Distillation detection processing device

Abstract

The invention discloses a distillation detection treatment device which comprises a closed box body, a heating distillation unit, a gas collection unit, a liquid collection unit, a negative pressure mechanism and a waste gas treatment mechanism. The box body is provided with a sealing door and a visible observation window; the heating distillation unit comprises an electric heater and a heating container, and the heating container is sequentially connected with a condenser, a liquid collection bottle and a gas collection bottle through a distillation pipeline; the negative pressure mechanism is used for maintaining a negative pressure state in the box and preventing gas leakage; and the waste gas treatment mechanism performs harmless treatment on the extracted gas and then discharges the gas. Harmful gas is fundamentally prevented from escaping through the closed negative pressure design, environment-friendly operation is achieved through integrated waste gas treatment, the safety, flexibility and automation degree can be further improved through the design of a modular treatment box, safety interlocking control, automatic fraction collection and the like, and the device is suitable for safe distillation pretreatment in a laboratory.

Description

Technical Field

[0001] This invention relates to the field of laboratory equipment or testing instruments, specifically a pretreatment device for distillation testing. Background Technology

[0002] Distillation is a crucial pretreatment step in fields such as chemical analysis, environmental monitoring, food safety, and drug development, aiming to separate and purify target components from complex matrices. Traditional distillation apparatuses are typically open or semi-open, with heating, condensation, and collection units arranged independently within laboratory fume hoods, relying on the overall laboratory ventilation system to remove harmful gases generated during the experiment.

[0003] However, such traditional devices have significant safety and environmental drawbacks. First, even when operating within a fume hood, it is difficult to completely prevent harmful, corrosive, or malodorous gases from escaping into the laboratory environment during heating, transfer, and collection, posing a long-term potential threat to the health of operators and potentially contaminating precision instruments. Second, for highly volatile and toxic samples (such as cyanide, volatile phenols, and certain organic solvents), conventional ventilation cannot guarantee absolute safety, posing an accident risk. Third, traditional devices directly discharge untreated waste gas into the ventilation system, merely transferring it spatially rather than providing substantial treatment, increasing the burden of end-of-pipe environmental remediation and failing to meet increasingly stringent green laboratory standards. Finally, existing devices have low levels of automation and integration, are cumbersome to operate, and rely on manual judgment and switching for the collection of different component fractions, resulting in low efficiency and poor reproducibility.

[0004] To address the aforementioned issues, some improvements have been attempted in this field, such as adding local exhaust hoods to the distillation unit or integrating some units. However, these solutions often fail to fundamentally achieve an organic combination of "fully enclosed process" and "in-situ waste gas treatment," either lacking sufficient airtightness or having rudimentary waste gas treatment units that cannot flexibly adapt to waste gases with different chemical properties. Therefore, developing an intelligent distillation detection and treatment device capable of achieving fully enclosed operation, actively maintaining a negative pressure environment to prevent leakage, and efficiently and modularly treating waste gases according to their properties has become a pressing technical problem to be solved in this field. Summary of the Invention

[0005] The present invention aims to overcome the shortcomings of the prior art and provide a distillation detection and processing device. Its core purpose is to achieve fully enclosed, highly safe and environmentally friendly operation of the distillation pretreatment process. Through the synergistic effect of active negative pressure protection and modular waste gas treatment, it fundamentally solves the problems of harmful gas leakage and secondary pollution, while improving the automation level and ease of operation of the device.

[0006] To achieve the above objectives, the technical solution adopted is as follows: a distillation detection and processing device, comprising a sealed chamber and a heating distillation unit, wherein the chamber is provided with a sealed door and a viewing window; the heating distillation unit includes an electric heater and a heating container for placing the sample to be processed, the heating container being connected to a condenser, a gas collection unit and a liquid collection unit via distillation pipelines, the liquid collection unit being provided with a liquid collection bottle, and the gas collection unit being provided with a gas collection bottle; the chamber is also provided with a negative pressure mechanism and a waste gas treatment mechanism; the negative pressure mechanism includes a negative pressure air pump for maintaining a negative pressure state inside the chamber; the waste gas treatment mechanism is connected to the inside of the chamber for treating the gas extracted by the negative pressure air pump to render it harmless before discharging it into the external environment.

