Modular fully static emulsion explosive production line and control method thereof

Abstract

The application relates to the field of explosive production lines, and discloses a modular full-static emulsion explosive production line which comprises a power module, a medicine preparation module, a charging module, a packaging module and a transportable carrier, the power module, the medicine preparation module, the charging module and the packaging module are all packaged by using the carrier; the production line adopts a full-static emulsion process and is configured to realize oil-water phase fusion through a jet shearing principle, the power module, the medicine preparation module, the charging module and the packaging module are independently packaged in standardized containers, and the modules are connected through standardized interfaces (including fluid pipeline interfaces, electrical signal interfaces and mechanical fixing interfaces) with a preset fixed size. The design realizes plug-and-play of the production line, supports multiple logistics modes such as sea transportation, land transportation and railway transportation, greatly reduces the transportation and installation cost of overseas factories, and shortens the production line installation period without complex civil construction and secondary processing.

Description

Technical Field

[0001] This invention relates to the field of explosives production lines, and more particularly to a modular, fully static emulsion explosives production line and its control method. Background Technology

[0002] As a crucial component of the civil explosives industry, the production process of emulsion explosives has evolved from early intermittent methods to fully continuous automated production lines. However, in the current context of globalization, existing production processes and equipment still exhibit significant shortcomings in terms of modularity and flexible deployment. 1. High Costs of Cross-Regional Deployment and Transportation: Traditional emulsion explosive production lines are mostly fixed-building layouts, resulting in dispersed enterprise distribution. When constructing factories for overseas markets, traditional equipment is bulky and complex, leading to high logistics and transportation costs, and is highly dependent on complex on-site installation environments. Equipment components lack standardized protective carriers during transportation, making them susceptible to damage.

[0003] 2. Lengthy on-site installation and commissioning cycle: Existing production line systems have low integration levels, with functional units such as power systems, pharmaceutical systems, and packaging systems often being procured independently and installed in stages. This "non-modular" approach requires extensive on-site piping connections, electrical wiring, and software integration work, which not only increases labor costs but also results in extremely long installation cycles due to inconsistent component interfaces, making rapid production difficult.

[0004] 3. Lack of Capacity Adaptability and Flexibility: While some existing international technical solutions involve static technologies, their modular integration is relatively low, resulting in insufficient system flexibility. When facing varying market demands of different sizes, existing production lines have a narrow capacity adjustment range, making it difficult to quickly achieve flexible production by adding or removing modules.

[0005] 4. Limitations in Safety and Operation Management: In mainstream domestic processes, mechanical stirring is still widely used in the roughing stage (involving Class 0, Class I, or Class II hazardous equipment), posing safety hazards such as frictional heat accumulation and accidents caused by metal friction. Under a non-modular layout, safety supervision and intelligent monitoring systems are difficult to deploy with a single click at the physical level, and the underlying hardware support for remote fault self-diagnosis and data traceability is weak.

[0006] In conclusion, there is an urgent need to develop a fully static emulsion explosive production line that can achieve no dynamic equipment, intelligent control, and modular deployment. Summary of the Invention

[0007] The purpose of this invention is to provide a modular, fully static emulsion explosive production line and its control method to solve the above-mentioned problems. The specific technical solution is as follows: A modular, fully static emulsion explosive production line includes a power module, a pharmaceutical module, a loading module, a packaging module, and a transportable carrier. The power module, pharmaceutical module, loading module, and packaging module are all encapsulated using the carrier. The production line adopts a fully static emulsification process. The pharmaceutical module is equipped with a fully static emulsifier configured to achieve oil-water phase fusion through a jet shearing principle.

[0008] As an improvement to the above technical solution, the transportable carrier includes a standardized container, which includes at least two specifications. The modules are connected through a standardized interface, and the docking dimensions of the standardized interface are preset to a fixed value.

[0009] As an improvement to the above technical solution, the fully static emulsifier adopts a static mixer with a combination of coarse and fine cutting mechanisms, which refines the emulsion step by step through shearing holes of different diameters; the internal working pressure of the fully static emulsifier is controlled at ≤1.2Mpa.

