Ultraviolet irradiation control method and system for a reaction vessel

Abstract

The application relates to the technical field of chemical synthesis, in particular to a reaction kettle ultraviolet irradiation control method and system. When the application is applied, the reaction efficiency is improved by controlling the circulation of the to-be-reacted gas along the inner wall, improving the gas-liquid contact sufficiency, reducing raw material waste, slightly disturbing the liquid surface, and further improving the reaction efficiency. Low-power irradiation is used in the induction period to induce the reaction, then the gas pressure change rate is switched to the active period, high-power acceleration is used to accelerate the reaction and shorten the time, and then the liquid level is switched to the end period to avoid energy waste and excessive reaction. The stages are closely connected and matched with the reaction process. The vertical power gradient design solves the problem of light intensity attenuation, eliminates reaction dead angles, and improves product purity. In the end period, only the near-liquid surface lamp body is turned on and the adaptive power is used to ensure the reaction efficiency while reducing the energy consumption. Finally, the safety liquid level is used to turn off the lamp and leave the liquid redundancy, so that the residual substances continue to react, the raw material utilization is improved, and the overall reaction control is efficient, energy-saving and safe.

Description

Technical Field

[0001] This application relates to the field of chemical synthesis technology, specifically to a method and system for controlling ultraviolet irradiation of reaction vessels. Background Technology

[0002] In the field of chemical synthesis, especially in the production of fine chemicals such as solid phosgene, ultraviolet (UV) photocatalysis is widely used due to its high efficiency and controllability. Traditional UV irradiation control in reactors often employs fixed power or a single operating mode, which is difficult to adapt to the dynamic needs of each stage of the reaction: high power during the induction phase can easily lead to violent local reactions of raw materials, generating excessive byproducts; insufficient power during the active phase prolongs the reaction time and reduces production efficiency; and continuous full-power operation during the final stage results in energy waste and equipment wear. Simultaneously, problems such as uneven gas-liquid mixing within the reactor and asynchronous changes in UV lamp power and liquid level further lead to fluctuations in product purity and low raw material utilization, making it difficult to meet the stability and economic requirements of continuous industrial production. Furthermore, the existing UV lamp heat dissipation system lacks sufficient linkage with power regulation. High-flow-rate heat dissipation during low-power stages results in redundant energy consumption, while insufficient heat dissipation during high-power stages affects lamp life. Moreover, operating condition switching often relies on single parameters (such as time or liquid level), lacking precise judgment of the actual reaction progress. Under complex conditions such as fluctuations in raw material purity and changes in gas flow rate, switching delays or misjudgments are prone to occur, leading to decreased production efficiency or increased safety risks. Therefore, there is an urgent need for a control method that can dynamically adapt to all stages of the reaction and precisely regulate UV irradiation and auxiliary systems to improve reaction efficiency, reduce energy consumption, and ensure product quality stability. Summary of the Invention

[0003] In view of this, this application provides a method and system for controlling ultraviolet irradiation in a reactor, which can dynamically adapt to the entire reaction process and precisely control ultraviolet irradiation to optimize reaction efficiency, reduce energy consumption, and ensure product quality stability.

[0004] Firstly, this application provides a method for controlling ultraviolet irradiation of a reaction vessel, applied to a reaction vessel in which multiple ultraviolet lamps are vertically arranged, a liquid to be reacted is stored at the bottom of the reaction vessel, and a gas to be reacted is filled inside the reaction vessel. The method includes: controlling the gas to be reacted inside the reaction vessel to circulate along the inner wall of the reaction vessel; switching to an induced irradiation mode, controlling the multiple ultraviolet lamps to perform irradiation at a first power range; if the gas pressure change inside the reaction vessel reaches a first preset rate, switching to an active phase mode; and in the active phase mode, controlling... Multiple ultraviolet lamps are controlled to increase their power to a second power range for irradiation; the multiple ultraviolet lamps are controlled to irradiate in an upward sequence according to a power gradient; wherein the difference between adjacent gradients is positively correlated with the distance between adjacent ultraviolet lamps; if the liquid level of the liquid to be reacted drops to a set level, the process switches to the finishing stage; in the finishing stage, the ultraviolet lamp closest to the liquid surface is controlled to irradiate at a third power range; the third power range is greater than the first power range; if the liquid level of the liquid to be reacted drops to a safe level, all ultraviolet lamps are controlled to turn off.

[0005] In conjunction with the first aspect, in one possible implementation, a water-cooling system is connected in series among the plurality of ultraviolet lamps; wherein, switching to induced irradiation mode and controlling the plurality of ultraviolet lamps to perform irradiation at a first power range includes: controlling the power mode of the plurality of ultraviolet lamps to gradually increase to the first power range; and controlling the water-cooling system to perform water cooling at a first flow rate.

[0006] In conjunction with the first aspect, in one possible implementation, after switching to the induced irradiation mode and controlling the multiple ultraviolet lamps to perform irradiation at a first power range, the method further includes: if the first preset rate is not reached within the set start-up time, then switching to the active period mode.

