An ultra-pure synthetic quartz sand roasting device

Abstract

The present application relates to the technical field of synthetic quartz sand, and particularly relates to a super-pure synthetic quartz sand roasting device, which comprises a temperature acquisition unit, a plurality of reaction temperature sensors arranged on the inner side of the furnace wall of a reaction furnace and used for acquiring the temperature of each temperature control area, and a gas temperature sensor; a data acquisition unit, a plurality of machine vision devices used for acquiring the reaction time of each temperature control area, and a signal detection device; a data analysis unit used for determining a plurality of same quartz sand roasting characteristic values as a quartz sand roasting characteristic value group, and calculating a diffraction peak dispersion characteristic value to determine a target quartz sand roasting characteristic value; a data processing unit used for determining whether the dispersion of quartz sand raw materials in the reaction furnace is uniform; and a finished product detection unit used for calculating the temperature difference threshold and the temperature deviation value of each temperature control area to determine whether the reaction furnace works normally. The present application significantly improves the accuracy of super-pure synthetic quartz sand roasting.

Description

Technical Field

[0001] This invention relates to the field of synthetic quartz sand technology, and in particular to an ultrapure synthetic quartz sand roasting apparatus. Background Technology

[0002] Synthetic silica sand is an indispensable basic material for the semiconductor and high-end optical device industries. Its core value lies in its extremely high purity and extremely low impurity element content. The preparation of synthetic silica sand usually involves a high-temperature reactor where the chemical reaction of gaseous raw materials or solid precursors is precisely controlled to generate amorphous or crystalline silica in a specific temperature range. In this highly sensitive synthesis process, ensuring that the reactants are evenly distributed in each temperature-controlled zone of the furnace and fully coupled with the heat field is the core prerequisite for determining the purity, particle size distribution, phase structure, and even the performance of downstream products of the final product. However, the existing production process of synthetic silica sand faces severe challenges. Uneven distribution of reactants directly leads to fluctuations in the quality of the synthesized product. Assessing the uniformity of synthetic silica sand is crucial for overcoming the quality bottleneck in the production of synthetic silica sand.

[0003] Chinese Patent Publication No. CN120664550A discloses a method for preparing high-purity quartz sand using organosilicon as a raw material through combustion, belonging to the field of synthetic quartz sand technology. This invention introduces purified organosilicon into a burner to obtain nano-silica powder; then, it undergoes sintering to remove surface moisture, hydroxyl groups, and carbon impurities, resulting in sintered silica powder. This sintered silica powder is then acid-leached and washed to remove surface and internal metallic impurities. The washed silica powder is then calcined in a chlorine atmosphere to remove moisture, hydroxyl groups, and residual metallic impurities. The calcined silica powder is then subjected to high-temperature densification treatment, followed by crushing, grinding, and sieving to obtain high-purity quartz sand. The high-purity quartz sand prepared by this invention has a particle size of 50μm~300μm, a purity of ≥99.999%, and an apparent density of ≥2.1g / cm3. This method overcomes the limitations of natural mineral purification and provides a new pathway for the large-scale production of high-value-added quartz sand.

[0004] Therefore, it is evident that the existing technology has the following problems:

[0005] In existing technologies, impurities are removed directly during the roasting process without considering whether the quartz sand reacts uniformly in the reactor. The reactor is not properly functioning by detecting the concentration of volatilized impurities and combining the temperature difference thresholds of each temperature control zone. This results in low quality consistency of the quartz sand after roasting. Summary of the Invention

[0006] To address this, the present invention provides an ultrapure synthetic quartz sand calcination apparatus to overcome the problems in the prior art where impurities are directly removed during the calcination process without considering whether the quartz sand reacts uniformly in the reactor, and without using the detection of impurity volatilization concentration combined with the temperature difference threshold of each temperature control zone to determine whether the reactor is working properly, resulting in low quality consistency of the quartz sand after calcination.

[0007] To achieve the above objectives, the present invention provides an ultrapure synthetic quartz sand calcination apparatus, comprising:

[0008] The temperature acquisition unit includes several reaction temperature sensors installed on the inner side of the reactor wall to acquire the temperature of each temperature control zone, and gas temperature sensors installed at the reactor inlet and outlet respectively.

[0009] The data acquisition unit includes several machine vision devices for acquiring the reaction time of each temperature control zone, and a signal detection device for acquiring the diffraction signal of each temperature control zone.

[0010] The data analysis unit, which is connected to the temperature acquisition unit and the data acquisition unit respectively, includes a method for determining a number of identical quartz sand calcination characteristic values ​​as a quartz sand calcination characteristic value group, and calculating the diffraction peak dispersion characteristic value corresponding to each of the quartz sand calcination characteristic value groups to determine the target quartz sand calcination characteristic value.

