High-temperature material flow regulating device and control method thereof

Abstract

The application relates to the technical field of valves, in particular to a high-temperature material flow regulating device and a control method thereof, which comprises a device body, a spring hanger fixed on the device body, an inlet and return water system, a control system, a monitoring device and a connecting pipe fixed on a discharge port of the device body. The device is aimed at the problems of poor linearity of traditional gate valves and flap valves, insufficient precision of manual regulation and open-loop control, realizes linear regulation of high-temperature material flow through the curved surface fitting design of a valve head and a valve seat, completely solves the disadvantages of small opening sensitivity and large opening sluggishness, accurately adapts to trace regulation requirements, relies on the monitoring device to collect material level and temperature signals in real time, constructs a closed-loop control through a PLC control system, automatically drives an electric actuator to adjust the position of a valve rod, does not need manual intervention, avoids human judgment errors, eliminates high-temperature scene operation safety hazards, greatly improves flow control precision and stability, and solves the problem of instability of a traditional control loop.

Description

Technical Field

[0001] This invention relates to the field of valve technology, specifically to a high-temperature material flow regulating device and its control method. Background Technology

[0002] In long-process industries such as power generation, steel, metallurgy, chemicals, building materials, and waste incineration, there are numerous high-temperature solid materials (800-1200℃) that require transfer, transportation, or disposal, such as circulating fluidized bed boiler bottom ash, metallurgical slag, and steel slag. During production, it is typically necessary to regulate and control the flow rate of these solid materials under high-temperature conditions. Stable flow control of these materials is crucial for ensuring the efficiency, safety, and environmental performance of subsequent processes such as cooling, reaction, and combustion.

[0003] Currently, the industry commonly uses several methods or devices for flow regulation of such high-temperature materials, such as gate valves, rotary feeders, and flap valves. However, they all have certain limitations: Gate valves: poor linearity of regulation. Because the flow rate and opening degree of a gate valve are non-linear, it is too sensitive at small openings and sluggish at large openings, making it difficult to achieve precise micro-adjustments; frequent wear and jamming. In high-temperature and high-dust environments, the valve plate and valve body guide rail are prone to severe wear, jamming, or failure to close tightly due to material scouring, uneven thermal expansion, or material accumulation; and they are sensitive to material characteristics. For materials with poor flowability, easy caking, or agglomeration, they cannot automatically clear the agglomerated material, resulting in high operating resistance or even failure to operate.

[0004] Rotary feeders have limited adjustment ranges, with flow rate mainly regulated by rotational speed. However, they are unstable at extremely low speeds, and the application of speed-regulating motors in high-temperature environments is limited. They are typically used as coarse quantitative feeding devices rather than continuous and precise regulating valves. They also have poor high-temperature adaptability, as the thermal expansion gap between the rotor and the housing is difficult to control at high temperatures, which can easily lead to jamming or excessive leakage. Furthermore, the lifespan of moving parts such as bearings is short in high-temperature and high-dust environments.

[0005] Flap valve: Low adjustment accuracy, also has the problem of nonlinear flow characteristics, and is greatly affected by material accumulation. Vortex is easily formed at the rear of the valve plate, resulting in material accumulation. Insufficient wear resistance, the edge of the valve plate and the valve seat wear extremely quickly under the scouring of high-speed particles, resulting in drift of adjustment characteristics and sealing failure.

[0006] Regarding material flow control, most systems employ manual adjustment. Operators manually adjust the gate valve opening or feeder frequency by observing the flow rate of high-temperature materials or referring to downstream data. However, since the adjustment is based on human judgment and manual adjustment has low accuracy, and given that most scenarios involve high temperatures, manual adjustment poses a significant safety threat to operators. Currently, some systems use open-loop control based on setpoints, rather than closed-loop control relying solely on flowmeter feedback. However, high-temperature solid flowmeters generally suffer from low accuracy, frequent maintenance, high cost, and measurement lag or unreliability under harsh conditions, leading to unstable control loops.

[0007] In summary, existing high-temperature material flow regulation devices and control methods suffer from a dual bottleneck: mechanical structural defects in the regulation devices and outdated control strategies. Existing high-temperature material flow regulation devices generally suffer from poor linearity and accuracy, susceptibility to wear and jamming, sensitivity to material blockage, and poor adaptability to high temperatures. Furthermore, they cannot effectively achieve linked closed-loop control. Summary of the Invention

