A method and device for online monitoring and failure isolation of a cyclone separator bundle

Abstract

The application is suitable for the field of solid-liquid separation device, and provides a method and device for online monitoring and failure isolation of cyclone separator tube bundle, which comprises a cyclone separator, a Venturi tube section and a central processing system; the cyclone separator comprises a straight pipe section and a conical pipe section; the top and side of the straight pipe section are respectively provided with an overflow pipe and a tangential inlet; the cyclone separator has an inlet zone, a disturbance zone and a deceleration zone inside; a plurality of radar water flow detectors are arranged on the inner wall of the cyclone separator in a uniform manner from top to bottom; the Venturi tube section comprises a compression section, a diffusion section and a throat pipe located between the two; the throat pipe is provided with a distribution disc; the distribution disc is provided with a distribution blocking mechanism and a distribution detection mechanism; the distribution blocking mechanism and the distribution detection mechanism are each provided with one or more on the distribution disc. Therefore, the device can non-contactly capture the complete flow velocity profile from the inlet to the bottom flow inside in real time; the specific flow channel on the control value distribution disc can realize the rapid physical isolation of the fault unit.

Description

Technical Field

[0001] This invention relates to the field of solid-liquid separation devices and provides a method and apparatus for online monitoring and failure isolation of cyclone separator tube bundles. Background Technology

[0002] A hydrocyclone separator is a static device for separating multiphase media based on the principle of centrifugal sedimentation. It is widely used in mining, petroleum, chemical, and environmental protection fields, especially for the separation and concentration of fluids containing solid and liquid phases. Its working principle is as follows: the mixed fluid enters a high-speed rotating conical cavity tangentially. Under the strong centrifugal force of its own motion, the denser solid particles are thrown against the wall and spiral downwards, exiting through the underflow port. The clarified liquid or lighter phase accumulates in the central low-pressure zone and is output upwards from the overflow port, thus achieving efficient solid-liquid separation.

[0003] In tunnel boring machine (TBM) construction, riverbank construction, and underground building excavation, multiple hydrocyclones are often integrated in parallel into a bundle-type structure specifically for treating the continuously generated solids-containing wastewater. Typically, the feed for each hydrocyclone is drawn from a large mud storage tank or directly from the source wastewater at the work face for continuous treatment. This continuous treatment mode requires the hydrocyclone separator to possess stable and highly efficient separation performance.

[0004] However, in actual operation, the solid content parameters of the feed, such as concentration, density, and particle size, fluctuate dynamically, whether from the mud pit or the source. For example, after sedimentation and treatment in the mud pit, the concentration may increase to some extent during the later stages of pumping; and in another scenario, the solid content of the source material varies due to differences in excavation depth and geological conditions. This unsteady nature of the feed characteristics poses a serious challenge to the separation efficiency of hydrocyclones operating at a fixed pumping power. Specifically, when the feed solid concentration is low, excessively high inlet flow rates result in energy waste and equipment wear; when the feed solid concentration increases, the separation capacity at a fixed flow rate is insufficient, and solid waste accumulates and clogs at the underflow outlet, causing a large number of particles to reach the overflow outlet, resulting in substandard effluent quality, significant fluctuations in separation efficiency, and even failure. Existing operating methods rely on manual experience for intermittent parameter adjustments, which suffer from severe lag and inaccuracy.

[0005] To overcome the aforementioned problems and achieve consistently optimal separation conditions, the key lies in real-time sensing of feed fluctuations and flow rates in each section of the hydrocyclone, along with targeted dynamic responses. Specifically, it is necessary to monitor pressure changes and underflow solids discharge information inside the hydrocyclone tubes and at key nodes of related tube bundles in real time, as pressure signals are directly related to fluid density, velocity, and internal flow conditions. By acquiring real-time data, the output power of the pump unit or the distribution flow rate of each tube bundle can be dynamically adjusted, thereby automatically maintaining the core parameters of the hydrocyclone separator, such as inlet velocity and operating pressure drop, within the optimal range matching the current solids load. This avoids separation failure due to insufficient power at high concentrations and prevents ineffective energy consumption and wear due to excessive power at low concentrations.

[0006] Therefore, there is an urgent need for a method and device that can achieve online condition sensing and adaptive closed-loop control of cyclone separators to solve the problem of intelligent and precise operation and maintenance of cyclone separator tube bundles under dynamic feeding conditions. Summary of the Invention

[0007] To address the aforementioned deficiencies, the present invention aims to provide a method and apparatus for online monitoring and failure isolation of a cyclone separator tube bundle, in order to solve the problems raised in the background art. The apparatus includes a cyclone separator and a Venturi tube section installed at the inlet of the cyclone separator; the cyclone separator includes a straight tube section and a tapered tube section; the top and side of the straight tube section are respectively provided with an overflow pipe and a tangential inlet, characterized in that it also includes a central processing system;

[0008] The internal space of the cyclone separator is divided into an inlet section, a disturbance section and a deceleration section from top to bottom; the inner wall of the cyclone separator is provided with a number of radar flow detectors that are evenly arranged from top to bottom and electrically connected to the central processing system.

[0009] The Venturi tube section includes a compression section, a diffusion section, and a throat located between the two. A distribution plate is provided on the throat, and a distribution blocking mechanism and a distribution detection mechanism are provided on the distribution plate. One or more distribution blocking mechanisms and distribution detection mechanisms are provided on the distribution plate.

[0010] Furthermore, both the distribution blocking mechanism and the distribution detection mechanism include an injection mechanism and a detection mechanism. The distribution blocking mechanism also includes an electromagnetic shut-off valve. The injection mechanism is a connecting tube bundle that connects to an external liquid supply device. The detection mechanism is a pressure sensor.

[0011] Furthermore, the distribution plate has a central flow channel in the middle, and the distribution plate has a plurality of distribution channels with both ends connected to the outer ring side of the distribution plate and the central flow channel respectively; the distribution channels have two branch flow paths that are connected to the two end faces of the distribution plate respectively.

