Automatic filtering and oil smoke removing device for powder metallurgy

Abstract

The invention discloses an automatic filtering and oil smoke removing device for powder metallurgy. The problems that an existing oil smoke removing device is low in filtering efficiency, prone to blockage, high in maintenance cost, poor in adaptability and serious in energy waste are solved. The device comprises a composite filtering module, an electrostatic adsorption pretreatment module, an automatic operation and maintenance module, an intelligent regulation and control module, a modular integrated structure, a waste heat recovery module, a dust resource recovery module, a VOCs advanced treatment module and an energy-saving driving module. Through a composite filter material design of wire mesh pre-filtration, porous ceramic fine filtration and a catalytic decomposition layer, electrostatic adsorption synergistic purification is combined, so that three functions of dust removal, oil removal and odor removal are realized; automatic operation and maintenance are realized by utilizing online pressure difference monitoring, automatic back flushing and cleaning, intelligent oil discharge and recovery and IoT remote monitoring; a modular integrated and high-temperature-resistant compact structure is adopted, so that the requirements of different production lines are met; through waste heat recovery, dust recycling and variable frequency driving, energy conservation, consumption reduction and circular economy are achieved.

Description

An automatic oil fume filtration device for powder metallurgy Technical Field

[0001] This invention relates to the field of environmental protection equipment technology for powder metallurgy, specifically to an automatic filtration and fume removal device for powder metallurgy. Background Technology

[0002] Powder metallurgy is a technology that produces metal products through processes such as metal powder forming and sintering, and it is widely used in industries such as automobiles, machinery, and electronics. During powder metallurgy production, especially in processes like sintering and pressing, a large amount of mixed pollutants containing oil fumes, metal dust (such as iron and copper powder), and volatile organic compounds (VOCs) are generated. Direct emission of these pollutants not only causes serious air pollution and harms the health of operators, but also leads to the waste of metal raw materials, which is inconsistent with environmental protection policies and the requirements of a circular economy.

[0003] Existing oil fume removal devices have several shortcomings in treating mixed pollutants from powder metallurgy: First, they rely on a single filtration method, often using a single filter media or a simple combination, making it difficult to simultaneously and efficiently remove dust, oil mist, and VOCs. Furthermore, oil mist adhesion and dust accumulation easily clog the filter media, leading to a rapid decline in filtration efficiency. Second, they lack temperature resistance. The oil fume temperatures generated during the powder metallurgy sintering process can reach over 200℃, causing ordinary filter media to easily deform and fail. At high temperatures, oil mist also easily solidifies and adheres, further exacerbating clogging. Third, their operation and maintenance methods are outdated, relying heavily on manual periodic cleaning or replacement of filter media, resulting in high maintenance costs. The problems are as follows: First, the cleaning process requires shutdown, affecting production efficiency; second, the adaptability is poor, as powder metallurgy production lines have diverse layouts and different processing requirements for individual equipment and the entire line. Existing equipment is mostly fixed in structure and difficult to adapt flexibly; third, there is serious energy waste, as the waste heat from high-temperature oil fumes is not effectively utilized, and the fans are mostly driven at fixed speeds, still consuming high energy even under low load conditions; fourth, environmental protection is incomplete, as some equipment can only remove dust and oil mist, and the treatment effect on VOCs is poor, making it difficult to meet increasingly stringent environmental emission standards, and the collected metal dust is not recycled.

[0004] To solve the above-mentioned technical problems, there is an urgent need to develop an automatic filtration and fume removal device for powder metallurgy that combines functions such as high-efficiency filtration, anti-clogging, high-temperature resistance, automated operation and maintenance, flexible adaptation, energy saving and consumption reduction, and environmental recycling, so as to meet the needs of industry development. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide an automatic filtration and fume removal device for powder metallurgy. Through the integration and innovation of multiple technologies, it achieves efficient purification of mixed pollutants in powder metallurgy, while solving problems such as clogging, difficult maintenance, poor adaptability, high energy consumption, and resource waste, thus meeting the dual requirements of environmental protection and production efficiency.

[0006] This invention provides the following technical solution: an automatic filtration and fume removal device for powder metallurgy, comprising an air inlet channel, a pretreatment module, a composite filtration module, a purification channel, and an air outlet channel connected in sequence, as well as an intelligent control module electrically connected to each module and an automated operation and maintenance module cooperating with the composite filtration module; the pretreatment module is an electrostatic adsorption module used to pre-capture charged metal dust and oil mist particles; the composite filtration module includes a gradient composite filter material, which is composed of a metal wire mesh pre-filtration layer, a porous ceramic fine filtration layer, and a catalytic decomposition layer arranged in sequence, and the surface of the filter material is provided with a high-temperature resistant hydrophobic coating; the automated operation and maintenance module includes a differential pressure monitoring unit, an automatic backflushing cleaning unit, and an intelligent oil discharge and recovery unit; the intelligent control module includes a sensor group, a data processing unit, a control unit, and a remote communication unit.

