Calcium carbide method PVC production system and method integrated with solar heating system

Abstract

The invention relates to the technical field of chemical production equipment and energy conservation, in particular to a calcium carbide method PVC (polyvinyl chloride) production system and method integrated with a solar heating system, a solar heat collector array is connected with a heat storage device, and the heat storage device is connected with a heat exchange device; the heat exchange device is respectively connected with heat supply pipelines of the calcium carbide crushing and feeding device, the acetylene generator, the purification device, the vinyl chloride synthesis tower and the polymerization reaction kettle; the intelligent control system is respectively connected with the solar heat collector array, the heat storage device, the heat exchange device and a sensor on the calcium carbide method PVC production equipment. Solar energy is adopted as an active clean heat source, the solar heat collector array efficiently captures the solar energy and converts the solar energy into heat energy, stable heat energy storage is achieved in cooperation with the heat storage device made of the paraffin or sodium nitrate composite phase-change material, and fossil energy consumption of a traditional coal-fired or gas-fired boiler is greatly replaced.

Description

Technical Field

[0001] This invention relates to the field of chemical production equipment and energy-saving technology, specifically to a calcium carbide PVC production system and method with an integrated solar heating system. Background Technology

[0002] Polyvinyl chloride (PVC), as one of the five major general-purpose plastics, occupies an indispensable position in many fields such as building materials, industrial products, and daily necessities, and widely serves all aspects of social production and life.

[0003] However, the calcium carbide-based PVC production process is characterized by significant high energy consumption from start to finish, making it a typical high-energy-consuming chemical industry. The core processes, especially the acetylene production via calcium carbide hydrolysis and the vinyl chloride monomer polymerization, have strict temperature requirements—the calcium carbide hydrolysis reaction needs to be maintained at 75-85℃, and the vinyl chloride polymerization reaction needs to be controlled within the 50-60℃ range. Both of these critical processes require a continuous and stable supply of large amounts of heat energy. For a long time, the industry has generally relied on coal-fired or gas-fired boilers to provide heat for these processes. This heating model not only consumes huge amounts of non-renewable fossil fuels such as coal and natural gas, exacerbating the energy shortage, but also leads to the emission of large amounts of greenhouse gases and pollutants such as carbon dioxide and sulfides. This exposes companies to increasingly stringent environmental policies, and the fluctuation of fossil fuel prices also brings significant uncertainty to production costs, hindering the sustainable development of the calcium carbide-based PVC industry.

[0004] To address the dual challenges of energy consumption and environmental pollution, the industry has begun actively exploring the application of renewable energy in chemical production, aiming to achieve a green transformation of the industry. Among these efforts, Chinese patent CN102515165B discloses a device for producing calcium carbide using solar energy. This technology innovatively attempts to directly provide high-temperature heat energy (up to 2000℃) to the calcium carbide furnace using solar heating equipment, while simultaneously recovering waste heat generated during the calcium carbide cooling process for power generation. This provides a valuable exploration for the integration of solar energy with calcium carbide-related industries.

[0005] However, the aforementioned existing technologies still have significant limitations: First, the technology focuses on the extremely high-temperature process of calcium carbide preparation, while failing to provide targeted heating solutions for the crucial acetylene generation and vinyl chloride polymerization stages in the subsequent processes of calcium carbide-based PVC production, thus failing to cover the core thermal energy needs of the entire production process. Second, the technology is designed for extremely high-temperature scenarios of 2000℃, which is technically difficult to implement and has high equipment investment costs, making it difficult to directly adapt to medium- and low-temperature thermal demand scenarios such as acetylene generation and polymerization reactions. More importantly, solar energy itself has inherent intermittency and volatility, significantly affected by day-night cycles, weather conditions such as sunshine, rain, and snow. Chemical production has extremely high requirements for the continuity and stability of thermal energy supply. Existing technologies lack efficient heat storage and regulation mechanisms that can effectively balance the contradiction between the volatility of solar energy and production stability, making it difficult for solar energy to truly replace traditional fossil fuels as a reliable heat source in the key processes of calcium carbide-based PVC production. Summary of the Invention

[0006] To address the problems existing in the prior art, the present invention provides a calcium carbide PVC production system and method with an integrated solar heating system.

