Ethylene oxide filling system

Abstract

The invention relates to the technical field of ethylene oxide filling, in particular to an ethylene oxide filling system which comprises an ethylene oxide storage tank, a filling pump, a mass flow meter, an electronic scale, a control unit, a filling gun and a plurality of connecting pipelines, and all the components are communicated with one another through the connecting pipelines. According to the ethylene oxide filling system, by means of the Coriolis mass flow meter, the high-precision electronic scale and a PID algorithm in the control unit, the filling amount is accurately controlled. The mass flow meter is not only high in precision, but also capable of compensating temperature and pressure; the electronic scale measures the mass of the receiving container in real time, and the control unit adjusts the rotating speed of the filling pump based on feedback data of the electronic scale and the receiving container.

Description

Technical Field

[0001] This invention relates to the field of ethylene oxide filling technology, and more specifically to an ethylene oxide filling system. Background Technology

[0002] Ethylene oxide, as an important organic synthesis raw material and a broad-spectrum sterilizing agent, is widely used in chemical, medical, and other fields. However, ethylene oxide is flammable, explosive, toxic, and harmful, posing significant safety risks to its filling operations and imposing stringent requirements on the safety, accuracy, and stability of the filling system.

[0003] Early ethylene oxide filling systems had numerous shortcomings in design and function. Some systems used only simple volumetric metering methods, making it difficult to accurately control the filling amount, resulting in inconsistent product quality and failing to meet the precise requirements of applications demanding precise ethylene oxide usage. In terms of safety, traditional systems lacked comprehensive real-time monitoring and emergency response mechanisms, failing to detect and handle dangerous situations such as ethylene oxide leaks and abnormal pressure in a timely manner, easily leading to serious safety accidents. Furthermore, due to unreasonable material and structural design of pipelines and storage equipment, not only could ethylene oxide suffer vaporization losses and impurity contamination during transportation and storage, reducing product quality, but it could also lead to material residue and leakage, polluting the environment. Summary of the Invention

[0004] In view of the above-mentioned shortcomings of the existing technology, the present invention provides an ethylene oxide filling system that can effectively solve the problems of poor filling accuracy, insufficient safety protection, and serious material loss and pollution in the existing ethylene oxide filling operation.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] This invention provides an ethylene oxide filling system, which includes an ethylene oxide storage tank, a filling pump, a mass flow meter, an electronic scale, a control unit, a filling gun, and several connecting pipes, with each component interconnected through the connecting pipes;

[0007] Ethylene oxide storage tank: used to store liquid ethylene oxide. The storage tank is equipped with a pressure sensor and a liquid level sensor to monitor the pressure and liquid level inside the tank in real time and transmit the monitoring data to the control unit.

[0008] Filling pump: One end is connected to the ethylene oxide storage tank, and the other end is connected to the mass flow meter through a pipeline. The filling pump is used to extract ethylene oxide from the storage tank and deliver it to the mass flow meter. The filling pump is started, stopped and its speed is controlled by the control unit.

[0009] Mass flow meter: Installed on the pipeline between the filling pump and the filling gun, it is used to accurately measure the filling mass of ethylene oxide and feed the measurement data back to the control unit;

[0010] Electronic scale: Placed at the filling station, it is used to support the ethylene oxide receiving container to be filled, and to measure the mass of the receiving container in real time, transmitting the measurement data to the control unit;

[0011] Control unit: It is electrically connected to the pressure sensor, liquid level sensor, mass flow meter, electronic scale and filling pump respectively. Based on the data fed back by each sensor, it controls the start and stop and speed of the filling pump to achieve precise control of the ethylene oxide filling process.

[0012] Filling gun: Connected to the end of the pipe downstream of the mass flow meter, used to inject ethylene oxide into the receiving container to be filled. The filling gun is equipped with a valve, which is controlled by a control unit to open and close.

[0013] Preferably, the ethylene oxide storage tank is provided with a heat insulation layer, which is made of vacuum insulation material, to effectively reduce the vaporization loss of ethylene oxide in the tank caused by external heat transfer.