[0008] The purpose of this invention is to provide a high-temperature material flow rate regulating device and its control method to solve the problems mentioned in the background art, such as poor regulation linearity, insufficient control accuracy, easy wear and jamming due to high temperature thermal expansion and material scouring, poor adaptability to easily caking and agglomerated materials and easy to be affected by blockage, and insufficient operational stability under high temperature conditions. At the same time, the existing control methods are difficult to achieve the linkage closed-loop control of flow rate and cooling system, and cannot adapt to the dynamic needs of high temperature material processing.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a high-temperature material flow rate regulating device, comprising a device body, a spring hanger fixed on the device body, an inlet and return water system, a control system, a monitoring device, and a connecting pipe fixed at the outlet of the device body; the spring hanger is used to suspend and fix the device body and to provide a buffering effect; the inlet and return water system is connected to the valve stem assembly of the device body to form a cooling water circuit; the control system is connected to the monitoring device, the inlet and return water system, and the electric actuator of the device body respectively; the device body includes a housing assembly, a valve seat, a valve stem assembly, a sealing assembly, a support assembly, a sliding block, an adjusting screw, an electric actuator, a linear slide rail, and a fluidizing air duct; the valve seat is embedded in the inlet of the housing assembly; the support assembly is fixed to the other end face of the housing assembly by a flange; the linear slide rail is fixed to the support assembly; the valve stem assembly is concentrically arranged with the housing assembly and passes through the sealing assembly in the middle; one end of the sliding block is fixedly connected to the valve stem assembly; the other end of the sliding block is connected to the electric actuator by an adjusting screw; the fluidizing air duct is circumferentially mounted on the outside of the housing assembly, and a branch pipe passes through the valve seat.

[0010] Furthermore, the shell assembly includes an outer shell, thermal insulation castable, Y-shaped clamps, wear-resistant castable, aerogel mesh, and L-shaped clamps. The Y-shaped and L-shaped clamps are staggered and evenly welded to the inner wall of the outer shell. The thermal insulation castable is fixed to the inner wall of the outer shell. The wear-resistant castable is concentrically fixed to the middle of the outer shell and directly contacts the high-temperature material at 800-1200℃. A 2-3mm gap is maintained between the outer diameter of the wear-resistant castable and the inner diameter of the thermal insulation castable, and the aerogel mesh fills the gap.

[0011] Furthermore, the valve stem assembly includes a valve head, a front flange, an outer pipe, an inner pipe, baffles, a water outlet, a plug plate, and a rear flange. The valve head has a hollow structure and is connected to the front flange by bolts to form a cooling water chamber. The front flange is fitted and welded to the outer pipe. Several sets of spiral baffles are welded to the outside of the inner pipe, and the baffles slide with the outer pipe to achieve support. The water outlet is located at the tail end of the outer pipe. The rear flange is welded to the tail end of the inner pipe and is fixedly connected to the outer pipe by a plug plate.

[0012] Furthermore, the water inlet and outlet system includes a return water electric regulating valve and a water inlet electric regulating valve, which are respectively connected to the water inlet and water outlet of the valve stem assembly to form a complete cooling water circuit.

[0013] Furthermore, the control system includes a PLC control box, input signal lines, a first output signal line, a second output signal line, and a third output signal line. The PLC control box is connected to a monitoring device via the input signal line, to an electric actuator via the first output signal line, and to a return water electric regulating valve and an inlet water electric regulating valve via the second and third output signal lines, respectively.

[0014] Furthermore, the valve seat has a dumbbell-shaped segmented structure with a 2mm expansion gap between each segment, and adopts a "concave-convex" snap-fit ​​structure, while one end of it is flush with the outer side of the housing assembly.

[0015] Furthermore, the sealing assembly is fitted into the middle of the valve stem assembly and fits tightly against the inner wall of the housing assembly to achieve high-temperature sealing under operating conditions of 800-1200℃; the linear slide rail is fixed to the bracket assembly by countersunk screws, and the sliding block slides with the linear slide rail to drive the valve stem assembly to move horizontally.

[0016] Furthermore, the monitoring device is a composite sensor used to detect the material level height in the connecting pipe and the outer wall temperature of the wear-resistant castable in the shell assembly; the medium introduced into the fluidizing air duct is compressed air or inert gas, used to fluidize the high-temperature material at 800-1200℃ at the fluidizing valve seat to avoid material caking or bridging.

[0017] Furthermore, the input signal line is used to transmit the detection signal of the monitoring device, and the first output signal line, the second output signal line and the third output signal line are respectively used to transmit the control commands of the PLC control box to the electric actuator, the return water electric regulating valve and the inlet water electric regulating valve.

[0018] This invention also provides a control method for a high-temperature material flow rate regulating device, comprising the following steps:

[0019] S1: The monitoring device detects the material level in the connecting pipe and the outer wall temperature signal of the wear-resistant castable in the shell assembly in real time, and transmits the detection signal to the control system.

[0020] S2: After processing the received signal, the control system sends a control command to the electric actuator. The electric actuator drives the adjusting screw to rotate, which in turn drives the sliding block to move horizontally along the linear slide rail, thereby driving the valve stem assembly to move synchronously and adjusting the gap between the valve stem assembly and the valve seat to achieve linear regulation of the flow rate of high-temperature materials at 800-1200℃.

