Liquid phase foaming control device, absorption tower and liquid phase foaming control method

Abstract

This invention relates to a liquid-phase foaming control device, an absorption tower including the device, and a liquid-phase foaming control method. The device includes an absorption tower, an ultrasonic defoaming device disposed in the middle of the absorption tower, and a DCS control system. The DCS control system includes an early warning system, and the ultrasonic defoaming device includes an ultrasonic generator and a sensor. When the liquid level of the absorbent in the absorption tower increases to a first predetermined height increase and / or the pressure increase increases to a first predetermined pressure increase, the early warning system issues an alarm signal and activates the ultrasonic generator. The early warning system shuts down the ultrasonic generator when the liquid level increase decreases to a second predetermined height increase and / or the pressure increase decreases to a second predetermined pressure increase. The liquid-phase foaming control device can automatically and quickly respond to and handle the foaming problem of the absorbent in the absorption tower. Its defoaming method does not introduce secondary pollution of the absorbent, making it highly practical and applicable, facilitating its application and promotion.

Description

Technical Field

[0001] This invention relates to the field of foaming control technology for gas-liquid reactors, and in particular to a liquid-phase foaming control device, an absorption tower, and a liquid-phase foaming control method. Background Technology

[0002] In conventional desulfurization and decarbonization absorption towers, amine liquid is frequently used as an absorbent to remove hydrogen sulfide or carbon dioxide from the gas. However, foaming often occurs as the amine liquid is used for extended periods. This foaming can be caused by surface-active components in the amine liquid, especially under conditions of prolonged use or significant temperature variations. Foaming not only affects the normal operation of the absorption tower but can even lead to plant shutdowns, severely impacting production efficiency.

[0003] To alleviate foaming problems, defoamers are typically added to the absorbent liquid to reduce bubble stability and decrease foaming. However, traditional defoamers often only alleviate the problem to a certain extent and cannot fundamentally solve the root cause of foaming. Furthermore, excessive use of defoamers may cause other problems, such as increased foaming potential or secondary pollution. Summary of the Invention

[0004] To address the aforementioned problems in the prior art, the present invention aims to provide a liquid-phase foaming control device to solve the common problem of absorbent foaming in absorption towers (especially desulfurization and decarbonization absorption towers). Another objective of the present invention is to provide an absorption tower equipped with the aforementioned liquid-phase foaming control device and a method for controlling liquid-phase foaming in the absorption tower using the aforementioned liquid-phase foaming control device.

[0005] Therefore, in a first aspect, the present invention provides a liquid-phase foaming control device, comprising an absorption tower, an ultrasonic defoaming device disposed in the middle of the absorption tower, and a DCS control system, wherein the DCS control system includes an early warning system.

[0006] The ultrasonic defoaming device includes an ultrasonic generator and a sensor. The sensor is communicatively connected to the early warning system. The sensor is used to monitor the liquid level and / or pressure increase of the absorbent in the absorption tower in real time and transmit the monitored signal to the early warning system. The early warning system is communicatively connected to the ultrasonic generator to control the start and stop of the ultrasonic generator.

[0007] When the liquid level of the absorbent in the absorption tower increases to a first predetermined height increase and / or the pressure increase increases to a first predetermined pressure increase, the early warning system issues an alarm signal and activates the ultrasonic generator; until the liquid level of the absorbent in the absorption tower decreases to a second predetermined height and / or the pressure increase decreases to a second predetermined pressure increase, the early warning system shuts down the ultrasonic generator.

[0008] The liquid-phase foaming control device provided by this invention can automatically and quickly respond to and handle the foaming problem of absorbent liquid in the absorption tower. Its defoaming method does not introduce secondary pollution of the absorbent liquid, making it highly practical and applicable, and facilitating its application and promotion. The ultrasonic generator in the liquid-phase foaming control device can generate high-frequency oscillating ultrasonic waves and is quickly activated through monitoring by an early warning system.

[0009] The early warning system provided by this invention can monitor the absorption liquid level and tower pressure in real time, make comprehensive judgments through intelligent algorithms, and ultimately detect foaming problems in a timely manner and take measures to deal with them quickly, thereby maximizing the protection of the safe operation of the device.

[0010] The liquid phase foaming control device provided by this invention is particularly suitable for solving the foaming problem of absorbent liquid, such as amine liquid, in desulfurization and decarbonization absorption towers.

[0011] In a specific embodiment of the present invention, the first predetermined height increase is 20-40% of the working height of the absorbent liquid. The working height of the absorbent liquid refers to the standard liquid level when the device is operating normally. Generally, the working height of the absorbent liquid is 30% of the highest liquid level in the device (the entire level gauge display range). For example, if the total height of the level gauge is 1000mm, then the highest liquid level in the device is 1000mm, and the working height of the absorbent liquid is 300mm. The specific height needs to be determined based on the specific circumstances of each device.