[0012] For the distribution blocking mechanism: its injection mechanism is located at one end of the distribution channel away from the middle channel; the detection mechanism and the electromagnetic shut-off valve are respectively located on the two branch channels corresponding to the distribution channel;

[0013] For the distribution detection mechanism: one injection mechanism is located at the end of the distribution channel away from the middle channel; the detection mechanism and the other injection mechanism are respectively located on the two branch channels corresponding to the distribution channel.

[0014] Furthermore, the electromagnetic shut-off valve includes a valve plate that can be moved in a controlled manner to block the distribution channel. The distribution channel is provided with a valve plate groove corresponding to the valve plate. When the electromagnetic shut-off valve is closed in a controlled manner, it can block the connection between the first injection mechanism and the distribution channel.

[0015] Furthermore, the compression section and the diffusion section of the Venturi tube are respectively equipped with a first detection mechanism and a third detection mechanism.

[0016] A method for online monitoring and failure isolation of cyclone separator tube bundles, based on a device for online monitoring and failure isolation of cyclone separator tube bundles, includes the following steps:

[0017] S1. The system monitors the flow velocity data of each height layer in the cyclone separator in real time, which is measured by the radar flow detector. The system numbers and stores the data as several real-time profile flow velocities. The system also monitors the pressure signals of all detection mechanisms in real time. The system calculates the pressure difference and stores the data as real-time flow rate.

[0018] S2. The system dynamically defines each "internal velocity profile" in the cyclone separator in real time based on the velocity profile of each number: the area near the tangential inlet with stable velocity and close to the inlet design value is marked as the inlet interval; the area near the underflow outlet with velocity significantly lower than the reference value is marked as the deceleration interval; the transition area between the two with obvious velocity gradient changes is marked as the disturbance interval; the range of each interval changes dynamically with the operating conditions.

[0019] S3. The system performs data fusion analysis based on the manually set reference flow velocity profile, the reference flow rate calibrated in the venturi tube, and the real-time interval range obtained in step S2, and judges the trend of separation efficiency.

[0020] S4. The system sends control command sets to the corresponding actuators to achieve dynamic adjustment of the working conditions;

[0021] S5. When adaptive adjustment is ineffective and the operating conditions continue to deteriorate to a dangerous threshold, the system initiates a protective isolation procedure.

[0022] Furthermore, step S3 includes the following sub-steps:

[0023] S3.1 The system compares and analyzes the real-time "internal velocity profile" with the stored baseline velocity profile, compares the pattern changes in the profile morphology, and determines different abnormal trends; the specific determination process is as follows:

[0024] If the system detects that the deceleration zone extends continuously upward from the bottom outlet and the flow velocity value in this zone decreases systematically, it is diagnosed as "bottom flow sedimentation trend".

[0025] If the system detects abnormal or disordered enhancement of radar echo Doppler signal intensity in the disturbance zone, it indicates a surge in solid concentration and turbulence in that region. Combined with the degree of disorder in the velocity gradient in that region, it is diagnosed as "solid phase escape tendency".

[0026] S3.2 The system performs a collaborative analysis of the judgment result obtained in step S3.1 with the "instantaneous feed volume flow rate" to generate a set of control instructions that includes specific adjustment targets and required actuators.

[0027] Furthermore, step S4 specifically includes the following process:

[0028] S4.1 When the decision is that flow or pressure needs to be adjusted, the corresponding distribution blocking mechanism on the central processing system integrated control distribution panel or the injection mechanism on the distribution detection mechanism;

[0029] S4.2 When the decision is that the solid-phase polymerization effect needs to be improved, the central processing system controls the injection mechanism of the designated distribution and detection unit to start the addition of additives.

[0030] Furthermore, step S5 specifically includes the following sub-steps:

[0031] S5.1 The system continuously monitors various data during the adjustment process; detects the upward trend of the deceleration zone after adjustment; if the system reaches the critical height of the deceleration zone, or the abnormal signal strength of the disturbance zone exceeds the safety threshold, and is accompanied by slurry leakage at the overflow port, the system will ultimately determine that the separation has failed.

[0032] S5.2 After the failure determination is established, the system immediately sends a command to the distribution blocking mechanism corresponding to the faulty unit. The electromagnetic shut-off valve quickly acts to cut off the injection mechanism corresponding to the distribution channel, and at the same time the cyclone separator stops feeding.

[0033] Furthermore, the steps also include:

[0034] S6. Subsequent data iteration and model optimization; the system builds case storage, and through long-term operation, automatically optimizes the diagnostic thresholds and decision parameters in step S3.

[0035] This invention utilizes a radar flow detector array embedded in the wall of the cyclone separator to capture the complete velocity profile from the inlet to the bottom in real time without contact. The central processing system intelligently analyzes the dynamic morphological changes of this profile. When specific patterns indicating deterioration in separation efficiency are identified, such as abnormal upward extension of the low-velocity zone at the bottom or a surge in signals in the turbulent zone in the middle, the risk of siltation or particle escape is diagnosed in advance. The system then drives a multi-functional distribution plate installed at the throat of the feed venturi tube to perform two types of precise intervention: first, by injecting pressurized fluid to directly increase the inlet kinetic energy of the corresponding separation unit to clear the flow field; second, by using the high-speed turbulence at the throat as a natural and efficient mixer to add and disperse chemical agents in real time, thereby optimizing separation conditions. If the control is ineffective, the system can quickly shut off specific flow channels on the distribution plate to achieve rapid physical isolation of the faulty unit and ensure the continuous and stable operation of the entire tube bundle system. Attached Figure Description

[0036] Figure 1 This is a schematic cross-sectional view of the overall structure of the device;

[0037] Figure 2 This is a schematic cross-sectional view of a Venturi tube section.

[0038] Figure 3 This is a cross-sectional view of the distribution plate;

[0039] Figure 4 for Figure 2 Enlarged view of the A-section structure;

[0040] Figure 5 for Figure 2 Enlarged view of the structure of section B;

[0041] Figure 6 This is a schematic cross-sectional view of a hydrocyclone separator.

