High-pressure filter pressing device for oil-sludge separation treatment and method of high-pressure filter pressing device

Abstract

The invention relates to a high-pressure filter-pressing device and method for oil-sludge separation treatment, and belongs to the technical field of oil-sludge separation treatment and high-pressure filter-pressing dehydration, and the method comprises the following steps: S1, setting a tempering reaction unit, a high-pressure feeding unit and a diaphragm filter-pressing unit; s2, hardening and tempering are started, the change rate of the stirring resistance moment is monitored, and when the change rate of the stirring resistance moment crosses zero or is lower than a threshold value, flocculation is judged to be completed and stirring is stopped; s3, collecting pressure and flow velocity during feeding, and calculating a specific resistance coefficient to characterize the characteristics of a filter cake; and S4, after feeding is finished, controlling the squeezing mode according to the specific resistance coefficient, and executing differential squeezing to form a filter cake. According to the invention, the pure torsional moment in the stirring process can be accurately obtained, and the optimal rheological state of the locked material can be accurately obtained.

Description

Technical Field

[0001] This invention relates to the field of oil sludge separation and high-pressure filtration dehydration, specifically to a high-pressure filtration device and method for oil sludge separation. Background Technology

[0002] With increasingly stringent industrial environmental standards and a continuous increase in the amount of oily sludge produced, the complexity of oily sludge components has significantly increased. This complexity presents many challenges to separation and treatment processes, especially in terms of dewatering efficiency control and equipment operational stability.

[0003] Currently, deep dewatering of oil sludge generally employs a combination of chemical conditioning and mechanical filtration. Technicians typically set equipment operating parameters, such as stirring time, feed pressure, and pressing sequence, based on historical experience or fixed procedures. However, traditional control methods rely on preset fixed parameters and lack real-time awareness of material property fluctuations. Because the moisture content, viscosity, and other properties of oil sludge vary significantly in actual production, fixed procedures often fail to match the real-time state of the material. This mismatch leads to unstable dewatering results, frequently resulting in substandard sludge cake moisture content or equipment blockage and energy waste due to blindly operating at high pressure. Furthermore, traditional monitoring methods struggle to detect abnormal conditions within the conveying and pressing equipment in real time, making it difficult to effectively prevent equipment damage or metering distortion caused by cavitation or overload.

[0004] Therefore, how to achieve adaptive adjustment based on material changes and improve dehydration efficiency while ensuring equipment safety has become an urgent problem to be solved in this field.

[0005] The information disclosed in the background section is only intended to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to provide a high-pressure filter press device and method for oil sludge separation and treatment, so as to solve the problems mentioned in the background art. The technical solution of this invention includes: S1. A conditioning reaction unit, a high-pressure feeding unit, and a diaphragm filter press unit are set up. The conditioning reaction unit is located at the front end of the process flow. The high-pressure feeding unit is connected between the conditioning reaction unit and the diaphragm filter press unit. The conditioning reaction unit is equipped with a non-load-bearing dynamic torque sensor. The high-pressure feeding unit is equipped with a ceramic plunger pump, a flow monitoring assembly, and a pressure sensing terminal. The diaphragm filter press unit is equipped with a pressing water station. S2. Start the conditioning reaction unit, monitor the stirring resistance torque in real time during the conditioning process of sludge, calculate the rate of change of the stirring resistance torque over time after low-pass filtering, and determine that flocculation and agglomeration are completed and stop stirring when the rate of change changes from a positive value and passes through zero or is lower than the preset convergence threshold. S3. Start the ceramic plunger pump to feed the diaphragm filter press unit, collect the feed pressure value and instantaneous flow rate value in real time, calculate the rate of change of feed pressure relative to time, and divide the rate of change by the square of the instantaneous flow rate value to obtain the specific resistance coefficient characterizing the filter cake characteristics. S4. After the feeding is completed, the operation mode of the pressing water station is controlled according to the specific resistance coefficient, and differentiated pressing actions are performed on the material in the diaphragm filter press unit to form a dehydrated filter cake.

[0007] Preferably, step S3 includes the following steps before calculating the specific drag coefficient: S3.1 Calculate the effective hydraulic power obtained from the fluid side, divide the effective hydraulic power by the real-time input power of the ceramic plunger pump drive motor and correct it in combination with the hydraulic oil temperature coefficient to obtain the current mechanical-hydraulic energy conversion efficiency; S3.2. Compare the current mechanical-hydraulic energy conversion efficiency with the standard mechanical-hydraulic energy conversion efficiency curve. If the current mechanical-hydraulic energy conversion efficiency is lower than the benchmark value, instruct the ceramic plunger pump to enter the low-speed exhaust protection mode. After the low-speed exhaust protection mode has been running for a preset time, control the ceramic plunger pump to restore the normal speed and re-detect the current mechanical-hydraulic energy conversion efficiency. If the efficiency is still lower than the benchmark value, trigger the shutdown alarm.

