A control module for high-purity gas source purification and distribution based on micro-positive pressure protection

Abstract

This invention discloses a control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection, comprising an inlet interface assembly (1), a multi-stage filtration assembly (2), a drying and purification assembly (3), a main pressure stabilizing assembly (4), a multi-branch distribution valve group (5), and a modular base plate (6) or housing; each functional unit is arranged sequentially according to the gas flow direction and fixedly installed in the modular base plate (6) or housing to form an integrated gas supply device. The advantages of this invention are that it integrates filtration, drying, pressure stabilization, and distribution, outputs high-cleanliness gas with a stable dew point in real time, facilitates installation and subsequent maintenance, and is used for the basic gas supply of multi-channel micro-positive pressure systems.

Description

Technical Field

[0001] This invention belongs to the technical field of industrial gas source treatment and distribution systems, and particularly relates to a control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection. Background Technology

[0002] In heavy industrial settings such as coking, metallurgy, mining, and chemicals, equipment is exposed to harsh environments with high dust, high humidity and heat, and corrosive gases for extended periods. To protect precision equipment such as hydraulic station tanks, precision bearings, and electrical instruments, the industry is increasingly adopting "micro-positive pressure protection" technology. This involves injecting clean air into the equipment's interior or critical gaps, creating an outward airflow to block the intrusion of external contaminants. However, achieving micro-positive pressure protection relies on a high-quality air supply. Current industrial air supply systems generally suffer from the following problems: First, poor air quality: The compressed air pipeline network in the factory area usually contains a lot of condensate, oil and rust. If it is directly introduced into the protection system, it will not only fail to play a protective role, but will also "blow" the pollutants into the precision equipment, causing oil emulsification or component jamming.

[0003] Second, large pressure fluctuations: The pressure of the main pipeline fluctuates with the production load, resulting in unstable slight positive pressure at the protection end. If it is too low, the protection will be lost, and if it is too high, the seal will be damaged.

[0004] Third, there is a lack of system integration: filters, pressure reducing valves and tee fittings are usually temporarily put together on site, the pipelines are messy, there are many leaks at the joints, and it is impossible to achieve unified management and differentiated air supply for multiple devices. For example, the oil tank needs extremely low pressure, while the air curtain needs medium pressure.

[0005] Fourth, maintenance is difficult: there is a lack of standardized drainage and maintenance design, and it relies on frequent manual inspections, resulting in low maintenance efficiency. Summary of the Invention

[0006] The purpose of this invention is to solve the problems of poor quality, large pressure fluctuations, low integration, and difficult maintenance of existing micro-positive pressure protection gas sources. It provides a high-cleanliness gas source purification and distribution control module based on micro-positive pressure protection, which integrates filtration, drying, pressure stabilization, and distribution. It can output high-cleanliness gas with a stable dew point in real time, is easy to install and maintain, and is suitable for the basic gas supply of multi-channel micro-positive pressure systems.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: A control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection includes an inlet interface assembly, a multi-stage filter assembly, a drying and purification assembly, a main pressure stabilizing assembly, a multi-branch distribution valve group, and a modular base plate or housing; each functional unit is arranged sequentially according to the gas flow direction and fixedly installed in the modular base plate or housing to form an integrated gas supply device.

[0008] The air intake interface component is connected to the factory's compressed air or fresh air system and is equipped with an air intake valve and an air intake pressure gauge for air source on / off control and real-time monitoring of air intake pressure to ensure air supply safety and observability. The multi-stage filtration assembly is connected in series downstream of the air intake interface assembly and adopts a graded progressive purification structure, which includes a coarse filter and a precision filter to remove solid particulate matter, suspended matter and oil mist pollutants from the air source step by step, so as to achieve high-precision gas purification. The drying and purification component is connected downstream of the multi-stage filtration component and is one of a refrigerated dryer, a small adsorption dryer, or a combined dryer. It is equipped with an automatic drainage system for deep dehumidification and drying of the filtered gas. The main pressure stabilizing component is connected downstream of the drying and purification component. It adopts a two-stage pressure regulating and stabilizing structure, which includes a main pressure reducing valve and a pressure stabilizing valve. It is used to eliminate gas source pressure fluctuations and output a stable, continuous, and pulsation-free micro-positive pressure reference gas source, providing a constant pressure basis for subsequent multi-path distribution and ensuring that the pressure in the tank headspace is not affected by front-end gas source fluctuations. The multi-branch distribution valve group is connected to the outlet of the main pressure stabilizing component to realize a centralized gas supply mode with single gas source input and multiple independent outputs. The multi-branch distribution valve group is equipped with at least 2 to 8 independent output branches, each branch is equipped with an independent regulating needle valve or branch pressure reducing valve for individual adjustment of output pressure and flow. Each branch outlet is equipped with a branch pressure gauge and a quick output interface for realizing visual pressure monitoring and synchronous access and independent control of multiple oil tank devices.

