Explosion-proof dust removal system and method based on intelligent sensing and multi-dimensional collaborative control risk

Abstract

The present application relates to the explosion-proof dust removal system and method based on intelligent sensing and multi-dimensional collaborative control risk, the system includes exhaust passage, dust suppressor, filter, state sensing unit and control unit. The present application is based on the amount of first and second fillers in the transition layer, which realizes the essential compatibility of the conductive layer and the hydrophobic layer, simultaneously meets the requirements of conductivity stability and persistent hydrophobic performance, effectively slows down the attenuation of the filter element, and prolongs the service life. On the other hand, based on the state sensing of the first and second monitoring modules to the state of the filter cavity and the filter element, the internal conductivity of the filter element and the external temperature control are implemented through active control of the response element and the cooling element, realizing the all-round and multi-level collaborative control from the external risk of "dust-gas" to the internal risk of "filter element", the emergency response is more accurate and timely, the explosion risk is effectively inhibited and eliminated, and the production safety is greatly improved.

Description

Technical Field

[0001] This invention belongs to the field of industrial dust removal and intrinsic safety technology, specifically relating to an explosion-proof dust removal system and method based on intelligent sensing and multi-dimensional collaborative risk control. Background Technology

[0002] Coal mine surface production systems (such as belt conveyor transfer points, crushers, and screening towers) are the core areas for the generation of explosive coal dust. They may also be accompanied by the overflow of methane gas, resulting in the coexistence of suspended coal dust and overflowing methane gas, creating a "double explosion" risk. The ignition energy requirement is reduced, and the explosive power is multiplied, leading to high risk and high danger in production operations. Therefore, dust control in production operation areas is of paramount importance to ensure safe production.

[0003] Currently, existing explosion-proof dust removal equipment generally includes an exhaust channel based on the suction force generated by a negative pressure fan, a dust suppressor and a filter arranged sequentially along the exhaust channel. The dust suppressor sprays air into the exhaust channel to control the temperature and humidity of the airflow to suppress dust diffusion. Then, the airflow with a certain humidity passes through a sintered plastic filter element with a conductive layer and a hydrophobic layer in the filter to filter the dust in the airflow onto the surface of the hydrophobic layer, and the charge generated by filtration is discharged through the conductive layer.

[0004] However, in actual production processes, existing technologies have the following drawbacks: 1. Conventional sintered plastic plate filter elements face the dilemma of performance degradation caused by the contradiction between conductive materials and hydrophobic surface materials (i.e., the hydrophobic coating is easily worn under scouring). In high humidity environments, the filter element surface is prone to caking and bagging, which not only makes dust removal difficult and severely reduces the effective filtration area of ​​the filter element, but also covers and blocks the conductive path, causing the filter element's anti-static function to fail, increasing the equipment load. In addition, factors such as friction, compression and gas oxidation heat release during equipment operation may lead to internal temperature rise, further increasing the risk of explosion. 2. During the treatment process, only macroscopic parameters (such as methane concentration, pressure, temperature, etc.) are monitored, while microscopic risks such as static electricity accumulation inside the filter element, local overheating, and hidden grounding failure are completely in a "black box" state. Only periodic offline inspections can be carried out, resulting in passive and lagging safety protection measures and a lack of proactive suppression methods to provide timely warnings and eliminate risk factors. Summary of the Invention

[0005] In order to overcome the shortcomings of the prior art, the purpose of this invention is to provide an improved explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control.

[0006] It also involves an explosion-proof dust removal method.

[0007] To solve the above technical problems, the present invention adopts the following technical solution: An explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control includes an exhaust channel connected to the emission port of a methane dust-containing airflow, a dust suppressor and a filter arranged sequentially along the exhaust channel, and the filter including a cavity and a filter element built into the cavity. The filter element is divided into a hydrophobic layer and a conductive layer along its thickness direction. The airflow passes through the hydrophobic layer and the conductive layer sequentially. A transition layer is also formed on the filter element between the hydrophobic layer and the conductive layer. The transition layer includes a first working layer and a second working layer. The first working layer is filled with a first filler material that is conductive and mixed with a second filler material that is chemically compatible with the hydrophobic layer. The amount of the first filler material in the first working layer is greater than the amount of the second filler material, and the amount of the first filler material is along the airflow direction. The filter further includes a second working layer filled with a second filler and located between the hydrophobic layer and the first working layer; the filter also includes a response element arranged in a conductive layer and capable of releasing conductive material in sections based on the filter element's filtration area to restore the conductivity of the corresponding sections, and a cooling element for cooling the interior of the chamber; the explosion-proof dust removal system also includes a status sensing unit and a control unit, the status sensing unit including a first monitoring module for monitoring the interior temperature and methane concentration, and a second monitoring module for monitoring the conductivity of the filter element in sections based on the filter element's filtration area; the control unit controls the cooling element to reduce the chamber temperature and / or controls the response element to release conductive material in sections with abnormal conductivity based on the data monitored by the first monitoring module and / or the second monitoring module to collaboratively suppress the risk of explosion.

[0008] According to a specific embodiment and preferred aspect of the present invention, the dust suppressor includes a sealed dust suppression hood cavity disposed at the air inlet end of the exhaust channel, and a dust suppression module disposed within the dust suppression hood cavity for controlling the humidity of the airflow, wherein the exhaust port extends into the dust suppression hood cavity. This facilitates precise control of the airflow humidity, suppresses dust diffusion, and simultaneously achieves preliminary temperature control.

