Intelligent carbonization device and carbonization method for recovering CO2 and solid waste

Abstract

The invention relates to the technical field of industrial solid waste resource utilization, and discloses an intelligent carbonization device and method for recovering CO2 and solid waste, the intelligent carbonization device comprises a tail gas treatment system, the tail gas treatment system comprises a gas-solid separation unit, a fly ash bin and a gas separation unit, the gas-solid separation unit is used for receiving power plant tail gas and separating the power plant tail gas into gas and solid, and the gas separation unit is used for separating the gas and the solid; the separated solid enters the fly ash bin, and the separated gas enters the gas separation unit; the multifunctional carbonization reaction kettle, the fly ash bin and the gas separation unit respectively convey CO, N and fly ash into the multifunctional carbonization reaction kettle, and the fly ash is subjected to carbonization modification in the multifunctional carbonization reaction kettle; and the intelligent regulation and control system is used for monitoring and regulating a plurality of parameters in the carbonization reaction process. The method is simple in process and high in intelligent degree, can be directly connected to a power plant tail gas system, effectively solves the problems of low activity of traditional fly ash, delayed carbonization process control and the like, and improves the carbonization efficiency and the product value.

Description

Technical Field

[0001] This invention relates to the field of industrial solid waste resource utilization technology, and in particular to an intelligent carbonization device and carbonization method for recovering CO2 and solid waste. Background Technology

[0002] Currently, coal-fired power plants account for a large proportion of power plants, and high-calcium fly ash (HCFA) is an industrial byproduct of these plants. Due to its high content of free calcium oxide (f-CaO) and active silica-alumina, it possesses certain cementitious activity and can be used as an auxiliary cementitious material in cement and concrete. However, fly ash obtained through traditional electrostatic precipitator (ESP) technology has low carbonation activity. Furthermore, the free calcium oxide (f-CaO) in fly ash readily reacts with water to form calcium hydroxide, leading to volume expansion and potentially causing stability issues in concrete, thus limiting its widespread application in building materials. Improving the carbonation activity of fly ash through supercritical activation devices yields "activated fly ash." Simultaneously, carbonation curing technology utilizes the active components in fly ash (such as Ca(OH)2, CSH, etc.) to react and generate stable calcium carbonate (CaCO3) and silica gel. This not only solidifies CO2 but also improves the volume stability and mechanical properties of fly ash. Dry carbonization curing technology directly carbonizes high-calcium fly ash by controlling environmental humidity, CO2 concentration and reaction temperature, and has advantages such as low energy consumption, fast reaction speed and no need for water resources.

[0003] Therefore, there is an urgent need for an intelligent carbonization device and carbonization method for recovering CO2 and solid waste to solve the above problems. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent carbonization device and carbonization method for recovering CO2 and solid waste, so as to solve the problems existing in the prior art.

[0005] To achieve the above objectives, the present invention provides the following solution: The present invention provides an intelligent carbonization device for recovering CO2 and solid waste, comprising: The exhaust gas treatment system includes a gas-solid separation unit, a fly ash silo, and a gas separation unit. The gas-solid separation unit is used to receive power plant exhaust gas and separate it into gas and solid. The separated solid enters the fly ash silo, and the separated gas enters the gas separation unit. A multifunctional carbonization reactor, wherein the fly ash silo and the gas separation unit respectively supply CO2, N2 and fly ash into the multifunctional carbonization reactor, and the fly ash undergoes carbonization modification in the multifunctional carbonization reactor; The intelligent control system is used to monitor and adjust multiple parameters during the carbonization reaction process.

[0006] Preferably, the gas-solid separation unit includes a supercritical conversion / mixing unit, a supercritical activator, and a supercritical centrifuge connected in sequence. The supercritical conversion / mixing unit is used to receive power plant tail gas, and the fly ash silo and the gas separation unit are respectively connected to the output end of the supercritical centrifuge.

[0007] Preferably, the supercritical conversion / mixing unit includes an exhaust gas buffer tank, a main heater, and a supercritical homogenizer connected in sequence, and the main heater is equipped with a multi-stage series compressor.

[0008] Preferably, the supercritical activator is equipped with an ultrasonic cavitation generator and a precision injection system.

