Self-sensing temperature control sludge drying system and dynamic adjusting method

Abstract

The invention discloses a self-sensing temperature control sludge drying system and a dynamic adjusting method, and belongs to the technical field of sludge drying. The system comprises a sludge treatment module, a self-sensing module, a central control module and an execution module. The sludge treatment module integrates a pre-wall-breaking unit, a pre-concentration dehydration unit, a sludge drying unit, a sludge gasification unit and a residue treatment unit; the self-sensing module is used for collecting temperature, sludge water content and gas component data; the central control module analyzes and compares the data and issues a regulation and control instruction; the execution module adjusts parameters such as temperature and material feeding amount. The system is combined with a dynamic regulation and control method, and the process is dynamically regulated in real time in the sludge drying and gasification process, so that the production process of the synthesis gas is close to a preset value, and the dynamic self-regulation of the sludge drying and gasification process is realized. The sludge treatment process integration is realized, the energy consumption is reduced and the cost is saved through waste heat recovery, meanwhile, the high quality of the synthesis gas is guaranteed through intelligent dynamic adjustment, and the system and the method are suitable for sludge resource treatment scenes.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of sludge drying, and particularly relates to a self-sensing temperature control sludge drying system and a dynamic adjustment method. BACKGROUND

[0002] With the development of industrialization and urbanization, the sludge output in China is increasing day by day. If not properly disposed, it will cause environmental risks such as heavy metal pollution and pathogen spread. The traditional landfill method is gradually limited due to the shortage of land resources, and co-disposal by incineration becomes the mainstream choice, but the moisture content of sludge needs to be reduced to below 40% through drying to ensure the burning efficiency. At the same time, the industry is experiencing a paradigm shift from end-of-pipe treatment to resource recycling, and the high calorific value of dried sludge provides a basis for resource recycling paths such as co-disposal in cement kilns and gasification to produce synthesis gas, which puts higher requirements on the energy efficiency and product stability of the drying system. The mainstream drying technology has obvious shortcomings: thermal drying can reduce the moisture content to below 10%, but it is energy-intensive and has low waste heat recovery rate; solar and biological non-thermal technologies need to be equipped with emergency heat sources due to climate or cycle limitations. More importantly, the drying and subsequent gasification steps in existing systems are disconnected, the drying temperature is preset by experience, and cannot respond to changes in gas composition in the gasifier, resulting in fluctuations in synthesis gas production; and the gasification waste heat is not recycled, further increasing energy consumption. In order to solve this problem, it is necessary to improve the recycling of waste heat by the sludge drying system. The Chinese patent with publication number CN117945621A discloses a controllable temperature sludge drying system and a temperature control method. The system includes a sludge drying module, a heat exchange module, a heating module, a temperature control module, and a thermoelectric module. The sludge drying module is used to load wet sludge, the heat exchange module is used to exchange heat with the wet sludge in the sludge drying module, the heating module is used to heat the heat exchange medium in the heat exchange module, the temperature control module is used to increase or decrease the temperature of the heat exchange medium, and the thermoelectric module is used to convert solar energy into electricity and power the sludge drying system. By combining the heating module and the temperature control module, the temperature of the heat exchange medium can be adjusted to precisely control the drying degree of the sludge. By setting the thermoelectric module to use solar power, low consumption and no pollution are achieved.

[0003] However, the existing technology cannot dynamically adjust the treatment process during sludge treatment, resulting in inconsistent quality of synthesis gas, and the drying and gasification processes of sludge are disconnected, leading to increased production costs. Therefore, there is an urgent need to develop a self-sensing and self-regulating sludge drying and gasification treatment system. SUMMARY

[0004] In view of the problems in the prior art, a primary object of the present application is to provide a self-sensing temperature control sludge drying system and a dynamic adjustment method, which integrates sludge pretreatment, sludge drying and sludge gasification intelligently together, controls the sludge treatment process through an intelligent system, regulates the sludge treatment process, solves the problem of uneven quality of synthesis gas, and solves the problem of disconnection between sludge drying and gasification through integration.

