Cement dust removal system

Abstract

The invention belongs to the technical field of cement production, and particularly relates to a cement dust removal system which comprises a source dust suppression module, a dust removal module and a dust removal module, the ventilation and dust removal module is arranged at a dust generation point in the closed equipment; the resource recovery module is arranged at the downstream of a dust collector of a packaging workshop, a bulk station and a grinding system; according to the packaging machine recycling unit, filling of the cement bags is completed in the customized negative-pressure dust removal cabin, and escaped dust is instantly captured by a dust suction hood at the top of the cabin body. According to the invention, the type of the collected dust is identified through the resource recovery module, and the dust which should be mixed originally is classified into products which can be sold directly, raw materials which can be calcined in a kiln and raw materials which can be used for batching and are used for correcting material deviation through online component analysis and intelligent distribution, so that the dust treatment cost can be reduced, and the production efficiency is improved. And the dust removal system is converted into a center capable of saving cost and realizing resource regeneration from environment-friendly cost, so that the popularization of the system is facilitated.

Description

Technical Field

[0001] This invention relates to the field of cement production technology, specifically to a cement dust removal system. Background Technology

[0002] The cement industry, as a vital foundation of the national economy, is also a typical high-energy-consuming and high-polluting industry. In its production process, from raw material crushing, pre-homogenization, raw meal and coal powder preparation, clinker calcination to cement grinding, packaging, and shipping, almost every stage generates a large amount of dust. This dust mainly consists of limestone, clay, coal powder, clinker, and gypsum, and its fine particles pose a serious threat to human health and the ecological environment.

[0003] Besides the health hazards, it also means huge economic losses. According to data, the national standard plan "Technical Requirements for Complete Sets of Equipment for New Dry Process Cement Production Part 5: Dust Removal System" was mainly drafted by Tianjin Cement Industry Design and Research Institute Co., Ltd. and China Building Materials Machinery Industry Association. It points out that a large amount of dust is generated during the cement production process. The amount of dust generated in the production of 1 ton of cement is about 3 tons. Therefore, a large number of dust removal equipment and systems are equipped in the system. On the one hand, it is for the recovery of materials in the process, such as the main dust collectors of the raw material grinding and cement preparation workshop mills. On the other hand, it is to reduce the emission of particulate matter and improve the atmospheric environment of the workshop and the surrounding area.

[0004] Most dust collectors on the market currently use timed cleaning control, which cannot detect the actual dust accumulation on the filter bags. At the same time, existing systems usually treat the collected dust as waste or simply backfill it, failing to classify and utilize dust of different qualities. For example, the dust recovered from packaging machines and bulk packaging machines is already qualified product, and the dust recovered from raw material mills is raw material with specific components. However, existing technology lacks an effective online detection and automatic diversion mechanism, making it impossible to accurately return it to the production process, resulting in a huge waste of resources.

[0005] Therefore, we propose a cement dust removal system that uses a resource recovery module to identify the type of collected dust. Through online component analysis and intelligent diversion, the dust that should have been mixed is classified into products that can be sold directly, raw materials that can be returned to the kiln for calcination, and raw materials that can be used to correct material deviations in batching. This can reduce the cost of dust treatment and transform the dust removal system from an environmental cost center into a cost-saving and resource-recycling center, which is conducive to the promotion of the system. Summary of the Invention

[0006] In order to overcome the above-mentioned defects of the prior art, the present invention provides a cement dust removal system to solve the problems existing in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a source dust suppression module, which is installed in an open or semi-open area; Ventilation and dust removal module: It is installed at the dust generation point inside the enclosed equipment; Resource recycling module: It is installed downstream of the dust collectors in the packaging workshop, bulk station, and grinding system; In the packaging machine recycling unit, cement bags are filled in a customized negative pressure dust removal chamber. The escaping dust is instantly captured by the dust collection hood on the top of the chamber. The dust-laden gas is purified by the dust collector, and the dust is collected in the ash hopper. The bulk loading machine recycling unit connects the bulk loading machine to the dust removal hood. The micro differential pressure sensor unit monitors the pressure difference between the inside of the dust removal hood and the inside of the tank truck in real time. The bulk loading machine discharge valve, dust removal fan and bulk loading machine recycling unit are hard-wired interlocked to send the collected dust back to the finished product warehouse in a pneumatic manner. Grinding mill recovery unit: A main dust collector is installed in the grinding mill as the core filter. An FU chain conveyor or air conveying chute is used for horizontal conveying of the collected dust. An online component analyzer is installed downstream of the main dust collector. A bidirectional / multidirectional distribution valve serves as the core actuator for recovering materials or temporarily storing substandard materials. Intelligent energy efficiency control module: It is located in the central control room and constructs a three-layer architecture of perception layer, decision layer and execution layer; The perception layer consists of the core sensor group; The decision-making layer belongs to the ECU energy efficiency control unit, which has built-in AI algorithms and process rule library; The execution layer uses a high-voltage frequency converter to steplessly regulate the speed of the fan and electrically adjusts the air valves in the dust removal pipeline to quickly adjust the air volume distribution.