[0009] Preferably, the multifunctional carbonization reactor is provided with a CO2 inlet, an inert gas inlet, and an exhaust port. The CO2 inlet and the inert gas inlet are respectively connected to the gas separation unit. The multifunctional carbonization reactor is provided with an integrated stirring and scraping device.

[0010] Preferably, the gas separation unit includes a vacuum flash tank with a low-temperature distillation unit connected to its tail end. The low-temperature distillation unit is connected to a CO2 storage tank and an N2 storage tank. The CO2 storage tank and the N2 storage tank are used to store CO2 and N2, respectively. The CO2 storage tank is connected to the CO2 inlet, and the N2 is connected to the inert gas inlet.

[0011] Preferably, the intelligent control system includes an acoustic emission sensor array, an isothermal calorimeter, an integrated temperature acquisition and control device, a pressure sensor, and a heat flow sensor installed on the multifunctional carbonization reactor. The acoustic emission sensor array, the isothermal calorimeter, the integrated temperature acquisition and control device, the pressure sensor, and the heat flow sensor are electrically connected to the intelligent control system.

[0012] Preferably, the side wall of the multifunctional carbonization reactor is provided with a discharge port, and a discharge cooling device is provided on the discharge port.

[0013] Preferably, the integrated mixing and scraping device includes a mixing module and a scraping module, wherein the mixing module is used to mix the material and the scraping module is used to convey the mixed material to the discharge cooling device.

[0014] A carbonization method for recovering CO2 and solid waste includes the following steps: The power plant exhaust gas is fed into the gas-solid separation unit for gas-solid separation. The separated solids are transported to the fly ash silo, and the separated gas is transported to the gas separation unit. The gas is separated by the gas separation unit to obtain CO2 and N2. The separated solid fly ash is transported to a multi-functional carbonization reactor. First, N2 is introduced to replace the air, and then CO2 is introduced to carry out the carbonization reaction. The reaction conditions are monitored and adjusted in real time by an intelligent control system. Once the carbonization rate reaches the target, the reaction is stopped and the carbonized product is discharged.

[0015] Compared with the prior art, the present invention has the following advantages and technical effects: This invention provides an intelligent carbonization device and method for recovering CO2 and solid waste. It involves gas-solid separation and gas purification of exhaust gas to obtain fly ash with high carbonization activity and pure CO2 and N2 gases. The recovered CO2 is then used for carbonization modification. System calculations visually represent the carbonization rate, and phase analysis of the carbonization products is performed. The carbonized powder can be blended with cement to prepare a green and environmentally friendly cementitious material for application in construction and other fields. The prepared carbonized fly ash exhibits high strength, high durability, and high cementitious activity. Compared with traditional carbonization devices, it saves on gas storage and material transportation costs, significantly reduces cumbersome steps in practical applications, and simplifies the carbonization and reuse of solid waste. This invention features a simple process and high level of intelligence, allowing direct connection to power plant exhaust gas systems. It effectively solves problems such as low fly ash activity and delayed carbonization process control in traditional methods, improving carbonization efficiency and product value. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly described below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the multifunctional reaction vessel structure of the present invention; Figure 3 This is a process flow diagram of the present invention; The components include: 1. Supercritical conversion / mixing unit; 2. Supercritical activator; 3. Supercritical centrifugal separator; 4. Fly ash silo; 5. Gas separation unit; 6. CO2 inlet; 7. Inert gas inlet; 8. Integrated stirring and scraping device; 9. Exhaust port; 10. Multifunctional carbonization reactor; 11. Discharge cooling device; 12. Feed inlet; 13. Acoustic emission sensor array; 14. Isothermal calorimeter; 15. Integrated temperature acquisition and control device; 16. Pressure sensor; 17. Discharge port; 18. Heat flow sensor; and 19. Intelligent control system. Detailed Implementation

[0017] 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 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.

[0018] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0019] Reference Figures 1-3 This invention provides an intelligent carbonization device for recovering CO2 and solid waste, comprising: The exhaust gas treatment system includes a gas-solid separation unit, a fly ash silo 4, and a gas separation unit 5. The gas-solid separation unit is used to receive the exhaust gas from the power plant and separate it into gas and solid. The separated solid enters the fly ash silo 4, and the separated gas enters the gas separation unit 5. The multifunctional carbonization reactor 10, the fly ash silo 4, and the gas separation unit 5 respectively supply CO2, N2, and fly ash into the multifunctional carbonization reactor 10, and the fly ash undergoes carbonization modification in the multifunctional carbonization reactor 10. The intelligent control system is used to monitor and adjust multiple parameters during the carbonization reaction process.