[0007] In conjunction with the first aspect, one possible implementation also includes: if the system is in the active operating period, controlling the water cooling system to increase to a second flow rate.

[0008] In conjunction with the first aspect, one possible implementation further includes: acquiring the liquid level parameter of the liquid to be reacted; and obtaining the liquid level drop rate based on the liquid level parameter, and uniformly increasing the power of all the ultraviolet lamps by a first preset fine-tuning rate; the absolute value of the first preset fine-tuning rate is positively correlated with the absolute value of the liquid level drop rate.

[0009] In conjunction with the first aspect, one possible implementation further includes: acquiring the liquid level parameter of the liquid to be reacted; and obtaining the liquid level drop rate based on the liquid level parameter, and controlling the power of each of the ultraviolet lamps to increase at a second preset fine-tuning rate; wherein the absolute value of the second preset fine-tuning rate is positively correlated with the absolute value of the distance between the corresponding ultraviolet lamp and the liquid surface.

[0010] In conjunction with the first aspect, in one possible implementation, after controlling the multiple ultraviolet lamps to increase their power to the second power range to perform irradiation during the active period, the method further includes: if the multiple ultraviolet lamps performing irradiation at the second power range do not reach the active period duration threshold and the liquid level of the liquid to be reacted decreases to the set liquid level, then switching to the closing period.

[0011] In conjunction with the first aspect, in one possible implementation, after controlling the multiple ultraviolet lamps to increase their power to a second power range to perform irradiation during the active period, the method further includes: if the multiple ultraviolet lamps perform irradiation at the second power range to reach an active period duration threshold, then switching to the closing period.

[0012] In conjunction with the first aspect, in one possible implementation, after controlling all the ultraviolet lamps to be turned off if the liquid level of the liquid to be reacted drops to a safe level, the method further includes: controlling the water cooling system to delay operation for a preset time.

[0013] Secondly, this application provides a reaction vessel ultraviolet irradiation control system, applied to a reaction vessel, wherein multiple ultraviolet lamps are vertically arranged in the reaction vessel, a liquid to be reacted is stored at the bottom of the reaction vessel, and the interior of the reaction vessel is filled with a gas to be reacted; the system includes: a circulation control module configured to control the gas to be reacted in the reaction vessel to circulate along the inner wall of the reaction vessel; an induced irradiation module communicatively connected to the circulation control module, the induced irradiation module configured to switch to induced irradiation mode and control the multiple ultraviolet lamps to perform irradiation at a first power range; and an active period irradiation module communicatively connected to the induced irradiation module, the active period irradiation module configured to: when the gas pressure change in the reaction vessel reaches a first preset rate... The system switches to an active phase operating mode. In this active phase, multiple UV lamps are controlled to increase their power to a second power range for irradiation. The multiple UV lamps are controlled to irradiate in an upward sequence, increasing their power gradient. The difference between adjacent gradients is positively correlated with the distance between adjacent UV lamps. A closing phase irradiation module is communicatively connected to the active phase irradiation module. This closing phase irradiation module is configured to: switch to a closing phase operating mode if the liquid level of the liquid to be reacted drops to a set level; in this closing phase, the UV lamp closest to the liquid surface is controlled to irradiate at a third power range, which is greater than the first power range; and if the liquid level of the liquid to be reacted drops to a safe level, all UV lamps are controlled to turn off.

[0014] In application, this application achieves three key improvements: First, it optimizes the fundamental conditions of the gas-liquid reaction by controlling the circulating flow of the reactant gas along the inner wall, enhancing gas-liquid contact and reducing raw material waste. Simultaneously, it slightly agitates the liquid surface, further improving reaction efficiency. Second, it achieves precise dynamic adaptation of operating conditions. During the induction phase, low-power irradiation initiates the initial induction reaction. Then, it switches to the active phase based on the rate of gas pressure change, using high power to accelerate the reaction and shorten the reaction time. Finally, it switches to the final phase based on the liquid level, avoiding energy waste and over-reaction. Each stage is tightly integrated and matched to the reaction progress. Third, it balances efficiency, energy consumption, and safety. A vertical power gradient design addresses light intensity attenuation, eliminating reaction dead zones and improving product purity. During the final phase, only the lamp near the liquid surface is activated with an appropriate power, ensuring reaction efficiency while reducing energy consumption. Finally, the lamp is turned off at a safe liquid level, leaving liquid redundancy to allow residual substances to continue reacting, improving raw material utilization. Overall, this application achieves highly efficient, energy-saving, and safe reaction control. This application can dynamically adapt to all stages of the reaction and precisely control ultraviolet irradiation to optimize reaction efficiency, reduce energy consumption, and ensure product quality stability. Attached Figure Description

[0015] Figure 1 The diagram shows a schematic representation of the steps of a method for controlling ultraviolet irradiation in a reactor according to an embodiment of this application.

