An integrated steam treatment system and method for filter rod forming equipment

Abstract

This patent provides an integrated steam treatment system and method for filter rod forming equipment, belonging to the field of filter rod processing technology. The system includes: an integrated frame with a skid-mounted structure; a primary treatment module located within the frame, having a gas-liquid separation component and a condensate drain outlet; a pressure regulating module located within the frame, connected to the outlet of the primary treatment module and maintaining downstream pressure stability; a secondary treatment module located within the frame, with its outlet being a large-diameter steam interface; a condensate management module located within the frame, connected to the condensate drain outlets of the primary and / or secondary treatment modules; and a control unit that communicates with each module and automatically adjusts the heating power based on steam temperature feedback. Through the high integration of multi-stage heating, intermediate pressure stabilization, large-diameter output, and intelligent control, ordinary steam is converted into high-dryness, high-stability superheated steam, significantly improving the filter rod forming quality and production efficiency.

Description

Technical Field

[0001] This invention relates to the field of filter rod forming technology, and more specifically to an integrated steam treatment system and method for filter rod forming equipment. Background Technology

[0002] Filter rod forming is a crucial process in cigarette manufacturing, especially for filters with special structures (such as hollow structures), where the forming quality directly affects the smoking experience and product quality. In this process, after the tobacco tow is sprayed with adhesive, it needs to be heat-set with high-temperature steam to solidify and shape the tow. This process places extremely high demands on the quality of the steam, including its dryness (low moisture content), temperature stability, and pressure constancy. The quality of the steam directly determines the physical properties of the filter rod, such as its circumference, hardness, length, and the consistency of its hollow pattern.

[0003] Currently, the commonly used steam supply solution in the industry involves saturated steam generated in a centralized boiler room, transported to the production workshop via pipelines within the plant area, and then pre-treated by steam-water separators and pressure reducing valves before being connected to the steam-using end of the filter rod forming equipment via a relatively long on-site pipeline. However, even with insulation measures, saturated steam inevitably loses heat to the environment during long-distance transportation, causing a temperature drop. This temperature drop causes some steam to condense into water, significantly reducing the steam dryness and transforming it from saturated steam into unsaturated steam with a higher water content. This "wet steam" has low activity and poor heat transfer efficiency. Furthermore, due to pipeline resistance, changes in the load of steam-using equipment, and fluctuations in boiler output, the steam pressure and temperature delivered to the equipment are unstable. When the equipment speeds up, the steam demand increases instantaneously, making a sudden pressure drop even more likely. Unstable, low-temperature, and low-dryness steam cannot uniformly and fully heat-set the fiber bundles. This directly leads to an increased coefficient of variation (CV) of the formed filter rod circumference, length fluctuations, unstable hollow structure, and a reduced product qualification rate. Meanwhile, limitations in steam quality prevent the equipment from operating stably at higher speeds, hindering capacity increases. Furthermore, heat loss during transport results in significant energy waste. Additionally, condensate generated in the pipelines, if not promptly and completely removed, will be injected into the heat-setting zone with the steam, further deteriorating the process. Exposed, lengthy pipelines also impact workshop safety management. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated steam treatment system and method for filter rod forming equipment.

[0005] The following technical solutions are provided: An integrated steam treatment system for filter rod forming equipment includes: an integrated frame; The primary processing module, housed within an integrated frame, includes an inlet for receiving external steam and a primary outlet for outputting primary heating steam. The primary processing module also includes a gas-liquid separation component and a condensate drain outlet at the bottom. The pressure regulating module, housed within an integrated frame, has its inlet connected to the steam outlet of the primary processing module and is configured to maintain downstream pressure stability. The secondary processing module, housed within an integrated frame, has its inlet connected to the outlet of the pressure regulating module. It includes a secondary outlet for outputting superheated steam, and the secondary outlet is configured as a large-diameter steam interface. The condensate management module is housed within an integrated frame and connected to the condensate discharge port of the primary treatment module and / or the secondary treatment module. The control unit is connected in communication with the primary processing module, the pressure regulation module and the secondary processing module, and is configured to automatically adjust the heating power based on the downstream steam temperature feedback.

[0006] Furthermore, the integrated frame is a skid-mounted structure.

[0007] Furthermore, the primary processing module includes a primary heater and a primary drain valve.

[0008] Furthermore, the secondary processing module includes a secondary heater and a secondary drain valve.

[0009] Furthermore, the condensate management module includes a mechanical condensate recovery pump.

[0010] Furthermore, the pressure regulating module includes a pneumatic regulating valve or an electric regulating valve.

[0011] Furthermore, the rated heating power of the primary processing module is greater than that of the secondary processing module, with a heating power ratio of 1.5:1 to 4:1.

[0012] Furthermore, the vapor-liquid separation component is a baffle plate fixed inside the primary heater, and the baffle plate is configured to cause the steam flow to change direction at least once.

[0013] Furthermore, the first detection unit is located at the steam outlet of the primary processing module and is used to detect the temperature and / or pressure of the primary heating steam.

[0014] Furthermore, the second detection unit, located at the steam outlet of the secondary processing module, is used to detect the temperature and / or pressure of the superheated steam.

[0015] Furthermore, both the first detection unit and the second detection unit are communicatively connected to the control unit.

