A screening, crushing, and sieving system for waste catalysts in residual oil

Abstract

This invention relates to a screening and crushing system for waste catalysts in residual oil, belonging to the field of screening equipment technology. It integrates intelligent metering and feeding, grading and screening, closed-loop crushing, high-efficiency stirring output, and centralized control and environmental purification units. Through a closed-loop process of "screening-crushing-re-screening," it ensures that the finished product particle size meets standards. The core innovation lies in installing pressure and acoustic sensors on the conveyor belt of the vibrating screen's discharge section. Real-time quantitative monitoring of the screen clogging rate is achieved by cross-validating the impact dynamics spectrum of the discharge material with the acoustic characteristic modes. The entire system adopts an explosion-proof design and is equipped with an emergency feeding port and a flue gas treatment system. This invention has advantages such as high automation, accurate metering, real-time diagnosis of screen status, safety and environmental protection, and strong production continuity.

Description

Technical Field

[0001] This invention belongs to the field of screening equipment technology, specifically relating to a screening and crushing powder screening system for waste catalysts in residual oil. Background Technology

[0002] Waste catalyst from residual oil is a typical solid waste generated during petroleum refining. Screening, crushing, and sieving are crucial steps in realizing the resource utilization of solid waste. However, existing treatment systems still have the following significant problems in practical applications: 1. In traditional waste catalyst processing, material loading relies heavily on manual drum tipping or simple lifting equipment, which is not only labor-intensive and inefficient but also makes accurate batch metering difficult. Because waste catalyst residue has a certain degree of flammability, traditional equipment often lacks adequate explosion-proof design and automated drum lifting mechanisms in specific environments such as chemical warehouses, making it highly susceptible to safety accidents.

[0003] 2. In the screening process, screen clogging is a core problem affecting system stability. Due to the irregular shape or stickiness of spent catalyst particles, the screen openings are prone to clogging. Current industry practice mainly relies on manual periodic shutdowns for inspection or observation of changes in the discharge rate to determine the screen condition. This method not only has significant time lag but is also difficult to monitor in real time in a fully enclosed, dust-free environment, making it impossible to quantitatively obtain "clogging rate" data, resulting in poor production continuity.

[0004] 3. Existing crushing systems are often disconnected from screening systems, lacking an effective closed-loop circulation mechanism. After primary crushing, whether the particle size of the material meets the process requirements of being smaller than rice grains is often not confirmed by secondary screening, which directly affects the uniformity and finished product quality during subsequent mixing in a twin-shaft mixer.

[0005] In view of this, this solution was developed. Summary of the Invention

[0006] In view of the shortcomings of the prior art, the technical problem to be solved by the present invention is to provide a screening and crushing system for waste catalysts in residual oil, which realizes intelligent metering, closed-loop circulation processing, and an automated system that can monitor the screen blockage status in real time through multimodal sensing.

[0007] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a screening and crushing system for waste catalysts in residual oil, including a metering and feeding unit, a vibrating screen, a screen blockage detection unit and a closed-loop crushing unit; The metering and feeding unit is used for automatic lifting and precise weighing of waste catalyst; the vibrating screen is used to screen fine materials with a particle size of less than or equal to 5 mm to the belt conveyor and send fine materials with a particle size greater than 5 mm to the closed-loop crushing unit. A pressure sensing platform is installed below the transport plane of the belt conveyor corresponding to the material feeding area of ​​the vibrating screen. Fine materials fall onto the pressure sensing platform to form pressure points. The pressure points and time form a pressure spectrum. The blockage of the screen holes on the vibrating screen is determined based on the pressure spectrum. The closed-loop crushing unit includes a vertical shaft crusher and a return conveying screw. Fine materials with a particle size greater than 5mm are fed into the vertical shaft crusher for secondary crushing. The input end of the return conveying screw is connected to the vertical shaft crusher, and the output end of the return conveying screw is connected to the inlet of the vibrating screen.

[0008] Furthermore, before extracting dynamic pressure, the pressure sensing platform uses a high-pass filter to remove background vibration noise from the motor on the vibrating screen, thus extracting the pure impact component of the falling material.

[0009] Furthermore, the formula for calculating the integral area of ​​the pressure curve per unit time is: ; P represents the dynamic pressure sensed by the pressure sensing platform, and t represents time.

[0010] Furthermore, the screen blockage detection unit also includes a sound sensor, which is installed on one side of the transport plane of the belt conveyor corresponding to the material feeding area of ​​the vibrating screen. The sound sensor is used to collect sound frequencies and form an acoustic spectrum diagram in conjunction with time.