[0011] A data processing unit, connected to the data analysis unit, is used to determine whether the quartz sand raw material is uniformly dispersed in the reactor based on the comparison results between the quartz sand roasting characteristic value corresponding to each temperature control zone and the target quartz sand roasting characteristic value under the condition that the quartz sand raw material is in contact with several temperature control zones.

[0012] The finished product testing unit is connected to the temperature acquisition unit and the data processing unit respectively. It is used to calculate the temperature difference threshold of each temperature control zone based on the characterization value of the finished quartz sand product when it is determined that the quartz sand raw material is unevenly dispersed in the reactor. It calculates the temperature deviation value based on the temperature difference threshold and the actual temperature difference value of each temperature control zone. It determines whether the reactor is working normally based on the comparison result of the temperature deviation value and several preset temperature deviation values.

[0013] The calcination characteristic value of the quartz sand is determined by the reaction temperature difference and the reaction time, wherein the reaction temperature difference is the difference between the maximum and minimum temperature values ​​of the temperature control zone during the contact process with the quartz sand raw material, and the reaction time is the time difference between the start time and the end time of the temperature control zone during the contact process with the quartz sand raw material.

[0014] The diffraction peak dispersion characteristic value is determined by the diffraction peak intensity and diffraction peak width of the diffraction signal corresponding to each quartz sand calcination characteristic value in the quartz sand calcination characteristic value group.

[0015] The data analysis unit responds to the fact that the diffraction peak dispersion characteristic value is less than the preset diffraction peak dispersion characteristic value, determines the quartz sand calcination characteristic value group corresponding to the diffraction peak dispersion characteristic value, and determines the quartz sand calcination characteristic value corresponding to the quartz sand calcination characteristic value group as the target quartz sand calcination characteristic value.

[0016] The data processing unit determines whether the quartz sand raw material is uniformly dispersed in the reactor based on the comparison results between each of the quartz sand calcination characteristic values ​​and the target quartz sand calcination characteristic value. If the quartz sand calcination characteristic value is the same as any of the target quartz sand calcination characteristic values, the target diffraction signal corresponding to the quartz sand calcination characteristic value is determined. The difference characterization value is determined based on the target diffraction signal and the diffraction signal corresponding to the temperature control region to determine whether the quartz sand raw material is uniformly dispersed in the reactor.

[0017] The difference characterization value is determined by the diffraction peak intensity difference ratio and the diffraction peak width difference ratio;

[0018] The data processing unit determines that the quartz sand raw material is unevenly dispersed in the reactor when the difference characterization value is greater than or equal to a preset difference characterization value.

[0019] The finished product testing unit determines the finished product characterization value of the quartz sand product by weighted sum of the gas temperature difference and the impurity volatilization concentration, under the condition that the quartz sand raw material is unevenly dispersed in the reactor. The gas temperature difference is the difference between the inlet gas temperature at the reactor feed port and the outlet gas temperature at the reactor outlet, and the impurity volatilization concentration is the difference between the hydrogen chloride concentration at the quartz sand inlet and the hydrogen chloride concentration at the outlet.

[0020] Furthermore, in response to the temperature deviation value being greater than or equal to a first preset temperature deviation value and less than or equal to a second preset temperature deviation value, the finished product detection unit determines that the temperature control area corresponding to the temperature deviation value is working normally.

[0021] The finished product detection unit determines that the temperature control area corresponding to the temperature deviation value is not working properly when the temperature deviation value is less than the first preset temperature deviation value or greater than the second preset temperature deviation value.

[0022] Furthermore, the finished product detection unit determines that the reactor is operating normally when the abnormal operation ratio is less than or equal to a preset ratio.

[0023] The abnormal operation ratio is the ratio of the number of temperature control zones that are not functioning properly to the number of temperature control zones that are functioning properly.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention achieves accurate temperature acquisition of the temperature control zone by using a number of reaction temperature sensors installed on the inner side of the reactor wall of the temperature acquisition unit to acquire the temperature of each temperature control zone; gas temperature sensors are respectively installed at the feed inlet and discharge outlet of the reactor; a number of machine vision devices are used to acquire the reaction time of each temperature control zone through the data acquisition unit; and a number of diffraction signal detection devices are used to acquire the diffraction peaks of each temperature control zone. By setting different devices in the quartz sand reactor to acquire data from different regions, the causes affecting the calcination results of quartz sand during the quartz sand reaction process can be determined, which significantly improves the accuracy of calcination of ultrapure synthetic quartz sand.