[0008] Furthermore: The dry fog dust suppression unit of the source dust suppression module has a high-pressure water pump and nozzles, which allows the fine water mist to collide and combine with dust particles, causing them to increase in weight and settle. It is equipped with dust concentration sensors, humidity sensors, geomagnetic sensors, and infrared beam detectors to form an intelligent sensing unit that can perceive the dust source status in real time.

[0009] Furthermore: A pulse bag dust collector is installed at the dust generation point. When the ventilation and dust removal module is activated, the dust-laden gas is drawn into the pulse bag dust collector under the negative pressure generated by the fan. The real-time differential pressure value at the inlet and outlet of the dust collector is continuously monitored by a differential pressure transmitter and reported to the ECU for decision-making. After the dust removal program is started, the pulse controller triggers the electromagnetic pulse valves in a preset sequence to perform powerful jet cleaning.

[0010] Furthermore, the ventilation and dust removal module includes a differential pressure feedback cleaning unit, which automatically adjusts the cleaning frequency and intensity based on the pressure difference between the inside and outside of the pulse bag dust collector. The differential pressure transmitter continuously measures and reports the real-time resistance differential pressure value of the pulse bag dust collector body, and the intelligent energy efficiency control module compares the real-time differential pressure with the preset cleaning start value.

[0011] Furthermore: if the real-time differential pressure is less than the dust cleaning start value, no operation will be performed, and monitoring will continue; When the real-time differential pressure is greater than or equal to the dust removal start value, the intelligent energy efficiency control module sends a start command to the differential pressure feedback dust removal unit. According to the pulse controller, one or more electromagnetic pulse valves are triggered in a preset sequence to inject compressed air into the filter bag to complete the dust removal. The dust removal action will be carried out in sequence for all compartments, or the area with the highest differential pressure will be targeted for key dust removal. During the dust removal process, the differential pressure transmitter continuously monitors the differential pressure change and compares the real-time differential pressure with the lower dust removal stop value. As long as the real-time differential pressure remains higher than the stop value, continue cleaning the next set of filter bags.

[0012] When the real-time differential pressure drops back to the dust removal stop value, the intelligent energy efficiency control module terminates the dust removal program.

[0013] Furthermore: The packaging machine requires a customized negative pressure dust removal chamber, which completely seals the packaging machine's discharge port inside a stainless steel chamber. An operation window with a flexible transparent curtain is opened on the front of the chamber, forming both visual monitoring and physical isolation. A two-stage recovery screw conveyor is installed, in which the first stage screw is directly connected to the dust hopper of the pulse bag dust collector to transport the collected pure cement; The secondary screw receives material from the primary screw and is equipped with a two-way material distribution valve to return the filtered pure cement powder to the packaging machine inlet, while abnormal materials are directed to the waste bin.

[0014] Furthermore: the dust-laden gas from the mill is treated by the main dust collector, and the dust is efficiently collected in the ash hopper. The dust collected and transported in the ash hopper is gathered at a point by the FU chain conveyor or air conveying chute, and then quality judgment and path decision are made. The recycled dust generated by the cement mill is considered a qualified product and is directed to the finished product warehouse by the feed valve. The raw material composition is a key parameter of the recycled dust generated by the raw material milling equipment, which is determined by online component analyzers or by data linkage with the quality control system. When the analyzer shows that the composition of the recovered dust is within the control range, the dispensing valve directs it to the raw material homogenization silo. When the composition deviates, the distribution valve directs it to the designated recycling bin.

[0015] Furthermore, the sensing layer is equipped with material flow meters, environmental status sensors, fan body sensors, and filter bag status sensors at key locations of the dust removal point.

[0016] Furthermore: the decision-making layer's process rule base is based on process knowledge, and the AI ​​algorithm is based on historical data and real-time learning to dynamically find the lowest energy consumption operating point that meets the current operating conditions.

