311, forming a detachable connection with the microchannel substrate 311 through elastic gaskets. This detachable connection refers to a sealed connection structure achieved by bolt fastening, facilitating maintenance and cleaning. The turbulence fins 313 are micro-protrusion structures disposed inside the microchannels, used to disrupt the fluid boundary layer and enhance turbulence, thereby improving heat exchange efficiency. The phase change microchannel cooling unit 31 achieves uniform fluid distribution through fractal tree-like flow channels, enhances heat transfer with turbulence fins 313, and ensures system sealing with a sealing cover plate 312, together forming a highly efficient and reliable heat exchange device.

[0047] In this embodiment, the phase change microchannel cooling unit 31 optimizes the fluid flow path and significantly increases the heat exchange area through fractal tree-like flow channels etched on the surface of the microchannel substrate 311. Meanwhile, the sealing cover 312, with its detachable connection formed by elastic gaskets, ensures the device's airtightness and ease of maintenance. Furthermore, the turbulence-inducing fins 313 located inside the microchannel effectively disrupt the fluid boundary layer and enhance turbulence, thereby significantly improving heat exchange efficiency. Through the synergistic effect of the fractal tree-like flow channels, the sealing cover 312, and the turbulence-inducing fins 313, the phase change microchannel cooling unit 31 ensures uniform fluid distribution, enhances heat transfer, and maintains the system's airtight reliability, ultimately forming a highly efficient, stable, and easy-to-maintain heat exchange device.

[0048] Furthermore, in this embodiment, the phase change working fluid circulation system 32 includes a storage tank 321, a vacuum injection device 322, and a reflux pipe 323. The vacuum injection device 322 connects the storage tank 321 to the microchannel substrate 311, and the reflux pipe connects the condenser 33 to the vacuum injection device 322. A liquid pump 324 is provided on the reflux pipe 323.

[0049] In this embodiment, the phase change working fluid circulation system 32 refers to the key subsystem for realizing the phase change of the working fluid, including two main components: a storage tank 321 and a vacuum filling device 322. The storage tank 321 is a sealed container used to store the phase change working fluid, made of corrosion-resistant material, to ensure the stability and safety of the working fluid during circulation. The vacuum filling device 322 is a dedicated device connecting the storage tank 321 and the microchannel substrate 311. This device establishes a negative pressure environment to transport the working fluid from the storage tank 321 to the microchannel substrate 311, enabling efficient filling and circulation of the working fluid. The special design of the vacuum filling device 322 prevents the generation of air bubbles in the working fluid during filling, thereby ensuring the stability and heat exchange efficiency of the phase change process. The phase change working fluid circulation system 32, through the coordinated operation of the storage tank 321 and the vacuum filling device 322, ensures both reliable storage of the working fluid and efficient circulation of the working fluid within the system, providing a stable phase change heat transfer function for the entire cooling system. Furthermore, the working fluid mentioned in this embodiment is a low-boiling-point organic working fluid, such as perfluorohexanone compounds. The selection of the working fluid is based on the thermophysical properties and chemical stability of the reference material, with a boiling point range of 49-55℃, a matching dilute acid cooling temperature range of 60-100℃, and a high latent heat of vaporization ≥110kJ / kg. To achieve efficient heat absorption, the working fluid needs to have low viscosity to improve the fluidity within the microchannel. At the same time, the working fluid needs to be inert and not react with metals, and it needs to be non-flammable and non-explosive to meet the safety requirements of hazardous chemical working conditions. Its heat exchange working principle is based on the liquid-gas phase change latent heat transfer mechanism. The heat of dilute acid is conducted to the working fluid through the inner wall surface of the microchannel substrate 311. After being heated, the working fluid absorbs latent heat and changes from liquid to gas. The pressure difference of vapor expansion pushes the working fluid to flow towards the condenser. Then, through the power of the return pipe 323 and the liquid pump 324, the liquid working fluid returns to the storage tank 321.

