Intelligent defoaming agent filling analysis method

Abstract

According to the scheme, defoaming agent filling is improved, the defoaming agent is intelligently filled, the production efficiency is improved, the quality of produced products is guaranteed, and the production cost is saved. (1) the defoaming agent is automatically prepared; raw materials are prepared according to different defoaming agents, control logic is set, required defoaming agent particles or stock solution and demineralized water are automatically added, and the defoaming agents are prepared. The workload of workers is reduced, the working environment is improved, and the concentration of the defoaming agent is more accurate. (2) the filling amount of the defoaming agent is timely and accurately calculated; according to the technical process and the characteristics of the defoaming agent, detection instruments of various parameters are set in a targeted mode, a targeted filling amount algorithm is developed, and the filling amount calculation result is accurate. And (3) the defoaming agent is timely and accurately filled. According to the characteristics of the technological process, filling equipment and control logic are arranged, and the filling amount of the defoaming agent is flexibly controlled through a pump and a valve. And (4) the system is perfectly combined with an existing control system and an Internet of Things system, so that conditions can be provided for remote monitoring and management of the intelligent defoaming agent adding system.

Description

Technical Field

[0001] This invention relates to the fields of chemical, food, and pharmaceutical industries, which require the addition of defoamers to production equipment. Specifically, it relates to a method for intelligent control of defoamer preparation and addition based on the process flow and characteristics of the production equipment and the physical properties of the defoamer. Background Technology

[0002] In modern industrial production processes, such as chemical, pharmaceutical, and food processing, as well as certain liquid handling processes, a large amount of foam is often generated. This foam can have many impacts on normal production, such as reducing production efficiency, increasing labor intensity and workload, affecting product appearance, and in severe cases, even causing safety hazards. Adding a suitable defoamer can quickly and effectively reduce the surface tension of the foam, preventing the formation of foam or eliminating existing foam, thereby eliminating the negative impacts of this foam.

[0003] In my country, defoamers permitted for use can be broadly classified into seven categories: organosilicon, polyether, higher alcohols, fatty acids and fatty acid esters, amides, polyether-modified polysiloxanes, and natural oils. Polyether and organosilicon defoamers exhibit the best performance and are the focus of research and development in defoamer research and modification. However, research on defoamer application has received insufficient attention and is relatively limited.

[0004] Currently, defoamers are mostly added manually. During the addition process, workers rely on their experience and the actual site conditions, such as the amount of material being processed, the foaming situation, and the performance of the defoamer, to manually adjust the amount of defoamer added. This method requires a high level of skill from the workers, and the adjustment of the amount added is relatively slow. It is difficult to accurately control the amount and timing of defoamer addition, which can easily lead to untimely addition, insufficient addition affecting production, or excessive addition resulting in waste.

[0005] In light of this, some domestic researchers have developed a series of technologies to assist in the addition of defoamers. These technologies include defoaming and foaming linkage technology, automatic defoamer preparation technology, automatic foam volume monitoring technology, and artificial intelligence technology. These technologies have improved the timeliness and accuracy of defoamer dispensing to some extent. However, the integration of these technologies with production equipment is still insufficient, and they are significantly affected by the reliability, real-time performance, accuracy, and comprehensiveness of detection technologies. The accuracy of algorithms and the accuracy of the dispensing control system also hinder the promotion and application of defoamer dispensing technology. Summary of the Invention

[0006] The intelligent defoamer dispensing system consists of a defoamer preparation system, a defoamer dispensing system, and a monitoring system. The defoamer preparation system is responsible for preparing the defoamer; the defoamer dispensing system is responsible for dispensing the defoamer; and the monitoring system is responsible for acquiring the necessary data from the process system, the defoamer preparation system, and the defoamer dispensing system, and after calculation, transmitting the control data to field equipment and facilities such as valves, pumps, and mixers. Simultaneously, it displays defoamer-related production and operation data on an IoT monitoring platform.

[0007] The intelligent defoamer dispensing system is deeply integrated with the production equipment in terms of defoamer configuration, dispensing, and control.