[0020] The scheme is further optimized so that the gas-solid separation unit includes a supercritical conversion / mixing unit 1, a supercritical activator 2 and a supercritical centrifugal separator 3 connected in sequence. The supercritical conversion / mixing unit 1 is used to receive power plant tail gas, and the fly ash silo 4 and the gas separation unit 5 are respectively connected to the output end of the supercritical centrifugal separator 3.

[0021] In one embodiment of the present invention, the supercritical centrifugal separator 3 in the exhaust gas treatment zone generates a rotating magnetic field by driving an external magnetic rotor with a motor. The magnetic field passes through a high-strength non-magnetic alloy isolation sleeve and drives the internal magnetic rotor and centrifugal drum, which are completely enclosed in the container, to rotate. After the device is installed in the supercritical activator, it receives a mixture of fly ash and N2 that has completed surface activation. Under strong centrifugal force, the highly active fly ash that has completed "surface modification" is thrown against the wall and collected. The material is discharged from the solid phase outlet (with a spring-loaded full-lift safety valve) to the fly ash silo through a pressure lock (the upper valve is a high-pressure sealing valve and the lower valve is a normal-pressure discharge valve, and the upper and lower valves are opened and closed alternately to maintain the system pressure). The separated pure N2 and N2 mixture enters the next step through the fluid outlet (with a spring-loaded full-lift safety valve).

[0022] Further optimization of the scheme: the supercritical conversion / mixing unit 1 includes an exhaust gas buffer tank, a main heater and a supercritical homogenizer connected in sequence, and the main heater is equipped with a multi-stage series compressor.

[0023] In one embodiment of the present invention, the supercritical conversion / mixing unit of the exhaust gas treatment zone is composed of an exhaust gas buffer tank, a multi-stage series compressor, a main heater and a supercritical homogenizer. The buffer tank performs preliminary flow stabilization and pressure stabilization on the exhaust gas (after desulfurization and denitrification) from the power plant. The compressor and the main heater convert the exhaust gas from normal state to supercritical state (CO2 is converted to sCO2). The supercritical homogenizer is equipped with a static mixing element, which achieves microscopic homogenization of sCO2 and fly ash particles by dividing and rotating the fluid, forming a stable "supercritical aerosol" system.

[0024] To further optimize the design, the supercritical activator 2 is equipped with an ultrasonic cavitation generator and a precision injection system.

[0025] In one embodiment of the present invention, the supercritical activator 2 in the exhaust gas treatment zone is a high-pressure resistant tubular container with a built-in ultrasonic cavitation generator and a precision injection system. First, the excellent permeability and dissolving power of sCO2 are used to extract residual organic pollutants and capillary water on the surface of fly ash particles in situ to achieve "dry purification". Then, a trace amount of "solid activator" (e.g., solid organometallic compound) is dissolved in a small amount of sCO2 through the precision injection system and then injected into the reaction chamber. The ultrasonic cavitation generator provides energy to promote the decomposition and reaction of the activator precursor on the particle surface to form nanoscale active calcium sites. At the same time, these active sites are guided to arrange in an orderly manner, laying the foundation for the growth of calcium carbonate during subsequent carbonization.

[0026] Further optimization of the design: the multi-functional carbonization reactor 10 is equipped with a CO2 inlet 6, an inert gas inlet 7, and an exhaust port 9. The CO2 inlet 6 and the inert gas inlet 7 are respectively connected to the gas separation unit 5. The multi-functional carbonization reactor 10 is equipped with an integrated stirring and scraping device 8.

[0027] In one embodiment of the present invention, the multifunctional carbonization reactor 10 is a cylindrical double-walled container with a vacuum jacket, and is kept horizontal by a reactor frame.

[0028] In one embodiment of the present invention, axial heat-guiding fins are laid at the bottom of the reactor. The fins are 10 mm high, 2 mm thick, and have a helix angle of 15° to ensure uniform heat transfer.