[0050] In this embodiment, the phase change working fluid circulation system 32 ensures the safe and stable storage of the working fluid through the sealed and corrosion-resistant characteristics of the storage tank 321. Simultaneously, the vacuum filling device 322 establishes a negative pressure environment to achieve efficient, bubble-free transport of the working fluid from the storage tank 321 to the microchannel substrate 311. This unique system design ensures both the stability of the working fluid circulation process and maintains high efficiency in phase change heat transfer. The coordinated operation of the storage tank 321 and the vacuum filling device 322 not only achieves reliable storage and precise transport of the working fluid but also provides a continuous and stable phase change heat transfer function for the entire cooling system, thereby significantly improving the overall performance of the system.

[0051] Furthermore, in some embodiments, the condenser 33 includes a shell 331, a cooling water storage tank 332, a cooling water inlet pipe 333, a condensation chamber 334, a dilute acid flow channel 335, and a cooling water outlet pipe 336. The shell 331 is provided with a rib structure inside; the cooling water inlet pipe 333 is connected to one end of the chilled water storage tank 332; the condensation chamber 334 is disposed inside the shell 331; the dilute acid flow channel 335 is provided with the condensation chamber 334 outside; and the cooling water outlet pipe 336 connects the condensation chamber and the cooling water storage tank.

[0052] In this embodiment, the condenser 33 refers to the key device for realizing heat exchange between dilute acid and cooling water, including six core components: shell 331, cooling water storage tank 332, cooling water inlet pipe 333, condensation chamber 334, dilute acid flow channel 335, and cooling water outlet pipe 336. The shell 331 is a metal container forming the external frame of the condenser 33, and its internal rib structure refers to metal heat sinks with a specific geometric arrangement to increase the heat exchange contact area. The cooling water storage tank 332 is a pressure-resistant container for temporarily storing cooling water to stabilize the cooling water supply pressure. The cooling water inlet pipe 333 is a conveying channel connecting the cooling water storage tank 332 and the condensation chamber 334, used to introduce cooling water into the heat exchange area. The condensation chamber 334 is a sealed space surrounding the dilute acid flow channel 335, used to contain cooling water and realize heat transfer. The dilute acid flow channel 335 is a corrosion-resistant pipe penetrating the condensation chamber 334, used to transport the dilute acid to be cooled, and its exterior is wrapped by the condensation chamber 334 to achieve all-round heat exchange. The cooling water outlet pipe 336 is a return channel connecting the condenser chamber 334 and the cooling water storage tank 332, used to guide the heated cooling water back to the storage tank 321. The condenser 33 enhances heat dissipation through a finned structure, and in conjunction with the nested design of the dilute acid flow channel 335 and the condenser chamber 334, it achieves efficient counter-current heat exchange between the dilute acid and the cooling water. At the same time, the cooling water inlet pipe 333 and the cooling water outlet pipe 336 form a closed loop to ensure the recycling of the cooling medium. Furthermore, the condenser 33 cools the phase change working fluid. The vaporized working fluid comes into contact with the outer surface of the cooling chamber 334, and the temperature difference drives heat transfer. The working fluid releases its latent heat of vaporization and condenses into a liquid state. The liquefied working fluid then returns to the storage tank 321 for recycling.

[0053] In this embodiment, the condenser 33 significantly increases the heat exchange contact area through the finned structure inside the shell 331; the cooling water storage tank 332 ensures stable cooling water supply pressure; the cooling water inlet pipe 333 precisely guides the cooling water into the condensing chamber 334; the condensing chamber 334 forms a closed heat exchange space around the dilute acid flow channel 335, realizing all-round heat transfer between the dilute acid and the cooling water; the dilute acid flow channel 335 serves as a corrosion-resistant transport channel to ensure the safety of the medium; and the cooling water outlet pipe 336 forms a closed loop to realize the recycling of the cooling medium. This condenser 33 achieves efficient counter-current heat exchange through finned heat dissipation and a nested flow channel design, combined with a closed-loop cooling system to achieve efficient energy utilization, comprehensively optimizing heat exchange efficiency and operational stability.

[0054] Furthermore, in some embodiments, the secondary mixing module 4 also includes a clean water replenishment valve 45 and a concentrated acid replenishment valve 46, with the clean water replenishment valve 45 connected to the clean water replenishment pipe 43 and the concentrated acid replenishment valve 46 connected to the concentrated acid replenishment pipe 44.