[0017] Compared with the prior art, the technical effects and advantages of the present invention are as follows: 1) The cement dust removal system of the present invention, through modular collaboration of source dust suppression and process dust control, can treat dust in the entire cement production process from open areas to closed points without dead ends. The source dust suppression module settles some of the floating dust, reducing the load on the downstream ventilation and dust removal system. The ventilation and dust removal module, with differential pressure feedback cleaning technology, ensures the efficient and stable operation of the filtration system under any working conditions.

[0018] 2) The cement dust removal system of the present invention identifies the type of collected dust through a resource recycling module. Through online component analysis and intelligent diversion, the dust that should have been mixed is classified into products that can be sold directly, raw materials that can be returned to the kiln for calcination, and raw materials that can be used to correct material deviations in batching. This can reduce the cost of dust treatment and transform the dust removal system from an environmental protection cost center into a cost-saving and resource reuse center, which is conducive to the promotion of the system.

[0019] 3) The cement dust removal system of the present invention reduces the total air volume requirement by suppressing dust at the source through an intelligent energy efficiency control module, avoids the waste of compressed air and electricity by differential pressure feedback dust removal, and uses AI dynamic optimization and sleep strategy to keep the fan running in the optimal efficiency range, thereby reducing the power cost of the dust removal system and thus reducing the operating cost of enterprises. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall system workflow and module collaboration of the present invention; Figure 2 This is a schematic diagram of the differential pressure feedback dust removal unit of the present invention; Figure 3 This is a schematic diagram of the workflow of the resource recycling module of the present invention; Figure 4 This is a flowchart of the intelligent energy efficiency control strategy of the present invention. Detailed Implementation

[0021] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. The structures involved in the present invention are not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example

[0022] Please see Figure 1-4 The present invention provides a technical solution: Source dust suppression module: Dust suppression modules are installed in open / semi-open areas such as raw material storage yards, crusher inlets and outlets, pre-homogenization storage yards, and key transfer stations.

[0023] Installed in open or semi-open areas such as stacker-reclaimers and key material drop points, the system atomizes water into fine mist below 10μm, which fully combines with dust particles, causing them to settle. By generating a fine water mist that fully collides and combines with dust particles, it increases their weight and causes them to settle. This intervention at the starting point of dust generation reduces the total amount of dust that needs to be removed by the fan.

[0024] Dry fog dust suppression unit: Through a high-pressure water pump and a special nozzle, it generates a fine water mist of <10μm, which collides and combines with dust particles, causing them to increase in weight and settle.

[0025] Intelligent sensing unit: Equipped with dust concentration sensor, humidity sensor, geomagnetic sensor and infrared beam detector to sense the dust source status in real time.

[0026] Dust concentration sensor and humidity sensor to monitor ambient dust concentration and air humidity in real time.

[0027] Install geomagnetic sensors to detect vehicles, and install infrared beam sensors to detect material flow or interlock with the equipment PLC.

[0028] Linkage control: Interlocked with the equipment PLC, the water mist turns on when dust is raised and stops when dust settles.

[0029] Ventilation and dust removal module: The ventilation and dust removal module is set up to enclose dust generation points inside the equipment, especially core dust-generating equipment such as grinding systems, raw material mills, coal mills, cement mills, packaging machines, and bulk loading machines.

[0030] Pulse jet baghouse dust collectors are available in two types. The general-purpose pulse bag dust collector is used in raw material mills or cement mills. It uses high-strength, high-permeability filter bags to deal with high-concentration, highly adhesive ultrafine dust.

[0031] Explosion-proof pulse bag dust collectors are used in coal mills. They are equipped with explosion-proof valves, static electricity discharge devices, and flame-retardant filter media to ensure safety.

[0032] When the ash level gauge in the dust removal and conveying ash hopper reaches the set height, the primary screw conveyor automatically starts, and at the same time, the pulse valve performs a brief jet of air to shake off the dust from the surface of the filter bags.

[0033] Differential pressure feedback cleaning unit: Automatically adjusts the cleaning frequency and intensity based on the pressure difference between the inside and outside of the pulse bag dust collector.

[0034] Intelligent dust removal saves energy. Differential pressure feedback avoids the problems of over-duration or untimely dust removal caused by traditional timed dust removal, extends the life of filter bags, and stabilizes the system air volume.

[0035] The differential pressure transmitter continuously measures and reports the real-time resistance differential pressure value of the pulse bag dust collector body.

[0036] The intelligent energy efficiency control module compares the real-time differential pressure with the preset dust removal start value.

[0037] Based on the actual situation, the following procedures shall be followed: Scenario A (No dust cleaning required): Real-time differential pressure < dust cleaning start value. The system does not perform any operation, continues monitoring, and the filter bag is in "normal working state".