[0007] Furthermore, the exhaust gas treatment mechanism is a replaceable modular exhaust gas treatment box; the modular exhaust gas treatment box is equipped with one or more combinations of physical adsorption materials, chemical treatment liquids, or membrane filters.

[0008] Furthermore, the condenser includes a heat exchange section disposed inside the housing and a heat dissipation section extending outside the housing; a cooling fan is disposed outside the heat dissipation section; the distillation pipeline is arranged in a meandering or spiral winding manner within the heat exchange section.

[0009] Furthermore, it also includes a controller; a negative pressure detector for detecting the internal air pressure is provided inside the box; the negative pressure detector, the negative pressure mechanism and the electric heater are all electrically connected to the controller; the controller is configured to allow or start the electric heater only when the negative pressure detector detects that the internal air pressure of the box is within a preset negative pressure range.

[0010] Furthermore, the preset negative pressure range is -10Pa to -20Pa.

[0011] Furthermore, a temperature sensor is provided inside the electric heater or outside the heating container; an electrically controlled valve is provided on the inlet pipe of the liquid collection bottle and the gas collection bottle; the temperature sensor and the electrically controlled valve are electrically connected to the controller, and the controller is configured to control the opening and closing of the corresponding electrically controlled valve according to the temperature value detected by the temperature sensor, so as to perform diversion and collection.

[0012] Furthermore, the viewing window is a transparent window set on the wall of the enclosure, or a combination of a camera set inside the enclosure and a display screen set on the outside.

[0013] Furthermore, the heating container is provided with a leak-proof and explosion-proof protective cover on the outside, and an emergency drainage device is connected to the bottom of the protective cover.

[0014] Furthermore, the gas collecting bottle is a sealed gas bottle with a piston.

[0015] Furthermore, the heating container, the liquid collecting bottle, and the gas collecting bottle are available in various specifications and models, and can be installed in the box using universal clamps.

[0016] Compared with the prior art, the distillation detection and processing device provided by the present invention has the following beneficial effects: Enhanced operational safety: The combination of a sealed enclosure and a negative pressure mechanism maintains a stable, slightly negative pressure within the enclosure during operation. This design ensures airflow from the outside in, even with minute gaps in the enclosure, effectively reducing the escape of toxic, harmful, or odorous gases into the laboratory environment and lowering the risk of direct exposure for operators.

[0017] In-situ waste gas treatment: The waste gas treatment mechanism integrated into the enclosure can perform preliminary treatment on the gases generated during the distillation process. The modular waste gas treatment box design allows for flexible selection of treatment methods such as adsorption, absorption, or filtration based on the waste gas composition, helping to reduce the subsequent treatment load on the laboratory's centralized ventilation system and improving the environmental friendliness of the experimental process.

[0018] Enhanced process controllability: Interlocking of the controller, negative pressure detector, and heating unit enables a safe start-up process of "negative pressure first, then heating," reducing the possibility of gas leakage due to misoperation. Combined with temperature sensors and electrically controlled valves, automatic collection of fractions at different temperatures can be achieved, improving operational standardization and result repeatability.

[0019] Enhancing equipment usability: The condenser employs a combined internal and external heat dissipation design and optimized piping, improving condensation efficiency. The heating container is equipped with a protective cover and emergency drainage, providing basic protection against unexpected situations. Modular handling boxes and replaceable containers of various sizes allow the device to better adapt to different experimental needs and consumable management. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the distillation detection and processing device of the present invention; Figure 2 This is a flowchart of the distillation detection and processing device of the present invention. In the diagram, 1. Electric heater; 2. Heating container; 3. Protective cover; 4. Distillation pipeline; 5. Gas collecting bottle; 6. Negative pressure detector; 7. Negative pressure mechanism; 8. Waste gas treatment mechanism; 9. Liquid collecting bottle; 10. Emergency drainage device; 11. Heat dissipation section; 12. Heat exchange section; 13. Electrically controlled valve. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that the following embodiments are only used to illustrate the technical solutions of this invention and should not be construed as limiting the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention. In the description of this invention, the terms "upper," "lower," "inner," and "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 the invention and not a requirement that the invention must be constructed and operated in a specific orientation; therefore, they should not be construed as limiting the invention.

