A sludge deep dewatering device and system

Abstract

This invention relates to a sludge deep dewatering device and system for sludge treatment, comprising a belt filter press with two circulating roller filter cloths, each equipped with a cleaning mechanism. It also includes two filter cloth monitoring mechanisms, each mounted on one of the two filter cloths. Each monitoring mechanism includes an upper monitoring box and a lower monitoring box, each matching the filter cloth. A monitoring lamp is fixedly installed in the upper monitoring box, and multiple brightness sensors arranged in a rectangular array are installed in the lower monitoring box. An air inlet pipe is connected to the top of the upper monitoring box. This system enables real-time monitoring of the filter cloth's condition and can issue an alarm when cracks are detected, allowing technicians to promptly identify and maintain the filter cloth, significantly reducing the adverse effects of cracks. Furthermore, the system cleverly utilizes air pressure differences to actively open the cracks during monitoring, greatly improving monitoring accuracy.

Description

Technical Field

[0001] This invention relates to a dewatering device, and more particularly to a deep sludge dewatering device and system for use in the field of sludge treatment. Background Technology

[0002] Sludge treatment is the process of reducing, stabilizing, and rendering harmless sludge. Dewatering is the core step in sludge treatment. Sludge typically has a moisture content as high as 95%-99%. After dewatering, the volume of sludge is significantly reduced, which can significantly reduce transportation and disposal costs.

[0003] Chinese invention patent CN113716830B discloses a single filter cloth deep sludge dewatering device and its working method. The patent improves the dewatering rate of the filter press by adding an ultrasonic vibration mechanism to the sludge conditioning tank, using the action of ultrasonic waves to break down some of the sludge flocs, accelerate the dissolution of soluble pollutants, and enhance the aggregation effect of flocculants.

[0004] Chinese invention patent CN118005251B discloses a belt sludge filter press and a filter press method. This patent can simultaneously complete the synchronous adjustment of multiple tensioning components by operating a synchronous drive mechanism, without having to operate the tensioning components repeatedly in sequence.

[0005] Belt filter presses are widely used for deep sludge dewatering due to their high efficiency during continuous operation. They separate solids and liquids by clamping sludge between two tensioned filter cloths and applying pressure and shearing action from rollers. If the sludge contains hard particles such as sand, metal fragments, or glass shards, these particles will repeatedly rub against the filter cloth surface as it moves with the rollers. The sharp edges of these particles may directly scratch the filter cloth fibers, especially in high-pressure areas (such as the press rollers), where the scratches can quickly expand into cracks. As a critical component of the belt filter press, cracks in the filter cloth will lead to solid phase leakage and reduced dewatering efficiency. Current technology relies mainly on manual inspection for filter cloth condition monitoring, which is significantly delayed and cannot detect filter cloth damage in a timely manner. Therefore, we propose a deep sludge dewatering device and system. Summary of the Invention

[0006] The technical problem that this invention aims to solve in view of the above-mentioned prior art is that in the prior art, the monitoring of filter cloth status mainly relies on manual inspection, which has serious lag and cannot detect filter cloth damage in a timely manner.

[0007] To address the aforementioned problems, this invention provides a sludge deep dewatering device, comprising a belt filter press. The belt filter press is equipped with two circulating roller filter cloths, each of which is equipped with a cleaning mechanism. It also includes two filter cloth monitoring mechanisms respectively disposed on the two filter cloths. Each filter cloth monitoring mechanism includes an upper monitoring box and a lower monitoring box that match the filter cloth. The upper and lower monitoring boxes are symmetrically arranged about the filter cloth and slide against it. The bottom of the upper monitoring box and the top of the lower monitoring box are both open. A monitoring lamp is fixedly installed inside the upper monitoring box, and multiple brightness sensors distributed along a rectangular array are disposed inside the lower monitoring box. An air inlet pipe is connected to the top of the upper monitoring box, and an air pump is connected to the end of the air inlet pipe away from the upper monitoring box. An exhaust pipe is connected to the outer wall of the lower monitoring box.

[0008] The filter cloth monitoring agency also includes a smart alarm system, which includes a monitoring and control module, a crack detection module, and an anomaly alarm module. The monitoring and control module is connected to the monitoring light source, brightness sensor, and air pump. The brightness sensor is connected to the crack detection module, and the crack detection module is connected to the anomaly alarm module.