[0009] Preferably, the dust suppression module includes multiple spray nozzles, wherein the spray direction of each spray nozzle is set opposite to the airflow direction.

[0010] According to another specific embodiment and preferred aspect of the invention, the responsive element is a functional responsive microcapsule capable of releasing conductive material by stimulating a molten shell at high temperatures; and / or, the filter further includes heating elements for zoned heating of the responsive element to stimulate the release of conductive material. When high-temperature stimulation is applied, the heating elements can precisely and minutely heat the responsive element via micro-resistive heating wires pre-embedded in each zone or external directional electromagnetic induction sensors.

[0011] According to another specific embodiment and preferred aspect of the present invention, the second monitoring module includes a first sensor disposed in the conductive layer for zoned monitoring of temperature and strain, and a second sensor disposed in the transition layer for zoned monitoring of the surface charge density of the filter element. Here, temperature monitoring is used to provide early warning of localized blockage, overheating, or fire risks; strain monitoring is used to assess the structural health of the filter element and the impact uniformity of the cleaning pulse; and by zonedly monitoring the surface charge density of the filter element, a holographic, online perception of the filter element's operating status (physical field, cleaning effect, electrostatic level) is achieved, transforming the filter element from a "silent" part into a "talking" intelligent terminal. In short, the monitoring of temperature, strain, and charge density reflects the filter element's conductivity.

[0012] Preferably, the first sensor is an optical fiber sensor integrated with an optical fiber Bragg grating array. The optical fiber sensor is embedded in the middle of the conductive layer and is wavy in the length or short side direction of the conductive layer. The optical fiber sensor also integrates distributed acoustic sensing, which is used to monitor the distribution of dust adhesion thickness on the surface of the hydrophobic layer in zones. Here, based on the optical fiber Bragg grating array, it is inscribed at specific wavelength intervals, which can monitor the temperature and strain at key locations inside the filter element in real time and in a quasi-distributed manner. At the same time, the optical fiber is arranged in a wavy, meandering layout in the middle of the conductive layer, which can achieve uniform zoned and high-density precise monitoring. In addition, by demodulating the propagation and reflection signals of the vibration sound waves generated by the dust removal pulse airflow inside the filter element, it is possible to non-invasively invert the adhesion distribution and thickness change of the dust layer on the filter element surface, so as to facilitate online quantitative evaluation of the dust removal effect.

[0013] Preferably, the second sensor employs an interdigitated electrode array, which is electrically connected to the conductive network formed by the conductive layer. In the interdigitated electrode array, multiple interdigitated electrodes are spaced apart along a wavy path in the length or width direction of the filter element to achieve zoned monitoring.

[0014] According to another specific embodiment and preferred aspect of the present invention, the filter element includes a plurality of filter element bodies spaced apart along the thickness direction, a plurality of partition strips connecting each adjacent filter element body, and a connecting end seat fixing the plurality of filter element bodies relatively. The partition strips are arranged side-by-side at intervals along a direction perpendicular to the thickness of the filter element bodies, dividing adjacent filter element bodies into multiple filter cavities. Each filter element body sequentially forms a hydrophobic layer, a transition layer, and a conductive layer along its own thickness direction. Here, based on the diversion filtration of multiple filter cavities, dust distribution can be effectively dispersed, extending the service life and improving the filtration effect.

[0015] Preferably, there are two filter element bodies, each wavy in shape, and each filter element body has multiple grooves formed based on the multiple troughs of the wavy shape. The connecting end seat includes a connecting seat body and a supporting seat body respectively installed on the top and bottom of the two filter element bodies. The connecting seat body includes a seat body, terminals disposed at both ends of the seat body, two self-locking modules disposed on the seat body and corresponding to the two filter element bodies, a sealing strip, a buffer pad, and multiple contact pieces corresponding to each filter element body for conduction. The self-locking module includes multiple plug-in modules corresponding to the multiple grooves and elastic elements corresponding to the plug-in modules and the inner wall of the grooves. Here, the elastic elements ensure strong stability of the installation structure between the connecting seat body and the filter element body, fundamentally overcoming the loosening problem caused by equipment vibration and ensuring electrical conductivity stability.

[0016] According to another specific embodiment and preferred aspect of the invention, the cooling element includes a cooling conduit, a circulating pump that drives coolant to circulate along the cooling conduit, and a refrigeration component for cooling the coolant. The cooling conduit has a cooling section installed within the chamber, which is close to the filter element and arranged in a meandering, vertical layout. Here, the area where the filter element is located is a high-temperature risk area, thus ensuring the cooling capacity of this area.

[0017] According to another specific embodiment and preferred aspect of the invention, the filter further includes a flameless explosion venting device disposed on one side of the chamber; and / or, the explosion-proof dust removal system further includes an explosion-proof valve disposed on the exhaust passage and located between the dust suppressor and the filter. Here, a rapid response is achieved to improve safety in extreme risk situations, such as a pressure surge rate exceeding the limit and suspected explosion, filter element grounding circuit failure, or chamber temperature > 80°C.