[0008] Preferably, step S3 further includes: S3.3 Read the final stable resistance torque value at the end of the tempering process in step S2 to construct the specific resistance determination threshold; S3.4 If the specific drag coefficient is higher than the specific drag determination threshold, control the ceramic plunger pump to perform stepped speed reduction operation; if the specific drag coefficient is lower than the specific drag determination threshold, control the ceramic plunger pump to perform constant pressure and high flow operation.

[0009] Preferably, step S4 specifically includes: When the instantaneous flow rate value is detected to naturally decrease to less than five percent of the rated flow rate of the ceramic plunger pump, the ceramic plunger pump is triggered to perform a shutdown action, and the pump body is completely stopped after the shutdown action is completed. If the specific resistance coefficient is higher than the specific resistance determination threshold, the pressing water station is controlled to perform multi-stage pulse water injection, sequentially performing the action sequence of low pressure maintenance, rapid pressure increase to medium pressure, and impact to high pressure. If the specific resistance coefficient is lower than the specific resistance determination threshold, the pressing water station is controlled to perform linear rapid pressurization.

[0010] A high-pressure filter press for oil sludge separation and treatment includes: The conditioning reaction unit is used to receive raw sludge and perform chemical conditioning; The high-pressure feeding unit has its inlet connected to the conditioning reaction unit and its outlet connected to downstream equipment. A diaphragm filter press unit is connected to the outlet of the high-pressure feeding unit and is used to construct a sealed filter chamber. A coordinating controller is electrically connected to the conditioning reaction unit, the high-pressure feeding unit, and the diaphragm filter press unit, respectively. The coordinating controller is configured to execute control logic for a high-pressure filter press method for oil sludge separation.

[0011] Preferably, the conditioning reaction unit includes: Conditioning tank; The bearing housing assembly is disposed at the top of the conditioning tank; The stirring drive mechanism is vertically installed on the top of the conditioning tank; The stirring shaft extends through the bearing housing assembly into the interior of the conditioning tank; A dynamic torque sensor is installed between the stirring drive mechanism and the bearing housing assembly. The input and output ends of the dynamic torque sensor are respectively connected to the output shaft of the stirring drive mechanism and the top end of the stirring shaft via flexible couplings.

[0012] Preferably, the high-pressure feeding unit includes: The ceramic plunger pump adopts a hydraulically driven dual-cylinder ceramic plunger structure. A flow monitoring assembly is installed on the discharge pipe of the ceramic plunger pump for real-time feedback of instantaneous flow rate; The pressure sensing terminal is installed on the side wall of the discharge port of the ceramic plunger pump, and its sensing surface is in direct contact with the material.

[0013] Preferably, the diaphragm filter press unit includes: The main beam frame has longitudinally extending guide rails on its sides; The filter media assembly includes a chamber filter plate and a diaphragm filter plate that are alternately suspended on the main beam frame. The chamber filter plate and the diaphragm filter plate are provided with support handles or roller assemblies on both sides, and the support handles or roller assemblies are attached to the guide rail. The press water station has its output end connected to a common distribution manifold, which is connected to the internal interlayer inlet of the diaphragm filter plate via a high-pressure cloth-coated hose.

[0014] Preferably, the high-pressure fabric-coated hose is equipped with a drag chain guiding mechanism or a suspension pulley traction mechanism.

[0015] Compared with the prior art, the present invention has the following improvements and advantages: 1. The conditioning reaction unit of this invention can accurately obtain the pure torsional torque during the stirring process through a non-load-bearing dynamic torque sensor; the system calculates the rate of change of the stirring resistance torque over time, and determines that flocculation and agglomeration are completed when the rate of change turns from a positive value and passes through zero, thereby accurately locking the optimal rheological state of the material; 2. The high-pressure feeding unit of this invention collects the feed pressure and instantaneous flow rate in real time during the feeding process. By calculating the rate of change of the feed pressure relative to time and dividing it by the square of the instantaneous flow rate, the specific resistance coefficient characterizing the filter cake is obtained. The system automatically switches between stepped speed reduction operation mode and constant pressure high flow rate operation mode based on the comparison result between the specific resistance coefficient and the specific resistance judgment threshold. 3. This invention calculates the effective hydraulic power obtained from the fluid side and combines it with the input power of the drive motor and the hydraulic oil temperature coefficient to calculate the current hydraulic energy conversion efficiency in real time. When the efficiency is lower than the benchmark value of the standard hydraulic energy conversion efficiency curve, it is determined that there is a gas compression phenomenon in the pump chamber and the ceramic plunger pump is instructed to enter the low-speed exhaust protection mode. 4. The diaphragm filter press unit of the present invention performs differentiated pressing actions based on the specific resistance coefficient inverted during the feeding stage. For high specific resistance materials that are difficult to dewater, it performs multi-stage pulsed water injection including low pressure maintenance, rapid pressure increase and impact high pressure, and uses pulse gradient to break capillary tension; for low specific resistance materials, it performs linear rapid pressure increase. 5. The tempering reaction unit of this invention uses a bearing housing assembly to independently bear the mechanical load, and with the help of a flexible coupling, it realizes the non-load-bearing floating installation of the dynamic torque sensor, which isolates vibration interference; the high-pressure feeding unit adopts a direct contact pressure sensing terminal and an unobstructed flow monitoring assembly to adapt to the wear conditions of high solids oil sludge; the diaphragm filter press unit is equipped with a drag chain guiding mechanism or a suspended pulley traction mechanism to ensure the stability of the trajectory of the high-pressure cloth hose during large displacements. Attached Figure Description