[0016] Furthermore, the control unit is configured to automatically adjust the heating power of the primary and secondary processing modules using a cascade control strategy based on the difference between the superheated steam temperature fed back by the second detection unit and the preset target temperature.

[0017] Furthermore, the primary processing module serves as a secondary regulation loop to quickly suppress temperature disturbances.

[0018] Furthermore, the secondary processing module serves as the main control loop for precise adjustment to the target temperature.

[0019] Furthermore, the flow cross-sectional area of ​​the secondary outlet is larger than that of the primary outlet to reduce the output resistance of superheated steam.

[0020] An integrated steam treatment method for filter rod forming equipment, employing the integrated steam treatment system described above, includes the following steps: S1: Introduce an external steam source into the primary processing module within the integrated frame; S2: The steam is initially heated and separated into steam and water in the primary processing module; S3: The pressure of the initially heated steam is stabilized through the pressure regulation module; S4: The pressure-stabilized steam is reheated in the secondary processing module to generate superheated steam; S5: Collect the condensate generated by the primary treatment module and / or the secondary treatment module, and recycle it in a closed loop through the condensate management module; S6: Superheated steam is delivered to downstream workstations with low pressure loss via a large-diameter steam interface.

[0021] This patent has the following beneficial effects: This invention employs a skid-mounted integrated frame to compactly integrate the core steam treatment module into an independent functional unit, achieving integrated and seamless installation with the filter rod forming host. This completely eliminates steam quality degradation caused by long-distance transportation, while achieving zero leakage of steam and condensate throughout the entire process, significantly improving the equipment and workshop operating environment. It utilizes a two-stage tiered heating architecture with synergistic primary heating and gas-liquid separation, and secondary precise superheating. The primary heating power is strictly configured to be greater than the secondary heating power, with the power ratio controlled within an optimal range. Combined with a pressure regulating module for rapid pressure stabilization of intermediate steam, the steam dryness is significantly increased from the conventional 80-90% to over 98%. The superheating temperature can be precisely stabilized within any set value in the range of 100-450℃, with temperature control accuracy reaching ±2℃ and pressure fluctuations suppressed within ±3%. This solves long-standing process pain points such as increased filter rod circumferential variation coefficient, poor length consistency, and unstable hollow structure forming caused by high steam moisture content and large temperature and pressure fluctuations. In particular, the secondary treatment module outlet uses a large-diameter steam interface, significantly reducing the output flow resistance and pressure of high-temperature superheated steam. The system boasts a 50% or more increase in instantaneous flow rate, resolving the capacity bottleneck caused by insufficient steam supply when the equipment speed is increased to 800-1250 units / minute. Its built-in purely mechanical condensate recovery pump enables fully enclosed, leak-free forced recovery of high-temperature condensate (80-100℃) without external power, improving waste heat utilization by 8-12% and eliminating leaks on-site, offering both safety and energy-saving advantages. Furthermore, an intelligent control unit based on a dual-closed-loop cascade control algorithm collects key node status parameters in real time through primary and secondary temperature / pressure sensors. Using the secondary outlet superheat temperature as the primary control variable and the primary outlet temperature as the secondary control variable, it automatically and dynamically matches the coordinated output of fine adjustment of the secondary heater and coarse adjustment compensation of the primary heater. It also adaptively corrects the target steam parameters based on the real-time operating speed of the filter rod forming equipment. This significantly reduces reliance on operator experience while improving the stability and batch consistency of the filter rod's physical properties, enabling a leap from experience-driven to data-driven heat setting process for filter rods. This provides end-to-end technical support for the high-speed, stable, and intelligent production of high-end filter rods. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of this patent, the drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this patent and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained from these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of an integrated steam treatment system. Figure 2This is a schematic diagram of the front view of an integrated steam treatment system. Figure 3 This is a schematic side view of the integrated steam treatment system structure. Figure 4 This is a schematic diagram of the overall structure of an integrated steam treatment system.

[0024] The reference numerals in the attached figures are explained as follows: 100: Integrated Framework 101: Door Panel 102: Side panel 103: Pry bar 110: Level 1 processing module 111: Primary heater 112: Primary steam trap 113: Gas-liquid separation component 114: Primary Export 120: Pressure Regulation Module 121: Insulated connection pipe 130: Secondary processing module 131: Secondary heater 132: Secondary steam trap 133: Secondary Export 140: Condensate Management Module 141: Primary condensate branch 142: Secondary condensate branch 150: Human-Computer Interaction Interface Detailed Implementation

[0025] The detailed features and advantages of this application are described below in the specific embodiments. The content of this description is sufficient to enable any person skilled in the art to understand the technical content of this application and implement it accordingly. Based on the specification, claims and drawings disclosed in this specification, a person skilled in the art can easily understand the related objectives and advantages of this application.

[0026] The invention will now be described with reference to the accompanying drawings, in which similar reference numerals denote similar elements. While specific structures and arrangements are discussed, it should be understood that this is done merely for illustrative purposes. Those skilled in the art will recognize that other structures and arrangements can be used without departing from the spirit and scope of the invention. It will be apparent to those skilled in the art that the invention can also be used in a variety of other applications.