[0021] S3: The control system synchronously sends instructions to the inlet and outlet water systems to adjust the cooling water volume in the cooling water circuit and provide cooling protection for the valve stem assembly.

[0022] S4: The fluidizing duct continuously supplies the medium, and through the branch pipe passing through the valve seat, it fluidizes the high-temperature material at 800-1200℃ at the valve seat, preventing material caking or bridging.

[0023] Compared with the prior art, the beneficial effects of the present invention are:

[0024] 1. This device addresses the issues of poor linearity and insufficient precision in manual adjustment and open-loop control of traditional gate valves and flap valves. Through the curved surface fit design of the valve head and valve seat, it achieves linear regulation of high-temperature material flow, completely solving the shortcomings of being sensitive at small openings and sluggish at large openings. It precisely adapts to the needs of micro-adjustment. Relying on the monitoring device to collect material level and temperature signals in real time, the PLC control system constructs a closed-loop control, automatically driving the electric actuator to adjust the valve stem position without manual intervention. This avoids human judgment errors and eliminates safety hazards in high-temperature operation, greatly improving the accuracy and stability of flow control and solving the problem of instability in traditional control loops.

[0025] 2. This device addresses the pain points of traditional devices, such as easy thermal expansion and jamming, severe wear, and sealing failure under high temperatures. It adopts a split valve seat design with a reserved expansion gap and a "concave-convex" snap-fit ​​structure to effectively release thermal expansion stress and prevent valve seat cracking or jamming. The shell assembly adopts a combination structure of double-layer castable and aerogel mesh. The wear-resistant castable improves wear resistance, while the aerogel mesh absorbs radial expansion and isolates radiant heat, ensuring the low-temperature safety of the shell. The valve stem assembly adopts a double-layer structure of inner and outer tubes and a spiral baffle design to improve cooling effect and prevent cooling water vaporization and valve stem thermal deformation. Combined with the sealing assembly, it enhances sealing performance and significantly extends service life in high-temperature and high-dust environments.

[0026] 3. This device addresses the issues of traditional devices being sensitive to easily caking materials and prone to clogging. It features a fluidizing duct annularly mounted on the outer side of the casing, with branch pipes extending through the valve seat to the material channel. Compressed air or inert gas is continuously introduced to fluidize the material, preventing caking or bridging of high-temperature materials from the source. Simultaneously, the valve head and valve seat's mating structure, during adjustment, can moderately compress and guide accumulated materials, completely resolving the drawbacks of traditional devices such as high operating resistance or even inoperability. This ensures smooth material transport, reduces production losses caused by material blockages and downtime, and is suitable for various scenarios involving the processing of easily caking high-temperature solid materials.

[0027] 4. This device addresses the problems of unreasonable design and inability to adapt to changes in flow rate in traditional cooling systems. By linking the control system with the temperature and material level signals fed back by the device, it synchronously regulates the electric regulating valves of the inlet and outlet water systems to dynamically adjust the cooling water volume. When the flow rate increases and the contact area between the valve head and the material increases, the cooling water volume is automatically increased to ensure stable operation of the valve stem assembly at high temperatures. When the flow rate decreases, the cooling water volume is reduced accordingly to avoid water waste. This coordinated intelligent regulation of flow rate and cooling not only solves the problems of uneven cooling and easy thermal deformation of valve stems in traditional devices, but also achieves efficient resource utilization and improves the economy and reliability of the device operation. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0029] Figure 2 This is a schematic diagram of the structure of the device body of the present invention (P in the figure represents the flow direction of high-temperature materials).

[0030] Figure 3 This is an isometric view of the main body of the device of the present invention;

[0031] Figure 4 This is a schematic diagram of the valve stem assembly structure of the present invention;

[0032] Figure 5 This is a schematic diagram of the valve seat structure of the present invention;

[0033] Figure 6For the present invention Figure 2 Schematic diagram of the sectional structure of the middle AA section;

[0034] Figure 7 This is a schematic diagram of the control system structure of the present invention;

[0035] Figure 8 This is a schematic diagram of the valve seat and valve body mating structure of the present invention.

