Sludge curing equipment based on cooperation of CO2 carbonization and industrial waste residue-based curing agent

Abstract

The invention relates to the technical field of geotechnical engineering and environmental protection, and discloses sludge curing equipment based on cooperation of CO2 carbonization and an industrial waste residue-based curing agent, the sludge curing equipment comprises a movable rack, the top of the movable rack is provided with a stirring tank, a booster tank and two conveying pumps, the two conveying pumps communicate with the stirring tank and the pressurizing tank through connecting pipes correspondingly, the output ends of the conveying pumps are fixedly connected with output pipes, the top of the movable rack is rotationally connected with a supporting base, the top of the supporting base is rotationally connected with a transverse frame, and the outer side of the transverse frame is fixedly connected with a limiting plate; the output pipe is fixedly connected to the middle of the limiting plate, and an air cylinder is rotationally connected to the bottom of the transverse frame. According to the invention, the problems of sensor failure and uneven mixing are solved through a squeezing-in sampling structure of fluid pressure difference in combination with an intermittent control strategy of pulse cleaning, balance measurement and feedback adjustment, and accurate regulation and control of deep sludge solidification reaction and high-quality soil improvement are realized.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of geotechnical engineering and environmental protection, in particular to a silt solidification equipment based on CO2 carbonization and industrial waste residue-based solidifying agent cooperation. BACKGROUND

[0002] With the extension of infrastructure construction to complex geological environments, the traditional method of soft soil reinforcement using high-energy building materials such as cement and lime is facing transformational pressure. Using industrial alkaline waste residues such as carbide slag, steel slag, and blast furnace slag, which are rich in calcium and magnesium components, to replace cement and injecting carbon dioxide (CO2) into the soil, through carbonation reaction to generate carbonate precipitate to fill pores and cement soil particles, has become a cutting-edge technology route that realizes waste resource utilization, carbon dioxide sequestration, and foundation reinforcement.

[0003] Currently, the existing technical equipment that realizes the above process is mainly based on the improvement of traditional deep mixing pile machines. This type of equipment is usually composed of a tracked or walking mobile chassis, a vertical guide frame, a power head, a drill pipe, and a drill bit, and is equipped with a ground grouting pump station and a storage tank. During construction, the equipment drives the hollow drill pipe to rotate down to the predetermined depth through the power head, and the pre-prepared solidifying agent slurry or gas is transported to the drill bit nozzle through the drill pipe channel using the ground pump station. Under the mechanical action of the rotating drill bit stirring blade, the solidifying agent is forcibly mixed with the in-situ soil, and after the slurry solidifies, a reinforced pile body is formed.

[0004] Although the use of existing mixing equipment can complete the grouting and mixing actions, there are still significant technical limitations when facing the complex physicochemical process of carbon dioxide and waste residue cooperative solidification, making it difficult to ensure the solidification quality. First, the reaction process in the deep operation environment is in a blind control state, lacking a real and effective in-situ closed-loop monitoring mechanism. The effect of carbonation reaction is highly dependent on the real-time balance of silt moisture content, pH value, CO2 concentration, CO2 pressure, and reaction temperature. However, if sensors are installed at the drill bit of the existing equipment, the sensor probe will be wrapped or washed by the high-speed flowing slurry in continuous high-pressure grouting operations, resulting in distorted data. Once the pump is stopped, the sticky silt can easily clog the probe or cause the grouting channel to be blocked. This fouling effect makes it impossible for construction personnel to obtain real deep reaction data, and they can only blindly inject gas based on experience, which can easily lead to uneven reactions or gas escape and damage the stratum.

[0005] Secondly, the mixing and diffusion of gas-liquid two-phase flow in deep soil is difficult to control. Due to the huge difference in rheological properties between carbon dioxide gas and waste residue-based solidifying agent slurry, under a single pumping or simple continuous injection mode, high-pressure gas can easily form a dominant channel in dense silt and directly escape (channel effect), leading to gas-liquid separation and preventing effective contact and mineralization at the microscopic level, resulting in large dispersion of solidified body strength.

[0006] Furthermore, existing equipment lacks the ability to actively intervene in the thermodynamic environment of the reaction. Carbonization is an exothermic reaction and is sensitive to temperature. The existing material storage and transportation system is in a thermodynamically passive state. In winter, the insufficient activation energy of the reaction leads to delayed solidification, while in summer or when the reaction is intense, the accumulation of heat causes thermal stress microcracks to form inside the pile.

[0007] Finally, as drilling depth increases, the dynamic management of external connection pipelines also becomes a major challenge. Existing flexible delivery hoses typically lack automated tensioning and retraction mechanisms. During significant lifting, lowering, rotation, or twisting of the drill rod, loosened pipelines are prone to accumulation, wear, or even being caught in rotating components, posing serious safety hazards. Summary of the Invention

[0008] To address the shortcomings of existing technologies, this invention provides a sludge solidification device based on the synergistic effect of CO2 carbonization and industrial waste residue-based solidifying agents. This solves the problems of uneven gas-liquid mixing of reactants, easy clogging and failure of in-situ monitoring sensors, lack of reaction temperature and pressure control, and lack of pipeline follow-up management in deep sludge solidification operations, which make it difficult to guarantee the solidification quality.