[0014] Preferably, the connecting pipe is made of stainless steel, and the inner wall of the pipe is polished to a roughness Ra≤0.8μm, which reduces the residue and adsorption of ethylene oxide when it flows in the pipe. At the same time, all connections of the pipe are sealed by welding to ensure the system's airtightness.

[0015] Preferably, the system further includes an emergency shut-off valve, which is installed on the pipeline between the ethylene oxide storage tank and the filling pump. When the system detects an abnormal situation, such as excessive pressure or leakage, the control unit immediately triggers the emergency shut-off valve to cut off the delivery of ethylene oxide.

[0016] Preferably, the control unit is a PLC controller with a pre-set filling quality target value. Based on the data fed back from the mass flow meter and the electronic scale, the PLC controller adjusts the speed of the filling pump through a PID algorithm to achieve precise control of the ethylene oxide filling quality, with the filling accuracy controlled within ±0.5kg.

[0017] Preferably, the system is also equipped with a gas leak detection device, which is installed around the filling station and storage tank to detect the concentration of ethylene oxide gas in the environment in real time. When the concentration of ethylene oxide gas exceeds the preset alarm value, an alarm is immediately issued and the emergency shut-off valve is closed in conjunction with the system.

[0018] Preferably, the filling gun is equipped with an anti-drip structure. After filling is completed, the anti-drip structure is automatically activated when the filling gun valve is closed to prevent residual ethylene oxide from dripping into the working environment.

[0019] Preferably, a filter is installed on the pipeline between the ethylene oxide storage tank and the filling pump. The filter uses a high-precision filter element with a filtration accuracy of 0.1μm, which effectively filters impurities in the ethylene oxide and ensures the quality of the filled ethylene oxide.

[0020] The technical solution provided by this invention has the following advantages compared with the known prior art:

[0021] 1. This ethylene oxide filling system utilizes a Coriolis mass flow meter, a high-precision electronic scale, and a PID algorithm in the control unit to achieve precise control of the filling volume. The mass flow meter is not only highly accurate but also compensates for temperature and pressure; the electronic scale measures the mass of the receiving container in real time, and the control unit adjusts the filling pump speed based on the feedback data from both, effectively meeting the needs of high-precision applications and ensuring stable product quality.

[0022] 2. The system establishes a comprehensive safety protection system through a catalytic combustion gas leak detection device, a high-precision pressure sensor, and a pneumatic emergency shut-off valve. The gas leak detection device and pressure sensor monitor the environment and storage tank status in real time. Once an anomaly is detected, the control unit immediately triggers the emergency shut-off valve, which is also equipped with a manual operation device, greatly reducing the possibility of safety accidents.

[0023] 3. The system employs multiple measures in the storage and transportation stages to reduce material loss and pollution. Storage tanks utilize vacuum insulation materials to minimize vaporization losses, and connecting pipes are made of 316L stainless steel with high-precision polishing and argon arc sealing welding to reduce material residue and leakage. Simultaneously, basket filters remove impurities, and a differential pressure alarm device ensures filtration effectiveness, thereby guaranteeing product quality and reducing environmental pollution. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0025] Figure 1 This is a schematic diagram of the pre-filling preparation process of the present invention;

[0026] Figure 2 This is a schematic diagram of the testing process of the equipment of the present invention;

[0027] Figure 3 This is a schematic diagram of the container preparation process for the present invention;

[0028] Figure 4 This is a schematic diagram of the parameter setting process for the present invention;

[0029] Figure 5 This is a schematic diagram of the filling process of the present invention;

[0030] Figure 6 This is a schematic diagram of the filling process of the present invention;

[0031] Figure 7 This is a schematic diagram of the exception handling process of the present invention. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0033] The present invention will be further described below with reference to embodiments.

[0034] Example: Refer to Figures 1 to 7 An ethylene oxide filling system is disclosed. The system mainly consists of an ethylene oxide storage tank, a filling pump, a mass flow meter, an electronic scale, a control unit, a filling gun, and several connecting pipes. The components are interconnected through the connecting pipes.

