A sludge fluidized bed drying operation health diagnosis system and method

Abstract

The application discloses a sludge fluidized bed drying operation health diagnosis system and method, which comprises: a multi-fault monitoring module, which is used for monitoring leakage of a steam inlet pipeline, wear of a sludge inlet screw, fluctuation of sludge inlet moisture content, operation cycle of an ash bin, a blowdown tank and a cutting machine, belt breakage of a cooling fan and state of a tower body and a heat exchanger; an intelligent control and adjustment module, which is used for acquiring monitoring data of the multi-fault monitoring module, analyzing and judging the monitoring data, triggering a fault early warning and issuing instructions and suggestions; and a visual monitoring and early warning platform, which is used for displaying the monitoring data of the multi-fault monitoring module and fault prompts of the intelligent control and adjustment module and setting an audible and visual alarm and a pop-up prompt. The application realizes all-round real-time health monitoring and intelligent diagnosis of a sludge fluidized bed drying system, early warning of potential faults, reduction of unplanned downtime, optimization of process parameter control logic, precise adjustment and reduction of sludge treatment cost.

Description

Technical Field

[0001] This invention relates to sludge treatment equipment technology, and more specifically, to a sludge fluidized bed drying operation health diagnosis system and method. Background Technology

[0002] The core equipment of a fluidized bed incineration system is the fluidized bed incinerator. Inside the furnace, there is a suspended combustion zone. When stationary, a 1-1.5m thick fine sand bed, with silica sand of several mesh sizes, sits above the air distribution pipes in the furnace. During operation, primary air is introduced through the lower air distribution pipes and blown downwards at a certain speed from nozzles installed below the pipes, causing the fine sand bed to "boil," creating a fluidized bed of approximately 2-2.5m. The primary air consists of circulating air from the sludge bins and a portion of fresh air, ensuring the fluidization of the silica sand and the combustion of the material. A portion of the washed carrier gas is introduced into the combustion chamber as secondary air to ensure complete combustion. Each incinerator has two sludge feed inlets to ensure uniform feeding and stable combustion. The lower part of the incinerator is conical for easy slag removal.

[0003] However, traditional sludge fluidized bed drying systems mainly rely on manual experience to judge faults, and only have basic operating parameter display functions, lacking a systematic fault monitoring and early warning mechanism; fault diagnosis requires manual comparison and analysis of multiple parameters, and the detection of hidden faults (such as steam coil leakage and screw pump stator and rotor wear) is delayed; process parameters are adjusted manually, which has problems such as lag and insufficient accuracy; the system lacks visual monitoring, automatic adjustment and intelligent alarm functions, which is inconsistent with the current background of digital transformation in the wastewater treatment industry.

[0004] In summary, the main disadvantages of traditional fluidized bed sludge drying systems are:

[0005] (1) Delayed fault diagnosis: Hidden faults cannot be intuitively judged by a single parameter, lack intelligent early warning and automatic adjustment functions, and require manual intervention for analysis. By the time they are discovered, they have already caused serious impacts such as a decrease in processing capacity and an increase in energy consumption.

[0006] (2) Poor operational stability: Fluctuations in the moisture content of the feed mud and equipment malfunctions can easily lead to system interlock shutdowns, with recovery time of up to 3 to 6 hours after shutdown, affecting operational stability;

[0007] (3) Low accuracy: The accuracy of fault diagnosis depends on the operator's experience, resulting in low efficiency and high energy consumption due to untimely fault handling. Summary of the Invention

[0008] To address the shortcomings of existing technologies, the purpose of this invention is to provide a health diagnosis system and method for the drying operation of sludge fluidized bed, enabling comprehensive real-time health monitoring and intelligent diagnosis of the sludge fluidized bed drying system, providing early warning of potential faults, reducing unplanned downtime; optimizing process parameter control logic to achieve precise adjustment and reduce sludge treatment costs; and improving the level of intelligent system operation and maintenance, reducing manual intervention.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] The first aspect of this invention provides a health diagnostic system for the drying operation of a sludge fluidized bed, comprising:

[0011] The multi-fault monitoring module monitors in real time the leakage of steam inlet pipe, wear of mud screw, fluctuation of mud moisture content, operating cycle of ash silo / sewage tank / cutting machine, belt breakage of cooling fan and status of tower body / heat exchanger.

[0012] The intelligent control and adjustment module acquires the monitoring data from the multi-fault monitoring module, analyzes and judges the monitoring data, triggers fault warnings, and issues instructions and suggestions.

[0013] A visual monitoring and early warning platform is used to display the monitoring data of the multi-fault monitoring module, as well as the fault prompts and settings for audible and visual alarms and pop-up prompts of the intelligent control and adjustment module.

[0014] Preferably, the multi-fault monitoring module includes:

[0015] The steam-to-material ratio monitoring unit collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the mud screw pump in real time, calculates the steam-to-material ratio, and sets leakage warning thresholds and screw wear warning thresholds.

[0016] The pressure control unit collects data from the pressure sensor on the feed screw pump in real time to assess the fluctuation of the feed sludge moisture content;

[0017] The equipment operates a timer unit to collect real-time data from the timer on the ash silo conveying screw / sewage pump in the ash silo, and presets an early warning cycle;

[0018] The current / response ratio monitoring unit collects the current and load data of the cooling tower cooling fan in real time, and provides early warning of belt breakage faults through changes in the ratio;

[0019] The liquid level / flow rate monitoring unit collects real-time liquid level / flow rate data of the cooling tower to assess the liquid level status of the cooling tower and the opening status of the water supply valve of the carrier gas scrubbing tower.