[0009] To achieve the above objectives, the present invention provides the following technical solution: a sludge solidification device based on the synergistic effect of CO2 carbonization and industrial waste-based solidifying agent, comprising a mobile frame. The top of the mobile frame is equipped with a mixing tank, a pressurizing tank, and two transport pumps. Both transport pumps are connected to the mixing tank and the pressurizing tank respectively via connecting pipes. The output end of each transport pump is fixedly connected to an output pipe. A support base is rotatably connected to the top of the mobile frame, and a crossbeam is rotatably connected to the top of the support base. A limit plate is fixedly connected to the outer side of the crossbeam, and the output pipe is fixedly connected to the middle of the limit plate. A cylinder is rotatably connected to the bottom of the crossbeam, and the output end of the cylinder is fixedly connected to... The system includes a pipeline, with the output end of the output pipe connected to the pipeline. A hollow tube one is installed at the bottom end of the pipeline, and a hollow tube two is installed at the bottom end of the hollow tube one. A connector is fixedly connected to the bottom end of the hollow tube two, and a sensor array is fixedly connected inside the connector. A stirring mechanism is fixedly connected to the outer periphery of the pipeline. The stirring mechanism is used to stir and mix the sludge and the injected solidified material. An anti-clogging mechanism is provided inside the hollow tube two. The anti-clogging mechanism is designed to open under injection pressure to empty the hollow tube two, and to close after the injection pressure is removed to allow external sludge to squeeze into the hollow tube two and contact the sensor array. A winding mechanism is fixedly connected to the middle of the crossbeam.

[0010] Preferably, the anti-clogging mechanism includes a cross plate, which is fixedly connected to the inner bottom of the hollow tube II. A sealing ball is provided on the upper side of the cross plate, and a stop block is provided on the upper side of the sealing ball. The stop block is fixedly connected to the inside of the hollow tube II. The sealing ball and the stop block abut against each other. When the transport pump stops working, the sealing ball abuts against the stop block under the pressure of the sludge to seal it.

[0011] Preferably, the winding mechanism includes a storage box, which is fixedly connected to the middle of the crossbeam. A pay-off wheel is rotatably connected to the middle of the storage box. A spring is fixedly connected to both ends of the pay-off wheel. The other end of the spring is fixedly connected to the inside of the storage box. Two pull ropes are fixedly connected to the outside of the pay-off wheel. A roller is fixedly connected to the other end of the pull ropes. A limiting block is fixedly connected to the middle of the two rollers. The output tube is fixedly connected to the middle of the limiting block, which is used to automatically adjust the length of the tube as the tube rises and falls.

[0012] Preferably, a temperature control mechanism is fixedly connected to the top of both the mixing tank and the pressurizing tank, and the temperature control mechanism is used to adjust the temperature inside the mixing tank and the pressurizing tank.

[0013] Preferably, the two transport pumps are a first pump body and a second pump body; the first pump body is a curing agent pump for conveying waste residue-based curing agent slurry, and the second pump body is a gas booster pump for conveying carbon dioxide gas.

[0014] Preferably, the sensor array integrates at least one of a pH sensor, a carbon dioxide concentration sensor, a temperature sensor, and a pressure sensor; the data output terminal of the sensor array is electrically connected to a central control unit.

[0015] Preferably, the processing equipment further includes a central control unit, which is electrically connected to the transport pump, the sensor array, and the cylinder respectively; The central control unit is configured to execute an intermittent closed-loop control mode: control the transport pump to start for a preset pulse time to empty the hollow tube 2, then control the transport pump to shut down and wait for a preset equilibrium time, and then collect the sludge parameters squeezed into the hollow tube 2 through a sensor array.

[0016] Preferably, the central control unit is further configured to adjust the flow rate of the next pulse cycle according to the current curing stage: During the waste residue injection stage, the central control unit adjusts the flow rate of the curing agent slurry in the first pump body according to the pH value data; during the carbon dioxide injection stage, the central control unit adjusts the flow rate and pressure of the carbon dioxide in the second pump body according to the pH value and carbon dioxide concentration data.

[0017] Preferably, the central control unit is electrically connected to the temperature control mechanism; during the carbon dioxide injection stage, when the temperature detected by the sensor array drops sharply below the reaction threshold due to gas expansion and heat absorption, the central control unit controls the activation of the temperature control mechanism's heating function to provide thermal compensation for the input carbon dioxide, thereby offsetting the physical heat absorption effect; in the later stage of the curing reaction, when the detected temperature accumulates above the safety threshold due to carbonization exothermic accumulation, the central control unit controls the activation of the temperature control mechanism's cooling function to reduce the material temperature and avoid thermal stress cracks in the cured body.

[0018] Preferably, the stirring mechanism includes a frame and a base plate. The frame and the base plate are fixedly connected to the outer periphery of the pipe from top to bottom. A motor is fixedly connected to the top of the frame, and a gear is fixedly connected to the output end of the motor. A gear ring is rotatably connected between the frame and the base plate. The gear and the gear ring mesh with each other. A telescopic plate is installed at the bottom of the gear ring, and a stirring plate is installed on the other side of the telescopic plate. A dust cover is fixedly connected to the top of the frame, and the motor is located inside the dust cover.