[0035] Ethylene oxide storage tank: As the material source of the entire filling system, the ethylene oxide storage tank is constructed from high-quality corrosion-resistant metal materials. Its excellent pressure resistance and chemical corrosion resistance provide a stable and safe environment for ethylene oxide storage. The pressure sensor inside the tank utilizes high-precision piezoresistive sensing technology to accurately capture pressure changes in real time, with a measurement accuracy of ±0.01MPa. The liquid level sensor employs an advanced ultrasonic liquid level measuring device, which accurately calculates the ethylene oxide level in the tank by emitting and receiving ultrasonic signals, with a measurement error controlled within ±1cm. The data collected by these two sensors is rapidly transmitted to the control unit in digital signal form via shielded cables, greatly reducing interference during signal transmission and ensuring the accuracy of information obtained by the control unit.

[0036] In addition, the insulation layer of the storage tank uses vacuum insulation material, which consists of multiple layers of high-reflectivity metal foil and low-thermal-conductivity spacer material. After vacuuming, heat conduction and heat radiation are effectively reduced, reducing the vaporization loss of ethylene oxide in the tank caused by external heat transfer by more than 80%, greatly reducing material waste and lowering production costs.

[0037] Filling pump: The filling pump plays a crucial role in the system by transporting ethylene oxide. A magnetically driven pump specifically designed for transporting flammable, explosive, toxic, and hazardous fluids is selected. This pump employs a seal-less design, achieving power transmission through magnetic coupling. This avoids the leakage problems that easily occur at the shaft seals of traditional pumps, fundamentally reducing the safety risks associated with ethylene oxide leakage.

[0038] The control unit utilizes advanced variable frequency drive (VFD) technology to start, stop, and control the speed of the filling pump. Based on a preset filling plan and feedback data from various sensors, the control unit sends control signals to the VFD. The VFD precisely adjusts the power frequency input to the filling pump motor, thereby achieving stepless speed regulation of the filling pump with an accuracy of 0.1Hz. In this way, the system can flexibly and accurately control the delivery volume of ethylene oxide, meeting the needs of different filling scenarios.

[0039] Mass Flow Meter: The mass flow meter employs a Coriolis mass flow meter, utilizing the Coriolis force generated when fluid flows in a vibrating tube to directly measure the mass flow rate of the fluid, with a measurement accuracy of up to ±0.1%. This flow meter not only measures the filling mass of ethylene oxide in real time and accurately, but also features temperature and pressure compensation functions, automatically correcting for measurement errors caused by temperature and pressure changes, ensuring accurate and reliable data for the control unit under various operating conditions. Measurement data is transmitted to the control unit via an RS485 communication interface using the Modbus protocol, ensuring the stability and compatibility of data transmission.

[0040] Electronic Scale: The electronic scale uses a high-precision platform scale with a weighing range covering the weight range of common ethylene oxide receiving containers, achieving an accuracy of ±0.1kg. The scale body is made of high-strength alloy steel with an anti-corrosion surface treatment, enabling long-term stable operation in harsh working environments. The built-in load cell uses a strain gauge principle, providing fast response and real-time measurement of the receiving container's mass. Measurement data is transmitted to the control unit wirelessly via Bluetooth or Wi-Fi, reducing wiring complexity and improving system flexibility.

[0041] Control Unit: The control unit is based on a PLC controller, equipped with a high-performance central processing unit and abundant input / output interfaces. Its software system adopts a modular design, including a data acquisition module, a data processing module, a control algorithm module, and a human-machine interface module. The data acquisition module is responsible for collecting data from various sensors in real time and performing preliminary screening and preprocessing. The data processing module analyzes and calculates the collected data, providing accurate data support for the control algorithm module. The control algorithm module uses a PID algorithm to accurately calculate the speed control signal of the filling pump based on the preset filling quality target value and actual measurement data. The human-machine interface module provides operators with an intuitive and convenient operating interface, allowing them to set filling parameters, monitor the filling process, and view the system's operating status and historical records.