[0029] In a further optimized scheme, the gas separation unit 5 includes a vacuum flash tank, with a cryogenic distillation unit connected to its tail end. A CO2 storage tank and an N2 storage tank are connected to the cryogenic distillation unit. The CO2 storage tank and the N2 storage tank are used to store CO2 and N2, respectively. The CO2 storage tank is connected to the CO2 inlet 6, and the N2 storage tank is connected to the inert gas inlet 7.

[0030] In one embodiment of the present invention, the gas separation unit of the tail gas treatment zone consists of a vacuum flash tank, a cryogenic distillation unit, a CO2 storage tank, and an N2 storage tank. After receiving the mixed fluid, the vacuum flash tank rapidly reduces the pressure of the supercritical fluid from the centrifuge to subcritical (e.g., 4 MPa). The CO2 rapidly vaporizes due to the pressure being below the critical pressure, absorbing a large amount of heat, while the N2 remains gaseous. The cryogenic distillation unit further cools the gas, causing the CO2 to liquefy, while the N2 remains gaseous. The CO2 storage tank converts the liquefied CO2 into normal CO2 for use as a raw material for the carbonization reaction in the device. The N2 storage tank stores N2 gas for use as a protective gas for the carbonization reaction in the device.

[0031] In one embodiment of the present invention, pressure and micro-leakage sensors are installed at the joints and valves of key pressure-bearing components such as the CO2 / N2 inlet and the outlet of the gas separation unit 5. The sensors are electrically connected to the intelligent control system to periodically monitor leakage at key connection points. When an abnormal leakage is detected, the system buzzer alarms and automatically starts the emergency sealing compensation program. The electromagnetically driven emergency sealing valve closes to prevent air infiltration or leakage of reaction gas, thus ensuring the purity and safety of the reaction.

[0032] Further optimization of the scheme: the intelligent control system includes an acoustic emission sensor array 13, an isothermal calorimeter 14, an integrated temperature acquisition and control device 15, a pressure sensor 16, and a heat flow sensor 18 installed on the multifunctional carbonization reactor 10. The acoustic emission sensor array 13, the isothermal calorimeter 14, the integrated temperature acquisition and control device 15, the pressure sensor 16, and the heat flow sensor 18 are electrically connected to the intelligent control system 19.

[0033] In one embodiment of the present invention, the integrated temperature acquisition and control device accurately acquires the reaction temperature through a thermocouple temperature probe. The probe is installed on the inner wall of the reactor with six measuring points evenly distributed radially (two each at the top, middle, and bottom, symmetrically distributed with an interlayer angle of 90°). It measures the temperature at multiple locations within the reactor (such as the gas inlet zone, stirring zone, and bottom reaction zone). The probe tip protrudes 5-10 mm (to avoid interference from the stirring blades), constructing a spatial temperature field for the carbonization reaction. The probe is resistant to high temperatures and corrosion. The device employs a PID control algorithm. The intelligent control system receives the spatial temperature distribution data provided by the thermocouple temperature array and dynamically adjusts the device's setpoint accordingly. Simultaneously, it controls the rotation speed of the integrated stirring and scraping device to maintain the thermal uniformity of the reaction system.

[0034] In one embodiment of this invention, a closed-loop optimization system of "perception-analysis-decision-execution" is formed. The system uses multi-dimensional sensing through sound, heat, temperature, and pressure, and integrates and analyzes the data using built-in chemical reaction kinetics, thermodynamics, and data-driven models. The decision-making layer calculates the optimal combination of operating parameters (temperature, pressure, CO2 concentration, and stirring strategy) in real time using a multi-objective optimization algorithm based on the analysis results (such as carbonization rate, product crystal form distribution, and reaction dead zone location) and preset optimal production targets (such as maximum carbonization efficiency, proportion of specific crystal form products, and minimum energy consumption). The execution layer then drives the corresponding actuators (temperature control system, air intake valve, and stirring motor) for precise adjustments. The entire process represents a leap from experience-based control to model prediction and data-driven control. The triple effect of pressure, temperature, and CO2 concentration jointly promotes the carbonization reaction, supplemented by heat flow sensors and isothermal calorimeters to monitor the exothermic crystallization of the reaction products, indirectly reflecting the crystal form of the carbonized products and achieving more comprehensive carbonized product production. This allows the system to significantly improve the utilization value of the carbonized products.

[0035] The design is further optimized by providing a discharge port 17 on the side wall of the multi-functional carbonization reactor 10, and a discharge cooling device 11 is installed on the discharge port 17.