[0020] Preferably, the intelligent control and adjustment module includes:

[0021] The sensing unit is used to collect data from each sensor;

[0022] The control unit acquires data from the sensing unit, analyzes and judges the monitoring data, triggers fault warnings, and issues instructions and suggestions.

[0023] The execution unit receives instructions and suggestions from the control unit.

[0024] The second aspect of this invention provides a method for health diagnosis of the drying operation of a sludge fluidized bed, comprising the following steps performed using the sludge fluidized bed health diagnosis system provided in the first aspect of this invention:

[0025] S1, the multi-fault monitoring module monitors in real time the leakage of steam inlet pipe, wear of mud screw, fluctuation of mud moisture content, operating cycle of ash silo / sewage tank / cutting machine, belt breakage of cooling fan and status of tower body / heat exchanger;

[0026] S2, the intelligent control and adjustment module determines whether the warning threshold has been triggered. If yes, proceed to step S3; if no, continue collecting and judging data.

[0027] S3, the intelligent control and adjustment module executes an audible and visual alarm, and the visual monitoring and early warning platform provides fault indication;

[0028] S4 processes responses in a tiered manner and provides feedback on the processed data.

[0029] S5, process parameters optimized, fault database updated.

[0030] Preferably, the intelligent control and adjustment module determines whether the warning threshold is triggered by specifically including:

[0031] The system includes warnings for various parameters such as feed mud moisture content, feed mud screw pump pressure, steam coil leakage, steam-to-material ratio, feed mud screw pump speed, feed mud screw pump malfunction, ash silo timer, ash silo system conveying malfunction, sludge discharge tank timer, sludge discharge tank malfunction, and current / combination ratio, as well as warnings for cooling tower malfunction.

[0032] Preferably, the influent sludge moisture content-influent screw pump pressure linkage early warning specifically includes the following steps:

[0033] S1, the pressure control unit in the multi-fault monitoring module collects data from the pressure sensor on the mud feed screw pump in real time;

[0034] S2, determine whether the outlet pressure of the sludge screw pump is ≥ the warning threshold? If yes, the moisture content of the sludge screw pump is within the set range; if no, proceed to step S3;

[0035] S3, determine whether the outlet pressure of the sludge screw pump is less than the warning threshold? If yes, proceed to step S4; if no, the moisture content of the sludge screw pump is within the set range.

[0036] S4 triggers dual warnings: low pressure, high moisture content;

[0037] S5, the intelligent control and adjustment module pushes an early warning to the operator;

[0038] S6, activate the pressure control unit;

[0039] S7, calculate the actual speed of the mud feed screw pump = (screw pump speed × 7) + base speed + pressure compensation, and determine whether the pressure control unit is turned on;

[0040] S8, the operator adjusts the dehydration process to restore the moisture content;

[0041] S9, pressure rises, warning lifted, maintain adjusted speed.

[0042] Preferably, the steam coil leakage-steam-fuel ratio linkage early warning specifically includes the following steps:

[0043] S1, the steam-to-material ratio monitoring unit in the multi-fault monitoring module collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the mud screw pump in real time;

[0044] S2, calculate the steam-to-material ratio = total speed of the screw pump / steam inlet flow rate;

[0045] S3, determine if the steam-to-material ratio is ≤ the warning threshold? If yes, then there is no leakage in the steam inlet pipe; if no, proceed to step S4.

[0046] S4. Determine if the steam-to-material ratio is greater than the warning threshold. If yes, proceed to step S5; otherwise, the steam inlet pipe is leak-free.

[0047] S5, triggering a suspected warning from the gas-to-material ratio monitoring unit;

[0048] S6. Determine if both steam pressure and condensate flow rate have decreased. If yes, proceed to step S7; otherwise, it is a misjudgment, and other causes should be investigated.

[0049] S7, leakage is confirmed, and the gas-to-material ratio monitoring unit triggers a fault alarm;

[0050] S8, shutdown for maintenance, repair of leaks;

[0051] S9, system restart, parameters restored.

[0052] Preferably, the screw pump speed-screw pump fault early warning specifically includes the following steps:

[0053] S1, the steam-to-material ratio monitoring unit in the multi-fault monitoring module collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the mud screw pump in real time;

[0054] S2, determine if the actual gas-to-feed ratio is greater than the warning threshold? If yes, proceed to step S3; if no, the parameters of the sludge screw pump are normal; and / or

[0055] Is the outlet pressure of a single sludge screw pump less than the warning threshold? If yes, proceed to step S3; if no, the parameters of the sludge screw pump are normal.

[0056] S3, determine if the outlet pressure of the sludge feed screw pump is abnormal. If yes, proceed to step S4; if no, determine the fluctuation of moisture content and implement linkage control with the steam coil leakage-steam-feed ratio early warning system; and / or

[0057] Determine if the outlet pressure of all the aforementioned sludge screw pumps drops simultaneously. If yes, determine the fluctuation of moisture content and implement a linked early warning and control system for steam coil leakage and steam-to-feed ratio. If no, proceed to step S4.

[0058] S4, determine that the rotor of the sludge feed screw pump is worn, trigger an alarm, and shut down the pump for replacement; and / or

[0059] If the universal joint of the sludge feed screw pump is found to be broken, an alarm should be triggered and the pump should be shut down for replacement.