[0042] Filling Gun: The main body of the filling gun is made of high-strength, corrosion-resistant engineering plastic, ensuring both the gun's lightweight design and improved chemical corrosion resistance. The valve on the gun body is a solenoid valve with a fast response time, capable of opening and closing within 0.1 seconds. The anti-drip structure employs a unique double-seal design. As the valve closes at the end of filling, the sealing components in the anti-drip structure quickly activate, forming a double seal to effectively prevent residual ethylene oxide from dripping into the working environment, avoiding environmental pollution and threats to personnel health.

[0043] Furthermore, the ethylene oxide filling system of the present invention also has the following optimized design:

[0044] Connecting Pipelines: All connecting pipelines are made of 316L stainless steel, a material with excellent corrosion resistance and strength, meeting the special requirements for ethylene oxide transportation. The inner walls of the pipelines undergo high-precision polishing, with a roughness Ra≤0.8μm, significantly reducing resistance and residual adsorption of ethylene oxide during flow within the pipeline. All pipeline connections utilize argon arc sealing welding, and the welding quality is strictly tested according to relevant standards to ensure the sealing of the connections and prevent ethylene oxide leakage.

[0045] Emergency Shut-off Valve: The emergency shut-off valve is a pneumatic shut-off valve, powered by compressed air. When the system detects an abnormality, such as excessive pressure or leakage, the control unit immediately sends a control signal to activate the pneumatic device, rapidly closing the emergency shut-off valve within 1 second, cutting off the delivery of ethylene oxide and effectively preventing further escalation of the accident. The emergency shut-off valve is also equipped with a manual operation device, allowing operators to manually close the valve in emergencies, ensuring system safety.

[0046] Gas Leak Detection Device: The gas leak detection device uses a catalytic combustion sensor, which has high sensitivity and rapid response characteristics to ethylene oxide gas. It can detect the concentration of ethylene oxide gas in the environment in real time, with a detection accuracy of ±1ppm. When the detected ethylene oxide gas concentration exceeds the preset alarm value, the detection device immediately issues an audible and visual alarm and outputs a signal through a relay to activate the emergency shut-off valve. At the same time, the alarm information is transmitted to the control unit so that operators can take timely measures to handle the situation.

[0047] Filter: The filter adopts a basket filter with a high-precision sintered metal powder filter element, achieving a filtration accuracy of 0.1μm. This effectively filters impurities in ethylene oxide, ensuring the quality of the filled ethylene oxide. The filter is also equipped with a differential pressure alarm device. When the filter element becomes clogged, causing the inlet and outlet pressure difference to exceed the preset value, the alarm device will immediately sound, reminding operators to replace the filter element in time to ensure the normal operation of the filter.

[0048] The working principle of this invention is as follows:

[0049] Preparations before filling:

[0050] Equipment Inspection: The staff first conducted a comprehensive and meticulous inspection of all components of the ethylene oxide filling system. Using a professional pressure calibrator, a standard pressure signal was applied to the pressure sensors to observe the accuracy of the output electrical signals. The error needed to be controlled within the allowable range to verify its ability to accurately monitor pressure changes within the storage tank. For the level sensor, different liquid levels were simulated to test whether the output level data matched the actual set value. Standard weights were used to calibrate the electronic scale and check its weighing accuracy. Simultaneously, the mass flow meter's self-test program was initiated to check if the instrument was working properly and if there were any error messages. The filling pump was inspected for external damage and secure connections. The pump shaft was manually rotated to ensure smooth rotation without jamming. Power was then connected to test its no-load operation, and the pump's vibration and noise were observed to be within normal ranges. The filling gun valves were checked to ensure they could open and close normally, and the anti-drip structure was intact. Leakage testing tools were used to check all system connections for leaks, ensuring the system was leak-free and fault-free.