[0042] Figure 7 for Figure 6 Enlarged view of the C-section structure;

[0043] Figure 8 Schematic diagram of the hydrocyclone separator partition;

[0044] In the diagram: 01-Inlet section; 02-Deceleration section; 03-Disturbance section; 1-Venturi tube section; 101-First detection mechanism; 102-Second detection mechanism; 103-Third detection mechanism; 11-Liquid inlet; 12-Compression section; 13-Throat; 14-Diffusion section; 2-Distribution detection mechanism; 3-Detection circuit; 31-Signal collection unit; 4-Swirl separator; 401-Outer shell layer; 402-Isolation layer; 41-Tangential entry 42-Straight pipe section; 43-Cone pipe section; 44-Underflow pipe section; 45-Overflow pipe; 5-Distribution plate; 501-First injection mechanism; 502-Second injection mechanism; 51-Central flow channel; 52-Distribution flow channel; 53-Placement cavity; 54-Branch flow path; 55-Reserved hole; 56-Raft plate groove; 6-Distribution blocking mechanism; 61-Electromagnetic shut-off valve; 62-Valve plate; 7-Distribution detection mechanism; 71-Filter element; 8-Radar flow detector. Detailed Implementation

[0045] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0046] It should be noted that, in the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention 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 invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0047] Furthermore, in the description of this invention, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0048] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0049] Hydrocyclones are used in engineering projects such as tunnel boring and riverbank construction to continuously treat solid-containing wastewater. The solid content of the feed material often exhibits dynamic fluctuations. For example, typically, the solid-liquid mixture to be separated is continuously fed into the hydrocyclone for separation. For a single solid-liquid mixing tank, the solid-liquid density at the output of the liquid is not constant. If the construction environment has multiple solid-liquid mixing tanks, and the liquid from each tank enters the hydrocyclone sequentially, the solid-liquid mixing density in each tank will be inconsistent. Furthermore, even within the same tank, the solid-liquid density of the liquid entering the hydrocyclone varies at different times during the continuous flow of liquid. For instance, the solid content is relatively low in the initial stage of filling the same tank, but higher when the tank is nearly empty.

[0050] This leads to fluctuations in separation efficiency due to varying levels of impurities in the liquid as it is continuously fed from the solid-liquid mixing tank into the hydrocyclone separator under the same input power. Consequently, impurities may be present in the liquid output from the overflow outlet. Furthermore, this fluctuation results in a severe imbalance in separation efficiency at a fixed pumping power. At low concentrations, excessively high inlet velocities lead to energy waste and equipment wear, while at high concentrations, insufficient separation capacity causes blockage at the underflow outlet, allowing particles to escape to the overflow outlet, resulting in substandard effluent quality and equipment failure.

[0051] See Figure 1-8 The purpose of this invention is to provide a method and apparatus for online monitoring and failure isolation of a cyclone separator tube bundle, including a cyclone separator 4 and a Venturi tube section 1 installed on the inlet of the cyclone separator 4.

[0052] The cyclone separator 4 includes a straight pipe section 42, a tapered pipe section 43 installed at the bottom of the straight pipe section 42, and an underflow pipe 44 installed at the bottom of the tapered pipe section 43. The straight pipe section 42, the tapered pipe section 43, and the underflow pipe 44 are internally interconnected, and the inner diameter of the tapered pipe section 43 gradually decreases from top to bottom. An overflow pipe 45 is provided at the top of the straight pipe section 42, and a tangential inlet 41 is provided on the side of the straight pipe section 42 along the tangential direction of its outer contour. An underflow outlet is provided at the bottom of the underflow pipe 44. A Venturi pipe section 1 is installed on the tangential inlet 41.

[0053] Therefore, the overall structural principle of the cyclone separator 4 proposed in this invention is the same as that of existing cyclone separators. An external drive device is connected to the tangential inlet 41 (through the Venturi tube section 1). The solid-liquid mixture to be separated flows at high speed into the straight tube section 42 through the tangential inlet 41 under the pressure of the external drive device. Since the solid-liquid mixture enters tangentially along the inner wall of the cylindrical straight tube section 42, the fluid is forced to rotate downwards at high speed along the tube wall due to the constraint of the tube wall and the force of gravity. This creates a rotating vortex inside the straight tube section 42 and the conical tube section 43. The centrifugal force generated in this process causes the heavier components with higher density or particle size in the mixture to experience a greater centrifugal force than the fluid, thus throwing the solid waste towards the walls of the straight tube section 42 and the lower conical tube section 43. Simultaneously, the lighter components with lower density experience a weaker centrifugal force and are pushed towards the central axis region of the rotating vortex under the pressure difference, forming an upward internal vortex.

[0054] Subsequently, in the conical section 43, the large amount of rotating solid waste, as the flow area decreases, further increases the linear velocity of the rotating fluid, thus strengthening the centrifugal force field and causing the heavy particles thrown towards the lower wall to aggregate. Finally, the concentrated heavy component descends along the wall of the conical section 43, enters the underflow pipe 44, and exits from the underflow port at its bottom. The light, clean component, collected in the center, is carried upwards by the internal swirling flow and returns to the top of the straight section 42, exiting from the overflow pipe 45. Thus, the separated two-phase components are discharged from the equipment via different paths, achieving the purpose of separation.

[0055] During this process, since the power of the external equipment remains constant, that is, the rate at which the solid waste liquid enters the device under the drive of the external equipment remains constant, when the proportion of solid waste in the solid waste liquid changes, firstly, under the drive of centrifugal force, more heavy components descend along the wall of the cone section 43. The heavier components with increased linear velocity located at the bottom cause collisions and disturbances between them, as well as the influence of a large amount of friction with the pipe wall under the drive of centrifugal force. As a result, under the condition that the power of the external equipment remains constant, the flow velocity in the bottom area slows down, while the vortex of the internal swirl intensifies, causing more solid waste to be carried upward and discharged from the overflow port.

