Ash bin and ash removal method

Abstract

The application discloses an ash hopper and an ash cleaning method. The ash hopper comprises an ash hopper body, an ultrasonic oscillator, a sensor assembly and a controller. The ultrasonic oscillator is arranged on the ash hopper body. The sensor assembly is used to acquire parameters representing the state of accumulated ash in the ash hopper, and the parameters at least include real-time flue gas temperature in the ash hopper body and actual accumulated ash thickness of the inner side wall of the ash hopper body. The controller generates an actual temperature deviation value according to the real-time flue gas temperature and a preset flue gas temperature. When the absolute value of the actual temperature deviation value is greater than a preset temperature deviation value, or the actual accumulated ash thickness is greater than a preset accumulated ash thickness, a start instruction is generated and executed to control the ultrasonic oscillator to start. The application can timely destroy the bonding structure between fly ash particles by arranging the ultrasonic oscillator and combining real-time monitoring data, thereby reducing the cleaning difficulty and labor intensity.

Description

Technical Field

[0001] This invention relates to the field of waste incineration, and more particularly to ash hoppers and ash removal methods. Background Technology

[0002] Municipal solid waste contains high levels of ash and salts. These salts exhibit strong agglomeration properties during high-temperature incineration, making fly ash particles in the flue gas prone to agglomeration during flow. This leads to fly ash accumulation and caking, resulting in frequent blockages in the ash hopper.

[0003] In related technologies, when the ash hopper is clogged or after a period of use, the fly ash inside the ash hopper accumulates and hardens severely. At this point, manual cleaning is carried out by using a coke-cleaning rod, which increases the difficulty of cleaning and the labor intensity. Summary of the Invention

[0004] The present invention aims to at least solve one of the technical problems existing in the prior art. To this end, one object of the present invention is to provide an ash hopper that, by setting an ultrasonic oscillator and combining it with real-time monitoring data, can apply high-frequency vibration in a timely manner when fly ash begins to show a tendency to adhere and caking, effectively destroying the adhesion structure between fly ash particles, preventing them from further agglomerating, hardening and forming a dense caking layer, and reducing the difficulty and labor intensity of cleaning.

[0005] The present invention also proposes a method for cleaning dust.

[0006] A first aspect of the present invention provides an ash hopper, which includes an ash hopper body, an ultrasonic oscillator, a sensor assembly, and a controller.

[0007] An ultrasonic oscillator is mounted on the ash hopper body; a sensor assembly is used to acquire parameters characterizing the ash accumulation state inside the ash hopper, the parameters including at least the real-time flue gas temperature inside the ash hopper body and the actual ash accumulation thickness on the inner wall of the ash hopper body; a controller is communicatively connected to the sensor assembly and the ultrasonic oscillator. The controller is configured to: generate an actual temperature deviation value based on the real-time flue gas temperature and a preset flue gas temperature; when the absolute value of the actual temperature deviation value is greater than the preset temperature deviation value, or the actual ash accumulation thickness is greater than the preset ash accumulation thickness, generate and execute a start command to control the ultrasonic oscillator to start; when the absolute value of the actual temperature deviation value is not greater than the preset temperature deviation value and the actual ash accumulation thickness is not greater than the preset ash accumulation thickness, generate and execute a stop command to stop the ultrasonic oscillator.

[0008] In some embodiments, the controller is configured to adjust the operating frequency and power of the ultrasonic oscillator based on the actual dust accumulation thickness and the absolute value of the actual temperature deviation.

[0009] In some embodiments, the controller is configured to: control the ultrasonic oscillator to operate at a first frequency and a first power when the actual dust accumulation thickness is greater than a preset dust accumulation thickness but not greater than a second thickness threshold, and the absolute value of the actual temperature deviation is greater than a preset temperature deviation value but less than a second temperature threshold; and control the ultrasonic oscillator to operate at a second frequency higher than the first frequency and a second power higher than the first power when the actual dust accumulation thickness is greater than the second thickness threshold, or the absolute value of the actual temperature deviation value is greater than the second temperature threshold.

