Online diagnosis system for pulse valve and filter bag of roasting purification dust remover

Abstract

The invention relates to the technical field of monitoring of roasting purification dust removal equipment in the electrolytic aluminum industry, and discloses a roasting purification dust remover pulse valve and filter bag online diagnosis system which comprises a pulse valve diagnosis instrument, a dust concentration detector, a detector distribution box, communication equipment and an upper computer. The pulse valve diagnostic instrument is vertically and downwards mounted on a pulse compressed air pipeline of the dust remover, and the mounting position is closest to a compressed air source; the dust concentration detector is composed of a probe, an insulator and a signal processing part, and is mounted on a flue section with uniformly distributed particulate matters and good flow layer linearity of an outlet pipeline of the dust remover; the detector distribution box supplies power to the pulse valve diagnostic instrument and the dust concentration detector respectively; and the communication equipment is connected with the pulse valve diagnostic instrument, the dust concentration detector and the upper computer through an RS485 bus. According to the invention, online real-time monitoring can be realized, and the position of the damaged filter bag can be quickly locked.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of monitoring of roasting and purification dust removal equipment in the electrolytic aluminum industry, and in particular to a roasting and purification dust removal device pulse valve and filter bag online diagnosis system. BACKGROUND

[0002] In the production process of the electrolytic aluminum industry, the roasting and purification process produces flue gas containing a large amount of particulate matter, which needs to be purified by a bag filter to meet the particulate matter emission limit value 10 of the industrial air pollutant emission standard. A single roasting and purification bag filter usually contains multiple independent bag chambers, each chamber is equipped with multiple sets of pulse valves and filter bags, the pulse valves realize filter bag dust removal by blowing compressed air, and the filter bags are responsible for intercepting particulate matter in the flue gas. The normal operation of the two directly determines the purification efficiency and emission standard of the dust removal device.

[0003] Currently, the state detection of the pulse valve and filter bag of the roasting and purification dust removal device mainly relies on artificial field confirmation and traditional fluorescent powder leak detection method: when it is judged that there is a filter bag leak in the bag chamber, fluorescent powder tracer needs to be added manually at the inlet of the dust removal device, and after it is attached to the leak point with the flue gas, the machine is stopped and the workers enter the chamber to find the leak point one by one with the help of ultraviolet lamp. This method has the following defects: first, the detection affects production, the roasting process of electrolytic aluminum is a continuous production process, and stopping for leak detection will interrupt the production rhythm and cause economic losses; second, the efficiency is low, the number of filter bags in a large dust removal device can reach several thousand, and manual bag-by-bag detection needs to consume several hours or even several days, and the amount of fluorescent powder used is large and the detection cost is high; third, the state of the pulse valve cannot be monitored synchronously, the traditional method can only detect filter bag leakage, but cannot judge problems such as pulse valve diaphragm damage, electromagnetic valve failure, and insufficient blowing pressure, so that hidden dangers such as incomplete dust removal and filter bag blockage caused by pulse valve failure cannot be found; fourth, the positioning accuracy is low, only the chamber where the leak bag is located can be roughly judged, and the specific pulse valve corresponding to the filter bag position cannot be accurately locked, and a large amount of manual detection is still needed for subsequent maintenance. SUMMARY

[0004] The present application aims to provide a roasting and purification dust removal device pulse valve and filter bag online diagnosis system to solve the technical problems that the existing roasting and purification dust removal device needs to stop for leak detection, the efficiency is low, a lot of manpower and material resources are consumed, and the position of the damaged filter bag cannot be located in real time and the running state of the pulse valve cannot be accurately judged.

[0005] To solve the above problems, the present application adopts the following technical solutions: Basic scheme: a roasting and purification dust removal device pulse valve and filter bag online diagnosis system, comprising: a pulse valve diagnostic instrument, a dust concentration detector, a detector distribution box, a communication device, and an upper computer. The pulse valve diagnostic instrument is vertically installed on the pulse compressed air pipeline of the dust remover, and the installation position is selected to be closest to the compressed air source. The dust concentration detector is composed of a probe, an insulator and a signal processing component, and is installed on the flue section of the dust remover outlet pipeline where the particulate matter is uniformly distributed and the flow layer is linear. The detection instrument distribution box supplies power to the pulse valve diagnostic instrument and the dust concentration detector. The communication equipment connects the pulse valve diagnostic instrument, the dust concentration detector and the upper computer through the RS485 bus. The upper computer is installed in the central control room and is used to receive data and generate trend analysis graphs and early warning information.