[0056] See appendix Figure 8As shown, that is, while maintaining the power of the external drive equipment, when the solid waste content in the solid waste liquid increases and approaches the limit of separation efficiency: the flow velocity of the solid waste liquid near the tangential inlet 41 does not change much or decreases slightly due to the increase in overall internal pressure; this region is subsequently defined as inlet zone 01. The flow velocity in the region near the underflow pipe 44 is gradually reduced due to the influence of accumulated solid waste, and the influence range of this region gradually extends upwards due to the influence of time and the rate of change of solid waste concentration; this region is subsequently defined as deceleration zone 02. The region near the bottom of the overflow pipe 45 and the top of deceleration zone 02 is defined as disturbance zone 03; the upward inward swirling flow formed at the central axis of disturbance zone 03 is defined as inward swirling zone 04. Within the disturbance zone 03: the closer to its top, the greater the relative velocity of the fluid, due to the accelerated upward swirling flow in the inner swirling zone 04 and the constant fluid velocity in the inlet zone 01; while the closer to its bottom, the greater the relative velocity, due to the influence of the downward solid waste in the deceleration zone 02 and the upward movement of the bottom interface of the inner swirling flow, the greater the relative velocity.

[0057] Therefore, this invention monitors the flow rate of solid waste liquid in the inlet section 01, disturbance section 03, and deceleration section 02 from top to bottom in real time, and uses mathematical analysis to detect the overall separation effect of the device.

[0058] An isolation layer 402 is provided on the inner wall of the straight pipe section 42 and the tapered pipe section 43 of the cyclone separator 4. Several radar flow detectors 8 are embedded inside the isolation layer 402. Specifically, the radar flow detectors 8 are fixedly connected to the isolation layer 402 and are evenly arranged along the overall height direction of the cyclone separator 4.

[0059] The radar flow detector 8 used in this invention is a monitor that uses microwave radar technology to measure fluid velocity non-contactly. Its core principle is to emit microwave signals, which, when irradiated by a flowing liquid, especially water containing solid particles or bubbles, are reflected back by scattering bodies. By accurately analyzing the frequency change caused by the Doppler effect between the emitted and reflected waves, the linear velocity of the fluid can be calculated. Detecting fluid velocity using the radar flow detector 8 has significant advantages such as high accuracy, no interference with the flow field, and no mechanical wear.

[0060] Preferably, the radar flow detector 8 used in this invention is a model employing frequency-modulated continuous wave technology to ensure stable measurement of the continuous flow field. In terms of key performance indicators, the measurement accuracy should reach ±1% or higher to sensitively capture subtle changes in flow velocity; simultaneously, a 24GHz radar frequency is selected that meets the requirements of narrow beamwidth and good directivity, suitable for accurate detection of the internally defined area from the wall of the cyclone separator 4.

[0061] Preferably, in terms of installation method, the external shape of the radar flow detector 8 is adapted to the reserved position for embedding on the isolation layer 402, and a customized encapsulation is adopted to achieve flush installation, combined with precision sealing and isolation, to avoid protrusions from disturbing the flow field.

[0062] Therefore, the radar flow detector 8 analyzes the frequency changes caused by the Doppler effect between the transmitted and reflected waves, thereby monitoring the flow velocity data at various height profiles in real time. During this process, when the solid waste content in the liquid increases and approaches the limit of separation efficiency: for inlet zone 01, the radar flow detector 8 can detect that the flow velocity of the liquid containing solid waste near the tangential inlet 41 does not change significantly or decreases slightly due to increased overall internal pressure. For deceleration zone 02, the radar flow detector 8 can detect that the flow velocity in the region gradually decreases, and that the range of deceleration zone 02 gradually extends upwards over time. For disturbance zone 03, due to the increased solid waste content in the upward swirling flow, the radar flow detector 8 can detect a significantly enhanced Doppler effect within disturbance zone 03; and closer to the bottom of disturbance zone 03, due to the influence of downward solid waste in deceleration zone 02 and the upward shift of the bottom interface of the swirling flow, the relative velocity of the flow is significantly reduced.

[0063] This device is equipped with a central processing system capable of data processing. The central processing system is electrically connected to several radar flow detectors 8. The radar flow detectors 8 detect monitoring data at various points and send it to the central processing system for statistical analysis. This allows the system to determine the distribution of data across different zones and the real-time flow velocity information at each point within each zone. Through external statistical analysis, based on the principle that the solid waste separation status at the bottom of the cyclone separator 4 affects the flow velocity within each zone, the solid waste separation status can be analyzed inversely from the flow velocity. In other words, by analyzing the flow velocity at each point, it is possible to indirectly reflect whether the power of the external drive equipment is suitable for the separation effect of the solid waste liquid with the current concentration.

[0064] This device accurately reflects whether the power of the external drive equipment is suitable for the separation effect of the solid-containing waste liquid at the current concentration, while simultaneously performing real-time front-end monitoring and control of the output of the external drive equipment. Specifically, it relies on a detection line 3 that can detect the flow rate at the front end of the tangential inlet 41 in real time, and the detection line 3 is located on the Venturi tube section 1.

[0065] See appendix Figure 2As shown, the Venturi tube section 1 includes a compression section 12 connected to an external drive device via a pipe, and a diffuser section 14 connected to a tangential inlet 41 via a pipe; a throat 13 is provided between the compression section and the diffuser section 14, and a distribution plate 5 is provided on the throat 13. The distribution plate 5 is provided with one or more distribution blocking mechanisms 6, and / or one or more distribution detection mechanisms 7. A first detection mechanism 101 and a third detection mechanism 103 are respectively provided on the compression section 12 and the diffuser section 14 of the Venturi tube section 1.

[0066] For allocation disk 5, see Appendix Figure 3 As shown, the distribution plate 5 has several pre-drilled holes 55 on its end face, allowing it to be flange-connected to the compression section 12 and the diffusion section 14 respectively. A central flow channel 51 is provided in the middle of the distribution plate 5, which communicates with the compression section 12 and the diffusion section 14. The distribution plate 5 has several distribution channels 52, each with its two ends communicating with the outer ring side of the distribution plate 5 and the central flow channel 51 respectively. Specifically, each distribution channel 52 of the distribution plate 5 has two branch flow paths 54 that communicate with the two end faces of the distribution plate 5 respectively. That is, the two ends of each branch flow path 54 are connected to both the distribution channel 52 and the end face of the distribution plate 5.