[0038] Case B (Dust cleaning required): If the real-time differential pressure is greater than or equal to the dust cleaning start value, the intelligent energy efficiency control module sends a start command to the differential pressure feedback dust cleaning unit.

[0039] To ensure precise execution, the pulse controller triggers one or more electromagnetic pulse valves in a preset sequence, injecting compressed air into the filter bag within milliseconds to complete a powerful dust removal.

[0040] The cleaning process will be carried out sequentially for all compartments, or the area with the highest differential pressure will be cleaned in a focused manner. During the cleaning process, the differential pressure transmitter will continuously monitor the differential pressure change and compare the real-time differential pressure with the lower cleaning stop value.

[0041] Cyclic cleaning: As long as the real-time differential pressure is still higher than the stop value, the cleaning process continues for the next set of filter bags.

[0042] Stop cleaning: When the real-time differential pressure drops back to the cleaning stop value, the intelligent energy efficiency control module immediately terminates the cleaning program.

[0043] The differential pressure feedback cleaning unit ensures that the powerful cleaning mode is activated as soon as the resistance rises to the critical point affecting energy consumption. This can break down stubborn dust layers, stabilize system airflow, and guarantee mill output and quality, avoiding the problems of incomplete cleaning and persistently high resistance that may occur with timed cleaning.

[0044] In the coal milling process, due to the risk of coal powder explosion, frequent and unnecessary dust cleaning will increase the dust concentration in the system and increase the risk. The differential pressure feedback dust cleaning unit reduces the number of dust cleanings and only cleans when necessary, which reduces the probability of explosion and also reduces the consumption of compressed air. At the same time, it avoids mechanical damage to the explosion-proof filter bags caused by excessive dust cleaning.

[0045] Resource recycling module: The resource recycling module is located downstream of the dust collectors in the packaging workshop, bulk station, and grinding system.

[0046] The packaging process includes adding a recycling unit to the packaging machine and a vacuum negative pressure dust removal mechanism to create a local negative pressure at the filling port of the packaging machine, which directly sucks away the escaping dust.

[0047] It should be noted that the dust removal and product recycling structure of the packaging machine is more refined, requiring a customized negative pressure dust removal chamber. The entire discharge port of the packaging machine is sealed in a stainless steel chamber, and an operation window with a flexible transparent curtain is opened on the front of the chamber to achieve visual monitoring and physical isolation.

[0048] Two-stage recovery screw conveyor: The first stage screw is directly connected to the dust hopper of the pulse bag dust collector to transport the collected pure cement.

[0049] Secondary spiral: Receives material from the primary spiral and is equipped with a two-way material distribution valve to return the filtered pure cement powder to the packaging machine inlet, while abnormal materials are directed to the waste bin.

[0050] If an anomaly is detected, such as a broken bag containing impurities, the dispensing valve can be switched manually or automatically to direct the material into the waste bin for inspection, preventing contamination of the entire batch of products.

[0051] The bulk loading machine recovery unit connects the bulk loading machine to the dust removal hood. The bulk loading head is equipped with a flexible sealing ring and an automatic linkage dust removal valve to ensure a tight connection with the tank truck inlet before the dust removal is started.

[0052] The structure of the dust removal unit for the bulk loading machine is described. The fully automatic dust removal hood uses a multi-stage hydraulically driven telescopic sleeve and is equipped with an inflatable sealing ring at the end.

[0053] The pressure difference between the inside of the dust collector hood and the inside of the tanker truck is monitored in real time using a micro differential pressure sensing unit.

[0054] The bulk loader's discharge valve, dust removal fan, and bulk loader recycling unit are all hard-wired interlocked.

[0055] A pneumatic conveying unit can be added to pneumatically send the collected dust back to the finished product warehouse.

[0056] Step 1: Automatic docking and sealing confirmation. After the driver positions the tanker truck, the operator presses the start button, and the fully automatic dust removal hood descends and docks with the tanker truck's inlet. The sealing ring is inflated to achieve a tight seal. When the micro-differential pressure sensor detects the formation of a stable negative pressure inside the hood, a docking success signal is sent back.

[0057] Step 2: Interlock Start-up and Loading After receiving the docking success signal, the system starts the dust removal fan in sequence, then starts the recovery screw conveyor, and sends it to the unloading valve of the bulk loader, and then loading begins.