[0018] Another technical solution of the present invention is an explosion-proof dust removal method, which adopts the above-mentioned explosion-proof dust removal system and includes the following steps: S1, Dust Suppression The methane-containing dust airflow emitted by the equipment enters the exhaust channel, and the dust suppressor controls the humidity of the airflow within a safe range to inhibit dust diffusion. S2, Filtration As the airflow passes through the filter along the exhaust channel, it sequentially passes through the hydrophobic layer, transition layer, and conductive layer of the filter element. Dust is intercepted on the surface of the hydrophobic layer, and the conductive layer conducts the charge generated during filtration to prevent accumulation. S3. Hierarchical and collaborative risk control Based on the range of changes in methane concentration, airflow temperature, and filter element conductivity, a multi-level interlocking emergency logic is preset; the first monitoring module monitors the internal temperature and methane concentration of the chamber, and the second monitoring module monitors the conductivity of the filter element in zones based on the filter area; the control unit controls the cooling element and / or the response element to work together under the corresponding level of emergency logic based on the information monitored by the first monitoring module and / or the second monitoring module, to implement internal temperature control of the chamber and / or restoration of the internal conductivity of the filter element in order to jointly suppress the risk of explosion.

[0019] Compared with the prior art, the present invention has the following advantages: Existing plastic sintered plate filter elements face the dilemma of performance degradation caused by the conflicting properties of conductive and hydrophobic surface materials (i.e., the hydrophobic coating is easily worn away under scouring). In high-humidity environments, the filter element surface is prone to caking and sticking, which not only makes dust removal difficult and severely reduces the effective filtration area of ​​the filter element, but also covers and blocks the conductive path, causing the filter element's anti-static function to fail, increasing the equipment load. Furthermore, factors such as friction, compression, and gas oxidation exothermic factors during equipment operation may lead to internal temperature rise, further exacerbating the risk of explosion. In the treatment process, only macroscopic parameters (such as methane concentration, pressure, and temperature) are monitored, while microscopic risks such as static electricity accumulation, local overheating, and grounding failure inside the filter element are completely in a "black box" state. Only periodic offline inspections can be carried out, resulting in passive and lagging safety protection measures and a lack of proactive suppression methods to provide timely warnings and eliminate risk factors. This application presents a comprehensive structural design for an explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control, cleverly addressing the shortcomings and defects of existing technologies. When this explosion-proof dust removal system is adopted, the methane-containing dust-laden airflow emitted by the equipment enters the exhaust channel, where a dust suppressor controls the airflow humidity within a safe range to inhibit dust diffusion. As the airflow passes through the filter along the exhaust channel, it sequentially passes through the hydrophobic layer, transition layer, and conductive layer of the filter element. Dust is intercepted on the surface of the hydrophobic layer, and the conductive layer conducts the charge generated during filtration to prevent accumulation. A first monitoring module monitors the internal temperature and methane concentration of the chamber, while a second monitoring module performs zoned monitoring of the filter element's conductivity based on its filtration area. The control unit, based on the information monitored by the first and / or second monitoring modules, controls cooling elements and / or response elements to implement internal temperature control and / or restore the internal conductivity of the filter element to collaboratively suppress the explosion risk. Therefore, compared with the prior art, the present invention, on the one hand, achieves the essential compatibility of the conductive layer and the hydrophobic layer based on the dosage layout of the first and second fillers in the transition layer, simultaneously meeting the requirements of conductivity stability and long-lasting hydrophobic performance, effectively slowing down filter element degradation and extending service life; on the other hand, based on the state perception of the cavity and filter element by the first and second monitoring modules, it restores the internal conductivity of the filter element and controls the external temperature by actively controlling the response element and cooling element, realizing all-round, multi-level collaborative management and control from the external risk of "dust-gas" to the internal risk of "filter element", making the emergency response more accurate and timely, effectively suppressing and eliminating the risk of explosion, and greatly improving production safety. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the explosion-proof dust removal system in Example 1; Figure 2 This is a schematic diagram of the control logic of the explosion-proof dust removal system in Example 1; Figure 3 for Figure 1 A partial structural diagram of the filter; Figure 4 for Figure 3 A left-view diagram; Figure 5 for Figure 3 Exploded and enlarged structural diagram of the middle filter element; Figure 6 for Figure 5 A partial half-section diagram of the filter element body; Figure 7 Here is a schematic diagram of the plan layout of the second monitoring module: Figure 8 This is a schematic diagram of the response element not being triggered during functional verification in Example 2; Figure 9 This is a schematic diagram illustrating the working principle of the response element in the thermally triggered state during functional verification in Example 2. Figure 10 The graph shows a performance comparison between the filter element prepared in Example 2 and a conventional filter element under simulated risk conditions during functional verification. The components include: 1. Exhaust channel; 2. Dust suppressor; 20. Dust suppressor hood cavity; 200. Temperature and humidity sensor; 21. Dust suppressor module; 210. Spray head; 3. Filter; 30. Chamber; k1. Air inlet; k2. Air outlet; 31. Filter element; 310. Filter element body; c1. Hydrophobic layer; c2. Transition layer; c21. First working layer; c22. Second working layer; c3. Conductive layer; t1. First packing; t2. Second packing; 311. Separator strip; 312. Connecting end; a1. Connecting seat body; a10. Seat body. Body; a11, Terminal block; a12, Self-locking module; a120, Plug-in module; a121, Elastic element; a13, Sealing strip; a14, Buffer pad; a15, Contact piece; a2, Support base; 32, Response element; 33, Cooling element; 330, Cooling pipe; d, Cooling section; 34, Flameless explosion relief device; 35, Explosion-proof ash discharge device; 4, Status sensing unit; 42, Second monitoring module; 420, First sensor; 421, Second sensor; 5, Explosion-proof valve; F, Explosion-proof main fan; D, Discharge port. Detailed Implementation

[0021] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0022] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, 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, and therefore should not be construed as a limitation of this application.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0024] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0025] In this application, unless otherwise expressly specified and limited, "above" or "below" a second feature can mean that the first and second features are in direct contact, or that they are in indirect contact through an intermediate medium. Furthermore, "above," "over," and "on top" of a second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" a second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature. It should be noted that when an element is referred to as "fixed to" or "set on" another element, it can be directly on the other element or there may be an intermediate element present. When an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element present. The terms "vertical," "horizontal," "above," "below," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible embodiments.