[0055] In this embodiment, the secondary mixing module 4 refers to a functional unit used for precise correction of the dilute acid concentration, which includes two key components: a clean water replenishment valve 45 and a concentrated acid replenishment valve 46. The clean water replenishment valve 45 is a control valve installed on the clean water replenishment pipe 43, used to adjust the clean water replenishment amount. When the dilute acid concentration is detected to be too high, this valve opens to replenish an appropriate amount of clean water. The concentrated acid replenishment valve 46 is a regulating device installed on the concentrated acid replenishment pipe 44, used to control the concentrated acid replenishment flow rate. When the dilute acid concentration is too low, this valve activates to replenish the required concentrated acid. The clean water replenishment pipe 43 is a conveying pipe connecting the clean water source and the secondary mixing tank 41, used to introduce clean water into the mixing system. The concentrated acid replenishment pipe 44 is a conveying channel connecting the concentrated acid source and the secondary mixing tank 41, used to transport concentrated acid to the mixing area. These two replenishment valves, by independently controlling the replenishment amounts of clean water and concentrated acid, can achieve precise adjustment of the dilute acid concentration. The secondary mixing module 4, through the coordinated operation of the clean water replenishment valve 45 and the concentrated acid replenishment valve 46, ensures both the accuracy of concentration adjustment and the stability of system operation, providing a reliable concentration correction function for the entire dilution and cooling process.

[0056] In this embodiment, the secondary mixing module 4 achieves bidirectional precise adjustment of the dilute acid concentration through independent control of the water replenishment valve 45 and the concentrated acid replenishment valve 46. When the dilute acid concentration is detected to be too high, the water replenishment valve 45 opens to add an appropriate amount of water; when the dilute acid concentration is too low, the concentrated acid replenishment valve 46 activates to add the required concentrated acid. The water replenishment pipe 43 and the concentrated acid replenishment pipe 44 serve as the delivery channels for water and concentrated acid, respectively, ensuring that the replenishment medium can be accurately delivered to the mixing area. Through the coordinated operation of the two replenishment valves, this module ensures both the accuracy of concentration adjustment and the stability of system operation, providing a reliable concentration correction function for the entire dilution and cooling process, thereby ensuring that the final dilute acid product can reach the expected concentration requirements.

[0057] Furthermore, in some embodiments, the control module 5 further includes an infrared scanning device 54, a partition controller 55, and a safety interlock unit 56. The infrared scanning device 54 is disposed facing the surface of the microchannel substrate 311; the partition controller 55 is communicatively connected to the infrared scanning device 54; and the safety interlock unit 56 is used to respond to the signal of the concentration detection device 52 and is communicatively connected to the signal of the concentration detection device 52.

[0058] In this embodiment, the control module 5 refers to the core unit used to realize intelligent monitoring and automatic adjustment of the system, which includes three key components: an infrared scanning device 54, a zone controller 55, and a safety interlock unit 56. The infrared scanning device 54 is a detection device positioned facing the surface of the microchannel substrate 311, used to acquire real-time temperature distribution information of the microchannel substrate 311 surface. The zone controller 55 is a control unit that establishes a communication connection with the infrared scanning device 54, used to perform zoned adjustment of the cooling system based on the temperature data acquired by the infrared scanning device 54. The safety interlock unit 56 is a protection device that establishes a signal connection with the concentration detection device 52, used to trigger corresponding safety protection measures when an abnormal concentration signal is detected.

[0059] In this embodiment, the infrared scanning device 54 achieves comprehensive monitoring of the surface temperature of the microchannel substrate 311 through non-contact temperature measurement. The zone controller 55, by analyzing temperature distribution data, can independently adjust the cooling intensity of each zone. The safety interlock unit 56, by monitoring the concentration signal in real time, ensures that the system can take timely protective actions when abnormal concentrations occur. Through the coordinated operation of the infrared scanning device 54, the zone controller 55, and the safety interlock unit 56, the control module 5 achieves precise monitoring of the system's operating status and ensures the safe and reliable operation of the system, providing intelligent control and protection for the entire dilution cooling process.