[0009] Furthermore, the precision filter has a filtration accuracy of 0.1μm, and a high-efficiency filter can be selected according to the working conditions to further improve the gas cleanliness and meet the ultra-clean protection requirements in extremely harsh environments.

[0010] Furthermore, the main pressure reducing valve and the pressure regulating valve of the main pressure regulating component control the gas source pressure at 0.03 to 0.10 MPa.

[0011] Furthermore, the gas source is compressed air or nitrogen that has been dried.

[0012] Furthermore, the final output gas of the module meets the following requirements: dew point ≤ −20℃, particle size ≤ 0.1 μm, and maximum particle size preferably ≤ 0.1 μm.

[0013] Furthermore, the control module connects to a host computer or digital twin platform via a communication interface, supporting real-time data upload and remote control.

[0014] The working principle of this invention is as follows: Compressed air or fresh air from the plant's ventilation system enters the module through the air inlet assembly. It then undergoes coarse and fine filtration through a multi-stage filtration system to remove large particles, oil mist, and fine particles of 0.1 μm and above. The filtered gas then enters the drying assembly for deep dehumidification, and condensate is discharged via an automatic drainage system, achieving gas drying. The dried and clean gas is then regulated by the main pressure reducing valve and pressure regulating valve of the main pressure regulating assembly before entering the multi-branch distribution valve group. This distribution valve group is divided into 2 to 8 independent branches, each with its own output pressure and flow rate regulated by a needle valve or branch pressure reducing valve. Ultimately, it outputs high-cleanliness, slightly positive-pressure gas with a dew point ≤−20℃ and a particle size ≤0.1 μm to the headspace of each oil storage device, achieving multi-channel oil tank headspace slightly positive-pressure clean protection.

[0015] Compared with the prior art, the advantages of the technical solution of the present invention are as follows: (1) The control module of the present invention is highly integrated, integrating the functional units such as filtration, drying, pressure stabilization and distribution into a unified module with a compact layout, which greatly simplifies on-site construction and pipeline layout, realizes plug-and-play, and significantly improves the equipment's versatility and engineering adaptability. (2) The present invention can continuously provide a high-quality gas source with high cleanliness, stable dew point and constant pressure. The gas dew point is controllable and the cleanliness meets the standards, thus fundamentally eliminating the problem of protection failure caused by poor gas source quality. (3) The present invention adopts standardized interface, standardized module and standardized parameter design, which has strong universality and interchangeability. It is not only applicable to the headspace micro positive pressure protection of oil storage equipment in industries such as coking, metallurgy and mining, but can also be extended to various industrial scenarios such as air curtain isolation, clean room pressure maintenance and equipment sealing gas protection, and has extremely strong cross-scenario adaptability. (4) The module of the present invention is easy to maintain and has low operating cost. It is suitable for long-term continuous operation. It is equipped with an automatic drainage system that can automatically drain condensate without frequent manual operation. Each functional component adopts a modular design, which makes replacement quick and maintenance simple. It can greatly reduce the intensity of manual maintenance and downtime, and improve the online rate of equipment. (5) By continuously supplying high-cleanliness, low-dew-point micro-positive pressure gas, the present invention keeps the headspace of the oil tank stable positive pressure, completely blocking the intrusion of external dust, water vapor and corrosive gas, effectively inhibiting oil emulsification, oxidation, deterioration and internal corrosion, extending the service life of lubricating oil, hydraulic oil and transmission equipment, and reducing failure rate and maintenance costs. Attached Figure Description

[0016] Figure 1This is a schematic diagram of the control module for gas source purification and distribution according to the present invention; Figure 2 This is a schematic diagram of the gas path flow of the present invention; Figure 3 This is a schematic diagram of the modular base plate installation of the present invention. Detailed Implementation Example

[0017] To make the present invention clearer, the following description, in conjunction with the accompanying drawings, further illustrates a control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection. The specific embodiments described herein are for illustrative purposes only and are not intended to limit the present invention.