[0010] As one of the improvements to the above technical solution, the power module includes a hot water tank, a power distribution cabinet, an electric steam generator, and an air compressor.

[0011] As one of the improvements to the above technical solution, the pharmaceutical module also includes an oil phase melting tank, a protective box, a crusher, a screw conveyor, an aqueous phase preparation tank, an aqueous phase pump, an aqueous phase storage tank, an oil phase preparation tank, an oil phase pump, and an oil phase storage tank.

[0012] As one of the improvements to the above technical solution, an intelligent control system is also included. The intelligent control system includes a PLC controller and an Internet of Things module. The intelligent control system is configured to monitor the oil-water phase flow rate in the pharmaceutical module in real time, and automatically adjust the operating frequency of the oil phase pump and the water phase pump according to the monitoring data to maintain a constant oil-water phase ratio.

[0013] As one of the improvements to the above technical solution, the drug loading module includes a sensitization accelerator tank, a sensitization accelerator pump, a static sensitizer, a main control cabinet drug loading machine, a conveyor belt conveyor, and a protective housing.

[0014] As one of the improvements to the above technical solution, the packaging module includes a packing platform, a conveyor belt, a boxing platform, a mesh chain conveyor, a dryer, and a cooling water tank.

[0015] A control method, applying the above-mentioned modular fully static emulsion explosive production line, includes the following steps: Step S1, System Start-up and Self-Check: The intelligent control system performs status checks on each module of the production line to confirm that the standardized interface connections are normal and there are no alarms from Class 0, Class I or Class II hazardous equipment. Step S2, oil-water phase preparation and preheating: Prepare oil-water raw materials, preheat the oil-water raw materials, and monitor the flow rate of the oil-water phase in real time using a flow meter; Step S3, fully static emulsification: The preheated oil-water phase is pumped into the fully static emulsifier. Emulsification is carried out through the jet shear principle without the use of mechanical stirring. The working pressure inside the emulsifier is controlled to be ≤1.2Mpa. The intelligent control system automatically adjusts the working frequency of the oil-water phase pump according to the flow monitoring data to maintain a constant ratio. Step S4, Static sensitization: The emulsified latex matrix is ​​fed into a static sensitizer, and the sensitizer is uniformly dispersed by a multi-stage static mixer in conjunction with closed-loop flow regulation. Step S5, loading and cooling: The sensitized explosive is loaded into the explosive cartridge and cooled and shaped by a cooling water tank; Step S6, Packaging: The finished product is packed and boxed using the packaging module; Step S7, Cleaning and Purging: After the production process is completed, a cleaning procedure is performed. First, high-pressure air is used to blow out the residual material tails in the equipment to eliminate the material tails. Then, hot water is used to clean the pipelines and equipment. Finally, high-pressure air is used to purge the residual moisture.

[0016] As an improvement to the above technical solution, in step S2, the preheating of raw materials specifically includes: collecting the waste heat of steam condensate and heating the raw materials in the aqueous phase storage tank or oil phase preparation tank through a heat exchanger.

[0017] The beneficial effects of this invention are as follows: This invention adopts a fully static emulsification process, achieving oil-water phase fusion through the principle of jet shearing, completely eliminating the need for traditional mechanical stirring devices. The emulsifier has no high-speed rotating parts, fundamentally eliminating safety hazards caused by mechanical friction, heat accumulation, and static electricity buildup.

[0018] This invention independently encapsulates the power module, pharmaceutical module, drug loading module, and packaging module within a standardized container. The modules are connected via standardized interfaces of pre-defined, fixed dimensions (including fluid piping interfaces, electrical signal interfaces, and mechanical fixing interfaces). This design enables plug-and-play production lines, supports multiple logistics methods such as sea, land, and rail transport, and significantly reduces transportation and installation costs for overseas factory construction. On-site deployment requires no complex civil engineering or secondary processing, shortening the production line installation cycle.