[0016] The present invention will be further explained below with reference to the accompanying drawings and embodiments: Figure 1 This is a schematic diagram of the overall structure of the device; Figure 2 This is a schematic diagram of the structure of the conditioning reaction unit; Figure 3 This is a schematic diagram of the flow monitoring assembly and the diaphragm filter press unit; Figure 4 This is a schematic diagram of the process flow of the method of the present invention.

[0017] In the diagram: 100, conditioning reaction unit; 110, conditioning tank; 120, stirring drive mechanism; 140, dynamic torque sensor; 200, high-pressure feeding unit; 210, ceramic plunger pump; 220, flow monitoring assembly; 230, pressure sensing terminal; 300, diaphragm filter press unit; 310, main beam frame; 320, filter media group; 330, pressing water station; 400, coordinating controller. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0019] Example 1: Please see Figure 1-4 This invention provides a high-pressure filtration method for oil sludge separation and treatment, comprising: S1. A conditioning reaction unit 100, a high-pressure feeding unit 200, and a diaphragm filter press unit 300 are set up. The conditioning reaction unit 100 is located at the front end of the process flow. The high-pressure feeding unit 200 is connected between the conditioning reaction unit 100 and the diaphragm filter press unit 300. The conditioning reaction unit 100 is equipped with a non-load-bearing dynamic torque sensor 140. The high-pressure feeding unit 200 is equipped with a ceramic plunger pump 210, a flow monitoring assembly 220, and a pressure sensing terminal 230. The diaphragm filter press unit 300 is equipped with a pressing water station 330. S2. Start the conditioning reaction unit 100, monitor the stirring resistance torque in real time during the conditioning process of sludge, calculate the rate of change of the stirring resistance torque over time after low-pass filtering, and determine that flocculation and agglomeration are completed and stop stirring when the rate of change changes from a positive value and passes through zero or is lower than the preset convergence threshold. The judgment logic is based on the following physical process: To eliminate high-frequency noise interference caused by mechanical vibration, the low-pass filtering process mentioned in step one specifically adopts a moving average filtering algorithm, and the sampling window width is set to... Or use a cutoff frequency of The system employs a first-order RC digital filtering algorithm. In stage one, the co-controller 400 performs differential calculations on the real-time acquired torque signal to obtain the rate of change. In stage two, at the initial stage of the agent's action, floc formation leads to a surge in viscosity, resulting in a positive rate of change. In stage three, when the flocs grow to their limit size or begin to break down under shear, the viscosity reaches its peak and then remains stable or slightly decreases; at this point, the rate of change curve crosses zero. In stage four, the system captures this zero-crossing signal or detects that the absolute value of the rate of change is lower than the preset convergence threshold as the endpoint of the flocculation reaction, preventing excessive stirring and breakage of the formed flocs. S3. Start the ceramic plunger pump 210 to feed the diaphragm filter press unit 300, collect the feed pressure value and instantaneous flow rate value in real time, calculate the rate of change of feed pressure relative to time, and divide the rate of change by the square of the instantaneous flow rate value to obtain the specific resistance coefficient characterizing the filter cake characteristics. S4. After the feeding is completed, the operating mode of the pressing water station 330 is controlled according to the specific resistance coefficient, and the material in the diaphragm filter press unit 300 is subjected to differentiated pressing action to form a dehydrated filter cake.