[0026] like Figures 1 to 7 As shown, the explosion-proof dust removal system of this embodiment is used to treat the methane-containing coal dust airflow generated by the coal mine ground production system. It includes an exhaust channel 1 connected to the exhaust port D of the methane-containing coal dust airflow, a dust suppressor 2 and a filter 3 arranged sequentially along the exhaust channel 1, a status sensing unit 4, and a control unit.

[0027] Specifically, the exhaust duct 1 is connected to the explosion-proof main fan F to generate suction force; the dust suppressor 2 includes a sealed dust suppressor hood 20 located at the air inlet end of the exhaust duct 1, and a dust suppressor module 21 located inside the dust suppressor hood 20 for controlling airflow humidity, wherein the exhaust port D extends into the dust suppressor hood 20. This facilitates precise control of airflow humidity, suppresses dust diffusion, and achieves preliminary temperature control.

[0028] Meanwhile, the dust suppression module 21 includes multiple spray heads 210, each of which uses a micron-level dry fog generator, and the multiple spray heads 210 are arranged in an array, with the spray direction of each spray head 210 being opposite to the airflow direction; a temperature and humidity sensor 200 is installed inside the dust suppression hood cavity 20 to monitor the temperature and humidity inside the dust suppression hood cavity online in real time, wherein the spray volume of each spray head 210 is dynamically adjusted according to the sensor feedback information to keep the airflow humidity closed-loop controlled within a safe range (preferably 95%-100%RH).

[0029] In this example, the filter 3 includes a cavity 30, multiple filter elements 31, a response element 32, and a cooling element 33. The cavity 30 has an air inlet k1 at the bottom and an air outlet k2 at the top. The multiple filter elements 31 are built into the cavity 30 and are arranged side by side and spaced between the air inlet k1 and the air outlet k2 in a horizontal direction. The specific installation method can refer to the existing plastic sintered plate filter element, which will not be described in detail here.

[0030] In some specific embodiments, the lower part of the cavity 30 is tapered from top to bottom, so that the dust generated by filtration can be collected and discharged from top to bottom.

[0031] In this example, each filter element 31 includes a plurality of filter element bodies 310 spaced apart along the thickness direction, a plurality of partition strips 311 connected between each adjacent filter element body 310, and a connecting end seat 312 that fixes the plurality of filter element bodies 310 relative to each other. The plurality of partition strips 311 are arranged side by side at intervals along the thickness direction perpendicular to the filter element body 310 and divide the adjacent filter element bodies 310 into a plurality of filter cavities. Each filter element body 310 has a hydrophobic layer c1, a transition layer c2 and a conductive layer c3 formed sequentially in its own thickness direction. During filtration, the airflow passes through the hydrophobic layer c1, the transition layer c2 and the conductive layer c3 in sequence.

[0032] In some specific embodiments, there are two filter element bodies 310, each of which is wavy, and each filter element body 310 has multiple grooves formed based on multiple troughs of the wavy shape; the connecting end seat 312 includes a connecting seat body a1 and a supporting seat body a2 respectively installed on the top and bottom of the two filter element bodies 310, wherein the connecting seat body a1 includes a seat body a10, wiring terminals a11 disposed at both ends of the seat body a10, two self-locking modules a12 disposed on the seat body a10 and corresponding one-to-one with the two filter element bodies 310, a sealing strip a13, a buffer pad a14, and multiple contact pieces a15 corresponding to the metal conductive inserts pre-embedded on each filter element body 310, wherein the self-locking module a12 includes multiple plug-in modules a120 corresponding to the multiple grooves, and elastic members a121 corresponding to the plug-in modules a120 and the inner wall of the groove. The elastic element a121 is a shape memory alloy (SMA) ring spring; the sealing strip a13 and the buffer pad a14 are installed on the seat body a10, both of which are conventional sealing and buffering settings. Here, the elastic element makes the installation structure between the connecting end seat and the filter element body highly stable, fundamentally overcoming the loosening problem caused by equipment vibration and ensuring the extreme stability of the grounding resistance.