[0025] Furthermore, this invention uses a data analysis unit to identify several identical quartz sand calcination characteristic values ​​as a quartz sand calcination characteristic value group, and calculates the diffraction peak dispersion characteristic value corresponding to each quartz sand calcination characteristic value group to determine the target quartz sand calcination characteristic value. If the dispersion characteristic value of a certain quartz sand calcination characteristic value group is very small, it indicates that the quartz sand particles in the temperature control area are diffracting synchronously and uniformly. If the dispersion characteristic value is very large, it indicates that the crystal structure of some quartz sand particles in the temperature control area has changed significantly, and the diffraction effect is obvious, while others are very weak. The reaction of quartz sand particles in this temperature control area is asynchronous and uneven. Different diffraction reaction dispersion characteristics of quartz sand in the reactor correspond to different target reaction characteristics. By analyzing the diffraction reaction dispersion characteristics, the corresponding target reaction characteristics can be accurately identified, significantly improving the accuracy of ultrapure synthetic quartz sand calcination.

[0026] Furthermore, this invention uses a data processing unit to determine whether the quartz sand raw material is uniformly dispersed in the reactor under conditions where it is in contact with quartz sand raw material in several temperature-controlled zones. This is based on the comparison between the quartz sand roasting characteristic values ​​corresponding to each temperature-controlled zone and the target quartz sand roasting characteristic values. The quartz sand roasting characteristic values ​​corresponding to each temperature-controlled zone can indicate the reaction state of the quartz sand in the reactor. By comparing and analyzing the real-time reaction state with the reaction state under normal working conditions corresponding to the target quartz sand roasting characteristic values, the uniformity of the quartz sand raw material dispersion in the reactor can be directly detected. Furthermore, adjustments can be made in a timely manner for cases where the quartz sand raw material is not uniformly dispersed in the reactor. At the same time, by analyzing the diffraction peaks of the diffraction signal, the phase composition of the quartz sand reaction process can be directly obtained. When a change in the quartz sand phase is detected, it means that the quartz sand may be unevenly dispersed due to local low temperatures. Moreover, when the quartz sand distribution is uneven, even if the diffraction peak positions are consistent in each temperature zone, the intensity of the diffraction peaks will also differ, significantly improving the accuracy of ultrapure synthetic quartz sand roasting.

[0027] Furthermore, the finished product detection unit of this invention is used to calculate the temperature difference threshold of each temperature control zone based on the characterization value of the finished quartz sand when the quartz sand raw material is determined to be unevenly dispersed in the reactor. The temperature difference threshold is then used to calculate the temperature deviation value based on the actual temperature difference value of each temperature control zone. The reactor is then compared with several preset temperature deviation values ​​to determine whether the reactor is working properly. By detecting the difference between the inlet temperature value and the outlet temperature value of the reactor, as well as the volatilization rate of the main impurities in the gas discharged from the reactor outlet per unit time, the quality of the calcined quartz sand can be directly understood. The temperature difference threshold of each temperature control zone is confirmed by the quartz sand quality so that the working status of the reactor can be accurately judged by the temperature deviation value. The whole process is logically rigorous, reducing the probability of misjudging the working status of the reactor based on a single reaction characteristic, and significantly improving the accuracy of calcination of ultrapure synthetic quartz sand. Attached Figure Description

[0028] Figure 1 This is an overall structural block diagram of the ultrapure synthetic quartz sand calcination device according to an embodiment of the present invention;

[0029] Figure 2 A logic diagram for determining whether the quartz sand raw material is uniformly dispersed in the reactor in an embodiment of the present invention;

[0030] Figure 3 This is a logic diagram for determining whether the temperature control area corresponding to the temperature deviation value is working properly in an embodiment of the present invention.

[0031] Figure 4 This is a logic diagram for determining whether the reactor is operating normally according to an embodiment of the present invention. Detailed Implementation

[0032] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0033] Furthermore, it should be noted that, in the description of this invention, 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 according to the specific circumstances.

[0034] It is understood that in this embodiment, when the ultrapure synthetic quartz sand is calcined in the reactor, the reactor is continuously rotated to ensure that the quartz sand is heated evenly, enhance the heat transfer efficiency, and prevent the material from agglomerating.

[0035] Understandably, to ensure the diversity of the test samples and sufficient reaction time for the quartz sand, several temperature control zones are set up in the axial region downstream of the combustion flame zone of the reactor, where the quartz sand reaction is most intense and the combustion temperature reaches its peak and stabilizes. Detection windows with low X-ray absorption, high temperature resistance, and thermal shock resistance are installed on one side of each temperature control zone and at a 180° angle to it. Each detection window is equipped with a forced water-cooling jacket and a clean gas purging system to ensure its long-term cleanliness and safety in a high-temperature dust environment. The X-ray source and detector of the signal detection device are mounted in a 2θ configuration on independent and robust supports on both sides of the reactor cylinder. This ensures that when the furnace rotates, the detection windows are aligned with the X-ray source and detector, allowing the X-ray beam to pass through the detection windows and irradiate the quartz sand material closely attached to the inner wall of the reactor, so that the diffraction signal is captured by the detector.