[0012] As a specific embodiment of the present invention, the first predetermined pressure increase is 30%-50% of the initial working pressure in the absorption tower within 30-45 minutes.

[0013] As a specific embodiment of the present invention, the second predetermined height increase is 5%-15% of the working height of the absorbent liquid.

[0014] As a specific embodiment of the present invention, the first predetermined pressure increase is 10%-20% of the initial working pressure in the absorption tower within 30-45 minutes.

[0015] In a specific embodiment of the present invention, the ultrasonic defoaming device is positioned above the highest liquid level of the absorbent liquid in the absorption tower.

[0016] As a specific embodiment of the present invention, the early warning system stops emitting alarm signals after the ultrasonic generator is activated.

[0017] As a specific embodiment of the present invention, when the liquid level of the absorbent in the absorption tower decreases to a second predetermined height and / or the pressure increase rate decreases to a second predetermined pressure increase rate, the early warning system stops issuing alarm signals.

[0018] As a specific embodiment of the present invention, the early warning system is further provided with an intelligent algorithm module for classifying early warning levels based on the first and second predetermined height increases and the first and second predetermined pressure increases; the ultrasonic defoaming device further includes a regulator for adjusting the frequency and power of the ultrasonic waves emitted by the ultrasonic generator; the early warning system controls the regulator to adjust the frequency and power of the ultrasonic waves emitted by the ultrasonic generator according to the early warning level.

[0019] As a specific embodiment of the present invention, the intelligent algorithm module classifies the warning level according to the following formula:

[0020] Warning level = α × liquid level deviation + β × pressure increase deviation (I)

[0021] In formula (I), α and β are weighting coefficients used to balance the influence of liquid level deviation and pressure increase deviation on the warning level. Liquid level deviation represents the deviation between the absorption liquid level and the first predetermined height, and pressure increase deviation represents the deviation between the pressure increase in the absorption tower and the first predetermined pressure increase. 0≤α≤2; 0≤β≤4.

[0022]

[0023] Where h is the current liquid level, h1 is the first predetermined height, and h max and h min ΔP represents the maximum and minimum values ​​of the absorbent liquid level, ΔP is the current pressure increase rate, ΔP1 is the first predetermined pressure increase rate, and ΔPmax and ΔPmin are the maximum and minimum values ​​of the pressure increase rate.

[0024] In this invention, α and β can be adjusted according to the priority of liquid level deviation or pressure increase in actual production. For example, if the foaming risk increases rapidly with the increase in pressure, the value of β can be appropriately increased to make the pressure increase deviation have a greater impact on the warning level. The specific values ​​of α and β are determined according to the actual situation. For example, in some embodiments, when the foaming risk is mainly judged based on liquid level changes and the liquid level changes have a significant impact on the system, the value of α is relatively large and the value of β is relatively small; while when the pressure increase has a significant impact on the system, the value of β is relatively large and the value of α is relatively small, so as to accurately reflect the importance of different factors in the foaming risk assessment.

[0025] In this invention, ΔPmax and ΔPmin are set based on the allowable and set pressure fluctuation range of the absorption tower and its auxiliary equipment, combined with the safety margin in the process, and can be finely adjusted according to the actual situation during operation.

[0026] When the liquid level in the absorption tower increases to a first predetermined height increase, and / or the pressure increases to a first predetermined pressure increase, the early warning system will determine that there is a risk of foaming and automatically activate the ultrasonic generator. When the liquid level in the absorption tower increases to a second predetermined height increase, and / or the pressure increases to a second predetermined pressure increase, the early warning system will determine that the foaming problem has been alleviated and automatically shut down the ultrasonic generator.

[0027] The liquid phase foaming control device provided by this invention can automatically evaluate the foaming degree of the absorbent liquid in the absorption tower and automatically adjust the frequency and power of the ultrasonic waves according to the foaming degree of the absorbent liquid to achieve rapid and effective defoaming.

[0028] As a specific embodiment of the present invention, when the warning level is <0.5, the warning level is classified as Level 1 warning, and the regulator controls the frequency of the ultrasonic wave of the ultrasonic generator to 20-25kHz and the power to 30-50 watts.

[0029] When 0.5 ≤ warning level < 0.8, the warning level is classified as Level II warning. The regulator controls the frequency of the ultrasonic wave generated by the ultrasonic wave generator to 25-30kHz and the power to 50-70 watts.

[0030] When 0.8 ≤ warning level, the warning level is divided into three levels. The regulator controls the frequency of the ultrasonic wave of the ultrasonic generator to 30-35kHz and the power to 70-100 watts.

[0031] When the warning level is Level 1, the system determines the absorption tower has a slight foaming risk; when the warning level is Level 2, it determines the absorption tower has a moderate foaming risk; and when the warning level is Level 3, it determines the absorption tower has a severe foaming risk. Based on the different warning levels, the controller adjusts the frequency and power of the ultrasonic waves to better control the defoaming effect. The warning level is not only used to calculate the foaming risk but also directly controls the frequency and power of the ultrasonic waves, achieving intelligent, tiered control.