[0060] Preferably, the ash silo timer-ash silo system ash conveying fault early warning specifically includes the following steps:

[0061] S1, the material level probe in the ash hopper and the timer on the ash conveying screw in the ash hopper are started;

[0062] S2, determine if the material level in the ash hopper has triggered the high-level probe? If not, the material level is normal; if so, start the ash conveying screw of the ash hopper, and the timer records the running time; and / or

[0063] Determine if the material level in the ash hopper has triggered the high-high level probe. If not, the material level is normal; if so, the system should trip immediately.

[0064] S3, determine whether the high level alarm in the ash hopper is cleared within 1 hour. If not, issue a warning; if yes, determine whether the ash hopper level triggers the low level probe. If not, the level is normal; if yes, proceed to step S4.

[0065] S4, stop the ash conveying screw and reset the timer;

[0066] S5. Determine whether the cumulative operation of the ash conveying spiral is greater than the warning threshold. If yes, issue a warning; otherwise, end the process.

[0067] Preferably, the sewage tank timer-sewage tank fault early warning specifically includes the following steps:

[0068] S1, monitoring of the inlet water level in the sewage tank and starting of the timer on the sewage tank;

[0069] S2, Determine if the liquid level in the sewage tank triggers the high liquid level gauge. If not, the liquid level is normal; if yes, proceed to step S3.

[0070] S3, start the sewage pump of the sewage tank, and the timer records the running time;

[0071] S4. Determine if the running time of the sewage pump is ≤ the warning threshold. If not, proceed to step S5. If yes, continue to determine if the liquid level of the sewage tank triggers the low liquid level gauge. If no, the liquid level is normal. If yes, stop the sewage pump and reset the timer.

[0072] S5, triggering an audible and visual alarm, indicating an abnormality in the sewage tank;

[0073] S6. Isolate the sewage tank and troubleshoot the fault.

[0074] Preferably, the current / response ratio-cooling tower fault early warning specifically includes the following steps:

[0075] S1, the current / compliance ratio monitoring unit in the multi-fault monitoring module collects the current and load data of the cooling tower cooling fan, the liquid level of the cooling tower, the opening degree of the water supply valve of the carrier gas scrubbing tower and the outlet pressure of the circulating pump in real time.

[0076] S2, calculate the current-to-load ratio of the cooling tower's cooling fan and determine if this ratio continues to decrease. If yes, trigger a suspected belt breakage warning for the cooling tower's cooling fan; if no, the cooling tower's cooling fan is operating normally; and / or

[0077] Does the cooling tower's liquid level trigger a low liquid level warning? If yes, trigger the cooling tower's low liquid level audible and visual alarm; if no, the cooling tower's liquid level is normal; and / or

[0078] Determine if the water supply valve of the carrier gas scrubbing tower is fully open. If yes, trigger the insufficient water supply warning for the cooling tower; if no, the water supply to the cooling tower is normal; and / or

[0079] Determine if the outlet pressure of the circulating pump is abnormal. If yes, the circulating pump is overloaded and the fluidizing air temperature is rising; if no, the circulating pump pressure is normal.

[0080] S3, determine if the current-to-load ratio of the cooling tower's cooling fan is 0? If yes, determine that the cooling tower's cooling fan belt is broken and shut down for maintenance; if no, issue a warning; and / or

[0081] The cooling tower is activated to replenish water using reclaimed water; and / or

[0082] Troubleshooting the water supply valve of the carrier gas scrubbing tower; and / or

[0083] Adjust the parameters of the circulating pump.

[0084] This invention provides a sludge fluidized bed drying operation health diagnosis system and method. Through multi-module collaborative monitoring, it solves the problem of delayed fault diagnosis in traditional systems. Modules such as gas-to-material ratio monitoring and timers can diagnose faults in real time, reducing the fault judgment time from 2-3 weeks to within one day. Automatic parameter adjustment is achieved through a visualization platform, audible and visual alarm functions, and intelligent control logic, solving the problem of untimely response to manual adjustments, preventing continuous system deterioration, and ensuring continuous and stable system operation. Based on preset parameters from operational experience, the system automatically judges faults, resulting in more objective and accurate fault diagnosis. It also has the following beneficial effects:

[0085] (1) No need to replace the core equipment of sludge fluidized bed drying. It can be directly modified on the basis of the existing automatic control system. The modification cost is low and the cycle is short. It is suitable for sludge drying projects of all sizes.

[0086] (2) Multi-module collaborative monitoring can diagnose the core faults of the system in real time, with high accuracy and reduce fault handling time by more than 60%;

[0087] (3) Through parameter optimization and early fault handling, the cost reduction and efficiency improvement effects are significant;

[0088] (4) Intelligent early warning and visualization interface reduce the intensity of manual labor, reduce the number of unplanned shutdowns, and increase the continuous running time of the system, creating significant economic and environmental benefits for existing sewage treatment plants. Attached Figure Description

[0089] Figure 1 This is a schematic flowchart of the drying operation health diagnosis method of the present invention;

[0090] Figure 2 This is a schematic diagram of the process for early warning of the linkage between the moisture content of the feed mud and the pressure of the feed mud screw pump in the drying operation health diagnosis method of the present invention;

[0091] Figure 3 This is a schematic diagram of the steam coil leakage-steam-material ratio linkage early warning process in the dry operation health diagnosis method of the present invention;

[0092] Figure 4This is a flowchart illustrating the process of screw pump speed and screw pump fault early warning in the drying operation health diagnosis method of the present invention.