[0036] Please see Figure 1 As shown, it is an overall structural block diagram of the ultrapure synthetic quartz sand calcination device according to an embodiment of the present invention, including:

[0037] The temperature acquisition unit includes several reaction temperature sensors installed on the inner side of the reactor wall to acquire the temperature of each temperature control zone, and gas temperature sensors installed at the reactor inlet and outlet respectively.

[0038] The data acquisition unit includes several machine vision devices for acquiring the reaction time of each temperature control zone, and a signal detection device for acquiring the diffraction signal of each temperature control zone.

[0039] The data analysis unit, which is connected to the temperature acquisition unit and the data acquisition unit respectively, includes a method for determining several identical quartz sand calcination characteristic values ​​as a quartz sand calcination characteristic value group, and for calculating the diffraction peak dispersion characteristic values ​​corresponding to each quartz sand calcination characteristic value group, so as to determine the target quartz sand calcination characteristic value.

[0040] The data processing unit, which is connected to the data analysis unit, is used to determine whether the quartz sand raw material is uniformly dispersed in the reactor based on the comparison results between the quartz sand roasting characteristic value corresponding to each temperature control zone and the target quartz sand roasting characteristic value under the condition that the quartz sand raw material is in contact with several temperature control zones.

[0041] The finished product testing unit is connected to the temperature acquisition unit and the data processing unit respectively. It is used to calculate the temperature difference threshold of each temperature control zone based on the characterization value of the finished quartz sand under the condition that the quartz sand raw material is unevenly dispersed in the reactor. It calculates the temperature deviation value based on the temperature difference threshold and the actual temperature difference value of each temperature control zone. It determines whether the reactor is working normally based on the comparison result of the temperature deviation value and several preset temperature deviation values.

[0042] Specifically, this invention achieves precise temperature acquisition of the temperature control zones by using a temperature acquisition unit installed inside the furnace wall with several reaction temperature sensors to collect the temperature of each temperature control zone, gas temperature sensors installed at the furnace inlet and outlet, machine vision devices to collect the reaction time of each temperature control zone through a data acquisition unit, and diffraction signal detection devices to collect diffraction peaks of each temperature control zone. By setting different devices in the quartz sand reactor to obtain data from different regions, the invention can determine the causes affecting the calcination results of quartz sand during the reaction process, significantly improving the accuracy of calcination of ultrapure synthetic quartz sand.

[0043] Specifically, the characteristic values ​​of quartz sand calcination are determined by the reaction temperature difference and the reaction time. The reaction temperature difference is the difference between the maximum and minimum temperature values ​​of the temperature-controlled zone during the contact with the quartz sand raw material, and the reaction time is the time difference between the start and end times of the contact with the quartz sand raw material in the temperature-controlled zone.

[0044] Specifically, the process of calculating the characteristic value of quartz sand roasting involves determining the ratio of the reaction temperature difference to the general temperature difference as the temperature difference factor.

[0045] The ratio of reaction time to typical reaction time is defined as the time factor.

[0046] The weighted sum of the temperature difference factor and the time factor is determined to be the characteristic value of quartz sand roasting.

[0047] Specifically, in practice, the temperature difference is generally the average of the difference between the maximum and minimum temperature values ​​of several temperature-controlled zones in contact with the quartz sand raw material within a predetermined time, and the reaction time is generally the average of the time taken for several temperature-controlled zones to contact the quartz sand raw material.

[0048] Specifically, the sum of the weighting coefficients of the temperature difference factor and the time factor is 1. The temperature difference has a greater impact on the reaction characteristics of quartz sand in the reactor than the reaction time. Therefore, the weighting coefficient of the temperature difference factor is generally taken as 0.6 and the weighting coefficient of the time factor is 0.4.

[0049] Understandably, the diffraction peak intensity and width are acquired using the pulse counting method. A detector records the number of X-ray photons at different diffraction angles, with a single measurement time of 50–200 milliseconds. A complete diffraction pattern is generated every 1–5 minutes. The horizontal axis represents the diffraction angle, ranging from 20° to 80°, and the vertical axis represents the X-ray photon count. The measured intensity value at each angle in the entire pattern is subtracted from the corresponding background intensity value to obtain a net diffraction pattern. On the net diffraction pattern, the main diffraction peak of the quartz sand is located. Two boundary points are determined at the base of the peak on both sides. The angular range between these two points is the integration interval of the peak. The diffraction peak intensity is the area under the curve of the peak within the integration interval. On the net diffraction pattern, a horizontal line parallel to the background baseline is drawn at half the maximum peak height. This line intersects the diffraction peak outline at two points on the left and right. The difference in diffraction angles corresponding to these two points is the full width at half maximum (FWHM), i.e., the diffraction peak width.