[0018] The device of this invention is applied in the intelligent hydraulic station system of a coking plant. See [link to relevant documentation]. Figure 1 and Figure 2 A control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection, characterized in that: The air intake interface assembly 1 is used to connect to the compressed air or fresh air system in the plant area, and is equipped with an air intake valve 11 and an air intake pressure gauge 12. The multi-stage filtration assembly 2, located downstream of the air intake interface assembly 1, includes a coarse filter 21 and a precision filter 22, with an optional high-efficiency filter; the coarse filter 21 is used to remove large particles and oil mist, and the precision filter 22 has a filtration accuracy of 0.1 μm. The drying and purification component 3 is located downstream of the multi-stage filtration component 2 and adopts a refrigerated dryer, a small adsorption dryer or a combined dryer, and is equipped with an automatic drainage system 31. The main pressure regulating component 4 is located downstream of the drying and purification component 3 and includes a main pressure reducing valve and a pressure regulating valve, used to output stable slightly positive pressure gas; A multi-branch distribution valve group 5 is connected to the outlet of the main pressure regulating component 4. The multi-branch distribution valve group 5 is provided with at least 2 to 8 branches 51. Each branch 51 is equipped with an independent needle valve or a branch pressure reducing valve 52. The outlet of the branch 51 is provided with a branch pressure gauge 53 and a quick output interface 54. See Figure 3 The modular base plate 6 or housing, the aforementioned air intake interface assembly 1, multi-stage filter assembly 2, drying and purification assembly 3, main pressure stabilizing assembly 4, and multi-branch distribution valve group 5 are all installed in a fixed layout on the modular base plate 6 or housing.

[0019] In this embodiment, the plant's compressed air system 7 is used as the air source. After being processed by a precision filter and dryer, it outputs clean air with a particle size of less than 0.1 μm and a dew point of less than −20°C.

[0020] The above control module operates according to the following steps: S1: Connect to an external air source through the air intake interface component 1, and perform coarse filtration, fine filtration and drying treatment on the air source; S2: Remove moisture from the gas source through the drying and purification component 2 to keep the dew point below -20°C; S3: Adjust the gas source pressure to the preset range through the main pressure reducing valve, and maintain a stable output pressure through the pressure regulating valve, controlling the gas source pressure at 0.03~0.10MPa; S4: The air source is distributed to each equipment branch 51 through the multi-branch distribution module 5, and the air source flow of each branch 51 is adjusted to distribute the air source to each hydraulic station equipment and oil cylinder to ensure a balanced air flow supply.

[0021] After 6 months of operation, the equipment's sealing performance was significantly improved, oil emulsification was reduced, and the equipment failure rate decreased by 40%.

[0022] In addition to the embodiments described above, the present invention may have other implementations. All technical solutions formed by equivalent substitution or equivalent transformation fall within the protection scope claimed by the present invention.

Claims

1. A control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection, characterized in that: It includes an air intake interface assembly (1), a multi-stage filter assembly (2), a drying and purification assembly (3), a main pressure stabilizing assembly (4), a multi-branch distribution valve group (5), and a modular base plate (6) or a housing; each functional unit is arranged in sequence according to the air flow direction and fixedly installed in the modular base plate (6) or housing to form an integrated air supply device; The air inlet assembly (1) is connected to the compressed air or fresh air system in the plant area and is equipped with an air inlet valve (11) and an air inlet pressure gauge (12). The multi-stage filtration assembly (2) is connected in series downstream of the air intake interface assembly (1) and adopts a graded progressive purification structure, which includes a coarse filter (21) and a precision filter (22). The drying and purification component (3) is connected downstream of the multi-stage filtration component (2) and is one of a refrigerated dryer, a small adsorption dryer or a combined dryer, and is equipped with an automatic drainage system (31). The main pressure regulating component (4) is connected downstream of the drying and purification component (3) and adopts a two-stage pressure regulating structure, which includes a main pressure reducing valve and a pressure regulating valve. The multi-branch distribution valve group (5) is connected to the outlet of the main pressure regulating component (4). It is equipped with at least 2 to 8 independent output branches (51). Each branch (51) is equipped with an independent regulating needle valve or a branch pressure reducing valve (52). Each branch (51) is equipped with a branch pressure gauge (53) and a quick output interface (54) at the outlet of each branch (51).

2. The control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection according to claim 1, characterized in that: The precision filter (52) has a filtration accuracy of 0.1μm, and a high-efficiency filter can be selected according to the working conditions.

3. The control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection according to claim 1 or 2, characterized in that: The main pressure reducing valve and the pressure regulating valve of the main pressure regulating component (4) control the gas source pressure at 0.03 to 0.10 MPa.

4. The control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection according to claim 1 or 2, characterized in that: The air source for the air intake interface assembly (1) is dried compressed air or nitrogen.

5. The control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection according to claim 1 or 2, characterized in that: The final output gas of the control module meets the following requirements: dew point ≤ −20℃, particle size ≤ 0.1 μm, and fine filter filtration accuracy of 0.1~1μm, preferably 0.1μm.

6. The control module for high-cleanliness gas source purification and distribution based on micro-positive pressure protection according to claim 1 or 2, characterized in that: The control module connects to a host computer or digital twin platform via a communication interface, supporting real-time data upload and remote control.

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