[0005] To achieve the above object, the present application provides the following technical solutions:

[0006] In a first aspect, the present application provides a self-sensing temperature control sludge drying system, comprising:

[0007] a sludge treatment module for drying and gasifying the sludge;

[0008] a self-sensing module for collecting temperature, sludge moisture content and gas composition data in the sludge drying and gasification process;

[0009] a central control module for regulating the sludge treatment process, generating and issuing control instructions;

[0010] an execution module for receiving control instructions and adjusting sludge drying and gasification process parameters.

[0011] Further, the sludge treatment module comprises a pre-wall breaking unit for breaking the wall of the sludge and loosening the structure of the sludge, a pre-concentration and dehydration unit for concentrating and dehydrating the sludge by waste heat, a sludge drying unit for drying the sludge by waste heat, a sludge gasification unit for cracking the organic components of the sludge to obtain synthesis gas, and a residue treatment unit for treating the remaining sludge residue after the gasification reaction is completed.

[0012] Further, the pre-wall breaking unit comprises a wall breaker, the pre-concentration and dehydration unit comprises a concentration and dehydration bin and a waste heat heater a, the sludge drying unit comprises a sludge drying bin, a waste heat heater b, a heat exchange pipeline and a heat exchanger, and the residue treatment unit comprises a residue recovery furnace.

[0013] Further, the sludge gasification unit comprises a sludge gasification furnace and a heat-oxygen circulation device, the heat-oxygen circulation device uses ilmenite or red mud as a circulation carrier, and the circulation carrier also serves as a catalyst for the gasification reaction in the sludge gasification furnace.

[0014] Further, the self-sensing module comprises a communication unit, a sludge moisture detection sensor a, a sludge moisture detection sensor b, a temperature sensor a, a temperature sensor b, a temperature sensor c, and a gas component detection sensor; the communication unit is used to receive sensor data and upload to the central control module.

[0015] Further, the central control module comprises a central processor, a controller, a data storage, and a data display screen.

[0016] Further, the execution module comprises a material regulator, a waste heat regulator a, a waste heat regulator b, and a heat-oxygen cycle regulator.

[0017] Further, the cell wall breaker is connected with the concentration and dehydration bin, sludge is transported from the cell wall breaker to the concentration and dehydration bin after cell wall treatment; the concentration and dehydration bin is connected with the sludge drying bin, sludge enters the sludge drying bin after pre-dewatering; the sludge drying bin is connected with the sludge gasification furnace, sludge enters the sludge gasification furnace after drying; the sludge gasification furnace is connected with the residue recovery furnace, the remaining residue is transported to the residue recovery furnace after sludge gasification; the sludge gasification furnace is connected with the waste heat heater a and the waste heat heater b through the heat exchange pipeline; a heat exchanger is arranged in the middle of the heat exchange pipeline; the waste heat heater a is arranged in the concentration and dehydration bin; the waste heat heater b is arranged in the sludge drying bin; the temperature sensor a is arranged in the concentration and dehydration bin; the temperature sensor b is arranged in the sludge drying bin, and the temperature sensor c is arranged in the sludge gasification furnace; the sludge moisture detection sensor a is arranged in the concentration and dehydration bin; the sludge moisture detection sensor b is arranged in the sludge drying bin; the gas component detection sensor is arranged in the sludge gasification furnace; the material regulator is arranged at the material inlet of the cell wall breaker; the waste heat regulator a is arranged in the waste heat heater b; the waste heat regulator b is arranged in the waste heat heater a; and the heat-oxygen cycle regulator is arranged in the heat-oxygen cycle device.

[0018] In a second aspect, the application provides a dynamic adjustment method of a self-sensing temperature control sludge drying system, comprising:

[0019] S1. The self-sensing module collects temperature, moisture content, and gas component data in real time in the sludge drying and gasification process, and transmits the data to the central control module;

[0020] S2. The central control module compares the collected data with the preset data, analyzes the deviation type and reason, and issues control instructions;

[0021] S3. The execution module receives the instructions and adjusts the corresponding regulator;

[0022] S4. After the adjustment is completed, steps S1-S3 are continued until the production process approaches the preset process.