[0007] To achieve the above objectives, the technical solution of the present invention is as follows:

[0008] A calcium carbide-based PVC production system integrating a solar heating system includes calcium carbide-based PVC production equipment and a solar heating system. The calcium carbide-based PVC production equipment includes a calcium carbide crushing and feeding device, an acetylene generator, a purification device, a vinyl chloride synthesis tower, and a polymerization reactor connected in sequence. The solar heating system includes a solar collector array, a heat storage device, a heat exchange device, and an intelligent control system. The solar collector array is connected to the heat storage device, and the heat storage device is connected to the heat exchange device. The heat exchange device is connected to the heating pipelines of the calcium carbide crushing and feeding device, the acetylene generator, the purification device, the vinyl chloride synthesis tower, and the polymerization reactor. The intelligent control system is connected to sensors on the solar collector array, the heat storage device, the heat exchange device, and the calcium carbide-based PVC production equipment.

[0009] Furthermore, the solar collector array is a flat plate collector or a vacuum tube collector, and the solar collector array is located in an open area with good lighting.

[0010] Furthermore, the heat storage device uses a phase change heat storage material, which is a composite phase change material of paraffin or sodium nitrate.

[0011] Furthermore, the heat exchange device is a shell-and-tube heat exchanger or a plate heat exchanger.

[0012] Furthermore, the sensors include a temperature sensor, a light sensor, and a flow sensor. The temperature sensor is respectively installed on the calcium carbide crushing and feeding device, the acetylene generator, the purification device, the vinyl chloride synthesis tower, the polymerization reactor, the solar collector array, and the heat storage device. The light sensor is installed on the solar collector array, and the flow sensor is installed on the pipeline of the heat exchange device.

[0013] This invention also includes the following technical solutions:

[0014] A method for producing calcium carbide-based PVC based on the above-mentioned integrated solar heating system includes the following steps:

[0015] S1. Solar radiation energy is captured by a solar collector array and converted into heat energy, which is then transported to a heat storage device for storage.

[0016] S2. The intelligent control system monitors the process temperature of the calcium carbide PVC production equipment in real time.

[0017] S3. When the process temperature of the calcium carbide PVC production equipment is detected to be lower than the required production temperature range, the intelligent control system controls the heat storage device to release heat energy and transfers the heat energy to the heating pipeline of the corresponding equipment through the heat exchange device.

[0018] S4. When the heat energy released by the heat storage device cannot maintain the temperature range required for production, the intelligent control system automatically switches to or turns on the traditional heat source for supplementary heating.

[0019] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0020] This invention provides a calcium carbide PVC production system and method integrating a solar heating system. It utilizes solar energy as an active clean heat source, efficiently capturing solar energy and converting it into heat energy through a solar collector array. Combined with a heat storage device using paraffin or sodium nitrate composite phase change material, it achieves stable heat energy storage, significantly replacing the fossil fuel consumption of traditional coal-fired or gas-fired boilers, substantially reducing energy costs for enterprises, and simultaneously reducing carbon dioxide and pollutant emissions, thus contributing to the green transformation of the industry. Through a smart control system that dynamically regulates the collector tracking angle, heat storage device charging and discharging, and heat exchange efficiency, combined with a complementary heating mechanism to traditional heat sources, it effectively balances the contradiction between the intermittency and volatility of solar energy and the continuity and stability of chemical production, ensuring smooth production. Attached Figure Description

[0021] The embodiments of the present invention will be further described below with reference to the accompanying drawings, wherein:

[0022] Figure 1A schematic diagram of an embodiment of a calcium carbide-based PVC production system with an integrated solar heating system is shown.