[0093] Figure 5 This is a schematic diagram of the process for early warning of ash conveying faults in the ash silo timer-ash silo system in the drying operation health diagnosis method of the present invention;

[0094] Figure 6 This is a schematic diagram of the process of drain tank timer-drain tank fault early warning in the dry operation health diagnosis method of the present invention;

[0095] Figure 7 This is a schematic diagram of the current / compliance ratio-cooling tower fault early warning process in the dry operation health diagnosis method of the present invention. Detailed Implementation

[0096] To better understand the above-mentioned technical solutions of the present invention, the technical solutions of the present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0097] This invention provides a health diagnostic system for the drying operation of a sludge fluidized bed, comprising:

[0098] The multi-fault monitoring module monitors in real time the leakage of steam inlet pipe, wear of mud inlet screw, fluctuation of mud moisture content, operating cycle of ash silo / sewage tank / cutting machine, belt breakage of cooling fan, and status of tower body / heat exchanger.

[0099] The intelligent control and adjustment module acquires monitoring data from multiple fault monitoring modules, analyzes and judges the monitoring data, triggers fault warnings, and issues instructions and suggestions.

[0100] The visual monitoring and early warning platform reconstructs the monitoring interface to display monitoring data from multiple fault monitoring modules (integrating monitoring data, fault prompts, and process parameter curves from each module), as well as fault prompts from the intelligent control and adjustment module and the setting of audible and visual alarms and pop-up prompts (setting audible and visual alarms and pop-up prompts; pushing fault information in real time when a fault occurs, clearly identifying the fault location and handling steps; storing historical data when faults occur through the server, supporting traceability analysis).

[0101] In this invention, the multi-fault monitoring module includes:

[0102] The steam-to-material ratio monitoring unit collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the sludge screw pump in real time, calculates the steam-to-material ratio, sets leakage warning thresholds and screw wear warning thresholds, and, in conjunction with steam inlet pressure and condensate return flow data, accurately diagnoses operational faults in real time.

[0103] The pressure control unit collects data from the pressure sensor on the feed screw pump in real time to assess fluctuations in the moisture content of the feed mud.

[0104] The equipment operates a timer unit that collects real-time timer data from the ash conveying screw / sewage pump in the ash silo and presets an early warning cycle. If the threshold is exceeded, an audible and visual alarm is triggered.

[0105] The current / response ratio monitoring unit collects real-time current and load data of the cooling tower's cooling fans and provides early warning of belt breakage faults based on changes in the ratio.

[0106] The liquid level / flow rate monitoring unit collects real-time liquid level / flow rate data of the cooling tower to assess the liquid level status of the cooling tower and the opening status of the water supply valve of the carrier gas scrubbing tower.

[0107] In this invention, the intelligent control and adjustment module includes:

[0108] The sensing unit collects data from pressure, temperature, flow rate, and speed sensors, covering key components such as the sludge feeding system, steam system, and ash silo system, and transmits the data to the control unit.

[0109] The control unit optimizes the original PLC control logic, acquires data from the sensing unit, analyzes and judges the monitoring data, triggers fault warnings, and issues instructions and suggestions to the execution unit or operator.

[0110] The execution unit receives instructions and suggestions from the control unit to achieve more precise PID control.

[0111] Combination Figure 1 As shown, the present invention also provides a method for health diagnosis of sludge fluidized bed drying operation, which involves performing the following steps using the drying operation health diagnosis system of the present invention:

[0112] S1, a multi-fault monitoring module, monitors in real time the leakage of steam inlet pipe, wear of mud screw, fluctuation of mud moisture content, operating cycle of ash silo / sewage tank / cutting machine, belt breakage of cooling fan and status of tower body / heat exchanger.

[0113] S2, the intelligent control and adjustment module determines whether the warning threshold has been triggered. If yes, proceed to step S3; otherwise, continue collecting and judging data.

[0114] S3, the intelligent control and adjustment module executes audible and visual alarms, and the visual monitoring and early warning platform provides fault location and prompts;

[0115] S4 processes responses in a tiered manner and provides feedback on the processed data.

[0116] S5, process parameters are optimized, fault database is updated, and continuous monitoring is performed in the return step S1.

[0117] In this invention, the hierarchical processing response specifically includes:

[0118] (1) Online maintenance: Isolate the faulty subsystem (such as the sewage tank / filter);

[0119] (2) Parameter adjustment: Automatic / manual optimization (speed / pressure / feed rate);

[0120] (3) Component replacement: quick-opening valve auxiliary replacement (venting valve / stator / rotor / cutter head).

[0121] In this invention, the intelligent control and adjustment module determines whether the warning threshold is triggered by specifically including:

[0122] The system includes warnings for various parameters such as feed mud moisture content, feed mud screw pump pressure, steam coil leakage, steam-to-material ratio, feed mud screw pump speed, feed mud screw pump malfunction, ash silo timer, ash silo system conveying malfunction, sludge discharge tank timer, sludge discharge tank malfunction, and current / combination ratio, as well as warnings for cooling tower malfunction.

[0123] Combination Figure 2 As shown, the early warning system for the linkage between the moisture content of the feed mud and the pressure of the feed mud screw pump in this invention specifically includes the following steps:

[0124] S1, the fluidized bed drying system is started. In this invention, the pressure control unit in the multi-fault monitoring module collects the data of the pressure sensor on the mud screw pump and the rotation speed data of the mud screw pump in real time.