[0036] The components represented by each number in the attached diagram are listed below: 1. Device body; 2. Spring hanger; 3. Inlet and outlet water system; 31. Return water electric regulating valve; 32. Inlet water electric regulating valve; 4. Control system; 41. PLC control box; 42. Input signal line; 43. First output signal line; 44. Second output signal line; 45. Third output signal line; 5. Monitoring device; 6. Connecting pipe; 11. Housing assembly; 111. Outer shell; 112. Thermal insulation castable; 113. Y 114. L-shaped grab pin; 115. Wear-resistant castable; 116. Aerogel mesh; 117. L-shaped grab pin; 12. Valve seat; 13. Valve stem assembly; 138. Valve head; 139. Front flange; 130. Outer pipe; 131. Inner pipe; 132. Baffle plate; 133. Outlet; 14. Blocking plate; 15. Rear flange; 16. Sealing assembly; 17. Support assembly; 18. Sliding block; 19. Adjusting screw; 20. Electric actuator; 21. Linear slide rail; 21. Fluidized air duct. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Example 1: Please refer to Figure 1 - Figure 8A high-temperature material flow regulating device includes a device body 1, a spring hanger 2 fixed on the device body 1, an inlet and outlet water system 3, a control system 4, a monitoring device 5, and a connecting pipe 6 fixed to the outlet of the device body 1. The spring hanger 2 is used to suspend and fix the device body 1 and also serves as a buffer. The inlet and outlet water system 3 is connected to the valve stem assembly 13 of the device body 1 to form a cooling water circuit. The control system 4 is connected to the monitoring device 5, the inlet and outlet water system 3, and the electric actuator 18 of the device body 1. The device body 1 includes a housing assembly 11, a valve seat 12, a valve stem assembly 13, a sealing assembly 14, and a support assembly 15. 5. Sliding pressure block 16, adjusting screw 17, electric actuator 18, linear slide rail 19 and fluidizing air duct 20, valve seat 12 is embedded in the feed port of housing assembly 11, support assembly 15 is fixed to the other end face of housing assembly 11 by flange, linear slide rail 19 is fixed to support assembly 15, valve stem assembly 13 is arranged concentrically with housing assembly 11 and passes through sealing assembly 14 in the middle, one end of sliding pressure block 16 is fixedly connected to valve stem assembly 13, the other end of sliding pressure block 16 is connected to electric actuator 18 by adjusting screw 17, fluidizing air duct 20 is ring-fitted on the outside of housing assembly 11 and branch pipe passes through valve seat 12.

[0039] The shell assembly 11 includes an outer shell 111, a thermal insulation castable 112, Y-shaped catch studs 113, a wear-resistant castable 114, an aerogel mesh 115, and L-shaped catch studs 116. The Y-shaped catch studs 113 and L-shaped catch studs 116 are staggered and evenly welded to the inner wall of the outer shell 111. The thermal insulation castable 112 is fixed to the inner wall of the outer shell 111. The wear-resistant castable 114 is concentrically fixed to the middle of the outer shell 111 and directly contacts the high-temperature material at 800-1200℃. A 2-3mm gap is maintained between the outer diameter of the wear-resistant castable 114 and the inner diameter of the thermal insulation castable 112. The aerogel mesh 115 fills the gap.

[0040] The valve stem assembly 13 includes a valve head 131, a front flange 132, an outer pipe 133, an inner pipe 134, a baffle 135, a water outlet 136, a plug plate 137, and a rear flange 138. The valve head 131 is a hollow structure and is connected to the front flange 132 by bolts to form a cooling water chamber. The front flange 132 is fitted and welded to the outer pipe 133. Several sets of spiral baffles 135 are welded to the outside of the inner pipe 134, and the baffles 135 slide with the outer pipe 133 to achieve support. The water outlet 136 is located at the tail end of the outer pipe 133. The rear flange 138 is welded to the tail end of the inner pipe 134 and is fixedly connected to the outer pipe 133 by the plug plate 137.

[0041] The water inlet and outlet system 3 includes a return water electric regulating valve 31 and a water inlet electric regulating valve 32. The water inlet electric regulating valve 32 and the return water electric regulating valve 31 are respectively connected to the water inlet and water outlet 136 of the valve stem assembly 13, forming a complete cooling water circuit.

[0042] The control system 4 includes a PLC control box 41, an input signal line 42, a first output signal line 43, a second output signal line 44, and a third output signal line 45. The PLC control box 41 is connected to the monitoring device 5 through the input signal line 42, to the electric actuator 18 through the first output signal line 43, and to the return water electric regulating valve 31 and the inlet water electric regulating valve 32 through the second output signal line 44 and the third output signal line 45, respectively.

[0043] The valve seat 12 has a dumbbell-shaped split structure with a 2mm expansion gap between each split and adopts a "concave-convex" snap-fit ​​structure. At the same time, one end of it is flush with the outer side of the housing assembly 11.

[0044] The sealing assembly 14 is fitted in the middle of the valve stem assembly 13 and fits tightly against the inner wall of the housing assembly 11 to achieve high-temperature sealing under operating conditions of 800-1200℃; the linear slide rail 19 is fixed to the bracket assembly 15 by countersunk screws, and the sliding pressure block 16 slides with the linear slide rail 19 to drive the valve stem assembly 13 to move horizontally.

[0045] The monitoring device 5 is a composite sensor used to detect the material level in the connecting pipe 6 and the outer wall temperature of the wear-resistant castable 114 in the housing assembly 11; the medium introduced into the fluidizing air duct 20 is compressed air or inert gas, used to fluidize the high-temperature material at 800-1200℃ at the fluidizing valve seat 12 to avoid material caking or bridging.