[0033] For ease of implementation, the hydrophobic layer c1 is a fluorosilicone-modified nanocomposite coating firmly attached to the surface of the transition layer c2 via chemical bonding. This coating contains fluorocarbon resin (such as PVDF), silane coupling agent, and pre-treated hydrophobic nano-silica particles, forming a micro-nano secondary rough structure. This imparts superhydrophobic properties to the surface, with a water contact angle greater than 150° and a roll-off angle less than 10°, and significantly improves wear resistance. The conductive layer c3 uses ultra-high molecular weight polyethylene (UHMWPE) as the base material, and a first conductive filler t1 is uniformly dispersed in the base material. The transition layer c2 uses ultra-high molecular weight polyethylene (UHMWPE) as the base material and includes a first working layer c21 and a second working layer c22. The first working layer c21 is filled with a conductive first filler t1 and a chemically compatible second filler t2, which are mixed with the hydrophobic layer. The amount of the first filler t1 in the first working layer c21 is greater than the amount of the second filler t2, and the amount of the first filler t1 increases along the airflow direction. The second working layer c21 is filled with the second filler t2 and is located between the hydrophobic layer c1 and the first working layer c21. That is to say, based on the change in the amount of the first filler t1, the first working layer c21 contains a mixture of base material, first filler t1 and second filler t2. The second working layer c22 contains a mixture of base material and second filler t2 (i.e., does not contain the first filler t1), so the second working layer is not conductive.

[0034] In some specific embodiments, the first filler t1 can be any conductive filler used in conventional filter cartridges, such as a mixture of carbon nanotubes (CNTs) and vapor-grown carbon fibers (VGCF); the second filler t2 can be a fluoropolymer (such as PTFE micro powder) that is chemically compatible with the three phases of the hydrophobic layer.

[0035] In this example, the response element 32 is arranged in the conductive layer c3 and can release conductive material based on the filter area of ​​the filter cartridge to restore the conductivity of the corresponding zone.

[0036] In some specific embodiments, the response element 32 is a functional response microcapsule containing conductive material. Its shell is a polymer and can release the conductive material by stimulating the melting of the shell at high temperature. The conductive material is a low-melting-point alloy or ionic liquid (preferably with a melting point of 50°C to 150°C). During release, the liquid conductive material diffuses circumferentially and combines with the first filler of the corresponding partition to form a conductive path. The filter 3 also includes a heating element (not shown in the figure, but easy to imagine) for partitioning the response element 32 to stimulate the release of conductive material. The heating element can precisely and slightly heat the functional response microcapsules of abnormal partitions through micro-resistance heating wires embedded in each partition or external directional electromagnetic sensors, triggering the release of conductive material, actively constructing a locally enhanced conductive path, realizing "pre-emptive" risk reduction, and achieving the adaptive protection mechanism of the filter element.

[0037] In this example, the cooling element 33 uses water cooling to cool the interior of the chamber 30. It includes a cooling pipe 330, a circulating pump that drives the coolant to circulate along the cooling pipe 330, a refrigeration component for cooling the coolant, and a heat exchanger (not shown in the figure, but easily understood). The cooling pipe 330 has a cooling section d, which is arranged along the inner wall of the chamber and meanders around the area where the filter element 31 is installed. The cooling sections d on each side are connected in series or in parallel. This ensures effective temperature control of the area where the filter element is located.

[0038] In some specific embodiments, the water inlet and outlet of the cooling section d are located close to the air inlet k1 and air outlet k2 of the chamber 30, respectively; the cooling pipe 330 is made of stainless steel or copper coil; the circulating pump, heat exchanger and refrigeration components realize multi-level power adjustment according to PLC instructions (e.g., low power mode, high power mode and maximum cooling mode to correspond to different cooling requirements).

[0039] In addition, the filter includes one or more flameless explosion relief devices 34 disposed on one side of the chamber 30, and an explosion-proof ash discharge device 35 disposed at the bottom of the chamber 30, all of which are commercially available products; the explosion-proof dust removal system also includes an explosion-proof valve 5 disposed on the exhaust channel 1 and located between the dust suppressor 2 and the filter 3. Here, in response to extreme risk situations, such as a pressure rise rate exceeding the limit and suspected explosion, or failure of the filter element grounding circuit, or chamber temperature > 80°C, a rapid response is achieved to improve safety.

[0040] In this example, the state sensing unit 4 includes a first monitoring module that monitors the internal temperature and methane concentration of the filter cavity online, and a second monitoring module 42 that monitors the conductivity of the filter element by zone based on the filter area of ​​the filter element.

[0041] In some specific embodiments, the first monitoring module includes multiple temperature sensors and a methane concentration sensor arranged in a multi-point layout within the cavity 30. More preferably, the first monitoring module also includes a pressure sensor arranged within the cavity 30 to achieve multi-dimensional monitoring of the temperature, pressure, and methane concentration inside the cavity.

[0042] The second monitoring module 42 includes a first sensor 420 disposed in the conductive layer c3 for zoned monitoring of temperature and strain, a second sensor 421 disposed in the transition layer c2 for zoned monitoring of the surface charge density of the filter element, an online monitoring circuit for grounding loop integrity disposed on the connection terminal 312, and a data acquisition and wireless communication module. Here, temperature monitoring is used to provide early warning of localized blockage, overheating, or fire risks; strain monitoring is used to assess the structural health of the filter element and the impact uniformity of the cleaning pulse; and by monitoring the surface charge density of the filter element in zones, a holographic, online perception of the filter element's working state (physical field, cleaning effect, electrostatic level) is achieved, transforming the filter element from a "silent" part into a "talking" intelligent terminal. In short, this embodiment accurately reflects the conductivity state of the filter element based on the monitoring of temperature, strain, and charge density.