[0032] As a specific embodiment of the present invention, the early warning system is also provided with a recording module, which can record the numerical change curves of the absorbent liquid level and / or pressure in the absorption tower during the entire process from the start-up to the shutdown of the early warning system.

[0033] As a specific embodiment of the present invention, the early warning system is further provided with a feedback control module, which is used to issue a reminder signal when the time of the warning level of level three exceeds 20-50 minutes, and control the regulator to increase the frequency and power of the ultrasonic wave of the ultrasonic generator by 10%-20% respectively, until the warning level drops to level two, then stop issuing the reminder signal and stop controlling the regulator.

[0034] In this invention, the feedback control module can ensure that the system is always in the most suitable operating state.

[0035] Therefore, in a second aspect, the present invention provides an absorption tower equipped with the above-mentioned liquid phase foaming control device, wherein the absorption tower is provided with a packing section containing multiple layers of packing and a piping system for introducing bottom absorbent liquid and discharging top absorbent liquid, and the packing section is located above the ultrasonic defoaming device.

[0036] In a specific embodiment of the present invention, the packing material is a ring packing material or a foam packing material.

[0037] In a specific embodiment of the present invention, the absorption tower is made of stainless steel.

[0038] Therefore, in a third aspect, the present invention provides a method for controlling liquid phase foaming in an absorption tower using the aforementioned liquid phase foaming control device, comprising the following steps:

[0039] S1. The sensor monitors the liquid level and / or pressure of the absorbent liquid in the absorption tower in real time;

[0040] S2. When the liquid level of the absorbent increases to a first predetermined height increase and / or the pressure increases to a first predetermined pressure increase, the early warning system issues an alarm signal and starts the ultrasonic generator.

[0041] S3. When the increase in the liquid level of the absorbent decreases to the second predetermined height increase and / or the increase in pressure decreases to the second predetermined pressure increase, the early warning system shuts down the ultrasonic generator.

[0042] As a specific embodiment of the present invention, the method further includes: after the ultrasonic defoaming device is started in step S2, the early warning system controls the regulator to adjust the frequency and power of the ultrasonic waves of the ultrasonic generator according to the early warning level.

[0043] Beneficial effects of the present invention

[0044] Intelligent early warning: The early warning system integrates the DCS control system of the absorption tower, which can monitor the absorption liquid level and tower pressure in real time. Through intelligent algorithms, it makes comprehensive judgments and realizes intelligent early warning and handling of foaming problems.

[0045] Rapid Response: When the absorption liquid level exceeds the predetermined height or the predetermined tower pressure increase, the early warning system will be activated immediately and trigger the ultrasonic defoaming device to achieve rapid and timely treatment, thereby quickly and effectively eliminating foaming problems, ensuring the normal operation of the absorption tower, and minimizing the impact of foaming problems on the process.

[0046] Safe and environmentally friendly: The ultrasonic defoaming device adopts physical defoaming technology without chemical additives, which avoids secondary pollution to the environment and ensures the safety of operators, meeting the environmental protection requirements of modern chemical production.

[0047] Adverse results avoidance: Even if the early warning system malfunctions and activates the ultrasonic defoaming device, it will not cause adverse results for the device.

[0048] Highly practical: The device is simple to operate, safe and reliable, and will not pose any safety risks to operators. Attached Figure Description

[0049] Figure 1 A schematic diagram of the structure of an absorption tower equipped with the liquid phase foaming control device described in this invention;

[0050] Figure 2 This is a cross-sectional view of an ultrasonic defoaming device.

[0051] Wherein: 1-Absorption tower; 2-Packing section; 3-Ultrasonic defoaming device; 4-Level gauge; 5-Design level of 30% HH; 6-Design level of 60% H; 7-Ultrasonic rod. Detailed Implementation

[0052] The technical solution of the present invention will be further illustrated below through specific embodiments. Those skilled in the art should understand that the embodiments are merely illustrative of the invention and should not be considered as specific limitations thereof. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall apply. Reagents or instruments whose manufacturers are not specified are all commercially available conventional products.

[0053] See Figure 1 and Figure 2 As shown, the present invention provides a liquid phase foaming control device, including an ultrasonic defoaming device 3 disposed in the middle of an absorption tower 1 and an early warning system (not shown) disposed in the DCS control system (not shown) of the absorption tower. The ultrasonic defoaming device 3 includes an ultrasonic generator (i.e., Figure 2 The ultrasonic rod 7) and sensor are connected in communication with the early warning system. The sensor is used to monitor the liquid level and / or pressure increase of the absorbent in the absorption tower in real time and transmit the monitored signal to the early warning system. The early warning system is connected in communication with the ultrasonic generator and controls the start and stop of the ultrasonic generator.