[0050] Specifically, the diffraction peak dispersion characteristic value is determined by the diffraction peak intensity and diffraction peak width of the diffraction signal corresponding to each quartz sand calcination characteristic value in the quartz sand calcination characteristic value group.

[0051] Specifically, the standard deviation and average value of the diffraction peak intensity, as well as the standard deviation and average value of the diffraction peak width, are calculated for each temperature control region.

[0052] The ratio of the standard deviation of diffraction peak intensity to the average value of diffraction peak intensity is the relative intensity fluctuation rate.

[0053] The ratio of the standard deviation of the diffraction peak width to the average value of the diffraction peak width is the relative width volatility.

[0054] Calculate the mean values ​​of the relative volatility of intensity and the relative volatility of width, and determine the mean value as the characteristic value of diffraction peak dispersion.

[0055] Specifically, the relative intensity volatility and relative width volatility represent the relative volatility of the diffraction signal, and are dimensionless data.

[0056] Specifically, the target quartz sand calcination characteristic value is determined by comparing the diffraction peak dispersion characteristic value with the preset diffraction peak dispersion characteristic value. If the diffraction peak dispersion characteristic value is less than the preset diffraction peak dispersion characteristic value, then the quartz sand calcination characteristic value group corresponding to the diffraction peak dispersion characteristic value is determined, and the quartz sand calcination characteristic value corresponding to the quartz sand calcination characteristic value group is determined as the target quartz sand calcination characteristic value.

[0057] Specifically, the purpose of setting a preset diffraction peak dispersion characteristic value is to characterize the consistency of diffraction peak intensity and diffraction peak width of the diffraction signal. Therefore, the value range of the preset diffraction peak dispersion characteristic value is 0.05 to 0.2.

[0058] Specifically, this invention uses a data analysis unit to identify several identical quartz sand calcination characteristic values ​​as a quartz sand calcination characteristic value group, and calculates the diffraction peak dispersion characteristic value corresponding to each quartz sand calcination characteristic value group to determine the target quartz sand calcination characteristic value. If the dispersion characteristic value of a certain quartz sand calcination characteristic value group is very small, it indicates that the quartz sand particles in the temperature control area are diffracting synchronously and uniformly. If the dispersion characteristic value is very large, it indicates that the crystal structure of some quartz sand particles in the temperature control area has changed significantly, and the diffraction effect is obvious, while others are very weak. The reaction of quartz sand particles in this temperature control area is asynchronous and uneven. Different diffraction reaction dispersion characteristics of quartz sand in the reactor correspond to different target reaction characteristics. By analyzing the diffraction reaction dispersion characteristics, the corresponding target reaction characteristics can be accurately identified, significantly improving the accuracy of ultrapure synthetic quartz sand calcination.

[0059] Please see Figure 2 As shown, this is a logic diagram for determining whether the quartz sand raw material is uniformly dispersed in the reactor according to an embodiment of the present invention. The data processing unit determines whether the quartz sand raw material is uniformly dispersed in the reactor based on the comparison results between the calcination characteristic value of each quartz sand and the calcination characteristic value of the target quartz sand. If the calcination characteristic value of the quartz sand is the same as any target quartz sand calcination characteristic value, the target diffraction signal corresponding to the calcination characteristic value of the quartz sand is determined. The difference characterization value is determined based on the target diffraction signal and the diffraction signal corresponding to the temperature control area to determine whether the quartz sand raw material is uniformly dispersed in the reactor.

[0060] If the calcination characteristic value of the quartz sand is different from that of any target quartz sand, then several characteristic diffraction signals corresponding to the same calcination characteristic value of the quartz sand are recorded, the characteristic standard deviation of the characteristic diffraction peak intensity of the characteristic diffraction signal is calculated, and the characteristic standard deviation is compared with the preset standard deviation. If the characteristic standard deviation is less than or equal to the preset standard deviation, it is determined that the quartz sand raw material is uniformly dispersed in the reactor. If the characteristic standard deviation is greater than the preset standard deviation, it is determined that the quartz sand raw material is not uniformly dispersed in the reactor.

[0061] It is understandable that the target diffraction signal refers to the X-ray diffraction spectrum corresponding to the phase composition that the quartz sand raw material should have when it reaches a uniform reaction state during the quartz sand calcination process. At this time, multiple quartz sand calcination characteristic values ​​collected from each temperature control zone are determined as the target quartz sand calcination characteristic values.