[0027] In this specification and claims, several terms will be used, and unless otherwise indicated, these terms will be defined to have the following meanings: The singular forms “a” and “the” include their corresponding plural forms. “At least one” means one or more, and “more” means two or more. “At least one of the following” or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one of a, b, or c can be expressed as: a, b, c, ab, ac, bc, or abc, where a, b, and c can be single or multiple.

[0028] It should be understood that the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. A and B can be singular or plural. Additionally, the character " / " in this article generally indicates an "or" relationship between the preceding and following related objects, but it can also represent an "and / or" relationship. Please refer to the context for a more accurate understanding.

[0029] In the description of this embodiment, it should be noted that the terms "upper", "lower", "inner", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product is usually placed during use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0030] Unless otherwise indicated, the following abbreviations have the following meanings, and any other abbreviations used herein but not defined have their generally accepted standard meanings: All other terms used herein for special definition are intended to have the general meaning understood by one of ordinary skill in the art, and in particular, meaning that one of ordinary skill in the art, upon reading the claims, specification and drawings of this patent, can directly and without doubt determine how the technical solution of this patent can be implemented.

[0031] Even if there are incomplete descriptions, omissions, or ambiguities in the grammar, words, punctuation, graphics, symbols, etc. of the claims, specification, and drawings of this patent, a person skilled in the art can still arrive at the only correct understanding by reading the claims, specification, and drawings as a whole without extensive reasoning or experimentation, and effectively exclude various incorrect interpretations that are not aimed at achieving the purpose of this patent.

[0032] Those skilled in the art would first choose to read the claims, specification, and drawings of this patent to reasonably interpret the terms; secondly, they would choose to refer to the relevant definitions in other documents published by the applicant before the filing date to reasonably interpret the terms; thirdly, they would choose the references cited in this patent to reasonably interpret the terms; and finally, they would choose to combine the technical dictionaries, technical manuals, reference books, textbooks, national or industry technical standards, etc., commonly used by those skilled in the art to reasonably interpret the terms.

[0033] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0034] refer to Figures 1 to 4 This embodiment discloses an integrated steam treatment system for a filter rod forming equipment. The system mainly includes an integrated frame 100, a primary treatment module 110, a pressure regulating module 120, a secondary treatment module 130, a condensate management module 140, and a control unit.

[0035] See Figure 4 The integrated frame 100 serves as the support and housing structure for the entire system, and it preferably adopts a closed skid-mounted structure. The frame 100 is welded from shaped steel (e.g., square tubing) and covered with cold-rolled steel or stainless steel panels, forming a essentially enclosed box structure. Specifically, the frame 100 has an openable door panel 101 at the front and side panels 102 on both sides for easy inspection and maintenance of the internal equipment. The integrated frame 100 also has an air inlet at the top for connecting to an external steam source and introducing the steam to be treated into the system. The external dimensions of the frame 100 are customized to accommodate the reserved installation space at the rear of the downstream filter rod forming unit. Taking the KDF2 hollow wire drawing equipment as an example, the frame 100 is designed as a rectangular vertical structure, with its length, width, and height controlled within the range of 780-800mm, 380-420mm, and 1650-1850mm respectively. Its top surface is flush with the top surface of the main unit, and its side profile closely fits the curved surface of the rear of the main unit. It is rigidly connected to the main unit body using bolts or quick-lock fasteners. Furthermore, the frame 100 is equipped with a skid base 103 at its bottom to facilitate overall transportation, hoisting, and rapid on-site positioning and installation.

[0036] See Figures 1-3The primary processing module 110 is fixedly installed inside the integrated frame 100, constituting the primary gas-liquid separation and heating unit of the system. It includes a primary heater 111, a primary drain valve 112, and a gas-liquid separation component 113. The primary heater 111 is preferably an electric heating tube-type steam heater with a rated heating power of 8-12KW, preferably 10KW. The primary heater 111 is installed vertically, utilizing gravity to enhance the gas-liquid separation effect, allowing condensate to flow naturally down the pipe wall under gravity. The internal flow channel of the primary heater 111 is equipped with baffles 113, which are formed by stamping metal sheets and fixed to the inner wall of the flow channel in an alternating manner. When saturated or unsaturated steam from an external boiler or steam network enters through the inlet of the primary processing module 110, it flows through the primary heater 111 and the baffle 113. On one hand, it is initially heated; on the other hand, under the turbulence and impact of the baffles, denser liquid water droplets collide with the baffle surface due to inertia and coalesce, then collect downwards under gravity. The condensate collected at the bottom is automatically and continuously discharged through the primary steam trap 112 (e.g., a thermostatic or float-type steam trap). The steam, after initial heating and moisture separation, is output from the primary outlet at the top of the module. The primary steam trap 112 is located at the bottom of the primary heater 111, preferably a thermostatic steam trap (automatically opening and closing based on the temperature difference between steam and condensate) or a lever float-type steam trap (mechanically draining water using buoyancy and a lever mechanism). The inlet of the primary steam trap 112 is connected to the condensate collection chamber at the bottom of the primary heater 111, and the outlet is connected to the condensate management module 140 through the primary condensate branch 141. The steam trap 112 is configured to be normally open or intermittently automatically drain liquid, ensuring that no condensate accumulates at the bottom of the heater 111 and maintaining heat transfer efficiency.