[0043] To further facilitate implementation, the first sensor 420 employs a fiber optic sensor integrated with a fiber Bragg grating (FBG) array. The fiber optic sensor is embedded in the middle of the conductive layer and is wavy along either the length or short side of the conductive layer c3. The fiber optic sensor also integrates distributed acoustic sensing (DAS) functionality, which is used for zoned monitoring of the dust adhesion thickness distribution on the hydrophobic layer surface. Here, based on the fiber Bragg grating array, with specific wavelength intervals, temperature and strain at key locations inside the filter element can be monitored in real-time and in a quasi-distributed manner. Simultaneously, the wavy, meandering fiber optic arrangement in the middle of the conductive layer enables uniform zoning and high-density, precise monitoring. Furthermore, by demodulating the propagation and reflection signals of the vibrational sound waves generated by the cleaning pulse airflow within the filter element, the adhesion distribution and thickness changes of the dust layer on the filter element surface can be non-invasively retrieved, facilitating online quantitative evaluation of the cleaning effect.

[0044] Meanwhile, the second sensor 421 employs an interdigitated electrode array, which is electrically connected to the conductive network formed by the conductive layer c3. In the interdigitated electrode array, multiple interdigitated electrodes are spaced apart along a wavy path in the length or width direction of the filter element to achieve zoned monitoring.

[0045] By integrating and analyzing monitoring data, early warning of filter element risks can be achieved: for example, identifying the coupled risk pattern of "continuously high charge density accompanied by local temperature rise" in a certain area of ​​the filter element and issuing an early warning of static electricity accumulation; or analyzing "decreased dust removal efficiency" based on DAS data and issuing a preventive maintenance reminder; grounding status diagnosis: real-time judgment of whether the grounding circuit of each filter element is intact and prediction of the slow deterioration trend of contact resistance.

[0046] In this example, the control unit controls the cooling element to reduce the cavity temperature and / or controls the response element to release conductive material in the abnormal conductivity zone based on the data monitored by the first monitoring module and / or the second monitoring module, in order to synergistically suppress the risk of explosion.

[0047] In some specific implementations, the control unit includes a PLC control module, an edge computing gateway for aggregating and processing monitoring data, and the control unit stores and runs control programs and algorithm models with multi-level interlocking emergency logic.

[0048] Therefore, the explosion-proof dust removal method of this embodiment includes the following steps: S1, Dust Suppression The methane-containing dust airflow emitted by the equipment enters the exhaust channel, and the dust suppressor controls the humidity of the airflow within a safe range to inhibit dust diffusion. S2, Dust Removal When the airflow passes through the dust collector along the exhaust channel, the airflow passes through the hydrophobic layer, transition layer and conductive layer of the filter element in sequence. The dust is intercepted on the surface of the hydrophobic layer, and the conductive layer conducts the charge generated by filtration to avoid accumulation. S3. Hierarchical and collaborative risk control Multi-level interlocking emergency logic is preset based on the variation range of methane concentration, airflow temperature, and filter element conductivity. The first monitoring module monitors the methane concentration and temperature online at multiple points along the exhaust channel, while the second monitoring module performs zoned monitoring of the filter element conductivity based on the filter element's filtration area. The control unit controls the cooling element and / or response element to work together under the corresponding level of emergency logic based on the information monitored by the first and / or second monitoring modules, implementing internal temperature control and / or restoration of internal conductivity of the filter element to collaboratively suppress the risk of explosion.

[0049] When implementing tiered and collaborative risk control, multi-level interlocking emergency logic includes: Level 1 Temperature Control Warning: When the methane concentration is detected to be >0.3% VOL, or the local charge density of the filter element is too high, or the chamber temperature is >50℃, an audible and visual alarm will be activated. The system will continue to operate normally but will strengthen recording and prompts, and the cooling element will be activated in low power mode. Level 2, Active Intervention and Enhanced Cooling: When methane concentration > 0.5% VOL is detected, or the filter element shows a risk of "charge increase accompanied by local temperature rise", or the chamber temperature > 65°C, the ventilation butterfly valve at the exhaust channel inlet is immediately interlocked and shut off, the power supply to the explosion-proof main fan and explosion-proof ash discharge device is cut off and an alarm is continuously triggered, while the cooling element switches to high power mode; it can trigger an adaptive protection mechanism for specific high-risk filter elements (i.e., the control response element releases conductive material in the abnormal conductivity zone to enhance the local conductive path to restore conductivity).

[0050] Level 3, Emergency Explosion Relief and Maximum Cooling: When methane concentration >1% VOL is detected, or the chamber pressure rises suddenly and the temperature >80℃, or the filter element grounding circuit fails completely, the flameless explosion relief device is triggered on the basis of Level 2 action, and the highest level alarm is uploaded. At the same time, the cooling element enters the maximum cooling mode to suppress the subsequent thermal chain reaction.

[0051] In summary, this invention achieves inherent compatibility between the conductive and hydrophobic layers based on the arrangement of the first and second fillers in the transition layer, simultaneously meeting the requirements for conductivity stability and long-lasting hydrophobic performance, effectively slowing down filter element degradation and extending service life. Furthermore, based on the state perception of airflow and filter element by the first and second monitoring modules, it restores the internal conductivity of the filter element and controls the external temperature through active control of response and cooling elements. This enables comprehensive, multi-level collaborative management from external risks ("dust-gas") to internal risks ("filter element"), resulting in more precise and timely emergency response, effectively suppressing and eliminating explosion risks, and significantly improving production safety.