[0125] S2, determine whether the outlet pressure of the sludge screw pump is ≥ the warning threshold (e.g., 6.5 bar)? If yes, the moisture content of the sludge screw pump is within the set range (e.g., 77%~79%), and the operating parameters are maintained; if not, proceed to step S3;

[0126] S3, determine if the outlet pressure of the sludge screw pump is less than the warning threshold (e.g., 6.5 bar)? If yes, proceed to step S4; if no, the moisture content of the sludge screw pump is within the set range (e.g., 77%~79%), and maintain the operating parameters.

[0127] S4 triggers a dual warning: low pressure + high moisture content;

[0128] S5, the intelligent control and regulation module pushes early warnings to the operators of the drying / upstream dehydration process;

[0129] S6, activate the pressure control unit (activation switch on).

[0130] S7, calculate the actual speed of the feed screw pump = (screw pump speed × 7) + base speed + pressure compensation (pressurize if low, depressurize if high);

[0131] S8, the operator adjusts the dehydration process to restore the moisture content;

[0132] S9, pressure rises, warning lifted, maintain adjusted speed;

[0133] S10, End: Fluidized bed is operating stably.

[0134] In this invention, step S1 also simultaneously determines whether the pressure control unit is activated. If not, proceed to step S7; if so, manually adjust the base speed (original logic: cutting machine speed = screw pump speed × 7 + base speed) before proceeding to step S10 to end.

[0135] Combination Figure 3 As shown, the steam coil leakage-steam-fuel ratio linkage early warning system in this invention specifically includes the following steps:

[0136] S1, the fluidized bed drying system is started. In this invention, the steam-to-material ratio monitoring unit in the multi-fault monitoring module collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the mud screw pump in real time, as well as the steam inlet pressure and condensate return flow rate.

[0137] S2, calculate the steam-to-material ratio = total speed of the screw pump for mud feeding (rpm) / steam inlet flow rate (t / h), with a baseline of 17.14;

[0138] S3, determine if the steam-to-material ratio is ≤ the warning threshold (e.g., 20 rpm / t / h)? If yes, there is no leakage in the steam inlet pipeline, and operation is maintained until step S10 is reached; otherwise, proceed to step S4.

[0139] S4. Determine if the steam-to-material ratio is greater than the warning threshold (e.g., 20 rpm / t / h). If yes, proceed to step S5; otherwise, if there is no leakage in the steam inlet pipeline, continue operation until step S10 is reached.

[0140] S5 triggered a suspected warning from the gas-to-material ratio monitoring unit;

[0141] S6. Determine if both steam pressure and condensate flow rate have decreased. If yes, proceed to step S7; otherwise, it is a misjudgment (e.g., moisture content fluctuation), and other causes should be investigated.

[0142] S7, leakage confirmed, gas-to-material ratio monitoring unit triggers fault alarm;

[0143] S8, shutdown for maintenance, repair of leaks;

[0144] S9, system reboot, parameters restored;

[0145] S10, End: System is running stably.

[0146] Combination Figure 4 As shown, the screw pump speed-screw pump fault early warning method in this invention specifically includes the following steps:

[0147] S1, the mud screw pump starts running, and the steam-to-material ratio monitoring unit in the multi-fault monitoring module collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the mud screw pump in real time;

[0148] S2, monitor stator / rotor wear, calculate the steam-to-material ratio (baseline 30.39, fluctuation ±10%), and determine if the actual steam-to-material ratio > the warning threshold (e.g., 32 rpm / t / h). If yes, proceed to step S3; if no, the parameters of the sludge screw pump are normal, there is no fault, and operation is maintained; and / or

[0149] Determine if the outlet pressure of a single sludge screw pump is less than the warning threshold (e.g., 2 bar). If yes, proceed to step S3; otherwise, the parameters of the sludge screw pump are normal, there is no fault, and operation continues.

[0150] S3, determine if the outlet pressure of the sludge screw pump is abnormal. If yes, proceed to step S4; if no, determine the fluctuation of moisture content and implement linkage control with the steam coil leakage-steam-feed ratio early warning system; and / or

[0151] Determine if the outlet pressure of all the sludge screw pumps drops simultaneously. If yes, determine the fluctuation of the moisture content and implement a linkage control system with the steam coil leakage-steam-feed ratio early warning. If no, proceed to step S4.

[0152] S4, determine rotor wear of the mud feed screw pump, trigger an alarm and shut down for replacement; and / or

[0153] If the universal joint of the sludge feed screw pump is found to be broken, trigger an alarm and shut down the machine for replacement;

[0154] S5, End: Sludge entry stabilized.

[0155] Combination Figure 5 As shown, the ash silo timer-ash silo system ash conveying fault early warning in this invention specifically includes the following steps:

[0156] S1, fluidized bed operation, dust collection in ash hopper, material level probe in ash hopper and timer on ash conveying screw in ash hopper start;

[0157] S2, determine if the material level in the ash hopper has triggered the high-level sensor? If not, the material level is normal, continue operation; if so, start the ash conveying screw in the ash hopper, and the timer records the running time; and / or

[0158] Determine if the material level in the ash hopper has triggered the high-high level probe. If not, the material level is normal and operation continues; if so, the system should be shut down immediately and the ash hopper emptied (3-6 hours) to troubleshoot the fault.

[0159] S3, determine if the high level alarm in the ash hopper is cleared within 1 hour? If not, issue a warning: check the high level alarm probe and adjust process parameters (feed distributor / ash conveying speed); if yes, then determine if the ash hopper level triggers the low level probe? If no, the level is normal and operation continues; if yes, proceed to step S4.