[0019] This invention provides a sludge solidification device based on the synergistic effect of CO2 carbonization and industrial waste-based solidifying agents. It has the following beneficial effects: 1. This invention, through the synergistic effect of an asynchronous gas-phase purging strategy and an anti-clogging mechanism, completely solves the problems of sensor contamination and pipeline self-curing in deep high-pressure grouting environments. Before the grouting pulse ends, the system prioritizes stopping the delivery of the curing agent while maintaining gas delivery, using pure high-pressure gas to thoroughly purge the residual active grout in the pipeline into the external soil. During the equilibrium measurement phase, the pressure difference in the formation allows fresh silt to be passively squeezed into the emptied connector to contact the sensor. This mechanism ensures that the sensor probe is not encapsulated and cured by residual grout, guaranteeing the authenticity of key data such as pH value, moisture content, CO2 concentration, temperature, and pressure, as well as the stability of long-term monitoring.

[0020] 2. This invention employs a stepwise injection process of alkalization and reconstruction followed by carbonization enhancement, coupled with adaptive feedback of stoichiometry and linkage control of mechanical rotation and torsion, effectively solving the problems of chaotic flow patterns and channel effects in traditional gas-liquid co-injection processes. The first stage establishes a uniform alkaline framework through waste residue injection, while the second stage achieves deep carbonization through CO2 injection. When the CO2 concentration is detected to be too high but the pH value is not up to standard (i.e., gas escape), the stirring mechanism is automatically triggered to achieve forced mixing of the gas, liquid, and solid phases, improving mass transfer efficiency and reaction completeness without increasing the injection volume.

[0021] 3. This invention achieves proactive intervention in the thermal environment of the carbonization reaction through a bidirectional temperature control mechanism and a thermodynamic range control strategy. Addressing the Joule-Thomson effect (endothermic volume expansion) during CO2 injection, the system automatically performs thermal compensation to prevent pore water from freezing and blocking the reaction pathway. Regarding the exothermic characteristics of the subsequent carbonization reaction, cooling is performed during high-temperature accumulation to neutralize heat buildup, prevent thermal stress cracking, and ensure the reaction remains within the optimal activation energy temperature range.

[0022] 4. This invention introduces an initial geological survey and feedforward control mechanism. Before the operation begins, in-situ geological background parameters are obtained using pore water pressure sensors and pH sensors, and the theoretical grouting volume and optimal injection pressure are calculated in advance. Combined with the dynamic pressure regulation function of the pressurization tank, customized intelligent variable pressure injection is achieved: physical pressurization is performed when the gas pressure is insufficient to overcome formation resistance to ensure permeability; automatic pressure relief is performed when the pressure is too high and may damage the formation, avoiding the risk of hydraulic fracturing, thus achieving adaptive construction in deep and complex geological environments.

[0023] 5. This invention eliminates errors from human experience-based judgment through an automatic layered lifting mechanism based on a multi-parameter coupling model. Only when the pH value meets the standard, the free water content decreases to the threshold, and the temperature change rate approaches zero can the cylinder drive the pipeline to the next layer. This intelligent decision-making logic avoids both the partial lifting caused by excessive speed and the waste of time caused by overwork, ensuring the uniformity and continuity of the solidified body's quality in the vertical direction. Attached Figure Description

[0024] Figure 1 This is a perspective view of the present invention; Figure 2 This is a schematic diagram of the anti-blocking mechanism of the present invention; Figure 3 This is a schematic diagram of the winding mechanism of the present invention; Figure 4 This is a schematic diagram of the structure of the spring of the present invention; Figure 5 This is a schematic diagram of the structure of the sealing ball of the present invention; Figure 6 This is a schematic diagram of the structure of the motor of the present invention; Figure 7 This is a schematic diagram of the toothed ring of the present invention.

[0025] The components include: 1. Mobile frame; 2. Mixing tank; 3. Transport pump; 4. Connecting pipe; 5. Output pipe; 6. Support base; 7. Horizontal frame; 8. Limiting plate; 9. Cylinder; 10. Pipeline; 11. Hollow tube one; 12. Hollow tube two; 13. Connector; 14. Sensor array; 20. Winding mechanism; 201. Storage box; 202. Feeding reel; 203. Pull rope; 204. Clock spring; 205. Roller; 206. Limiting block; 30. Anti-blocking mechanism; 301. Cross plate; 302. Blocking ball; 303. Stop block; 40. Temperature control mechanism; 15. Pressure tank; 50. Mixing mechanism; 501. Frame; 502. Base plate; 503. Motor; 504. Gear; 505. Gear ring; 506. Telescopic plate; 507. Mixing plate; 508. Dust cover. Detailed Implementation

[0026] The technical solutions in 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.