[0007] As a preferred embodiment of the present invention, the electrostatic adsorption module includes a high-voltage electrostatic generator, an electrode plate assembly, and an insulating support. The electrode plate assembly is fixed in the air intake channel by the insulating support. The high-voltage electrostatic generator is electrically connected to the electrode plate assembly and has an output voltage of 5-30kV, which is used to break down large molecular oil mist and adsorb charged particles.

[0008] As a preferred embodiment of the present invention, the mesh pre-filter layer has a pore size of 50-200μm, is woven from 304 stainless steel or high-temperature alloy material, has a wire diameter of 0.1-0.5mm, and a porosity of 40%-60%.

[0009] As a preferred embodiment of the present invention, the porous ceramic fine filter layer has a pore size of 1-20μm, a porosity of 50%-70%, and is made of cordierite, silicon carbide or alumina-based ceramic, and has interconnected honeycomb flow channels inside.

[0010] As a preferred embodiment of the present invention, the catalytic decomposition layer is composed of a support and a catalytic material loaded on the surface of the support. The support is honeycomb activated carbon or alumina, and the catalytic material is a TiO2 / activated carbon composite material, MnO2 or Pt-Pd alloy, with a loading of 5%-20%.

[0011] As a preferred embodiment of the present invention, the high-temperature resistant hydrophobic coating is made of polytetrafluoroethylene, polyimide or ceramic-based hydrophobic material, the coating thickness is 5-50μm, the contact angle is ≥120°, and the temperature resistance range is -20℃ to 300℃.

[0012] As a preferred embodiment of the present invention, the differential pressure monitoring unit includes a high-precision differential pressure sensor, which is set on both sides of the air inlet and outlet of the composite filter module. The measurement range is 0-5 kPa and the accuracy is ≤ ±0.01 kPa. The differential pressure data is transmitted to the intelligent control module in real time.

[0013] As a preferred embodiment of the present invention, the automatic backflushing cleaning unit includes a pulse backflushing component and an ultrasonic cleaning component. The pulse backflushing component includes an air tank, a solenoid valve, and a nozzle. The nozzle is oriented towards the composite filter material, the working pressure is 0.3-0.8MPa, and the backflushing frequency is 1-10 times / hour. The ultrasonic cleaning component includes an ultrasonic generator and a transducer, the output power is 500-3000W, and the frequency is 20-80kHz.

[0014] As a preferred embodiment of the present invention, the intelligent oil discharge and recovery unit includes an oil-water separation tank, a liquid level sensor, an automatic oil discharge valve, and an oil collection tank, which are installed at the bottom of the composite filtration module. The oil-water separation tank is equipped with an inclined plate separator with a separation efficiency of ≥95%. The liquid level sensor is capacitive or float type. When the oil level reaches 5-15cm, the control unit triggers the automatic oil discharge valve to open and discharge oil.

[0015] As a preferred embodiment of the present invention, it further includes a modular integrated structure, a waste heat recovery module, a dust resource recovery module, a VOCs deep treatment module, and a variable frequency drive module; the modular integrated structure includes standardized functional modules and quick-release connectors, and the functional modules can be flexibly combined; the waste heat recovery module includes a waste heat exchanger, which is set in the purification channel; the dust resource recovery module includes a magnetic separator, a screening machine, and a recovery bin; the VOCs deep treatment module is a low-temperature plasma or photocatalytic oxidation module, which is set at the front end of the gas outlet channel; the variable frequency drive module includes a variable frequency motor and a fan, which are electrically connected to the intelligent control module.

[0016] Compared with the prior art, the present invention has the following beneficial effects: (1) High filtration efficiency and comprehensive purification effect: The synergistic purification technology of electrostatic adsorption + gradient composite filter material can simultaneously and efficiently remove metal dust (removal efficiency ≥99%), oil mist (removal efficiency ≥98%) and VOCs (removal efficiency ≥90%), realizing the triple functions of dust removal, oil removal and odor removal. All indicators of the treated gas meet the environmental protection standards.

[0017] (2) Good anti-clogging effect and long service life: The high temperature resistant hydrophobic coating on the surface of the filter material effectively prevents oil mist from sticking and solidifying. Combined with automatic backflushing + ultrasonic dual-mode cleaning, it can remove dust and oil stains on the surface of the filter material in real time, significantly reducing the probability of clogging. The layered design of the gradient composite filter material extends the overall service life of the filter material, and the replacement cycle is 2-3 times longer than that of traditional filter materials.

[0018] (3) High degree of automation and low maintenance cost: Through differential pressure monitoring, automatic cleaning, intelligent oil drainage, remote monitoring and fault early warning, the equipment can be automatically operated and maintained without the need for regular manual cleaning, reducing downtime, reducing the labor intensity and maintenance cost of maintenance personnel, and improving production efficiency.