[0010] In some embodiments, the controller is further configured to: after the ultrasonic oscillator is started, monitor the changes in the actual dust accumulation thickness and the actual temperature deviation value within a preset time window; if the actual dust accumulation thickness does not show a decreasing trend or the actual temperature deviation value does not show a decreasing trend, then trigger an alarm signal.

[0011] In some embodiments, the sensor assembly includes at least two sets of thickness gauges spaced apart along the axial direction of the ash hopper body, each set of the thickness gauges including at least two thickness gauges spaced apart along the circumferential direction of the ash hopper body.

[0012] In some embodiments, the sensor assembly includes a temperature sensor disposed at the upper opening of the ash hopper body.

[0013] In some embodiments, the ultrasonic oscillator is mounted on the outer wall of the ash hopper body.

[0014] In some embodiments, an insulation layer is also included covering the outer wall of the ash hopper body.

[0015] In some embodiments, the insulation layer is constructed of ceramic fiber material.

[0016] A second aspect of the present invention provides a dust removal method applied to the ash hopper described in the first aspect of the present invention. The dust removal method includes the following steps:

[0017] Step S1: Obtain parameters characterizing the ash accumulation state inside the ash hopper through the sensor assembly. The parameters include at least the real-time flue gas temperature inside the ash hopper body and the actual ash accumulation thickness on the inner wall of the ash hopper body.

[0018] Step S2: Receive the real-time flue gas temperature inside the ash hopper body and the actual ash accumulation thickness on the inner wall of the ash hopper body through the controller, and generate an actual temperature deviation value based on the real-time flue gas temperature and the preset flue gas temperature.

[0019] Step S3: When the actual temperature deviation value is greater than the preset temperature deviation value, or the actual dust accumulation thickness is greater than the preset dust accumulation thickness, the controller generates and executes a start command to control the ultrasonic oscillator to start.

[0020] Step S4: During the operation of the ultrasonic oscillator, the controller generates and executes a shutdown command when the actual temperature deviation value is not greater than the preset temperature deviation value and the actual dust accumulation thickness is not greater than the preset dust accumulation thickness, thereby shutting down the ultrasonic oscillator.

[0021] As can be seen from the technical solution, the embodiments provided by the present invention have the following advantages:

[0022] (1) By setting up an ultrasonic oscillator and combining it with real-time monitoring data, the present invention can automatically and timely apply high-frequency vibration to destroy the bonding structure between fly ash particles, prevent them from further agglomerating and hardening and forming a dense caking layer, and reduce cleaning difficulty and labor intensity.

[0023] (2) Through real-time monitoring and precise control, ash cleaning is only started when needed (started when conditions are met and shut down when conditions return to normal), which avoids unnecessary energy consumption and equipment wear and tear, which helps to improve the energy efficiency of the entire incineration system, while reducing maintenance costs and production stoppage losses caused by blockages;

[0024] (3) In related technologies, the need for cleaning is determined by detecting the thickness of the ash accumulation. However, the uneven ash accumulation in the ash hopper leads to misjudgment of the cleaning time, which in turn causes the fly ash to accumulate and harden, making it difficult to clean. This application uses two parameters, the actual temperature deviation value and the ash accumulation thickness, to more accurately and comprehensively evaluate the degree of ash accumulation in the ash hopper. Therefore, the actual temperature deviation value can effectively make up for the lack of local and direct measurement of the thickness parameter and improve reliability. Attached Figure Description

[0025] 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.

[0026] Figure 1 This is a schematic diagram of the structure of the ash hopper according to an embodiment of the present invention;

[0027] Figure 2 This is a schematic flowchart of a dust removal method according to an embodiment of the present invention.

[0028] Explanation of reference numerals in the attached figures:

[0029] Ash bucket 100;

[0030] Ash hopper body 1, inlet 11, outlet 12, flue 13;

[0031] Ultrasonic oscillator 2, main oscillator 21, standby oscillator 22;

[0032] Sensor assembly 3, thickness gauge 31, temperature sensor 32;

[0033] Controller 4;

[0034] Insulation layer 5;

[0035] 6. Signal transmission cable. Detailed Implementation

[0036] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0037] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, features defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0038] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0039] The following is for reference. Figures 1-2 The ash hopper 100 and the ash cleaning method according to embodiments of the present invention are described.