[0020] The specific drag coefficient is a rheologically normalized index. The rate of change of feed pressure relative to time reflects the rate of filter resistance buildup. Dividing by the square of the instantaneous flow velocity eliminates the kinetic energy effects and nonlinear turbulence effects caused by flow velocity fluctuations, thus quantifying the density and permeability characteristics of the filter cake layer itself. It should be noted that, to prevent the influence of the instantaneous flow velocity value at the end of filtration... The calculated specific drag coefficient may overflow or diverge if it approaches zero. Therefore, the system sets a calculation cutoff flow threshold, such as 5% of the rated flow. When the instantaneous flow velocity value is lower than the threshold, the real-time update of the specific drag coefficient is stopped and the effective calculated value of the previous moment is retained. It should be noted that, to ensure the accuracy of the threshold determination, the unit of the physical quantity used to calculate the specific drag coefficient in this embodiment is set as follows: feed pressure value. The unit of measurement is ,time The unit of measurement is Instantaneous flow velocity value The unit of measurement is Furthermore, the specific resistance coefficient is a control process variable derived in real time from the equipment operating parameters, used to characterize the current filtration resistance construction characteristics of the system. Its numerical meaning is different from the sludge specific resistance measured in the laboratory through a standard funnel experiment.

[0021] In this embodiment, an adaptive control scheme is proposed to address the problem that existing sludge dewatering processes often rely on fixed empirical parameters, which cannot cope with incomplete dewatering or energy waste caused by fluctuations in material properties. The conditioning reaction unit 100 continuously senses the viscosity changes of the slurry during stirring using a non-load-bearing dynamic torque sensor 140. The transition of sludge from liquid to floc is accompanied by a sudden change in viscosity, and the rate of change of stirring resistance torque over time can quantify this process. When the rate of change changes from a positive value and passes through zero or falls below a preset convergence threshold, it indicates that the floc structure has been formed and has not yet been excessively sheared. Stopping stirring at this point locks in the optimal rheological state of the material. The high-pressure feeding unit 200 utilizes ceramic... The ceramic plunger pump 210 delivers the conditioned material to the diaphragm filter press unit 300. During this process, the flow monitoring assembly 220 and the pressure sensing terminal 230 provide real-time feedback on the delivery data. As filtration proceeds, the accumulation of solid particles causes the pressure to rise. The rate of change of the feed pressure relative to time reflects the rate of filter cake thickening. Dividing it by the square of the instantaneous flow rate value can eliminate the influence of feed rate fluctuations, thereby obtaining a normalized specific resistance coefficient. Based on the specific resistance coefficient, the diaphragm filter press unit 300 uses the pressing water station 330 to perform differentiated pressing actions. For materials that are difficult to dewater, a specific mode is used to avoid clogging, while for materials that are easy to dewater, an aggressive mode is used to improve efficiency, thereby achieving precise dewatering tailored to the characteristics of the current batch of materials.

[0022] Step S3 includes the following steps before calculating the specific drag coefficient: S3.1 Calculate the effective hydraulic power obtained from the fluid side, divide the effective hydraulic power by the real-time input power of the ceramic plunger pump 210 drive motor and correct it in combination with the hydraulic oil temperature coefficient to obtain the current mechanical-hydraulic energy conversion efficiency. The hydraulic oil temperature coefficient is used to compensate for the increase in internal leakage caused by the decrease in hydraulic oil viscosity as the temperature rises, ensuring that the calculated hydraulic-hydraulic energy conversion efficiency excludes the interference of thermodynamic losses and purely reflects the volumetric compression ratio in the pump cavity. The specific correction calculation formula is as follows: in, The current mechanical-hydraulic energy conversion efficiency; Effective hydraulic power on the fluid side, unit: The calculation formula is: ,in Feed pressure, unit: , Instantaneous flow velocity, unit: ,constant Unit conversion factor; To provide real-time power input to the drive motor, For real-time monitoring of hydraulic oil temperature, For example, the standard reference oil temperature , This is a preset hydraulic oil viscosity-temperature correction coefficient, typically ranging from... The specific range is determined based on the hydraulic oil grade. Increased hydraulic oil temperature typically leads to a natural decrease in volumetric efficiency due to increased internal leakage. This can be addressed by introducing a correction term greater than 1. The measured efficiency under the current high-temperature operating conditions is normalized to the theoretical efficiency at the standard temperature. If the normalized efficiency is still lower than the benchmark value, thermodynamic factors can be ruled out, and it can be confirmed that the abnormal volume loss is caused by air intake or cavitation in the pump chamber, thereby accurately triggering the exhaust protection.

[0023] S3.2. Compare the current mechanical-hydraulic energy conversion efficiency with the standard mechanical-hydraulic energy conversion efficiency curve. If the current mechanical-hydraulic energy conversion efficiency is lower than the benchmark value, instruct the ceramic plunger pump 210 to enter the low-speed exhaust protection mode. After the low-speed exhaust protection mode has been running for a preset time, control the ceramic plunger pump 210 to resume normal speed and re-detect the current mechanical-hydraulic energy conversion efficiency. If the efficiency is still lower than the benchmark value, trigger a shutdown alarm.