[0011] Furthermore, the screening and crushing sieve system uses pressure spectrum and acoustic spectrum fusion analysis to determine whether the screen of the vibrating screen is blocked; If the integral area of ​​the pressure spectrum decreases and the amplitude of the acoustic characteristic spectral lines in the ascent spectrum decreases synchronously, it confirms that the screen is physically blocked.

[0012] Furthermore, the power calculated based on the dynamic blockage rate is as follows: ; Ireal / Ibase is the ratio of the current pressure integral to the integral under standard clean conditions; Sreal / Sbase is the ratio of the current audio frequency characteristic amplitude to that under standard conditions; α and β are weighting coefficients, α+β=1, and α and β are dynamically adjusted according to the on-site calibration structure.

[0013] Furthermore, the metering and feeding unit includes a raw material metering hopper with a weighing sensor and a material bucket lifting and tipping device; The bottom of the raw material metering hopper is equipped with four weighing sensors; the material bucket lifting and tipping device includes a winch.

[0014] Furthermore, the screening and crushing powder sieve system also includes a high-efficiency mixing output unit, which includes a twin-shaft mixer. The twin-shaft mixer is used for mixing raw materials, and the output end of the twin-shaft mixer is connected to the receiving and storage silo via a pneumatic or electric control valve.

[0015] Furthermore, the screening and crushing powder screening system also includes a flue gas treatment unit, which guides the dust and odor generated during the production process to the flue gas and odor treatment system for centralized purification through a flue gas extraction pipe and an induced draft fan.

[0016] Furthermore, the metering and feeding unit, vibrating screen, screen blockage detection unit, and closed-loop crushing unit are modularly supported by a steel structure frame constructed from channel steel and angle iron.

[0017] Compared with the prior art, the present invention has the following beneficial effects: 1. Achieved quantitative real-time monitoring and intelligent early warning of screen status: This invention introduces a cross-validation mechanism combining material impact dynamics analysis and acoustic spectral feature reference for the first time by installing pressure sensors and acoustic sensors on the fine material conveyor below the vibrating screen. Through a fusion algorithm of pressure-time spectrum integration and acoustic feature values, the system can calculate the dynamic clogging rate of the screen openings in real time and quantitatively, completely solving the industry problem of lagging screen clogging monitoring and inability to quantitatively assess it in traditional processes. The introduction of multimodal sensing greatly reduces the false alarm rate in high-vibration chemical environments, providing accurate data support for predictive maintenance.

[0018] 2. An efficient closed-loop processing mechanism has been established to ensure the finished product particle size qualification rate: The system forms a complete "screening-crushing-rescreening" closed-loop process through the linkage of the vibrating screen, vertical shaft crusher, and return material conveying screw. This design ensures that the particle size of all materials entering the next process can be strictly controlled below 5mm, effectively avoiding the mixing of large aggregate particles into the finished product, thereby ensuring the uniformity of subsequent twin-shaft mixer mixing and the quality stability of the final product.

[0019] 3. Significantly improved automation and metering accuracy, reduced labor costs. The system integrates a material bucket lifting and tipping device with a raw material metering hopper equipped with four weighing sensors, achieving full automation from feeding to metering. This design not only replaces the traditional manual bucket tipping mode, reducing the labor intensity of operators, but also ensures the accuracy of batch feeding through high-precision real-time weight monitoring, improving the overall production line efficiency. Attached Figure Description

[0020] Figure 1 This is a simplified schematic diagram of a screening, crushing, and sieving system for waste catalysts in residual oil according to the present invention. Figure 2This is a schematic diagram of the planar structure of the metering and feeding unit, the vibrating screen, and the high-efficiency stirring and output unit in this invention; Figure 3 This is a flowchart of the screening and crushing powder screening system in this invention.

[0021] The markings in the diagram are: 1. Metering and feeding unit; 2. Vibrating screen; 3. Screen blockage detection unit; 31. Pressure sensing platform; 32. Sound sensor; 4. Closed-loop circulation crushing unit; 41. Vertical shaft impact crusher; 5. High-efficiency mixing and output unit. Detailed Implementation

[0022] To make the above features and advantages of the present invention more apparent and understandable, specific embodiments are described below in conjunction with the accompanying drawings. Figures 1-3 As shown, this embodiment provides a screening and crushing system for waste catalysts in residual oil, including a metering and feeding unit 1, a vibrating screen 2, a screen blockage detection unit 3, a closed-loop circulation crushing unit 4, a high-efficiency stirring and output unit 5, and a flue gas treatment unit.

[0023] The system is supported by a steel frame, which is mainly welded from No. 10 channel steel and angle iron. According to the environmental protection requirements on site, a fully enclosed or semi-enclosed protective structure is constructed using sheet metal, canvas and magnetic door curtains.