[0009] In the aforementioned sludge deep dewatering device, the filter cloth monitoring mechanism can monitor the status of the filter cloth in real time and issue an alarm when cracks are detected in the filter cloth, so that relevant technicians can promptly discover and perform corresponding maintenance and treatment on the filter cloth.

[0010] As a further improvement of this application, the filter cloth monitoring mechanism also includes two connecting frames for connecting the upper monitoring box and the lower monitoring box. The connecting frames are C-shaped, and the two ends of the connecting frames are fixedly connected to the upper monitoring box and the lower monitoring box, respectively. The two connecting frames are located on the left and right sides of the upper monitoring box, respectively. The connecting frames are fixedly connected to the body of the belt filter press. Along the filter cloth forward direction, the filter cloth monitoring mechanism is located downstream of the cleaning mechanism.

[0011] As another improvement of this application, an upper air pressure sensor is installed in the upper monitoring box, and a lower air pressure sensor is installed in the lower monitoring box. Both the upper and lower air pressure sensors are connected to the crack judgment module.

[0012] As a supplement to another improvement of this application, the crack detection module is preset with a brightness threshold and a pressure difference reduction threshold. The crack detection module is configured to calculate the real-time pressure difference based on the pressure data monitored by the upper and lower pressure sensors, and to determine whether there are cracks on the filter cloth by analyzing the brightness data monitored by the brightness sensor and the real-time pressure difference.

[0013] As a supplement to this application, the logic for the crack detection module to determine whether there is a crack on the filter cloth is as follows:

[0014] When the brightness data detected by at least one brightness sensor exceeds the brightness threshold and the real-time air pressure difference is lower than the air pressure difference drop threshold, the crack detection module determines that there is a crack on the filter cloth and controls the abnormal alarm module to issue an alarm.

[0015] As a supplement to another improvement of this application, the intelligent monitoring and alarm system also includes a blockage judgment module. The upper air pressure sensor and the lower air pressure sensor are both connected to the blockage judgment module, and the blockage judgment module is connected to the abnormal alarm module.

[0016] As a supplement to another improvement in this application, the blockage judgment module is preset with a pressure difference rise threshold. The pressure difference rise threshold is greater than the pressure difference fall threshold. The blockage judgment module is configured to calculate the real-time pressure difference based on the pressure data monitored by the upper and lower pressure sensors, and to determine whether the filter cloth is blocked by analyzing the real-time pressure difference.

[0017] As a supplement to this application, the logic for the blockage detection module to determine whether the filter cloth is blocked is as follows:

[0018] When the real-time air pressure difference exceeds the air pressure difference rise threshold, the blockage judgment module determines that the filter cloth is blocked and controls the abnormal alarm module to issue an alarm.

[0019] The present invention also provides a sludge deep dewatering system, comprising:

[0020] The above-mentioned sludge deep dewatering device;

[0021] Sludge conditioning equipment is used to add chemical conditioning agents to sludge;

[0022] The feed pump is used to feed the sludge, after it has been conditioned by the sludge conditioning device, into the belt filter press.

[0023] A sludge cake conveyor is installed at the discharge end of the belt filter press;

[0024] The central control unit is connected to the sludge conditioning unit, belt filter press, feed pump, and sludge cake conveyor via signal connections.

[0025] The management and control unit has a preset delay duration;

[0026] The crack detection module is connected to the management control unit. When the crack detection module determines that there is a crack on the filter cloth, the management control unit controls the sludge conditioning device, feed pump and belt filter press to stop immediately, and controls the sludge cake conveyor to stop after a delay according to the delay time.