[0036] In one embodiment of the present invention, after the carbonization reaction is completed, the discharge cooling device 11 stably and continuously conveys the carbonized fly ash and performs preliminary cooling during this process to prevent the high-temperature material from directly contacting the air and absorbing moisture or undergoing secondary reactions. After the internal and external air pressure of the multifunctional carbonization reactor 10 is balanced, the discharge port 17 is opened, and the carbonized fly ash is taken out by the conveyor belt for reuse. The discharge cooling device has a spiral conveying structure, and a cooling water jacket is set on the outside of the conveying cylinder to cool the material during the conveying process through circulating cooling water. The conveying speed can be adjusted by the intelligent control system according to the reaction endpoint temperature and material characteristics to achieve uniform discharge. After the internal and external air pressure of the multifunctional carbonization reactor 10 is balanced, the discharge port 17 is opened, and the intelligent control system switches the stirring mode of the integrated stirring and scraping device 8 to scrape the reacted material out of the reactor. Combined with the cooling of the material by the discharge cooling device 11, the carbonized fly ash is discharged at a uniform speed for reuse.

[0037] Further optimizing the scheme, the integrated mixing and scraping device 8 includes a mixing module and a scraping module. The mixing module is used to mix the material, and the scraping module is used to convey the mixed material to the discharge cooling device 11.

[0038] In one embodiment of the present invention, the stirring module consists of a main rod and a pair of auxiliary rods, which are responsible for stirring the materials during the carbonization reaction. The scraping module consists of two pairs of detachable scraping arms, installed below the main stirring rod. During the reaction stage, the scraping module rotates with the stirring body to fully stir the materials and promote mass and heat transfer. After the reaction, during the discharge stage, the device switches the stirring mode and uses the scraping arms at a low speed to continuously scrape up the materials deposited in the rib grooves and the center of the bottom of the vessel. Under the pushing force of the scraping arms and the gravity of the materials themselves, the scraped materials are guided and collected at the discharge port. The scraping arms are made of wear-resistant and corrosion-resistant materials (such as special alloys or silicon carbide coated steel), and their shape is adapted to the spiral direction of the bottom ribs (spiral angle 15°). The bottom surface of the scraping arm is slightly lower than the top of the ribs (for example, the ribs are 10 mm high, and the bottom surface of the scraping arm is 8 mm from the bottom of the vessel) to ensure that it can reach deep between the ribs to scrape the materials.

[0039] A carbonization method for recovering CO2 and solid waste includes the following steps: The power plant exhaust gas is fed into the gas-solid separation unit for gas-solid separation. The separated solids are transported to the fly ash silo 4, and the separated gas is transported to the gas separation unit 5. The gas is separated by the gas separation unit 5 to obtain CO2 and N2. The separated solid fly ash is transported to the multi-functional carbonization reactor 10. First, N2 is introduced to replace the air, and then CO2 is introduced to carry out the carbonization reaction. The reaction conditions are monitored and adjusted in real time by an intelligent control system. Once the carbonization rate reaches the target, the reaction is stopped and the carbonized product is discharged.

[0040] In one embodiment of the present invention, the exhaust gas treatment and raw material preparation are as follows: the exhaust gas after desulfurization and denitrification emitted from the coal-fired power plant is introduced into the device and undergoes dust removal activation and purification separation processes in sequence. The exhaust gas is converted into a supercritical state through the supercritical conversion / mixing unit 1. The mixed supercritical aerosol system is activated by the supercritical activator 2 to "activate" the fly ash. The separation process is further completed by the supercritical centrifuge 3 and the gas separation unit 5 to obtain "activated fly ash" with good carbonization activity as well as pure CO2 and N2. The relevant characteristics are shown in Table 1. In one embodiment of the present invention, the "dry purification" and "surface activation" processes of fly ash are monitored by an intelligent control system: The system monitors the pressure drop (ΔP) and / or fluid density changes at the inlet and outlet of the supercritical activator to assess the purification progress. Impurities (oil, moisture) on the fly ash surface will partially dissolve or disperse in the supercritical CO2, slightly altering the fluid properties and potentially causing minor fluctuations in pressure drop. As purification proceeds, impurities are extracted and removed, and the fluid gradually tends towards a two-phase flow of pure supercritical CO2 and clean particles. The pressure drop and density readings will tend to a stable value. The degree of fly ash activation is calculated by the following formula: (1) In formula (1): A represents the activation level (0-1). ΔP current For the current pressure drop, ΔP clean To ensure a stable pressure drop in the pure CO2 and clean particulate system, ΔP dirty The initial pressure drop of the system containing impurities; The operation of the supercritical centrifuge is monitored by an intelligent control system: it monitors the current of its drive motor and the speed difference between the inner and outer drums to assess the separator's load status and separation accuracy. Stable current matching the speed difference indicates a normal load. An abnormally high current may indicate poor solid phase discharge or mechanical friction; fluctuations in the speed difference directly affect the separation accuracy.