[0019] This invention integrates a PLC controller and an IoT module into an intelligent control system that can monitor key parameters such as oil-water phase flow rate, pressure, and temperature in real time, and automatically adjust the pump frequency to maintain a constant mixing ratio. The system features one-button start / stop, fault self-diagnosis, remote monitoring, and full production data traceability. It supports cloud management and recipe data synchronization, significantly reducing the difficulty of manual operation and the risk of misoperation, and improving the intelligence level and operational stability of production management.

[0020] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Of course, implementing any product or method of this application does not necessarily require achieving all of the advantages described above at the same time. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a framework diagram of the present invention.

[0023] Figure 2 This is a schematic diagram of the structure of the present invention.

[0024] In the diagram: 1. Container; 2. Air compressor; 3. Electric steam generator; 4. Distribution cabinet; 5. Hot water tank; 7. Oil phase storage tank; 8. Oil phase pump; 9. Oil phase preparation tank; 10. Static emulsifier; 11. Aqueous phase storage tank; 12. Aqueous phase pump; 13. Aqueous phase preparation tank; 14. Screw conveyor; 15. Crusher; 16. Protective enclosure; 17. Oil phase melting tank; 20. Conveyor belt conveyor; 21. Loading machine; 22. Main control cabinet; 23. Static sensitizer; 24. Sensitizer accelerator pump; 25. Sensitizer accelerator tank; 26. Cooling water pool; 27. Mesh conveyor; 28. Dryer; 30. Packing platform; 31. Packing platform. Detailed Implementation

[0025] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0027] Please see Figure 1 and Figure 2This embodiment provides a modular, fully static emulsion explosive production line, which aims to solve the technical problems of traditional emulsion explosive production lines, such as difficult deployment, high safety hazards of dynamic equipment, and high energy consumption.

[0028] The modular, fully static emulsion explosive production line described in this embodiment mainly includes a power module, a pharmaceutical manufacturing module, a loading module, a packaging module, and a transportable carrier. The power module, pharmaceutical manufacturing module, loading module, and packaging module are all independently packaged using the transportable carrier, forming four independent functional units.

[0029] Regarding the transportable carrier, in this embodiment, the transportable carrier is preferably a standardized container 1. Using the container 1 as the carrier enables each module of the production line to have independent sea, land, and rail transport capabilities. Each module's container 1 has standardized lifting points on its exterior, facilitating rapid loading, unloading, and transportation.

[0030] The modules are connected via standardized interfaces. These standardized interfaces include fluid piping interfaces, electrical signal interfaces, and mechanical fixing interfaces. The dimensions of the docking interfaces are preset to fixed values ​​(e.g., standardized interface diameters) to achieve seamless docking and compatibility between modules. In actual deployment, after the four containerized modules are transported to the site, only physical connections and pipeline docking are required through the standardized interfaces, eliminating the need for complex on-site civil engineering and secondary processing.

[0031] Preferably, the standardized container 1 includes at least two specifications, and the modules are connected through a standardized interface. The docking dimensions of the standardized interface are preset to a fixed value. Specifically, the transportable carrier adopts the standardized container 1. In order to adapt to the size requirements of different equipment, the standardized container 1 in this embodiment includes two specifications: The first specification has the following dimensions: 13716mm long × 2438mm wide × 2896mm high, which is mainly used to accommodate larger pharmaceutical or packaging modules. The second specification has the following dimensions: 12192mm long × 2438mm wide × 2591mm high, and is mainly used to accommodate the power module or the charge module.

[0032] The modules are connected via standardized interfaces, including fluid piping interfaces, electrical signal interfaces, and mechanical fixing interfaces. The dimensions of the docking interfaces are preset to fixed values ​​(e.g., the interface diameter is standardized to 8cm) to achieve seamless docking and compatibility between modules.