[0023] Further, the conditioner comprises a material conditioner, a waste heat conditioner a, a waste heat conditioner b and a heat-oxygen circulation conditioner.

[0024] Advantages of the present application:

[0025] The present application realizes the integration of the sludge treatment process by integrating the functions of sludge pretreatment, sludge drying, sludge gasification, self-sensing, central processing and waste heat recycling, saves the cost of sludge treatment, and reduces the energy consumption of treatment; and through the intelligent control system, the sludge treatment process is dynamically adjusted to realize the high-quality production of synthesis gas. BRIEF DESCRIPTION OF DRAWINGS

[0026] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings needed in the embodiment description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor. In addition, the device structure schematic diagram provided by the embodiments of the present application only represents the functional structure relationship, not the actual structure diagram.

[0027] Figure 1 The self-sensing temperature control sludge drying system structure diagram provided by the present application.

[0028] Figure 2 The dynamic adjustment method flow chart of the self-sensing temperature control sludge drying system provided by the present application.

[0029] Reference signs: 1, pre-wall breaker; 2, pre-concentration dewatering bin; 3, waste heat heater a; 4, sludge drying bin; 5, waste heat heater b; 6, heat exchange pipeline; 7, heat exchanger; 8, sludge gasifier; 9, heat-oxygen circulation device; 10, communication unit; 11, sludge moisture sensor a; 12, sludge moisture sensor b; 13, temperature sensor a; 14, temperature sensor b; 15, temperature sensor c; 16, gas component detection sensor; 17, central processor; 18, controller; 19, data storage; 20, data display screen; 21, material conditioner; 22, waste heat conditioner a; 23, waste heat conditioner b; 24, heat-oxygen circulation conditioner; 25, residue recovery furnace. DETAILED DESCRIPTION

[0030] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific embodiments of the present application will be described in detail below with reference to the drawings of the specification.

[0031] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0032] The present application will be further described below with reference to the accompanying drawings and embodiments.

[0033] Example 1

[0034] like Figure 1 As shown, this application provides a self-sensing temperature-controlled sludge drying system, including a sludge treatment module, a self-sensing module, a central control module, and an execution module.

[0035] Specifically, the sludge treatment module includes a pre-cell disruption unit, a pre-concentration and dewatering unit, a sludge drying unit, a sludge gasification unit, and a residue treatment unit; the pre-cell disruption unit includes a cell disruptor 1; the pre-concentration and dewatering unit includes a concentration and dewatering chamber 2 and a waste heat heater a3; the sludge drying unit includes a sludge drying chamber 4, a waste heat heater b5, a heat exchange pipe 6, and a heat exchanger 7; the sludge gasification unit includes a sludge gasification furnace 8 and a heat-oxygen circulation device 9. In this embodiment, the sludge to be treated is fed into the wall-breaking device 1 through the inlet. After being broken down by the wall-breaking device 1, the clumps of sludge are dispersed, making the sludge loose and breathable, increasing the specific surface area and improving the water evaporation efficiency. The broken sludge then enters the concentration and dehydration chamber 2 from the wall-breaking device 1. The concentration and dehydration chamber 2 is heated by the waste heat heater a3 to evaporate the water in the sludge, controlling the water content of the sludge to be below 50%. Then the sludge enters the sludge drying chamber 4, where the sludge is dried using a circulating airflow. The circulating air exchanges heat with the waste heat heater b5. After being treated in the sludge drying chamber 4, the water content of the sludge is reduced to 10%. The dried sludge then enters the sludge gasification furnace 8, where the sludge first undergoes high-temperature decomposition. The organic matter in the sludge is decomposed into pyrolysis gas, tar, and semi-coke. Simultaneously, the circulating carrier ilmenite or red mud in the heat-oxygen circulation device 9 is oxidized by air and releases heat, forming a circulating carrier carrying heat and oxygen. This circulating carrier carrying heat and oxygen is blown into the sludge gasification furnace 8, where it reacts further with the pyrolysis gas and tar to generate syngas. The ilmenite or red mud, acting as the circulating carrier, can also act as a catalyst to promote the decomposition of pyrolysis gas and tar, increasing the syngas production. After the reaction is complete, the circulating carrier returns to the heat-oxygen circulation device 9. The high-temperature gas generated in the sludge gasification furnace 8 transfers heat to the heat exchanger 7 through the heat exchange pipe 6, and then the syngas is output for storage or reuse. The remaining sludge residue enters the residue recovery furnace 25.