[0022] Example 1 refer to Figure 1 This embodiment provides a distillation detection and processing device, the core of which is to achieve a fully enclosed distillation process and in-situ treatment of waste gas.

[0023] The device includes a sealed enclosure that forms the main operating and protective space. A sealed door is located on the front of the enclosure for inserting or removing samples and consumables. The door is typically equipped with an airtight sealing strip and a mechanical lock to ensure a tight seal when closed. A viewing window is also provided on the enclosure wall; in this embodiment, it is a double-layered tempered glass window embedded in the wall, allowing the operator to observe the internal processes without opening the door.

[0024] The core functional units inside the chamber include a heating distillation unit, a condenser, a liquid collection unit, and a gas collection unit. The heating distillation unit includes an electric heater 1 (e.g., a ceramic heating plate with programmed temperature control) and a heating container 2 (e.g., a standard-sized flask or beaker) placed on it. The heating container 2 holds the sample and solvent to be distilled. The outlet of the heating container 2 is connected to the condenser via a distillation pipe 4. In this embodiment, the condenser is an air-cooled condenser, mainly comprising a heat exchange section 12 located inside the chamber and a heat dissipation section 11 extending outside the chamber. The distillation pipe 4 is spirally wound inside the heat exchange section 12 to increase the contact area and contact time between the vapor and the heat exchange section 12, thereby improving condensation efficiency. The heat exchange section 12 can be made of a material with good thermal conductivity or connected to the heat dissipation section 11 using heat pipes. The outer side of the heat dissipation section 11 of the condenser is designed with dense metal fins. A cooling fan (not shown in the figure) is installed on the outer wall of the chamber directly opposite the heat dissipation section 11. The condensed liquid fraction and incompletely condensed gaseous substances are transported downstream through the pipes.

[0025] The liquid collection unit mainly includes a liquid collection bottle 9, used to collect the condensed target liquid fraction. The gas collection unit mainly includes a sealed gas collection bottle 5 with a piston, used to collect the uncondensed gas components that need to be analyzed. The distillation pipeline 4 branches off after the condenser, connecting to the liquid collection bottle 9 and the gas collection bottle 5 respectively. The gas collection bottle 5 has a stopper and an inlet on one side and an exhaust port on the other side, and a freely movable piston inside. Due to the slight negative pressure inside the chamber, when airflow enters through the inlet, the piston is pushed, and the gas collection bottle 5 can collect the distilled gas on its own.

[0026] To ensure safety, the enclosure also integrates a negative pressure mechanism and an exhaust gas treatment mechanism 8. The negative pressure mechanism 7 mainly consists of a negative pressure air pump (such as a corrosion-resistant diaphragm vacuum pump), with its air inlet located inside the enclosure. After startup, the pump continuously draws air from the enclosure, making the internal pressure slightly lower than the external atmospheric pressure, thus creating a stable micro-negative pressure environment. This pressure difference ensures that even if there are unavoidable tiny gaps in the enclosure, the airflow will still be from the outside into the enclosure, effectively preventing the leakage of harmful gases.

[0027] The air inlet of the exhaust gas treatment mechanism 8 is directly connected to the exhaust outlet of the negative pressure mechanism 7, and is responsible for treating the air containing residual pollutants drawn from the chamber. In this embodiment, the mechanism is a fixed treatment tank filled with granular activated carbon, suitable for adsorbing common organic solvent vapors. The treated gas is directly discharged into the laboratory environment through the outlet of the treatment tank.