[0046] The input signal line 42 is used to transmit the detection signal of the monitoring device 5. The first output signal line 43, the second output signal line 44 and the third output signal line 45 are respectively used to transmit the control commands of the PLC control box 41 to the electric actuator 18, the return water electric regulating valve 31 and the inlet water electric regulating valve 32.

[0047] In this embodiment, the device is specifically designed for flow regulation of high-temperature solid materials (such as circulating fluidized bed boiler bottom ash, metallurgical slag, etc.) at 800-1200℃. Its core relies on the structural adaptation and coordinated action of each component to solve problems such as poor high-temperature adaptability, low regulation accuracy, and easy jamming and clogging in traditional devices. The specific working principle is as follows:

[0048] Overall Fixing and Buffering: The main body 1 serves as the mounting base for all functional components. The spring hanger 2 is directly fixed to the top of the outer shell 111 of the main body 1. On one hand, it secures the entire device to the load-bearing structure of the industrial site through suspension; on the other hand, it absorbs vibrations during equipment operation through the elastic deformation of the spring. During the conveying of high-temperature materials, the device will experience slight vibrations due to material impact and actuator movement. The spring hanger 2 effectively counteracts these vibrations, preventing loosening of the flange connection between the support assembly 15 and the shell assembly 11, and wear of the threaded fit between the adjusting screw 17 and the sliding pressure block 16. This provides a fundamental guarantee for subsequent precise adjustment and stable operation.

[0049] High-Temperature Protection and Structural Reinforcement of Shell Assembly 11: Shell assembly 11 is the core component for resisting high temperatures and protecting internal parts. Its structural design is fully adapted to high-temperature operating conditions. The outer shell 111 is made of high-temperature resistant steel plate welded together. Y-shaped catch studs 113 and L-shaped catch studs 116 are evenly distributed on the inner wall. The end design of the two types of catch studs can enhance the interlocking force with the castable refractory, preventing the castable refractory from peeling off from the outer shell 111 under high temperature. The heat-insulating castable refractory 112 is directly applied to the inner wall of the outer shell 111, completely covering the catch studs. Its main function is to isolate high-temperature radiation. The wear-resistant castable refractory 114 is concentrically arranged in the middle of the outer shell 111, directly contacting the high-speed flowing high-temperature material. With its high wear resistance, it resists material erosion and extends the service life of the shell.

[0050] A special design feature is the presence of a 2-3mm gap between the outer diameter of the wear-resistant castable 114 and the inner diameter of the insulating castable 112. This gap is filled with an aerogel mesh 115. The aerogel mesh 115 is soft and compressible, capable of absorbing the radial expansion of the wear-resistant castable 114 due to continuous contact with high-temperature materials, thus preventing the wear-resistant castable 114 from cracking and falling off. At the same time, its excellent thermal insulation properties further block high-temperature conduction, ensuring that the surface temperature of the outer shell 111 remains below 60°C. This prevents damage to surrounding equipment at room temperature and ensures the safety of maintenance personnel.

[0051] Structural adaptation and high-temperature anti-deformation design of valve seat 12: Valve seat 12 is the first adaptation structure of the material entry device. The dumbbell-shaped design fits the channel shape of the feed inlet, so that the material is evenly stressed and there are no dead corners when it flows in. One end is flush with the outer side of the housing component 11, which further prevents the material from accumulating at the interface.

[0052] Considering the thermal expansion characteristics of metals at high temperatures, the valve seat 12 adopts a segmented structure with a 2mm expansion gap between each segment. When high-temperature materials come into contact with the valve seat 12, the valve seat 12 will expand due to heat. The expansion gap provides space for expansion and contraction, effectively releasing thermal stress and preventing the valve seat 12 from cracking or jamming with the housing assembly 11. The interlocking structure between the segments ensures the integrity of the valve seat 12 after assembly, ensuring a regular material flow channel. It also allows for individual replacement of worn segments during later maintenance without disassembling the entire device body 1, making maintenance easy. In addition, when the valve head 131 compresses the material accumulated at the valve seat 12, the segmented structure can also disperse the compressive stress, preventing local damage to the valve seat 12.

[0053] Precise actuation and efficient cooling of valve stem assembly 13: Valve stem assembly 13 is the core actuator for flow regulation. Its structural design takes into account both actuation accuracy and high temperature protection: Valve head 131 is a hollow structure and is tightly connected to front flange 132 by bolts to form a closed cooling water chamber, ensuring that cooling water can fully surround valve head 131 and resist direct baking of high temperature materials; front flange 132 is fitted onto the front end of outer pipe 133 and welded to ensure connection strength and prevent loosening at high temperature.