[0058] Step 3: Simultaneous dust removal and recycling. The dust-laden air displaced by the falling material is firmly locked inside the dust collector hood and drawn into the pulse bag dust collector through the top pipe for purification. The collected dust is then transported directly and over long distances back to the cement finished product warehouse via a pneumatic conveying pump, eliminating the need for vehicle transfer.

[0059] Step 4: After the interlock shutdown and unloading are completed, the discharge valve is closed. After a delay, ensure that the dust has been collected, shut down the machine in reverse order, and finally release the air from the dust collector hood seal and automatically lift it back to its original position.

[0060] Grinding mill recycling unit: A main dust collector, namely a pulse bag dust collector, is installed in the grinding mill as the core filter.

[0061] Install a chain conveyor or air conveying chute for horizontally conveying collected dust.

[0062] An online component analyzer is installed downstream of the main dust collector, with a bidirectional / multidirectional distribution valve as the core actuator, used to recover materials or temporarily store unqualified materials.

[0063] Step 1: All dust-laden gas coming out of the mill is efficiently collected and processed by the main dust collector, and the dust is efficiently collected in the ash hopper.

[0064] Step 2: Collect and transport all dust from the ash hoppers separately via FU chain conveyor or air conveying chute.

[0065] Step 3: Quality assessment and path decision.

[0066] Scenario A: Judgment logic of cement grinding equipment: The composition of finished cement is relatively stable. Recycled dust is assumed to be a qualified product.

[0067] The feed valve is directed to the finished product warehouse / packaging machine by default, and is only used to temporarily feed waste into the waste bin during the initial stage of equipment maintenance or abnormal operating conditions.

[0068] Scenario B: Raw material mill system judgment logic: Raw material composition is a key process parameter.

[0069] It relies on online component analyzers or data linkage with the quality control system.

[0070] Qualified path: When the analyzer shows that the composition of the recovered dust is within the control range, the material distribution valve directs it to the raw material homogenization silo and directly into the kiln.

[0071] Homogenization Path: When compositional deviations occur, such as CaO being too high / too low, the dispensing valve directs it to a designated recovery material bin. The material in this bin will serve as a corrective feedstock, being added in small, precise amounts to subsequent batches and returning to the production process.

[0072] Turning tens of thousands of tons of recycled dust from waste into raw materials or products maximizes resource utilization. Through intelligent diversion, the recycled materials not only do not disrupt production stability, but also become an effective means of finely controlling the composition of raw materials, improving clinker quality and system stability, and realizing full material circulation within the grinding system.

[0073] Intelligent energy efficiency control module: The intelligent energy efficiency control module is located in the central control room or the core unit and function of the field control cabinet: It constructs a three-layer architecture consisting of a perception layer, a decision-making layer, and an execution layer; The core sensor group of the sensing layer includes material flow meters, such as belt scale signals, material presence sensors, such as laser and radar level gauges, and equipment operation signals, such as mill main motor current and packaging machine operation signals, installed at key locations in the dust removal point.

[0074] Environmental condition sensors: Micro differential pressure sensors are installed on the dust collector hood and pipe inlet to detect changes in resistance in real time.

[0075] Fan body sensors: Vibration and temperature sensors are installed on the fan bearings, and smart meters are installed on the motor.

[0076] Filter bag status sensor: Differential pressure sensor at the inlet and outlet of the pulse bag dust collector body.

[0077] Decision-making level: This belongs to the ECU energy efficiency control unit, which has built-in AI algorithms and process rule library.

[0078] Process rule library: Based on process knowledge, for example: if the feed rate is less than 60% of the set value within 10 minutes after the mill is started, the blower will keep running at low speed; After the packaging machine stops filling, the fan speed drops to the sleep value after a 2-minute delay.

[0079] AI algorithm: Based on historical data and real-time learning, dynamically find the lowest energy consumption operating point that meets the current working conditions.

[0080] For example, it can automatically learn the optimal combination of dust removal damper opening and fan speed under different production volumes.

[0081] Execution layer: The high-voltage frequency converter is used to continuously regulate the speed of the fan.

[0082] The air volume distribution is quickly adjusted via an electrically adjustable damper in the dust collection duct.

[0083] Specific control strategy breakdown: AI algorithm optimization process under normal production conditions: ECU continuously receives all data from the perception layer.

[0084] The AI ​​algorithm aims to minimize total energy consumption by dynamically calculating and outputting the optimal fan speed and the optimal opening degree of each damper.

[0085] For example, when the output of the raw material mill drops from 100% to 80%, the system will not simply reduce the fan speed linearly. Instead, it will comprehensively calculate factors such as changes in pipeline resistance and filter bag pressure difference to find a more energy-efficient operating point than linear adjustment.