[0027] Please see the appendix Figure 1 - Appendix Figure 7This invention provides a sludge solidification device based on the synergistic effect of CO2 carbonization and an industrial waste-based solidifying agent. The device includes a mobile frame 1, with a mixing tank 2, a pressurizing tank 15, and two transport pumps 3 mounted on top of the frame 1. Both transport pumps 3 are connected to the mixing tank 2 and the pressurizing tank 15 respectively via connecting pipes 4. The mixing tank 2 stores and mixes the industrial waste-based solidifying agent slurry, while the pressurizing tank 15 stores carbon dioxide. One transport pump 3 is a solidifying agent pump used to transport the mixed materials, and the other transport pump 3 is a gas pressurizing pump used to transport carbon dioxide at regulated pressure. The output end of the transport pump 3 is fixedly connected to an output pipe 5. The top of the movable frame 1 is rotatably connected to a support base 6. The top of the support base 6 is rotatably connected to a cross frame 7. A limit plate 8 is fixedly connected to the outer side of the cross frame 7. The output pipe 5 is fixedly connected to the middle of the limit plate 8. The bottom of the cross frame 7 is rotatably connected to a cylinder 9. The output end of the cylinder 9 is fixedly connected to a pipe 10. The cylinder 9 drives the bottom of the pipe 10 and the components below it to move downwards, thereby descending to the preset working depth for curing. After the current layer is cured, the pipe 10 can also be raised to the next layer height. This achieves bottom-up layered solidification. The output end of output pipe 5 is connected to pipe 10. Hollow pipe 11 is installed at the bottom of pipe 10, and hollow pipe 2 12 is installed at the bottom of hollow pipe 11. Connector 13 is fixedly connected to the bottom of hollow pipe 2 12. Sensor array 14 is fixedly connected inside connector 13. The double rotating connection structure of support base 6 and crossbeam 7 can drive the entire component pipeline below to move at multiple angles in the sludge, accelerating the mixing efficiency. When uneven mixing is detected, such as excessive CO2 but pH not meeting the standard, the support base 6 and crossbeam 7 can be adjusted. The angle allows for direct physical stirring of the bottom-injected waste residue and CO2, improving the mixing efficiency and mass transfer efficiency of the reactant waste residue and CO2. A stirring mechanism 50 is fixedly connected to the outer periphery of the pipe 10. The stirring mechanism 50 is used to stir and mix the sludge and the injected solidified material. An anti-blocking mechanism 30 is provided inside the hollow tube 2 12. The anti-blocking mechanism 30 is designed to open under the action of injection pressure to empty the hollow tube 2 12, and to close after the injection pressure is removed to allow external sludge to squeeze into the hollow tube 2 12 to contact the sensor array 14. A winding mechanism 20 is fixedly connected to the middle of the crossbeam 7.

[0028] Please see the appendix Figure 1 and attached Figure 5The anti-clogging mechanism 30 includes a cross plate 301, which is fixedly connected to the inner bottom of the hollow tube 12. A blocking ball 302 is provided on the upper side of the cross plate 301. The cross plate 301 can provide limiting support for the blocking ball 302 above, preventing the ball from falling to the sludge discharge port below. The reserved gaps around it can ensure the smooth discharge of gas and waste residue and avoid blockage. A stop block 303 is provided on the upper side of the blocking ball 302. The stop block 303 is fixedly connected to the hollow tube 12. Inside the core tube 2 12, the sealing ball 302 and the baffle 303 abut against each other. When the transport pump 3 stops working, the sealing ball 302 abuts against the baffle 303 under the pressure of the sludge and seals. The sealing ball 302 has an annular structure made of rubber inside, with a through hole in the middle for material to pass through. Its lower surface is machined with a sealing slope that matches the spherical surface of the sealing ball 302. After the sealing ball 302 is squeezed by the sludge, it will contact the lower surface of the baffle 303 to prevent the sludge from flowing back in.

[0029] Please see the appendix Figure 2 - Appendix Figure 4 The winding mechanism 20 includes a storage box 201, which is fixedly connected to the middle of the crossbeam 7. The storage box 201 serves as the main outer shell of the mechanism, providing support and protection for the winding mechanism 20. A feed wheel 202 is rotatably connected to the middle of the storage box 201. Both ends of the feed wheel 202 are fixedly connected to a spring 204, the other end of which is fixedly connected inside the storage box 201. Two pull ropes 203 are fixedly connected to the outer side of the feed wheel 202, and rollers 205 are fixedly connected to the other ends of the pull ropes 203. A limiting block 206 is fixedly connected to the middle of the two rollers 205. The output pipe 5 is fixedly connected to the middle of the limiting block 206, allowing the output pipe 5 to automatically adjust its length as the pipe 10 rises and falls. Specifically, when cylinder 9 drives pipe 10 and the injection assembly below it to descend into the deep sludge, pipe 10 will pull the output pipe 5 connected to it to move downward. The downward pulling force of output pipe 5 is transmitted to pull rope 203 through limit block 206. The pull drives the wire feeding wheel 202 to rotate in the wire feeding direction. During the rotation, the spring 204 is twisted and compressed, so that output pipe 5 is relaxed when pipe 10 rises. The twisted and compressed spring 204 will release elastic potential energy and generate a reverse reset torque, thereby driving the wire feeding wheel 202 to rotate in the opposite direction to wind up pull rope 203. During the winding process, limit block 206 is retracted. At this time, the relaxed output pipe 5 is pulled back at the same time.

[0030] Please see the appendix Figure 1 A temperature control mechanism 40 is fixedly connected to the top of the mixing tank 2 and the pressure tank 15. The temperature control mechanism 40 has heating and cooling functions. The temperature control mechanism 40 is used to regulate the temperature inside the mixing tank 2 and the pressure tank 15. The temperature control mechanism 40 is a commercially available temperature controller. The temperature control mechanism 40 is existing technology and will not be described in detail in this article.

[0031] Please see the appendix Figure 1 The two transport pumps 3 are the first pump body and the second pump body, respectively. The first pump body is a curing agent pump for conveying waste residue-based curing agent slurry. Its internal impeller and pump casing are made of high chromium alloy or wear-resistant rubber lining. It can accommodate and convey high-viscosity slurry containing high concentrations of solid particles such as carbide slag and fly ash particles, preventing particle sedimentation or clogging of the pump body. The second pump body is a gas booster pump for conveying carbon dioxide gas. This pump body has a multi-stage booster function, which can pressurize the gas in the booster tank to ensure that CO2 has sufficient penetrating power. The curing agent pump and the gas booster pump are existing technologies and will not be described in detail in this article.