[0060] Please see Figure 5-8The present invention also provides a multi-level dynamic compensation sulfuric acid dilution cooling control method, comprising the following steps: S1, concentrated acid and water are initially mixed by a jet mixer 21 and then enter a mixing enhancement unit 22 for enhanced mixing;

[0061] S2, The mixture of concentrated acid and water flows through cooling module 3 for heat exchange;

[0062] S3, Control Module 5 monitors the temperature and concentration at the outlet of Cooling Module 3 in real time;

[0063] S4. The mixed and cooled dilute acid flows to the dilute acid storage module 6.

[0064] In this embodiment, the multi-level dynamic compensation sulfuric acid dilution cooling control method refers to an optimization method for the sulfuric acid dilution cooling process through graded control. The jet mixer 21 in step S1 refers to a device that uses high-speed jets to achieve liquid-liquid mixing, used to initially mix concentrated sulfuric acid with water. The mixing enhancement unit 22 is coaxially arranged downstream of the jet mixer 21 to enhance the fluid turbulence and improve mixing uniformity. The cooling module 3 in step S2 refers to a heat exchange module that includes a phase change microchannel cooling unit 31, a phase change working fluid circulation system 32, and a condenser 33, used to achieve efficient cooling of the mixture through working fluid phase change. The control module 5 in step S3 refers to a control unit that integrates a temperature sensor 51, a concentration detection device 52, a compensation control unit 53, an infrared scanning device 54, a zone controller 55, and a safety interlock unit 56. The dilute acid storage module 6 in step S4 refers to an acid-resistant container used to store the final product, which has anti-corrosion design and liquid level monitoring function.

[0065] In this embodiment, the multi-stage dynamic compensation sulfuric acid dilution cooling control method achieves rapid initial mixing of concentrated sulfuric acid and water through the jet mixer 21, and enhances the fluid turbulence by the mixing enhancement unit 22, significantly improving the mixing uniformity. The cooling module 3 achieves efficient cooling of the mixture through the synergistic effect of the phase change microchannel cooling unit 31, the phase change working fluid circulation system 32, and the condenser 33. The control module 5 ensures accurate monitoring and adjustment of system parameters through the integrated control of the temperature sensor 51, the concentration detection device 52, the compensation control unit 53, the infrared scanning device 54, the zone controller 55, and the safety interlock unit 56. The dilute acid storage module 6 ensures the safe storage of the final product through corrosion-resistant design and liquid level monitoring function. This method achieves high efficiency, stability, and safety in the sulfuric acid dilution cooling process through multi-stage coordinated control.

[0066] Furthermore, in some embodiments, step S3 includes three levels of compensation control:

[0067] S31, First-level temperature compensation: When the detected temperature exceeds the set threshold, reduce the concentrated acid feed flow rate;

[0068] S32, Second-level concentration compensation: When the detected concentration deviates from the target value, correction is initiated;

[0069] S33, the third-level cooling power compensation, dynamically adjusts the condensate flow rate based on real-time temperature and concentration.

[0070] In this embodiment, the three-level compensation control is implemented using a compensation control unit 53. The compensation control unit 53 executes a three-level dynamic compensation strategy, which is a control strategy to optimize system parameters through graded adjustment. This includes three key steps: first-level temperature compensation, second-level concentration compensation, and third-level cooling power compensation. First-level temperature compensation refers to the control measure of reducing the concentrated acid feed flow rate by adjusting the valve when the temperature sensor 51 detects that the mixed liquid temperature exceeds a preset safety threshold, to prevent system overheating. Second-level concentration compensation refers to the control process of activating the replenishment device to correct the concentration when the concentration detection device 52 detects that the diluted sulfuric acid concentration deviates from the target range, to ensure that the product concentration accurately meets the standard. Third-level cooling power compensation refers to the control method of dynamically adjusting the cooling water flow rate by frequency-controlled adjustment of the condensate pump speed based on real-time collected temperature and concentration data, to achieve optimal heat exchange efficiency.

[0071] In this embodiment, the three-level compensation control ensures safe system operation through temperature compensation, guarantees product quality through concentration compensation, and optimizes energy utilization through cooling power compensation. The synergistic effect of these three mechanisms achieves precise multi-parameter control of the sulfuric acid dilution and cooling process, improving both system stability and process economy.