[0062] Understandably, the preset standard deviation is set based on the average value of the diffraction peak intensities of several target diffraction signals. When the average value of the diffraction peak intensities of several target diffraction signals is 25,000 counts per second, the standard deviation is set to 112 counts per second to 120 counts per second.

[0063] Specifically, the difference characterization value is determined by the difference ratio of diffraction peak intensity and the difference ratio of diffraction peak width. In practice, when calculating the difference ratio of diffraction peak width, the average value of the diffraction peak width of the diffraction signal corresponding to the temperature control region and the average value of the diffraction peak width of the corresponding target diffraction signal can be calculated, and the difference ratio is calculated based on the average value of the diffraction peak width.

[0064] When calculating the diffraction peak intensity difference ratio, the average diffraction peak intensity of the diffraction signal corresponding to the temperature control region and the average diffraction peak intensity of the corresponding target diffraction signal can be calculated, and the difference ratio can be calculated based on the average diffraction peak intensity.

[0065] The difference ratio is the ratio of the absolute value of the difference between two values ​​to the mean of the two values.

[0066] It is understandable that the sum of the weighting coefficients of the diffraction peak intensity difference ratio and the diffraction peak width difference ratio is 1. Since the diffraction peak intensity and diffraction peak width have the same influence on determining whether the quartz sand raw material is uniformly dispersed in the reactor, the weighting coefficient of the diffraction peak intensity difference ratio and the weighting coefficient of the diffraction peak width difference ratio are generally taken as 0.5.

[0067] In one specific embodiment, a preset difference characterization value is set to 0.06. If the difference characterization value is greater than the preset difference characterization value, it is determined that the quartz sand raw material is unevenly dispersed in the reactor.

[0068] If the difference characterization value is less than the preset difference characterization value, it is determined that the quartz sand raw material is uniformly dispersed in the reactor.

[0069] Understandably, the closer the diffraction peak intensity and the diffraction peak width of the target diffraction signal and the corresponding diffraction signal in the temperature control region are, the more uniformly the quartz sand raw material is dispersed in the reactor. Conversely, the greater the difference between the diffraction peak intensity and the diffraction peak width of the target diffraction signal and the corresponding diffraction signal in the temperature control region, the less uniformly the quartz sand raw material is dispersed in the reactor. Therefore, the preset difference characterization value range is generally taken as 0.05 to 0.08.

[0070] Specifically, this invention uses a data processing unit to determine whether the quartz sand raw material is uniformly dispersed in the reactor under conditions where it is in contact with quartz sand raw materials in several temperature-controlled zones. This is based on the comparison between the quartz sand roasting characteristic values ​​corresponding to each temperature-controlled zone and the target quartz sand roasting characteristic values. The quartz sand roasting characteristic values ​​corresponding to each temperature-controlled zone can indicate the reaction state of the quartz sand in the reactor. By comparing and analyzing the real-time reaction state with the reaction state under normal working conditions corresponding to the target quartz sand roasting characteristic values, the uniformity of the quartz sand raw material dispersion in the reactor can be directly detected. Furthermore, adjustments can be made in a timely manner for cases of uneven dispersion of the quartz sand raw material in the reactor. At the same time, by analyzing the diffraction peaks of the diffraction signal, the phase composition of the quartz sand reaction process can be directly obtained. When a change in the quartz sand phase is detected, it means that the quartz sand may be unevenly dispersed due to local low temperatures. Moreover, when the quartz sand distribution is uneven, even if the diffraction peak positions are consistent in each temperature zone, the intensity of the diffraction peaks will also differ, significantly improving the accuracy of ultrapure synthetic quartz sand roasting.

[0071] Specifically, the finished product testing unit determines the finished product characterization value of the quartz sand product by weighted sum of the gas temperature difference and the impurity volatilization concentration, under the condition that the quartz sand raw material is unevenly dispersed in the reactor. The gas temperature difference is the difference between the inlet gas temperature at the reactor feed port and the outlet gas temperature at the reactor outlet, and the impurity volatilization concentration is the difference between the hydrogen chloride concentration at the quartz sand inlet and the hydrogen chloride concentration at the outlet.

[0072] Understandably, in practice, the concentration of hydrogen chloride can be detected from the exhaust pipe of the reactor using tunable diode laser absorption spectroscopy.

[0073] It is understandable that the sum of the weighting coefficients for the gas temperature difference and the impurity volatilization concentration is 1. Since the gas temperature difference and the impurity volatilization concentration have the same influence on the predicted temperature difference, the weighting coefficient for the gas temperature difference is generally taken as 0.5, and the weighting coefficient for the impurity volatilization concentration is also 0.5.