[0006] Beneficial effects: Through modular combination, the pulse valve and the filter bag are cooperatively monitored online, the installation positions of the components are optimized (such as the pulse valve diagnostic instrument near the air source, and the dust concentration detector selects the uniform flow section), the accuracy of data acquisition is ensured, and the trend analysis and early warning functions of the upper computer provide intuitive data support for operation and maintenance.

[0007] Preferably, the pulse valve diagnostic instrument is designed based on the load burst theory and is used to monitor the instantaneous change of the stress field in the compressed air pipeline when the pulse valve is opened each time, and the response time of the stress field monitoring is ≤0.1s.

[0008] Beneficial effects: The load burst theory is used to capture the instantaneous stress field change when the pulse valve is opened, and the response time of ≤0.1s can accurately capture the stress fluctuation corresponding to the "sound explosion" phenomenon of the pulse valve, avoiding false judgment of the pulse valve failure caused by response delay.

[0009] Preferably, the dust concentration detector adopts an alternating current coupling technology, detects the induced current generated by the charged particulate matter on the probe to obtain the particulate matter concentration, and the detection concentration range is 0.5-100 .

[0010] Beneficial effects: The detection range of 0.5-100 completely covers the particulate matter concentration at the outlet of the electrolytic aluminum calcination dust remover (normal emission ≤10 , leakage bag ≤100 ), and the alternating current coupling technology can detect without contacting the particulate matter, avoiding the influence of probe wear on precision, and being suitable for long-term online monitoring.

[0011] Preferably, the insulator of the dust concentration detector is made of an insulating material with stable chemical properties, and the assembly gap between the probe and the insulator is ≤0.1mm.

[0012] Beneficial effects: chemically stable insulation material avoids erosion of corrosive components in flue gas on the insulator, assembly gap ≤0.1mm prevents particulate matter from entering the gap and affecting charge induction, double protection ensures measurement stability and accuracy, and reduces equipment maintenance frequency.

[0013] Preferably, the host computer has a built-in software program that can determine whether the pulse valve is in action and the jet amount according to the stress field data collected by the pulse valve diagnostic instrument, and the jet amount determination threshold is 60% of the normal stress field peak value. When the monitored stress field peak value is less than 60% of the normal peak value, it is determined that the jet amount is weak.

[0014] Beneficial effects: By quantifying the jet amount determination threshold (60% of the normal peak value), subjective judgment errors are avoided, and problems such as insufficient jet amount caused by pulse valve diaphragm damage and electromagnetic valve failure can be quickly identified, providing a clear basis for pulse valve maintenance.

[0015] Preferably, the software program of the host computer can associate the pulse valve action time with the concentration data collected by the dust concentration detector. When the dust concentration increases by more than 5 times within 10s after the pulse valve is in action, it is determined that there is a risk of leakage in the corresponding filter bag.

[0016] Beneficial effects: By establishing a time-concentration correlation between pulse valve action and filter bag leakage through the quantitative standard of a concentration increase of more than 5 times within 10s, the corresponding pulse valve of the leaking filter bag can be accurately locked, avoiding the problem of ambiguous bag positioning in traditional methods.

[0017] Preferably, the RS485 bus data transmission rate of the communication device is 9600bps, and the data transmission error rate is less than or equal to .

[0018] Beneficial effects: The transmission rate of 9600bps meets the real-time monitoring requirements, and the low error rate of less than or equal to ensures that key data such as pulse valve stress field and dust concentration are not lost or transmitted incorrectly, ensuring the reliability of data analysis by the host computer.

[0019] Preferably, the detection probe of the pulse valve diagnostic instrument is made of high-temperature resistant alloy material, and can withstand temperatures ranging from -20℃ to 200℃.

[0020] Beneficial effects: The temperature resistance range of -20℃ to 200℃ covers the extreme environment of the electrolytic aluminum calcination workshop (workshop temperature can reach above 40℃ in summer and below -10℃ in winter), avoiding probe damage caused by temperature changes and prolonging the service life of the equipment.

[0021] Preferably, the trend analysis chart generated by the host computer includes a pulse valve stress field change curve and a dust concentration change curve in the last 72 hours, and supports export of historical data in Excel format.

[0022] Beneficial effects: The 72-hour trend curve facilitates the operation and maintenance personnel to trace the development process of the pulse valve failure and the filter bag leakage, and the historical data export function in Excel format supports offline analysis, thereby providing data support for preventive maintenance of equipment.