[0024] The standard mechanical-hydraulic energy conversion efficiency curve is a baseline data that has been calibrated in advance through a clean water experiment and stored in the coordinating controller 400. It characterizes the inherent characteristics of the volumetric efficiency of the ceramic plunger pump 210 under cavitation-free healthy conditions as a function of exhaust pressure. In this embodiment, the ceramic plunger pump 210 may encounter cavitation or air intake during the delivery process, leading to distortion of flow and pressure data, which in turn affects the accuracy of subsequent calculations. The ceramic plunger pump 210 calculates the effective hydraulic power obtained from the fluid side, i.e., the product of pressure and flow rate, and compares it with the real-time input power of the drive motor. At the same time, the hydraulic oil temperature coefficient is introduced to compensate for the heat loss of the hydraulic system, thereby obtaining the current hydraulic energy conversion efficiency reflecting the pumping state. This efficiency index can keenly capture volumetric losses. The current hydraulic energy conversion efficiency is compared with the preset standard hydraulic energy conversion efficiency curve. When the efficiency is abnormally low, it indicates that there is gas compression in the pump chamber. At this time, the ceramic plunger pump 210 is instructed to enter the low-speed exhaust protection mode. By reducing the operating frequency, not only is the pump body component protected, but also erroneous data is prevented from entering the subsequent resistance inversion logic, ensuring the robustness of the control system.

[0025] Step S3 also includes: S3.3 Read the final stable resistance torque value at the end of the tempering process in step S2 to construct the specific resistance determination threshold; S3.4 If the specific resistance coefficient is higher than the specific resistance judgment threshold, control the ceramic plunger pump 210 to perform stepped speed reduction operation; if the specific resistance coefficient is lower than the specific resistance judgment threshold, control the ceramic plunger pump 210 to perform constant pressure and high flow operation.

[0026] The final stable drag torque value is proportional to the yield stress of the material and can characterize the structural strength of the flocculent agglomerates. The co-controller 400 maps this drag torque value to the specific drag threshold for subsequent pressure filtration stages through a preset mapping function. The specific mapping relationship is as follows: ,in The threshold for determining specific resistance. This is a preset empirical proportionality coefficient, which includes a dimension conversion factor to map the unit value of torque to the dimension space of the specific drag coefficient. Its value range is typically within... The specific values ​​were determined based on the type of sludge through preliminary small-scale experiments. To ultimately stabilize the resistance torque value; the larger the resistance torque, the stronger the flocs, and the higher the corresponding specific resistance judgment threshold is set to match a higher intensity pressing strategy; In this embodiment, a data association is established between the conditioning reaction unit 100 and the high-pressure feeding unit 200, using the rheological characteristics of the material at the front end to guide the pumping strategy at the back end. The final stable resistance torque value of the conditioning reaction unit 100 at the end of conditioning directly reflects the compactness and initial viscosity of the flocs, thereby constructing a dynamic specific resistance judgment threshold and realizing the adaptive adjustment of the judgment standard. When the calculated specific resistance coefficient is higher than the specific resistance judgment threshold, it indicates that the filter cake is dense and has poor water permeability. The ceramic plunger pump 210 performs step-down speed reduction operation, that is, actively reduces the flow rate as the pressure increases, which can delay the premature formation of a dense layer on the surface of the filter cake and keep the internal flow channels unobstructed. Conversely, if the specific resistance coefficient is lower than the specific resistance judgment threshold, it indicates that the material has good water permeability. The ceramic plunger pump 210 performs constant pressure and high flow rate operation, which can significantly shorten the feeding cycle and improve the production capacity while ensuring safety.

[0027] The steps in S4 specifically include: When the instantaneous flow rate value is detected to decrease naturally to less than five percent of the rated flow rate of the ceramic plunger pump 210, the ceramic plunger pump 210 is triggered to perform a shutdown action, and the pump body is completely stopped after the shutdown action is completed. If the specific resistance coefficient is higher than the specific resistance judgment threshold, control the pressing water station 330 to perform multi-stage pulse water injection, sequentially performing the action sequence of low pressure maintenance, rapid pressure increase to medium pressure, and impact to high pressure. If the specific resistance coefficient is lower than the specific resistance judgment threshold, control the pressing water station 330 to perform linear rapid pressurization.

[0028] In this embodiment, after the ceramic plunger pump 210 stops working, the filter chamber in the diaphragm filter press unit 300 is filled with material. At this time, the pressing water station 330 needs to provide external power for deep dewatering. When the instantaneous flow rate value decays to a low level, it marks the end of the physical feeding stage. For materials that are determined to be difficult to dewater due to high specific resistance, the pressing water station 330 performs multi-stage pulsed water injection. In this action sequence, the low-pressure holding stage gives time for the moisture inside the filter cake to redistribute in the capillary channels. The rapid pressure increase to the medium-pressure stage initially compresses the pores. The impact to the high-pressure stage uses the instantaneous pressure gradient to break the capillary tension. This staged pulsed extrusion avoids the water-locking phenomenon caused by premature pore closure due to drastic pressure changes.