[0019] (4) Strong adaptability and flexible installation: The modular integrated structure can flexibly combine the number of modules according to the production line requirements, adapt to single machine or whole line processing, and the quick disassembly design is easy to install, replace and move, and is suitable for powder metallurgy production lines with different layouts.

[0020] (5) Energy saving and consumption reduction, resource recycling: The waste heat recovery module realizes the reuse of high-temperature oil fume waste heat, and the frequency conversion drive module reduces the energy consumption of the fan; the resource recycling of metal dust reduces raw material waste, and the recovered lubricating oil can be recycled, which is in line with the concept of circular economy and reduces the production cost of enterprises.

[0021] (6) Excellent high temperature resistance: The filter material, module shell and all components are made of high temperature resistant materials, which can withstand high temperature oil fumes above 200℃, and are suitable for the flue gas treatment requirements of high temperature processes such as powder metallurgy sintering, thus avoiding equipment failure due to high temperature. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0023] Figure 1 is a schematic diagram of the overall structure of the present invention; Figure 2 is a schematic diagram of the gradient composite filter material structure of the composite filtration module; Figure 3 is a schematic diagram of the structure of the automated operation and maintenance module; Figure 4 is a control logic block diagram of the intelligent control module.

[0024] In the diagram: 1-Intake channel; 2-Pretreatment module; 3-Composite filter module; 31-Metal wire mesh pre-filter layer; 32-Porous ceramic fine filter layer; 33-Catalytic decomposition layer; 34-High temperature resistant hydrophobic coating; 4-Purification channel; 5-Outlet channel; 6-Intelligent control module; 61-Sensor group; 611-Differential pressure sensor; 612-Temperature sensor; 613-Humidity sensor; 614-Particulate matter concentration sensor; 615-VOCs concentration sensor; 62-Data processing unit; 63-Control unit; 64-Remote communication unit 7-Automatic Operation and Maintenance Module; 71-Differential Pressure Monitoring Unit; 72-Automatic Backflushing Cleaning Unit; 721-Pulse Backflushing Component; 7211-Air Storage Tank; 7212-Solenoid Valve; 7213-Nozzle; 722-Ultrasonic Cleaning Component; 7221-Ultrasonic Generator; 7222-Transducer; 73-Intelligent Oil Drainage and Recovery Unit; 731-Oil-Water Separation Tank; 732-Liquid Level Sensor; 733-Automatic Oil Drain Valve; 734-Oil Collection Tank; 8-Modular Integrated Structure; 9-Waste Heat Recovery Module; 10-Dust Resource Recovery Module. Detailed Implementation

[0025] To make the technical problems solved by the present invention, the technical solutions adopted, and the technical effects achieved clearer, the technical solutions of the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] An automatic filtration and fume removal device for powder metallurgy includes an air inlet channel 1, a pretreatment module 2, a composite filtration module 3, a purification channel 4, and an air outlet channel 5 connected in sequence, as well as an intelligent control module 6 electrically connected to each module and an automated operation and maintenance module 7 that cooperates with the composite filtration module 3; it also includes a modular integrated structure 8, a waste heat recovery module 9, a dust resource recovery module 10, a VOCs deep treatment module, and a frequency conversion drive module.

[0027] Pretreatment module 2: This is an electrostatic adsorption module, including a high-voltage electrostatic generator, electrode plate assembly, and insulating support. The electrode plate assembly is fixed inside the air inlet channel 1 via the insulating support and is electrically connected to the high-voltage electrostatic generator. The output voltage is 5-30kV, which can be dynamically adjusted according to the oil fume concentration. Its function is to pretreat the mixed pollutants entering the device, using the principle of electrostatic adsorption to capture charged metal dust and oil mist particles. At the same time, the high-voltage electrostatic field can break down some large-molecule oil mist, reducing the processing load of the downstream composite filtration module 3 and improving the overall purification efficiency.

[0028] Composite filtration module 3: The core component is a gradient composite filter material, which adopts a three-layer structure of "metal wire mesh pre-filtration layer 31 + porous ceramic fine filtration layer 32 + catalytic decomposition layer 33", and each layer of filter material is provided with a high temperature resistant hydrophobic coating 34.

[0029] Metal wire mesh pre-filter layer 31: Woven from 304 stainless steel or high-temperature alloy, with a mesh size of 50-200μm, a wire diameter of 0.1-0.5mm, and a porosity of 40%-60%. It is mainly used to intercept large metal dust particles (particle size ≥50μm) in mixed pollutants, to prevent large particles from clogging the subsequent fine filter layer and to extend the overall service life of the filter material.