[0016] Figure 2The diagram shown is a schematic diagram of the structure of a reaction vessel provided in an embodiment of this application.

[0017] Figure 3 The diagram shows the startup process steps.

[0018] Figure 4 The diagram shows a method for switching active periods.

[0019] Figure 5 The diagram shows the steps for increasing flow rate during the active phase.

[0020] Figure 6 The diagram shows the steps of adjusting the power of the ultraviolet lamp according to the drop in liquid level.

[0021] Figure 7 The diagram shown illustrates the steps of adjusting the UV lamp power according to the drop in liquid level in another embodiment.

[0022] Figure 8 The diagram shows a step-by-step illustration of one embodiment of the process of entering the final stage.

[0023] Figure 9 The diagram shows another embodiment of the steps leading to the final stage.

[0024] Figure 10 The diagram shows the steps of the water-cooled delayed shutdown method.

[0025] Figure 11 The diagram shown is a schematic diagram of the system structure of a reactor ultraviolet irradiation control system provided in an embodiment of this application. Detailed Implementation

[0026] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0027] An exemplary method for controlling ultraviolet irradiation in a reactor is as follows:

[0028] Figure 1 The diagram shows a schematic representation of the steps of a method for controlling ultraviolet irradiation in a reactor according to an embodiment of this application. Figure 2 The diagram shown is a schematic representation of a reaction vessel according to an embodiment of this application. This application provides a method for controlling ultraviolet irradiation in a reaction vessel, such as... Figure 2As shown, multiple ultraviolet lamps 2 are vertically arranged in the reactor 1. The bottom of the reactor 1 contains the liquid 3 to be reacted, and the interior of the reactor 1 is filled with the gas to be reacted. An electrical control module 4 is electrically connected to each ultraviolet lamp 2 to control the start-up and power adjustment of the ultraviolet lamps 2. The ultraviolet lamps 2 are water-cooled, and a flow control valve 5 is connected to the water pipe of the water cooling system. The flow control valve 5 can adjust the water inlet flow. The water inlet 6 of the first ultraviolet lamp 2 is connected to a water pipe for water intake, and the water inlet 6 of the next ultraviolet lamp 2 is connected to the water outlet 7 of the previous ultraviolet lamp 2 via a water pipe. In one embodiment, as... Figure 1 As shown, the method for controlling ultraviolet irradiation of the reactor includes:

[0029] Step 110: Control the gas to be reacted in the reactor to flow in a circulating manner along the inner wall of the reactor.

[0030] When applied, this step optimizes the flow path of the gas to be reacted, allowing for more thorough gas-liquid contact between the gas (such as chlorine) and the liquid at the bottom. This prevents the gas from accumulating or lingering locally, reducing unreacted areas caused by uneven gas distribution and significantly improving raw material utilization. At the same time, the annular airflow can slightly disturb the liquid surface, further enhancing reaction efficiency.

[0031] Step 120: Switch to induced irradiation mode and control multiple ultraviolet lamps to perform irradiation at the first power range.

[0032] When applying this step, the induction period uses low-intensity irradiation within the first power range. This avoids the violent reaction between the gas and liquid to be reacted caused by high power in the initial stage, reducing the generation of byproducts. At the same time, low-power operation can reduce the initial heating of the lamp body, allowing the UV lamp to start up gradually and smoothly.

[0033] Step 130: If the gas pressure change inside the reactor reaches the first preset rate, switch to the active phase operating condition.

[0034] In application, this step uses the rate of change in gas pressure as the basis for switching operating conditions, which can accurately capture the reaction process. When the change in gas pressure gradually reaches the first preset rate, it indicates that the reaction rate between the gas and liquid is stabilizing. At this time, switching to the active phase operating condition ensures that the power is increased in time during the stage of optimal reaction efficiency, avoiding premature switching that leads to excessive irradiation and energy waste, or switching too late that delays the reaction progress, thus achieving precise matching between operating conditions and reaction stages.

[0035] Step 140: During the active period, control multiple ultraviolet lamps to increase their power to the second power range to perform irradiation.

[0036] When this step is applied, the active period is increased to the second power range, which is greater than the first power range. This provides sufficient energy to accelerate the gas-liquid reaction and significantly shorten the overall reaction time. High-power irradiation can ensure that each area in the reactor has enough energy to trigger the reaction, reducing reaction lag caused by insufficient energy. At the same time, in conjunction with the design of the pre-reaction gas circulation, the reaction uniformity is further improved and the product yield is increased.

[0037] Step 150: Control multiple UV lamps to perform irradiation in an upward sequence according to the increasing power gradient; wherein the difference between adjacent gradients is positively correlated with the distance between adjacent UV lamps.

[0038] In this step, the design of increasing power gradient from bottom to top can specifically address the light intensity attenuation problem of lamps at different heights. The bottom lamps are close to the liquid, so low power is sufficient to meet the reaction requirements. Also, because the ultraviolet lamps at the lower positions are too close, the irradiation intensity on the liquid surface is uneven. Low power can prevent the local reaction from being too intense to a certain extent. The upper lamps are far from the liquid, so high power can compensate for the light intensity loss. In addition, the ultraviolet lamps at the higher positions have a large irradiation range. The gradient difference is positively correlated with the lamp distance. High irradiation intensity and large irradiation range can reduce reaction dead zones and improve product purity.