[0032] Please see the appendix Figure 2 The sensor array 14 integrates at least one of a pH sensor, a carbon dioxide concentration sensor, a temperature sensor, and a pressure sensor; the data output terminal of the sensor array 14 is electrically connected to a central control unit. After cylinder 9 drives pipe 10 and sensor array 14 to the preset deep silt operation point, the initial geological survey mode is executed first: At this time, the transport pump 3 remains off, and the central control unit controls the anti-blocking mechanism 30 to be in a state that allows external silt to be squeezed in (or the pump is briefly opened to empty the silt and then immediately stopped, using the formation pressure difference to suck in fresh in-situ silt). The sensor array 14 collects background parameters of the undisturbed in-situ silt to obtain the initial water content and initial pH.

[0033] The central control unit calculates the theoretical injection volume of industrial waste slurry required to achieve the target curing strength based on the initial moisture content, ensuring that the water-cement ratio meets the hydration reaction requirements; at the same time, it calculates the optimal injection pressure of subsequent carbon dioxide based on the initial pore water pressure.

[0034] The stirring mechanism 50 includes a frame 501 and a base plate 502. The frame 501 and the base plate 502 are fixedly connected to the outer periphery of the pipe 10 from top to bottom. A motor 503 is fixedly connected to the top of the frame 501. A gear 504 is fixedly connected to the output end of the motor 503. A gear ring 505 is rotatably connected between the frame 501 and the base plate 502. The gear 504 and the gear ring 505 are meshed. A telescopic plate 506 is installed at the bottom of the gear ring 505. A stirring plate 507 is installed on the other side of the telescopic plate 506. A dust cover 508 is fixedly connected to the top of the frame 501. The motor 503 is located inside the dust cover 508.

[0035] After completing the above calculations, the central control unit executes Phase 1: Alkaliization and Reconstruction: First, the first pump is started, the second pump is paused, and waste residue slurry is injected into the sludge; at the same time, the central control unit drives the motor 503 to make the gear 504 rotate in conjunction with the gear ring 505, which drives the telescopic plate 506 and the stirring plate 507 to rotate in the sludge, and the forcibly injected waste residue slurry is violently mixed with the sludge.

[0036] During this stage, a pH sensor monitors the alkalinity rise of the sludge. If the pH value is still below the preset alkalization threshold after the theoretical amount is injected, the system automatically increases the delivery flow rate of the first pump until the pH value stabilizes within the preset alkaline range, completing the initial framework construction.

[0037] After injection is completed, the system enters the aforementioned intermittent closed-loop control mode. At this time, the data collected by the sensor array 14 is no longer the baseline value, but the process value reflecting the ongoing process. The central control unit compares the process value with the target value and makes fine adjustments to the theoretical flow rate calculated based on the initial survey.

[0038] For example, if the initially calculated amount of mixture has been injected, but the pH sensor shows that the local area is still acidic, the mixture pumping rate will be automatically increased.

[0039] When it is detected that the heat accumulation exceeds the safety threshold due to the intense carbonization reaction in the later stage, the central control unit is prompted to activate the cooling function or suspend the injection to avoid the generation of thermal stress microcracks inside the solidified body.

[0040] Moisture content sensor: This sensor detects the change in dielectric constant of sludge through a high-frequency electromagnetic field. It not only measures the absolute amount of moisture, but also indirectly characterizes the degree of reaction and crystallization hardening progress of solidifying agent waste residue + CO2 with sludge by capturing the attenuation of the dielectric signal of free water. This provides a key basis for the central control unit to determine whether to improve the stratification.

[0041] The data output terminal of the sensor array 14 is electrically connected to the central control unit (CCU) on the ground via a shielded cable or wireless transmission module built into the wall of the pipe 10, forming a high-speed data uplink channel.

[0042] The processing equipment also includes a central control unit, which is electrically connected to the transport pump 3, the sensor array 14, and the cylinder 9. The output of the central control unit is connected to the frequency converter of the transport pump 3 to control the pump's start / stop, speed, and flow rate; it is also connected to the solenoid valve of the cylinder 9 to control the lifting and lowering displacement of the pipeline 10. The input of the central control unit is connected to the data interface of the sensor array 14 to receive real-time feedback of physicochemical parameters from downhole. The central control unit is configured to execute a phased, intermittent closed-loop control mode. After completing the waste residue injection and detection in Phase One, if the pH value meets the standard, the system automatically switches to Phase Two: carbonization and solidification.

[0043] In Phase Two, the central control unit calculates the theoretical carbon dioxide demand based on the amount of waste residue injected and starts the second pump for high-pressure injection.

[0044] While injecting carbon dioxide, the central control unit executes the following multi-dimensional coupling control strategy: Temperature sensor: Used for real-time monitoring of the complex thermodynamic equilibrium state of the solidified area downhole. Given that high-pressure carbon dioxide undergoes a dramatic volume expansion and heat absorption phenomenon when injected into the sludge, it can easily lead to a sharp drop in local temperature or even cause pore water to freeze, thereby blocking ion migration and chemical reaction processes; while the subsequent carbonization process of the waste residue is a typical exothermic reaction.