[0037] The pressure regulating module 120 is located between the primary processing module 110 and the secondary processing module 130, forming the system's pressure buffer and adaptive pressure stabilization module. The inlet of this module is connected to the primary outlet of the primary processing module 110 via a short-distance insulated connecting pipe 121 (preferably no longer than 500mm, covered with an aerogel or rock wool insulation layer to reduce heat loss and pressure drop). The outlet of the pressure regulating module 120 is directly connected to the inlet of the secondary processing module 130. The pressure regulating module 120 includes a pressure adaptive regulator, specifically including: a pneumatic diaphragm regulating valve (using a 20-100kPa instrument air source to drive diaphragm deformation to change the valve core opening), an electrically actuated regulating valve (using a stepper motor or servo motor to drive a multi-turn actuator), or a self-operated spring-diaphragm pressure regulating valve (requiring no external power, automatically adjusting by balancing downstream pressure feedback and set spring force). In a preferred embodiment, the pressure regulating module 120 employs a pneumatic diaphragm regulating valve with a positioner. It receives a 4-20mA current signal or a 0-10V voltage signal output from the control unit, converts it into a pneumatic pressure signal via an electric valve positioner, and drives the valve core displacement to achieve a continuously adjustable opening degree of 0-100%. The pressure regulating module 120 is configured to attenuate upstream steam pressure fluctuations (e.g., pipeline pressure fluctuations of ±0.1MPa) to a downstream pressure fluctuation range of no more than ±5% (preferably ±3%), with a response time of no more than 2 seconds. This provides a stable steam source for the secondary processing module 130, eliminating the impact of load disturbances caused by changes in the traction speed of the filter rod forming equipment on heating stability.

[0038] The secondary processing module 130 is installed downstream of the pressure regulating module 120, constituting the system's fine-tuning superheat and high-flow-rate output module. It includes a secondary heater 131, a secondary steam trap 132, and a secondary outlet. The secondary heater 131 is preferably an electric heating tube-type steam heater with a rated heating power of 3-8KW, preferably 5KW, arranged horizontally, forming a spatial orthogonal layout with the vertical arrangement of the primary heater 111. The inlet of the secondary heater 131 is directly connected to the outlet of the pressure regulating module 120, receiving the pressure-stabilized steam and further heating it to a superheated steam state. The secondary outlet 133 is located at the steam outlet end of the secondary heater 131. In a specific embodiment of the invention, to match the KDF2 type hollow fiber drawing equipment, the external main steam source pressure is 700kPa, which enters the system after pressure stabilization and regulation. The key piping design within the system is as follows: the heating channels inside the primary processing module 110 and the secondary processing module 130 use DN10 flow channels, with steam velocity controlled between 15 and 35 m / s; to ensure low pressure loss at the system inlet and high downstream flow output, the inlet uses a DN25 pipe, while the final connection to the filter rod forming equipment uses a DN15 pipe. This stepwise diameter variation design effectively reduces the resistance at the system inlet and outlet while ensuring sufficient heating. Compared to the small-diameter steam inlets (typically DN8-DN10) at the end of traditional equipment, the secondary outlet 133 of this invention uses a DN15 inlet, which significantly increases the flow cross-sectional area, reducing the steam velocity at the end to 8-18 m / s. This greatly reduces the pressure drop of the high-temperature superheated steam before it reaches the heat setting station (measured pressure drop not exceeding 5 kPa), meeting the instantaneous high flow rate (50-80 kg / h) supply requirements of the filter rod forming equipment during high-speed operation of 800-1250 rods / minute.

[0039] A secondary steam trap 132 is located at the bottom of the secondary heater 131, preferably a thermodynamic or bimetallic strip type. Its outlet flows into the condensate management module 140 via the secondary condensate branch 142. The rated power ratio of the primary heater 111 to the secondary heater 131 is configured to be 1.5:1 to 4:1 (preferably 2:1 to 3:1, such as 10KW:5KW), allowing the primary processing module to handle the main heating and dehumidification tasks, while the secondary processing module performs fine-tuning of the temperature. This improves the system's thermal efficiency by 15-20% and achieves a temperature control accuracy of ±2℃.

[0040] Specifically, regarding the spatial arrangement of the two-stage heaters, this embodiment adopts a differentiated arrangement to achieve synergistic technical effects. The first-stage heater 111 is arranged vertically, with its axis forming an angle of 85°-90° with the horizontal plane. This arrangement utilizes gravity to enhance the gas-liquid separation effect: during the rising process of steam, denser liquid water droplets, due to inertia, impact the baffle plate and then flow naturally down the pipe wall to the bottom collection chamber under the action of gravity, preventing the droplets from being re-entrained by the high-speed steam. At the same time, the vertical arrangement creates a stable condensate liquid seal zone at the bottom, which, together with the first-stage drain valve 112, achieves continuous and unobstructed drainage. The second-stage heater 131 is arranged horizontally, with its axis forming an angle of 0°-10° with the horizontal plane. This arrangement, together with the large-diameter interface of the second-stage outlet 133, forms a low-resistance flow channel: the horizontal flow channel reduces steam turning losses, and the large-diameter interface controls the steam velocity at 8~18m / s, with a pressure drop of no more than 5kPa, meeting the instantaneous high-flow requirements of the filter rod forming equipment during high-speed operation. The orthogonal spatial layout of the two-stage heaters (one stage vertical, the other stage horizontal) balances gas-liquid separation efficiency with smooth output.