[0039] Step 160: If the liquid level of the liquid to be reacted drops to the set level, switch to the finishing stage mode.

[0040] When using this step, the liquid level drops to the set level as the end-stage switching point. This allows for accurate judgment that the reaction has entered the later stage. At this point, the concentration of the reactants in the liquid decreases. Switching the operating conditions in time before the reactants are used up can avoid the problems of empty tank irradiation and energy waste, and prevent over-reaction.

[0041] Step 170: During the final stage of operation, control the ultraviolet lamp closest to the liquid surface to perform irradiation at the third power range.

[0042] In this step, the third power range is greater than the first power range. During the final stage, or the closing stage, only the UV lamp closest to the liquid surface is controlled to irradiate within the third power range (above the first power range). This concentrates energy on the remaining reactants, ensuring sufficient reaction in the residual liquid and improving product yield. As the liquid level drops, the irradiation effect of the higher-positioned UV lamps deteriorates. Turning off the higher-positioned UV lamps at this time avoids unnecessary energy consumption. Compared to operating all lamps at low power, energy consumption is reduced in the closing stage, and the higher power range (third power range) ensures a certain degree of guarantee for the reaction rate during the closing stage.

[0043] Step 180: If the liquid level of the liquid to be reacted drops to the safe level, turn off all ultraviolet lamps.

[0044] In this step, the safety level is used to reserve redundant liquid for a slow, unlit reaction during a buffer period, which may last for several hours or even a day or two. By using the safety level as the point at which the lights are turned off and reserving liquid redundancy, the slow reaction is buffered by this liquid redundancy, allowing a small amount of residual reactants to continue reacting after the lights are turned off, thus improving raw material utilization and saving energy.

[0045] In application, this application achieves three key improvements: First, it optimizes the fundamental conditions of the gas-liquid reaction by controlling the circulating flow of the reactant gas along the inner wall, enhancing gas-liquid contact and reducing raw material waste. Simultaneously, it slightly agitates the liquid surface, further improving reaction efficiency. Second, it achieves precise dynamic adaptation of operating conditions. During the induction phase, low-power irradiation initiates the initial induction reaction. Then, it switches to the active phase based on the rate of gas pressure change, using high power to accelerate the reaction and shorten the reaction time. Finally, it switches to the final phase based on the liquid level, avoiding energy waste and over-reaction. Each stage is tightly integrated and matched to the reaction progress. Third, it balances efficiency, energy consumption, and safety. A vertical power gradient design addresses light intensity attenuation, eliminating reaction dead zones and improving product purity. During the final phase, only the lamp near the liquid surface is activated with an appropriate power, ensuring reaction efficiency while reducing energy consumption. Finally, the lamp is turned off at a safe liquid level, leaving liquid redundancy to allow residual substances to continue reacting, improving raw material utilization. Overall, this application achieves highly efficient, energy-saving, and safe reaction control. This application can dynamically adapt to all stages of the reaction and precisely control ultraviolet irradiation to optimize reaction efficiency, reduce energy consumption, and ensure product quality stability.

[0046] In some embodiments, the reaction liquid is dimethyl carbonate (DMC), and DMC reacts directly with the reaction gas chlorine without introducing any organic solvents. The synthesis reaction formula for solid phosgene is as follows: (H 3 CO) 2 C=O+6Cl 2 → (Cl 3 CO) 2 C=O+6HCl ↑, The liquid and gas to be reacted under the catalysis of ultraviolet light to produce solid phosgene.

[0047] Figure 3 The diagram illustrates the startup process steps. In one embodiment, a water-cooling system is connected in series between multiple UV lamps. Figure 3 As shown, step 120 includes:

[0048] Step 121: Control the power operation of multiple UV lamps to gradually increase the power to the first power range.

[0049] In this step, by controlling the UV lamp to start gradually, specifically by gradually increasing the starting power to the first power range, a sudden increase in power during the induction period can be avoided. Slowly increasing the power allows the gas and liquid to react to gradually adapt to the irradiation intensity, further reducing the probability of side reactions in the initial stage and ensuring a smooth start-up of the reaction. At the same time, it also avoids the lamp body being subjected to instantaneous high-temperature shock, thereby extending the lamp's service life.

[0050] Step 122: Control the water cooling system to perform water cooling at the first flow rate.

[0051] When applying this step, the water cooling system is controlled to operate at the first flow rate to meet the heat dissipation requirements of the low-power operation during the induction period. This avoids energy waste caused by high flow rates and can effectively remove the initial heat generated by the lamp body, keeping the lamp body temperature stable within a suitable range.