[0051] Container preparation: Place the ethylene oxide receiving container to be filled stably on the electronic scale. After the electronic scale displays stable data, record the initial mass at this time, accurate to the specified minimum scale division, for subsequent calculation of the filling volume.

[0052] Parameter setting: Operators access the PLC controller's parameter setting page through the control unit's human-machine interface and preset the filling quality target value in the system according to actual production needs. During the input process, the system will verify the reasonableness of the input value to prevent incorrect values ​​from being entered due to accidental operation.

[0053] Filling process:

[0054] Initiation of Delivery: The control unit sends a start command to the filling pump according to a preset program. Upon receiving the command, the filling pump's motor starts running, extracting liquid ethylene oxide from the ethylene oxide storage tank. The ethylene oxide is then transported along the pipeline to the mass flow meter. The mass flow meter uses the Coriolis force principle to measure the filling mass of ethylene oxide in real time and accurately, and feeds back the measurement data to the control unit via an RS485 communication interface using the Modbus protocol.

[0055] Injection Container: Ethylene oxide, after passing through the mass flow meter, continues to flow along the pipeline and is finally injected into the receiving container to be filled through the filling gun. Simultaneously, an electronic scale placed at the filling station, using a strain gauge weighing principle, measures the mass change of the receiving container in real time and transmits the measurement data to the control unit via Bluetooth or Wi-Fi through a wireless transmission module.

[0056] Precise Adjustment: The PLC controller in the control unit compares and analyzes the data fed back from the mass flow meter and electronic scale, and uses a PID algorithm to calculate the current filling deviation. When the actual filling mass approaches the preset filling mass target value, the PLC controller sends a control signal to the frequency converter based on the calculation result of the PID algorithm. The frequency converter adjusts the power frequency of the input filling pump motor, reducing the speed of the filling pump, thereby achieving precise control of the ethylene oxide delivery volume and achieving the purpose of precise filling.

[0057] Filling complete:

[0058] Stop delivery: When the PLC controller of the control unit determines that the actual filling quality has reached the preset target value, it immediately sends a shut-off command to the valves of the filling pump and the filling gun. Upon receiving the command, the filling pump motor stops running, stopping the delivery of ethylene oxide; the valve of the filling gun closes quickly, preventing ethylene oxide from continuing to flow out.

[0059] Anti-drip mechanism: When the filling gun valve is closed, the built-in anti-drip structure of the filling gun automatically activates. This structure, through mechanical linkage or electromagnetic control, causes the sealing components to move rapidly, forming a double seal and effectively preventing residual ethylene oxide from dripping into the working environment.

[0060] Data Recording: After filling, the staff removes the receiving container, reads the final mass data from the electronic scale again, and records it. Relevant data from this filling process, such as initial mass, final mass, filling volume, and filling time, is stored in the control unit's database for later querying and statistical analysis.

[0061] Exception handling:

[0062] Gas Leakage Handling: When the gas leak detection device, using a catalytic combustion sensor, detects that the concentration of ethylene oxide gas in the environment exceeds the preset alarm value, the device immediately issues an audible and visual alarm and simultaneously outputs a signal to the control unit via a relay. Upon receiving the signal, the control unit immediately triggers the emergency shut-off valve to close, stopping the delivery of ethylene oxide. Personnel quickly don protective gear and use gas detection instruments to conduct a comprehensive inspection of the work area to locate the leak. For minor leaks, professional sealing tools are used to plug them; for serious leaks, the emergency plan is immediately activated, personnel are evacuated, and appropriate safety measures are taken to prevent the accident from escalating.

[0063] Handling Overpressure: When the pressure sensor detects excessive pressure inside the ethylene oxide storage tank, it transmits the pressure data to the control unit. The PLC controller in the control unit determines the pressure based on a preset threshold. Once the pressure exceeds the threshold, it immediately triggers the emergency shut-off valve to close, cutting off the delivery of ethylene oxide and preventing safety accidents caused by excessive pressure. Simultaneously, personnel investigate the cause of the excessive pressure, which could be due to excessively high ambient temperature, excessively rapid filling speed, or a malfunction within the storage tank. Appropriate measures are taken based on the cause, such as cooling, adjusting the filling speed, or repairing the storage tank.