[0045] Therefore, when the temperature is detected to drop sharply below the reactivity threshold or close to the freezing point due to gas injection, the central control unit is prompted to immediately activate the temperature control mechanism 40 to perform thermal compensation on the input carbon dioxide in order to counteract the physical endothermic effect of the gas, prevent freezing, and maintain the activation energy required for the reaction. Injected with carbon dioxide.

[0046] Specifically, the central control unit integrates a stoichiometric ratio adaptive feedback module. This module does not perform simple linear adjustment, but rather executes the following flow correction algorithm based on real-time deviation: The preset target pH value for curing is set to... The actual pH value collected by the sensor is currently... The current carbon dioxide flow rate of the second pump is .

[0047] The central control unit calculates the flow setpoint for the next pulse cycle. : ; In the formula, The second pump (carbon dioxide delivery) is calculated for the next pulse cycle by the central control unit. This represents the actual flow rate of the pump body during the current pulse cycle. This is a preset proportional gain coefficient, used for rapid response adjustment based on the deviation of the pH value at the current moment; This represents the actual pH value of the sludge mixture collected by sensor array 14 at the current moment. The system's preset target pH value for the curing reaction; This is a preset integral gain coefficient used to eliminate the steady-state error of the system caused by the accumulation of deviations over a long period of time; This is the integral time variable, representing the length of time from the start of the control cycle to the current moment; This represents the cumulative integral of the pH deviation over time. The system uses this algorithm to dynamically calculate the flow rate increment required to maintain the optimal reaction ratio, thus achieving precise closed-loop control.

[0048] Furthermore, to address the channel effect problem that easily occurs in deep sludge during gas-liquid two-phase flow, the central control unit executes the following logical judgment strategy: The preset carbon dioxide concentration saturation threshold is (e.g., 85%), and the allowable pH error band is... The system performs real-time logical AND operations: ; In the formula, Boolean logic trigger signal to control the rotational connection structure between support 6 and crossbeam 7; This represents the actual carbon dioxide concentration within the sludge pores collected by sensor array 14 at the current moment. The preset carbon dioxide concentration saturation threshold represents the state where the gas source has reached saturation or oversupply in the sludge at the current depth. The logical AND operator indicates that the entire logical result is true only if both the conditional expressions on its left and right sides are true. A preset pH value determination tolerance band (or control dead zone) is used to prevent the system from frequently triggering rotation due to small fluctuations near the target value; This represents the actual pH value of the sludge mixture collected by sensor array 14 at the current moment. The target pH value for the curing reaction is preset for the system.

[0049] When the above logical expression When the result is true, it means that the gas supply is sufficient but the pH value has not decreased. The system determines that gas has escaped along the cracks or local bubble aggregation has occurred inside the sludge (i.e., the effective contact area is insufficient).

[0050] The central control unit is electrically connected to the temperature control mechanism 40; When the temperature detected by the sensor array 14 is lower than the reaction threshold, the central control unit controls the activation of the temperature control mechanism 40 to increase the temperature of the injected material. When the detected temperature exceeds the safety threshold, the central control unit activates the cooling function of the temperature control mechanism 40 to reduce the temperature of the injected material.

[0051] The central control unit analyzes the in-situ temperature data fed back by the sensor array 14 in real time. When the detected temperature is lower than the preset reaction threshold, such as in low winter temperatures or stagnant layer conditions, the system determines that the current thermal energy is insufficient to maintain a high-efficiency chemical reaction rate. Therefore, it instructs the temperature control mechanism 40 to activate the heating function to preheat the source materials in the mixing tank 2 and the pressurization tank 15, thereby increasing the activation energy of the reaction system and preventing the reaction from stalling. Conversely, when the detected temperature is higher than the preset safety threshold, such as when the exothermic reaction of carbonization is too intense, the system determines that there is a risk of thermal damage. Therefore, it instructs the temperature control mechanism 40 to activate the cooling function to cool the materials, using the low-temperature materials to neutralize the heat of reaction accumulated in the well. This mechanism ensures that the carbonization reaction always takes place within the optimal temperature range, effectively avoiding incomplete solidification and false setting caused by low temperature and micro-cracks in the solidified body caused by high-temperature thermal stress, thus improving the pile quality and structural strength.

[0052] The central control unit is also configured to determine the current curing state based on a multi-parameter coupling model; when the pH value reaches the preset curing standard and the temperature data is in a stable range, the central control unit controls the cylinder 9 to drive the pipe 10 to lift the preset layer height to enter the next curing layer.

[0053] Specifically, the multi-parameter coupled model no longer relies on a single numerical threshold, but instead determines the reaction progress by calculating the time-varying derivatives of physical quantities. Since carbonization is a typical exothermic reaction, the system performs the following dual-logic determination: Chemical equilibrium determination: Assume the current pH value is... The target value is The allowable error is The system determines whether the following conditions are met: ; In the formula, This represents the actual pH value of the sludge mixture collected by sensor array 14 at the current moment. The system is preset with a target pH value for the curing reaction (i.e., the neutral or weakly alkaline value required to achieve the harmlessness or curing standard). The preset pH value is used to determine the allowable error value.

[0054] Thermodynamic stability determination (reaction stagnation): Real-time temperature calculation of the system Over time The first derivative (i.e., the rate of temperature change) is approximated using the difference formula: ; In the formula, The rate of change of the temperature of the sludge mixture over time at the current moment is used to characterize the intensity of the exothermic reaction; For sensor array 14 at the current sampling time Real-time temperature values ​​collected; For sensor array 14 at the previous sampling time Historical temperature values ​​collected; The time interval between two temperature samples is preset for the central control unit.