[0027] In summary, this application, by setting up a filter cloth monitoring mechanism, achieves real-time monitoring of the filter cloth's condition and can issue an alarm when cracks are detected. This allows relevant technicians to promptly identify and maintain the filter cloth, significantly reducing the adverse effects of cracks. Furthermore, the clever use of air pressure difference to actively open cracks during monitoring greatly improves monitoring accuracy. The combined use of upper and lower air pressure sensors allows the crack detection module to comprehensively assess the presence of cracks based on both brightness and air pressure difference data, effectively avoiding misjudgments and further improving monitoring accuracy. Additionally, the combined use of a blockage detection module allows the filter cloth monitoring mechanism to also detect blockages and issue an alarm when blockages are detected, prompting relevant technicians to take timely action. This not only enhances the intelligence and functionality of the filter cloth monitoring mechanism but also further improves the effectiveness and efficiency of sludge dewatering. Attached Figure Description

[0028] Figure 1 This is a three-dimensional structural diagram of the filter cloth monitoring mechanism in the first embodiment of this application;

[0029] Figure 2 This is a cross-sectional view of the upper monitoring box in the first embodiment of this application;

[0030] Figure 3 This is a structural block diagram of the damage monitoring and early warning system in the first embodiment of this application;

[0031] Figure 4 This is a flowchart illustrating the logic of the crack detection module in the first embodiment of this application for determining whether there is a crack on the filter cloth.

[0032] Figure 5 This is a cross-sectional view of the upper monitoring box in the second embodiment of this application;

[0033] Figure 6 This is a structural block diagram of the damage monitoring and early warning system according to the second embodiment of this application;

[0034] Figure 7 This is a flowchart illustrating the logic of the crack detection module in the second embodiment of this application for determining whether there are cracks on the filter cloth.

[0035] Figure 8 This is a structural block diagram of the sludge deep dewatering system in the third embodiment of this application.

[0036] Explanation of the labels in the diagram:

[0037] 001, Filter cloth; 201, Upper monitoring box; 202, Lower monitoring box; 203, Connecting frame; 204, Monitoring light supply lamp; 205, Brightness sensor; 206, Inflation tube; 207, Air pump; 208, Exhaust pipe; 209, Upper air pressure sensor; 210, Lower air pressure sensor. Detailed Implementation

[0038] The three embodiments of this application will now be described in detail with reference to the accompanying drawings.

[0039] First implementation method:

[0040] Figures 1-4 A sludge deep dewatering device is shown, including a belt filter press. The belt filter press is equipped with two circulating roller filter cloths 001, and each filter cloth 001 is equipped with a cleaning mechanism. It also includes two filter cloth monitoring mechanisms respectively disposed on the two filter cloths 001. The filter cloth monitoring mechanisms include an upper monitoring box 201 and a lower monitoring box 202 that match the filter cloths 001. The upper monitoring box 201 and the lower monitoring box 202 are symmetrically arranged about the filter cloths 001, and the upper monitoring box 201 and the lower monitoring box 202 are... 02 are all slidably attached to the filter cloth 001. The bottom end of the upper monitoring box 201 and the top end of the lower monitoring box 202 are both set as open. A monitoring light 204 is fixedly installed inside the upper monitoring box 201. Multiple brightness sensors 205 distributed along a rectangular array are set inside the lower monitoring box 202. An air inflator 206 is connected to the top end of the upper monitoring box 201. An air pump 207 is connected to the end of the air inflator 206 away from the upper monitoring box 201. An exhaust pipe 208 is connected to the outer wall of the lower monitoring box 202.

[0041] As a further improvement of this application, the filter cloth monitoring mechanism also includes two connecting frames 203 for connecting the upper monitoring box 201 and the lower monitoring box 202. The connecting frames 203 are configured in a C-shape, and the two ends of the connecting frames 203 are fixedly connected to the upper monitoring box 201 and the lower monitoring box 202 respectively. The two connecting frames 203 are located on the left and right sides of the upper monitoring box 201 respectively, and the connecting frames 203 are fixedly connected to the body of the belt filter press.

[0042] The filter cloth monitoring mechanism also includes a smart alarm system, which includes a monitoring and control module, a crack judgment module, and an anomaly alarm module. The monitoring and control module is connected to the monitoring light 204, the brightness sensor 205, and the air pump 207. The brightness sensor 205 is connected to the crack judgment module, and the crack judgment module is connected to the anomaly alarm module. The crack judgment module has a preset brightness threshold.