[0054] When the liquid level of the absorbent in the absorption tower 1 increases to a first predetermined height increase and / or the pressure increase increases to a first predetermined pressure increase, the early warning system issues an alarm signal and activates the ultrasonic defoaming device 3; when the liquid level of the absorbent in the absorption tower 1 decreases to a second predetermined height increase and / or the pressure increase in the absorption tower decreases to a second predetermined pressure increase, the early warning system shuts down the ultrasonic defoaming device 3.

[0055] The ultrasonic defoaming device consists of an ultrasonic generator and sensors. It can automatically monitor the liquid level and pressure increase in the absorption tower, and defoam through ultrasonic vibration when the risk of foaming increases. The sensors feed back data to the DCS early warning system in real time. The system will control the ultrasonic defoaming device to turn on and off according to the set warning level to ensure the stable operation of the absorption tower.

[0056] After the ultrasonic generator of ultrasonic defoaming device 3 is activated, it generates high-frequency ultrasonic waves, which are emitted to the surface area of ​​the absorbent liquid layer. The generated ultrasonic vibrations destroy the foam structure in the absorbent liquid, quickly eliminating foaming in the liquid phase. The sensor is connected to the liquid level and pressure monitoring system inside the absorption tower to monitor changes in the liquid level and pressure increase of the absorbent liquid in real time.

[0057] See Figure 1 and Figure 2 As shown, the present invention also provides an absorption tower 1 equipped with the aforementioned liquid-phase foaming control device 3. The absorption tower 1 has a packing section 2 filled with packing material at its top and an absorption section for injecting absorbent liquid at its bottom. A level gauge 4 is provided in the absorption section. An ultrasonic defoaming device 3 is provided above the absorption section of the absorption tower 1, and a pipe for drawing in absorbent liquid is provided at the bottom of the absorption tower 1. A design liquid level 5 of 30% HH and a design liquid level of 60% H are provided on the tower wall between the ultrasonic defoaming device and the level gauge 4.

[0058] In some embodiments, the design liquid level 5 of 30% HH represents the design liquid level of the absorbent in the absorber tower. This liquid level is the standard liquid level of the absorber tower under normal operating conditions, also known as the working liquid level. In some embodiments, the design liquid level 5 of 30% HH is 30% of the highest liquid level of the absorbent.

[0059] In some embodiments, the design liquid level 6 of 60%H is 60% of the highest liquid level of the absorbent. When the liquid level of the absorbent exceeds the design liquid level 6 of 60%H, an early warning system will be triggered. When the liquid level exceeds 60%H or obvious foaming occurs (pressure increase exceeds a preset threshold), the early warning system will immediately issue an alarm and activate the ultrasonic defoaming device to avoid the risk of the absorber tower being overfilled or the operation being unstable due to foaming.

[0060] See Figure 1 and Figure 2 As shown, the present invention also provides a method for controlling liquid phase foaming in absorber tower 1 using the above-mentioned liquid phase foaming control device 3, comprising the following steps:

[0061] S1. The sensor monitors the liquid level and / or pressure of the absorbent liquid in the absorption tower in real time;

[0062] S2. When the liquid level of the absorbent increases to a first predetermined height increase and / or the pressure increases to a first predetermined pressure increase, the early warning system issues an alarm signal and starts the ultrasonic generator.

[0063] S3. When the increase in the liquid level of the absorbent decreases to the second predetermined height increase and / or the increase in pressure decreases to the second predetermined pressure increase, the early warning system shuts down the ultrasonic generator.

[0064] In specific implementation, preferably, after the ultrasonic defoaming device is started in step S2, the early warning system controls the regulator of the ultrasonic defoaming device to adjust the frequency and power of the ultrasonic waves of the ultrasonic defoaming device according to the early warning level.

[0065] The calculation formula for the warning level is as follows: Warning level = α × liquid level deviation + β × pressure increase deviation (I),

[0066] In formula (I), α and β are weighting coefficients used to balance the effects of liquid level deviation and pressure increase deviation on the warning level; liquid level deviation represents the difference between the absorption liquid level and the first predetermined height; pressure increase deviation represents the difference between the pressure increase in the absorption tower and the first predetermined pressure increase.

[0067]

[0068] Where h is the current liquid level, h1 is the first predetermined height, hmax and hmin are the maximum and minimum values ​​of the absorption liquid level, ΔP is the current pressure increase rate, ΔP1 is the first predetermined pressure increase rate, and ΔPmax and ΔPmin are the maximum and minimum values ​​of the pressure increase rate.

[0069] The absorption tower of this invention is a gas-liquid contact device for desulfurization and decarbonization operations, suitable for removing impurities such as hydrogen sulfide and carbon dioxide from gases using absorbents such as amine solutions. The absorption tower body is equipped with multiple layers of packing to increase the gas-liquid contact area and improve absorption efficiency.