[0008] The monitoring system of the intelligent defoamer dispensing system consists of three subsystems: intelligent defoamer dispensing system monitoring, DCS / PLC system monitoring, and an IoT monitoring platform. These three subsystems can be flexibly configured according to different existing process systems, facilitating timely and accurate acquisition of production operation data and transmitting control data to each control point, as well as various data to the IoT monitoring platform. There are three usage modes: (1) standalone use; (2) combined with the production unit's DCS or PLC; and (3) combined with both the production unit's DCS or PLC and the IoT monitoring platform.

[0009] The defoamer preparation system within the intelligent defoamer dispensing system can automatically prepare various defoamers as needed. The main raw materials for preparation include solid defoamers, liquid defoamer concentrate, and demineralized water. The defoamer preparation system offers multiple defoamer preparation schemes, allowing selection of the appropriate scheme based on different production processes.

[0010] The defoamer dispensing system within the intelligent defoamer dispensing system is responsible for the timely and accurate delivery of defoamer to the dispensing point. It is equipped with a defoamer delivery pump capable of precise flow control, combined with a flow control valve and flow metering instruments to precisely control the quantity of defoamer dispensed. The defoamer is injected into the process material at the dispensing point via the pump. Metering instruments on the defoamer dispensing pipeline precisely measure and control the dispensing volume, and the measurement data is fed back to the monitoring system in real time. The number of delivery pumps and the corresponding number and location of injection points can be flexibly configured according to different dispensing volume control requirements.

[0011] Algorithms for precise measurement and monitoring of data required by intelligent defoamer dispensing systems.

[0012] The dosage of defoamer is affected by various factors, such as the temperature, pressure, flow rate, and pH value of the process stream at the injection point, as well as data on liquid level, temperature, pressure, and foam height in material storage and separation equipment. Accurate measurement and monitoring of these data is the focus of this invention.

[0013] The intelligent defoamer dispensing system has a precise dispensing control mechanism.

[0014] The intelligent dosing system is characterized by its miniaturization and skid-mountability, facilitating transportation and installation. The intelligent dosing unit can integrate computer, PLC control system, and DCS control system, and can be configured with necessary valves, pipelines, instruments, pumps, storage tanks, high-precision flow meters, etc. It is a standalone skid-mounted system, occupying a small area, facilitating transportation and installation, and seamlessly integrating with existing equipment.

[0015] The integration of intelligent defoamer dispensing system with Internet of Things (IoT) technology.

[0016] A key feature of this invention is the use of Internet of Things (IoT) technology, enabling remote monitoring and management of the defoamer intelligent dispensing system. Production personnel can check the defoamer addition status, equipment operation status, and foam control effects anytime, anywhere via the internet, achieving remote monitoring of the production process. Simultaneously, IoT technology also enables remote equipment maintenance and fault diagnosis, improving equipment reliability and operational efficiency. Attached Figure Description

[0017] Figure 1 It consists of an intelligent defoamer dispensing system.

[0018] Figure 2 This is a detailed diagram of the intelligent defoamer dispensing system.

[0019] Figure 3 This is a simplified diagram of Example 1 of the intelligent defoamer dispensing monitoring system.

[0020] Figure 4 This is a simplified diagram of Example 2 of the intelligent defoamer dispensing monitoring system.

[0021] Figure 5 This is a simplified diagram of Solution 3 for the intelligent defoamer dispensing monitoring system.

[0022] Figure 6 This is a simplified diagram of defoamer preparation scheme 1.

[0023] Figure 7 This is a simplified diagram of defoamer preparation scheme 2.

[0024] Figure 8 This is a simplified diagram of defoamer addition scheme 1.

[0025] Figure 9 This is a simplified diagram of defoamer addition scheme 2.

[0026] Figure 10 It is a simplified diagram for comprehensive and timely monitoring of logistics data in the defoamer dispensing process. Detailed Implementation

[0027] The technical solution of this application will be further described in detail below through specific embodiments.

[0028] The intelligent defoamer dispensing system consists of a defoamer preparation system 1, a defoamer dispensing system 2, and a monitoring system 3.