[0030] Porous ceramic fine filter layer 32: The material is cordierite, silicon carbide or alumina-based ceramic with a pore size of 1-20μm and a porosity of 50%-70%. It has interconnected honeycomb flow channels inside, which can not only efficiently capture fine oil mist particles (particle size 1-50μm), but also achieve oil-water separation. After the oil mist condenses on the surface of the filter material, it flows down along the flow channels and enters the bottom oil-water separation tank 731.

[0031] Catalytic decomposition layer 33: Using honeycomb activated carbon or alumina as a carrier, it supports catalytic materials such as TiO2 / activated carbon composite material, MnO2 or Pt-Pd alloy, with a loading of 5%-20%, and is used to catalytically decompose VOCs in mixed pollutants to achieve deodorization and make the treated gas free of irritating odor.

[0032] High-temperature resistant hydrophobic coating 34: The material is polytetrafluoroethylene, polyimide or ceramic-based hydrophobic material, the coating thickness is 5-50μm, the contact angle is ≥120°, the temperature range is -20℃-300℃, which can effectively prevent oil mist from adhering and solidifying on the filter material surface, reduce the probability of clogging, and facilitate subsequent backflushing and cleaning.

[0033] The automated operation and maintenance module 7 includes a differential pressure monitoring unit 71, an automatic backflushing and cleaning unit 72, and an intelligent oil drainage and recovery unit 73, enabling automated maintenance without downtime.

[0034] Differential pressure monitoring unit 71: Composed of high-precision differential pressure sensors 611, it is set on both sides of the air inlet and outlet of the composite filter module 3. The measurement range is 0-5kPa and the accuracy is ≤±0.01kPa. It collects the differential pressure data on both sides of the filter material in real time and transmits it to the intelligent control module 6 to determine the degree of filter material blockage.

[0035] Automatic backflushing cleaning unit 72: Includes pulse backflushing component 721 and ultrasonic cleaning component 722, which work together. Pulse backflushing component 721 consists of air tank 7211, solenoid valve 7212, and nozzles 7213. The nozzles 7213 are evenly distributed on the air outlet side of the composite filter media. The working pressure is 0.3-0.8 MPa, and the backflushing frequency can be dynamically adjusted according to the pressure difference data (1-10 times / hour). It removes dust adhering to the filter media surface through high-pressure pulsed airflow. Ultrasonic cleaning component 722 includes ultrasonic generator 7221 and transducer 7222, with an output power of 500-3000W and a frequency of 20-80kHz. It uses the ultrasonic oscillation effect to peel off oil and dirt adhering to the filter media surface, ensuring the filter media restores its filtration performance. When the pressure difference reaches the set threshold (0.3-0.5 kPa), intelligent control module 6 automatically starts dual-mode cleaning. Cleaning stops when the pressure difference drops below the threshold after completion.

[0036] The intelligent oil discharge and recovery unit 73 includes an oil-water separation tank 731, a liquid level sensor 732, an automatic oil discharge valve 733, and an oil collection tank 734. The oil-water separation tank 731 is located at the bottom of the composite filter module 3 and contains an inclined plate separator with a separation efficiency of ≥95%. It is used to collect the oil flowing down from the filter media and separate it from the water. The liquid level sensor 732 is either capacitive or float-type, monitoring the oil level in real time. When the level reaches 5-15cm, the intelligent control module 6 triggers the automatic oil discharge valve 733 to open, discharging the separated oil into the oil collection tank 734 for recovery. The recovered lubricating oil can be purified and reused for equipment lubrication. The separated wastewater is piped to the factory's wastewater treatment system to avoid secondary pollution.

[0037] Intelligent control module 6: As the control core of the device, it includes sensor group 61, data processing unit 62, control unit 63 and remote communication unit 64.

[0038] Sensor group 61: In addition to differential pressure sensor 611, it also includes temperature sensor 612 (measuring range -20℃ to 300℃, accuracy ±0.5℃), humidity sensor 613 (measuring range 0% to 100% RH, accuracy ±2% RH), and particulate matter concentration sensor 614 (measuring range 0-100 mg / m³). 3 Accuracy ±0.1 mg / m 3 The VOCs concentration sensor 615 (measurement range 0-1000ppm, accuracy ±1ppm) is used to monitor the temperature, humidity, particulate matter concentration and VOCs concentration of cooking fumes, respectively.

[0039] Data processing unit 62: It adopts a microcontroller or PLC controller to receive data transmitted from various sensors, analyze and process the data, and generate control commands; at the same time, it stores the equipment operating parameters (such as differential pressure, temperature, concentration, backflushing frequency, oil discharge frequency, etc.).

[0040] Control unit 63: According to the instructions of data processing unit 62, it controls the voltage of electrostatic adsorption module, the working status of automatic backflushing cleaning unit 72, the start and stop of intelligent oil drainage and recovery unit 73, and the speed of variable frequency drive module 12.