[0086] Hibernation / Wake-up Strategy Process during Production Interruption / Low Load: Hibernation Decision: When the associated host equipment stops running and the material sensor detects no material, the ECU starts the hibernation timer.

[0087] Entering sleep mode: When the timer ends, the ECU controls the inverter to reduce the fan speed to an extremely low sleep speed, such as 20% of the rated speed, to maintain only a slight negative pressure in the system and prevent dust from overflowing.

[0088] When the host machine starts or the material arrives, the ECU immediately increases the fan speed to the preset operating speed within tens of seconds, thus achieving rapid wake-up. This process is much faster than a complete start-up and shutdown of the fan, and does not affect production.

[0089] Cost-first strategy process based on electricity price signals: ECU has built-in real-time clock and electricity price model.

[0090] During normal periods, the AI ​​algorithm optimization strategy described above is implemented. During peak periods: Under the premise of ensuring safe production and environmental compliance, the ECU appropriately relaxes the control target of the dust removal system, such as adjusting the negative pressure value of the dust collector hood from -50Pa to -30Pa, thereby instructing the fan to run at a lower speed, actively sacrificing a small amount of performance in exchange for electricity savings.

[0091] Off-peak hours: While ensuring production, operating standards can be appropriately raised to thoroughly clean up dust and prepare for peak daytime production.

[0092] Economic benefit quantification statement: Compared with the simple conversion from power frequency to variable frequency, this system can tap an additional 5%-15% energy saving potential through AI algorithms and cost strategies, thereby increasing the overall power saving rate.

[0093] The system has the capability to participate in the demand-side response of the power grid, and can further reduce the load according to instructions during power grid emergencies.

[0094] The workflow of this system is as follows: Step 1.1: The source dust suppression module is set up in open areas such as raw material storage yards, crushers, and transfer stations. It works continuously through dust concentration sensors, humidity sensors, geomagnetic sensors and infrared beam detectors to sense the environmental dust concentration, vehicle entry and exit and material flow status in real time.

[0095] Step 1.2: When the sensor detects that the dust concentration exceeds the standard, or senses that a vehicle / material is passing by, the intelligent energy efficiency control module (ECU) immediately sends a start command to the dry fog dust suppression unit in that area.

[0096] When the ambient dust concentration drops to a safe level and there is no trigger signal, the ECU instructs the dry fog dust suppression unit to enter standby mode.

[0097] Step 1.3: After receiving the instruction, the dry fog dust suppression unit starts and generates a fine water mist of <10μm through a high-pressure water pump and a special nozzle. This mist precisely covers the dust-generating point, causing the dust particles to become heavier and settle, thus reducing the amount of dust diffusion at the source.

[0098] Step 2.1: In the enclosed dust points of equipment such as grinding systems and packaging machines, the ventilation and dust removal module is activated, so that the dust-laden gas is drawn into the pulse bag dust collector under the negative pressure generated by the fan.

[0099] Step 2.2: The differential pressure transmitter continuously monitors the real-time differential pressure values ​​at the inlet and outlet of the dust collector and reports them to the intelligent energy efficiency control module.

[0100] Decision-making logic: If the real-time differential pressure is lower than the preset dust cleaning start value, the system will only maintain normal operation and will not trigger the dust cleaning action.

[0101] When the real-time differential pressure reaches or exceeds the dust removal start value, the intelligent energy efficiency control module immediately starts the differential pressure feedback dust removal program.

[0102] Step 2.3: After the dust removal program is started, the pulse controller triggers the electromagnetic pulse valves in a preset sequence to perform powerful jet cleaning.

[0103] During the dust removal process, the controller continuously compares the real-time differential pressure with the dust removal stop value; As long as the real-time differential pressure is higher than the stop value, the dust removal cycle continues. When the real-time differential pressure drops back to the stop value, the controller immediately terminates the dust removal program to ensure that there is no over-dust removal.

[0104] Packaging machine recycling process: Step 3.1.1: Cement bags are filled in a customized negative pressure dust removal chamber, and the escaping dust is instantly captured by the dust collection hood on the top of the chamber.

[0105] Step 3.1.2: Filtration and collection: The dust-laden gas is purified by the dust collector, and the dust is collected in the ash hopper.

[0106] Step 3.1.3: Normal path: The collected pure cement powder is transported by a two-stage recycling screw conveyor and automatically guided by a two-way material distribution valve to the finished product warehouse or packaging machine inlet, achieving 100% product recycling.