[0070] The absorption tower's structure is made of corrosion-resistant material (preferably stainless steel) to ensure its stability during long-term use. The tower body is equipped with a liquid inlet, a gas inlet, a liquid outlet, and a gas outlet to respectively introduce the bottom absorbent liquid and the gas to be treated, and to discharge the treated gas and absorbent liquid.

[0071] The packing section of the absorption tower comprises multiple layers of packing, which can be ring packing or foam packing. Preferably, it uses packing materials with good anti-foaming and corrosion resistance to improve absorption efficiency and adapt to harsh operating environments. The multi-layer packing design allows for sufficient contact between the absorbent and gas within the tower, thereby effectively improving the absorption efficiency of hydrogen sulfide and carbon dioxide.

[0072] The absorption tower is also equipped with a level gauge 4 and a pressure gauge (not shown). The level gauge 4 is used to monitor the height of the absorbent liquid to ensure that the liquid level is maintained within the design range (e.g., design level 5 for 30% HH, design level 6 for 60% HH). The ultrasonic defoaming device is positioned above the highest liquid level of the absorbent liquid so that it can respond immediately and act effectively on the absorbent liquid when foaming occurs.

[0073] To achieve efficient operation of the absorption tower during the desulfurization and decarbonization process, this invention provides a specific operating method. By controlling the foaming phenomenon of the absorbent liquid, the operating state of the absorption tower is stabilized, and the removal efficiency of hydrogen sulfide and carbon dioxide is significantly improved. The method includes the following steps:

[0074] System monitoring

[0075] At the start of operation, sensors monitor the liquid level and pressure increase of the absorbent in the absorption tower in real time, and the intelligent algorithm of the early warning system calculates the foaming risk level based on the deviation of the liquid level and pressure increase.

[0076] Foaming warning and defoaming

[0077] When the absorbent liquid level exceeds a first predetermined height (e.g., 20-40% of the working height) and / or the pressure increase exceeds a first predetermined value (e.g., an increase of more than 30% within 30 minutes), the early warning system will issue an alarm and immediately activate the ultrasonic defoaming device. The high-frequency ultrasonic oscillations generated by the defoaming device disrupt the stability of the foam, causing the bubbles to break rapidly and inhibiting foaming.

[0078] In addition, the intelligent algorithm module of the early warning system will dynamically adjust the frequency and power of the ultrasonic waves through the regulator according to the real-time early warning level to ensure the adaptability and rapid response of the defoaming process.

[0079] System recovery after foaming

[0080] When the increase in absorbent level decreases to a second predetermined height increase (e.g., 50% of the working height) and / or the increase in pressure decreases to a second predetermined value (e.g., the increase is less than 50% within 30 minutes), the early warning system will shut down the ultrasonic defoaming device and restore the absorber tower to normal operation. This process is recorded for subsequent operational analysis and improvement.

[0081] Absorbent circulation and regeneration

[0082] During long-term operation, the load on the absorbent gradually increases. The absorbed hydrogen sulfide and carbon dioxide are released by regenerating the absorbent (e.g., sending the rich solution to a regeneration tower for heating and desorption), restoring the activity of the absorbent. The regenerated absorbent is then recycled back to the absorption tower to continue the desulfurization and decarbonization operation.

[0083] Data recording and optimization

[0084] The system records data such as liquid level, pressure, and defoaming start time throughout the process in the DCS system, which facilitates subsequent optimization, adjustment, and technical improvement, thereby improving the overall efficiency and operational stability of the absorption tower.

[0085] The working height of the absorbent liquid refers to the standard liquid level when the device is operating normally. Typically, the working height of the absorbent liquid is 30% of the highest liquid level within the device (the entire display range of the level gauge). For example, if the total height of the level gauge is 1000mm, then the highest liquid level within the device is 1000mm, and the working height of the absorbent liquid is 300mm. The specific height needs to be determined based on the specific conditions of each device.

[0086] Example 1

[0087] Exceeding limits early warning and rapid response

[0088] In this embodiment, the highest liquid level of the absorbent in the absorption tower (the entire display range of the level gauge) is 1000mm. The design liquid level of 30%HH represents the design liquid level (also known as the working liquid level) h1 of the absorbent in the absorption tower, which is 300mm. The early warning system detects the real-time liquid level of the absorbent in the absorption tower as 360mm through the sensor. When the increase in the real-time liquid level reaches 20% of the working liquid level height of the absorbent in the absorption tower, the early warning system automatically starts, issues an alarm signal, and activates the ultrasonic defoaming device. After activating the ultrasonic defoaming device, the alarm signal is deactivated.

[0089] Simultaneously, the warning level is calculated using the intelligent algorithm module in the early warning system, with α and β being 1.2 and 0, respectively.