[0054] The inner tube 134 is coaxially arranged inside the outer tube 133. The multiple sets of spiral baffles 135 welded on the outside have two key functions: first, they serve as a support structure for the inner tube 134 and the outer tube 133, ensuring uniform coaxiality and gap between the two tubes and allowing the cooling water to flow smoothly; second, when the cooling water flows, the baffles 135 will disrupt the laminar flow layer, causing the cooling water to generate strong internal convection, which greatly improves the heat exchange efficiency. Compared with traditional straight tube cooling, the cooling effect is improved, and at the same time, it can prevent the cooling water from vaporizing at high temperatures and forming air resistance, ensuring continuous and effective cooling. A flange 138 is welded to the tail end of the inner tube 134 and fixed to the outer tube 133 by a plug plate 137, forming a complete cooling water flow channel: cooling water enters the inner tube 134 from the inlet of the rear flange 138, travels along the inner tube 134 to the cavity of the valve head 131, fully cools the valve head 131, and then turns back from the gap between the inner tube 134 and the outer tube 133, and finally flows out from the outlet 136 at the tail end of the outer tube 133, completing the cooling cycle.

[0055] The valve stem assembly 13 is driven by the cooperation of the sliding pressure block 16, the adjusting screw 17, and the electric actuator 18: the bracket assembly 15 is fixed to the other end face of the housing assembly 11 via a flange, the linear slide rail 19 is fastened to the top surface of the bracket assembly 15 with countersunk screws, one end of the sliding pressure block 16 is bolted to the rear flange 138 of the valve stem assembly 13, and the other end is threaded into the adjusting screw 17, the other end of which is rigidly connected to the output shaft of the electric actuator 18. After receiving a control signal, the electric actuator 18 drives the adjusting screw 17 to rotate forward or reverse, causing the sliding pressure block 16 to reciprocate horizontally along the linear slide rail 19, thereby pulling the valve stem assembly 13 to move axially synchronously.

[0056] The sealing component 14 is fitted in the middle of the valve stem assembly 13 and fits tightly against the inner wall of the housing assembly 11. Its sealing material is made of high-temperature resistant graphite, which can maintain sealing performance in high-temperature and high-dust environments, preventing high-temperature material dust from entering the support assembly 15 side and avoiding dust wear on the slider of the linear slide rail 19 and the threads of the adjusting screw 17, which could lead to adjustment jamming. The core of flow regulation is the cooperation between the valve head 131 and the valve seat 12: the contact surfaces of the valve head 131 and the valve seat 12 are both designed as curved surfaces. When the valve stem assembly 13 moves, the gap X between the curved surfaces will change linearly—the gap increases, the material flow increases; the gap decreases, the flow decreases; when the curved surfaces are fully fitted, the material flow is closed, thereby achieving precise linear regulation and solving the shortcomings of traditional gate valves that are sensitive at small openings but sluggish at large openings.

[0057] The anti-caking design of the fluidizing duct 20 addresses the problem of poor flowability and easy caking / bridging of high-temperature materials. The fluidizing duct 20 is circumferentially mounted on the outer wall of the housing assembly 11, with several branch pipes radially passing through the valve seat 12, their openings reaching directly into the material flow channel. During operation, compressed air or inert gas (such as nitrogen) is continuously introduced into the fluidizing duct 20. The gas is ejected from the branch pipe openings, forming a uniform airflow field that fluidizes and disturbs the material at the valve seat 12, disrupting the caking conditions and preventing bridging and blockage within the channel. Simultaneously, when the valve head 131 moves to adjust the clearance, it exerts moderate pressure on the material accumulated at the valve seat 12. Combined with the airflow fluidization effect, this further guides the material, ensuring smooth material transport and completely solving the problems of traditional gate valves being sensitive to easily caking materials, having high operating resistance, or even being unable to operate.

[0058] Cooling water volume control of the inlet and return water system 3: The inlet and return water system 3 consists of a return water electric regulating valve 31, an inlet water electric regulating valve 32, and connecting pipes, forming a complete closed-loop cooling water circuit. The inlet water electric regulating valve 32 connects to the external cooling water source and the inlet of the inner pipe 134 of the valve stem assembly 13, controlling the inflow of cooling water. The return water electric regulating valve 31 connects to the outlet 136 of the outer pipe 133 of the valve stem assembly 13 and the cooling return water pipe, controlling the outflow of cooling water. Through the coordinated regulation of the two valves, the water flow rate and volume in the cooling water circuit can be precisely controlled, ensuring that the valve stem assembly 13 can obtain an appropriate cooling effect under different operating conditions, preventing valve stem thermal deformation due to insufficient cooling and water waste due to excessive cooling.

[0059] The coordinated closed-loop control of the control system 4: The control system 4 realizes intelligent linkage between flow regulation and cooling protection. The core is the signal processing and instruction output of the PLC control box 41. The monitoring device 5 is a composite sensor. One detection end is installed on the side wall of the connecting pipe 6 to collect the material level height in the pipe in real time (the material level directly reflects the material flow rate); the other detection end is close to the outer wall of the wear-resistant castable 114 of the shell assembly 11 to collect the temperature of the wear-resistant castable 114 (the temperature indirectly reflects the contact strength and duration between the material and the shell).