[0064] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the protection scope of the technical solutions of the embodiments of the present invention.

Claims

1. An ethylene oxide filling system, characterized in that, The filling system includes an ethylene oxide storage tank, a filling pump, a mass flow meter, an electronic scale, a control unit, a filling gun, and several connecting pipes, with each component interconnected through the connecting pipes; Ethylene oxide storage tank: used to store liquid ethylene oxide. The storage tank is equipped with a pressure sensor and a liquid level sensor to monitor the pressure and liquid level inside the tank in real time and transmit the monitoring data to the control unit. Filling pump: One end is connected to the ethylene oxide storage tank, and the other end is connected to the mass flow meter through a pipeline. The filling pump is used to extract ethylene oxide from the storage tank and deliver it to the mass flow meter. The filling pump is started, stopped and its speed is controlled by the control unit. Mass flow meter: Installed on the pipeline between the filling pump and the filling gun, it is used to accurately measure the filling mass of ethylene oxide and feed the measurement data back to the control unit; Electronic scale: Placed at the filling station, it is used to support the ethylene oxide receiving container to be filled, and to measure the mass of the receiving container in real time, transmitting the measurement data to the control unit; Control unit: It is electrically connected to the pressure sensor, liquid level sensor, mass flow meter, electronic scale and filling pump respectively. Based on the data fed back by each sensor, it controls the start and stop and speed of the filling pump to achieve precise control of the ethylene oxide filling process. Filling gun: Connected to the end of the pipe downstream of the mass flow meter, used to inject ethylene oxide into the receiving container to be filled. The filling gun is equipped with a valve, which is controlled by a control unit to open and close.

2. The ethylene oxide filling system according to claim 1, characterized in that, The ethylene oxide storage tank is equipped with a heat insulation layer, which is made of vacuum insulation material, effectively reducing the vaporization loss of ethylene oxide in the tank due to the introduction of external heat.

3. The ethylene oxide filling system according to claim 1, characterized in that, The connecting pipes are made of stainless steel, and the inner wall of the pipes is polished to a roughness Ra≤0.8μm, which reduces the residue and adsorption of ethylene oxide when it flows in the pipes. At the same time, all connections of the pipes are sealed by welding to ensure the system's airtightness.

4. The ethylene oxide filling system according to claim 1, characterized in that, The system also includes an emergency shut-off valve, which is installed on the pipeline between the ethylene oxide storage tank and the filling pump. When the system detects an abnormality, such as excessive pressure or leakage, the control unit immediately triggers the emergency shut-off valve to cut off the delivery of ethylene oxide.

5. The ethylene oxide filling system according to claim 1, characterized in that, The control unit adopts a PLC controller, which has a pre-set target value for filling quality. Based on the data fed back by the mass flow meter and the electronic scale, the PLC controller adjusts the speed of the filling pump through a PID algorithm to achieve precise control of the filling quality of ethylene oxide, with the filling accuracy controlled within ±0.5kg.

6. The ethylene oxide filling system according to claim 1, characterized in that, The system is also equipped with a gas leak detection device, which is installed around the filling station and storage tank to detect the concentration of ethylene oxide gas in the environment in real time. When the concentration of ethylene oxide gas exceeds the preset alarm value, an alarm is immediately issued and the emergency shut-off valve is activated to close.

7. The ethylene oxide filling system according to claim 1, characterized in that, The filling gun is equipped with an anti-drip structure. After filling is completed, the anti-drip structure is automatically activated when the filling gun valve is closed to prevent residual ethylene oxide from dripping into the working environment.

8. The ethylene oxide filling system according to claim 1, characterized in that, A filter is installed on the pipeline between the ethylene oxide storage tank and the filling pump. The filter uses a high-precision filter element with a filtration accuracy of 0.1μm, which effectively filters impurities in the ethylene oxide and ensures the quality of the filled ethylene oxide.

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