[0160] S4: Stop the ash conveyor screw and reset the timer;

[0161] S5, determine if the cumulative operation of the ash conveying screw is greater than the warning threshold (e.g., 24h). If yes, issue a warning: check the low alarm probe (adjust parameters normally / replace if abnormal); if no, end: the ash silo is operating stably.

[0162] Combination Figure 6 As shown, the sewage tank timer-sewage tank fault early warning system of this invention specifically includes the following steps:

[0163] S1, the carrier gas scrubbing system is running, the sewage tank is put into use, the sewage tank is filled with water (differential pressure + timer), the water level in the sewage tank is monitored and the timer of the sewage pump on the sewage tank is started;

[0164] S2, Determine if the liquid level in the sewage tank triggers the high level gauge. If not, the liquid level is normal, continue operation and proceed directly to step S7; if yes, proceed to step S3.

[0165] S3, start the sewage pump of the sewage tank, and the timer records the running time;

[0166] S4. Determine if the running time of the sewage pump is ≤ the warning threshold (e.g., 20 min). If not, proceed to step S5. If yes, continue to determine if the liquid level in the sewage tank triggers the low liquid level gauge. If not, the liquid level is normal, continue running and proceed directly to step S7. If yes, stop the sewage pump, reset the timer and proceed directly to step S7.

[0167] S5 triggers an audible and visual alarm, indicating an abnormality in the sewage tank;

[0168] S6, isolate the sewage tank (without affecting the fluidized bed), troubleshoot the fault (level probe / sewage pump universal joint / inlet valve), repair the fault, restore operation, and clear the alarm;

[0169] S7, End: Carrier gas system is stable.

[0170] Combination Figure 7 As shown, the current / results ratio-cooling tower fault early warning system in this invention specifically includes the following steps:

[0171] S1, the cooling tower system starts up, supplying water / cooling the carrier gas scrubbing system. The current / compliance ratio monitoring unit in the multi-fault monitoring module collects the current and load data of the cooling tower cooling fan, the liquid level of the cooling tower, the opening of the water supply valve of the carrier gas scrubbing tower, and the outlet pressure of the circulating pump in real time.

[0172] S2, Cooling Tower Cooling Fan Fault Monitoring Branch: Calculates the ratio of cooling tower cooling fan current to load and determines if this ratio is continuously decreasing. If yes, it triggers a suspected belt breakage warning for the cooling tower cooling fan; if no, the cooling tower cooling fan is operating normally, maintaining load control; and / or

[0173] Cooling tower liquid level monitoring branch: Determine if the cooling tower liquid level has triggered a low liquid level warning. If yes, trigger the low liquid level audible and visual alarm and upgrade the alarm response level; if no, the cooling tower liquid level is normal, and maintain the original water supply method (soft water device supply); and / or

[0174] Insufficient water supply warning branch: Determine if the water supply valve of the carrier gas scrubber is fully open. If yes, trigger the insufficient water supply warning for the cooling tower; if not, the cooling tower's water supply is normal, maintaining the valve opening; and / or

[0175] Circulating pump outlet pressure monitoring branch: Determine if the circulating pump outlet pressure is abnormal (displaying bad points / too high)? If yes, the circulating pump load is out of control and the fluidizing air temperature rises; if no, the circulating pump pressure is normal and maintains the water supply to the plate heat exchanger.

[0176] S3, Cooling Tower Cooling Fan Fault Monitoring Branch: Determine if the cooling tower cooling fan current-to-load ratio is 0. If yes, confirm an abnormal shutdown / belt breakage of the cooling tower cooling fan, trigger a fault alarm, and shut down for maintenance; if no, issue a warning: belt aging, prompt inspection and replacement; and / or

[0177] Cooling tower liquid level monitoring branch: The cooling tower starts reclaimed water for replenishment (adding a new water source) to reduce water consumption and take emergency measures: reduce on-site sewage discharge, and provide emergency water replenishment; and / or

[0178] Water supply shortage early warning branch: Troubleshoot the water supply valve of the carrier gas scrubber: abnormal inlet filter / front-end water supply process, restore water supply function, restore water supply flow; and / or

[0179] Circulating pump outlet pressure monitoring branch: Adjust the parameters of the circulating pump to avoid triggering fluidized bed over-temperature shutdown;

[0180] S4, End: The cooling tower has resumed stable operation.

[0181] In summary, this invention is applicable to fault monitoring, parameter optimization, and intelligent operation and maintenance of core equipment in sludge drying processes at wastewater treatment plants, and can be extended to health management scenarios for similar drying equipment in environmental protection, chemical, and other industries. It also features multi-module collaborative monitoring: integrating a steam-to-material ratio monitoring module, a running timer module, and a pressure / temperature sensor linkage module, covering seven types of core faults including steam coil leakage, screw pump failure, and ash silo anomalies; intelligent control logic: developing a pressure control module and automatic adjustment algorithm to dynamically adjust parameters such as feed distributor speed and steam flow rate, adapting to fluctuations in sludge moisture content and maintaining system operational balance; visualization and alarm upgrades: reconstructing the monitoring interface, integrating fault prompts, parameter curves, and audible and visual alarm functions, and pushing fault locations and handling suggestions in real time; and modular and compatible design: each monitoring module can be installed and debugged independently, supporting direct modification of existing automatic control systems and adapting to fluidized bed drying equipment of different treatment scales. This invention builds upon existing fluidized bed drying automatic control systems, collecting, analyzing, and processing system data to achieve visualized monitoring, audible and visual alarms, and automatic adjustment functions. This reduces manual intervention, shortens fault diagnosis and handling time, and improves the safety, stability, and continuity of system operation. It eliminates the need for large-scale replacement of core equipment, resulting in low-cost, short-cycle modifications and easy implementation.