[0060] The detection signal is transmitted to the PLC control box 41 in real time through the input signal line 42. The PLC control box 41 has built-in preset control logic and parameter thresholds to calculate and convert the signal: when the material level is too high and the temperature rises, it is determined that the material flow is too large. The PLC control box 41 sends a command to the electric actuator 18 through the first output signal line 43 to drive the adjusting screw 17 to rotate in the opposite direction, which drives the sliding pressure block 16 and the valve stem assembly 13 to move away from the valve seat 12, increasing the gap X between the valve head 131 and the valve seat 12, and linearly reducing the flow. At the same time, due to the increase in flow, the contact area and contact time between the valve head 131 and the material increase, requiring more cooling water. The PLC control box 41 controls the return water electric regulating valve 31 and the inlet water electric regulating valve 32 to increase the opening degree through the second output signal line 44 and the third output signal line 45, respectively, to increase the cooling water volume and ensure the temperature of the valve stem assembly 13 is stable.

[0061] Conversely, when the material level is too low and the temperature drops, the PLC control box 41 controls the electric actuator 18 to rotate forward, reducing the gap X between the valve head 131 and the valve seat 12, thus increasing the flow rate; at the same time, it reduces the opening of the two electric regulating valves, reducing the cooling water volume. The entire control process requires no manual intervention, avoiding the problems of low accuracy and high safety risks associated with traditional manual adjustment, and solving the lag and instability of single flow meter feedback control, thus achieving automated and efficient regulation.

[0062] Material flow and output: The high-temperature material, after flow regulation, flows into the device body 1 from the gap X between the valve head 131 and the valve seat 12, moves smoothly along the internal channel of the shell assembly 11, and is finally transported to the subsequent process section (such as cooling and reaction section) through the connecting pipe 6 fixed at the outlet of the device body 1. The entire flow process is free of dead corners and material accumulation, ensuring stable and controllable flow.

[0063] This invention also provides a control method for a high-temperature material flow rate regulating device, comprising the following steps:

[0064] S1: The monitoring device 5 detects the material level in the connecting pipe 6 and the outer wall temperature signal of the wear-resistant castable 114 in the shell assembly 11 in real time, and transmits the detection signal to the control system 4.

[0065] S2: After processing the received signal, the control system 4 sends a control command to the electric actuator 18. The electric actuator 18 drives the adjusting screw 17 to rotate, which drives the sliding block 16 to move horizontally along the linear slide rail 19, thereby driving the valve stem assembly 13 to move synchronously, adjusting the gap between the valve stem assembly 13 and the valve seat 12, and realizing the linear regulation of the flow rate of high-temperature materials at 800-1200℃.

[0066] S3: The control system 4 synchronously sends instructions to the inlet and outlet water system 3 to adjust the cooling water volume of the cooling water circuit and provide cooling protection for the valve stem assembly 13.

[0067] S4: The fluidizing duct 20 continuously supplies the medium, and through the branch pipe passing through the valve seat 12, it fluidizes the high-temperature material at 800-1200℃ at the valve seat 12, avoiding material caking or bridging.

[0068] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0069] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-temperature material flow rate regulating device, characterized in that: Includes the device body (1), spring hanger (2) fixed on the device body (1), water inlet and outlet system (3), control system (4), monitoring device (5) and connecting pipe (6) fixed on the outlet of the device body (1); The spring hanger (2) is used to suspend the main body (1) of the fixing device and to provide a buffering effect; The inlet and outlet water system (3) is connected to the valve stem assembly (13) of the device body (1) to form a cooling water circuit; The control system (4) is connected to the monitoring device (5), the water inlet and outlet system (3), and the electric actuator (18) of the device body (1) respectively; The device body (1) includes a housing assembly (11), a valve seat (12), a valve stem assembly (13), a sealing assembly (14), a support assembly (15), a sliding block (16), an adjusting screw (17), an electric actuator (18), a linear slide rail (19), and a fluidizing duct (20). The valve seat (12) is embedded in the feed inlet of the housing assembly (11). The support assembly (15) is fixed to the other end face of the housing assembly (11) by a flange. The linear slide rail (19) is fixed to the support assembly (15). The valve stem assembly (13) is arranged concentrically with the housing assembly (11) and passes through the sealing assembly (14) in the middle. One end of the sliding block (16) is fixedly connected to the valve stem assembly (13). The other end of the sliding block (16) is connected to the electric actuator (18) by the adjusting screw (17). The fluidizing duct (20) is encircled on the outside of the housing assembly (11), and the branch pipe passes through the valve seat (12). The shell assembly (11) includes a shell (111), thermal insulation castable (112), Y-shaped catch studs (113), wear-resistant castable (114), aerogel mesh (115), and L-shaped catch studs (116). The Y-shaped catch studs (113) and L-shaped catch studs (116) are staggered and evenly welded to the inner wall of the shell (111). The thermal insulation castable (112) is fixed to the inner wall of the shell (111). The wear-resistant castable (114) is concentrically fixed to the middle of the shell (111) and directly contacts the high-temperature material at 800-1200℃. The outer diameter of the wear-resistant castable (114) and the inner diameter of the thermal insulation castable (112) maintain a gap of 2-3mm. The aerogel mesh (115) fills the gap. The valve stem assembly (13) includes a valve head (131), a front flange (132), an outer tube (133), an inner tube (134), a baffle (135), a water outlet (136), a plug plate (137), and a rear flange (138). The valve head (131) is a hollow structure and is connected to the front flange (132) by bolts to form a cooling water chamber. The front flange (132) is fitted and welded to the outer tube (133). Several sets of spiral baffles (135) are welded to the outside of the inner tube (134), and the baffles (135) slide with the outer tube (133) to achieve support. The water outlet (136) is located at the tail end of the outer tube (133). The rear flange (138) is welded to the tail end of the inner tube (134) and is fixedly connected to the outer tube (133) by the plug plate (137).