[0033] In some embodiments, the fully static emulsifier 10 employs a static mixer combining coarse and fine cutting mechanisms, progressively refining the emulsion through shearing orifices of different apertures. Specifically, the pharmaceutical module is equipped with a fully static emulsifier 10, preferably a KC-type fully static emulsifier 10. This emulsifier does not contain a mechanical stirring device and is configured to achieve oil-water phase fusion through a jet shearing principle. The fully static emulsifier 10 employs a static mixer combining coarse and fine cutting mechanisms, where the material first undergoes coarse emulsification through large-aperture shearing orifices, and then undergoes fine emulsification through small-aperture shearing orifices, progressively refining the emulsion. The internal working pressure of the fully static emulsifier 10 is controlled at ≤1.2 MPa to ensure operation within a safe pressure range.

[0034] The power module includes a hot water tank 5, a power distribution cabinet 4, an electric steam generator 3, and an air compressor 2. The electric steam generator 3 provides a heat source for the production line, and the air compressor 2 provides a high-pressure air source for cleaning and purging.

[0035] The pharmaceutical module also includes an oil phase melting tank 17, a protective box 16, a crusher 15, a screw conveyor 14, an aqueous phase preparation tank 13, an aqueous phase pump 12, an aqueous phase storage tank 11, an oil phase preparation tank 9, an oil phase pump 8, and an oil phase storage tank 7.

[0036] The system also includes an intelligent control system, comprising a PLC controller and an IoT module. This intelligent control system is configured to monitor the oil-water phase flow rate in the pharmaceutical module in real time and automatically adjust the operating frequencies of the oil phase pump 8 and the water phase pump 12 based on the monitoring data to maintain a constant oil-water phase ratio. The system supports one-button start / stop and has data traceability capabilities, allowing pressure, flow rate, and temperature data during the production process to be uploaded to the cloud.

[0037] The loading module includes a sensitizer accelerator tank 25, a sensitizer accelerator pump 24, a static sensitizer 23, a main control cabinet 22, a loading machine 21, a conveyor belt 20, and a protective housing 16. The static sensitizer 23 adopts a multi-stage static mixer with closed-loop flow regulation to ensure uniform dispersion of the sensitizer, with a dispersion uniformity error ≤5%.

[0038] The packaging module includes a packing platform 31, a conveyor belt 20, a boxing platform 30, a mesh chain conveyor 27, a dryer 28, and a cooling water tank 26.

[0039] A control method, applying the above-mentioned modular fully static emulsion explosive production line, includes the following steps: Step S1, System Startup and Self-Test Before a production task begins, the operator issues a start command through the interactive interface of the intelligent control system. The intelligent control system then performs comprehensive status monitoring of each module on the production line.

[0040] Specifically, the system automatically detects the sealing and continuity of the fluid pipeline interfaces, electrical signal interfaces, and mechanical fixing interfaces between each standardized container module 1, confirming that the standardized interface connections are normal and there are no leaks or signal interruptions.

[0041] Simultaneously, the system scans the safety status of all equipment on the production line, confirming that there are no alarms for Class 0, Class I, or Class II hazardous equipment. If any interface abnormality or hazardous equipment alarm is detected, the system will prevent the production line from starting and issue a warning signal until the fault is resolved. This step ensures that the production line operates under intrinsically safe conditions.

[0042] Step S2, oil-water phase preparation and preheating After confirming that the system is functioning normally, the raw material preparation stage begins. Oil-phase and aqueous-phase raw materials are prepared separately and then transported to their respective storage tanks.

[0043] To achieve energy conservation and consumption reduction, a heat recovery mechanism is introduced in this step. Specifically, this includes collecting the waste heat from the steam condensate generated during production and using a heat exchanger to heat the raw materials in the aqueous phase storage tank 11 or the oil phase preparation tank 9. In this way, waste heat resources are fully utilized, reducing the overall energy consumption of the production line by 30%-40%.

[0044] During this process, the intelligent control system monitors the flow data of the oil and water phases in real time through a high-precision flow meter and feeds the data back to the control center to prepare for subsequent ratio adjustment.