[0041] The gas separation process is monitored by an intelligent control system: It monitors the pressure and temperature changes in the vacuum flash tank to determine the degree of CO2 vaporization through the flash temperature drop phenomenon. Due to the endothermic effect of CO2 vaporization, the temperature inside the tank exhibits a characteristic sharp drop range. It also monitors the temperature gradient distribution and CO2 level within the cryogenic distillation unit to assess the stability and efficiency of the distillation separation. Under normal separation conditions, a stable temperature gradient field is formed, with a specific location corresponding to the CO2 liquefaction temperature zone maintaining a relatively constant low temperature. Simultaneously, a level gauge at the bottom of the distillation unit monitors the liquefied CO2 level in real time. By analyzing the stability of the temperature gradient curve and the steady rate of rise of the CO2 level, and correlating this with the feed flow rate, the intelligent control system can determine whether the distillation process is proceeding stably and efficiently, achieving continuous separation of CO2 and N2.

[0042] Table 1 Comparison of Critical Physical Properties of CO2 and N2 Intelligent carbonization reaction: Fly ash is placed in a multi-functional carbonization reactor. After replacing the air with N2, CO2 is introduced to a set pressure (denoted as P0) to carry out the carbonization reaction. Simultaneously, an integrated temperature acquisition and control device measures the reactor temperature (denoted as T) and maintains it at a constant temperature. During this process, the intelligent control system monitors the reaction process in real time and dynamically adjusts the reaction conditions based on the monitoring information: Acoustic emission sensor arrays collect acoustic signals during the fly ash carbonization reaction process. The intelligent control system compares these signals with the established "acoustic signal (S) - carbonization rate (η)" prediction curve f(η) to obtain the carbonization rate in real time and displays it on the control screen. Heat flow sensors and isothermal calorimeters monitor the exothermic crystallization of the carbonization products. The reaction region identification module of the intelligent control system receives the exothermic signal, judges the reaction dead zone, the crystal type and crystallization position of the product, and adaptively optimizes the reaction temperature, CO2 concentration, pressure and stirring strategy in a closed loop to drive the carbonization reaction process.

[0043] ; ; .

[0044] In one embodiment of the present invention, an acoustic emission sensor array is installed on the outer wall of the reactor. An acoustic coupling agent is coated between the sensor and the reactor wall to collect the acoustic signals from the reaction. The intelligent control system establishes a standard curve f(η) based on the signal, representing the "acoustic signal (S) - carbonization rate (η)". The specific steps are as follows: samples with known carbonization rates (carbonization gradients of 0%, 20%, 40%, 60%, 80%, and 100%) are prepared using fly ash from the same batch. The acoustic signals of each sample are recorded, and the standard curve f(η) is obtained through multiple trials and fitting. The standard curve f(η) is not fixed. The machine learning module built into the intelligent control system, in each carbonization reaction, not only calls the initial model for prediction but also uses the real-time collected acoustic signal sequence, the corresponding final product carbonization rate, and operating parameters (temperature, pressure, material batch) as new training data. Through incremental learning, the model is continuously optimized, enabling the system to automatically perform model transfer and calibration for "activated fly ash" from different sources and batches, improving the universality and accuracy of online carbonization rate prediction and achieving increasing intelligence. The initial model for carbonization rate η (%) is determined by the following formula: Calculation of comprehensive acoustic emission eigenvalues: (2) In equation (2): S(t) is the comprehensive acoustic emission characteristic value; Φi(t) is the acoustic signal characteristic parameter (such as energy, amplitude, frequency, etc.) collected by the i-th acoustic emission sensor; wi is the weight coefficient corresponding to Φi(t), which is obtained by training historical data through the machine learning module built into the intelligent control system of this patent; n is the total number of acoustic emission characteristic parameters used.

