Differential pressure type solid-to-liquid ratio automatic monitoring system
By using a differential pressure automatic solid-liquid ratio monitoring system and a pressure strain gauge and a linear regression model, the problems of long monitoring time and low accuracy in salt production have been solved. The system achieves real-time and accurate solid-liquid ratio monitoring, reducing the risks of manual operation and the impact of external pollutants.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-06
- Publication Date
- 2026-04-07
AI Technical Summary
In existing technologies, monitoring the solid-liquid ratio during salt production relies on manual sampling, which is time-consuming, has a low monitoring frequency, and results in data lag and low accuracy, making it impossible to achieve real-time and accurate monitoring.
A differential pressure automatic solid-liquid ratio monitoring system is adopted. First and second pressure strain gauges are installed in the circulation pipe of the evaporator. Combined with the flushing system and control system, the differential pressure value is used for real-time monitoring and is quickly and accurately converted into solid-liquid ratio through a linear regression model.
It enables rapid and accurate monitoring of the solid-liquid ratio, ensuring the accuracy of real-time monitoring, avoiding the impact of external contaminants on the product, and reducing the risk of manual operation.
Smart Images
Figure CN121805072A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of salt production, and in particular to a system for automatically monitoring solid-liquid ratio in differential pressure mode. BACKGROUND
[0002] In the process of salt production, the volume ratio of solid particles in the solid-liquid mixture in the evaporation tank, i.e. the solid-liquid ratio, is a key control parameter in the evaporation crystallization process, which directly affects the product quality and production efficiency.
[0003] The traditional method relies on manual sampling and measures the solid volume ratio by the static sedimentation method, but this method has defects such as long time consumption for a single measurement, low monitoring frequency, data feedback lag, and high risk of scalding for operators in high temperature.
[0004] In the prior art, a tuning fork densimeter is often used to achieve automatic monitoring, but there are problems such as large data deviation and frequent trend chart jumps, which cannot meet the actual needs. Meanwhile, other existing solid-liquid ratio monitoring methods have low monitoring accuracy and strong data lag, and cannot monitor the solid-liquid ratio in real time. SUMMARY
[0005] To solve or partially solve the problems in the related art, the present application provides a system for automatically monitoring solid-liquid ratio in differential pressure mode, which can quickly and accurately convert the measured differential pressure value into the solid-liquid ratio, and ensure the accuracy of real-time monitoring.
[0006] The present application provides a system for automatically monitoring solid-liquid ratio in differential pressure mode, comprising a measurement system, a flushing system and a control system. The measurement system comprises a first pressure strain gauge and a second pressure strain gauge. The first pressure strain gauge and the second pressure strain gauge are arranged in the lower circulating pipe of the evaporation tank. The flushing system comprises a condensate water tank, which is connected to the first pressure strain gauge and the second pressure strain gauge through pipelines, and an electric valve is arranged on each pipeline to control flushing. The control system comprises a controller, which is electrically connected to the first pressure strain gauge, the second pressure strain gauge and the electric valve. The control method of the controller comprises: The flushing system is controlled to perform flushing operation, and the measurement system is controlled to perform measurement operation after flushing; When the controller receives the monitoring data of the measurement system, the differential pressure ΔP is obtained by processing through an operation module; According to the differential pressure ΔP, the solid-liquid ratio value is calculated through a solid-liquid ratio conversion model; The solid-liquid ratio value is range checked, and if the solid-liquid ratio value exceeds the preset threshold range, a data abnormality alarm is triggered.
[0007] Optionally, in some embodiments of the present application: The first pressure strain gauge and the second pressure strain gauge are built in the same vertical axis of the lower circulating pipe, and the installation spacing of the first pressure strain gauge and the second pressure strain gauge is 80 cm.
[0008] Optionally, in some embodiments of the present application: The differential pressure ΔP is obtained by processing the operation module, specifically including: The pressure signals collected by the first pressure strain gauge and the second pressure strain gauge are subjected to digital filtering processing; The differential pressure value is calculated by the formula ΔP = P2 - P1, wherein P2 is the pressure value of the second pressure strain gauge, and P1 is the pressure value of the first pressure strain gauge; The calculated differential pressure value is compensated and corrected.
[0009] Optionally, in some embodiments of the present application: The solid-liquid ratio value is calculated by the solid-liquid ratio conversion model, specifically including: The differential pressure ΔP is brought into the linear regression model to calculate the solid-liquid ratio value, wherein the solid-liquid ratio value = K × (ΔP / (g × Δh)) - B, K is a proportional coefficient 0.1697, B is a constant term -205.1, the unit of the solid-liquid ratio value is volume percentage, and the unit of ΔP is Pa; The calculated solid-liquid ratio value is verified.