[0045] Step S3, fully static emulsification The preheated oil-water phase raw materials are pumped into the fully static emulsifier 10 in the pharmaceutical module via a transfer pump.

[0046] This step is primarily a completely static process. Emulsification is achieved using the jet shear principle without any mechanical stirring. The oil and water phases are driven by pressure through specific fluid channels inside the emulsifier, where high-speed jetting and strong shearing forces fully fuse them to form a latex matrix.

[0047] In terms of control strategy, the intelligent control system strictly monitors the internal working pressure of the emulsifier and keeps it within a safe range of ≤1.2 MPa. At the same time, based on the flow data monitored in step S2, the system automatically adjusts the operating frequency (variable frequency control) of the oil phase pump 8 and the water phase pump 12 to form a closed-loop feedback, so as to maintain a constant oil-water phase ratio and ensure the stability of emulsification quality.

[0048] Step S4, Static Sensitization The emulsified latex matrix is ​​fed into the static sensitizer 23 in the drug loading module.

[0049] Unlike traditional mechanical sensitization, this step employs a multi-stage static mixer combined with closed-loop flow regulation. The intelligent control system precisely controls the flow rate of the sensitizer accelerator pump 24, creating a closed-loop feedback with the latex matrix flow rate. This ensures the sensitizer is uniformly dispersed in the matrix, with a dispersion uniformity error controlled within ≤5%, thereby guaranteeing the consistent performance of the explosive product.

[0050] Step S5, loading and cooling The sensitized explosive is loaded into a cartridge via a loading machine 21. The cartridge is then conveyed by a belt conveyor 20 into a cooling water tank 26 for cooling and shaping.

[0051] In this embodiment, the length of the cooling water tank 26 is configured to be 10 meters to ensure that the medicine rolls have enough time to cool down fully and prevent the packaging quality or storage safety from being affected by excessive temperature.

[0052] Step S6, Packaging After cooling and shaping, the finished drug rolls enter the packaging module. Through the coordinated operation of the mesh conveyor 27, dryer 28, packing platform 31 and boxing platform 30, the drying, counting, boxing and packaging of the finished products are completed, forming the final deliverable product.

[0053] Step S7, Cleaning and Blowing After the production process is completed, an automatic cleaning procedure is executed to eliminate material residue and achieve environmentally friendly production. This step specifically includes the following sub-processes: High-pressure purging and discharge: First, compressed air provided by the power module is used to blow out the residual material tails in the equipment and pipelines. The high-pressure air purging pressure is controlled at 0.4-0.8 MPa. This process aims to eliminate material tails, avoid waste, and achieve zero waste discharge.

[0054] Hot water cleaning: Then, hot water is used to circulate and clean the inside of the pipes and equipment. The hot water cleaning temperature is controlled at 60-80℃ to effectively dissolve residual oily substances.

[0055] Drying and purging: Finally, use high-pressure air to purge any remaining moisture. Each purge should last at least 5 minutes until no moisture remains in the exhaust gas. This ensures that the inside of the equipment is dry, prevents corrosion, and prepares the equipment for the next production run.

[0056] Based on the above, the raw material preheating process in step S2 is further refined. In step S2, the raw material preheating specifically includes: opening a system control valve to guide the condensate from steam use into a waste heat recovery pipeline. The condensate flows through a plate heat exchanger, exchanging heat with the raw materials in the aqueous phase storage tank 11 or oil phase preparation tank 9 on the other side of the heat exchanger. The raw material temperature is monitored by a temperature sensor. When the raw material reaches a preset process temperature (e.g., the aqueous phase reaches above 80°C), the condensate flow rate is automatically adjusted or switched to a backup heat source. This process not only reduces steam consumption but also shortens the raw material heating time, further improving production efficiency.