[0090] Liquid level deviation = (h-h1) / (hmax-hmin) = (360-300) / (1000-0) = 0.06;

[0091] Pressure growth rate deviation = 0;

[0092] Warning level = α × liquid level deviation + β × pressure increase deviation = 1.2 × 0.06 + 0 × 0 = 0.072.

[0093] According to formula (I), the warning level is calculated to be Level 1; the regulator controls the ultrasonic frequency of the ultrasonic defoaming device to be 20kHz and the power to be set to 30 watts.

[0094] Continuous monitoring and automatic adjustment of defoaming intensity

[0095] During the defoaming process, the early warning system continuously monitors the liquid level and gradually reduces the ultrasonic power based on the recovery of the liquid level. When the real-time liquid level drops to 310mm and approaches the working height, the ultrasonic defoaming device gradually reduces the power (reducing by 5 watts per minute, from 30 watts to 20 watts and then stopping), and the ultrasonic power is maintained at 20 watts until the liquid level is completely restored to a safe range.

[0096] Defoaming complete and system restore

[0097] Within 15 minutes, the warning level and the liquid level of the absorbent in the absorption tower dropped to 300mm. When the liquid level of the absorbent returned to the normal range, the ultrasonic defoaming device stopped working, and the system returned to normal operation.

[0098] Example 2

[0099] Exceeding limits early warning and rapid response

[0100] In this embodiment, the highest liquid level of the absorbent in the absorption tower (the entire liquid level gauge display range) is 1000mm. The design liquid level of 30%HH represents the design liquid level (also known as the working liquid level) of the absorbent in the absorption tower as 300mm. The early warning system detects the real-time liquid level of the absorbent in the absorption tower as 420mm through the sensor. The increase in the real-time liquid level reaches 40% of the working liquid level height of the absorbent in the absorption tower. The early warning system is automatically activated, issues an alarm signal, and starts the ultrasonic defoaming device. After starting the ultrasonic defoaming device, the alarm signal is turned off.

[0101] Simultaneously, the warning level is calculated using the intelligent algorithm module in the early warning system, with α and β being 1.5 and 0, respectively.

[0102] Liquid level deviation = (h-h1) / (hmax-hmin) = (420-300) / (1000-0) = 0.12;

[0103] Warning level = α × liquid level deviation + β × pressure increase deviation = 1.5 × 0.12 + 0 × 0 = 0.18;

[0104] According to formula (I), the warning level is calculated to be Level 1.

[0105] The regulator controls the ultrasonic frequency of the ultrasonic defoaming device to 25kHz and the power to 35 watts.

[0106] Continuous monitoring and automatic adjustment of defoaming intensity

[0107] During the defoaming process, the early warning system continuously monitors the liquid level and gradually reduces the ultrasonic power based on the recovery of the liquid level. When the real-time liquid level drops to 310mm and approaches the working height, the ultrasonic defoaming device gradually reduces the power (reducing by 5 watts per minute, from 35 watts to 20 watts and then stopping), and the ultrasonic power is maintained at 20 watts until the liquid level is completely restored to a safe range.

[0108] Defoaming complete and system restore

[0109] After 10 minutes of operation, the warning level and the liquid level of the absorbent in the absorption tower dropped to 300mm. When the liquid level of the absorbent returned to the normal range, the ultrasonic defoaming device stopped working, and the system returned to normal operation.

[0110] Example 3

[0111] Exceeding limits early warning and rapid response

[0112] In this embodiment, the initial working pressure P0 inside the absorption tower is 0.5 MPa. The early warning system detects through sensors that the real-time pressure inside the absorption tower increases to 0.65 MPa in 35 minutes, which means that the pressure increase inside the absorption tower has reached 30%. The early warning system is automatically activated, issuing an alarm signal and starting the ultrasonic defoaming device. After the ultrasonic defoaming device is activated, the alarm signal is turned off. The values ​​ΔPmax and ΔPmin of this device are determined according to the allowable and set pressure fluctuation range of the absorption tower and its auxiliary equipment, where ΔPmax = 0.2 MPa and ΔPmin = 0 MPa.

[0113] Simultaneously, the warning level is calculated by the intelligent algorithm module in the early warning system, with α and β being 0 and 2.0 respectively, and the liquid level deviation being 0 (no abnormal liquid level detected).

[0114] Pressure increase deviation = (ΔP - ΔP1) / (ΔPmax - ΔPmin) = [(0.65 - 0.5) / 35 - 0.15] / (0.2 - 0)

[0115] Warning level = α × liquid level deviation + β × pressure increase deviation = 0 × 0 + 2.0 × [(0.65 - 0.5) / 35 - 0.15] / (0.2 - 0) = 0.3

[0116] According to formula (I), the warning level is calculated to be Level 1.

[0117] The regulator controls the ultrasonic frequency of the ultrasonic defoaming device to 25kHz and the power to 40 watts. This effectively alleviates the abnormal pressure caused by foam accumulation inside the tower.