[0023] Figure reference numerals: 101-Calcium carbide crushing and feeding device, 102-Acetylene generator, 103-Purification device, 104-Vinyl chloride synthesis tower, 105-Polymerization reactor, 201-Solar collector array, 202-Heat storage device, 203-Heat exchange device, 204-Intelligent control system. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0025] Reference Appendix Figure 1 A calcium carbide-based PVC production system integrating a solar heating system includes calcium carbide-based PVC production equipment and a solar heating system. The calcium carbide-based PVC production equipment includes a calcium carbide crushing and feeding device 101, an acetylene generator 102, a purification device 103, a vinyl chloride synthesis tower 104, and a polymerization reactor 105 connected in sequence. The solar heating system includes a solar collector array 201, a heat storage device 202, a heat exchange device 203, and an intelligent control system 204. The solar collector array 201 is connected to the heat storage device 202 for capturing… Solar energy is converted into heat energy and transmitted to the heat storage device 202; the heat storage device 202 is connected to the heat exchange device 203 to store heat energy and transmit heat energy to the heat exchange device 203; the heat exchange device 203 is connected to the heating pipelines of the calcium carbide crushing and feeding device 101, the acetylene generator 102, the purification device 103, the vinyl chloride synthesis tower 104, and the polymerization reactor 105; the intelligent control system 204 is connected to the sensors on the solar collector array 201, the heat storage device 202, the heat exchange device 203, and the calcium carbide PVC production equipment.

[0026] In one embodiment of the present invention, the solar collector array 201 is a flat plate collector or a vacuum tube collector. The selection and layout of the solar collector array 201 are determined based on the distribution of solar energy resources and climate conditions at the location of the production line. The solar collector array 201 is set in an open area with good lighting.

[0027] In one embodiment of the present invention, the heat storage device 202 uses a phase change heat storage material, which is a composite phase change material of paraffin or sodium nitrate. The heat storage device 202 has high heat storage density and stable thermal performance, and is used to store heat energy when solar radiation is sufficient and release heat energy when solar radiation is insufficient.

[0028] In one embodiment of the present invention, the heat exchange device 203 is a shell-and-tube heat exchanger or a plate heat exchanger.

[0029] In one embodiment of the present invention, the sensors include a temperature sensor, a light sensor, and a flow sensor. The temperature sensor is respectively installed on the calcium carbide crushing and feeding device 101, the acetylene generator 102, the purification device 103, the vinyl chloride synthesis tower 104, the polymerization reactor 105, the solar collector array 201, and the heat storage device 202. The light sensor is installed on the solar collector array 201, and the flow sensor is installed on the pipeline of the heat exchange device 203.

[0030] A method for producing calcium carbide-based PVC based on the above-mentioned integrated solar heating system includes the following steps:

[0031] S1. Solar radiation energy is captured by solar collector array 201 and converted into heat energy, which is then transported to heat storage device 202 for storage.

[0032] S2. The intelligent control system 204 monitors the process temperature of the calcium carbide PVC production equipment in real time. The preset algorithm of the intelligent control system 204 is formulated based on the production process temperature requirements and the real-time data collected by the sensors. It is used to automatically adjust the tracking angle of the solar collector, the charging and discharging process of the heat storage device, and the heat exchange efficiency of the heat exchange device.

[0033] S3. When the process temperature of the calcium carbide PVC production equipment is detected to be lower than the temperature range required for production, the intelligent control system 204 controls the heat storage device 202 to release heat energy, and transfers the heat energy to the heating pipeline of the corresponding equipment through the heat exchange device 203.

[0034] S4. When the heat energy released by the heat storage device 202 cannot maintain the temperature range required for production, the intelligent control system 204 automatically switches or turns on the traditional heat source to supplement the heat supply.