[0074] Specifically, under the condition that the quartz sand raw material is unevenly dispersed in the reactor but the temperature control zone is working normally, the temperature difference threshold of each temperature control zone corresponding to the characterization value of the finished quartz sand is determined to generate several sets of training data. Based on the training data, a quartz sand reaction model is constructed. The characterization value of the finished quartz sand is input into the quartz sand reaction model to output the temperature difference threshold. At the same time, the actual temperature of each temperature control zone is measured to calculate the actual temperature difference value. The absolute value of the difference between the temperature difference threshold and the actual temperature difference value is determined to be the temperature deviation value.

[0075] Please see Figure 3As shown, it is a logic judgment diagram for determining whether the temperature control area corresponding to the temperature deviation value is working normally according to an embodiment of the present invention. The finished product detection unit determines whether the temperature control area corresponding to the temperature deviation value is working normally based on the comparison result between the temperature deviation value and several preset temperature deviation values. If the temperature deviation value is greater than or equal to the first preset temperature deviation value and less than or equal to the second preset temperature deviation value, then the temperature control area corresponding to the temperature deviation value is determined to be working normally.

[0076] If the temperature deviation value is less than the first preset temperature deviation value or greater than the second preset temperature deviation value, the temperature control zone corresponding to the temperature deviation value is determined to be malfunctioning.

[0077] Specifically, the actual temperature difference is the difference between the maximum temperature value and the minimum temperature value within a temperature change cycle.

[0078] It is understandable that the gas inlet and the feed inlet are on the same side.

[0079] In one specific embodiment, a first preset temperature deviation value is set to 5°C and a second preset temperature deviation value is set to 6°C. If the temperature deviation value is greater than the first preset temperature deviation value and less than the second preset temperature deviation value, it is determined that the temperature control area corresponding to the temperature deviation value is working normally.

[0080] If the temperature deviation value is less than the first preset temperature deviation value, it is determined that the temperature control area corresponding to the temperature deviation value is not working properly.

[0081] If the temperature deviation value is greater than the second preset temperature deviation value, it is determined that the temperature control zone corresponding to the temperature deviation value is not working properly.

[0082] Understandably, in implementation, the normal operating state of each temperature control zone is determined by the normal operating range consisting of a first preset temperature deviation value and a second preset temperature deviation value. The first preset temperature deviation value can be determined based on the minimum temperature difference between the minimum rotation rate of the reactor and the minimum growth rate of the diffraction peak intensity. The second preset temperature deviation value can be determined based on the maximum temperature difference between the minimum degree of consistency of grain size and morphology during the quartz sand reaction and the maximum value of the diffraction peak width. Preferably, the range of the first preset temperature deviation value is 4℃~6℃, and the range of the second preset temperature deviation value is 7℃~8℃.

[0083] Please see Figure 4 As shown, it is a logic determination diagram for determining whether the reactor is working properly in an embodiment of the present invention. The finished product detection unit determines whether the reactor is working properly based on the abnormal working ratio of the number of abnormal temperature control areas to the number of normal temperature control areas. If the abnormal working ratio is less than or equal to a preset ratio, the reactor is determined to be working properly.

[0084] If the abnormal operation ratio is greater than the preset ratio, the reactor is determined to be malfunctioning.

[0085] In one specific embodiment, a preset ratio value is set to 0.08. If the abnormal operation ratio value is less than the preset ratio value, the reactor is determined to be working normally.

[0086] If the abnormal operation ratio is greater than the preset ratio, the reactor is determined to be malfunctioning.

[0087] Specifically, the number of temperature control zones collected is all data under the high-frequency operating state of the reactor. The number of temperature control zones that are not working properly should not exceed one-tenth of the number of temperature control zones that are working properly. Therefore, the preset ratio range is generally taken as 0.05 to 0.1.

[0088] Specifically, the finished product detection unit of this invention is used to calculate the temperature difference threshold of each temperature control zone based on the characterization value of the finished quartz sand when the quartz sand raw material is determined to be unevenly dispersed in the reactor. The temperature difference threshold is then used to calculate the temperature deviation value based on the actual temperature difference value of each temperature control zone. The reactor is then compared with several preset temperature deviation values ​​to determine whether the reactor is working properly. By detecting the difference between the inlet temperature value and the outlet temperature value of the reactor, as well as the volatilization rate of the main impurities in the gas discharged from the reactor outlet per unit time, the quality of the calcined quartz sand can be directly understood. The temperature difference threshold of each temperature control zone is confirmed by the quartz sand quality so that the working status of the reactor can be accurately judged by the temperature deviation value. The whole process is logically rigorous, reducing the probability of misjudging the working status of the reactor based on a single reaction characteristic, and significantly improving the accuracy of calcination of ultrapure synthetic quartz sand.