[0040] like Figure 1 and Figure 2 As shown, a first aspect of the present invention provides an ash hopper 100, which includes an ash hopper body 1, an ultrasonic oscillator 2, a sensor assembly 3, and a controller 4.

[0041] An ultrasonic oscillator 2 is mounted on the ash hopper body 1. The sensor assembly 3 is capable of acquiring parameters characterizing the ash accumulation state inside the ash hopper body 1, including at least the real-time flue gas temperature inside the ash hopper body 1 and the actual ash accumulation thickness on the inner wall of the ash hopper body 1.

[0042] The controller 4 is communicatively connected to the sensor assembly 3, allowing it to receive real-time flue gas temperature and actual ash thickness generated by the sensor assembly 3. The controller 4 is also communicatively connected to the ultrasonic oscillator 2 and can control the ultrasonic oscillator 2 to start or stop.

[0043] Controller 4 generates an actual temperature deviation value based on the real-time flue gas temperature and the preset flue gas temperature. When the absolute value of the actual temperature deviation value is greater than the preset temperature deviation value, or the actual ash accumulation thickness is greater than the preset ash accumulation thickness, controller 4 generates and executes a start command to control the ultrasonic oscillator 2 to start. When the absolute value of the actual temperature deviation value is not greater than the preset temperature deviation value and the actual ash accumulation thickness is not greater than the preset ash accumulation thickness, controller 4 generates and executes a stop command to turn off the ultrasonic oscillator 2.

[0044] The preset flue gas temperature here is the ideal temperature reference point under normal system conditions and no ash accumulation. It is set based on historical normal operation data and must be higher than the acid dew point temperature to ensure that the inner wall of the ash hopper body 1 is dry and free from sticky ash accumulation.

[0045] The actual temperature deviation value refers to the difference between the real-time flue gas temperature and the preset flue gas temperature. The actual temperature deviation value is a key parameter characterizing the ash accumulation state: when the actual temperature deviation value is negative, it indicates that the real-time temperature is lower than the preset temperature, reflecting severe ash accumulation inside the ash hopper body 1. The ash adheres to the inner wall of the ash hopper body 1, hindering heat transfer and causing a decrease in flue gas temperature. Therefore, an increase in the absolute value of the actual temperature deviation value indicates a more severe degree of ash accumulation inside the ash hopper body 1.

[0046] The preset ash accumulation thickness here is a pre-set threshold value used to determine whether to initiate the ash cleaning operation. The preset ash accumulation thickness is used as a benchmark and compared with the actual ash accumulation thickness obtained from real-time monitoring. When the actual ash accumulation thickness is greater than the preset ash accumulation thickness, it indicates that the ash accumulation in the ash hopper 100 has exceeded the normal operating range and the ash cleaning device needs to be activated; otherwise, it is considered that the ash accumulation in the ash hopper 100 is within the normal operating range.

[0047] In a specific application scenario, sensor component 3 continuously monitors the flue gas temperature and ash thickness inside the ash hopper body 1, generates real-time flue gas temperature and actual ash thickness, and sends them to controller 4. Controller 4 receives the real-time flue gas temperature and calculates the difference between the real-time flue gas temperature and the preset flue gas temperature to obtain the absolute value of the actual temperature deviation. Then, it compares the absolute value of the actual temperature deviation with the preset temperature deviation. At the same time, controller 4 compares the actual ash thickness with the preset ash thickness.

[0048] When controller 4 meets one of the following conditions:

[0049] Condition 1: The absolute value of the actual temperature deviation is greater than the preset temperature deviation value;

[0050] Condition 2: The actual dust accumulation thickness is greater than the preset dust accumulation thickness;

[0051] This indicates that the ash accumulation in the ash hopper 100 has exceeded the normal operating range. At this time, the controller 4 controls the ultrasonic oscillator 2 to start. The ultrasonic oscillator 2 uses high-frequency vibration to loosen the ash accumulation in the ash hopper body 1 by impact, thereby reducing ash accumulation and reducing the possibility of fly ash accumulating and caking in the ash hopper 100.