[0067] See appendix Figure 4 As shown, the distribution blocking mechanism 6 includes a first injection mechanism 501, a second detection mechanism 102, and an electromagnetic shut-off valve 61. (See attached diagram) Figure 5 As shown, the distribution and detection mechanism 7 includes a first injection mechanism 501, a second detection mechanism 102, and a second injection mechanism 502. The first injection mechanism 501 and the second injection mechanism 502 are connecting tube bundles for connecting to an external liquid supply device; the tube bundle of the first injection mechanism 501 is installed at the end of the distribution channel 52 away from the central channel 51 via a connector, and the tube bundle of the second injection mechanism 502 is installed at the end of the branch channel 54 away from the distribution channel 52 via a connector. The first detection mechanism 101, the second detection mechanism 102, and the third detection mechanism 103 are all pressure sensors.

[0068] Therefore, the Venturi section 1 is based on fluid mechanics, meaning that when an incompressible fluid flows through a reducing pipe, its velocity is inversely proportional to the pipe's cross-sectional area, while the fluid's static pressure is inversely proportional to the square of the velocity. In this device, the compression section 12 is a tapered tube with a gradually decreasing cross-sectional area along the flow direction. When the solid waste liquid enters the compression section 12, the fluid is compressed, its velocity increases, and according to Bernoulli's principle, its static pressure decreases accordingly. The solid waste liquid then passes through the throat 13, which has the smallest cross-sectional area, where the fluid velocity reaches its maximum value within the entire Venturi tube, and the static pressure drops to its minimum. Finally, the solid waste liquid enters the diffuser section 14, where the high-speed fluid is smoothly decelerated. Within the diffuser section, the fluid velocity decreases, and the pressure gradually increases. This process minimizes the permanent pressure loss of the entire pipeline, improving system efficiency.

[0069] The first detection mechanism 101, the second detection mechanism 102, and the third detection mechanism 103 work by measuring pressure and then calculating the pressure difference to accurately calculate the fluid flow rate and velocity. This device is equipped with a signal collection unit 31 capable of collecting and processing pressure data. The signal collection unit 31 is electrically connected to the first detection mechanism 101, the third detection mechanism 103, and several second detection mechanisms 102. The signal collection unit 31 is also electrically connected to the central processing system.

[0070] Therefore, after collecting monitoring data from various pressure sensors, the central processing system can calculate the instantaneous volumetric flow rate according to the flow formula derived from Bernoulli's equation. That is, the volumetric flow rate through the venturi tube is proportional to the square root of the static pressure difference between the high-pressure point at the inlet of compression section 12 and the low-pressure point of throat 13. This provides real-time, continuous feed flow rate data.

[0071] Meanwhile, the invention, through the distribution plate 5 and several injection mechanisms on the Venturi tube section 1, combined with the separation efficiency data detected by the radar water flow detectors 8 in the Venturi tube and the cyclone separator 4, can realize the function of actively adjusting the solid-containing waste liquid entering the cyclone separator 4 at the front end.

[0072] Specifically, when the central processing system determines, through mathematical analysis, that the device is in or about to enter a non-ideal separation state based on the real-time flow profile data fed back by several radar flow detectors 8 arranged along the height direction of the cyclone separator 4, the central processing system will control the output mechanisms corresponding to the first injection mechanism 501 and / or the second injection mechanism 502 located on the distribution plate 5 to inject fluid into the throat 13 accordingly.

[0073] More specifically, the first injection mechanism 501 and the second injection mechanism 502 are connected to an external pressure fluid supply device. Upon receiving a control command from the central processing system, the designated injection mechanism is activated, injecting one or more streams of pressurized fluid (in this embodiment, treated recycled water) into the corresponding distribution channel 52 and branch flow path 54, mixing with the main solid waste-containing liquid flow passing through the throat 13 to achieve dilution and regulation. During this process, the power of the main drive equipment containing solid waste liquid can be reduced to achieve dilution and regulation while maintaining a constant total fluid throughput.

[0074] On the other hand, it is worth noting that the injected fluid undergoes intense and thorough turbulent mixing with the main waste liquid as it flows through the throat 13 and diffuser section 14. During this process, specific chemical agents are added to the system through a portion of the first injection mechanism 501 or the second injection mechanism 502. The turbulence formed within the Venturi tube section 1 provides excellent mixing conditions for the agent and solid particles in the waste liquid, thereby achieving rapid and uniform dispersion of the agent.

[0075] For the distribution blocking mechanism 6: the first injection mechanism 501 is located at one end of the distribution channel 52 away from the central channel 51; the second detection mechanism 102 and the electromagnetic shut-off valve 61 are respectively located on the two branch channels 54 corresponding to the distribution channel 52. The electromagnetic shut-off valve 61 includes a valve plate 62 that can be controlled to move to block the distribution channel 52, and the distribution channel 52 is provided with a valve plate groove corresponding to the valve plate 62. When the electromagnetic shut-off valve 61 is closed in a controlled manner, it can block the conduction between the first injection mechanism 501 and the distribution channel 52. It is worth noting that when the electromagnetic shut-off valve 61 is closed in a controlled manner, the pressure value detected by the second detection mechanism 102 at this location is the pressure value at the throat 13. When the electromagnetic shut-off valve 61 is opened in a controlled manner, and the first injection mechanism 501 is injecting liquid, the pressure value detected by the second detection mechanism 102 at this location is the pressure value at the throat 13 minus the injection pressure of the first injection mechanism 501.

[0076] For the distribution detection mechanism 7: the first injection mechanism 501 is located at one end of the distribution channel 52 away from the middle channel 51; the second detection mechanism 102 and the second injection mechanism 502 are respectively located on the two branch channels 54 corresponding to the distribution channel 52.