[0028] To ensure basic safety logic, the device also includes a controller (not shown in the figure, such as a PLC). A negative pressure detector 6 (such as a piezoresistive pressure sensor) is installed inside the enclosure, and its signal output is connected to the input of the controller. The output of the controller controls the power supply circuit of the heater 1. The controller is programmed to allow the heater 1 to start heating only when it receives a signal from the negative pressure detector 6 and confirms that the pressure inside the enclosure has reached and stabilized within a preset safe negative pressure range (such as -10Pa to -20Pa). If the negative pressure fails during operation, the controller will cut off the heating power supply. A protective cover 3 made of a high-temperature resistant transparent material (such as polycarbonate) can be installed on the outside of the heating container 2. Its bottom is connected to an emergency drainage device 10 (such as a waste liquid collection tank) located at the bottom of the enclosure via a pipe. This is used to contain and divert leaks in the event of accidental container rupture, protecting other components inside the enclosure.

[0029] The processing flow of the above-mentioned device can be referred to Figure 2During operation, first place the sample and close the sealed door, then start the negative pressure mechanism 7; after the negative pressure detector 6 confirms that the set negative pressure has been reached inside the chamber, the controller unlocks and starts the electric heater 1 to heat; the generated steam is condensed and separated by the condenser, the liquid is collected in the liquid collection bottle 9, and the gas is collected in the gas collection bottle 5; the residual waste gas inside the chamber is extracted by the negative pressure mechanism 7, purified by the waste gas treatment mechanism 8, and then discharged outside the chamber.

[0030] After distillation is complete, turn off the heater 1, keep the negative pressure mechanism 7 running for 3-5 minutes, then open the sealed door of the chamber and remove the heating container 2, the liquid collecting bottle 9, and the gas collecting bottle 5 for the next testing operation. To ensure that the gas collecting bottle 5 does not leak after removal, tighten the sealing cap on the outside of the bottle opening.

[0031] Example 2 This embodiment, based on Embodiment 1, further introduces optional and alternative solutions to demonstrate the flexibility and scalability of the present invention.

[0032] Regarding the exhaust gas treatment unit 8, it can be designed as a replaceable modular exhaust gas treatment box. This treatment box connects to the exhaust pipe of the negative pressure unit 7 via a standard quick-connect interface. Depending on the properties of the exhaust gas to be treated, different internal filling materials can be selected for the treatment box. For example, for acidic gases, a chemical treatment box containing a dilute alkali absorption bottle can be selected; for applications requiring deep purification, a composite treatment box integrating a physical adsorption layer (activated carbon) and a membrane filter (such as a PTFE membrane) can be selected. This modular design makes exhaust gas treatment more targeted and convenient.

[0033] For the condensation solution, water cooling can be used instead of air cooling. Specifically, the heat exchange section 12 uses a water-cooled heat conduction head, and the distillation pipeline 4 adopts a meandering coil or spiral winding design outside the heat exchange section 12, which can effectively increase the heat exchange area. The water-cooled pipeline is then cooled by the heat dissipation section 11 and the cooling fan on the outside of the heat dissipation section 11.

[0034] For observation and intelligent control, the visual observation window can employ an electronic solution, i.e., a camera is installed in a safe location inside the chamber, and a display screen is provided outside the chamber for observation. Furthermore, a temperature sensor (such as a sheathed thermocouple) can be installed inside the heater 1 or outside the heating container 2. Simultaneously, multiple collection bottles 9 and gas collection bottles 5 are configured, and electrically controlled valves 13 (such as solenoid valves) are installed on the inlet pipes of the collection bottles 9 and 5. These sensors and valves are all connected to the controller. Users can preset temperature thresholds corresponding to different fractions. The controller automatically controls the opening and closing of the corresponding electrically controlled valves by comparing the real-time readings of the temperature sensors with the set values, achieving automatic fraction collection and switching based on temperature.

[0035] In terms of safety and versatility, the protective cover 3 and the emergency drainage device 10 can be used as standard safety accessories. Furthermore, the heating container 2, the liquid collection bottle 9, and the gas collection bottle 5 can all be installed using a universal adjustable clamp that can accommodate glassware of different diameters and heights, thus enabling the device to be compatible with a variety of standard laboratory containers and improving its applicability.