[0010] Optionally, in some embodiments of the present application: Both the first pressure strain gauge and the second pressure strain gauge adopt a convex diaphragm structure, the sensitivity is not less than 5 fF / kPa, and the accuracy is higher than ±0.05% FS.
[0011] Optionally, in some embodiments of the present application: The flushing operation is performed by controlling the flushing system, specifically including: The measurement system is intermittently flushed by controlling the electric control valve, and the flushing water pressure of the flushing system is ≥300 Kpa.
[0012] Optionally, in some embodiments of the present application: The condensate water in the condensate barrel is connected and laid by the pressure flushing water pipe of the lower circulating pipe. The flushing system further includes a water quality treatment unit for filtering the condensate water to ensure that the particulate matter content in the water is not greater than 1 μm.
[0013] Optionally, in some embodiments of the present application: The control system also includes an automatic calibration module for periodically calibrating the zero point and range of the pressure strain gauge.
[0014] Optionally, in some embodiments of this application: The control system also includes a data display module for real-time display of solid-liquid ratio monitoring data, historical trend curves, and alarm information.
[0015] Optionally, in some embodiments of this application: The control system also has a data storage module to store at least 30 days of monitoring data.
[0016] The technical solution provided in this application may include the following beneficial effects: This application monitors pressure data using a first and a second pressure strain gauge, and compensates and corrects the calculated differential pressure value. Then, through a linear regression model, the measured differential pressure value can be quickly and accurately converted into a solid-liquid ratio, ensuring the accuracy of real-time monitoring.
[0017] This application ensures accurate differential pressure measurement and guarantees accurate data monitoring by installing the first and second pressure strain gauges on the same vertical axis of the lower circulation pipe and strictly limiting the installation distance to 80cm.
[0018] This application uses condensate water in the lower circulation pipe and filters it, which prevents the introduction of external contaminants and avoids the risk of product contamination due to rinsing operations.
[0019] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description
[0020] The above and other objects, features and advantages of this application will become more apparent from the more detailed description of exemplary embodiments thereof in conjunction with the accompanying drawings, wherein the same reference numerals generally represent the same components in the exemplary embodiments thereof.
[0021] Fig. 1 This is a schematic diagram of the control method of the controller in an embodiment of this application; Fig. 2 This is a schematic diagram of a control structure of the controller in an embodiment of this application; Fig. 3 This is a schematic diagram of the composition structure of the control system in an embodiment of this application.
[0022] Figure reference numerals: 1-Controller, 2-First pressure strain gauge, 3-Second pressure strain gauge, 4-Electrically controlled valve. Detailed Implementation
[0023] Embodiments of this application will now be described in more detail with reference to the accompanying drawings. While embodiments of this application are shown in the drawings, it should be understood that this application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to make this application more thorough and complete, and to fully convey the scope of this application to those skilled in the art.
[0024] It should be understood that although the terms "first," "second," "third," etc., may be used in this application to describe various information, this information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.
[0025] In the description of this application, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.
[0026] Unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.
[0027] In the salt production process, the volume ratio of solid particles in the solid-liquid mixture of the evaporator feed liquid, also known as the solid-liquid ratio, is a key control parameter in the evaporation and crystallization process, which directly affects product quality and production efficiency.
[0028] Traditional methods rely on manual sampling and measure the solid volume ratio through static sedimentation. However, this method has drawbacks such as long sampling time, low monitoring frequency, delayed data feedback, and the risk of burns to operators due to high temperatures.
[0029] In existing technologies, tuning fork density meters are commonly used for automated monitoring, but this method suffers from problems such as large data deviations and frequent trend jumps, failing to meet practical needs. Meanwhile, other existing solid-liquid ratio monitoring methods suffer from low accuracy and significant data lag, making real-time monitoring of the solid-liquid ratio impossible.
[0030] To address the aforementioned issues, this application provides a differential pressure-based automatic solid-liquid ratio monitoring system that can quickly and accurately convert the measured differential pressure value into a solid-liquid ratio, ensuring the accuracy of real-time monitoring.
[0031] The technical solutions of the embodiments of this application are described in detail below with reference to the accompanying drawings.
[0032] Fig. 1 This is a schematic diagram of the control method of the controller in an embodiment of this application; Fig. 2 This is a schematic diagram of a control structure of the controller in an embodiment of this application; Fig. 3 This is a schematic diagram of the composition structure of the control system in an embodiment of this application.
[0033] See Figs. 1-3 A differential pressure automatic solid-liquid ratio monitoring system includes: a measurement system, a flushing system, and a control system.
[0034] The measurement system includes: a first pressure strain gauge 2 and a second pressure strain gauge 3; The first pressure strain gauge 2 and the second pressure strain gauge 3 are installed in the lower circulation pipe of the evaporator.
[0035] The flushing system includes a condensate tank, which is connected to a first pressure strain gauge 2 and a second pressure strain gauge 3 via pipes. Each pipe is equipped with an electrically controlled valve 4 for controlling the flushing process.