[0052] Figure 4 The diagram illustrates one method for switching active periods. In one embodiment, as shown... Figure 4 As shown, after step 120, the method for controlling ultraviolet irradiation of the reactor further includes:

[0053] Step 1201: If the first preset rate is not reached within the set startup time, switch to active period mode.

[0054] In application, this step solves the problem of reaction lag or judgment delay that may occur if the start-up time is set as a backup switching condition by setting the start-up time. When the gas pressure change during the induction period does not reach the first preset rate but has met the set start-up time, it automatically switches to the active period condition. This avoids the induction period being too long due to factors such as slow diffusion of the gas to be reacted or sensor errors, and prevents insufficient low-power irradiation from affecting the reaction progress, thus ensuring the overall reaction efficiency.

[0055] Figure 5 The diagram illustrates the steps of increasing flow velocity during the active phase. In one embodiment, as shown... Figure 5 As shown, the method for controlling ultraviolet irradiation of the reactor also includes:

[0056] Step 1309: If the system is in an active operating phase, increase the water cooling system to the second flow rate.

[0057] When applying this step, the flow rate of the water cooling system is adjusted to the second flow rate during the active operating period. This can accurately adapt to the heat dissipation requirements after the UV lamp is upgraded to the second power range at this stage. The second flow rate can remove heat faster than the first flow rate, avoiding the lamp body from being overheated and causing light intensity decay or shortened lifespan, thus ensuring the stability of high-power operation.

[0058] Figure 6 The diagram illustrates the steps of adjusting the power of the ultraviolet lamp based on the drop in liquid level. In one embodiment, as shown... Figure 6As shown, the method for controlling ultraviolet irradiation of the reactor also includes:

[0059] Step 210: Obtain the liquid level parameters of the liquid to be reacted.

[0060] Step 220: Based on the liquid level parameters, obtain the liquid level drop rate and uniformly increase the power of all ultraviolet lamps by the first preset fine-tuning rate.

[0061] This embodiment can be applied to any stage of the induced irradiation, active phase, and final phase conditions. The absolute value of the first preset fine-tuning rate is positively correlated with the absolute value of the liquid level drop rate. This embodiment links power adjustment with the reaction progress. The liquid level drop rate directly reflects the consumption rate of the reactant liquid. By synchronously increasing the power at the positively correlated first preset fine-tuning rate, it can provide suitable energy input for the reaction at any stage of the induction, active, or final phase. When the liquid level drops rapidly, the power is increased more quickly to avoid insufficient energy slowing down the reaction; when the drop is slow, the power is increased gradually to prevent excessive irradiation leading to side reactions, thus improving the accuracy of power control throughout the entire process. During this period, the UV lamp increases at the first preset fine-tuning rate within the first, second, or third power range, and the maximum value of the fine-tuning increase does not exceed the maximum value within the corresponding range.

[0062] Figure 7 The diagram illustrates the steps of another embodiment of a method for adjusting the power of an ultraviolet lamp based on a drop in liquid level. In one embodiment, as shown... Figure 7 As shown, the method for controlling ultraviolet irradiation of the reactor also includes:

[0063] Step 230: Obtain the liquid level parameters of the liquid to be reacted.

[0064] Step 240: Based on the liquid level parameters, obtain the liquid level drop rate and control the power of each ultraviolet lamp to increase at the second preset fine-tuning rate.

[0065] This embodiment can be applied to any stage of the induced irradiation, active phase, and final phase processes. The absolute value of the second preset fine-tuning rate is positively correlated with the absolute value of the distance between the corresponding UV lamp and the liquid surface. This embodiment links power adjustment with reaction progress. The rate of liquid level descent directly reflects the consumption rate of the reactant liquid, enabling spatial adaptation of power adjustment. The farther the UV lamp is from the liquid surface, the larger its second preset fine-tuning rate. This can specifically compensate for the increase in optical path (light intensity attenuation) caused by the liquid level descent, ensuring that lamps at different heights always provide appropriate energy to the reaction area, avoiding insufficient power from distant lamps or excessive irradiation from nearby lamps. This embodiment replaces uniform adjustment with individualized fine-tuning, which can more flexibly cope with non-uniform liquid level descent (such as liquid level fluctuations caused by local liquid disturbances), ensuring that the power change of each lamp matches the reaction demand of its irradiation area in real time, further improving energy utilization efficiency and product uniformity. During this period, the UV lamp increases at the second preset fine-tuning rate within the first, second, or third power range, and the maximum increase in fine-tuning does not exceed the maximum value in the corresponding range.

[0066] Figure 8 The diagram illustrates one embodiment of the steps involved in entering the final stage. In one embodiment, as... Figure 8 As shown, after step 140, the method for controlling ultraviolet irradiation of the reactor further includes:

[0067] Step 141: If multiple ultraviolet lamps perform irradiation at the second power range but do not reach the active period duration threshold, and the liquid level of the liquid to be reacted drops to the set level, then switch to the finishing period mode.