[0107] Abnormal path: If the system detects an abnormality (such as a broken bag), the dispensing valve will automatically switch to guide the material into the waste bin to prevent contamination.

[0108] Bulk loading machine recycling process: Step 3.2.1: Automatic docking and interlocking: The operator presses the button, and the fully automatic dust removal hood descends to dock with the tanker and seals. After the micro-pressure differential sensor confirms that a negative pressure is formed inside the hood, it sends feedback to the system that the docking is successful.

[0109] Step 3.2.2: Interlock Start-up: The system shall be started in strict sequence of dust removal fan, recycling system and bulk loading machine discharge valve to begin loading.

[0110] Step 3.2.3: The dusty air generated during loading is purified by a dust collector, and the collected dust is directly sent back to the finished product warehouse via a pneumatic conveying system.

[0111] Step 3.2.4: Interlock Shutdown: After loading is completed, the system interlocks and shuts down in the reverse order of the pressing valve, the recovery system, and the dust removal fan. Finally, the dust removal hood is lifted and returned to its original position.

[0112] Grinding system recycling process: Step 3.3.1: Collection and aggregation: Dust collected from the raw material mill and cement mill is filtered by the main dust collector and then transported separately by a chain conveyor or an air conveying chute.

[0113] Step 3.3.2: The dust generated by the cement mill is considered a qualified product, and the multi-directional material distribution valve directly sends it to the finished product warehouse.

[0114] The dust generated by the raw material grinding equipment needs to be detected in real time by an online component analyzer.

[0115] If the composition is qualified, the feed valve will guide it to the raw material homogenization silo.

[0116] If the composition deviates, the dispensing valve directs it to the recovery material bin, where it is used as a corrective material for precise use in subsequent batching.

[0117] Step 4.1: Various sensors in the sensing layer, including material flow, equipment operation, differential pressure, and electrical energy, continuously collect data from the entire system to the ECU energy efficiency control unit.

[0118] Step 4.2: Under normal production conditions, the ECU runs the AI ​​dynamic optimization algorithm to dynamically calculate and output the optimal speed of each fan and the optimal opening of each damper with the goal of minimizing the total energy consumption of the system.

[0119] In the event of a production interruption, when the main equipment stops and there is no material, the ECU initiates a sleep / wake-up strategy, reducing the corresponding fan speed to the sleep speed (approximately 20%); upon receiving a start signal, it quickly wakes up to the operating speed.

[0120] Taking into account electricity costs, the ECU, based on a real-time electricity price model, appropriately increases the dust removal intensity during peak electricity price periods to save on electricity costs; and strengthens dust removal during off-peak periods to prepare for peak production.

[0121] Step 4.3: All execution results, including emission concentration, system resistance, and energy consumption data, are captured by the sensing layer and fed back to the ECU.

[0122] The ECU uses a self-learning mechanism to compare the results with the target and continuously optimize its control model and strategy, forming a self-evolutionary closed loop.

[0123] The foregoing has shown and described the basic principles and main features of the present invention and its advantages. It will be apparent to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention. Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects. The scope of the present invention is defined by the appended claims rather than the foregoing description. Therefore, it is intended that all changes falling within the meaning and scope of the equivalents of the claims be included within the present invention, and no reference numerals in the claims should be regarded as limiting the scope of the claims.

[0124] 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 cement dust removal system, characterized in that: include Dust suppression module at the source: It is installed in open or semi-open areas; Ventilation and dust removal module: It is installed at the dust generation point inside the enclosed equipment; Resource recycling module: It is installed downstream of the dust collectors in the packaging workshop, bulk station, and grinding system; In the packaging machine recycling unit, cement bags are filled in a customized negative pressure dust removal chamber. The escaping dust is instantly captured by the dust collection hood on the top of the chamber. The dust-laden gas is purified by the dust collector, and the dust is collected in the ash hopper. The bulk loading machine recycling unit connects the bulk loading machine to the dust removal hood. The micro differential pressure sensor unit monitors the pressure difference between the inside of the dust removal hood and the inside of the tank truck in real time. The bulk loading machine discharge valve, dust removal fan and bulk loading machine recycling unit are hard-wired interlocked to send the collected dust back to the finished product warehouse in a pneumatic manner. Grinding mill recovery unit: A main dust collector is set in the grinding mill as the core filter. An FU chain conveyor or air conveying chute is set up to horizontally convey the collected dust. An online component analyzer is installed downstream of the main dust collector. A two-way / multi-way material distribution valve is used as the core actuator to recover materials or temporarily store unqualified materials. Intelligent energy efficiency control module: It is located in the central control room and constructs a three-layer architecture of perception layer, decision layer and execution layer; The perception layer consists of the core sensor group; The decision-making layer belongs to the ECU energy efficiency control unit, which has built-in AI algorithms and process rule library; The execution layer uses a high-voltage frequency converter to steplessly regulate the speed of the fan and electrically adjusts the air valves in the dust removal pipeline to quickly adjust the air volume distribution.