[0041] Remote communication unit 64: Based on Internet of Things (IoT) technology, it supports 4G / 5G / Wi-Fi communication and uploads device operation data to the cloud platform in real time. Users can remotely view the device operation status through a mobile APP or computer client. It also has a fault warning function. When filter media is damaged, motor fails, or sensor is abnormal, it will automatically send alarm information to the user and generate maintenance suggestions to achieve predictive maintenance.

[0042] Modular integrated structure 8: Filtration, purification, backflushing, oil drainage, and deep VOCs treatment functions are integrated into standardized modules. These modules are connected via quick-release connectors (such as flanges and clips), allowing for easy assembly and disassembly. It can be customized to accommodate different production lines' oil fume emissions (500-10000m³). 3 / h), flexibly combine the number of modules to adapt to the independent processing needs of single equipment (such as press, sintering furnace) or the centralized processing needs of the whole line; the module shell is made of high temperature resistant alloy material, and the internal flow channel design is optimized to reduce airflow resistance loss, while reducing the size of the equipment and saving workshop installation space.

[0043] Waste heat recovery module 9: includes a waste heat exchanger 91, installed within the purification channel 4, employing a shell-and-tube or plate heat exchange structure, with a heat exchange area of ​​5-50 m². 2 The heat exchange efficiency is ≥80%. The high temperature (100-200℃) of sintering oil fumes is used to preheat the workshop air supply or production water through the waste heat exchanger 91, realizing the cascade utilization of energy and reducing the overall energy consumption of the factory.

[0044] The dust resource recovery module includes a magnetic separator, a screening machine, and a recovery bin. The magnetic separator is used to separate the metal dust collected by the pretreatment module 2 and the composite filtration module 3, separating ferromagnetic dust (such as iron powder). The screening machine is used to screen metal dust of different particle sizes (particle size ≥ 1μm). The screened metal dust is stored in the recovery bin, and after purification, it can be reused in powder metallurgy batching, reducing raw material waste and realizing resource recycling.

[0045] The VOCs deep treatment module, located at the front end of the exhaust channel 5, is either a low-temperature plasma module or a photocatalytic oxidation module. It is used to deeply degrade the VOCs remaining after treatment by the composite filter module 3. The low-temperature plasma module has a discharge power of 1-10kW and a degradation efficiency ≥90%. The photocatalytic oxidation module uses UV lamps (wavelength 254nm or 185nm) and TiO2 photocatalysts, achieving a degradation efficiency ≥95%, ensuring that the VOCs concentration in the treated gas meets relevant environmental standards such as GB 37822-2019 "Standard for the Control of Unorganized Emissions of Volatile Organic Compounds". Simultaneously, a portion of the treated clean gas can be returned to the workshop to regulate the slightly positive pressure environment and prevent external dust from entering.

[0046] Variable frequency drive module: includes a variable frequency motor and a fan, with the fan connected to the variable frequency motor, and is located at the end of the air outlet channel 5 or the front of the air inlet channel 1, with an air volume range of 500-10000 m³ / h. 3The air pressure range is 500-5000Pa. The variable frequency motor is electrically connected to the intelligent control module 6. Based on the real-time data from the particulate matter concentration sensor 614 and the VOCs concentration sensor 615, the fan speed is automatically adjusted. The speed is reduced under low load and increased under high load, reducing power consumption while ensuring purification effect. Compared with the traditional fixed speed fan 122, it saves 30%-50% energy.

[0047] Example 1, as shown in Figures 1-4, describes an automatic filtration and fume removal device for powder metallurgy, comprising an air inlet channel 1, a pretreatment module 2, a composite filtration module 3, a purification channel 4, an air outlet channel 5 connected in sequence, as well as an intelligent control module 6, an automated operation and maintenance module 7, a modular integrated structure 8, a waste heat recovery module 9, a dust resource recovery module 10, a VOCs deep treatment module, and a frequency conversion drive module.

[0048] Pretreatment module 2 is an electrostatic adsorption module. The high-voltage electrostatic generator outputs a voltage of 15kV. The electrode plate group is made of titanium alloy and is fixed in the air intake channel 1 by an insulating bracket. The air intake channel 1 is made of stainless steel and has an inner diameter of 500mm.

[0049] In the gradient composite filter media of the composite filter module 3, the metal wire mesh pre-filtration layer 31 has a mesh size of 100μm, a wire diameter of 0.3mm, and a porosity of 50%; the porous ceramic fine filtration layer 32 is made of cordierite, with a pore size of 10μm, a porosity of 60%, and a honeycomb channel pore size of 8mm; the catalytic decomposition layer 33 uses honeycomb activated carbon as a carrier and loads TiO2 / activated carbon composite material with a loading of 10%; the high-temperature resistant hydrophobic coating 34 is made of polytetrafluoroethylene, with a coating thickness of 20μm, a contact angle of 135°, and a temperature resistance range of -20℃ to 280℃.