[0055] When the central control unit calculates that the rate of change of temperature at the current depth over time has decreased to the preset stable range (i.e., the temperature fluctuation amplitude per unit time approaches zero), it indicates that no new carbonization reaction heat is generated inside the downhole sludge, and it is determined that the solidification reaction of this layer has reached the limit state. If the solidification standard is not met and unsolidified sludge enters the connector 13 and is detected by the sensor array 14, the detected new parameters are used to perform the pulse injection cycle again at the current depth before proceeding to the next layer.

[0056] Only when both the above-mentioned chemical standards and thermal stability are met can the desired outcome be achieved. Only when the central control unit determines that the current layer is cured is qualified will it send a command to the cylinder 9 to drive the pipe 10 to precisely lift it upward by a preset layer height, thereby automatically entering the curing cycle of the next soil layer. This control strategy avoids the waste of construction time caused by human experience judgment errors or overwork, and ensures the uniformity and continuity of the quality of the entire cured pile in the vertical direction.

[0057] Working principle: Before the injection operation, select any number of hollow tubes 11 to stack and install according to the required length. After stacking, install hollow tube 2 12 at the bottom of hollow tube 11. Then drive cylinder 9 to lower pipe 10, hollow tube 11 and hollow tube 2 12 to the designated position of sludge to wait for the injection operation. When pipe 10 is lowered, it will pull the limit block 206, thereby releasing the pull rope 203 and driving the wire reel 202 to rotate, and linking the spring 204 to twist and compress. At the same time, during the descent, sludge enters hollow tube 2 12 and squeezes the sealing ball 302 upward, thereby making contact between the sealing ball 302 and the stop block 303 to prevent sludge backflow. After reaching the preset depth, grouting is not performed immediately. Instead, the central control unit performs initial detection: at this time, the anti-blocking mechanism is in the allowable squeezing state, and the sludge on both sides enters the connector 13 and contacts the sensor array 14. The sensor array 14 collects the background parameters of the in-situ sludge (initial moisture content, initial pH value). The central control unit calculates the theoretical stoichiometric ratio of the waste residue slurry required for the first round based on the initial moisture content and pH value. By driving the transport pump 3, the waste residue and solidifying agent mixed in the mixing tank 2 are transported through the output pipe 5 to the hollow tube 12 for mixing and discharge via the connecting pipe 4. The sludge entering the connector 13 is discharged to the bottom, and the injected sludge is discharged. Simultaneously, the drive motor 503 causes the gear 504 to rotate in conjunction with the gear ring 505, causing the telescopic plate 506 and the stirring plate 507 to stir the injected material and sludge in the part that needs to be solidified, thereby forcing the waste slurry and sludge to mix violently. When the injection stops, there is no pressure in the hollow tube 12. At this time, the sludge re-enters the connector 13 and contacts the sensor array 14. The sludge entering the hollow tube 12 will squeeze the sealing ball 302 upward, thereby causing the sealing ball 302 to contact the stop block 303 and prevent the sludge from being reinjected. At this time, the sensor array 14 collects the sludge parameters and determines whether to repeat the above injection operation or to perform the subsequent carbon dioxide injection operation.

[0058] Before injecting carbon dioxide, the central control unit controls the temperature control mechanism 40 to activate the heating or cooling function based on the temperature data fed back by the sensor array 14, so as to ensure that the mixture and the carbon dioxide to be injected are in the optimal temperature range. Carbon dioxide is injected here, and after the carbon dioxide is injected, it is determined whether the curing standard has been reached. If the curing standard has not been reached, and there is uncured sludge entering the connector 13 and being detected by the sensor array 14, the new parameters detected are used to perform the pulse injection cycle again at the current depth and then proceed to the next layer of work. If the curing standard has been reached, the cylinder 9 is controlled to drive the pipe 10 to rise to a preset layer height to proceed to the next layer of work. During the rising of the pipe 10, the output pipe 5 is not pulled. At this time, the twisted and compressed spring 204 drives the wire feeding wheel 202 to wind up the pull rope 203, thereby causing the limit block 206 to retract the output pipe 5.

[0059] 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 sludge solidification device based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent, comprising a moving frame (1), characterized in that, The top of the mobile frame (1) is equipped with a mixing tank (2), a pressurizing tank (15), and two transport pumps (3). The two transport pumps (3) are connected to the mixing tank (2) and the pressurizing tank (15) respectively through connecting pipes (4). The output end of the transport pump (3) is fixedly connected to an output pipe (5). The top of the mobile frame (1) is rotatably connected to a support base (6). The top of the support base (6) is rotatably connected to a cross frame (7). The outer side of the cross frame (7) is fixedly connected to a limiting plate (8). The output pipe (5) is fixedly connected to the middle of the limiting plate (8). The bottom of the cross frame (7) is rotatably connected to a cylinder (9). The output end of the cylinder (9) is fixedly connected to a pipe (10). The output end of the output pipe (5) is connected to the pipe (10). The pipe (10) Hollow tube one (11) is installed at the bottom end of the pipe (10), hollow tube two (12) is installed at the bottom end of the hollow tube one (11), a connector (13) is fixedly connected to the bottom end of the hollow tube two (12), a sensor array (14) is fixedly connected inside the connector (13), a stirring mechanism (50) is fixedly connected to the outer periphery of the pipe (10), the stirring mechanism (50) is used to stir and mix the sludge and the injected solidified material, an anti-blocking mechanism (30) is provided inside the hollow tube two (12), the anti-blocking mechanism (30) is constructed to open under the action of injection pressure to empty the hollow tube two (12), and to close after the injection pressure is removed to allow external sludge to squeeze into the hollow tube two (12) to contact the sensor array (14), and a winding mechanism (20) is fixedly connected to the middle of the cross frame (7).