[0077] It is worth noting that each of the sub-mechanisms corresponding to the aforementioned distribution blocking mechanism 6 and distribution detection mechanism 7 can be installed on the outer ring side of the distribution disc 5 through threaded connection, flange connection, fixed connection, etc., and the specific connection method is not limited.

[0078] Thus, the multiple independent distribution channels 52 on the distribution plate 5, along with the corresponding injection mechanism, detection mechanism, and electromagnetic shut-off valve 61, together constitute a multi-channel fluid distribution and control network.

[0079] The central processing system can independently control the opening, closing, and injection volume of different injection mechanisms based on the pressure information of each branch fed back by the second detection mechanism 102. This allows for precise adjustment of the total flow rate, and in tubular applications, independent control can be implemented for individual or several channels experiencing deterioration in operating conditions. Furthermore, the system can increase the fluid dynamics or reagent dosage at the inlet end without affecting other normally operating units, thus achieving failure isolation.

[0080] Example 1

[0081] In a preferred embodiment, in order to achieve precise and coordinated regulation of fluid dynamics and chemical agents, the dispensing detection mechanism 7 is provided with two sets on the dispensing disk 5, and the dispensing blocking mechanism 6 is provided with one set on the dispensing disk 5.

[0082] In this embodiment, the core function of the two sets of distribution and detection mechanisms 7 is to add chemical additives to the main solid waste liquid flow as needed and accurately, and to simultaneously monitor the pressure status of the addition point.

[0083] Specifically, each set of distribution and detection mechanisms 7 is configured according to the aforementioned structure: its first injection mechanism 501 is connected to an external independent chemical additive supply source, the chemical additives including flocculants, pH adjusters, etc.; the two branch flow paths 54 corresponding to the distribution channel 52 are respectively equipped with a second detection mechanism 102 and a second injection mechanism 502. The second injection mechanism 502 is also connected to an external liquid supply device, and the second injection mechanism 502 is preferably used as a clean water or recycled water injection port, used to flush or adjust the concentration and injection momentum of the additive solution when needed.

[0084] During operation, the central processing system can decide and initiate the addition procedure of specific additives based on the separation efficiency trend fed back by the radar flow detector 8. When the first injection mechanism 501 is opened under control and injects the additive, the second detection mechanism 102 located on the same branch can monitor the pressure change at that point in real time. This pressure value reflects the combined effect of the base pressure at the throat 13 and the additive injection pressure. Through real-time analysis of this pressure signal, the central processing system can reverse-verify whether the additive injection has started normally and whether the flow rate is stable, ensuring the reliability and consistency of the premixing effect.

[0085] In this embodiment, the distribution blocking mechanism 6 is used to provide precise branch flow regulation and rapid isolation capabilities.

[0086] Under normal operating conditions, the electromagnetic shut-off valve 61 remains open, ensuring unobstructed flow in this branch. When the central processing system needs to fine-tune the flow based on global flow balance calculations, it can control the electromagnetic shut-off valve 61 to partially adjust its opening, thereby changing the flow cross-sectional area of ​​this branch and achieving a throttling function. Simultaneously, if the system determines, through pressure data from the second detection mechanism 102 or other unit signals corresponding to this branch, that the downstream cyclone separator 4 exhibits signs of failure such as severe siltation or blockage, the central processing system can immediately instruct the electromagnetic shut-off valve 61 to fully close. This physically isolates the fault from the entire tubular system, preventing backflow from causing further deterioration and ensuring the continued stable operation of the rest of the system.

[0087] Example 2

[0088] Based on Embodiment 1, a placement cavity 53 is provided in the distribution channel, and a filter element 71 is installed in the placement cavity 53. The filter element 71 is used to isolate solid waste contained in the fluid and prevent blockage and damage to the injection mechanism during backflow.

[0089] In summary, the central processing system, acting as the intelligent command hub, can process the velocity profile signals from the radar flow detector 8 inside the cyclone separator 4, the differential pressure and flow signals from the first and third detection mechanisms on the Venturi tube section 1, and the pressure feedback signals from each of the second detection mechanisms 102 on the distribution plate 5. Based on the data processing results, the system can simultaneously drive the distribution detection mechanism 7 and the distribution blocking mechanism 6 to work together. This achieves automated control with real-time monitoring and failure isolation, ensuring that the cyclone separation system can adaptively maintain optimal separation efficiency when facing dynamically fluctuating feed conditions.

[0090] Based on the above-described apparatus, this invention also provides a method for online monitoring and failure isolation of cyclone separator tube bundles. This method achieves adaptive optimization of separation conditions and rapid isolation of failed units through real-time sensing, intelligent decision-making, and dynamic execution. The method is automatically executed by a central processing system and specifically includes the following steps:

[0091] S1. During operation, the system monitors the flow velocity data of each height layer in the cyclone separator 4 measured by the radar flow detector 8 in real time, numbers and stores them as several real-time profile flow velocities; it also monitors the pressure signals of all radar first detection mechanism 101, second detection mechanism 102 and third detection mechanism 103 in real time, and the system calculates and stores the real-time flow rate through pressure difference.

[0092] S2. The system dynamically defines each "internal velocity profile" in the cyclone separator 4 in real time based on the velocity profile of each numbered section: the area near the tangential inlet 41 with stable velocity and close to the inlet design value is marked as the inlet interval 01; the area near the underflow outlet with velocity significantly lower than the reference value is marked as the deceleration interval 02; the transition area between the two with obvious velocity gradient changes is marked as the disturbance interval 03; the range of each interval changes dynamically with the operating conditions.

[0093] S3. The system performs data fusion analysis based on the manually set baseline flow velocity profile, the baseline flow rate calibrated in the venturi tube, and the real-time range obtained in step S2, to determine the separation efficiency trend. In other words, it determines the separation efficiency trend by correlating the internal flow field profile with the external feed parameters and using a mathematical model.

[0094] This process includes the following steps:

[0095] S3.1 The system compares and analyzes the real-time "internal velocity profile" with the stored baseline velocity profile, comparing the pattern changes in the profile morphology to determine different abnormal trends. The specific determination process is as follows:

[0096] If the system detects that the deceleration zone 02 extends continuously upward from the bottom outlet and the flow velocity value in this zone decreases systematically, it is diagnosed as "bottom flow sedimentation trend".