[0023] Preferably, the detection instrument power distribution box is provided with an overload protection module, which automatically cuts off the power supply circuit when the input voltage exceeds 24V±10%.

[0024] Beneficial effects: The overload protection threshold of 24V±10% adapts to the power supply fluctuation on site, and the automatic power-off function can prevent voltage abnormalities from damaging precise components such as pulse valve diagnostic instruments and dust concentration detectors, thereby reducing equipment maintenance costs.

[0025] The advantages of the present application are: 1. Real-time online monitoring without shutdown: The dust collector does not need to be interrupted throughout the process, avoiding the shutdown loss of the traditional fluorescent powder leak detection method, and adapting to the continuous production requirements of the electrolytic aluminum roasting process.

[0026] 2. Accurate fault location: Through the correlation analysis of the pulse valve action time and the dust concentration change, the leak bag belonging to the chamber, the corresponding pulse valve and the specific position can be locked, and the positioning accuracy is improved from "chamber level" to "filter bag level".

[0027] 3. Full coverage monitoring of pulse valve state: Based on the stress field change, it can be judged whether the pulse valve is in action or not, and the jet quantity is strong or weak, solving the blank of the traditional method which cannot monitor the pulse valve failure, and preventing the filter bag from being blocked due to incomplete cleaning.

[0028] 4. High detection efficiency: The time for judging the state of a single pulse valve and filter bag is less than or equal to 1s, and the leak bag positioning time is shortened from several hours to minutes, greatly reducing the manual workload.

[0029] 5. Stable and reliable measurement: The dust concentration detector adopts chemical stable insulation technology, and the pulse valve diagnostic instrument adopts a high-temperature probe, which adapts to the complex environment of the roasting workshop and has a long-term operation precision deviation of less than or equal to 5%.

[0030] 6. Strong data visualization and traceability: The trend analysis chart and historical data storage function of the host computer facilitate the operation and maintenance personnel to review the failure causes and develop preventive maintenance plans. BRIEF DESCRIPTION OF DRAWINGS

[0031] Figure 1 The logical block diagram of the present application.

[0032] Figure 2 This is a schematic diagram of the trend chart for Embodiment 1 of the present invention. Detailed Implementation

[0033] The following detailed description illustrates the specific implementation method: like Figure 1 As shown, the online diagnostic system for pulse valves and filter bags of the calcination purification dust collector of the present invention includes: a pulse valve diagnostic instrument, a dust concentration detector, a detector power distribution box, communication equipment, and a host computer; The pulse valve diagnostic instrument is installed vertically downwards in the pulse compressed air pipeline of the dust collector, with the installation position chosen to be as close as possible to the compressed air source. Designed based on load burst theory, the instrument monitors the instantaneous change in the stress field within the compressed air pipeline each time the pulse valve opens, with a stress field monitoring response time ≤0.1s. The detection probe of the pulse valve diagnostic instrument is made of high-temperature resistant alloy material, with a temperature tolerance range of -20℃ to 200℃.

[0034] The dust concentration detector consists of a probe, an insulator, and a signal processing component. It is installed in the cross-section of the flue gas duct at the dust collector outlet where particulate matter is evenly distributed and the flow path is linear. The dust concentration detector uses AC coupling technology to detect the induced current generated by charged particles on the probe to obtain the particulate matter concentration. The detection concentration range is 0.5-100. The insulator of the dust concentration detector is made of a chemically stable insulating material, and the assembly gap between the probe and the insulator is ≤0.1mm.

[0035] The power distribution box of the detector supplies power to the pulse valve diagnostic instrument and the dust concentration detector; the power distribution box of the detector has a built-in overload protection module, which automatically cuts off the power supply circuit when the input voltage exceeds 24V±10%.

[0036] The communication device connects the pulse valve diagnostic instrument, the dust concentration detector, and the host computer via an RS485 bus; the RS485 bus data transmission rate of the communication device is 9600bps, and the data transmission error rate is ≤ .