[0068] In this embodiment, the liquid level is prioritized for replenishing the active phase switching logic. When the liquid level drops to the set value in advance, it indicates that the reaction consumption rate is faster than expected. Even if the preset active phase duration threshold is not reached, the system will switch to the closing phase in time, improving the adaptability to fluctuations in the reaction progress.

[0069] Figure 9 The diagram illustrates another embodiment of the process entering the final stage. In one embodiment, as shown... Figure 9 As shown, after step 140, the method for controlling ultraviolet irradiation of the reactor further includes:

[0070] Step 142: If multiple UV lamps perform irradiation at the second power range to reach the active period duration threshold, then switch to the end-of-period operation mode.

[0071] In this embodiment, a time threshold is used as a fallback switching condition. When the active period reaches the target duration, the system switches to the closing period regardless of whether the liquid level drops to the set value. This prevents the active period from being too long due to liquid level detection errors (such as reading delay caused by sensor scaling), avoids excessive reaction and generation of byproducts, and improves the batch stability of product quality.

[0072] Figure 10 The diagram illustrates the steps of a water-cooled delayed shutdown method. In one embodiment, as shown... Figure 10 As shown, after step 180, the ultraviolet irradiation control method for the reactor further includes:

[0073] Step 181: Control the water cooling system to run with a preset delay.

[0074] In this embodiment, water cooling delays shutdown, allowing residual heat from the lamp body to continue to dissipate after the UV lamp is turned off, thus preventing high-temperature damage to the LED chip or lamp body components and extending the lamp's lifespan.

[0075] Specifically, the reference value ranges for each parameter are as follows:

[0076] First power range (induction period): 50-150W (single lamp power, 10%-30% of rated power, to avoid initial violent reaction);

[0077] Second power range (active period): 350-450W (single lamp power, 70%-90% of the rated power, providing sufficient energy to accelerate the reaction);

[0078] Third power range (final stage): 200-300W (single lamp power, higher than the induction stage, concentrated energy to treat residual liquid).

[0079] First preset rate (pressure change): 0.02-0.05 MPa / h (the rate of pressure drop caused by chlorine consumption, used to determine when the reaction enters the active phase);

[0080] Liquid level drop rate: Induction phase: 0.2-0.5 cm / h (slow reaction, low liquid consumption); Active phase: 1-3 cm / h (violent reaction, rapid liquid consumption); Finishing phase: 0.1-0.3 cm / h (residual liquid reacts, consumption slows down).

[0081] First preset fine-tuning rate (uniform fine-tuning): a value between 0.5% and 2% / h (increases by a percentage of the current power, positively correlated with the rate of liquid level drop, e.g., 1% / h when the liquid level drops at a rate of 1cm / h).

[0082] Second preset fine-tuning rate (differentiated fine-tuning): Bottom light (0.5m from the liquid surface): a value between 0.5% and 1% / h; Middle light (1.5m from the liquid surface): a value between 1% and 2% / h; Top light (2.5m from the liquid surface): a value between 2% and 3% / h (positively correlated with the distance from the liquid surface to compensate for light intensity attenuation).

[0083] First flow rate (induction period): a value between 0.5-1 L / min (adapted to low-power heat dissipation to avoid energy waste);

[0084] Second flow rate (active period): a value between 2-3 L / min (high power heat generation increases, increasing the flow rate enhances heat dissipation);

[0085] The startup duration set in step 1201 is generally set to a value between 1.5h and 3h.

[0086] Set liquid level (switching during the final stage): a value between 0.5-0.8m (when the initial liquid level is 1.5m, the liquid consumption is about 70%-80% before entering the final stage).

[0087] Safe liquid level (lights-off node): a value between 0.1-0.2m (reserve redundant liquid to buffer subsequent slow reactions);

[0088] Active period duration threshold: a value between 6 and 8 hours (set according to capacity demand to avoid side reactions caused by excessively long active periods).

[0089] Preset delay (water cooling delay): a value between 30-60 minutes (after the lamp is turned off, it continues to dissipate heat until the temperature stabilizes).

[0090] An exemplary ultraviolet irradiation control system for a reactor is as follows:

[0091] Figure 11 The diagram shown is a schematic representation of the system structure of a reaction vessel ultraviolet irradiation control system according to an embodiment of this application. This application provides a reaction vessel ultraviolet irradiation control system, applied to a reaction vessel, such as... Figure 2 As shown, multiple ultraviolet lamps 2 are vertically arranged in the reactor 1. The bottom of the reactor 1 contains the liquid 3 to be reacted, and the interior of the reactor 1 is filled with the gas to be reacted. An electrical control module 4 is electrically connected to each ultraviolet lamp 2 to control the start-up and power adjustment of the ultraviolet lamps 2. The ultraviolet lamps 2 are water-cooled, and a flow control valve 5 is connected to the water pipe of the water cooling system. The flow control valve 5 can adjust the water inlet flow. The water inlet 6 of the first ultraviolet lamp 2 is connected to a water pipe for water intake, and the water inlet 6 of the next ultraviolet lamp 2 is connected to the water outlet 7 of the previous ultraviolet lamp 2 via a water pipe. In one embodiment, as... Figure 11 As shown, the ultraviolet irradiation control system of the reactor includes: a circulation control module 1101, an induced irradiation module 1102, an active phase irradiation module 1103, and a closing phase irradiation module 1104.