[0029] For materials with high specific resistance, the capillary pore size is very small and the surface tension of water is extremely high. By adopting multi-stage pulsed water injection, the instantaneous pressure gradient wave generated by the impact to high pressure can forcibly break the liquid bridge balance in the capillary. Combined with the low-pressure holding stage, it provides relaxation time for water to redistribute in the micro-channels inside the filter cake, thereby effectively solving the pore sealing problem of difficult-to-dewater sludge. For materials with low specific resistance and easy dehydration, the 330 pressing water station performs linear rapid pressurization and uses the maximum pressure difference to quickly discharge water, which greatly reduces the time spent on pressing while ensuring that the moisture content of the filter cake meets the standard.

[0030] Example 2: Please see Figure 1-3 A high-pressure filter press for oil sludge separation and treatment, comprising: The conditioning reaction unit 100 is used to receive raw sludge and perform chemical conditioning. The high-pressure feeding unit 200 has its inlet connected to the conditioning reaction unit 100 and its outlet connected to subsequent equipment. The diaphragm filter press unit 300 is connected to the outlet of the high-pressure feeding unit 200 and is used to construct a closed filtration chamber. The co-controller 400 is electrically connected to the conditioning reaction unit 100, the high-pressure feeding unit 200, and the diaphragm filter press unit 300, respectively. The co-controller 400 is configured to execute the control logic of a high-pressure filter press method for oil sludge separation treatment.

[0031] In this embodiment, the device achieves automation of sludge treatment through hardware integration and the overall coordination of the collaborative controller 400. The conditioning reaction unit 100 serves as the site for material modification, ensuring that the sludge entering subsequent processes has suitable dehydration performance; the high-pressure feeding unit 200 undertakes the dual functions of material conveying and process data acquisition, connecting the upstream and downstream process links; the diaphragm filter press unit 300 provides the physical space for solid-liquid separation; the collaborative controller 400, specifically a PLC programmable logic controller or an industrial control computer, connects each unit through electrical signals and communication buses, and can collect low-level data such as torque, pressure, and flow rate, and execute the logical operations in the aforementioned methods, coordinating the action sequence of each unit, realizing intelligent control of the entire process from material conditioning to final pressing, and solving the problem of fragmented processes and inability to coordinate and optimize in traditional equipment.

[0032] The conditioning reaction unit 100 includes: Conditioning tank 110; The bearing housing assembly is located at the top of the conditioning tank 110; The stirring drive mechanism 120 is vertically installed on the top of the conditioning tank 110; The stirring shaft extends through the bearing housing assembly into the conditioning tank 110; A dynamic torque sensor 140 is installed between the stirring drive mechanism 120 and the bearing housing assembly. The input and output ends of the dynamic torque sensor 140 are connected to the output shaft of the stirring drive mechanism 120 and the top of the stirring shaft respectively through a flexible coupling.

[0033] In this embodiment, the structural design of the conditioning reaction unit 100 focuses on accurately acquiring rheological signals. The stirring drive mechanism 120, such as a variable frequency motor, provides rotational power. However, if directly connected to the stirring shaft, the radial runout and axial load of the shaft system would interfere with torque measurement. Therefore, a bearing housing assembly is set to independently bear the mechanical load of the stirring shaft, including its own weight and the radial force generated by stirring. The dynamic torque sensor 140 is integrated into the power transmission chain through a non-load-bearing installation, with its two ends connected by flexible couplings. This floating connection method isolates mechanical vibration and hard impact, allowing the dynamic torque sensor 140 to sense only pure torsional torque. This torque truly reflects the resistance of the material in the conditioning tank 110 to the impeller, thereby providing high signal-to-noise ratio data support for determining the flocculation state and avoiding the misleading influence of mechanical friction noise on process judgment.

[0034] The high-pressure feeding unit 200 includes: The ceramic plunger pump 210 adopts a hydraulically driven double-cylinder ceramic plunger structure; The flow monitoring assembly 220 is installed on the discharge pipe of the ceramic plunger pump 210 for real-time feedback of instantaneous flow rate; The pressure sensing terminal 230 is installed on the side wall of the discharge port of the ceramic plunger pump 210, and its sensing surface is in direct contact with the material.

[0035] The flow monitoring assembly 220 preferably uses an electromagnetic flow meter to accommodate unobstructed measurement of conductive mud with high solids content; In this embodiment, the high-pressure feeding unit 200 needs to maintain long-term data accuracy under high-wear conditions. The ceramic plunger pump 210 utilizes the high hardness of alumina or zirconia ceramic materials to withstand the abrasion of sand and gravel in the sludge, and is hydraulically driven, with power provided by a hydraulic cylinder and hydraulic station to provide stable high-pressure output, suitable for conveying materials with high solids content. The flow monitoring assembly 220, such as an electromagnetic flowmeter, is installed on the pipeline to measure the instantaneous flow velocity of conductive sludge without obstruction; the pressure sensing terminal 230, such as a diaphragm pressure transmitter, adopts a flat diaphragm structure and is installed on the side wall, with its sensing surface directly contacting the material, eliminating the risk of pressure tap blockage; the combination of the two provides a continuous and reliable physical quantity input for the aforementioned specific resistance coefficient inversion.