[0024] The total power of the system is set at approximately 86.2kW. To adapt to the flammable environment of the waste catalyst warehouse, all electrical components (such as motors, sensors, instruments, etc.) have undergone strict explosion-proof treatment.

[0025] Implementation of Intelligent Metering and Feeding Unit 1: Located at the beginning of the system, Intelligent Metering and Feeding Unit 1 is responsible for receiving and accurately feeding materials. It includes a raw material metering hopper equipped with weighing sensors and a bucket lifting and tipping device. The bucket lifting and tipping device is equipped with a 15kW winch and matching guide rails. During operation, the device automatically grabs the bucket containing waste catalyst, lifts it along the guide rail to the unloading point, and the tipping mechanism, in conjunction with a limit device, completes the automatic bucket lifting and tipping action, replacing the traditional manual tipping mode. The raw material metering hopper is located below the tipping device, with dimensions of 2100×2550×1120mm. Four weighing sensors (each with a 2-ton capacity) are installed at its bottom, working in conjunction with the weighing instrument in the control cabinet to capture the feeding weight data in real time.

[0026] The vibrating screen 2 is used to screen fine materials with a particle size of 5mm or less to the belt conveyor and to send fine materials with a particle size greater than 5mm to the closed-loop crushing unit 4. The vibrating screen 2 (driven by a 3kW vibrating motor) has a screen body size of 2150×1500×450mm. The screen mesh size is set to 5mm to achieve preliminary screening of the material. The vibrating screen 2 is used to screen fine materials with a particle size of 5mm or less to the belt conveyor and to send fine materials with a particle size greater than 5mm to the closed-loop crushing unit 4. The closed-loop crushing unit 4 includes a vertical shaft impact crusher 41 and a return conveying screw. Fine materials with a particle size greater than 5mm are fed into the vertical shaft impact crusher 41 for secondary crushing. The input end of the return conveying screw is connected to the vertical shaft impact crusher 41, and the output end of the return conveying screw is connected to the inlet of the vibrating screen 2. The crushed material is returned to the vibrating screen 2 via the return conveying screw for secondary screening. This "screen-crush-return" cycle ensures that the particle size of the finished material meets 100% of the process requirements.

[0027] The high-efficiency mixing output unit 5 includes a twin-shaft mixer, which is used for mixing raw materials. The output end of the twin-shaft mixer is connected to the receiving and storage silo through a pneumatic or electric control valve. Fine materials with a particle size of less than or equal to 5mm enter the mixing stage after screening. The twin-shaft mixer is equipped with an 18.5kW motor and a special reducer to perform high-intensity and uniform mixing of fine materials. The finished product after mixing enters the receiving and storage silo. The outlet of the silo is equipped with a pneumatic valve or an electric slide valve to control the final metering, bagging, or transfer of the finished product.

[0028] The flue gas treatment unit guides the dust and odors generated during the production process to the flue gas and odor treatment system for centralized purification through the flue gas extraction pipe and induced draft fan.

[0029] The screen blockage detection unit 3 includes a sound sensor 32 and a pressure sensing platform 31, with the pressure sensor mounted on the belt support. When material falls, the sensor senses the impact pressure in real time and generates a pressure-time graph in the control system. By calculating the integral area of ​​the pressure curve, the system can quantitatively determine the amount of material falling per unit time.

[0030] Before extracting dynamic pressure, the pressure sensing table 31 uses a high-pass filter to remove the background vibration noise from the motor on the vibrating screen 2, and extracts the pure impact component of the falling material.

[0031] The formula for calculating the integral area of ​​the pressure curve per unit time is: ; P represents the dynamic pressure sensed by the pressure sensing station 31, and t represents time.

[0032] Acoustic sensors (industrial microphones) are installed synchronously. A specific frequency signal generated by material impacting the belt is extracted using a convolution algorithm. Sound sensor 32 is positioned on one side of the transport plane corresponding to the material feeding area of ​​the vibrating screen 2 on the belt conveyor. Sound sensor 32 is used to collect sound frequencies and, in conjunction with time, form an acoustic spectrum diagram.

[0033] The screening and crushing sieve system uses pressure spectrum and acoustic spectrum to perform fusion analysis to determine whether the screen of vibrating screen 2 is blocked; if the integral area of ​​the pressure spectrum decreases and the amplitude of the acoustic characteristic spectral line of the acoustic spectrum decreases synchronously, it is confirmed that the screen is physically blocked.

[0034] The power is calculated based on the dynamic blockage rate as follows: ; Ireal / Ibase is the ratio of the current pressure integral to the integral under standard clean conditions; Sreal / Sbase is the ratio of the current audio frequency characteristic amplitude to that under standard conditions; α and β are weighting coefficients, α+β=1, and α and β are dynamically adjusted according to the on-site calibration structure.