[0052] During the operation of the ultrasonic oscillator 2, the controller 4 shall simultaneously meet the following conditions:

[0053] Condition 3: The absolute value of the actual temperature deviation is not greater than (less than or equal to) the preset temperature deviation value;

[0054] Condition 4: The actual dust accumulation thickness is not greater than (less than or equal to) the preset dust accumulation thickness;

[0055] If the ash accumulation in the ash hopper 100 is considered to be within the normal operating range, then the controller 4 will control the ultrasonic oscillator 2 to shut down.

[0056] It is also important to emphasize that related technologies rely solely on detecting ash thickness to determine the need for cleaning. However, uneven ash accumulation within the ash hopper 1 leads to misjudgments of when to clean: if the sensor happens to be installed in an area with less ash, the system will not initiate cleaning even if other areas are severely caking, missing the optimal processing opportunity, allowing fly ash to further accumulate and caking, making it difficult to clean. This application introduces actual temperature deviation as a second key criterion, using parameters of both actual temperature deviation and ash thickness. Flue gas flow and heat transfer are macroscopic reflections of the overall internal state of the ash hopper 100. When ash accumulation and caking begin to occur locally, it alters the flow field and heat exchange efficiency of the flue duct 13, resulting in abnormal changes in the overall flue gas temperature. Therefore, the actual temperature deviation can effectively compensate for the shortcomings of localized and direct measurement of the thickness parameter.

[0057] As can be seen from the technical solution, the embodiments provided by the present invention have the following advantages:

[0058] (1) By setting up an ultrasonic oscillator 2 and combining it with real-time monitoring data, high-frequency vibration can be applied automatically and in a timely manner to destroy the bonding structure between fly ash particles, prevent them from further agglomerating and hardening and forming a dense caking layer, and reduce cleaning difficulty and labor intensity.

[0059] (2) Through real-time monitoring and precise control, ash cleaning is only started when needed (started when conditions are met and shut down when conditions return to normal), which avoids unnecessary energy consumption and equipment wear and tear, which helps to improve the energy efficiency of the entire incineration system, while reducing maintenance costs and production stoppage losses caused by blockages;

[0060] (3) In related technologies, the need for cleaning is determined by detecting the thickness of the ash accumulation. However, the uneven ash accumulation in the ash hopper body 1 leads to misjudgment of the timing of cleaning, which in turn causes fly ash to accumulate and clump together, making it difficult to clean. This application uses two parameters, the actual temperature deviation value and the ash accumulation thickness, to more accurately and comprehensively evaluate the degree of ash accumulation in the ash hopper body 1. Therefore, the actual temperature deviation value can effectively compensate for the lack of locality and direct measurement of the thickness parameter, thereby improving reliability.

[0061] Furthermore, the controller 4 is configured to adjust the operating frequency and power of the ultrasonic oscillator 2 based on the actual thickness of the ash accumulation and the absolute value of the actual temperature deviation. This means that the controller 4 can adjust according to the degree of temperature anomaly and the specific thickness of the ash accumulation to achieve a better balance between cleaning efficiency and energy consumption.

[0062] Specifically, when the actual dust accumulation thickness is greater than the preset dust accumulation thickness but not greater than the second thickness threshold, and the absolute value is greater than the preset temperature deviation value but less than the second temperature threshold, the ultrasonic oscillator 2 is controlled to operate at the first frequency and the first power; when the actual dust accumulation thickness is greater than the second thickness threshold, or the absolute value of the actual temperature deviation value is greater than the second temperature threshold, the ultrasonic oscillator 2 is controlled to operate at a second frequency higher than the first frequency and a second power higher than the first power.

[0063] Controller 4 takes the absolute values ​​of the actual dust accumulation thickness and the actual temperature deviation as dual-dimensional input parameters, where h represents the actual dust accumulation thickness and Δt represents the actual temperature deviation. The formula for calculating Δt is as follows:

[0064] t represents the real-time flue gas temperature, and t0 represents the preset flue gas temperature;

[0065] The controller 4 adjusts the frequency (kHz) and power (% of rated power) of the ultrasonic oscillator 2 in segments according to the following rules:

[0066] When 5mm < h ≤ 10mm and 5℃ < Δt ≤ 30℃, the ultrasonic oscillator 2 outputs a frequency of 30kHz and a power of 60% (when the actual ash accumulation thickness is greater than the preset ash accumulation thickness and not greater than the second thickness threshold, and at the same time the absolute value is greater than the preset temperature deviation value and less than the second temperature threshold, the ultrasonic oscillator 2 is controlled to operate at the first frequency and the first power);

[0067] When h > 10mm or Δt > 30℃, the ultrasonic oscillator 2 outputs a frequency of 40kHz and a power of 80% (when the actual ash accumulation thickness is greater than the second thickness threshold, or the absolute value of the actual temperature deviation value is greater than the second temperature threshold, the ultrasonic oscillator 2 is controlled to operate at a second frequency higher than the first frequency and a second power higher than the first power);

[0068] When h ≤ 5mm and Δt ≤ 5℃, the ultrasonic oscillator 2 stops (when the absolute value of the actual temperature deviation value is not greater than the preset temperature deviation value and the actual ash accumulation thickness is not greater than the preset ash accumulation thickness, the controller 4 generates and executes a shutdown instruction to shut down the ultrasonic oscillator 2).

[0069] Optionally, the controller 4 further adjusts the frequency (kHz) and power (% rated power) of the ultrasonic oscillator 2 according to the following rules:

[0070] When 3mm < h ≤ 5mm and 10℃ < Δt ≤ 20℃, the output frequency of the ultrasonic oscillator 2 is 20kHz and the power is 40%; <00​​​​​​​​​Furthermore, after the ultrasonic oscillator 2 is started, the controller 4 monitors the changes in the actual ash thickness and the actual temperature deviation within a preset time window. If the actual ash thickness does not show a decreasing trend or the actual temperature deviation does not show a decreasing trend, an alarm signal is triggered. After the cleaning action is started, if the key performance parameters (ash thickness, temperature deviation) do not change in the expected direction, this state is judged as a system abnormality. Triggering an alarm signal can promptly notify the operator, indicating the risk of malfunction or performance degradation. This enables rapid identification and response to ineffective cleaning states, reduces reliance on regular manual inspections, and prevents problems such as equipment overheating and reduced efficiency that may be caused by ineffective ash removal, thereby improving the stability and reliability of the ash hopper 100 operation.

[0075] Example 2

[0076] like Figure 1 As shown, the sensor assembly 3 further includes at least two sets of thickness gauges, which are spaced apart along the axial direction of the ash hopper body 1. Each set of thickness gauges includes at least two thickness gauges 31, which are spaced apart along the circumferential direction of the ash hopper body 1.

[0077] It should be noted that the ash hopper body 1 is cylindrical or conical. Here, the axial direction of the ash hopper body 1 refers to the axial direction of the cylindrical or cylindrical structure; the circumferential direction of the ash hopper body 1 refers to the circumferential direction of the cylindrical or cylindrical structure.

[0078] At least two sets of thickness gauges are distributed along the axial direction of the ash hopper 100 to monitor ash accumulation at different depths or in different areas. At least two thickness gauges 31 in each set are distributed circumferentially in the ash hopper 100 to monitor ash accumulation at different azimuth angles on that cross section.

[0079] Furthermore, the sensor assembly 3 includes a temperature sensor 32, which is located at the upper opening of the ash hopper body 1.

[0080] It should be noted that the ash hopper body 1 has an inlet 11 and an outlet 12. The inlet 11 can be connected to the ash discharge port of the incinerator, and the outlet 12 is connected to the ash discharge device. The inlet 11 is usually located above the outlet 12 so that the fly ash falls into the outlet 12 under the action of gravity, while the flue gas is usually discharged upward and to one side of the inlet 11. The temperature sensor 32 is located at the upper opening (inlet 11), which is exactly on the critical path of flue gas discharge, thus improving the accuracy of monitoring data.

[0081] Furthermore, the ultrasonic oscillator 2 is installed on the outer wall of the ash hopper body 1.

[0082] Specifically, the ultrasonic oscillator 2 is welded to the outer wall of the ash hopper body 1. A welding tool head is provided on the outer wall of the ash hopper body 1, and the welding tool head is used to weld the ultrasonic oscillator 2.