[0029] In the intelligent defoamer dispensing system, the defoamer preparation system is responsible for the preparation of defoamer; the defoamer dispensing system is responsible for the dispensing of defoamer; and the monitoring system is responsible for obtaining the required data from the process system, the defoamer preparation system, and the defoamer dispensing system, and after calculation, transmitting the control data to field equipment and facilities such as valves, pumps, and mixers, while displaying the defoamer-related production and operation data in the Internet of Things monitoring platform.

[0030] The overall structure of the intelligent defoamer dispensing system is as follows: Figure 1 As shown.

[0031] The intelligent defoamer dispensing system is deeply integrated with the production equipment.

[0032] In the intelligent defoamer dispensing process, the defoamer solution is prepared in the defoamer preparation system. In the intelligent defoamer dispensing system, the defoamer solution is temporarily stored and pressurized, and then delivered to the designated injection point in the process system according to the actual production situation.

[0033] In the intelligent defoamer dispensing control system, production and operation data from the defoamer preparation system, defoamer dispensing system, and production process system are acquired through detection instruments, including data on flow rate, temperature, pressure, and pH value, and transmitted to the monitoring system. The monitoring system then performs calculations and transmits control signals to the defoamer preparation system, defoamer dispensing execution system, and production process system to regulate and control equipment such as the defoamer dispensing pump and valves.

[0034] In actual production facilities, measuring instruments such as flow rate, temperature, pressure, and pH value are configured and installed according to the specific needs of the facility, and their quantity is not limited. The intelligent defoamer dispensing system is deeply integrated with the production facility, such as... Figure 2 As shown.

[0035] The intelligent defoamer dispensing system consists of three subsystems: intelligent defoamer dispensing system monitoring, DCS / PLC system monitoring, and IoT monitoring platform.

[0036] Depending on the existing production process system, the three subsystems can be flexibly configured to facilitate timely and accurate acquisition of production operation data, transmit control data to each control point, and transmit various data to the Internet of Things monitoring platform.

[0037] Depending on the actual conditions of the production equipment, the intelligent defoamer dispensing system has three usage methods.

[0038] Example 1: Standalone use. The intelligent defoamer dispensing system directly acquires the required data from the production unit's instruments, calculates the defoamer dispensing amount, and transmits control signals to the production unit to adjust the defoamer dispensing equipment. For example... Figure 3 As shown.

[0039] Example 2: Used in conjunction with the DCS or PLC of the production unit. The data required for calculating the defoamer dosage can be directly obtained from the DCS or PLC control system of the production unit. The control signal for the defoamer injection amount can be transmitted to the production unit through the DCS or PLC system, or transmitted to the production unit by the intelligent defoamer dosing system. Figure 4 As shown.

[0040] Example 3: Used in conjunction with the DCS or PLC and IoT monitoring platform of the production unit. Based on the second method, an IoT monitoring platform is added. Field monitoring data is transmitted to the IoT monitoring platform for display. For example... Figure 5 As shown.

[0041] The defoamer preparation system can automatically prepare various defoamers as needed.

[0042] The main raw materials for defoamer preparation include solid defoamer, liquid defoamer concentrate, and demineralized water. The defoamer preparation system is equipped with contingency plans.

[0043] Example 1: Solid Defoamer Raw Material Preparation Scheme. Solid defoamer granules are stored in a silo. When the liquid level in the defoamer storage tank is insufficient, the defoamer raw material preparation system automatically starts. Following a preset program, the relevant feeding and preparation equipment and valves are opened. By controlling equipment such as a screw feeder that can precisely control the feeding amount, the required solid defoamer granules are transported from the silo to the defoamer preparation tank. The required demineralized water is added by controlling the demineralized water pipeline valve. Then, the agitator in the defoamer preparation tank is started sequentially to mix the raw materials evenly. If necessary, a circulating pump can be started to assist in the preparation of the defoamer. Figure 6 As shown.