[0072] Furthermore, in some embodiments, step S32 includes:

[0073] S321. When the concentration sensor detects that the concentration of dilute acid is too high, the water replenishment valve 45 is opened through the safety interlock unit 56.

[0074] S322. When the concentration sensor detects that the concentration of dilute acid is too low, the concentrated acid replenishment valve 46 is opened through the safety interlock unit 56.

[0075] S323, after adding water or concentrated acid, mix with stirring device 42 and retest the concentration.

[0076] In this embodiment, step S32 refers to the specific implementation process of the second-level concentration compensation, including three key operational steps. In step S321, the concentration sensor is a detection device used to monitor the concentration of dilute acid in real time. When the dilute acid concentration is detected to be too high, the safety interlock unit 56 automatically opens the water replenishment valve 45. The water replenishment valve 45 is a regulating valve that controls the amount of water replenished, used to dilute the excessively high concentration of dilute acid. In step S322, when the concentration sensor detects that the dilute acid concentration is too low, the safety interlock unit 56 automatically opens the concentrated acid replenishment valve 46. The concentrated acid replenishment valve 46 is a regulating valve that controls the amount of concentrated acid replenished, used to increase the concentration of the excessively low dilute acid. In step S323, the stirring device 42 is a mechanical stirrer installed in the mixing container, used to thoroughly mix the added water or concentrated acid with the original solution. After mixing, the system automatically re-detects the concentration to ensure that the target value is reached. The concentration compensation process achieves closed-loop control of the dilute acid concentration through real-time monitoring by the concentration sensor, automatic control by the safety interlock unit 56, precise adjustment of the replenishment valve, and uniform mixing by the stirring device 42, ensuring that the final product concentration remains stable within the range required by the process.

[0077] In this embodiment, the second-stage concentration compensation accurately identifies dilute acid concentration deviations through the real-time monitoring function of the concentration sensor. When the concentration is too high, the safety interlock unit 56 automatically opens the clean water replenishment valve 45 for dilution adjustment; when the concentration is too low, the safety interlock unit 56 automatically opens the concentrated acid replenishment valve 46 to increase the concentration. Subsequently, the stirring device 42 ensures thorough mixing of the replenished medium with the original solution and automatically re-detects the concentration value. This compensation process achieves complete closed-loop control from concentration detection and deviation judgment to automatic adjustment. Through the coordinated work of the concentration sensor, safety interlock unit 56, replenishment valve, and stirring device 42, precise control of dilute acid concentration and process stability are ensured, ultimately maintaining the product concentration within the target range.

[0078] Furthermore, in some embodiments, step S33 includes:

[0079] S331. Based on the temperature distribution data obtained by the infrared scanning device 54;

[0080] S332 and zone controller 55 enhance the working fluid circulation intensity in high-temperature areas;

[0081] S333 and zone controller 55 maintain basic cooling power for low-temperature areas.

[0082] In this embodiment, step S33 refers to the specific implementation process of the third-level cooling power compensation, including three key control steps. In step S331, the infrared scanning device 54 is a detection device positioned facing the surface of the microchannel substrate 311, used to acquire real-time temperature distribution data for each region of the microchannel. In step S332, the zone controller 55 is the control unit that establishes a communication connection with the infrared scanning device 54. When a high-temperature region is detected, the controller enhances the working fluid circulation intensity in that region by adjusting the speed of the working fluid circulation pump. The working fluid circulation intensity refers to the flow rate of the working fluid flowing through the microchannel per unit time. Step S333 refers to the protection device that establishes a signal connection with the concentration detection device 52. This cooling power compensation, through the precise temperature measurement of the infrared scanning device 54 and the intelligent judgment and dynamic adjustment of the zone controller 55, achieves zoned optimized control of the cooling system, ensuring effective cooling of the high-temperature region while avoiding energy waste in the low-temperature region, thus achieving optimal heat exchange efficiency throughout the cooling process.