[0083] Furthermore, the ultrasonic oscillator 2 includes a main oscillator 21 and a backup oscillator 22, both of which are communicatively connected to the controller 4. As can be seen from the above embodiment, after the main oscillator 21 is started, the controller 4 monitors the changes in the actual dust accumulation thickness and the actual temperature deviation value within a preset time window; if the actual dust accumulation thickness does not show a decreasing trend or the actual temperature deviation value does not show a decreasing trend, then the backup oscillator 22 is started; after the backup oscillator 22 is started, the controller 4 continues to monitor the changes in the actual dust accumulation thickness and the actual temperature deviation value within the preset time window; if the actual dust accumulation thickness still does not show a decreasing trend or the actual temperature deviation value still does not show a decreasing trend, then a first alarm signal is generated; if the actual dust accumulation thickness still does not show a decreasing trend or the actual temperature deviation value still does not show a decreasing trend, then a second alarm signal is generated.

[0084] The ash hopper 100 also includes an alarm device, which is connected to the controller 4 and is used to receive a first alarm signal and a second alarm signal, and to trigger a first alarm message and a second alarm message respectively according to the first alarm signal and the second alarm signal. The alarm message can be expressed as light, sound, etc., and the first alarm message and the second alarm message are different.

[0085] Furthermore, the ash hopper 100 also includes an insulation layer 5 covering the outer wall of the ash hopper body 1. The insulation layer 5 is constructed of ceramic fiber material. The insulation layer 5 is used to maintain the temperature of the ash hopper 100 above the acid dew point, thereby slowing down the condensation of sulfur dioxide-containing flue gas into acidic droplets, which exacerbates fly ash caking.

[0086] Example 3

[0087] like Figure 2 As shown, a second aspect embodiment of the present invention provides a dust removal method, which should be able to clean the ash hopper 100 of the first aspect embodiment of the present invention. The dust removal method includes the following steps:

[0088] Step S1: Obtain parameters characterizing the ash accumulation state inside the ash hopper 100 through the sensor assembly 3. The parameters include at least the real-time flue gas temperature inside the ash hopper body 1 and the actual ash accumulation thickness on the inner wall of the ash hopper body 1.

[0089] Step S2: Receive the real-time flue gas temperature inside the ash hopper body 1 and the actual ash accumulation thickness on the inner wall of the ash hopper body 1 through the controller 4, and generate an actual temperature deviation value based on the real-time flue gas temperature and the preset flue gas temperature.

[0090] Step S3: When the actual temperature deviation value is greater than the preset temperature deviation value, or the actual dust accumulation thickness is greater than the preset dust accumulation thickness, the controller 4 generates and executes a start command to control the ultrasonic oscillator 2 to start.

[0091] Step S4: During the operation of the ultrasonic oscillator 2, the controller 4 generates and executes a shutdown command when the actual temperature deviation value is not greater than the preset temperature deviation value and the actual dust accumulation thickness is not greater than the preset dust accumulation thickness, thereby shutting down the ultrasonic oscillator 2.

[0092] As can be seen from the technical solution, the embodiments provided by the present invention have the following advantages:

[0093] (1) By setting up an ultrasonic oscillator 2 and combining it with real-time monitoring data, high-frequency vibration can be applied automatically and in a timely manner, which can effectively destroy the bonding structure between fly ash particles, prevent them from further agglomerating and hardening and forming a dense caking layer, and reduce cleaning difficulty and labor intensity.

[0094] (2) Through real-time monitoring and precise control, ash cleaning is only started when needed (started when conditions are met and shut down when conditions return to normal), which avoids unnecessary energy consumption and equipment wear and tear, which helps to improve the energy efficiency of the entire incineration system, while reducing maintenance costs and production stoppage losses caused by blockages;

[0095] (3) In related technologies, the need for cleaning is determined by detecting the thickness of the ash accumulation. However, the uneven ash accumulation in the ash hopper body (1) leads to misjudgment of the timing of cleaning, which in turn causes the fly ash to further accumulate and clump together, making it difficult to clean. This application uses parameters of actual temperature deviation and ash thickness to more accurately and comprehensively evaluate the degree of ash accumulation in the ash hopper body (1). Therefore, the actual temperature deviation can effectively compensate for the lack of locality and direct measurement of the thickness parameter, thereby improving reliability.