[0097] If the system detects abnormal and disordered enhancement of radar echo Doppler signal intensity in the disturbance interval 03, it indicates a surge in solid concentration and turbulence in this region. Combined with the degree of disorder in the velocity gradient in this region, it is diagnosed as "solid phase escape tendency".

[0098] S3.2 The system performs a collaborative analysis of the judgment result obtained in step S3.1 with the "instantaneous feed volume flow rate" to generate a set of control instructions that includes specific adjustment targets and required actuators.

[0099] Based on the above embodiments, for example, when a "bottom flow sedimentation trend" is diagnosed, and the feed flow rate is stable, the system determines that the solid content is increasing, and decides that dilution adjustment and an increase in the discharge capacity of the bottom flow outlet are needed. If the feed flow rate itself is too low, the system decides that the feed flow rate needs to be increased. Other specific adjustment targets include target inlet pressure, target additive dosing rate, dilution adjustment, etc.

[0100] S4. The system sends control command sets to the corresponding actuators to achieve dynamic adjustment of operating conditions. This includes the following steps:

[0101] S4.1 When the decision indicates that flow rate or pressure needs to be adjusted, the injection mechanism on the corresponding distribution blocking mechanism 6 or distribution detection mechanism 7 on the central processing system's integrated control distribution panel 5 is activated. For example, to alleviate underflow siltation, the second injection mechanism 502 of a specific branch can be opened to inject pressurized clean water. The injected fluid mixes violently with the main liquid flow in the throat 13 and diffuser section 14, locally increasing the kinetic energy and pressure of the fluid entering the corresponding cyclone separator 4 without significantly changing the main pump power, thereby improving the separation capacity. This causes the upward internal cyclone interface to shift downward, increasing underflow discharge.

[0102] S4.2 When the decision indicates a need to improve solid-phase agglomeration, the central processing system controls the first injection mechanism 501 of the designated distribution and detection mechanism 7 to initiate the addition of additives. Utilizing the high-speed turbulence at the throat of the Venturi tube as a natural and efficient mixer, the additives are instantly sheared and dispersed after injection at the throat 13, achieving rapid and uniform premixing at the molecular level with the solid-containing waste liquid, greatly improving the subsequent flocculation and separation efficiency in the hydrocyclone separator 4.

[0103] During the dosing process, the second detection unit 102 on the same branch monitors the pressure feedback in real time to achieve closed-loop control of the dosing amount.

[0104] S5. Failure Isolation Process: When adaptive adjustment is ineffective and the operating conditions continue to deteriorate to a dangerous threshold, the system initiates a protective isolation procedure.

[0105] S5.1 The system continuously monitors various data during the adjustment process; detects the upward trend of the deceleration zone 02 after adjustment. If the system reaches the critical height of the deceleration zone 02, or the abnormal signal strength of the disturbance zone 03 exceeds the safety threshold, and is accompanied by slurry leakage at the overflow port, the system will ultimately determine that the separation has failed.

[0106] S5.2 Upon successful failure determination, the system immediately sends a command to the distribution blocking mechanism 6 corresponding to the faulty unit. The valve plate 62 of its electromagnetic shut-off valve 61 quickly actuates, completely cutting off the injection mechanism corresponding to the distribution channel 52, while the cyclone separator 4 stops feeding. This step prevents backflow or deterioration of the flow field from affecting adjacent units through rapid isolation, and simultaneously triggers an alarm to prompt maintenance.

[0107] S6. Subsequent data iteration and model optimization; system case storage. Through long-term operation, the diagnostic thresholds and decision parameters in step S3 are automatically optimized, enabling the system's adaptive control capability to continuously improve with usage time.

[0108] In summary, this invention constructs an adaptive closed-loop control system based on real-time diagnosis of the internal flow field morphology and linked with the front end. A radar flow detector array embedded in the cyclone separator tube wall captures the complete velocity profile from the inlet to the underflow in real time without contact. The central processing system does not monitor a single data point but intelligently analyzes the dynamic morphological changes of this profile. When it identifies specific patterns indicating deterioration in separation efficiency, such as abnormal upward extension of the low-velocity zone at the bottom or a surge in signals in the turbulent zone in the middle, it diagnoses the risk of siltation or particle escape in advance. The system then drives a multi-functional distribution plate installed at the throat of the feed venturi tube to perform two types of precise intervention: first, by injecting pressurized fluid to directly increase the inlet kinetic energy of the corresponding separation unit to clear the flow field; second, by utilizing the high-speed turbulence at the throat as a natural, efficient mixer to add and disperse chemical agents in real time, thereby optimizing separation conditions. If the control is ineffective, the system can quickly shut off specific channels on the distribution plate to achieve rapid physical isolation of the faulty unit, ensuring the continuous and stable operation of the entire tube bundle system.

[0109] Of course, the present invention may have other various embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and modifications according to the present invention, but these corresponding changes and modifications should all fall within the protection scope of the appended claims.

Claims

1. A device for online monitoring and failure isolation of a cyclone separator tube bundle, comprising a cyclone separator (4) and a Venturi tube section (1) installed at the inlet of the cyclone separator (4); the cyclone separator (4) comprises a straight tube section (42) and a tapered tube section (43); the straight tube section (42) is provided with an overflow pipe (45) and a tangential inlet (41) at its top and side, respectively, characterized in that: It also includes the central processing system; The internal space of the cyclone separator (4) is divided into an inlet section (01), a disturbance section (03) and a deceleration section (02) from top to bottom; the inner wall of the cyclone separator (4) is provided with a number of radar flow detectors (8) that are evenly arranged from top to bottom and electrically connected to the central processing system. The Venturi tube section (1) includes a compression section (12), a diffusion section (14), and a throat (13) located on both. A distribution plate (5) is provided on the throat (13), and a distribution blocking mechanism (6) and a distribution detection mechanism (7) are provided on the distribution plate (5). One or more of the distribution blocking mechanism (6) and the distribution detection mechanism (7) are provided on the distribution plate (5).