[0092] The circulation control module 1101 is configured to control the gas to be reacted in the reactor to circulate along the inner wall of the reactor.

[0093] The induced irradiation module 1102 is communicatively connected to the circulating control module 1101. The induced irradiation module 1102 is configured to switch to induced irradiation mode and control multiple ultraviolet lamps to perform irradiation at a first power range.

[0094] The active period irradiation module 1103 is communicatively connected to the induced irradiation module 1102. The active period irradiation module 1103 is configured to: switch to active period mode when the gas pressure change in the reactor reaches the first preset rate; in active period mode, control multiple ultraviolet lamps to increase their power to the second power range to perform irradiation; control multiple ultraviolet lamps to perform irradiation in an upward order according to the power gradient; wherein, the difference between adjacent gradients is positively correlated with the distance between adjacent ultraviolet lamps.

[0095] The irradiation module 1104 in the final stage is communicatively connected to the irradiation module 1103 in the active stage. The irradiation module 1104 in the final stage is configured as follows: if the liquid level of the liquid to be reacted drops to the set liquid level, it switches to the final stage mode; in the final stage mode, it controls the ultraviolet lamp closest to the liquid surface to perform irradiation at the third power range; the third power range is greater than the first power range; if the liquid level of the liquid to be reacted drops to the safe liquid level, it controls all ultraviolet lamps to be turned off.

[0096] In application, this application achieves three key improvements: First, it optimizes the fundamental conditions of the gas-liquid reaction by controlling the circulating flow of the reactant gas along the inner wall, thus enhancing gas-liquid contact and reducing raw material waste. Simultaneously, slight disturbance of the liquid surface further improves reaction efficiency. Second, it achieves precise dynamic adaptation of operating conditions. Low-power irradiation is used for the initial induction phase, followed by switching to the active phase at a higher power rate based on the rate of gas pressure change, accelerating the reaction and shortening the reaction time. Then, it switches to the final phase based on the liquid level, avoiding energy waste and over-reaction. Each stage is tightly integrated and matched to the reaction progress. Third, it balances efficiency, energy consumption, and safety. A vertical power gradient design addresses the issue of light intensity attenuation, eliminating reaction dead zones and improving product purity. During the final phase, only the lamp near the liquid surface is activated with an appropriate power, ensuring reaction efficiency while reducing energy consumption. Finally, the lamp is switched off at a safe liquid level, leaving liquid redundancy to allow residual substances to continue reacting, improving raw material utilization. Overall, it achieves highly efficient, energy-saving, and safe reaction control.

[0097] The basic principles of this application have been described above with reference to specific embodiments. However, it should be noted that the advantages, benefits, and effects mentioned in this application are merely examples and not limitations, and should not be considered as essential features of each embodiment of this application. Furthermore, the specific details disclosed above are for illustrative and facilitative purposes only, and are not limitations. These details do not limit the application to the necessity of employing the aforementioned specific details for implementation.

[0098] The block diagrams of devices, apparatuses, devices, and systems involved in this application are merely illustrative examples and are not intended to require or imply that they must be connected, arranged, or configured in the manner shown in the block diagrams. As those skilled in the art will recognize, these devices, apparatuses, devices, and systems can be connected, arranged, and configured in any manner. Words such as “comprising,” “including,” “having,” etc., are open-ended terms meaning “including but not limited to,” and are used interchangeably with them. The terms “or” and “and” as used herein refer to the terms “and / or,” and are used interchangeably with them unless the context clearly indicates otherwise. The term “such as” as used herein refers to the phrase “such as but not limited to,” and is used interchangeably with it.

[0099] It should also be noted that in the apparatus, equipment, and methods of this application, the components or steps can be disassembled and / or recombined. These disassemblies and / or recombinations should be considered as equivalent solutions of this application.

[0100] The above description of the disclosed aspects is provided to enable any person skilled in the art to make or use this application. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other aspects without departing from the scope of this application. Therefore, this application is not intended to be limited to the aspects shown herein, but rather to be carried out within the widest scope consistent with the principles and novel features of the invention herein.