[0089] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. A calcining apparatus for ultrapure synthetic quartz sand, characterized in that, include: The temperature acquisition unit includes several reaction temperature sensors installed on the inner side of the reactor wall to acquire the temperature of each temperature control zone, and gas temperature sensors installed at the reactor inlet and outlet respectively. The data acquisition unit includes several machine vision devices for acquiring the reaction time of each temperature control zone, and a signal detection device for acquiring the diffraction signal of each temperature control zone. The data analysis unit, which is connected to the temperature acquisition unit and the data acquisition unit respectively, includes a method for determining a number of identical quartz sand calcination characteristic values ​​as a quartz sand calcination characteristic value group, and calculating the diffraction peak dispersion characteristic value corresponding to each of the quartz sand calcination characteristic value groups to determine the target quartz sand calcination characteristic value. A data processing unit, connected to the data analysis unit, is used to determine whether the quartz sand raw material is uniformly dispersed in the reactor based on the comparison results between the quartz sand roasting characteristic value corresponding to each temperature control zone and the target quartz sand roasting characteristic value under the condition that the quartz sand raw material is in contact with several temperature control zones. The finished product testing unit is connected to the temperature acquisition unit and the data processing unit respectively. It is used to calculate the temperature difference threshold of each temperature control zone based on the characterization value of the finished quartz sand product when it is determined that the quartz sand raw material is unevenly dispersed in the reactor. It calculates the temperature deviation value based on the temperature difference threshold and the actual temperature difference value of each temperature control zone. It determines whether the reactor is working normally based on the comparison result of the temperature deviation value and several preset temperature deviation values. The calcination characteristic value of the quartz sand is determined by the reaction temperature difference and the reaction time, wherein the reaction temperature difference is the difference between the maximum and minimum temperature values ​​of the temperature control zone during the contact process with the quartz sand raw material, and the reaction time is the time difference between the start time and the end time of the temperature control zone during the contact process with the quartz sand raw material. The diffraction peak dispersion characteristic value is determined by the diffraction peak intensity and diffraction peak width of the diffraction signal corresponding to each quartz sand calcination characteristic value in the quartz sand calcination characteristic value group. The data analysis unit responds to the fact that the diffraction peak dispersion characteristic value is less than the preset diffraction peak dispersion characteristic value, determines the quartz sand calcination characteristic value group corresponding to the diffraction peak dispersion characteristic value, and determines the quartz sand calcination characteristic value corresponding to the quartz sand calcination characteristic value group as the target quartz sand calcination characteristic value. The data processing unit determines whether the quartz sand raw material is uniformly dispersed in the reactor based on the comparison results between each of the quartz sand calcination characteristic values ​​and the target quartz sand calcination characteristic value. If the quartz sand calcination characteristic value is the same as any of the target quartz sand calcination characteristic values, the target diffraction signal corresponding to the quartz sand calcination characteristic value is determined. The difference characterization value is determined based on the target diffraction signal and the diffraction signal corresponding to the temperature control region to determine whether the quartz sand raw material is uniformly dispersed in the reactor. The difference characterization value is determined by the diffraction peak intensity difference ratio and the diffraction peak width difference ratio; The data processing unit determines that the quartz sand raw material is unevenly dispersed in the reactor when the difference characterization value is greater than or equal to a preset difference characterization value. The finished product testing unit determines the finished product characterization value of the quartz sand product by weighted sum of the gas temperature difference and the impurity volatilization concentration, under the condition that the quartz sand raw material is unevenly dispersed in the reactor. The gas temperature difference is the difference between the inlet gas temperature at the reactor feed port and the outlet gas temperature at the reactor outlet, and the impurity volatilization concentration is the difference between the hydrogen chloride concentration at the quartz sand inlet and the hydrogen chloride concentration at the outlet.

2. The ultrapure synthetic quartz sand roasting apparatus according to claim 1, characterized in that, The finished product detection unit determines that the temperature control area corresponding to the temperature deviation value is working normally when the temperature deviation value is greater than or equal to the first preset temperature deviation value and less than or equal to the second preset temperature deviation value. The finished product detection unit determines that the temperature control area corresponding to the temperature deviation value is not working properly when the temperature deviation value is less than the first preset temperature deviation value or greater than the second preset temperature deviation value.

3. The ultrapure synthetic quartz sand roasting apparatus according to claim 2, characterized in that, The finished product detection unit determines that the reactor is operating normally when the abnormal operation ratio is less than or equal to a preset ratio. The abnormal operation ratio is the ratio of the number of temperature control zones that are not functioning properly to the number of temperature control zones that are functioning properly.

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