[0118] Continuous monitoring and automatic adjustment of defoaming intensity

[0119] During the defoaming process, the early warning system continuously monitors the liquid level and gradually reduces the ultrasonic power based on the recovery of the liquid level. When the real-time pressure drops to 0.52 MPa, approaching the initial working pressure, the ultrasonic defoaming device gradually reduces the power (e.g., 5 watts per minute, from 40 watts to 20 watts and then stops reducing), and the ultrasonic power is maintained at 20 watts until the liquid level is completely restored to the initial working pressure.

[0120] Defoaming complete and system restore

[0121] After 15 minutes of operation, the pressure inside the absorption tower returned to 0.5 MPa, and the absorbent liquid level remained within the normal operating range. At this point, the early warning system shut down the alarm, the ultrasonic defoaming device stopped working, and the system returned to normal operation.

[0122] Example 4

[0123] Exceeding limits early warning and rapid response

[0124] In this embodiment, the initial working pressure inside the absorption tower is 0.6 MPa. The early warning system detects through sensors that the real-time pressure inside the absorption tower increases to 0.9 MPa in 35 minutes, and ΔP1 (the pressure increase value corresponding to the first predetermined pressure increase rate) is 0.3 MPa, that is, the pressure increase inside the absorption tower has reached 50%. The early warning system is automatically activated, issuing an alarm signal and starting the ultrasonic defoaming device. After starting the ultrasonic defoaming device, the alarm signal is turned off. ΔPmax and ΔPmin are determined according to the allowable and set permissible range of pressure fluctuation of the absorption tower and its auxiliary equipment, ΔPmax = 0.4 MPa, ΔPmin = 0 MPa.

[0125] Meanwhile, the warning level is calculated by the intelligent algorithm module in the warning system. α and β are 0 and 3.0 respectively (pressure increase has a significant impact on the system). The liquid level is not abnormal, so α does not affect the calculation, and the liquid level deviation is 0.

[0126] Pressure increase deviation = (ΔP - ΔP1) / (ΔPmax - ΔPmin) = [(0.9 - 0.6) / 35 - 0.3] / (0.4 - 0)

[0127] Warning level = α × liquid level deviation + β × pressure increase deviation = 0 × 0 + 3.0 × [(0.9 - 0.6) / 35 - 0.3] / (0.4 - 0) = 0.9

[0128] According to formula (I), the warning level is calculated to be Level III.

[0129] The regulator controls the ultrasonic frequency of the ultrasonic defoaming device to 30kHz and the power to 100 watts. This effectively alleviates the abnormal pressure caused by foam accumulation inside the tower.

[0130] Continuous monitoring and automatic adjustment of defoaming intensity

[0131] During the defoaming process, the early warning system continuously monitors the liquid level and gradually reduces the ultrasonic power based on the recovery of the liquid level. When the real-time pressure drops to 0.75 MPa, approaching the initial working pressure, the ultrasonic defoaming device gradually reduces the power (reducing by 5 watts per minute, from 100 watts to 20 watts and then stopping), maintaining the ultrasonic power at 20 watts until the liquid level is completely restored to the initial working pressure.

[0132] Defoaming complete and system restore

[0133] After 30 minutes of operation, the pressure inside the absorption tower returned to 0.6 MPa, and the absorbent liquid level remained within the normal operating range. At this point, the early warning system shut down its alarm, the ultrasonic defoaming device stopped working, and the system returned to normal operation.

[0134] It should be noted that the embodiments described above are only for explaining the present invention and do not constitute any limitation on the present invention. The present invention has been described with reference to typical embodiments, but it should be understood that the words used therein are descriptive and explanatory terms, not limiting terms. Modifications can be made to the present invention within the scope of the claims, and revisions can be made to the present invention without departing from the scope and spirit of the present invention. Although the present invention described herein relates to specific methods, materials, and embodiments, it does not mean that the present invention is limited to the specific examples disclosed herein; on the contrary, the present invention can be extended to all other methods and applications with the same function.

Claims

1. A liquid phase foaming control device, characterized by, It includes an absorption tower, an ultrasonic defoaming device located in the middle of the absorption tower, and a DCS control system, wherein the DCS control system includes an early warning system. The ultrasonic defoaming device includes an ultrasonic generator and a sensor. The sensor is communicatively connected to the early warning system. The sensor is used to monitor the liquid level and / or pressure increase of the absorbent in the absorption tower in real time and transmit the monitored signal to the early warning system. The early warning system is communicatively connected to the ultrasonic generator to control the start and stop of the ultrasonic generator. When the liquid level of the absorbent in the absorption tower increases to a first predetermined height increase and / or the pressure increase increases to a first predetermined pressure increase, the early warning system issues an alarm signal and starts the ultrasonic generator. The early warning system then shuts down the ultrasonic generator when the liquid level of the absorbent in the absorption tower decreases to a second predetermined height and / or the pressure increase decreases to a second predetermined pressure increase.