[0041] The condensate management module 140 is located in the bottom space inside the frame 100 (preferably above or to the side of the skid), forming the system's non-powered condensate forced recovery unit. This module includes a purely mechanical condensate recovery pump, a condensate collection manifold, and a discharge port. The purely mechanical condensate recovery pump is a power-driven mechanical pump that requires no external electricity or gas source. Its working principle is based on steam pressure drive or condensate flash pressurization: when the high-temperature condensate (80-100℃, including residual heat) discharged from the primary steam trap 112 and the secondary steam trap 132 enters the pump's inlet chamber, the system's own steam pressure (or the secondary steam generated by the flash evaporation of condensate in the low-pressure chamber) pushes the piston or float mechanism, pressurizing the condensate to 0.1-0.3 MPa higher than the back pressure of the return pipe network, and forcibly transporting it through mechanical reciprocating motion. This design avoids the explosion hazards and cavitation risks of electric pumps and is suitable for intrinsically safe operation in steam environments. The condensate collection main is made of stainless steel or carbon steel and connects to the outlets of primary and secondary condensate drain valves 112 and 132 respectively via primary and secondary condensate branch lines. Preferably, the main is equipped with a sight glass or level observation window to monitor the drainage status. The collection main slopes towards the condensate recovery pump at a 1-3% gradient to ensure that the condensate flows by gravity to the pump inlet, preventing accumulation. The discharge port connects to the factory's centralized condensate recovery network via a flexible metal hose or rigid pipe (the connection distance can reach 50-200 meters, depending on the pump head). The discharge port is equipped with a check valve to prevent backflow due to back pressure in the network and can be optionally equipped with a waste heat recovery heat exchanger (cooling the 80-100℃ condensate to 40-60℃ before discharging it into the network, recovering heat for preheating boiler feedwater or space heating). This module enables fully enclosed, non-powered, and zero-leakage transportation of condensate from the point of generation to the recovery network, with no leaks or spills on site, and waste heat recovery improves the overall energy efficiency of the system by 8-12%.

[0042] The integrated steam treatment system also includes a first detection unit, a second detection unit, a control unit, and a human-machine interface.

[0043] The first detection unit is located at the steam outlet of the primary processing module, including a primary temperature sensor and / or a primary pressure sensor, used to detect the temperature and pressure values ​​of the steam after preliminary heating in real time. The second detection unit is located at the steam outlet of the secondary processing module, including a secondary temperature sensor and / or a secondary pressure sensor, used to detect the temperature and pressure values ​​of the final output superheated steam in real time. The control unit is integrated into the electrical control cabinet and installed on the side or top of the integrated frame. Its core is a programmable logic controller, equipped with analog input / output modules and a communication module. The control unit establishes electrical or communication connections with the primary heater, secondary heater, pressure regulation module, primary temperature sensor, primary pressure sensor, secondary temperature sensor, and secondary pressure sensor, respectively.

[0044] The human-machine interface 150 is preferably a touch screen, installed on the inclined operating surface of the control cabinet or frame at an angle of 15° to 30°. This interface communicates with the control unit and is equipped with a temperature setting area, a real-time trend graph area, an alarm information area, and a manual / automatic mode switching key for parameter input, status monitoring, and operation control.

[0045] The human-machine interface 150 is equipped with a parameter setting function area, allowing operators to input and set process parameters via a touchscreen. Specifically, the heating temperature setting range for the primary and secondary processing modules is 100-600℃, covering the entire process requirements from low-temperature preheating to high-temperature superheating, with a preferred setting range of 250-350℃. The superheated steam temperature output from the secondary outlet 133 can be set within a range of 100-450℃, matching the heat setting requirements of different filament materials (such as cellulose acetate and polypropylene fibers) and different filter rod specifications (such as fine, medium, and coarse fibers) in the filter rod forming process, with a preferred setting range of 300-380℃. After receiving the above settings, the control unit automatically adjusts the power output of the two-stage heaters through a cascade control strategy, stabilizing the actual outlet temperature within ±2℃ of the set value.

[0046] The control unit is configured to execute a dual closed-loop cascade control algorithm, using the superheated steam temperature fed back by the second detection unit at the outlet of the secondary processing module 130 as the primary controlled variable, and the primary heating steam temperature fed back by the first detection unit at the outlet of the primary processing module 110 as the secondary controlled variable. During steady-state operation, the control unit prioritizes adjusting the power of the secondary heater for fine-tuning, with a response time of 5-15 seconds and a temperature overshoot of less than 2℃. When the power of the secondary heater reaches 90% of its rated upper limit or the deviation between the measured temperature and the set value exceeds ±10℃, the control unit activates the primary heater for coarse-tuning compensation. A 2-5℃ control dead zone is established between the primary and secondary heaters, and the power change rate is limited to no more than 10% of the rated power per minute. When a steam pressure fluctuation exceeding ±5% is detected, the control unit synchronously adjusts the opening of the pressure regulating module to maintain downstream pressure stability. All real-time and historical data are displayed on the human-machine interface and can store 30-90 days of historical data logs.