[0101] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications or equivalent substitutions made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for controlling ultraviolet irradiation in a reaction vessel, characterized in that, The method is applied to a reaction vessel, wherein multiple ultraviolet lamps are vertically arranged in the reaction vessel, the bottom of the reaction vessel contains a liquid to be reacted, and the interior of the reaction vessel is filled with a gas to be reacted; the method includes: The gas to be reacted in the reactor is controlled to circulate along the inner wall of the reactor; Switch to induced irradiation mode and control multiple ultraviolet lamps to perform irradiation at a first power range; If the gas pressure change inside the reactor reaches the first preset rate, the system switches to the active phase operating condition. During the active operating period, the power of multiple ultraviolet lamps is increased to a second power range to perform irradiation; Multiple UV lamps are controlled to perform irradiation in an upward sequence, according to an increasing power gradient; wherein the difference between adjacent gradients is positively correlated with the distance between adjacent UV lamps. If the liquid level of the liquid to be reacted drops to the set level, switch to the finishing stage mode; During the final stage of operation, the ultraviolet lamp closest to the liquid surface is controlled to perform irradiation at a third power range; the third power range is greater than the first power range. If the liquid level of the liquid to be reacted drops to a safe level, all the ultraviolet lamps are turned off.

2. The method for controlling ultraviolet irradiation of a reactor according to claim 1, characterized in that, A water-cooling system is connected in series among the multiple ultraviolet lamps; wherein, switching to induced irradiation mode and controlling the multiple ultraviolet lamps to perform irradiation at a first power range includes: Controlling the power operation of the multiple ultraviolet lamps to gradually increase the power output to the first power range; and The water cooling system is controlled to perform water cooling at a first flow rate.

3. The method for controlling ultraviolet irradiation of a reactor according to claim 1, characterized in that, After switching to induced irradiation mode and controlling the plurality of ultraviolet lamps to perform irradiation at a first power range, the method further includes: If the first preset rate is not reached within the set startup time, the system switches to the active period mode.

4. The method for controlling ultraviolet irradiation of a reactor according to claim 2, characterized in that, Also includes: If the system is in the active operating phase, the water cooling system is controlled to increase to the second flow rate.

5. The method for controlling ultraviolet irradiation of a reactor according to claim 1, characterized in that, Also includes: Obtain the liquid level parameters of the liquid to be reacted; as well as Based on the liquid level parameters, the liquid level drop rate is obtained, and the power of all the ultraviolet lamps is increased uniformly by a first preset fine-tuning rate; the absolute value of the first preset fine-tuning rate is positively correlated with the absolute value of the liquid level drop rate.

6. The method for controlling ultraviolet irradiation of a reactor according to claim 1, characterized in that, Also includes: Obtain the liquid level parameters of the liquid to be reacted; as well as Based on the liquid level parameters, the liquid level drop rate is obtained, and the power of each of the ultraviolet lamps is controlled to increase at a second preset fine-tuning rate; wherein, the absolute value of the second preset fine-tuning rate is positively correlated with the absolute value of the distance between the corresponding ultraviolet lamp and the liquid surface.

7. The method for controlling ultraviolet irradiation of a reactor according to claim 1, characterized in that, During the active period, after controlling the multiple ultraviolet lamps to increase their power to a second power range to perform irradiation, the method further includes: If the multiple ultraviolet lamps perform irradiation at the second power range but do not reach the active period duration threshold, and the liquid level of the liquid to be reacted drops to the set level, then the process switches to the closing period condition.

8. The method for controlling ultraviolet irradiation of a reactor according to claim 1, characterized in that, During the active period, after controlling the multiple ultraviolet lamps to increase their power to a second power range to perform irradiation, the method further includes: If multiple UV lamps perform irradiation at the second power range to reach the active period duration threshold, then switch to the closing period condition.

9. The method for controlling ultraviolet irradiation of a reactor according to claim 2, characterized in that, After the liquid level of the liquid to be reacted drops to a safe level and all the ultraviolet lamps are turned off, the method further includes: The water cooling system is controlled to operate with a preset delay.

10. A reaction vessel ultraviolet irradiation control system, characterized in that, The system is applied to a reaction vessel, wherein multiple ultraviolet lamps are vertically arranged in the reaction vessel, the bottom of the reaction vessel contains a liquid to be reacted, and the interior of the reaction vessel is filled with a gas to be reacted; the system includes: The circulation control module is configured to control the gas to be reacted in the reactor to circulate along the inner wall of the reactor. The induced irradiation module is communicatively connected to the circulating control module. The induced irradiation module is configured to switch to induced irradiation mode and control multiple ultraviolet lamps to perform irradiation at a first power range. An active phase irradiation module, communicatively connected to the induced irradiation module, is configured to: switch to active phase operation when the pressure change within the reactor reaches a first preset rate; in the active phase operation, control multiple ultraviolet lamps to increase their power to a second power range for irradiation; control multiple ultraviolet lamps to irradiate in an upward sequence according to an increasing power gradient; wherein the difference between adjacent gradients is positively correlated with the distance between adjacent ultraviolet lamps; and The irradiation module for the final stage is communicatively connected to the irradiation module for the active stage. The irradiation module for the final stage is configured to: switch to the final stage mode if the liquid level of the liquid to be reacted drops to a set level; in the final stage mode, control the ultraviolet lamp closest to the liquid surface to perform irradiation at a third power range; the third power range is greater than the first power range; and control all ultraviolet lamps to turn off if the liquid level of the liquid to be reacted drops to a safe level.

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