[0096] The following is combined with Figures 1-2 Describe a specific example.

[0097] The ash hopper 100 includes an ash hopper body 1, a temperature sensor 32, a controller 4, a main oscillator 21, a signal transmission cable 6, a thickness gauge 31, a backup oscillator 22, and a flue 13.

[0098] The inlet 11 of the ash hopper body 1 is connected to a flue 13. The flue 13 extends along the axial direction of the ash hopper body 1 and away from the outlet 12 of the ash hopper body 1. The flue 13 can guide the flue gas to be discharged from the ash hopper body 1.

[0099] Temperature sensor 32 is arranged on the inner wall of flue 13 near ash hopper body 1 for real-time monitoring of flue gas temperature; thickness gauge 31 includes two equidistantly arranged along the axial direction on the inner wall of ash hopper 100 for real-time monitoring of ash accumulation thickness.

[0100] The controller 4 includes an input module, a calculation module, a judgment module, and an output module.

[0101] The input module of the controller 4 is connected to the temperature sensor 32 and the thickness gauge 31 via the signal transmission cable 6 to obtain the real-time flue gas temperature and the actual ash accumulation thickness.

[0102] The calculation module generates the actual temperature deviation value based on the real-time flue gas temperature and the preset flue gas temperature.

[0103] The judgment module compares the absolute value of the actual temperature deviation with the preset temperature deviation value, and compares the actual dust accumulation thickness with the preset dust accumulation thickness, and outputs the judgment result.

[0104] The output module receives the judgment result. When the absolute value of the actual temperature deviation is greater than the preset temperature deviation value, or the actual dust accumulation thickness is greater than the preset dust accumulation thickness, the output module generates and executes a start command to control the ultrasonic oscillator 2 to start. When the absolute value of the actual temperature deviation is not greater than the preset temperature deviation value and the actual dust accumulation thickness is not greater than the preset dust accumulation thickness, the output module generates and executes a stop command to stop the ultrasonic oscillator 2.

[0105] An ultrasonic oscillator 2 is welded onto the ash hopper body 1, and the output module of the controller 4 is connected to the ultrasonic oscillator 2 via a signal transmission cable 6.

[0106] It needs to be emphasized that:

[0107] Traditional dust removal technologies, such as manual dust removal, are inefficient and pose significant safety risks; while mechanical vibration, pulse blowing, steam blowing, and sonic blowing technologies suffer from incomplete dust removal, frequent equipment failures, and insufficient safety performance.

[0108] In related technologies, the cleaning operation of the ash hopper 100 has been automated by using electric push rods and coke-clearing rods. However, this system still faces challenges in practical applications. On the one hand, due to the internal structural characteristics of the ash hopper 100, the coke-clearing rods may not be able to reach all ash accumulation areas, resulting in some ash residue not being effectively removed and potentially causing re-clogging after long-term accumulation. On the other hand, when the electric push rods drive the coke-clearing rods for cleaning, improper operation or encountering exceptionally hard coke blocks may generate enormous impact forces. If such impact forces act directly on the wall surface of the ash hopper 100, they may not only damage the wall surface but also affect the overall safety and stability of the ash hopper 100. Therefore, the development of an efficient, stable, and safe automatic anti-clogging ash hopper 100 is particularly urgent.

[0109] (1) The high-frequency vibration of the ultrasonic oscillator 2 can break the agglomeration between fly ash particles, prevent fly ash from accumulating and caking in the ash hopper 100, and the vibration coverage is wide, reaching every corner inside the ash hopper 100; (2) By integrating the processor, ultrasonic oscillator, temperature sensor 32 and thickness gauge 31, etc., the ash accumulation in the ash hopper 100 can be monitored and analyzed in real time, ensuring the stability and reliability of the ash removal effect; (3) Automated ash removal operation reduces manual intervention and lowers safety risks. At the same time, the real-time monitoring and intelligent adjustment function can detect and handle abnormal situations in a timely manner, further improving safety; (4) The insulation layer 5 can maintain the temperature of the ash hopper 100, keeping the fly ash in the ash hopper 100 at a certain fluidity, further improving the ash removal efficiency.