[0044] Example 2: Preparation Scheme for Liquid Defoamer Stock Solution. The defoamer is stored in a defoamer stock solution storage tank. When the liquid level in the storage tank is insufficient, the defoamer raw material preparation system automatically starts. Following a preset program, the relevant feeding and preparation equipment and valves are opened. Using flow meters, control pumps, and other equipment that can precisely control the feeding amount, the required raw materials are transported from the storage tank to the defoamer preparation tank. The required demineralized water is added by controlling the demineralized water pipeline valve. Then, the agitator in the defoamer preparation tank is started sequentially to stir and ensure that all raw materials are mixed evenly. If necessary, a circulation pump can be started to assist in the preparation of the defoamer. Figure 7 As shown.

[0045] Both of the above defoamer preparation schemes include pipelines for delivering the defoamer to the defoamer storage tank and pressure balancing pipelines. The prepared defoamer can be easily delivered to the storage tank by gravity. If necessary, a delivery pump can be added to deliver the prepared defoamer to the storage tank. During the defoamer preparation process, a preset control program will automatically initiate the preparation process once conditions such as a low liquid level in the storage tank are met.

[0046] In the defoamer preparation function, the precise control of the amount of defoamer granules or defoamer concentrate and demineralized water added is particularly important and is also the focus of this invention.

[0047] The defoamer dispensing system delivers the defoamer to the dispensing point in a timely and accurate manner.

[0048] There may be multiple defoamer dispensing points, and the required injection volume at each point may differ. Therefore, this invention incorporates a defoamer delivery pump, such as a metering pump, with precisely controllable flow rate, combined with a flow control valve to precisely control the dispensing volume. The defoamer is injected into the process material at each dispensing point via the defoamer delivery pump. The number of delivery pumps and the corresponding number and location of injection points can be flexibly configured according to different dispensing volume control requirements.

[0049] Example 1: A single defoamer delivery pump controls the defoamer flow rate at each dispensing point via a flow control valve. This solution is suitable for scenarios with large defoamer dispensing volumes, concentrated dispensing points, and less stringent dispensing volume requirements. Figure 8 As shown.

[0050] Example 2: Each injection point is equipped with a separate delivery pump. The delivery pump and flow control valve work together to control the defoamer dosage. This solution is suitable for scenarios where the defoamer dosage is small, the injection points are scattered, and the dosage requirements are strict. Figure 9 As shown.

[0051] Both of these methods offer precise defoamer dosing control, automatically adjusting the dosage and speed based on analysis results. This ensures the defoamer is accurately added to the location where foam is generated, improving defoaming efficiency while avoiding waste.

[0052] Meanwhile, this invention has real-time dynamic adjustment capabilities, enabling it to adjust the defoamer dosing strategy in real time according to changes in the foam situation on site. For example, when the system detects a sudden increase or decrease in foam, it can react quickly by increasing or decreasing the amount of defoamer added to ensure the stability of the defoaming effect.

[0053] The intelligent defoamer dispensing system uses an algorithm to accurately monitor the on-site data required for defoamer dispensing and to accurately calculate the amount of defoamer to be dispensed.

[0054] The dosage of defoamer is affected by various factors, such as the temperature, pressure, flow rate, and pH value of the process stream at the injection point, as well as data on liquid level, temperature, pressure, and foam height in material storage and separation equipment. Accurate measurement of these data is the focus of this invention. Based on the acquired parameters, an intelligent algorithm is used to analyze and determine the required dosage of defoamer. The formula for the defoamer dosage algorithm is as follows: f: Defoamer dosage f1: Process material flow rate T1: Process material temperature A1: Composition of Process Materials P1: Process material pressure pH1: pH value of process materials T2: Temperature of process material storage tank L2: Liquid level in process material storage tank H2: Foam height in process material storage tanks like Figure 10 As shown.

[0055] The intelligent dispensing system is characterized by its small size and skid-mountability, making it easy to transport and install.

[0056] The equipment and facilities used in this invention are designed for miniaturization and portability. The intelligent defoamer dosing device is smaller, lighter, and easier to install and use, meeting the needs of miniaturized production and experimental research. Depending on the production equipment and defoamer dosing requirements, the intelligent dosing device can integrate a computer system, PLC control system, or DCS control system. If necessary, it can be configured with required valves, pipes, instruments, pumps, storage tanks, flow meters, etc. It is a standalone skid-mounted unit, occupying a small area, facilitating transportation and installation, and seamlessly integrating with existing equipment.