[0036] Example 3 Based on Embodiments 1 and 2, this embodiment further provides a highly integrated design scheme that integrates optimized heat dissipation, intelligent air curtain protection, and remote monitoring functions.

[0037] The structure of the distillation detection and processing device is basically as described in Example 1, including a housing, a heating unit (heater 1, heating container 2), a condensation unit (heat exchange section 12, heat dissipation section 11), a collection unit (liquid collection bottle 9, gas collection bottle 5), a negative pressure mechanism 7, a negative pressure detector 6, and a waste gas treatment mechanism 8. Based on this, this embodiment supplements and integrates the following key functions: 1. Integrated high-efficiency heat dissipation system The condensation system in this embodiment employs an integrated, high-efficiency air-cooled heat dissipation module. The heat dissipation unit 11 is an integrated aluminum finned heat sink, which is tightly connected to the copper heat exchange unit 12 located inside the casing via a thermal bridge, forming a highly efficient heat conduction path. A low-speed, large-diameter, silent cooling fan is installed at a corresponding position on the outer wall of the casing. This fan is controlled by a controller using PWM speed regulation based on feedback from a temperature sensor (which can be located on the heat dissipation unit 11 or the heat exchange unit 12). When the condensation load increases, the fan accelerates to enhance heat dissipation; when distillation is complete or the load is low, the fan maintains a low speed or stops completely, achieving energy saving and noise reduction. Simultaneously, the side walls of the casing are designed with directional ventilation grilles, which, together with the fan, form a highly efficient, low-turbulence external heat dissipation airflow. This design eliminates the reliance on an external water cooling system, reduces installation complexity and the risk of leakage, and achieves a balance between heat dissipation efficiency and energy consumption through intelligent temperature control.

[0038] 2. Intelligent air curtain airlock and differential pressure gradient control To enhance safety during door opening operations, this embodiment integrates a ring of miniature high-speed airflow nozzles on the inner door frame of the sealed door, forming an intelligent air curtain generator. When the controller receives a door opening request (such as a signal from a button or sensor on the door), it first activates the negative pressure mechanism 7 to its maximum power to ensure stable negative pressure inside the chamber. Subsequently, the air curtain device activates, forming a continuous downward / inward high-speed clean air curtain at the door seam, effectively preventing the escape of gas from inside the chamber at the moment of door opening. Furthermore, the internal space of the chamber is designed with a dynamic pressure gradient. Based on the readings of multiple pressure sensors located above the heating container 2, in the middle of the chamber, and near the exhaust outlet, the controller dynamically adjusts the extraction rate in different areas to ensure that the source of pollutants (above the heating container) is always at the lowest pressure point, forming a "directional airflow" directed towards the exhaust gas treatment mechanism, preventing pollutants from spreading inside the chamber and keeping the observation window and sensors clean.

[0039] 3. Remote monitoring and digital twin service interface The controller in this embodiment has network communication capabilities (such as Wi-Fi or Ethernet) and runs an embedded operating system. Through the accompanying software platform, users can monitor key parameters in real time on remote terminals (such as computers or tablets), including the negative pressure value inside the chamber, heating temperature, condenser temperature, and the status of the exhaust gas treatment box (e.g., estimating adsorption saturation by monitoring the pressure difference before and after). Users can also remotely start or stop the distillation program or adjust the temperature setpoint. The device's built-in data logging function can completely record the operating curve of each experiment. More advancedly, this embodiment provides a preliminary digital twin service interface for each device: the device encrypts and uploads operating parameters (such as sample type, heating power, and temperature curve) to the cloud. The cloud model can perform simulation calculations and provide users with feedback on the energy efficiency assessment of this distillation, the expected lifespan of the exhaust gas treatment box, and suggestions for optimizing operating parameters, thus achieving predictive maintenance and process optimization guidance.