[0037] The host computer, installed in the central control room, receives data and generates trend analysis charts and early warning information. The host computer has built-in software that determines whether the pulse valve has activated and the strength of the jet flow based on stress field data collected by the pulse valve diagnostic instrument. The threshold for determining the jet flow strength is 60% of the normal stress field peak value; when the monitored stress field peak value is less than 60% of the normal peak value, the jet flow is considered weak. The host computer's software can also correlate the pulse valve's activation time with the concentration data collected by the dust concentration detector. If the dust concentration increases by more than 5% within 10 seconds after the pulse valve activates, the software will detect a weak jet flow. When the risk of leakage of the corresponding filter bag is determined. The trend analysis chart generated by the host computer includes a pulse valve stress field change curve and a dust concentration change curve in the last 72 hours, and supports export of historical data in Excel format.

[0038] The difference and advantage of the present application compared with the prior art in the art are that: 1. Compared with the traditional fluorescent powder leak detection method: Difference: The present application does not need to stop for online monitoring, and the traditional method needs to stop for manual addition of fluorescent powder; the present application is positioned to the specific pulse valve corresponding to the filter bag, and the traditional method can only be positioned to the bin.

[0039] Advantage: Avoid production interruption, reduce leakage bag positioning time from several hours to ≤5 minutes, and reduce detection cost by 80% (no fluorescent powder and manual labor hours).

[0040] 2. Compared with the manual visual leak detection method: Difference: The present application automatically collects data through instruments, and the traditional method needs workers to enter the bin to check each bag; the present application can monitor the pulse valve state, and the traditional method can only check the filter bag.

[0041] Advantage: Avoid the safety risk of workers entering the high-dust and high-temperature bin, improve the pulse valve fault detection rate from 0 to 100%, and reduce the excessive wear of the filter bag caused by the pulse valve fault.

[0042] 3. Compared with the single dust concentration monitoring method: Difference: The present application correlates the pulse valve stress field and the dust concentration, and the traditional method only measures the outlet concentration; the present application can judge the source of concentration anomaly (pulse valve fault / filter bag leakage), and the traditional method cannot distinguish.

[0043] Advantage: Avoid misjudgment (such as misjudgment of concentration rise caused by insufficient air injection of the pulse valve as filter bag leakage), and improve the accuracy of fault cause identification to more than 95%.

[0044] The specific application of the present application is shown in the following examples.

[0045] Example 1 This example is the application of the online diagnosis system of the 3# dust collector in the calcination workshop of a certain electrolytic aluminum plant, and the trend analysis chart generated by the host computer is shown in Figure 2 .

[0046] System configuration: pulse valve diagnostic instrument (installed near the air source of the main compressed air pipeline of the 3# dust collector, resistant to temperatures of -20℃-200℃), dust concentration detector (installed in the outlet horizontal flue, the probe rod is made of polytetrafluoroethylene), detector distribution box (24V power supply with overload protection), RS485 communication equipment (transmission rate 9600bps), host computer (installed in the central control room, stores 72 hours of historical data).

[0047] Implementation process: after the system is running, the host computer collects the stress field data of 16 pulse valves and the outlet dust concentration data in real time. When the 8# pulse valve is actuated, the pulse valve diagnostic instrument monitors that the peak value of the stress field is 45% of the normal peak value (<60% threshold value), and determines that the jet flow is weak; at the same time, the dust concentration detector monitors that the concentration increases from 8 (7 >5 threshold value) within 8s after the 8# pulse valve is actuated, and determines that the corresponding filter bag leaks.

[0048] Implementation effect: the operation and maintenance personnel directly go to the filter bag row corresponding to the 8# pulse valve according to the prompt of the host computer, find the damaged filter bag within 10 minutes and replace it, compared with the traditional method (4 hours of shutdown + 2 hours of manual investigation), the maintenance efficiency is improved by 24 times, and the production is not interrupted, and the particulate matter emission quickly recovers to 8

[0049] Example 2 This example is the networking monitoring of multiple dust collectors in a roasting workshop of an electrolytic aluminum plant.

[0050] System configuration: 5 roasting dust collectors are each configured with a set of the system of the application, which are aggregated to the host computer in the central control room through the RS485 bus, and the software program supports multi-device data comparison and analysis.

[0051] Implementation process: after running for 1 month, the trend analysis chart of the host computer shows that the peak value of the stress field of the 12# pulse valve of the 2# dust collector gradually decreases from the normal 1.2MPa to 0.8MPa (still >60% threshold value), and the corresponding dust concentration increases from 2 (5 threshold value). The operation and maintenance personnel predict that the diaphragm of the pulse valve is slightly worn and arrange to replace it in advance.