[0045] b. Core model for real-time prediction of carbonization rate: (3) In equation (3): η(t) is the real-time carbonization rate (%); ηMAX is the theoretical maximum carbonization rate (%), which is close to 100; λ is the overall reaction rate constant (λ>0); A is the activation degree of fly ash, A∈[0-1]; α is the activation degree influence index (α>0); β is the acoustic emission response coefficient (β>0); S(t) is the comprehensive acoustic emission characteristic value.

[0046] An isothermal calorimeter is installed at the top of the reactor to monitor the heat of reaction (ΔH) in the carbonization reaction zone at the bottom of the reactor. The signal is fed back to the reaction zone identification module of the intelligent control system to determine the crystal type of the carbonization product. ΔH is determined by the following formula: (4) In equation (4): x, y, z The mass fraction of each crystal form can be calculated by fitting the exothermic curve; the heat flow sensor is installed at the bottom of the reactor with the sensor surface flush with the inner wall to monitor the local heat flow density in the reaction zone, identify reaction hot spots or dead zones, and help determine the crystal formation location. A simplified diagram of the reaction zone is drawn on the display screen of the intelligent control system. After identifying the reaction dead zone, the system will instruct the integrated stirring and scraping device to adjust the blade angle or speed to enhance mass transfer in that area.

[0047] The intelligent control system further calculates the carbonization efficiency per unit time (Δt): Establish the equivalent reaction rate constant: (5) In equation (5): A is the activation degree of fly ash, A∈[0-1]; S(t) is the comprehensive acoustic emission characteristic value; T(t), P(t), CCO2(t), N(t) are the real-time temperature, pressure, CO2 concentration, and stirring speed; k0, γ, Ea, mP, mC, mN are the kinetic parameters (representing the pre-exponential factor, activation degree index, activation energy, pressure index, concentration index, and speed index, respectively); g(S(t)) is the acoustic emission correction function.

[0048] Establish a real-time kinetic model for the carbonization reaction: (6) In equation (6): r(t) is the instantaneous carbonization reaction rate (% / min); keff is the equivalent reaction rate constant at time t; represents the reactant consumption term, indicating that the rate naturally decreases as the reaction proceeds; n is the reaction order (usually 1).

[0049] In each control cycle, the intelligent control system performs the following closed-loop optimization: 1) Use the carbonization rate prediction model (Equation 3) to obtain the current carbonization rate η(t); 2) Combining the real-time monitored T(t), P(t), CCO2(t), N(t) and the inherent A and S(t), the current instantaneous reaction rate rcurrent is calculated using formulas (5) and (6); 3) With the optimization objective of "maximizing the average reaction rate over a future period of time" or "minimizing the estimated time and energy consumption to reach the target carbonization rate η0", adjust the operating parameters ΔT(t), ΔP(t), ΔCCO2(t), and ΔN(t); 4) Send adjustment instructions to the actuator of the device to accelerate the carbonization reaction process and improve carbonization efficiency.

[0050] The closed-loop control chain described above is as follows: .

[0051] Table 2. Correlation between acoustic emission signal characteristics and physical processes during carbonization. The exothermic crystallization of the carbonization products is monitored by a heat flow sensor and an isothermal calorimeter (see Table 3). The reaction region identification module of the intelligent control system receives the exothermic signal and determines the reaction dead zone, the crystal type of the product, and the crystallization position.

[0052] Table 3. Characteristic parameters of exothermic crystallization of calcium carbonate with different crystal forms. Reaction Termination and Discharge: Once the carbonization rate reaches the target, the system automatically executes a stop sequence: stopping stirring, slowly venting air, and opening the discharge valve after pressure equalization. Throughout the process, all key steps, parameter adjustments, and abnormal alarms are centrally displayed and recorded on the human-machine interface of the intelligent control system. The carbonized fly ash is removed through the combined action of the stirring and scraping device and the discharge cooling device, enabling reuse.

[0053] This equipment can activate and carbonize fly ash from the exhaust gas of coal-fired power plants to prepare high-value carbonized products, which can be mixed with cement to make cementitious materials and have a very wide range of applications.