[0043] Whenever the belt filter press is started for deep dewatering of sludge, the monitoring and control module activates the monitoring light 204, brightness sensor 205, and air pump 207. Brightness sensor 205 monitors brightness data in real time, and this data is transmitted to the crack detection module. The crack detection module analyzes the brightness data to determine if cracks exist on the filter cloth 001. During belt filter press operation, the filter cloth 001 slides cyclically through the upper monitoring box 201 and the lower monitoring box 202. Under normal circumstances, when there are no cracks on the filter cloth 001, the light emitted by the monitoring light 204 can only penetrate the lower monitoring box in small amounts (or even almost not at all). Inside the measuring box 202, the brightness data detected by each brightness sensor 205 is at a low level. However, if there is a crack in the filter cloth 001, when the crack passes through the upper measuring box 201 and the lower measuring box 202, a large amount of light emitted by the monitoring lamp 204 will enter the lower measuring box 202 through the crack, causing the brightness data detected by one (or more) brightness sensors 205 to increase significantly (the brightness data exceeds the brightness threshold). Therefore, the brightness sensor 205 can determine whether there is a crack in the filter cloth 001 by analyzing the brightness data. When the brightness sensor 205 determines that there is a crack in the filter cloth 001, the brightness sensor 205 will control the abnormal alarm module to issue an alarm.

[0044] After the air pump 207 is started, it will continuously fill the upper monitoring box 201 with air through the air filling pipe 206 at a constant volume flow rate, resulting in an air pressure difference between the upper monitoring box 201 and the lower monitoring box 202. When the crack passes between the upper monitoring box 201 and the lower monitoring box 202, the crack will be opened under the action of the air pressure difference, so that more light can enter the lower monitoring box 202, avoiding missed detection due to crack closure, which can greatly improve the accuracy and reliability of filter cloth 001 status monitoring.

[0045] Therefore, this application achieves real-time monitoring of the filter cloth status by setting up a filter cloth monitoring mechanism, and can issue an alarm when a crack is detected in the filter cloth 001, so that relevant technicians can promptly discover and perform corresponding maintenance and treatment on the filter cloth 001, thereby significantly reducing the adverse effects caused by the crack in the filter cloth 001. Moreover, during monitoring, the air pressure difference is cleverly used to actively open the crack, which greatly improves the accuracy of monitoring.

[0046] Along the forward direction of filter cloth 001, the filter cloth monitoring mechanism is located downstream of the cleaning mechanism, so that the filter cloth monitoring mechanism monitors the cleaned filter cloth 001, which can improve the accuracy of monitoring and judgment.

[0047] Second implementation method:

[0048] Figures 5-7A sludge deep dewatering device is shown. Unlike the first embodiment, the upper monitoring box 201 is also equipped with an upper air pressure sensor 209, and the lower monitoring box 202 is also equipped with a lower air pressure sensor 210. Both the upper air pressure sensor 209 and the lower air pressure sensor 210 are connected to the crack judgment module. The crack judgment module is also preset with a pressure difference reduction threshold. The crack judgment module is configured to calculate the real-time air pressure difference based on the air pressure data monitored by the upper air pressure sensor 209 and the lower air pressure sensor 210, and to determine whether there are cracks on the filter cloth 001 by analyzing the brightness data monitored by the brightness sensor 205 and the real-time air pressure difference.

[0049] The upper air pressure sensor 209 and the lower air pressure sensor 210 are used to monitor the air pressure in the upper monitoring box 201 and the lower monitoring box 202 in real time, respectively. The air pressure data monitored by the upper air pressure sensor 209 and the lower air pressure sensor 210 are transmitted to the crack judgment module in real time. The crack judgment module calculates the real-time air pressure difference between the upper monitoring box 201 and the lower monitoring box 202 based on the air pressure data. In this embodiment, when the crack judgment module judges whether there is a crack on the filter cloth 001, it also makes a comprehensive judgment based on the real-time air pressure difference. Since when the crack passes between the upper monitoring box 201 and the lower monitoring box 202, the air in the upper monitoring box 201 can flow quickly into the lower monitoring box 202 through the crack, which will also cause the real-time air pressure difference to drop significantly (the real-time air pressure difference is lower than the air pressure difference drop threshold). Therefore, when the brightness data increases significantly and the air pressure difference also drops significantly, the crack judgment module will determine that there is a crack on the filter cloth 001, which can effectively prevent false judgment.

[0050] Therefore, by combining the upper air pressure sensor 209 and the lower air pressure sensor 210, the crack detection module can make a comprehensive judgment based on both brightness and air pressure difference when determining whether there is a crack on the filter cloth 001. This can effectively avoid misjudgment and further improve the accuracy of monitoring.