[0050] In the automated operation and maintenance module 7, the differential pressure sensor 611 has a measurement range of 0-5 kPa and an accuracy of ±0.01 kPa; the pulse backflushing component 721 has a working pressure of 0.5 MPa and a backflushing frequency of 5 times / hour; the number of nozzles 7213 is 12, evenly distributed; the ultrasonic cleaning component 722 has an output power of 1500 W and a frequency of 40 kHz; the oil-water separation tank 731 has a volume of 50 L, the inclination angle of the internal inclined plate separator is 45°, the liquid level sensor 732 is capacitive, the oil level threshold is set to 10 cm, the automatic oil drain valve 733 is an electric ball valve, and the oil collection tank 734 has a volume of 100 L.

[0051] The data processing unit 62 of the intelligent control module 6 adopts a PLC controller (model S7-200SMART), the remote communication unit 64 supports 4G and Wi-Fi communication, and the cloud platform can realize data storage, curve analysis, fault alarm and other functions; in the sensor group 61, the temperature sensor 612 has a measurement range of -20℃ to 300℃, the humidity sensor 613 has a measurement range of 0% to 100%RH, the particulate matter concentration sensor 614 has a measurement range of 0 to 100mg / m³, and the VOCs concentration sensor 615 has a measurement range of 0 to 1000ppm.

[0052] The standardized functional modules of the modular integrated structure 8 include a pretreatment module, a composite filtration module, and a VOCs deep treatment module. Each module measures 1000mm×800mm×1500mm. The quick-release connectors are flange connections, and the bolts are made of stainless steel. The module shell is made of 316L stainless steel, and the internal flow channels have been optimized by fluid mechanics, with a resistance loss of ≤500Pa.

[0053] The waste heat recovery module 9 has a shell-and-tube heat exchanger 91 with a heat exchange area of ​​20m² and a heat exchange efficiency of 85%. It is connected to the workshop air supply system through pipelines, and the temperature of the preheated air can be increased by 30-50℃.

[0054] The magnetic separator of the dust resource recovery module is a drum type with a magnetic field strength of 10000Gs, the screen aperture of the screening machine is 1μm, the volume of the recovery bin is 500L, and the metal dust recovery rate is ≥95%.

[0055] The VOCs deep treatment module uses a low-temperature plasma module with a discharge power of 5kW and a VOCs degradation efficiency of ≥92%; the inner diameter of the gas outlet channel 5 is 500mm, and a rain cover is provided at the end.

[0056] The variable frequency drive module has a centrifugal fan with an air volume range of 2000-5000 m³ / h and an air pressure range of 1000-3000 Pa. The variable frequency motor has a power of 7.5 kW and a speed range of 5-50 Hz. It is electrically connected to the intelligent control module 6 and automatically adjusts the speed according to the particulate matter concentration and VOCs concentration.

[0057] The working process of this embodiment is as follows: Start the device, the fan of the variable frequency drive module starts to run, and the oil fumes, metal dust and VOCs mixed pollutants generated in the powder metallurgy production process enter the device through the air intake channel 1.

[0058] The mixed pollutants first enter the pretreatment module 2 (electrostatic adsorption module). The high-voltage electrostatic generator 2 generates a high-voltage electrostatic field in the electrode plate group. Charged metal dust and oil mist particles are adsorbed by the electrode plates, and large molecular oil mist is broken down into small molecules, thus completing the pretreatment.

[0059] The pretreated pollutants enter the composite filtration module 3. The metal wire mesh pre-filtration layer 31 intercepts large metal dust particles (particle size ≥ 50 μm), and the porous ceramic fine filtration layer 32 captures fine oil mist particles (particle size 1-50 μm) and achieves oil-water separation. The oil flows into the bottom oil-water separation tank 731 along the flow channel, and the catalytic decomposition layer 33 catalyzes and decomposes VOCs to achieve deodorization.

[0060] The waste heat exchanger 91 in the purification channel 4 uses the waste heat of the high-temperature purified gas to preheat the workshop air supply, thereby realizing waste heat recovery; then the gas enters the VOCs deep treatment module 11, where residual VOCs are deeply degraded and finally discharged through the gas outlet channel 5.

[0061] During operation, the differential pressure sensor 611 monitors the pressure difference across the composite filter media in real time. When the pressure difference reaches 0.4 kPa, the intelligent control module 6 starts the automatic backflushing cleaning unit 72. The pulse backflushing component 721 and the ultrasonic cleaning component 722 work together to remove dust and oil stains from the surface of the filter media. The level sensor 732 in the oil-water separation tank 731 monitors the oil level. When it reaches 10 cm, the automatic oil drain valve 733 opens, and the oil is discharged into the oil collection tank 734 for recycling.

[0062] The metal dust collected by the pretreatment module 2 and the composite filtration module 3 falls into the dust resource recovery module 10. After being separated by a magnetic separator and screened by a screening machine, it is stored in the recovery bin and purified for reuse in production.