2. The sludge solidification apparatus based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent according to claim 1, characterized in that, The anti-clogging mechanism (30) includes a cross plate (301), which is fixedly connected to the inner bottom of the hollow tube (12). A sealing ball (302) is provided on the upper side of the cross plate (301), and a stop block (303) is provided on the upper side of the sealing ball (302). The stop block (303) is fixedly connected to the inside of the hollow tube (12). The sealing ball (302) and the stop block (303) abut against each other. When the transport pump (3) stops working, the sealing ball (302) abuts against the stop block (303) under the sludge pressure to seal.

3. The sludge solidification apparatus based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent according to claim 1, characterized in that, The winding mechanism (20) comprises a storage box (201) fixedly connected to the middle part of the cross frame (7), a pay-off reel (202) rotatably connected to the middle part of the storage box (201), a clockwork spring (204) fixedly connected to both ends of the pay-off reel (202), the other end of the clockwork spring (204) fixedly connected to the inside of the storage box (201), two pull ropes (203) fixedly connected to the outside of the pay-off reel (202), a roller (205) fixedly connected to the other end of the pull rope (203), a limiting block (206) fixedly connected to the middle part of the two rollers (205), and the output pipe (5) fixedly connected to the middle part of the limiting block (206), so as to automatically adjust the length of the pipeline with the lifting of the pipeline (10).

4. The sludge solidification apparatus based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent according to claim 3, characterized in that, The top of the stirring tank (2) and the booster tank (15) is fixedly connected with a temperature control mechanism (40), which is used to adjust the temperature in the stirring tank (2) and the booster tank (15).

5. The sludge solidification apparatus based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent according to claim 4, characterized in that, The two transport pumps (3) are respectively a first pump body and a second pump body; the first pump body is a solidifying agent pump for conveying waste residue-based solidifying agent slurry, and the second pump body is a gas booster pump for conveying carbon dioxide gas.

6. The sludge solidification apparatus based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent according to claim 5, characterized in that, The sensor array (14) is integrated with at least one of a pH sensor, a carbon dioxide concentration sensor, a temperature sensor, and a pressure sensor; and the data output end of the sensor array (14) is electrically connected with a central control unit.

7. The sludge solidification apparatus based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent according to claim 6, characterized in that, The processing device further comprises a central control unit electrically connected with the transport pump (3), the sensor array (14), and the cylinder (9) respectively. The central control unit is configured to perform an intermittent closed-loop control mode: controlling the transport pump (3) to be turned on for a preset pulse time to empty the hollow pipe two (12), then controlling the transport pump (3) to be turned off and waiting for a preset balance time, and then collecting the sludge parameters in the extruded hollow pipe two (12) by the sensor array (14).

8. The sludge solidification apparatus based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent according to claim 7, characterized in that, The central control unit is further configured to adjust the flow rate of the next pulse cycle according to the current solidification stage: In the waste residue injection stage, the central control unit adjusts the solidifying agent slurry delivery flow rate of the first pump body according to the pH value data; in the carbon dioxide injection stage, the central control unit adjusts the carbon dioxide delivery flow rate and pressure of the second pump body according to the pH value and carbon dioxide concentration data.

9. The sludge solidification apparatus based on the synergy of CO2 carbonization and industrial waste residue-based solidification agent according to claim 8, characterized in that, The central control unit is electrically connected with the temperature control mechanism (40); in the carbon dioxide injection stage, when the temperature detected by the sensor array (14) suddenly drops below the reaction threshold value due to the heat absorption of gas expansion, the central control unit controls the temperature control mechanism (40) to start the temperature increasing function to heat compensate the input carbon dioxide to offset the physical heat absorption effect; in the later stage of the solidification reaction, when the detected temperature is higher than the safety threshold value due to the accumulation of carbonization heat release, the central control unit controls the temperature control mechanism (40) to start the temperature decreasing function to reduce the material temperature and avoid the thermal stress cracks of the solidification body.

10. The sludge solidification apparatus based on synergism of CO2 carbonization and industrial waste residue-based solidification agent according to claim 1, characterized by, The stirring mechanism (50) comprises a frame body (501) and a bottom plate (502), the frame body (501) and the bottom plate (502) are fixedly connected from top to bottom on the outer periphery of the pipeline (10), the top of the frame body (501) is fixedly connected with a motor (503), the output end of the motor (503) is fixedly connected with a gear (504), the frame body (501) and the bottom plate (502) are rotatably connected with a gear ring (505), the gear (504) and the gear ring (505) are meshedly connected, the bottom of the gear ring (505) is provided with an expansion plate (506), the other side of the expansion plate (506) is provided with a stirring plate (507), the top of the frame body (501) is fixedly connected with a dust cover (508), and the motor (503) is arranged in the dust cover (508).

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