[0051] The intelligent alarm monitoring system also includes a blockage judgment module. The upper air pressure sensor 209 and the lower air pressure sensor 210 are both connected to the blockage judgment module. The blockage judgment module is also connected to the abnormal alarm module. The blockage judgment module has a preset air pressure difference rise threshold, which is greater than the air pressure difference fall threshold.

[0052] The air pressure data monitored by the upper air pressure sensor 209 and the lower air pressure sensor 210 are also transmitted to the blockage judgment module in real time. The blockage judgment module also calculates the real-time air pressure difference between the upper monitoring box 201 and the lower monitoring box 202 based on the air pressure data, and judges whether there is a blockage in the filter cloth 001 by analyzing the real-time air pressure difference. When the filter cloth 001 is blocked, the airflow will be affected when the blockage passes through the upper monitoring box 201 and the lower monitoring box 202, causing the real-time air pressure difference to increase significantly (the real-time air pressure difference exceeds the air pressure difference rise threshold). Therefore, the blockage judgment module can judge whether there is a blockage in the filter cloth 001 by analyzing the real-time air pressure difference. When the blockage judgment module determines that the filter cloth 001 is blocked, the blockage judgment module will control the abnormal alarm module to issue an alarm.

[0053] Therefore, by combining the blockage detection module and other components, the filter cloth monitoring mechanism can also monitor whether there is a blockage in the filter cloth 001, and will also issue an alarm when a blockage is detected in the filter cloth 001, prompting relevant technicians to take timely action. This not only improves the intelligence and functionality of the filter cloth monitoring mechanism, but also further improves the effect and efficiency of sludge dewatering.

[0054] The third implementation method:

[0055] Figure 8 A sludge deep dewatering system is shown, comprising:

[0056] Sludge deep dewatering device;

[0057] Sludge conditioning equipment is used to add chemical conditioning agents to sludge;

[0058] The feed pump is used to feed the sludge, after it has been conditioned by the sludge conditioning device, into the belt filter press.

[0059] A sludge cake conveyor is installed at the discharge end of a belt filter press and is used to transport sludge cakes.

[0060] The central control unit is connected to the sludge conditioning unit, belt filter press, feed pump, and sludge cake conveyor via signal connections.

[0061] The management and control unit has a preset delay duration;

[0062] The crack detection module is connected to the management control unit. When the crack detection module determines that there is a crack on the filter cloth 001, the management control unit controls the sludge conditioning device, feed pump and belt filter press to stop immediately. It also controls the cake conveyor to stop after a delay. Immediately stopping the belt filter press can avoid the risks of continuous sludge leakage and aggravated filter cloth tearing. Immediately stopping the feed pump can prevent the belt filter press inlet from being blocked. Immediately stopping the sludge conditioning device can prevent the ineffective consumption of chemicals. The delayed stopping of the cake conveyor is to empty the formed cake.

[0063] In light of current practical needs, the above-described embodiments adopted in this application are not limited to these. Any changes made within the scope of knowledge possessed by those skilled in the art without departing from the concept of this application still fall within the protection scope of this invention.

Claims

1. A sludge deep dewatering device comprising a belt filter press provided with two circulating and rolling filter cloths (001), and each filter cloth (001) is configured with a cleaning mechanism, characterized in that, It also includes two filter cloth monitoring mechanisms respectively disposed on two filter cloths (001). The filter cloth monitoring mechanism includes an upper monitoring box (201) and a lower monitoring box (202) that match the filter cloth (001). The upper monitoring box (201) and the lower monitoring box (202) are symmetrically arranged about the filter cloth (001) and both the upper monitoring box (201) and the lower monitoring box (202) slide against the filter cloth (001). The bottom end of the upper monitoring box (201) and the lower monitoring box (202) are respectively disposed on the filter cloth (001). The top of each of the upper and lower monitoring boxes is open. A monitoring lamp (204) is fixedly installed inside the upper monitoring box (201). Multiple brightness sensors (205) are arranged in a rectangular array inside the lower monitoring box (202). An air inflator (206) is connected to the top of the upper monitoring box (201). An air pump (207) is connected to the end of the air inflator (206) away from the upper monitoring box (201). An exhaust pipe (208) is connected to the outer wall of the lower monitoring box (202). The filter cloth monitoring mechanism also includes a filter cloth monitoring and intelligent alarm system, which includes a monitoring and control module, a crack judgment module, and an abnormal alarm module. The monitoring and control module is connected to the monitoring light supply lamp (204), the brightness sensor (205), and the air pump (207). The brightness sensor (205) is connected to the crack judgment module, and the crack judgment module is connected to the abnormal alarm module.