[0063] The intelligent control module 6 uploads data from various sensors to the cloud platform in real time. Users can remotely monitor the equipment's operating status through a mobile app or computer client. When issues such as filter media damage or motor failure occur, the equipment will automatically alarm and generate maintenance suggestions.

[0064] The device in this embodiment was tested and found to have a metal dust removal efficiency of 99.5%, an oil mist removal efficiency of 98.8%, a VOCs removal efficiency of 92.3%, and no obvious clogging of the filter material during operation. The pressure difference recovery rate after backflushing was 98%, the fan energy saving rate was 40%, and the metal dust recovery rate was 96%, which fully meets the purification and production needs of the powder metallurgy industry.

[0065] Example 2 The difference between this example and Example 1 is that the high voltage electrostatic generator of the pretreatment module 2 has an output voltage of 25kV and the electrode plate group is made of stainless steel.

[0066] The porous ceramic fine filter layer 32 of the composite filter module 3 is made of silicon carbide with a pore size of 5μm and a porosity of 65%; the catalytic decomposition layer 33 uses alumina as a carrier and loads Pt-Pd alloy with a loading of 8%; the high-temperature resistant hydrophobic coating 34 uses ceramic-based hydrophobic material with a coating thickness of 30μm and a contact angle of 140°.

[0067] The automatic backflush cleaning unit 721 operates at a pressure of 0.7 MPa and a backflush frequency of 8 times per hour; the ultrasonic cleaning component 722 has an output power of 2500 W and a frequency of 60 kHz.

[0068] The VOCs deep treatment module uses a photocatalytic oxidation module with a UV lamp wavelength of 185nm, a TiO2 photocatalyst loading of 15%, and a VOCs degradation efficiency of 95.2%.

[0069] The variable frequency drive module has a fan air volume range of 5000-10000m³ / h, a wind pressure range of 2000-5000Pa, and a variable frequency motor power of 15kW.

[0070] The device in this embodiment is suitable for centralized processing in large-scale powder metallurgy production lines. After testing, the metal dust removal efficiency is 99.8%, the oil mist removal efficiency is 99.2%, the VOCs removal efficiency is 95.2%, the fan energy saving rate is 35%, and the metal dust recovery rate is 97%, with excellent performance indicators.

[0071] Example 3 The difference between this example and Example 1 is that the high voltage electrostatic generator of the pretreatment module 2 has an output voltage of 8kV and the electrode plate group is made of aluminum alloy.

[0072] The metal wire mesh pre-filtration layer 31 of the composite filter module 3 has a mesh size of 50μm, a wire diameter of 0.2mm, and a porosity of 45%; the porous ceramic fine filtration layer 32 is made of alumina-based ceramic with a pore size of 15μm and a porosity of 55%; and the catalytic decomposition layer 33 is loaded with MnO2 with a loading of 15%.

[0073] The waste heat recovery module 9 has a plate-type waste heat exchanger 91 with a heat exchange area of ​​10m² and a heat exchange efficiency of 82%. It is connected to the production water pipeline and can raise the water temperature by 20-30℃ after preheating.

[0074] The magnetic separator of the dust resource recovery module 10 is a flat plate type with a magnetic field strength of 8000Gs, and the screen aperture of the screening machine is 5μm.

[0075] The variable frequency drive module has a fan air volume range of 500-2000m³ / h, a wind pressure range of 500-1500Pa, and a variable frequency motor power of 3kW.

[0076] The device in this embodiment is suitable for independent processing of single-unit equipment (such as small sintering furnaces). It is compact in size and flexible in installation. After testing, the metal dust removal efficiency is 99.2%, the oil mist removal efficiency is 98.5%, the VOCs removal efficiency is 90.5%, the fan energy saving rate is 45%, and the metal dust recovery rate is 94%, which meets the environmental protection requirements of single-unit production.

[0077] Precautions: When installing the device, ensure that all modules are properly sealed to prevent gas leakage; the air inlet channel 1 should be as close as possible to the pollution source to shorten the flue gas delivery distance and reduce resistance loss.

[0078] Regularly check the high-temperature resistant hydrophobic coating on the surface of the filter media for integrity. If damage is found, repair or replace the filter media in time. The catalytic material of the catalytic decomposition layer has a service life of 1-2 years and needs to be replaced after the expiration date.

[0079] The oil-water separator 731 and the oil collection tank 734 should be cleaned regularly to remove sediment and prevent pipe blockage. The recovered lubricating oil should be purified (such as filtered and dehydrated) before use to ensure lubrication effect.

[0080] The electrostatic adsorption module generates high voltage during operation, so proper grounding is necessary to prevent electric shock. During maintenance, the power should be disconnected first, and the operation should only be carried out after the electrode plate group has discharged.

[0081] The sensors in the intelligent control module 6 should be calibrated regularly to ensure accurate measurement data; the cloud platform needs to be updated regularly to ensure normal remote monitoring and communication functions.