2. The device for online monitoring and failure isolation of cyclone separator tube bundles according to claim 1, characterized in that, Both the distribution blocking mechanism (6) and the distribution detection mechanism (7) include an injection mechanism and a detection mechanism. The distribution blocking mechanism (6) also includes an electromagnetic shut-off valve (61). The injection mechanism is a connecting tube bundle that connects to an external liquid supply device. The detection mechanism is a pressure sensor.

3. The device for online monitoring and failure isolation of cyclone separator tube bundles according to claim 1, characterized in that, The distribution plate (5) has a central flow channel (51) in the middle, and the distribution plate (5) has a plurality of distribution channels (52) with both ends connected to the outer ring side of the distribution plate (5) and the central flow channel (51); the distribution channels (52) have two branch flow paths (54) connected to the two end faces of the distribution plate (5). For the distribution blocking mechanism (6): its injection mechanism is located at one end of the distribution channel (52) away from the middle channel (51); the detection mechanism and the electromagnetic shut-off valve (61) are respectively located on the two branch channels (54) corresponding to the distribution channel (52); For the distribution detection mechanism (7): one of its injection mechanisms is located at one end of the distribution channel (52) away from the middle channel (51); the detection mechanism and the other injection mechanism are respectively located on the two branch channels (54) corresponding to the distribution channel (52).

4. The device for online monitoring and failure isolation of cyclone separator tube bundles according to claim 1, characterized in that, The electromagnetic shut-off valve (61) includes a valve plate (62) that can be moved in a controlled manner to block the distribution channel (52). The distribution channel (52) is provided with a valve plate groove corresponding to the valve plate (62). When the electromagnetic shut-off valve (61) is closed in a controlled manner, it can block the connection between the first injection mechanism (501) and the distribution channel (52).

5. The device for online monitoring and failure isolation of cyclone separator tube bundles according to claim 1, characterized in that, The compression section (12) and diffusion section (14) of the Venturi tube section (1) are respectively provided with a first detection mechanism (101) and a third detection mechanism (103).

6. A method for online monitoring and failure isolation of a cyclone separator tube bundle, characterized in that, The device for online monitoring and failure isolation of cyclone separator tube bundles according to any one of claims 1-5 includes the following steps: S1. The system monitors the flow velocity data of each height layer in the cyclone separator (4) measured by the radar flow detector (8) in real time, numbers and stores them as several real-time profile flow velocities; monitors the pressure signals of all detection mechanisms in real time, and the system calculates and stores them as real-time flow rates through pressure difference; S2. The system dynamically defines each "internal velocity profile" in the cyclone separator (4) in real time according to the profile velocity of each number: the area near the tangential inlet (41) with stable velocity and close to the inlet design value is marked as the inlet interval (01); the area near the underflow outlet with velocity significantly lower than the reference value is marked as the deceleration interval (02); the transition area between the two with obvious velocity gradient change is marked as the disturbance interval (03); the range of each interval changes dynamically with the operating conditions. S3. The system performs data fusion analysis based on the manually set reference flow velocity profile, the reference flow rate calibrated in the venturi tube, and the real-time interval range obtained in step S2, and judges the trend of separation efficiency. S4. The system sends control command sets to the corresponding actuators to achieve dynamic adjustment of the working conditions; S5. When adaptive adjustment is ineffective and the operating conditions continue to deteriorate to a dangerous threshold, the system initiates a protective isolation procedure.

7. The method for online monitoring and failure isolation of cyclone separator tube bundles according to claim 6, characterized in that, Step S3 includes the following sub-steps: S3.1 The system compares and analyzes the real-time "internal velocity profile" with the stored baseline velocity profile, compares the pattern changes in the profile morphology, and determines different abnormal trends; the specific determination process is as follows: If the system detects that the deceleration zone (02) extends continuously upward from the bottom outlet and the flow velocity value in this zone decreases systematically, it is diagnosed as "bottom flow sedimentation trend". If the system detects abnormal and disordered enhancement of radar echo Doppler signal intensity in the disturbance interval (03), it indicates a surge in solid concentration and turbulence in the region. Combined with the degree of disorder in the velocity gradient in the region, it is diagnosed as "solid phase escape trend". S3.2 The system performs a collaborative analysis of the judgment result obtained in step S3.1 with the "instantaneous feed volume flow rate" to generate a set of control instructions that includes specific adjustment targets and required actuators.

8. The method for online monitoring and failure isolation of cyclone separator tube bundles according to claim 6, characterized in that, Step S4 specifically includes the following process: S4.1 When the decision is that flow or pressure needs to be adjusted, the corresponding distribution blocking mechanism (6) on the central processing system integrated control distribution panel (5) or the injection mechanism on the distribution detection mechanism (7) is activated. S4.2 When the decision is that the solid phase polymerization effect needs to be improved, the central processing system controls the injection mechanism of the designated distribution and detection unit (7) to start the addition of additives.

9. The method for online monitoring and failure isolation of cyclone separator tube bundles according to claim 6, characterized in that, Step S5 specifically includes the following sub-steps: S5.1 The system continuously monitors various data during the adjustment process; detects the upward trend of the deceleration zone (02) after adjustment. If the abnormal signal strength of the deceleration zone (02) reaches the critical height or the disturbance zone (03) exceeds the safety threshold and is accompanied by slurry leakage at the overflow port, the system will ultimately determine that the separation has failed. S5.2 After the failure determination is established, the system immediately sends an instruction to the distribution blocking mechanism (6) corresponding to the fault unit. The electromagnetic shut-off valve (61) quickly acts to cut off the injection mechanism corresponding to the distribution channel (52), and at the same time the cyclone separator (4) stops feeding.

10. The method for online monitoring and failure isolation of cyclone separator tube bundles according to claim 6, characterized in that, The steps also include: S6. Subsequent data iteration and model optimization; the system builds case storage, and through long-term operation, automatically optimizes the diagnostic thresholds and decision parameters in step S3.

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