[0036] Specifically, the self-sensing module includes a communication unit 10, a sludge moisture detection sensor a 11, a sludge moisture detection sensor b 12, a temperature sensor a 13, a temperature sensor b 14, a temperature sensor c 15, and a gas component detection sensor 16. In this embodiment, the self-sensing module is responsible for collecting parameters such as temperature and humidity in the sludge drying and gasification process, feeding the parameters back to the central control module, and then adjusting the sludge drying and gasification process; wherein the communication unit 10 is responsible for collecting sensor data and then transmitting the data to the central control module; the sludge moisture detection sensor a 11 is arranged in the concentration and dehydration bin 2, the sludge moisture detection sensor b 12 is arranged in the sludge drying bin 4, the temperature sensor a 13 is arranged in the concentration and dehydration bin 2, the temperature sensor b 14 is arranged in the sludge drying bin 4, the temperature sensor c 15 is arranged in the sludge gasification furnace 8, and the gas component detection sensor 16 is arranged in the sludge gasification furnace 8.

[0037] Specifically, the central control module includes a central processor 17, a controller 18, a data storage 19, and a data display screen 20. In this embodiment, the central processor 17 serves as the brain of the sludge drying system and is responsible for regulating the sludge drying process, receiving data from the self-sensing module, comparing the data with the system preset process value, analyzing where the current process problem exists, and then generating instructions to regulate the sludge content or drying temperature through the controller 18; the data storage 19 is responsible for storing process data for easy viewing; and the data display screen 20 facilitates manual monitoring of equipment status.

[0038] Specifically, the execution module includes a material regulator 21, a waste heat regulator a 22, a waste heat regulator b 23, and a heat-oxygen circulation regulator 24. In this embodiment, the execution module is responsible for regulating each regulator to adjust the process; wherein the material regulator 21 is arranged at the sludge inlet of the wall breaker 1 and is responsible for adjusting the sludge feed amount; the waste heat regulator a 22 is arranged in the waste heat heater a 3 and is responsible for regulating the heating temperature of the waste heat heater a 3 on the concentration and dehydration bin 2; the waste heat regulator b 23 is arranged in the waste heat heater b 5 and is responsible for regulating the heat exchange temperature of the waste heat heater b 5; and the heat-oxygen circulation regulator 24 is arranged in the heat-oxygen circulation device 9 and is responsible for adjusting the amount of heat-oxygen circulation carrier.

[0039] Embodiment 2

[0040] As shown in Figure 2 The present application provides a dynamic adjustment method of a self-sensing temperature control sludge drying system, which comprises:

[0041] S1. The self-sensing module collects temperature, moisture content, and gas component data in the sludge drying and gasification process in real time, and transmits the data to the central control module;

[0042] Specifically, the self-sensing module monitors and collects data through sludge moisture detection sensor a11, sludge moisture detection sensor b12, temperature sensor a13, temperature sensor b14, temperature sensor b15 and gas composition detection sensor 16, and then the communication unit 10 transmits the data to the central control module.

[0043] S2. The central control module compares the collected data with the preset data, analyzes the type and cause of the deviation, and issues control instructions.

[0044] Specifically, the central control module pre-sets parameters, then compares the collected data with the parameters, the central processing unit 17 analyzes the type and cause of deviations in the actual process, then generates control commands, and the controller 18 adjusts the process that needs to be adjusted in the commands.