[0083] By adopting the above technical solution, the present invention has the following beneficial effects compared with the prior art:

[0084] Unlike existing technologies, the multi-stage dynamic compensation sulfuric acid dilution and cooling control system in the above technical solution includes a concentrated acid storage module 1, a mixing module 2, a cooling module 3, a secondary mixing module 4, a control module 5, and a dilute acid storage module 6. The concentrated acid storage module 1 refers to an acid storage unit equipped with an insulated storage tank 11, which is equipped with a liquid level monitoring device 12 for real-time monitoring of the concentrated sulfuric acid inventory. The mixing module 2 is connected to the concentrated acid storage module 1 through a flow pipe and includes a jet mixer 21 and a mixing enhancement unit 22. The jet mixer 21 is a device that uses a high-speed jet to achieve liquid-liquid mixing, used to mix concentrated sulfuric acid... Acid and water are initially mixed; the mixing enhancement unit 22 is coaxially arranged downstream of the jet mixer 21 to enhance the fluid turbulence and improve mixing uniformity; the cooling module 3 is connected to the outlet of the mixing module 2 and includes a phase change microchannel cooling unit 31, a phase change working fluid circulation system 32, and a condenser 33; the phase change microchannel cooling unit 31 refers to a heat exchange structure with a fractal tree-shaped microchannel substrate 311, used to achieve efficient heat transfer; the phase change working fluid circulation system 32 is connected to the microchannel substrate 311 and is used for working fluid circulation phase change heat absorption; the condenser 33 is connected to the working fluid circulation system and is used for working fluid vapor liquefaction and reflux. The secondary mixing module 4 includes a secondary mixing tank 41 and its internal stirring device 42. This module is located between the cooling module 3 and the dilute acid storage module 6. It achieves fine-tuning of concentration through a clean water replenishment pipe 43 and a concentrated acid replenishment pipe 44, and is used to correct the concentration of dilute acid that does not meet the standard. The control module 5 is connected to each functional module. Its temperature sensor 51 is located at the outlet of the mixing module 2, and its concentration detection device 52 is located at the outlet of the cooling module 3. The compensation control unit 53 is used to execute a three-level dynamic compensation strategy. The dilute acid storage module 6 is connected to the outlet of the cooling module 3 and is used to store the final product acid solution. This system achieves multi-level dynamic compensation control of the dilution and cooling process through modular collaborative operation. Furthermore, in the various embodiments of this invention, the functional units can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated units can be implemented in hardware or as software functional units.

[0085] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) or processor to execute all or part of the steps of the methods of various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0086] The above description is only a part of the embodiments of the present invention and does not limit the scope of protection of the present invention. Any equivalent device or equivalent process transformation made based on the content of the present invention specification and drawings, or direct or indirect application in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A multi-level dynamic compensation sulfuric acid dilution cooling control system, characterized in that, include: A concentrated acid storage module is used to store concentrated sulfuric acid. The concentrated acid storage module includes an insulated storage tank, a liquid level monitoring device, and a flow pipeline. The liquid level monitoring device is installed inside the insulated storage tank, and a concentrated acid flow meter and a first liquid pump are installed inside the flow pipeline. A mixing module is used to mix clean water and concentrated acid. The mixing module is connected to the concentrated acid storage module through a flow pipe. The mixing module includes a jet mixer, a mixing enhancement unit, and a clean water inlet pipe. The mixing enhancement unit is located downstream of the jet mixer and is coaxially arranged with the jet mixer. The clean water inlet pipe is connected to the jet mixer and is equipped with a clean water flow meter and a second liquid pump inside. A cooling module is used for heat exchange. The cooling module is connected to the outlet end of the mixing module. The cooling module includes a phase change microchannel cooling unit, a phase change working fluid circulation system, and a condenser. The phase change microchannel cooling unit has a fractal tree-shaped microchannel substrate. The phase change working fluid circulation system is connected to the microchannel substrate, and the condenser is connected to the phase change working fluid circulation system. A secondary mixing module is used to correct the concentration of fine-grained solutions that do not meet the concentration standards. The secondary mixing module includes a secondary mixing tank, a stirring device, a clean water replenishment pipe, and a concentrated acid replenishment pipe. The secondary mixing tank is located between the cooling module and the dilute acid storage module. The stirring device is installed inside the secondary mixing tank. The secondary mixing tank is connected to the clean water replenishment pipe and the concentrated acid replenishment pipe respectively. The control module is connected to the concentrated acid storage module, the mixing module, the cooling module, and the secondary mixing module. It includes a temperature sensor, a concentration detection device, and a compensation control unit. The temperature sensor is located at the outlet of the mixing module, and the concentration detection device is located at the outlet of the cooling module. A dilute acid storage module is connected to the outlet of the cooling module.