[0052] Example 2, this example relates to the preparation method of filter element 31 in Example 1, including the following steps: S1, Prepare base material (ultra-high molecular weight polyethylene (UHMWPE)), hydrophobic coating, conductive first filler t1, chemically compatible second filler t2 with hydrophobic coating, response element 32, first sensor 420, second sensor 421; S2. A base material, a first filler t1, a second filler t2, a response element 32, a first sensor 420, and a second sensor 421 are laid in a mold to form a conductive layer c3 and a transition layer c2 arranged sequentially. The conductive layer c3 contains the base material, the first filler t1, and the response element 32 dispersed in the first filler t1, and multiple metal conductive inserts are pre-embedded. The transition layer c2 includes a first working layer c21 and a second working layer c22. The first working layer c21 contains the base material, the first filler, and the second filler. The amount of the first filler t1 is greater than the amount of the second filler t2, and the amount of the first filler decreases from the inside to the outside. The amount of the first filler t1 increases along the airflow direction. The second working layer c21 is filled with the second filler t2. The first sensor 420 is laid in the conductive layer c3 and forms a zone monitoring based on the filtration area of ​​the filter element. The second sensor 421 is laid on the surface of the second working layer c21 and forms a zone monitoring based on the filtration area of ​​the filter element. S3. The conductive layer c3 and the transition layer c2 are cold-pressed and shaped at 15 MPa to form a compact. The compact is then placed in a sintering furnace and sintered at 180-200℃ for 3.5 hours under nitrogen protection to melt and bond the layers together. The first sensor 420 is firmly covered and forms a filter element blank. S4. A hydrophobic coating is applied to the surface of the transition layer c2 in the filter element blank, and after curing at 165°C for 40 minutes, a hydrophobic layer 3 is formed to complete the preparation of the filter element.

[0053] In some specific embodiments, the ratio of the base material, the first filler t1, and the responsive element 32 in the conductive layer c3 is 92:5:3; the ratio of the base material, the first filler t1, and the second filler t2 in the first working layer c21 is 90:1.5:8.5; the ratio of the base material and the second filler t2 in the second working layer c22 is 85:15; and the ratio of the PVDF resin liquid (solid content 20%), the silane coupling agent KH-570, and the hydrophobic nano-SiO2 (particle size 30nm) in the hydrophobic coating is 100:4:10.

[0054] To further facilitate implementation, when laying the transition layer c2, the base material, the first filler and the second filler are mixed sequentially based on the amount of the first filler to form multiple mixed fillers. The multiple mixed fillers are then laid layer by layer in order of decreasing amount of the first filler, thereby achieving changes in the amount of the first filler and the second filler. The operation is simple.

[0055] Therefore, combining Figures 8 to 9 As shown, when verifying the function of the filter element in this embodiment, firstly, the filter element of this embodiment is installed on the experimental filter tube sheet. Dust-laden gas with 90% humidity and containing coal powder is introduced into the experimental filter from the outside to the inside. Approximately 10% of the bottom area of ​​one of the filter elements is artificially blocked to simulate local blockage and monitoring is performed. During the monitoring process, the cloud platform shows that after running for 2 hours, the temperature of an FBG temperature measuring point corresponding to the blocked filter element is consistently higher than the average value by more than 15°C. At the same time, the charge sensing electrode near this area shows a slow increase in charge density. According to the preset algorithm, the system diagnostic engine determines that there is a risk of "local overheating accompanied by static electricity accumulation" and issues an orange warning. After confirmation by the maintenance personnel, an "adaptive protection" command is issued through the platform. The command is transmitted to the connection terminal of the corresponding filter element through the gateway, triggering the heating element embedded in the risk area to work for 3 seconds, so that the corresponding response element releases conductive material to restore the conductivity of the area, while monitoring data changes.

[0056] Combination Figure 10 As shown by curve A, within 30 minutes of heating, the charge density value of the shielded area decreased by approximately 60%, the temperature rise stopped, and the temperature began to fall. This successfully verified the effectiveness of the filter element's adaptive protection mechanism. Furthermore, throughout the entire test, the system continuously recorded the grounding loop resistance of all 20 filter elements, with fluctuations within ±5%, indicating extremely reliable connections.

[0057] The above functional verification process was repeated based on traditional filter elements, combined with Figure 10 As shown in curve B, it is clear that with local blockage, the temperature continues to rise and begins to fail, making adaptive protection impossible.

[0058] In addition, when evaluating the dust removal effect on the filter element surface, the system records the DAS acoustic signal during each pulse cleaning cycle during normal cleaning cycle. By analyzing the acoustic attenuation and reflection characteristics through the edge gateway algorithm, a "cleaning uniformity cloud map" is automatically generated. Operators can intuitively see which areas on the filter element are not thoroughly cleaned, thereby optimizing the start and stop sequence and duration of the pulse valve, achieving precise cleaning, and reducing energy consumption.