[0082] If a continuous increase in differential pressure or a decrease in purification efficiency occurs during the operation of the device, it may be due to severe clogging or damage of the filter media. The machine should be stopped immediately for inspection and repair.

[0083] This invention solves many defects of existing powder metallurgy fume removal devices through the integration of multiple technologies and structural innovation. It has the advantages of high filtration efficiency, anti-clogging, high degree of automation, strong adaptability, energy saving and consumption reduction, and resource recycling. It can be widely used in various powder metallurgy production scenarios and has significant economic value, environmental value and market promotion prospects.

[0084] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. An automatic filtration and fume removal device for powder metallurgy, characterized in that, The system includes an intake channel, a pretreatment module, a composite filtration module, a purification channel, and an exhaust channel connected in sequence, as well as an intelligent control module electrically connected to each module and an automated operation and maintenance module that works in conjunction with the composite filtration module. The pretreatment module is an electrostatic adsorption module used to pre-capture charged metal dust and oil mist particles. The composite filtration module includes a gradient composite filter material, which consists of a metal wire mesh pre-filtration layer, a porous ceramic fine filtration layer, and a catalytic decomposition layer arranged in sequence, and the surface of the filter material is provided with a high-temperature resistant hydrophobic coating. The automated operation and maintenance module includes a differential pressure monitoring unit, an automatic backflushing cleaning unit, and an intelligent oil drainage and recovery unit. The intelligent control module includes a sensor group, a data processing unit, a control unit, and a remote communication unit.

2. The automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, The electrostatic adsorption module includes a high-voltage electrostatic generator, an electrode plate assembly, and an insulating support. The electrode plate assembly is fixed in the air intake channel by the insulating support. The high-voltage electrostatic generator is electrically connected to the electrode plate assembly and has an output voltage of 5-30kV. It is used to break down large molecular oil mist and adsorb charged particles.

3. The automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, The metal wire mesh pre-filter layer has a mesh size of 50-200μm, is woven from 304 stainless steel or high-temperature alloy material, has a wire diameter of 0.1-0.5mm, and a porosity of 40%-60%.

4. The automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, The porous ceramic fine filter layer has a pore size of 1-20μm and a porosity of 50%-70%. It is made of cordierite, silicon carbide or alumina-based ceramic and has interconnected honeycomb channels inside.

5. The automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, The catalytic decomposition layer consists of a support and a catalytic material loaded on the surface of the support. The support is honeycomb activated carbon or alumina, and the catalytic material is a TiO2 / activated carbon composite material, MnO2 or Pt-Pd alloy, with a loading of 5%-20%.

6. The automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, The high-temperature resistant hydrophobic coating is made of polytetrafluoroethylene, polyimide, or ceramic-based hydrophobic material, with a coating thickness of 5-50 μm, a contact angle ≥120°, and a temperature resistance range of -20℃ to 300℃.

7. An automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, The differential pressure monitoring unit includes a high-precision differential pressure sensor, which is installed on both sides of the air inlet and outlet of the composite filter module. The measurement range is 0-5 kPa, and the accuracy is ≤ ±0.01 kPa. It transmits differential pressure data to the intelligent control module in real time.

8. An automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, The automatic backflush cleaning unit includes a pulse backflush component and an ultrasonic cleaning component. The pulse backflush component includes an air tank, a solenoid valve, and a nozzle. The nozzle is oriented towards the composite filter material. The working pressure is 0.3-0.8 MPa, and the backflush frequency is 1-10 times / hour. The ultrasonic cleaning component includes an ultrasonic generator and a transducer. The output power is 500-3000W, and the frequency is 20-80kHz.

9. An automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, The intelligent oil drainage and recovery unit includes an oil-water separation tank, a liquid level sensor, an automatic oil drain valve, and an oil collection tank, all located at the bottom of the composite filtration module. The oil-water separation tank is equipped with an inclined plate separator with a separation efficiency of ≥95%. The liquid level sensor is either capacitive or float-type. When the oil level reaches 5-15cm, the control unit triggers the automatic oil drain valve to open and drain the oil.

10. An automatic filtration and fume removal device for powder metallurgy according to claim 1, characterized in that, It also includes a modular integrated structure, a waste heat recovery module, a dust resource recovery module, a VOCs deep treatment module, and a variable frequency drive module; the modular integrated structure includes standardized functional modules and quick-release connectors, and the functional modules can be flexibly combined; the waste heat recovery module includes a waste heat exchanger, which is set in the purification channel; the dust resource recovery module includes a magnetic separator, a screening machine, and a recovery bin; the VOCs deep treatment module is a low-temperature plasma or photocatalytic oxidation module, which is set at the front end of the gas outlet channel; the variable frequency drive module includes a variable frequency motor and a fan, which are electrically connected to the intelligent control module.

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