[0045] S3. The execution module receives instructions and adjusts the corresponding regulators;

[0046] Specifically, under the control of the controller 18, the material regulator 21, waste heat regulator a22, waste heat regulator b23, and heat-oxygen cycle regulator 24 are adjusted to adjust the sludge drying and gasification process.

[0047] S4. After the adjustment is completed, continue to execute steps S1-S3 until the production process approaches the preset process.

[0048] Specifically, after the adjustment is completed, steps S1-S3 need to be repeated to identify the problems in the sludge drying and gasification process. Then, the corresponding process needs to be adjusted until the sludge drying and gasification process is close to the preset value, thereby improving the production quality of syngas.

[0049] The following is combined Figure 1 and Figure 2 This section elaborates on the operation mode of the self-sensing temperature-controlled sludge drying system.

[0050] Firstly, the material regulator 21 controls the sludge feeding amount, the sludge first enters the wall breaker 1, is subjected to wall breaking treatment, enters the concentration and dehydration bin 2, the central processing unit 17 reasonably adjusts the heating temperature of the waste heat heater a3 according to the data collected previously, after the sludge is concentrated and dehydrated at the adjusted temperature, enters the sludge drying bin 4, and similarly, the drying temperature of the sludge drying bin 4 is also adjusted, after the sludge is dried, enters the sludge gasification furnace 8, and the sludge is heated and decomposed to generate pyrolysis gas and tar and other substances, then the heat-oxygen circulation regulator 24 adjusts the circulation carrier amount, generates the circulation carrier carrying heat and oxygen by air oxidation, blows the circulation carrier into the sludge gasification furnace 8 to react with the pyrolysis gas and tar to generate synthesis gas, the gas component detection sensor 16 detects the gas component, the central processing unit 17 analyzes the gas component data to judge whether the gas component is qualified, if not, continues to carry out process adjustment until the gas component is qualified; and the heat generated in the sludge gasification furnace 8 is transported to the waste heat heater a3 and the waste heat heater b5 through the heat exchange pipeline 6 and the heat exchanger 7 to meet the needs of the concentration and dehydration and sludge drying processes.

[0051] The self-sensing temperature control sludge drying system and the dynamic adjustment method provided by the application make full use of the waste heat generated by the gasification reaction in the process of treating sludge, reduce the energy consumption of sludge treatment, use cheap ilmenite or red mud as the circulation carrier to play the role of gasification agent and catalyst, save the production cost, the integrated system reduces the pollution caused by sludge treatment, integrates sludge drying and sludge gasification, solves the problem that the sludge needs to be saved after traditional sludge drying and then gasified, saves energy as a whole and reduces the cost.

[0052] It should be noted that the above embodiments are only used to illustrate the technical solutions of the application and not to limit, although the application is described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the application can be modified or replaced equivalently without departing from the spirit and scope of the technical solutions of the application, and they should be covered in the scope of the claims of the application.

Claims

1. A self-sensing temperature-controlled sludge drying system, characterized in that, include: A sludge treatment module, which is used for drying and gasifying sludge; The self-sensing module is used to collect data on temperature, sludge moisture content and gas composition in the sludge drying and gasification process. A central control module, which is used to regulate the sludge treatment process and generate and issue control commands; An execution module is used to receive control commands and adjust the sludge drying and gasification process parameters.

2. The self-sensing temperature-controlled sludge drying system according to claim 1, characterized in that, The sludge treatment module includes a pre-cell disruption unit, which is used to disrupt the sludge cell walls and loosen the sludge structure; and a pre-concentration and dewatering unit, which uses waste heat to concentrate and dewater the sludge. A sludge drying unit, wherein the sludge drying unit uses waste heat to dry the sludge; The sludge gasification unit is used to decompose the organic components of sludge to obtain syngas; the residue treatment unit is used to treat the remaining sludge residue after the gasification reaction is completed.