[0059] The above embodiments are only for illustrating the technical concept and features of the present invention. Their purpose is to enable those skilled in the art to understand the content of the present invention and implement it accordingly. They should not be used to limit the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control, comprising an exhaust channel connected to the emission port of a methane dust-containing airflow, a dust suppressor and a filter arranged sequentially along the exhaust channel, the filter comprising a cavity and a filter element built into the cavity, wherein the filter element is divided into a hydrophobic layer and a conductive layer along its thickness direction, and the airflow passes through the hydrophobic layer and the conductive layer sequentially, characterized in that, The filter element also has a transition layer formed between the hydrophobic layer and the conductive layer. The transition layer includes a first working layer and a second working layer. The first working layer is filled with a first packing material that is conductive and mixed with a second packing material that is chemically compatible with the hydrophobic layer. The amount of the first packing material in the first working layer is greater than the amount of the second packing material, and the amount of the first packing material increases along the airflow direction. The second working layer is filled with the second packing material and is located between the hydrophobic layer and the first working layer. The filter also includes a response element arranged in the conductive layer that can release conductive material in sections based on the filter element's filtration area to restore the conductivity of the corresponding sections, and a cooling element for cooling the interior of the filter cavity. The explosion-proof dust removal system also includes a status sensing unit and a control unit. The status sensing unit includes a first monitoring module that monitors the internal temperature and methane concentration of the chamber, and a second monitoring module that monitors the conductivity of the filter element by zone based on the filter area of ​​the filter element. The control unit controls the cooling element to reduce the cavity temperature and / or controls the response element to release conductive material in the abnormal conductivity zone based on the data monitored by the first monitoring module and / or the second monitoring module, so as to synergistically suppress the risk of explosion.

2. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 1, characterized in that, The dust suppressor includes a sealed dust suppressor hood cavity disposed at the air inlet end of the exhaust channel, and a dust suppressor module disposed inside the dust suppressor hood cavity for controlling the humidity of the airflow, wherein the exhaust port extends into the dust suppressor hood cavity.

3. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 2, characterized in that, The dust suppression module includes multiple spray nozzles, wherein the spray direction of each spray nozzle is set opposite to the airflow direction.

4. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 1, characterized in that, The responsive element is a functional responsive microcapsule and is capable of releasing conductive material by stimulating a molten shell at high temperature; and / or, the filter further includes a heating element for partitioning the responsive element to stimulate the release of conductive material.

5. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 1, characterized in that, The second monitoring module includes a first sensor disposed in the conductive layer for zoned monitoring of temperature and strain, and a second sensor disposed in the transition layer for zoned monitoring of the surface charge density of the filter element.

6. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 5, characterized in that, The first sensor is an optical fiber sensor with an integrated fiber Bragg grating array. The optical fiber sensor is embedded in the middle of the conductive layer and is wavy in the length or short side direction of the conductive layer. The optical fiber sensor also integrates a distributed acoustic sensing function, which is used to monitor the distribution of dust adhesion thickness on the surface of the hydrophobic layer in different zones.

7. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 5, characterized in that, The second sensor employs an interdigitated electrode array, which is electrically connected to the conductive network formed by the conductive layer.

8. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 1, characterized in that, The filter element includes multiple filter element bodies spaced apart along the thickness direction, multiple partition strips connecting each adjacent filter element body, and a connecting end seat that fixes the multiple filter element bodies relatively. The multiple partition strips are distributed side by side at intervals along the thickness direction perpendicular to the filter element body and divide the adjacent filter element bodies into multiple filter cavities. Each filter element body has a hydrophobic layer, a transition layer and a conductive layer formed sequentially in its own thickness direction.

9. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 8, characterized in that, The filter element body has two parts, each of which is wavy, and each filter element body has multiple grooves formed based on multiple troughs of the wavy shape; the connecting end seat includes a connecting seat body and a supporting seat body respectively installed on the top and bottom of the two filter element bodies, wherein the connecting seat body includes a seat body, wiring terminals disposed at both ends of the seat body, two self-locking modules disposed on the seat body and corresponding to the two filter element bodies, a sealing strip, a buffer pad, and multiple contact pieces corresponding to and communicating with each filter element body, wherein the self-locking module includes multiple plug-in modules corresponding to be inserted into the multiple grooves, and an elastic element corresponding to abutting between the plug-in module and the inner wall of the groove.

10. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 1, characterized in that, The cooling element includes a cooling pipe, a circulation pump that drives the coolant to circulate along the cooling pipe, and a refrigeration component for cooling the coolant. The cooling pipe has a cooling section installed in the chamber, which is close to the filter element and arranged in a meandering manner.

11. The explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control according to claim 1, characterized in that, The filter also includes a flameless explosion relief device disposed on one side of the chamber; and / or, the explosion-proof dust removal system also includes an explosion-proof valve disposed on the exhaust channel and located between the dust suppressor and the filter.

12. A method for explosion-proof dust removal, characterized in that, It employs the explosion-proof dust removal system based on intelligent sensing and multi-dimensional collaborative risk control as described in any one of claims 1-11, and includes the following steps: S1, Dust Suppression The methane-containing dust airflow emitted by the equipment enters the exhaust channel, and the dust suppressor controls the humidity of the airflow within a safe range to inhibit dust diffusion. S2, Filtration As the airflow passes through the filter along the exhaust channel, it sequentially passes through the hydrophobic layer, transition layer, and conductive layer of the filter element. Dust is intercepted on the surface of the hydrophobic layer, and the conductive layer conducts the charge generated during filtration to prevent accumulation. S3. Hierarchical and collaborative risk control Multi-level interlocking emergency logic is preset based on the variation range of methane concentration, airflow temperature and filter element conductivity. The first monitoring module monitors the internal temperature and methane concentration of the chamber, while the second monitoring module monitors the conductivity of the filter element based on its filtration area. The control unit controls the cooling element and / or the response element to work together under the corresponding level of emergency logic based on the information monitored by the first and / or second monitoring modules, to implement internal temperature control and / or restoration of internal conductivity of the filter element in order to jointly suppress the risk of explosion.

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