2. The sludge deep dewatering device according to claim 1, characterized in that, The filter cloth monitoring mechanism also includes two connecting frames (203) for connecting the upper monitoring box (201) and the lower monitoring box (202). The connecting frames (203) are C-shaped. The two ends of the connecting frames (203) are fixedly connected to the upper monitoring box (201) and the lower monitoring box (202) respectively. The two connecting frames (203) are located on the left and right sides of the upper monitoring box (201) respectively. The connecting frames (203) are fixedly connected to the body of the belt filter press. Along the forward direction of the filter cloth (001), the filter cloth monitoring mechanism is located downstream of the cleaning mechanism.

3. The sludge deep dewatering device according to claim 1, characterized in that, The upper monitoring box (201) is equipped with an upper air pressure sensor (209), and the lower monitoring box (202) is equipped with a lower air pressure sensor (210). Both the upper air pressure sensor (209) and the lower air pressure sensor (210) are connected to the crack judgment module.

4. The sludge deep dewatering device according to claim 3, characterized in that, The crack detection module is preset with a brightness threshold and a pressure difference reduction threshold. The crack detection module is configured to calculate the real-time pressure difference based on the pressure data monitored by the upper pressure sensor (209) and the lower pressure sensor (210), and to determine whether there is a crack on the filter cloth (001) by analyzing the brightness data monitored by the brightness sensor (205) and the real-time pressure difference.

5. The sludge deep dewatering device according to claim 4, characterized in that, The logic for determining whether a crack exists on the filter cloth (001) by the crack detection module is as follows: When the brightness data detected by at least one brightness sensor (205) exceeds the brightness threshold and the real-time air pressure difference is lower than the air pressure difference drop threshold, the crack judgment module determines that there is a crack on the filter cloth (001) and controls the abnormal alarm module to issue an alarm.

6. The sludge deep dewatering device according to claim 5, characterized in that, The monitoring and intelligent alarm system also includes a blockage judgment module. The upper air pressure sensor (209) and the lower air pressure sensor (210) are both connected to the blockage judgment module. The blockage judgment module is also connected to the abnormal alarm module.

7. The sludge deep dewatering device according to claim 6, characterized in that, The blockage judgment module is preset with a pressure difference rise threshold, which is greater than the pressure difference fall threshold. The blockage judgment module is configured to calculate the real-time pressure difference based on the pressure data monitored by the upper pressure sensor (209) and the lower pressure sensor (210), and to determine whether there is a blockage in the filter cloth (001) by analyzing the real-time pressure difference.

8. The sludge deep dewatering device according to claim 7, characterized in that, The logic for determining whether the filter cloth (001) is blocked by the blockage detection module is as follows: When the real-time air pressure difference exceeds the air pressure difference rise threshold, the blockage judgment module determines that the filter cloth (001) is blocked and controls the abnormal alarm module to issue an alarm.

9. A sludge deep dewatering system, characterized in that, include: The sludge deep dewatering device as described in any one of claims 1-8; Sludge conditioning equipment is used to add chemical conditioning agents to sludge; The feed pump is used to feed the sludge, after it has been conditioned by the sludge conditioning device, into the belt filter press. A sludge cake conveyor is installed at the discharge end of the belt filter press; The central control unit is connected to the sludge conditioning unit, belt filter press, feed pump, and sludge cake conveyor via signal connections.

10. A sludge deep dewatering system according to claim 9, characterized in that, The management control unit has a preset delay duration; The crack detection module is connected to the management control unit. When the crack detection module determines that there is a crack on the filter cloth (001), the management control unit controls the sludge conditioning device, feed pump and belt filter press to stop immediately, and controls the sludge cake conveyor to stop after a delay according to the delay time.

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