[0047] As an optional implementation, the heaters in the primary and / or secondary processing modules are not limited to electric heating tubes, but may also be gas heaters, thermal oil indirect heaters, or heat exchangers utilizing waste heat sources from the plant (such as high-temperature flue gas). Accordingly, the controlled object of the control unit is adaptively adjusted to the actuators such as fuel valves, circulating pumps, or regulating dampers corresponding to the heaters.

[0048] Steam treatment process: System startup and warm-up phase: The operator starts the system through the human-machine interface and sets the target process parameters: for example, the secondary outlet superheated steam temperature is set to 350℃ and the pressure is set to 0.8MPa (gauge pressure). The system control mode is set to "automatic".

[0049] Saturated steam (approximately 0.9 MPa pressure, approximately 175°C temperature, and approximately 85% dryness) supplied by the external boiler room enters the integrated frame 100 through the DN25 air inlet.

[0050] Steam first enters the primary processing module 110. The primary heater 111 (10KW power) starts, initially heating the steam to approximately 250°C. During this process, the baffle 113 facilitates the separation of liquid water carried in the steam, and the condensate collects at the bottom and is discharged through the primary steam trap 112 (thermostatic type, drainage temperature set at 80°C). The dryness of the steam after initial heating and separation is increased to approximately 92%.

[0051] This steam then enters the pressure regulating module 120 (pneumatic diaphragm regulating valve). The control unit compares the pressure signal (approximately 0.88 MPa) fed back by the primary pressure sensor with the set value and adjusts the valve opening to approximately 65%, stabilizing the downstream pressure at 0.8 MPa ± 0.02 MPa (fluctuation < ± 3%).

[0052] Steady-state operation and fine-tuning phase: The stabilized steam enters the secondary processing module 130. The secondary heater 131 (5kW power) operates, further heating the steam to the target temperature of 350℃. A secondary temperature sensor monitors the temperature in real time, and the control unit, based on the deviation between the feedback value (e.g., 348℃) and the set value (350℃), fine-tunes the power of the secondary heater to 4.8kW using PID calculations, stabilizing the outlet temperature at 350±2℃. At this point, the steam has become superheated steam with a high dryness (>98%).

[0053] The superheated steam generated by the secondary processing module 130 is transported to the downstream filter rod forming machine heat setting station at a flow rate of approximately 15 m / s through its large-diameter secondary outlet (preferably DN15) for heat setting of the filament bundle. The steam parameters at this time fully meet the process requirements of high-speed production (e.g., 1000 pieces / minute).

[0054] Throughout the heating process, the small amounts of condensate produced by the primary and secondary heaters are discharged through steam traps and collected in the condensate collection manifold. The condensate temperature is approximately 85°C.

[0055] The purely mechanical condensate recovery pump in the condensate management module 140 automatically starts, using the system's own steam pressure to pressurize the collected high-temperature condensate to approximately 0.95 MPa. Overcoming back pressure through the discharge port, it is then transported to a centralized recovery pipeline approximately 50 meters away. This process achieves fully enclosed condensate recovery with no leakage on site.

[0056] Dynamic response and load conditioning phase: When the filter rod forming equipment increases its operating speed from 500 rods / minute to 1000 rods / minute due to production needs, the instantaneous steam consumption in the heat setting section increases, causing a brief drop in the system outlet pressure (at this time, the pressure was detected to drop to about 0.78 MPa).

[0057] The control unit responded immediately: Pressure regulation: Based on the pressure deviation, the opening of the pressure regulation module 120 is quickly increased to 72%, and the pressure is restored to 0.8MPa within 2 seconds.

[0058] Temperature Maintenance: Due to the potential temperature drop caused by increased flow, the secondary temperature sensor detected a slight decrease in temperature to 347.5℃. The control unit then increased the power of the secondary heater to its rated value of 5KW according to a preset algorithm. If the temperature still cannot recover quickly, the control unit will activate the auxiliary power adjustment of the primary heater (e.g., fine-tuning from 10KW to 10.5KW) to ensure that the outlet steam temperature remains stable within the range of 350±2℃. After the flow rate increases, the amount of condensate produced increases slightly, and the condensate recovery pump automatically adapts to the increased flow rate to maintain stable drainage.

[0059] Monitoring and data display: Throughout the entire operation, all key parameters, including the first-stage outlet temperature (approximately 250℃) and pressure (approximately 0.88MPa), the second-stage outlet temperature (350℃) and pressure (0.8MPa), the real-time power and cumulative energy consumption of the two-stage heaters, and the condensate recovery flow rate, are displayed in real time on the human-machine interface. The control unit records all operating data and allows for analysis of historical trend curves via the touchscreen.

[0060] Shutdown phase: At the end of production, the operator issues a shutdown command via the interface. The control unit sequentially stops the heating of the primary and secondary heaters, and the pressure regulating valve slowly closes. The system utilizes waste heat and a small amount of continuously supplied steam for natural cooling, while the condensate recovery pump continues to operate until the condensate is drained from the system. Finally, the system shuts down completely, ready for the next startup.

[0061] Integrated steam treatment method for filter rod molding : This method is based on the aforementioned integrated steam treatment system and specifically includes the following steps: S1: Steam introduction and system initialization An external steam source (e.g., saturated or unsaturated steam from a centralized boiler room with an initial pressure of 0.85-0.95 MPa, a temperature of 170-180°C, and a dryness of approximately 80-90%) is introduced into the integrated frame. Target process parameters are set via a human-machine interface, including the target temperature of the secondary outlet superheated steam (setting range 100-450°C, preferably 320-380°C, e.g., 350°C) and the target pressure (setting range 0.6-1.0 MPa, e.g., 0.8 MPa). The system control unit is powered on, and each detection unit and actuator completes a self-test.