[0035] This invention provides a calcium carbide PVC production system and method integrating a solar heating system. It utilizes solar energy as an active clean heat source, efficiently capturing solar energy and converting it into heat energy through a solar collector array. Combined with a heat storage device using paraffin or sodium nitrate composite phase change material, it achieves stable heat energy storage, significantly replacing the fossil fuel consumption of traditional coal-fired or gas-fired boilers, substantially reducing energy costs for enterprises, and simultaneously reducing carbon dioxide and pollutant emissions, thus contributing to the green transformation of the industry. Through a smart control system that dynamically regulates the collector tracking angle, heat storage device charging and discharging, and heat exchange efficiency, combined with a complementary heating mechanism to traditional heat sources, it effectively balances the contradiction between the intermittency and volatility of solar energy and the continuity and stability of chemical production, ensuring smooth production.

[0036] The foregoing descriptions have outlined some exemplary embodiments of the present invention. It is understood that these embodiments are merely illustrative and do not constitute a limitation on the scope of protection of the present invention. Features in these embodiments can be rearranged in suitable ways, and the resulting solutions remain within the scope of protection claimed by the present invention. All other embodiments obtained by those skilled in the art based on the foregoing embodiments without inventive effort, i.e., all modifications, equivalent substitutions, and improvements made within the spirit and principles of this application, fall within the scope of protection claimed by the present invention.

Claims

1. A calcium carbide-based PVC production system integrating a solar heating system, characterized in that, The system includes calcium carbide-based PVC production equipment and a solar heating system. The calcium carbide-based PVC production equipment comprises, in sequence, a calcium carbide crushing and feeding device (101), an acetylene generator (102), a purification device (103), a vinyl chloride synthesis tower (104), and a polymerization reactor (105). The solar heating system comprises a solar collector array (201), a heat storage device (202), a heat exchange device (203), and an intelligent control system (204). The solar collector array (201) is connected to the heat storage device (202). The heat storage device (202) is connected to the heat exchange device (203); the heat exchange device (203) is connected to the heating pipelines of the calcium carbide crushing and feeding device (101), the acetylene generator (102), the purification device (103), the vinyl chloride synthesis tower (104), and the polymerization reactor (105); the intelligent control system (204) is connected to the solar collector array (201), the heat storage device (202), the heat exchange device (203), and the sensors on the calcium carbide PVC production equipment.

2. The calcium carbide PVC production system with integrated solar heating system according to claim 1, characterized in that, The solar collector array (201) is a flat plate collector or a vacuum tube collector, and the solar collector array (201) is located in an open area with good lighting.

3. The calcium carbide-based PVC production system with an integrated solar heating system according to claim 1, characterized in that, The heat storage device (202) uses a phase change heat storage material, which is a composite phase change material of paraffin or sodium nitrate.

4. The calcium carbide PVC production system with integrated solar heating system according to claim 1, characterized in that, The heat exchange device (203) is a shell-and-tube heat exchanger or a plate heat exchanger.

5. The calcium carbide PVC production system with integrated solar heating system according to claim 1, characterized in that, The sensors include a temperature sensor, a light sensor, and a flow sensor. The temperature sensor is respectively installed on the calcium carbide crushing and feeding device (101), the acetylene generator (102), the purification device (103), the vinyl chloride synthesis tower (104), the polymerization reactor (105), the solar collector array (201), and the heat storage device (202). The light sensor is installed on the solar collector array (201), and the flow sensor is installed on the pipeline of the heat exchange device (203).

6. A method for producing PVC using the system described in any one of claims 1-5, characterized in that, Includes the following steps: S1. Solar radiation energy is captured by a solar collector array (201) and converted into heat energy, which is then transported to a heat storage device (202) for storage. S2, Intelligent Control System (204) monitors the process temperature of calcium carbide PVC production equipment in real time; S3. When the process temperature of the calcium carbide PVC production equipment is detected to be lower than the temperature range required for production, the intelligent control system (204) controls the heat storage device (202) to release heat energy and transfer the heat energy to the heating pipeline of the corresponding equipment through the heat exchange device (203). S4. When the heat energy released by the heat storage device (202) cannot maintain the temperature range required for production, the intelligent control system (204) automatically switches or turns on the traditional heat source to supplement the heat supply.

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