2. The cement dust removal system according to claim 1, characterized in that: The dry fog dust suppression unit of the source dust suppression module has a high-pressure water pump and nozzles, which allows the fine water mist to collide and combine with dust particles, making them heavier and settling. It is equipped with dust concentration sensors, humidity sensors, geomagnetic sensors, and infrared beam detectors to form an intelligent sensing unit that can perceive the dust source status in real time.

3. The cement dust removal system according to claim 1, characterized in that: A pulse bag dust collector is installed at the dust generation point. When the ventilation and dust removal module is activated, the dust-laden gas is drawn into the pulse bag dust collector under the negative pressure generated by the fan. The real-time differential pressure value at the inlet and outlet of the dust collector is continuously monitored by the differential pressure transmitter and reported to the ECU for decision-making. After the dust removal program is started, the pulse controller triggers the electromagnetic pulse valves in a preset sequence to perform powerful jet cleaning.

4. A cement dust removal system according to claim 3, characterized in that: The ventilation and dust removal module includes a differential pressure feedback cleaning unit, which automatically adjusts the cleaning frequency and intensity based on the pressure difference between the inside and outside of the pulse bag dust collector. The differential pressure transmitter continuously measures and reports the real-time resistance differential pressure value of the pulse bag dust collector body, and the intelligent energy efficiency control module compares the real-time differential pressure with the preset cleaning start value.

5. A cement dust removal system according to claim 4, characterized in that: If the real-time differential pressure is less than the dust cleaning start value, no operation is performed, and monitoring continues. When the real-time differential pressure is greater than or equal to the dust removal start value, the intelligent energy efficiency control module sends a start command to the differential pressure feedback dust removal unit. According to the pulse controller, one or more electromagnetic pulse valves are triggered in a preset sequence to inject compressed air into the filter bag to complete the dust removal. The dust removal action will be carried out in sequence for all compartments, or the area with the highest differential pressure will be targeted for key dust removal. During the dust removal process, the differential pressure transmitter continuously monitors the differential pressure change and compares the real-time differential pressure with the lower dust removal stop value. As long as the real-time differential pressure remains higher than the stop value, continue cleaning the next set of filter bags; When the real-time differential pressure drops back to the dust removal stop value, the intelligent energy efficiency control module terminates the dust removal program.

6. A cement dust removal system according to claim 5, characterized in that: The packaging machine requires a customized negative pressure dust removal chamber, which completely seals the packaging machine's discharge port inside a stainless steel chamber. An operation window with a flexible transparent curtain is opened on the front of the chamber, forming both visual monitoring and physical isolation. A two-stage recovery screw conveyor is installed, in which the first stage screw is directly connected to the dust hopper of the pulse bag dust collector to transport the collected pure cement; The secondary screw receives material from the primary screw and is equipped with a two-way material distribution valve to return the filtered pure cement powder to the packaging machine inlet, while abnormal materials are directed to the waste bin.

7. A cement dust removal system according to claim 1, characterized in that: The dust-laden gas from the mill is processed by the main dust collector, and the dust is efficiently collected in the ash hopper. The dust collected in the ash hopper is then gathered at a point by the FU chain conveyor or air conveying chute, and then quality judgment and path decision are made. The recycled dust generated by the cement mill is considered a qualified product by default and is directed to the finished product warehouse by default through the material distribution valve. The raw material composition is a key parameter of the recycled dust generated by the raw material milling equipment, which is determined by online component analyzers or by data linkage with the quality control system. When the analyzer shows that the composition of the recovered dust is within the control range, the dispensing valve directs it to the raw material homogenization silo. When the composition deviates, the distribution valve directs it to the designated recycling bin.

8. A cement dust removal system according to claim 1, characterized in that: The sensing layer is equipped with material flow meters, environmental status sensors, fan body sensors, and filter bag status sensors at key locations of the dust removal point.

9. A cement dust removal system according to claim 1, characterized in that: The decision-making layer's process rule base is based on process knowledge, while the AI ​​algorithm is based on historical data and real-time learning to dynamically find the lowest energy consumption operating point that meets the current operating conditions.

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