[0036] The control system includes a controller 1, which establishes electrical connections with a first pressure strain gauge 2, a second pressure strain gauge 3, and an electrically controlled valve 4.
[0037] The control method of controller 1 includes: S100: The rinsing operation is performed by controlling the rinsing system, and the measurement operation is performed by controlling the measurement system after rinsing.
[0038] Specifically: the rinsing operation is performed by controlling the rinsing system, including: The measuring system is intermittently flushed by controlling the electronically controlled valve 4, and the flushing water pressure of the flushing system is ≥300Kpa.
[0039] In this embodiment, by performing a flushing operation before measurement, the crystal deposits on the pressure tap and the sediment in the pipeline can be effectively removed, ensuring the authenticity and accuracy of the pressure data obtained in each measurement. Furthermore, by intermittent flushing under a water pressure of 300 kPa, continuous flushing can avoid continuous disturbance to the pressure strain gauge and save water resources.
[0040] Specifically: the condensate in this condensate tank is connected to a pressure flushing water pipe from the lower circulation pipe for use; The flushing system also includes a water treatment unit for filtering the condensate to ensure that the particulate matter content in the water is no greater than 1 μm.
[0041] In this embodiment, the flushing pipe is made of 304 stainless steel and is welded. The dielectric conductivity of the condensate is ≈20 ms / cm and the temperature is 43-48℃. By using condensate in the lower circulation pipe and filtering it, no external contaminants will be introduced, thus avoiding the risk of product contamination due to flushing operations.
[0042] S200: After the controller receives the monitoring data from the measurement system, it processes the data through the calculation module to obtain the differential pressure ΔP.
[0043] Specifically: the first pressure strain gauge 2 and the second pressure strain gauge 3 are built into the same vertical axis of the lower circulation pipe, and the installation distance between the first pressure strain gauge 2 and the second pressure strain gauge 3 is 80cm.
[0044] Specifically: Both the first pressure strain gauge 2 and the second pressure strain gauge 3 adopt a convex diaphragm structure, with a sensitivity of not less than 5fF / kPa and an accuracy of more than ±0.05%FS.
[0045] In this embodiment, by installing the first pressure strain gauge 2 and the second pressure strain gauge 3 on the same vertical axis of the lower circulation pipe and strictly limiting the installation spacing to 80cm, the accuracy of differential pressure measurement can be ensured and the accuracy of data monitoring can be guaranteed.
[0046] Specifically: the differential pressure ΔP is obtained through the calculation module, including: The pressure signals acquired by the first pressure strain gauge 2 and the second pressure strain gauge 3 are digitally filtered. The differential pressure value is calculated using the formula △P = P2 - P1, where P2 is the pressure value of the second pressure strain gauge 3 and P1 is the pressure value of the first pressure strain gauge 2. The calculated differential pressure value is compensated and corrected.
[0047] In this embodiment, by performing digital filtering on the original pressure signal, high-frequency random noise introduced by vibration of power equipment, electromagnetic interference, etc. can be effectively filtered out, ensuring the stability of monitoring data. By compensating and correcting the calculated differential pressure value, the measurement accuracy and reliability of the results can be further guaranteed.
[0048] S300: The solid-liquid ratio is calculated based on the differential pressure ΔP using the solid-liquid ratio conversion model.
[0049] Specifically: the solid-liquid ratio value is calculated using a solid-liquid ratio conversion model, including: Substituting the pressure difference ΔP into the linear regression model, the solid-liquid ratio is calculated, where: solid-liquid ratio = K × (ΔP / (g × Δh)) - B, where K is the proportionality coefficient 0.1697, B is the constant term -205.1, the unit of solid-liquid ratio is volume percentage, and the unit of ΔP is Pa; The calculated solid-liquid ratio is then verified.
[0050] In this embodiment, based on the installation distance of the first pressure strain gauge 2 and the second pressure strain gauge 3 being 80cm, the linear regression model was obtained by fitting a large amount of experimental data. Its coefficient of determination is high (R²≥0.94), indicating that its prediction results are highly consistent with the actual values. It can quickly and accurately convert the measured differential pressure value into the solid-liquid ratio, ensuring the accuracy of real-time monitoring.
[0051] S400: Perform range verification based on the solid-liquid ratio. If the solid-liquid ratio exceeds the preset threshold range, trigger a data anomaly alarm.
[0052] In this embodiment, if the solid-liquid ratio is within 10% of the threshold range, the system will not trigger an alarm and will continue the normal monitoring process. If the solid-liquid ratio exceeds 10% of the threshold range, the system will trigger an abnormal alarm.
[0053] Specifically, the control system also includes an automatic calibration module for periodically calibrating the zero point and range of the pressure strain gauge.