[0057] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

Claims

1. A modular, fully static emulsion explosive production line, characterized in that, The system includes a power module, a pharmaceutical module, a drug loading module, a packaging module, and a transportable carrier. The power module, pharmaceutical module, drug loading module, and packaging module are all encapsulated using the carrier. The production line adopts a fully static emulsification process. The pharmaceutical module is equipped with a fully static emulsifier configured to achieve oil-water phase fusion through the jet shear principle.

2. The modular fully static emulsion explosive production line according to claim 1, characterized in that: The transportable carrier includes standardized containers, which include at least two specifications. The modules are connected through standardized interfaces, and the docking dimensions of the standardized interfaces are preset to fixed values.

3. The modular fully static emulsion explosive production line according to claim 1, characterized in that: The fully static emulsifier is a static mixer that combines coarse and fine cutting mechanisms, and refines the emulsion step by step through shearing holes of different diameters; the internal working pressure of the fully static emulsifier is controlled at ≤1.2Mpa.

4. The modular fully static emulsion explosive production line according to claim 1, characterized in that: The power module includes a hot water tank, a power distribution cabinet, an electric steam generator, and an air compressor.

5. A modular, fully static emulsion explosive production line according to claim 1, characterized in that: The pharmaceutical module also includes an oil phase melting tank, a protective box, a crusher, a screw conveyor, an aqueous phase preparation tank, an aqueous phase pump, an aqueous phase storage tank, an oil phase preparation tank, an oil phase pump, and an oil phase storage tank.

6. The modular fully static emulsion explosive production line according to claim 5, characterized in that: It also includes an intelligent control system, which includes a PLC controller and an Internet of Things module; the intelligent control system is configured to monitor the oil-water phase flow rate in the pharmaceutical module in real time, and automatically adjust the operating frequency of the oil phase pump and the water phase pump according to the monitoring data to maintain a constant oil-water phase ratio.

7. A modular, fully static emulsion explosive production line according to claim 1, characterized in that: The drug loading module includes a sensitizer accelerator tank, a sensitizer accelerator pump, a static sensitizer, a main control cabinet drug loading machine, a conveyor belt conveyor, and a protective housing.

8. A modular, fully static emulsion explosive production line according to claim 1, characterized in that: The packaging module includes a packing platform, a conveyor belt, a boxing platform, a mesh conveyor, a dryer, and a cooling water tank.

9. A control method applied to a modular, fully static emulsion explosive production line as described in any one of claims 1-8, characterized in that, Includes the following steps: Step S1, System Start-up and Self-Check: The intelligent control system performs status checks on each module of the production line to confirm that the standardized interface connections are normal and there are no alarms from Class 0, Class I or Class II hazardous equipment. Step S2, oil-water phase preparation and preheating: Prepare oil-water raw materials, preheat the oil-water raw materials, and monitor the flow rate of the oil-water phase in real time using a flow meter; Step S3, fully static emulsification: The preheated oil-water phase is pumped into the fully static emulsifier. Emulsification is carried out through the jet shear principle without the use of mechanical stirring. The working pressure inside the emulsifier is controlled to be ≤1.2Mpa. The intelligent control system automatically adjusts the working frequency of the oil-water phase pump according to the flow monitoring data to maintain a constant ratio. Step S4, Static sensitization: The emulsified latex matrix is ​​fed into a static sensitizer, and the sensitizer is uniformly dispersed by a multi-stage static mixer in conjunction with closed-loop flow regulation. Step S5, loading and cooling: The sensitized explosive is loaded into the explosive cartridge and cooled and shaped by a cooling water tank; Step S6, Packaging: The finished product is packed and boxed using the packaging module; Step S7, Cleaning and Purging: After the production process is completed, a cleaning procedure is performed. First, high-pressure air is used to blow out the residual material tails in the equipment to eliminate the material tails. Then, hot water is used to clean the pipelines and equipment. Finally, high-pressure air is used to purge the residual moisture.

10. The control method according to claim 9, characterized in that: In step S2, the preheating of raw materials specifically includes: collecting the waste heat from the steam condensate and heating the raw materials in the aqueous phase storage tank or oil phase preparation tank through a heat exchanger.

Images