[0036] The diaphragm filter press unit 300 includes: The main beam frame 310 has longitudinally extending guide rails on its sides; The filter media assembly 320 includes a chamber filter plate and a diaphragm filter plate that are alternately suspended on the main beam frame 310. The chamber filter plate and the diaphragm filter plate are provided with support handles or roller assemblies on both sides, and the support handles or roller assemblies are attached to the guide rail. The press water station 330 has its output end connected to the common distribution manifold, which is connected to the internal interlayer inlet of the diaphragm filter plate through a high-pressure cloth-coated hose.

[0037] In this embodiment, the diaphragm filter press unit 300 achieves high-pressure extrusion through a specific mechanical structure. The main beam frame 310 serves as the load-bearing foundation, and the guide rails on it guide the opening and closing movement of the filter media assembly 320. The chamber filter plates and diaphragm filter plates are arranged alternately, forming a filter chamber when closed, wherein the diaphragm filter plates have elastically expandable diaphragm surfaces. The pressing water station 330, such as the high-pressure multi-stage centrifugal pump, generates high-pressure water flow, which is distributed through a common distribution manifold and injected into the internal interlayer of the diaphragm filter plates through high-pressure fabric-reinforced hoses. The water pressure forces the diaphragm surface to expand, thereby applying secondary extrusion force to the filter cake in the filter chamber. This flexible extrusion using hydrostatic pressure can adapt to uneven filter cake thickness, and in conjunction with the aforementioned variable mode control, achieves deep dewatering.

[0038] The high-pressure fabric-reinforced hose is equipped with a drag chain guide mechanism or a suspension pulley traction mechanism.

[0039] In this embodiment, during unloading, the diaphragm filter plate of the diaphragm filter unit 300 is pulled apart along the main beam frame 310, causing significant displacement and bending of the connected high-pressure cloth-coated hose. A drag chain guiding mechanism or a suspended pulley traction mechanism provides dynamic support and trajectory constraint for the high-pressure cloth-coated hose; when the filter plate moves, this mechanism guides the hose to bend or extend in an orderly manner according to a predetermined radius, preventing the hose from tangling, knotting, or breaking due to excessive stretching during movement. This design ensures the long-term reliability of the high-pressure water circuit and guarantees that the pressing action can respond to control commands at any time.

[0040] Specifically, one end of the drag chain guiding mechanism is fixed to the main beam frame 310, and the other end moves with the diaphragm filter plate. The high-pressure cloth-reinforced rubber hose is built into the pitch space of the drag chain. The bending radius of the drag chain is used to limit the minimum curvature of the hose and prevent tube wall fatigue caused by stress concentration. It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A high-pressure filtration method for separating and treating oil sludge, characterized in that, include: S1. A conditioning reaction unit (100), a high-pressure feeding unit (200), and a diaphragm filter press unit (300) are set up. The conditioning reaction unit (100) is located at the front end of the process flow. The high-pressure feeding unit (200) is connected between the conditioning reaction unit (100) and the diaphragm filter press unit (300). The conditioning reaction unit (100) is equipped with a non-load-bearing dynamic torque sensor (140). The high-pressure feeding unit (200) is equipped with a ceramic plunger pump (210), a flow monitoring assembly (220), and a pressure sensing terminal (230). The diaphragm filter press unit (300) is equipped with a pressing water station (330). S2. Start the conditioning reaction unit (100), monitor the stirring resistance torque in real time during the conditioning process of sludge, calculate the rate of change of the stirring resistance torque over time after low-pass filtering, and determine that flocculation and agglomeration are completed and stop stirring when the rate of change turns from a positive value and passes through zero or is lower than the preset convergence threshold. S3. Start the ceramic plunger pump (210) to feed the diaphragm filter press unit (300), collect the feed pressure value and instantaneous flow rate value in real time, calculate the rate of change of feed pressure relative to time, and divide the rate of change by the square of the instantaneous flow rate value to obtain the specific resistance coefficient characterizing the filter cake characteristics. S4. After the feeding is completed, the operating mode of the pressing water station (330) is controlled according to the specific resistance coefficient, and the material in the diaphragm filter press unit (300) is subjected to differentiated pressing action to form a dehydrated filter cake.