[0052] ​​​Implementation effect: avoid the pulse valve diaphragm damage caused by the sudden drop in the amount of jet (may cause filter bag blockage), preventive maintenance cost is 50% lower than after failure repair, 5 dust collector particulate matter emission monthly average of 6-8 , far lower than the limit of 10 .

[0053] Example 3 This example is the system stability test in high temperature and high humidity environment.

[0054] System configuration: pulse valve diagnostic instrument probe uses 316L stainless steel (resistant temperature -20℃-200℃), dust concentration detector insulator uses ceramic (strong chemical stability), installed in a southern electrolytic aluminum plant baking workshop (summer temperature 40℃+, humidity 80%+).

[0055] Implementation process: continuous operation for 3 months, record data accuracy deviation every day. The stress field monitoring deviation of pulse valve diagnostic instrument is ≤3%, the concentration measurement deviation of dust concentration detector is ≤4%, and no equipment failure caused by high temperature and high humidity occurs.

[0056] Implementation effect: verify the stability of the invention in extreme environment, the equipment failure-free operation time reaches 90 days, compared with the traditional detector (average failure-free time 30 days), the maintenance frequency is reduced by 67%, which meets the complex working condition requirements of electrolytic aluminum baking workshop.

[0057] The above is only an embodiment of the present application, and the specific technical solutions and / or common knowledge of characteristics in the scheme are not described in detail. It should be noted that for those skilled in the art, without departing from the technical solutions of the present application, some modifications and improvements can be made, which should also be considered as the protection scope of the present application, which will not affect the implementation effect and practicality of the patent. The protection scope of the present application should be subject to the content of its claims, and the specific implementation mode and the like in the specification can be used to explain the content of the claims.

Claims

1. A system for online diagnosis of a pulse valve and filter bag of a calciner purifying dust collector, mainly comprising: Pulse valve diagnostic instrument, dust concentration detector, detector distribution box, communication equipment and host computer; The pulse valve diagnostic instrument is vertically installed downward on the pulse compressed air pipeline of the dust collector, and the installation position is selected at the position closest to the compressed air source. The dust concentration detector is composed of a probe, an insulator and a signal processing component, and is installed on the flue section with uniform distribution of particulate matter and good linear flow layer of the dust collector outlet pipeline. The detector distribution box supplies power to the pulse valve diagnostic instrument and the dust concentration detector. The communication equipment connects the pulse valve diagnostic instrument, the dust concentration detector and the host computer through the RS485 bus. The host computer is installed in the central control room and is used for receiving data and generating trend analysis graphs and early warning information.

2. The system of claim 1, wherein, The pulse valve diagnostic instrument is designed based on the load blasting theory and is used for monitoring the instantaneous change of the stress field in the compressed air pipeline when the pulse valve is opened each time, and the response time of the stress field monitoring is ≤0.1s.

3. The system of claim 1, wherein, The dust concentration detector adopts an alternating coupling technology, detects the induced current generated by the charged particulate matter on the probe rod to obtain the particulate matter concentration, and the detection concentration range is 0.5-100 .

4. The system of claim 1, wherein, The insulator of the dust concentration detector is made of an insulating material with stable chemical properties, and the assembly gap between the probe and the insulator is ≤0.1mm.

5. The system of claim 1, wherein, The host computer has a built-in software program, which can determine whether the pulse valve is in action and the jet flow strength according to the stress field data collected by the pulse valve diagnostic instrument, and the jet flow strength determination threshold is 60% of the normal stress field peak value. When the monitored stress field peak value is <60% of the normal peak value, it is determined that the jet flow is weak.

6. The system of claim 1, wherein, The software program of the upper computer can associate the pulse valve action time with the concentration data collected by the dust concentration detector. When the dust concentration increases by more than 5% within 10s after the pulse valve acts, it is determined that there is a risk of leakage for the corresponding filter bag. ​ 7. The system of claim 1, wherein, The RS485 bus data transmission rate of the communication device is 9600bps, and the data transmission error rate is ≤ .

8. The system of claim 1, wherein, The detection probe of the pulse valve diagnostic instrument is made of a high-temperature resistant alloy material and can withstand a temperature range of -20℃-200℃.

9. The system of claim 1, wherein, The trend analysis graph generated by the host computer includes the pulse valve stress field change curve and the dust concentration change curve within 72 hours, and supports exporting historical data in Excel format.

10. The system of claim 1, wherein, The detector distribution box has an overload protection module, which automatically cuts off the power supply circuit when the input voltage exceeds 24V±10%.

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