[0062] S2: Preliminary heating and active vapor-liquid separation

[0063] In the primary processing module 110, the introduced steam undergoes preliminary heating and steam-water separation. Specifically, the control unit activates the primary heater to heat the steam to 250°C. During this process, the steam flows through the baffle 113 within the module, where the liquid water it contains is effectively separated under inertial impact and gravity. The separated condensate is discharged automatically and in real time through the primary steam trap. Through this step, the steam dryness is increased to ≥92%, achieving preliminary drying and heating.

[0064] S3: Adaptive Pressure Regulation

[0065] The steam, after preliminary heating and separation, is passed through the pressure regulating module. Based on the deviation between the preset target pressure and the actual pressure value fed back by the primary pressure sensor, the control unit dynamically adjusts the opening of the pressure regulating module, stabilizing the steam pressure within the target value ±0.03 MPa. This step eliminates pressure fluctuations caused by upstream steam source pressure fluctuations and downstream load changes, providing a stable steam source for subsequent precise temperature control.

[0066] S4: Precise overheat and temperature closed-loop control

[0067] The stabilized steam is introduced into the secondary processing module for reheating to generate the target superheated steam. The control unit starts the secondary heater and executes closed-loop temperature control: continuously comparing the difference between the actual outlet steam temperature fed back by the secondary temperature sensor and the preset target temperature, and automatically adjusting the power output of the secondary heater in real time through control algorithms such as PID. When the temperature deviation is large or the load changes drastically, the control unit will also adjust the power of the primary heater for auxiliary compensation. This step finally heats the steam to the set target superheated temperature, and the steam dryness is further increased to ≥98%, becoming superheated steam.

[0068] S5: Closed-loop condensate recovery

[0069] All condensate generated during the heating and separation processes in steps S2 and S4 is collected. The condensate is discharged through a primary drain valve and a secondary drain valve, flowing into the condensate collection manifold. Subsequently, a purely mechanical condensate recovery pump in the condensate management module pressurizes the collected high-temperature condensate (approximately 80-100°C) and delivers it to the factory's centralized condensate recovery network, achieving a fully closed, leak-free condensate recovery and waste heat resource utilization process.

[0070] S6: Stabilize steam supply to molding process

[0071] The high-dryness superheated steam generated in step S4, with its temperature and pressure stabilized, is directly and continuously delivered to the heat-setting station of the filter rod forming equipment through the large-diameter secondary outlet of the secondary processing module. Here, the superheated steam is used to heat and cure the adhesive-sprayed filaments. The control unit can dynamically fine-tune the target pressure value in step S3 and the target temperature value in step S4 based on the real-time operating speed signal of the filter rod forming equipment, so that the supplied steam parameters are adaptively matched with the production speed. This ensures that even when the equipment is running at high speed (e.g., 800-1250 pieces / minute), the filter rod products can still achieve a uniform and stable heat-setting effect, thereby significantly reducing the coefficient of variation (CV value) of key quality indicators such as circumference and length.

[0072] This method, through the above-mentioned orderly and coordinated steps, realizes the entire process of converting ordinary steam into stable, high-dryness superheated steam suitable for filter rod molding, effectively solving the problem of unstable product quality caused by steam quality fluctuations, while improving energy utilization efficiency and the cleanliness of the production environment.

[0073] Industrial applicability: This invention employs a skid-mounted integrated frame to compactly integrate the core steam treatment module into an independent functional unit, achieving integrated and seamless installation with the filter rod forming host. This completely eliminates steam quality degradation caused by long-distance transportation, while achieving zero leakage of steam and condensate throughout the entire process, significantly improving the equipment and workshop operating environment. It utilizes a two-stage tiered heating architecture with synergistic primary heating and gas-liquid separation, and secondary precise superheating. The primary heating power is strictly configured to be greater than the secondary heating power, with the power ratio controlled within an optimal range. Combined with a pressure regulating module for rapid pressure stabilization of intermediate steam, this ensures... The dryness has been increased from 80-90% of the conventional supply to over 98%, and the superheated temperature can be precisely stabilized within any set value in the range of 100-450℃. The temperature control accuracy reaches ±2℃, and the pressure fluctuation is suppressed within ±3%. This solves long-standing process pain points caused by high steam moisture content and large temperature and pressure fluctuations, such as increased circumferential variation coefficient of filter rods, poor length consistency, and unstable hollow structure molding. In particular, the outlet of the secondary treatment module adopts a large-diameter steam interface that is significantly larger than the traditional interface (for example, from the conventional DN8-DN10 to DN15), which significantly reduces... The reduced output flow resistance and pressure drop of low-temperature superheated steam improves instantaneous flow supply capacity by over 50%, resolving the capacity bottleneck caused by insufficient steam supply when equipment speeds up to 800-1250 units / minute. The system features a built-in purely mechanical condensate recovery pump, enabling fully enclosed, leak-free forced recovery of high-temperature condensate (80-100℃) without external power, increasing waste heat utilization by 8-12%, eliminating leaks and ensuring both safety and energy efficiency. Furthermore, an intelligent control unit based on a dual-closed-loop cascade control algorithm utilizes primary and secondary temperature / pressure sensors... The device collects key node status parameters in real time, with the secondary outlet superheat temperature as the primary control variable and the primary outlet temperature as the secondary control variable. It automatically and dynamically matches the coordinated output of the fine adjustment of the secondary heater and the coarse adjustment compensation of the primary heater. Based on the real-time operating speed of the filter rod forming equipment, it adaptively corrects the target steam parameters. While improving the stability of the physical indicators and batch consistency of the filter rod products, it significantly reduces the dependence on the operator's experience. It realizes the leap from experience-driven to data-driven in the filter rod heat setting process, and provides full-process technical support for the high-speed, stable and intelligent production of high-end filter rods.