[0057] Integration with Internet of Things (IoT) technology.

[0058] A significant feature of this invention is the use of Internet of Things (IoT) technology. The intelligent defoamer dispensing system supports wired and wireless connections to the public network, enabling production personnel to remotely monitor and manage the system. Production personnel can log in to the system anytime, anywhere via the internet to view the defoamer's configuration and status, the operating status of production equipment, and the foam control effect in real time, achieving remote monitoring of the production process. Simultaneously, IoT technology also enables remote equipment maintenance and fault diagnosis, improving the reliability and operational efficiency of defoamer preparation and delivery equipment.

[0059] The present invention has been described in detail above. However, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, any modifications or improvements that do not depart from the spirit of the present invention are within the scope of protection of the present invention. The scope of protection claimed in this application shall be determined by the content of its claims, and the specific embodiments in the specification can be used to interpret the content of the claims.

Claims

1. An intelligent dispensing analysis method for defoamers.

2. An intelligent defoamer dispensing system, characterized in that: It consists of a defoamer preparation system, a defoamer dispensing system, and a monitoring system.

3. The defoamer preparation system is responsible for preparing the defoamer; The defoamer dispensing system is responsible for dispensing the defoamer; The monitoring system is responsible for acquiring the required data from the process system, defoamer preparation system, and defoamer dosing system, and then transmitting the calculated control data to field equipment and facilities such as valves, pumps, and mixers. At the same time, it displays the defoamer-related production and operation data in the Internet of Things monitoring platform.

4. The intelligent defoamer dispensing system is characterized in that: The defoamer's preparation, dispensing, and control systems are deeply integrated with the production equipment.

5. The monitoring system consists of three subsystems, characterized in that: It consists of an intelligent defoamer dispensing system, a DCS / PLC, and an IoT monitoring platform.

6. The monitoring system, depending on the existing process system, has three subsystems that can be flexibly configured to facilitate timely and accurate acquisition of production operation data, transmit control data to each control point, and transmit various data to the IoT monitoring platform. There are three usage modes: (1) standalone use; (2) combined use with the production unit's DCS or PLC; and (3) combined use with the production unit's DCS or PLC and the IoT monitoring platform.

7. The defoamer preparation system, characterized in that: The system can automatically prepare various defoamers as needed. The main raw materials for preparation include solid defoamers, liquid defoamer concentrate, and demineralized water. The defoamer preparation system has contingency plans in place.

8. The defoamer dispensing system, characterized in that: Defoamer is delivered to the injection point in a timely and precise manner. A defoamer delivery pump with precisely controllable flow rate is installed, combined with a flow control valve, to accurately control the injection volume. The defoamer is injected into the process material at the injection point via the defoamer delivery pump. The number of delivery pumps and the corresponding number and location of injection points can be flexibly configured according to different injection volume control requirements.

9. The defoamer dispensing system, characterized in that: The required data is accurately monitored, and the algorithm for calculating the injection volume is used.

10. The amount of defoamer added is affected by a variety of factors, such as the temperature, pressure, flow rate, and pH value of the process stream at the injection point, as well as data on the liquid level, temperature, pressure, and foam height in the material storage and separation equipment. Accurate measurement of these data is a key focus of this invention.

11. The intelligent dispensing system, characterized in that: It features miniaturization and skid-mountability, and is easy to transport and install.

12. The intelligent dosing device can integrate a computer, PLC control system, and DCS control system. If necessary, it can be configured with the required valves, pipes, instruments, pumps, storage tanks, flow meters, etc. It is a skid-mounted unit with a small footprint, which is convenient for transportation and installation and can be perfectly integrated with existing devices.

13. The intelligent dispensing system, characterized in that: Integration with Internet of Things (IoT) technology.

14. A significant feature of this invention is the use of Internet of Things (IoT) technology. The intelligent defoamer addition system enables remote monitoring and management. Production personnel can view the defoamer addition status, the operating status of production equipment, and the foam control effect anytime, anywhere via the internet, achieving remote monitoring of the production process. Simultaneously, IoT technology also enables remote equipment maintenance and fault diagnosis, improving equipment reliability and operating efficiency.

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