[0182] Those skilled in the art should recognize that the above embodiments are merely illustrative of the present invention and are not intended to limit the present invention. Any variations or modifications to the above embodiments that are within the spirit and essence of the present invention will fall within the scope of the claims of the present invention.

Claims

1. A sludge fluidized bed drying operation health diagnosis system, characterized in that, include: The multi-fault monitoring module monitors in real time the leakage of steam inlet pipe, wear of mud screw, fluctuation of mud moisture content, operating cycle of ash silo / sewage tank / cutting machine, belt breakage of cooling fan and status of tower body / heat exchanger. The intelligent control and adjustment module acquires the monitoring data from the multi-fault monitoring module, analyzes and judges the monitoring data, triggers fault warnings, and issues instructions and suggestions. A visual monitoring and early warning platform is used to display the monitoring data of the multi-fault monitoring module, as well as the fault prompts and settings for audible and visual alarms and pop-up prompts of the intelligent control and adjustment module.

2. The sludge fluidized bed drying operation health diagnosis system according to claim 1, characterized in that, The multi-fault monitoring module includes: The steam-to-material ratio monitoring unit collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the mud screw pump in real time, calculates the steam-to-material ratio, and sets leakage warning thresholds and screw wear warning thresholds. The pressure control unit collects data from the pressure sensor on the feed screw pump in real time to assess the fluctuation of the feed sludge moisture content; The equipment operates a timer unit to collect real-time data from the timer on the ash silo conveying screw / sewage pump in the ash silo, and presets an early warning cycle; The current / response ratio monitoring unit collects the current and load data of the cooling tower cooling fan in real time, and provides early warning of belt breakage faults through changes in the ratio; The liquid level / flow rate monitoring unit collects real-time liquid level / flow rate data of the cooling tower to assess the liquid level status of the cooling tower and the opening status of the water supply valve of the carrier gas scrubbing tower.

3. The sludge fluidized bed drying operation health diagnosis system according to claim 2, characterized in that, The intelligent control and adjustment module includes: The sensing unit is used to collect data from each sensor; The control unit acquires data from the sensing unit, analyzes and judges the monitoring data, triggers fault warnings, and issues instructions and suggestions. The execution unit receives instructions and suggestions from the control unit.

4. A method for health diagnosis of a sludge fluidized bed during drying operation, characterized in that, The following steps are performed using the sludge fluidized bed drying operation health diagnosis system as described in any one of claims 1-3: S1, the multi-fault monitoring module monitors in real time the leakage of steam inlet pipe, wear of mud screw, fluctuation of mud moisture content, operating cycle of ash silo / sewage tank / cutting machine, belt breakage of cooling fan and status of tower body / heat exchanger; S2, the intelligent control and adjustment module determines whether the warning threshold has been triggered. If yes, proceed to step S3; if no, continue collecting and judging data. S3, the intelligent control and adjustment module executes an audible and visual alarm, and the visual monitoring and early warning platform provides fault indication; S4 processes responses in a tiered manner and provides feedback on the processed data. S5, process parameters optimized, fault database updated.

5. The method for health diagnosis of sludge fluidized bed drying operation according to claim 4, characterized in that, The intelligent control and adjustment module determines whether the warning threshold is triggered by specifically including: The system includes warnings for various parameters such as feed mud moisture content, feed mud screw pump pressure, steam coil leakage, steam-to-material ratio, feed mud screw pump speed, feed mud screw pump malfunction, ash silo timer, ash silo system conveying malfunction, sludge discharge tank timer, sludge discharge tank malfunction, and current / combination ratio, as well as warnings for cooling tower malfunction.

6. The method for health diagnosis of sludge fluidized bed drying operation according to claim 5, characterized in that, The specific details of the mud feed moisture content - mud feed screw pump pressure linkage early warning system are as follows: Includes the following steps: S1, the pressure control unit in the multi-fault monitoring module collects data from the pressure sensor on the mud feed screw pump in real time; S2, determine whether the outlet pressure of the sludge screw pump is ≥ the warning threshold? If yes, the moisture content of the sludge screw pump is within the set range; if no, proceed to step S3; S3, determine whether the outlet pressure of the sludge screw pump is less than the warning threshold? If yes, proceed to step S4; if no, the moisture content of the sludge screw pump is within the set range. S4 triggers dual warnings: low pressure, high moisture content; S5, the intelligent control and adjustment module pushes an early warning to the operator; S6, activate the pressure control unit; S7, calculate the actual speed of the mud feed screw pump = (screw pump speed × 7) + base speed + pressure compensation, and determine whether the pressure control unit is turned on; S8, the operator adjusts the dehydration process to restore the moisture content; S9, pressure rises, warning lifted, maintain adjusted speed.