[0074] The foregoing description of specific embodiments has fully disclosed the general features of the invention, enabling others to easily modify and / or adapt such embodiments for various applications by applying knowledge within the scope of the art, without excessive experimentation and without departing from the general conception of the invention. Therefore, based on the teachings and guidance provided herein, it is intended that such modifications and alterations be included within the meaning and scope of equivalents of the disclosed embodiments. It should be understood that the wording or terminology used herein is for descriptive purposes and is not intended to be limiting; thus, the wording or terminology in this specification will be interpreted by those skilled in the art based on the foregoing teachings and guidance.

[0075] Furthermore, the scope of the invention should not be limited to any of the exemplary embodiments described above, but only to the appended claims and their equivalents.

Claims

1. An integrated steam treatment system for filter rod forming equipment, characterized in that, include: Integrated framework (100); The primary processing module (110) is disposed within the integrated frame (100) and includes an inlet for receiving external steam and a primary outlet for outputting primary heating steam. The primary processing module also includes a gas-liquid separation component and a condensate discharge port at the bottom. A pressure regulating module (120) is disposed within the integrated frame (100), its inlet is connected to the steam outlet of the primary processing module (110) and configured to maintain downstream pressure stability; A secondary processing module (130) is disposed within the integrated frame (100), its inlet is connected to the outlet of the pressure regulating module (120), and includes a secondary outlet for outputting superheated steam, wherein the secondary outlet is configured as a large-diameter steam interface. A condensate management module (140) is disposed within the integrated frame (100) and connected to the condensate discharge port of the primary treatment module (110) and / or the secondary treatment module (130); The control unit is communicatively connected to the primary processing module (110), the pressure regulating module (120) and the secondary processing module (130), and is configured to automatically adjust the heating power based on feedback from the downstream steam temperature.

2. The system according to claim 1, characterized in that, The integrated frame (100) is a skid-mounted structure; The primary processing module (110) includes a primary heater (111) and a primary drain valve (112), wherein the primary heater (111) is arranged vertically. The secondary processing module (130) includes a secondary heater (131) and a secondary drain valve (132). The secondary heater (131) is arranged horizontally, and the rated heating power of the secondary heater (131) is less than the rated heating power of the primary heater (111).

3. The system according to claim 2, characterized in that, The condensate management module includes a mechanical condensate recovery pump.

4. The system according to claim 3, characterized in that, The pressure regulating module includes a pneumatic regulating valve or an electric regulating valve.

5. The system according to claim 2, characterized in that, The ratio of the rated heating power of the primary processing module to the rated heating power of the secondary processing module is 1.5:1 to 4:

1.

6. The system according to claim 5, characterized in that, The vapor-liquid separation component is a baffle plate fixed inside the primary heater, and the baffle plate is configured to cause the steam flow to change direction at least once.

7. The system according to claim 1, characterized in that, Also includes: The first detection unit is located at the steam outlet of the primary processing module and is used to detect the temperature and / or pressure of the primary heating steam. The second detection unit is located at the steam outlet of the secondary processing module and is used to detect the temperature and / or pressure of the superheated steam. Both the first detection unit and the second detection unit are communicatively connected to the control unit.

8. The system according to claim 7, characterized in that, The control unit is configured to: Based on the difference between the superheated steam temperature fed back by the second detection unit and the preset target temperature, the heating power of the first-level processing module (110) and the second-level processing module (130) is automatically adjusted using a cascade control strategy. The first-level processing module (110) serves as a secondary regulation loop to quickly suppress temperature disturbances, and the second-level processing module (130) serves as a primary regulation loop to precisely adjust to the target temperature.

9. The system according to claim 1, characterized in that, The flow cross-sectional area of ​​the secondary outlet is larger than that of the primary outlet to reduce the output resistance of superheated steam.

10. An integrated steam treatment method for filter rod forming equipment, characterized in that, The method, employing the integrated steam treatment system as described in any one of claims 1-9, comprises: S1: Introduce an external steam source into the primary processing module within the integrated frame; S2: The steam is initially heated and separated into steam and water in the primary processing module; S3: The pressure of the initially heated steam is stabilized through the pressure regulation module; S4: The pressure-stabilized steam is reheated in the secondary processing module to generate superheated steam; S5: Collect the condensate generated by the primary processing module and / or the secondary processing module, and perform closed-loop recycling through the condensate management module; S6: The superheated steam is delivered to the downstream workstation with low pressure loss through a large-diameter steam interface.

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