[0054] In this embodiment, the automatic calibration module can maintain the long-term measurement accuracy of the system and reduce the cost of manual maintenance.
[0055] Specifically, the control system also includes a data display module for real-time display of solid-liquid ratio monitoring data, historical trend curves, and alarm information.
[0056] Specifically, the control system also has a data storage module for storing at least 30 days of monitoring data.
[0057] The technical solutions in this application have the following beneficial effects: This application monitors pressure data using a first and a second pressure strain gauge, and compensates and corrects the calculated differential pressure value. Then, through a linear regression model, the measured differential pressure value can be quickly and accurately converted into a solid-liquid ratio, ensuring the accuracy of real-time monitoring.
[0058] This application ensures accurate differential pressure measurement and guarantees accurate data monitoring by installing the first and second pressure strain gauges on the same vertical axis of the lower circulation pipe and strictly limiting the installation distance to 80cm.
[0059] This application uses condensate water in the lower circulation pipe and filters it, which prevents the introduction of external contaminants and avoids the risk of product contamination due to rinsing operations.
[0060] Finally, it should be noted that in this document, relationships such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "include," "contain," or any other variations are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.
[0061] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.
[0062] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.
[0063] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, a server, or a network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this application.
[0064] The various embodiments of this application have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.
Claims
1. A differential pressure-based automatic solid-liquid ratio monitoring system, characterized in that, include: Measurement system, flushing system, and control system; The measurement system includes: a first pressure strain gauge (2) and a second pressure strain gauge (3); The first pressure strain gauge (2) and the second pressure strain gauge (3) are installed in the lower circulation pipe of the evaporator; The flushing system includes: a condensate tank, which is connected to a first pressure strain gauge (2) and a second pressure strain gauge (3) via pipes, and an electrically controlled valve (4) is installed on each pipe to control the flushing; The control system includes: a controller (1), which establishes electrical connections with a first pressure strain gauge (2), a second pressure strain gauge (3), and an electrically controlled valve (4); The control method of the controller (1) includes: The rinsing operation is performed by controlling the rinsing system, and the measurement operation is performed by controlling the measurement system after rinsing. When the controller (1) receives the monitoring data from the measurement system, it processes the data through the calculation module to obtain the differential pressure ΔP; The solid-liquid ratio is calculated based on the differential pressure ΔP using a solid-liquid ratio conversion model. The solid-liquid ratio is used for range verification. If the solid-liquid ratio exceeds the preset threshold range, a data anomaly alarm is triggered.
2. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 1, characterized in that: The first pressure strain gauge (2) and the second pressure strain gauge (3) are built on the same vertical axis of the lower circulation pipe, and the installation distance between the first pressure strain gauge (2) and the second pressure strain gauge (3) is 80cm.
3. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 2, characterized in that: The process of obtaining the differential pressure ΔP through the calculation module specifically includes: The pressure signals collected by the first pressure strain gauge (2) and the second pressure strain gauge (3) are digitally filtered; The differential pressure value is calculated using the formula △P = P2 - P1, where P2 is the pressure value of the second pressure strain gauge (3) and P1 is the pressure value of the first pressure strain gauge (2). The calculated differential pressure value is compensated and corrected.
4. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 3, characterized in that: The calculation of the solid-liquid ratio value through the solid-liquid ratio conversion model specifically includes: Substituting the pressure difference ΔP into the linear regression model, the solid-liquid ratio is calculated, where: solid-liquid ratio = K × (ΔP / (g × Δh)) - B, where K is the proportionality coefficient 0.1697, B is the constant term -205.1, the unit of solid-liquid ratio is volume percentage, and the unit of ΔP is Pa; The calculated solid-liquid ratio is then verified.
5. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 4, characterized in that: The first pressure strain gauge (2) and the second pressure strain gauge (3) both adopt a convex diaphragm structure, with a sensitivity of not less than 5fF / kPa and an accuracy of more than ±0.05%FS.
6. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 1 or 5, characterized in that: The rinsing operation via controlling the rinsing system specifically includes: The measurement system is intermittently flushed by controlling the electronically controlled valve (4), and the flushing water pressure of the flushing system is ≥300Kpa.
7. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 6, characterized in that: The condensate in the condensate tank is connected to a pressure flushing water pipe from the lower circulation pipe for use. The flushing system also includes a water treatment unit for filtering the condensate to ensure that the particulate matter content in the water is no greater than 1 μm.
8. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 7, characterized in that: The control system also includes an automatic calibration module for periodically calibrating the zero point and range of the pressure strain gauge.
9. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 8, characterized in that: The control system also includes a data display module for real-time display of solid-liquid ratio monitoring data, historical trend curves, and alarm information.
10. The differential pressure type automatic solid-liquid ratio monitoring system according to claim 9, characterized in that: The control system is also equipped with a data storage module for storing at least 30 days of monitoring data.