7. The method for health diagnosis of sludge fluidized bed drying operation according to claim 5, characterized in that, The steam coil leakage-steam-fuel ratio linkage early warning system is specifically... Includes the following steps: S1, the steam-to-material ratio monitoring unit in the multi-fault monitoring module collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the mud screw pump in real time; S2, calculate the steam-to-material ratio = total speed of the screw pump / steam inlet flow rate; S3, determine if the steam-to-material ratio is ≤ the warning threshold? If yes, then there is no leakage in the steam inlet pipe; if no, proceed to step S4. S4. Determine if the steam-to-material ratio is greater than the warning threshold. If yes, proceed to step S5; otherwise, the steam inlet pipe is leak-free. S5, triggering a suspected warning from the gas-to-material ratio monitoring unit; S6. Determine if both steam pressure and condensate flow rate have decreased. If yes, proceed to step S7; otherwise, it is a misjudgment, and other causes should be investigated. S7, leakage is confirmed, and the gas-to-material ratio monitoring unit triggers a fault alarm; S8, shutdown for maintenance, repair of leaks; S9, system restart, parameters restored.

8. The method for health diagnosis of sludge fluidized bed drying operation according to claim 5, characterized in that, The specific details of the mud feed screw pump speed and mud feed screw pump fault warning. Includes the following steps: S1, the steam-to-material ratio monitoring unit in the multi-fault monitoring module collects data from the flow sensor on the steam inlet pipeline and the speed sensor on the mud screw pump in real time; S2, determine whether the actual gas-to-material ratio is greater than the warning threshold? If yes, proceed to step S3; if no, the parameters of the sludge screw pump are normal. and / or Is the outlet pressure of a single sludge screw pump less than the warning threshold? If yes, proceed to step S3; if no, the parameters of the sludge screw pump are normal. S3, determine if the outlet pressure of the sludge feed screw pump is abnormal. If yes, proceed to step S4; if no, determine the fluctuation of moisture content and implement linkage control with the steam coil leakage-steam-feed ratio early warning system; and / or Determine if the outlet pressure of all the aforementioned sludge screw pumps drops simultaneously. If yes, determine the fluctuation of moisture content and implement a linked early warning and control system for steam coil leakage and steam-to-feed ratio. If no, proceed to step S4. S4, determine that the rotor of the sludge feed screw pump is worn, trigger an alarm, and shut down the pump for replacement; and / or If the universal joint of the sludge feed screw pump is found to be broken, an alarm should be triggered and the pump should be shut down for replacement.

9. The method for health diagnosis of sludge fluidized bed drying operation according to claim 5, characterized in that, The gray silo timer-gray silo system ash conveying fault early warning specifically includes the following steps: S1, the material level probe in the ash hopper and the timer on the ash conveying screw in the ash hopper are started; S2, determine if the material level in the ash hopper has triggered the high-level probe? If not, the material level is normal; if so, start the ash conveying screw of the ash hopper, and the timer records the running time; and / or Determine if the material level in the ash hopper has triggered the high-high level probe. If not, the material level is normal; if so, the system should trip immediately. S3, determine whether the high level alarm in the ash hopper is cleared within 1 hour. If not, issue a warning; if yes, determine whether the ash hopper level triggers the low level probe. If not, the level is normal; if yes, proceed to step S4. S4, stop the ash conveying screw and reset the timer; S5. Determine whether the cumulative operation of the ash conveying spiral is greater than the warning threshold. If yes, issue a warning; otherwise, end the process.

10. The method for health diagnosis of sludge fluidized bed drying operation according to claim 5, characterized in that, The sewage tank timer-sewage tank fault early warning system specifically includes the following steps: S1, monitoring of the inlet water level in the sewage tank and starting of the timer on the sewage tank; S2, Determine if the liquid level in the sewage tank triggers the high level gauge. If not, the liquid level is normal; if yes, proceed to step S3. S3, start the sewage pump of the sewage tank, and the timer records the running time; S4. Determine if the running time of the sewage pump is ≤ the warning threshold. If not, proceed to step S5. If yes, continue to determine if the liquid level of the sewage tank triggers the low liquid level gauge. If no, the liquid level is normal. If yes, stop the sewage pump and reset the timer. S5, triggering an audible and visual alarm, indicating an abnormality in the sewage tank; S6. Isolate the sewage tank and troubleshoot the fault.

11. The method for health diagnosis of sludge fluidized bed drying operation according to claim 5, characterized in that, The current / response ratio-cooling tower fault early warning system specifically includes the following steps: S1, the current / compliance ratio monitoring unit in the multi-fault monitoring module collects the current and load data of the cooling tower cooling fan, the liquid level of the cooling tower, the opening degree of the water supply valve of the carrier gas scrubbing tower and the outlet pressure of the circulating pump in real time. S2, calculate the current-to-load ratio of the cooling tower's cooling fan and determine if this ratio continues to decrease. If yes, trigger a suspected belt breakage warning for the cooling tower's cooling fan; if no, the cooling tower's cooling fan is operating normally; and / or Does the cooling tower's liquid level trigger a low liquid level warning? If yes, trigger the cooling tower's low liquid level audible and visual alarm; if no, the cooling tower's liquid level is normal; and / or Determine if the water supply valve of the carrier gas scrubbing tower is fully open. If yes, trigger the insufficient water supply warning for the cooling tower; if no, the water supply to the cooling tower is normal; and / or Determine if the outlet pressure of the circulating pump is abnormal. If yes, the circulating pump is overloaded and the fluidizing air temperature is rising; if no, the pressure of the circulating pump is normal. S3, determine if the current-to-load ratio of the cooling tower's cooling fan is 0? If yes, determine that the cooling tower's cooling fan belt is broken and shut down for maintenance; if no, issue a warning; and / or The cooling tower is activated to replenish water using reclaimed water; and / or Troubleshooting the water supply valve of the carrier gas scrubbing tower; and / or Adjust the parameters of the circulating pump.

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