2. The multi-level dynamic compensation sulfuric acid dilution and cooling control system as described in claim 1, characterized in that, The phase change microchannel cooling unit includes: A microchannel substrate, wherein fractal tree-like flow channels are etched on the surface of the microchannel substrate; A sealing cover plate, wherein the sealing cover plate is detachably connected to the microchannel substrate via a gasket; The turbulence fins are disposed inside the microchannel.

3. The multi-level dynamic compensation sulfuric acid dilution cooling control system as described in claim 1, characterized in that, The phase change working fluid circulation system includes: Storage tanks; A vacuum infusion device, wherein the vacuum infusion device is connected to the storage tank and the microchannel substrate; A reflux pipe is connected to the condenser and the vacuum filling device, and a liquid pump is installed on the reflux pipe.

4. The multi-level dynamic compensation sulfuric acid dilution and cooling control system as described in claim 1, characterized in that, The condenser includes: A housing, wherein a rib structure is provided inside the housing; Cooling water storage tank; A cooling water inlet pipe, which is connected to one end of a chilled water storage tank; A condensation chamber is disposed inside the housing; A dilute acid flow channel, with a condensation chamber provided on the outside of the dilute acid flow channel; Cooling water outlet pipe, which connects the condensation chamber and the cooling water storage tank.

5. The multi-level dynamic compensation sulfuric acid dilution cooling control system as described in claim 1, characterized in that, The secondary mixing module also includes: A clean water replenishment valve, wherein the clean water replenishment valve is connected to a clean water replenishment pipe; A concentrated acid replenishment valve is connected to a concentrated acid replenishment pipe.

6. The multi-level dynamic compensation sulfuric acid dilution cooling control system as described in claim 1, characterized in that, The control module also includes: An infrared scanning device is disposed facing the surface of the microchannel substrate; A partition controller, which is communicatively connected to an infrared scanning device; A safety interlock unit is provided, which is used to respond to signals from the concentration detection device and is connected in signal communication with the concentration detection device.

7. A multi-stage dynamic compensation method for sulfuric acid dilution and cooling control, applied to the system described in any one of claims 1-6, characterized in that, Includes the following steps: S1. Concentrated acid and water are initially mixed by a jet mixer and then enter the mixing enhancement unit for further mixing. S2. The mixture of concentrated acid and water flows through the cooling module for heat exchange; S3. The control module monitors the temperature and concentration at the outlet of the cooling module in real time. S4. The mixed and cooled dilute acid flows to the dilute acid storage module.

8. The multi-stage dynamic compensation method for sulfuric acid dilution and cooling control as described in claim 7, characterized in that, Step S3 includes three levels of compensation control: S31, First-level temperature compensation: When the detected temperature exceeds the set threshold, reduce the concentrated acid feed flow rate; S32, Second-level concentration compensation: When the detected concentration deviates from the target value, correction is initiated; S33, the third-level cooling power compensation, dynamically adjusts the condensate flow rate based on real-time temperature and concentration.

9. The multi-stage dynamic compensation method for sulfuric acid dilution and cooling control as described in claim 8, characterized in that, Step S32 includes: S321. When the concentration sensor detects that the concentration of dilute acid is too high, the clean water replenishment valve is opened through the safety interlock unit. S322. When the concentration sensor detects that the concentration of dilute acid is too low, the concentrated acid replenishment valve is opened through the safety interlock unit. S323. After adding water or concentrated acid, mix with a stirring device and retest the concentration.

10. The multi-stage dynamic compensation method for sulfuric acid dilution and cooling control as described in claim 8, characterized in that, Step S33 includes: S331. Based on the temperature distribution data obtained by the infrared scanning device; S332, the zone controller enhances the working fluid circulation intensity in high-temperature areas; S333, the zone controller maintains basic cooling power in low-temperature areas.

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