2. The high-pressure filtration method for oil sludge separation and treatment according to claim 1, characterized in that, Step S3, before calculating the specific drag coefficient, includes: S3.1 Calculate the effective hydraulic power obtained from the fluid side, divide the effective hydraulic power by the real-time input power of the ceramic plunger pump (210) drive motor and correct it in combination with the hydraulic oil temperature coefficient to obtain the current mechanical-hydraulic energy conversion efficiency; S3.

2. Compare the current mechanical-hydraulic energy conversion efficiency with the standard mechanical-hydraulic energy conversion efficiency curve. If the current mechanical-hydraulic energy conversion efficiency is lower than the benchmark value, instruct the ceramic plunger pump (210) to enter the low-speed exhaust protection mode. After the low-speed exhaust protection mode has been running for a preset time, control the ceramic plunger pump (210) to resume normal speed and re-detect the current mechanical-hydraulic energy conversion efficiency. If the efficiency is still lower than the benchmark value, trigger a shutdown alarm.

3. The high-pressure filtration method for oil sludge separation and treatment according to claim 1, characterized in that, Step S3 also includes: S3.3 Read the final stable resistance torque value at the end of the tempering process in step S2 to construct the specific resistance determination threshold; S3.4 If the specific resistance coefficient is higher than the specific resistance determination threshold, control the ceramic plunger pump (210) to perform stepped speed reduction operation; if the specific resistance coefficient is lower than the specific resistance determination threshold, control the ceramic plunger pump (210) to perform constant pressure and high flow operation.

4. The high-pressure filtration method for oil sludge separation and treatment according to claim 3, characterized in that, The steps in S4 specifically include: When the instantaneous flow rate value is detected to naturally decrease to less than five percent of the rated flow of the ceramic plunger pump (210), the ceramic plunger pump (210) is triggered to perform a shutdown action, and the pump body is completely stopped after the shutdown action is completed. If the specific resistance coefficient is higher than the specific resistance determination threshold, the pressing water station (330) is controlled to perform multi-stage pulse water injection, and the action sequence of low pressure maintenance, rapid pressure increase to medium pressure, and impact to high pressure is executed in sequence. If the specific resistance coefficient is lower than the specific resistance determination threshold, the pressing water station (330) is controlled to perform linear rapid pressurization.

5. A high-pressure filter press for oil sludge separation and treatment, characterized in that, include: A conditioning reaction unit (100) is used to receive raw sludge and perform chemical conditioning; A high-pressure feeding unit (200) has its inlet connected to the conditioning reaction unit (100) and its outlet connected to downstream equipment. A diaphragm filter press unit (300) is connected to the outlet of the high-pressure feeding unit (200) and is used to construct a closed filter chamber; A coordinating controller (400) is electrically connected to the conditioning reaction unit (100), the high-pressure feeding unit (200), and the diaphragm filter press unit (300), respectively, and the coordinating controller (400) is configured to execute the control logic of the method as described in any one of claims 1 to 4.

6. A high-pressure filter press for oil sludge separation and treatment according to claim 5, characterized in that, The conditioning reaction unit (100) includes: Conditioning tank (110); A bearing housing assembly is disposed on the top of the conditioning tank (110); A stirring drive mechanism (120) is vertically installed on the top of the conditioning tank (110); The stirring shaft extends through the bearing housing assembly into the interior of the conditioning tank (110); A dynamic torque sensor (140) is installed between the stirring drive mechanism (120) and the bearing housing assembly. The input and output ends of the dynamic torque sensor (140) are respectively connected to the output shaft of the stirring drive mechanism (120) and the top end of the stirring shaft through a flexible coupling.

7. A high-pressure filter press for oil sludge separation and treatment according to claim 5, characterized in that, The high-pressure feeding unit (200) includes: The ceramic plunger pump (210) adopts a hydraulically driven double-cylinder ceramic plunger structure; A flow monitoring assembly (220) is installed on the discharge pipe of the ceramic plunger pump (210) for real-time feedback of instantaneous flow rate; The pressure sensing terminal (230) is installed on the side wall of the discharge port of the ceramic plunger pump (210), and its sensing surface is in direct contact with the material.

8. A high-pressure filter press for oil sludge separation and treatment according to claim 5, characterized in that, The diaphragm filter press unit (300) includes: The main beam frame (310) has longitudinally extending guide rails on its sides; The filter media assembly (320) includes a chamber filter plate and a diaphragm filter plate alternately suspended on the main beam frame (310). The chamber filter plate and the diaphragm filter plate are provided with support handles or roller assemblies on both sides, and the support handles or roller assemblies are attached to the guide rail. The press water station (330) has its output end connected to a common distribution manifold, which is connected to the internal interlayer water inlet of the diaphragm filter plate via a high-pressure cloth-coated hose.

9. A high-pressure filter press for oil sludge separation and treatment according to claim 8, characterized in that, The high-pressure fabric-reinforced hose is equipped with a drag chain guiding mechanism or a suspension pulley traction mechanism.

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