3. The self-sensing temperature-controlled sludge drying system according to claim 2, characterized in that, The pre-breaking unit includes a cell disruptor (1); the pre-concentration and dewatering unit includes a concentration and dewatering chamber (2) and a waste heat heater a (3); the sludge drying unit includes a sludge drying chamber (4), a waste heat heater b (5), a heat exchange pipe (6), and a heat exchanger (7); the residue treatment unit includes a residue recycling furnace (25).

4. The self-sensing temperature-controlled sludge drying system according to claim 2, characterized in that, The sludge gasification unit includes a sludge gasification furnace (8) and a heat-oxygen circulation device (9); the heat-oxygen circulation device (9) uses ilmenite or red mud as the circulation carrier; the circulation carrier also serves as a catalyst for the gasification reaction in the sludge gasification furnace (8).

5. The self-sensing temperature-controlled sludge drying system according to claim 1, characterized in that, The self-sensing module includes a communication unit (10), a sludge moisture detection sensor a (11), a sludge moisture detection sensor b (12), a temperature sensor a (13), a temperature sensor b (14), a temperature sensor c (15), and a gas composition detection sensor (16); the communication unit (10) is used to receive sensor data and upload it to the central control module.

6. The self-sensing temperature-controlled sludge drying system according to claim 1, characterized in that, The central control module includes a central processing unit (17), a controller (18), a data storage device (19), and a data display screen (20).

7. The self-sensing temperature-controlled sludge drying system according to claim 1, characterized in that, The execution module includes a material regulator (21), a waste heat regulator a (22), a waste heat regulator b (23), and a heat-oxygen cycle regulator (24).

8. The self-sensing temperature-controlled sludge drying system according to claim 1, characterized in that, The sludge drying system's wall-breaking device (1) is connected to the concentration and dewatering chamber (2). After wall-breaking treatment, the sludge is transported from the wall-breaking device (1) to the concentration and dewatering chamber (2). The concentration and dewatering chamber (2) is connected to the sludge drying chamber (4). After pre-dewatering, the sludge enters the sludge drying chamber (4). The sludge drying chamber (4) is connected to the sludge gasification furnace (8). After drying, the sludge enters the sludge gasification furnace (8). The sludge gasification furnace (8) is connected to the residue recovery furnace (25). After gasification, the remaining residue is transported to the residue recovery furnace (25). The sludge gasification furnace (8) is connected to the waste heat heater a (3) and waste heat heater b (5) through a heat exchange pipe (6). A heat exchanger (7) is installed in the middle of the heat exchange pipe (6). The waste heat heater a (3) is installed in the concentration and dewatering chamber (2). The waste heat heater b (5) Set in sludge drying chamber (4); temperature sensor a (13) is set in thickening and dewatering chamber (2), temperature sensor b (14) is set in sludge drying chamber (4), temperature sensor c (15) is set in sludge gasification furnace (8); sludge moisture detection sensor a (11) is set in thickening and dewatering chamber (2), sludge moisture detection sensor b (12) is set in sludge drying chamber (4); gas composition detection sensor (16) is set in sludge gasification furnace (8); material regulator (21) is set at the material inlet of the wall breaker (1); waste heat regulator a (22) is set in waste heat heater a (3); waste heat regulator b (23) is set in waste heat heater b (5); heat-oxygen cycle regulator (24) is set in heat-oxygen cycle device (9).

9. A dynamic adjustment method for a self-sensing temperature-controlled sludge drying system, characterized in that, include: S1. The self-sensing module collects temperature, moisture content and gas composition data in the sludge drying and gasification process in real time and transmits the data to the central control module. S2. The central control module compares the collected data with the preset data, analyzes the type and cause of the deviation, and issues control instructions. S3. The execution module receives instructions and adjusts the corresponding regulators; S4. After the adjustment is completed, continue to execute steps S1-S3 until the production process approaches the preset process.

10. The dynamic adjustment method for a self-sensing temperature-controlled sludge drying system according to claim 9, characterized in that, The regulator includes a material regulator (21), a waste heat regulator a (22), a waste heat regulator b (23), and a heat-oxygen cycle regulator (24).

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