2. The high-temperature material flow rate regulating device according to claim 1, characterized in that: The water inlet and outlet system (3) includes a return water electric regulating valve (31) and a water inlet electric regulating valve (32). The water inlet electric regulating valve (32) and the return water electric regulating valve (31) are respectively connected to the water inlet and water outlet (136) of the valve stem assembly (13) to form a complete cooling water circuit.

3. The high-temperature material flow rate regulating device according to claim 1, characterized in that: The control system (4) includes a PLC control box (41), an input signal line (42), a first output signal line (43), a second output signal line (44), and a third output signal line (45). The PLC control box (41) is connected to the monitoring device (5) through the input signal line (42), to the electric actuator (18) through the first output signal line (43), and to the return water electric regulating valve (31) and the inlet water electric regulating valve (32) through the second output signal line (44) and the third output signal line (45), respectively.

4. The high-temperature material flow rate regulating device according to claim 1, characterized in that: The valve seat (12) has a dumbbell-shaped split structure with a 2mm expansion gap between each split and adopts a "concave-convex" buckle structure. At the same time, one end of it is flush with the outer side of the housing assembly (11).

5. The high-temperature material flow rate regulating device according to claim 1, characterized in that: The sealing component (14) is fitted into the middle of the valve stem assembly (13) and fits tightly against the inner wall of the housing assembly (11) to achieve high-temperature sealing under operating conditions of 800-1200℃; The linear slide rail (19) is fixed to the bracket assembly (15) by countersunk screws. The sliding block (16) slides with the linear slide rail (19) to drive the valve stem assembly (13) to move horizontally.

6. The high-temperature material flow rate regulating device according to claim 1, characterized in that: The monitoring device (5) is a composite sensor used to detect the material level height in the connecting pipe (6) and the outer wall temperature of the wear-resistant castable (114) in the shell assembly (11); The fluidizing duct (20) is supplied with compressed air or inert gas to fluidize high-temperature materials at 800-1200℃ at the fluidizing valve seat (12) to prevent material caking or bridging.

7. The high-temperature material flow rate regulating device according to claim 3, characterized in that: The input signal line (42) is used to transmit the detection signal of the monitoring device (5), and the first output signal line (43), the second output signal line (44) and the third output signal line (45) are respectively used to transmit the control commands of the PLC control box (41) to the electric actuator (18), the return water electric regulating valve (31) and the inlet water electric regulating valve (32).

8. A control method for a high-temperature material flow rate regulating device, wherein the high-temperature material flow rate regulating device according to any one of claims 1-7 is characterized in that, Includes the following steps: S1: The monitoring device (5) detects the material level in the connecting pipe (6) and the outer wall temperature signal of the wear-resistant castable (114) in the shell assembly (11) in real time, and transmits the detection signal to the control system (4). S2: After processing the received signal, the control system (4) sends a control command to the electric actuator (18). The electric actuator (18) drives the adjusting screw (17) to rotate, which drives the sliding block (16) to move horizontally along the linear slide rail (19), thereby driving the valve stem assembly (13) to move synchronously, adjusting the gap between the valve stem assembly (13) and the valve seat (12), and realizing the linear regulation of the flow rate of high-temperature materials at 800-1200℃. S3: The control system (4) synchronously sends instructions to the inlet and outlet water system (3) to adjust the cooling water volume of the cooling water circuit and provide cooling protection for the valve stem assembly (13); S4: The fluidizing duct (20) continuously supplies the medium, and through its branch pipe passing through the valve seat (12), the high-temperature material at 800-1200℃ at the valve seat (12) is fluidized to avoid material caking or bridging.

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