[0035] When the value exceeds the set warning threshold, the explosion-proof electrical control cabinet issues an alarm signal and adjusts the feed screw speed accordingly.

[0036] Preferably, an emergency feeding port is reserved at a critical location in the system (such as the material hopper in front of the scraper conveyor). When the lifting device or part of the screw conveyor experiences a sudden failure, operators can maintain basic production through the emergency port, ensuring that the system has a strong continuous operation capability.

[0037] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the present invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope. All such changes and modifications fall within the scope of the present invention as claimed, which is defined by the appended claims and their equivalents.

Claims

1. A screening and crushing system for waste catalysts in residual oil, characterized in that: It includes a metering and feeding unit, a vibrating screen, a screen blockage detection unit, and a closed-loop crushing unit; The metering and feeding unit is used for automatic lifting and precise weighing of waste catalyst; the vibrating screen is used to screen fine materials with a particle size of less than or equal to 5 mm to the belt conveyor and send fine materials with a particle size greater than 5 mm to the closed-loop crushing unit. The screen blockage detection unit includes a pressure sensing platform. The pressure sensing platform is set below the transport plane of the belt conveyor corresponding to the material feeding area of ​​the vibrating screen. Fine material falls onto the pressure sensing platform to form pressure points. The pressure points and time form a pressure spectrum. The blockage status of the screen holes on the vibrating screen is determined according to the pressure spectrum. The closed-loop crushing unit includes a vertical shaft crusher and a return conveying screw. Fine materials with a particle size greater than 5mm are fed into the vertical shaft crusher for secondary crushing. The input end of the return conveying screw is connected to the vertical shaft crusher, and the output end of the return conveying screw is connected to the inlet of the vibrating screen.

2. The screening and crushing system for waste catalysts in residual oil according to claim 1, characterized in that: Before extracting dynamic pressure, the pressure sensing table uses a high-pass filter to remove background vibration noise from the motor on the vibrating screen, thus extracting the pure impact component of the falling material.

3. The screening and crushing system for waste catalysts in residual oil according to claim 2, characterized in that: The formula for calculating the integral area of ​​the pressure curve per unit time is: ； P represents the dynamic pressure sensed by the pressure sensing platform, and t represents time.

4. The screening, crushing, and sieving system for waste catalysts in residual oil according to claim 3, characterized in that: The screen blockage detection unit also includes a sound sensor, which is set on one side of the transport plane of the belt conveyor corresponding to the material feeding area of ​​the vibrating screen. The sound sensor is used to collect sound frequencies and form an acoustic spectrum diagram in conjunction with time.

5. A screening and crushing system for waste catalysts in residual oil as described in claim 4, characterized in that: The screening and crushing sieve system uses pressure spectrum and acoustic spectrum to perform integrated analysis to determine whether the screen of the vibrating screen is blocked; If the integral area of ​​the pressure spectrum decreases and the amplitude of the acoustic characteristic spectral lines in the ascent spectrum decreases synchronously, it confirms that the screen is physically blocked.

6. A screening and crushing system for waste catalysts in residual oil as described in claim 5, characterized in that: The power is calculated based on the dynamic blockage rate as follows: ； Ireal / Ibase is the ratio of the current pressure integral to the integral under standard clean conditions; Sreal / Sbase is the ratio of the current audio frequency characteristic amplitude to that under standard conditions; α and β are weighting coefficients, α+β=1, and α and β are dynamically adjusted according to the on-site calibration structure.

7. The screening and crushing system for waste catalysts in residual oil according to claim 1, characterized in that: The metering and feeding unit includes a raw material metering hopper with a weighing sensor and a material bucket lifting and tipping device. The bottom of the raw material metering hopper is equipped with four weighing sensors; the material bucket lifting and tipping device includes a winch.

8. A screening and crushing system for waste catalysts in residual oil as described in claim 1, characterized in that: The screening and crushing powder sieve system also includes a high-efficiency mixing output unit, which includes a twin-shaft mixer. The twin-shaft mixer is used for mixing raw materials, and the output end of the twin-shaft mixer is connected to the receiving and storage silo via a pneumatic or electric control valve.

9. A screening and crushing system for waste catalysts in residual oil as described in claim 1, characterized in that: The screening and crushing powder screening system also includes a flue gas treatment unit, which guides the dust and odor generated during the production process to the flue gas and odor treatment system for centralized purification through a flue gas extraction pipe and an induced draft fan.

10. A screening and crushing system for waste catalysts in residual oil according to claim 1, characterized in that: The metering and feeding unit, vibrating screen, screen blockage detection unit, and closed-loop crushing unit are modularly supported by a steel structure frame constructed from channel steel and angle iron.

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