2. The liquid phase foaming control apparatus according to claim 1, wherein The first predetermined height increase is 20-40% of the working height of the absorbent; and / or The first predetermined pressure increase is an increase in pressure within the absorber tower of 30%-50% of the initial operating pressure over 30-45 minutes; and / or The second predetermined height increase is 5%-15% of the working height of the absorbent; and / or The second predetermined pressure increase is an increase in pressure within the absorber tower of 10%-20% of the initial operating pressure over 30-45 minutes; and / or The ultrasonic defoaming device is positioned above the highest liquid level of the absorbent liquid inside the absorption tower; and / or The early warning system stops issuing alarm signals after the ultrasonic generator is activated, or when the liquid level of the absorbent in the absorption tower decreases to a second predetermined height and / or the pressure increase decreases to a second predetermined pressure increase.

3. The liquid phase foaming control device according to claim 1 or 2, characterized in that, The early warning system is also equipped with an intelligent algorithm module, which is used to classify the early warning level based on the first and second predetermined height increase and the first and second predetermined pressure increase; the ultrasonic defoaming device also includes a regulator for adjusting the frequency and power of the ultrasonic waves emitted by the ultrasonic generator; the early warning system controls the regulator to adjust the frequency and power of the ultrasonic waves emitted by the ultrasonic generator according to the early warning level.

4. The liquid phase foaming control device according to claim 3, characterized in that, The intelligent algorithm module classifies the warning levels according to the following formula: Warning level = α × liquid level deviation + β × pressure increase deviation (I) In formula (I), α and β are weighting coefficients used to balance the influence of liquid level deviation and pressure increase deviation on the warning level. Liquid level deviation represents the deviation between the absorption liquid level and the first predetermined height, and pressure increase deviation represents the deviation between the pressure increase in the absorption tower and the first predetermined pressure increase. 0≤α≤2; 0≤β≤4. where h is the current liquid level, h1 is the first predetermined height, h max and h min are the maximum and minimum values of the absorption liquid level, ΔP is the current pressure rate of increase, ΔP1 is the first predetermined pressure rate of increase, and ΔPmax and ΔPmin are the maximum and minimum values of the pressure rate of increase. Preferably, when the warning level is <0.5, the warning level is classified as Level 1 warning, and the regulator controls the frequency of the ultrasonic wave of the ultrasonic generator to 20-25kHz and the power to 30-50 watts. When 0.5 ≤ warning level < 0.8, the warning level is classified as Level II warning. The regulator controls the frequency of the ultrasonic wave generated by the ultrasonic wave generator to 25-30kHz and the power to 50-70 watts. When 0.8 ≤ warning level, the warning level is divided into three levels. The regulator controls the frequency of the ultrasonic wave of the ultrasonic generator to 30-35kHz and the power to 70-100 watts.

5. The liquid phase foaming control device according to any one of claims 1-4, characterized in that, The early warning system is also equipped with a recording module, which can record the numerical change curves of the absorbent liquid level and / or pressure in the absorption tower during the entire process from the start-up to the shutdown of the early warning system.

6. The liquid phase foaming control device according to any one of claims 1-5, characterized in that, The early warning system is also equipped with a feedback control module, which is used to issue a reminder signal when the warning level of Level 3 exceeds 20-50 minutes, and control the regulator to increase the frequency and power of the ultrasonic wave of the ultrasonic generator by 10%-20% respectively, until the warning level drops to Level 2, at which point the reminder signal is stopped and the control of the regulator is stopped.

7. An absorption tower equipped with the liquid phase foaming control device according to any one of claims 1-6, characterized in that, The absorption tower is equipped with a packing section containing multiple layers of packing material, and a piping system for introducing bottom absorbent liquid and discharging top absorbent liquid. The packing section is located above the ultrasonic defoaming device.

8. The absorption tower according to claim 7, characterized in that, The packing material is a ring packing or foam packing; and / or, the absorption tower is made of stainless steel.

9. A method for controlling liquid phase foaming in an absorption tower using the liquid phase foaming control device according to any one of claims 1-6, characterized in that, Includes the following steps: S1. The sensor monitors the liquid level and / or pressure of the absorbent liquid in the absorption tower in real time; S2. When the liquid level of the absorbent increases to a first predetermined height increase and / or the pressure increases to a first predetermined pressure increase, the early warning system issues an alarm signal and starts the ultrasonic generator. S3. When the increase in the liquid level of the absorbent decreases to the second predetermined height increase and / or the increase in pressure decreases to the second predetermined pressure increase, the early warning system shuts down the ultrasonic generator.

10. The method according to claim 9, characterized in that, It also includes: after the ultrasonic defoaming device is activated in step S2, the early warning system controls the regulator to adjust the frequency and power of the ultrasonic waves of the ultrasonic generator according to the early warning level.

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