[0054] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0055] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. An intelligent carbonization device for recovering CO2 and solid waste, characterized in that, include: The exhaust gas treatment system includes a gas-solid separation unit, a fly ash silo (4) and a gas separation unit (5). The gas-solid separation unit is used to receive the exhaust gas from the power plant and separate it into gas and solid. The separated solid enters the fly ash silo (4) and the separated gas enters the gas separation unit (5). The multifunctional carbonization reactor (10) is provided with CO2, N2 and fly ash respectively by the fly ash silo (4) and the gas separation unit (5), and the fly ash is carbonized and modified in the multifunctional carbonization reactor (10). The intelligent control system is used to monitor and adjust multiple parameters during the carbonization reaction process.

2. The intelligent carbonization device for recovering CO2 and solid waste according to claim 1, characterized in that: The gas-solid separation unit includes a supercritical conversion / mixing unit (1), a supercritical activator (2), and a supercritical centrifugal separator (3) connected in sequence. The supercritical conversion / mixing unit (1) is used to receive power plant tail gas. The fly ash silo (4) and the gas separation unit (5) are respectively connected to the output end of the supercritical centrifugal separator (3).

3. The intelligent carbonization device for recovering CO2 and solid waste according to claim 2, characterized in that: The supercritical conversion / mixing unit (1) includes a tail gas buffer tank, a main heater and a supercritical homogenizer connected in sequence, and the main heater is equipped with a multi-stage series compressor.

4. The intelligent carbonization device and carbonization method for recovering CO2 and solid waste according to claim 2, characterized in that: The supercritical activator is equipped with an ultrasonic cavitation generator and a precision injection system.

5. The intelligent carbonization device for recovering CO2 and solid waste according to claim 4, characterized in that: The multifunctional carbonization reactor (10) is provided with a CO2 inlet (6), an inert gas inlet (7) and an exhaust port (9). The CO2 inlet (6) and the inert gas inlet (7) are respectively connected to the gas separation unit (5). The multifunctional carbonization reactor (10) is provided with an integrated stirring and scraping device (8).

6. The intelligent carbonization device for recovering CO2 and solid waste according to claim 5, characterized in that: The gas separation unit (5) includes a vacuum flash tank and a low-temperature distillation unit connected to its tail end. The low-temperature distillation unit is connected to a CO2 storage tank and an N2 storage tank. The CO2 storage tank and the N2 storage tank are used to store CO2 and N2, respectively. The CO2 storage tank is connected to the CO2 inlet (6), and the N2 storage tank is connected to the inert gas inlet (7).

7. The intelligent carbonization device for recovering CO2 and solid waste according to claim 1, characterized in that: The intelligent control system includes an acoustic emission sensor array (13), an isothermal calorimeter (14), an integrated temperature acquisition and control device (15), a pressure sensor (16), and a heat flow sensor (18) installed on the multifunctional carbonization reactor (10). The acoustic emission sensor array (13), the isothermal calorimeter (14), the integrated temperature acquisition and control device (15), the pressure sensor (16), and the heat flow sensor (18) are electrically connected to the intelligent control system (19).

8. The intelligent carbonization device for recovering CO2 and solid waste according to claim 5, characterized in that: The multifunctional carbonization reactor (10) has a discharge port (17) on its side wall, and a discharge cooling device (11) is provided on the discharge port (17).

9. The intelligent carbonization device for recovering CO2 and solid waste according to claim 8, characterized in that: The integrated mixing and scraping device (8) includes a mixing module and a scraping module. The mixing module is used to mix the material, and the scraping module is used to convey the mixed material to the discharge cooling device (11).

10. A carbonization method for recovering CO2 and solid waste, applicable to the intelligent carbonization device for recovering CO2 and solid waste as described in claim 1, characterized in that, Includes the following steps: The power plant exhaust gas is fed into the gas-solid separation unit for gas-solid separation. The separated solids are transported to the fly ash silo (4), and the separated gas is transported to the gas separation unit (5). The gas is separated by the gas separation unit (5) to obtain CO2 and N2. The separated solid fly ash is transported to a multi-functional carbonization reactor (10). First, N2 is introduced to replace the air, and then CO2 is introduced to carry out the carbonization reaction. The reaction conditions are monitored and adjusted in real time by an intelligent control system. Once the carbonization rate reaches the target, the reaction is stopped and the carbonized product is discharged.

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