[0110] Other configurations and operations of the ash hopper 100 according to embodiments of the present invention are known to those skilled in the art and will not be described in detail here. In the description of the present invention, "first feature" and "second feature" may include one or more of the features. The vertical, horizontal, and front-back directions are defined as shown in the figures.

[0111] In the description of this invention, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features not in direct contact but through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature.

[0112] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0113] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. An ash hopper, characterized in that, include: Ash bucket body; An ultrasonic oscillator is installed on the ash hopper body; A sensor assembly is used to acquire parameters characterizing the ash accumulation state within the ash hopper body, the parameters including at least the real-time flue gas temperature within the ash hopper body and the actual ash accumulation thickness on the inner wall of the ash hopper body. A controller, communicatively connected to the sensor assembly and the ultrasonic oscillator, is configured to: The absolute value of the actual temperature deviation is generated based on the real-time flue gas temperature and the preset flue gas temperature. When the absolute value of the actual temperature deviation is greater than the preset temperature deviation, or when the actual dust accumulation thickness is greater than the preset dust accumulation thickness, a start command is generated and executed to control the ultrasonic oscillator to start. When the absolute value of the actual temperature deviation is not greater than the preset temperature deviation and the actual dust accumulation thickness is not greater than the preset dust accumulation thickness, a shutdown command is generated and executed to shut down the ultrasonic oscillator. The controller is configured to adjust the operating frequency and power of the ultrasonic oscillator based on the actual dust accumulation thickness and the absolute value of the actual temperature deviation. The controller is configured to: When the actual dust accumulation thickness is greater than the preset dust accumulation thickness but not greater than the second thickness threshold, and the absolute value of the actual temperature deviation value is greater than the preset temperature deviation value but less than the second temperature threshold, the ultrasonic oscillator is controlled to operate at the first frequency and the first power. When the actual dust accumulation thickness is greater than the second thickness threshold, or the absolute value of the actual temperature deviation is greater than the second temperature threshold, the ultrasonic oscillator is controlled to operate at a second frequency higher than the first frequency and a second power higher than the first power. The controller is also configured to: After the ultrasonic oscillator is started, monitor the changes in the actual dust accumulation thickness and the actual temperature deviation value within a preset time window; If the actual dust accumulation thickness does not show a decreasing trend or the actual temperature deviation value does not show a decreasing trend, an alarm signal is triggered. The sensor assembly includes at least two sets of thickness gauges spaced apart along the axial direction of the ash hopper body, and each set of thickness gauges includes at least two thickness gauges spaced apart along the circumferential direction of the ash hopper body.

2. The ash hopper according to claim 1, characterized in that, The sensor assembly includes a temperature sensor, which is located at the upper opening of the ash hopper body.

3. The ash hopper according to claim 1, characterized in that, The ultrasonic oscillator is installed on the outer wall of the ash hopper body.

4. The ash hopper according to claim 3, characterized in that, It also includes an insulation layer covering the outer wall of the ash hopper body.

5. The ash hopper according to claim 4, characterized in that, The insulation layer is constructed of ceramic fiber material.

6. A method for cleaning ash, applied to the ash hopper according to any one of claims 1-5, characterized in that, Includes the following steps: Step S1: Obtain parameters characterizing the ash accumulation state inside the ash hopper through sensor components. The parameters include at least the real-time flue gas temperature inside the ash hopper body and the actual ash accumulation thickness on the inner wall of the ash hopper body. Step S2: Receive the real-time flue gas temperature inside the ash hopper body and the actual ash accumulation thickness on the inner wall of the ash hopper body through the controller, and generate the absolute value of the actual temperature deviation value based on the real-time flue gas temperature and the preset flue gas temperature. Step S3: When the absolute value of the actual temperature deviation is greater than the preset temperature deviation, or the actual dust accumulation thickness is greater than the preset dust accumulation thickness, the controller generates and executes a start command to control the ultrasonic oscillator to start. Step S4: During the operation of the ultrasonic oscillator, the controller generates and executes a shutdown command when the absolute value of the actual temperature deviation is not greater than the preset temperature deviation value and the actual dust accumulation thickness is not greater than the preset dust accumulation thickness, thereby shutting down the ultrasonic oscillator.

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