[0040] 4. Intelligent identification for modular waste gas treatment The modular exhaust gas treatment box in this embodiment (as described in Embodiment 2) further integrates a micro RFID chip. An RFID reader / writer is located in a corresponding position inside the box. When the treatment box is inserted, the controller automatically reads the information recorded in the chip, such as the box model, treatment medium type, initial capacity, and production date, and displays it on the human-machine interface. The controller can automatically recommend or match appropriate exhaust gas treatment process parameters (such as airflow rate) based on the selected treatment box type. Simultaneously, the system intelligently estimates the consumption of the treatment medium based on running time and accumulated airflow, and proactively issues a replacement warning to the user when the medium is nearing saturation, ensuring that exhaust gas treatment remains effective.

[0041] Through the above-described integrated design, this embodiment significantly improves the active safety protection level, operational intelligence level, and remote management capability of the device while maintaining the core functions of closed negative pressure and exhaust gas treatment. It is suitable for high-standard laboratory environments with higher requirements for safety, automation, and data traceability.

Claims

1. A distillation detection and processing device, comprising a sealed chamber and a heating distillation unit, characterized in that, The enclosure is equipped with a sealed door and a viewing window; The heating distillation unit includes an electric heater and a heating container for placing the sample to be processed. The heating container is connected to a condenser, a gas collecting unit, and a liquid collecting unit through a distillation pipeline. The liquid collecting unit is equipped with a liquid collecting bottle, and the gas collecting unit is equipped with a gas collecting bottle. The box is also equipped with a negative pressure mechanism and an exhaust gas treatment mechanism; The negative pressure mechanism includes a negative pressure air pump, used to maintain a negative pressure state inside the box. The exhaust gas treatment mechanism is connected to the inside of the housing and is used to treat the gas extracted by the negative pressure air pump to render it harmless before discharging it into the external environment.

2. The distillation detection and processing apparatus according to claim 1, characterized in that, The exhaust gas treatment mechanism is a replaceable modular exhaust gas treatment box; the modular exhaust gas treatment box is equipped with one or more combinations of physical adsorption materials, chemical treatment liquids, or membrane filters.

3. The distillation detection and processing apparatus according to claim 1, characterized in that, The condenser includes a heat exchange section disposed inside the housing and a heat dissipation section extending outside the housing; a cooling fan is disposed outside the heat dissipation section; the distillation pipeline is arranged in a meandering or spiral winding manner inside the heat exchange section.

4. The distillation detection and processing apparatus according to claim 1, characterized in that, It also includes a controller; a negative pressure detector for detecting the internal air pressure is provided inside the box; the negative pressure detector, the negative pressure mechanism and the electric heater are all electrically connected to the controller; the controller is configured to allow or start the electric heater only when the negative pressure detector detects that the internal air pressure of the box is within a preset negative pressure range.

5. The distillation detection and processing apparatus according to claim 4, characterized in that, The preset negative pressure range is -10Pa to -20Pa.

6. The distillation detection and processing apparatus according to claim 4, characterized in that, A temperature sensor is installed inside the electric heater or outside the heating container; an electrically controlled valve is installed on the inlet pipe of the liquid collection bottle and the gas collection bottle; the temperature sensor and the electrically controlled valve are electrically connected to the controller, and the controller is configured to control the opening and closing of the corresponding electrically controlled valve according to the temperature value detected by the temperature sensor, so as to perform diversion and collection.

7. The distillation detection and processing apparatus according to claim 1, characterized in that, The viewing window is a transparent window installed on the wall of the enclosure, or a combination of a camera installed inside the enclosure and a display screen installed on the outside.

8. The distillation detection and processing apparatus according to claim 1, characterized in that, The heating container is equipped with a leak-proof and explosion-proof protective cover on the outside, and an emergency drainage device is connected to the bottom of the protective cover.

9. The distillation detection and processing apparatus according to claim 1, characterized in that, The gas collecting bottle is a sealed gas bottle with a piston.

10. The distillation detection and processing apparatus according to claim 1, characterized in that, The heating container, the liquid collecting bottle, and the gas collecting bottle are available in various specifications and models, and can be installed in the box using universal clamps.

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