A safe treatment process for automatic purification of industrial wastewater

Abstract

This invention discloses a safe and automated industrial wastewater purification process, belonging to the field of water treatment technology. This process automatically determines the system's operating status by real-time acquisition of water quality and equipment operating parameters, combined with pattern recognition and intelligent control algorithms. Upon detecting abnormal fluctuations, it triggers a "safe treatment mode." This mode includes steps such as wastewater diversion, dynamic chemical dosing control, and deep treatment load adjustment, effectively isolating impact loads, protecting the core treatment unit, and smoothly restoring normal operation after the anomaly is eliminated. This invention achieves proactive defense and intelligent control of the wastewater treatment process, significantly improving the system's robustness, safety, and automation level, demonstrating outstanding substantive features and significant progress.

Description

Technical Field

[0001] This invention relates to the field of environmental water treatment technology, and in particular to a safe treatment process for automated purification of industrial wastewater. Background Technology

[0002] With increasingly stringent environmental regulations, industrial wastewater treatment systems are developing towards automation and intelligence. Existing automated systems typically operate according to preset programs, including units such as bar screens, regulating, neutralizing, coagulation, sedimentation, filtration, and advanced treatment. However, the quality and quantity of industrial wastewater fluctuate greatly, especially during industrial production anomalies, accidental discharges, or initial rainwater runoff, when parameters such as pH, heavy metal concentration, and COD in the influent may far exceed design standards.

[0003] Traditional control systems often suffer from deteriorating treatment performance when faced with impact loads due to feedback lag, and may even cause irreversible damage to subsequent biochemical or membrane treatment units, such as microbial death and membrane fouling and blockage, which increases operation and maintenance costs and poses an environmental risk of exceeding emission standards.

[0004] Therefore, there is an urgent need for an automated safety processing technology that can proactively identify anomalies and take protective measures. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a safe treatment process for automated purification of industrial wastewater. By introducing a master-slave mode switching mechanism driven by real-time data, the system automatically switches to a safe treatment mode when the influent is abnormal, protecting the core treatment unit and smoothly recovering after the abnormality is eliminated, thereby improving the safety and stability of the system.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A safe and automated industrial wastewater purification process includes the following steps: S1. Data Acquisition: Multiple sensors installed in the inlet pipe, equalization tank, treatment units at all levels, and outlet are used to collect wastewater quality parameters and equipment operating parameters in real time.

[0007] S2. Pattern Recognition and Judgment: The collected real-time parameters are compared with the safety threshold range preset in the control system to determine whether the system is currently in a normal processing state or an abnormal fluctuation state.

[0008] S3. Mode Switching and Execution: If the system is determined to be in a normal processing state, it will operate according to the preset normal processing mode; if the system is determined to be in an abnormal fluctuation state, the control system will automatically switch the process flow to a safe processing mode, which includes: S31. Wastewater diversion: By controlling the valve, the wastewater that causes abnormal fluctuations is diverted to the emergency regulating tank for temporary storage and homogenization. S32. Dynamic dosing adjustment: Based on the abnormal parameters monitored in real time, dynamically adjust the type and amount of chemicals added to the pretreatment unit; S33. Deep treatment load regulation: Reduce the treatment load of subsequent deep treatment units or start standby treatment units to ensure that the wastewater quality entering the deep treatment units is within its design tolerance range.

[0009] S4. Recovery and Switching: When the online monitoring system reports that the key water quality parameters have recovered to the preset safety threshold range, the control system automatically switches the process flow from the safe treatment mode back to the normal treatment mode, and pumps the wastewater in the emergency regulating tank into the front end in a certain proportion for re-treatment.

[0010] Preferably, the water quality parameters include at least one or more of pH value, chemical oxygen demand, suspended solids concentration, and characteristic heavy metal ion concentration; the equipment operating parameters include at least one or more of flow rate, liquid level, pressure, and temperature.

[0011] Preferably, the safety threshold range is a dynamically updated threshold, and the control system periodically optimizes and updates the safety threshold based on historical operating data and using machine learning algorithms.

[0012] As a preferred option, abnormal fluctuations that trigger the safety treatment mode include, but are not limited to: a sudden change in influent pH value exceeding 1.5 / min, a peak instantaneous COD concentration exceeding 30% of the design load, or an excessive concentration of characteristic heavy metal ions.

[0013] Preferably, the dynamic dosing adjustment is based on a fuzzy control algorithm or a feedforward-feedback composite control algorithm, which calculates the required dosing compensation value according to the degree of deviation of abnormal parameters and instructs the dosing pump to execute it.

[0014] Preferably, the pretreatment unit includes at least a neutralization reaction tank and a coagulation sedimentation tank.

[0015] Preferably, the deep processing unit includes at least a membrane separation component or an advanced oxidation reactor.

[0016] As a preferred option, in the safe processing mode, the system simultaneously sends audible and visual alarm information and fault diagnosis prompts to the mobile terminals of the central control room and on-site maintenance personnel.

[0017] Preferably, in step S4, the wastewater in the emergency regulating tank is pumped into the front end in a certain proportion. The proportion is dynamically calculated by the control system based on the current influent flow rate and water quality to avoid secondary impact on the conventional treatment process.

[0018] Preferably, the control system is a programmable logic controller or a distributed control system.

[0019] The beneficial effects of this invention are as follows: By setting a "safe treatment mode," it automatically isolates wastewater exceeding standards and adjusts operating parameters when influent anomalies occur, effectively protecting the deep treatment unit, preventing equipment damage or system failure, and eliminating the risk of excessive discharge. This invention can adaptively respond to drastic fluctuations in water quality and quantity, improving the system's shock resistance and operational stability. Combining pattern recognition, dynamic threshold updates, and intelligent control algorithms, it achieves a shift from passive response to proactive prevention, significantly improving the level of intelligence. Simultaneously, core equipment is effectively protected, extending its service life and reducing maintenance costs. Attached Figure Description

[0020] Figure 1 This is a flowchart of the automated purification and safe treatment process for industrial wastewater in an embodiment of the present invention.

[0021] Figure 2 This is a flowchart of mode switching and execution in an embodiment of the present invention. Detailed Implementation

[0022] The technical method of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0023] Furthermore, the accompanying drawings are merely illustrative of the invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and therefore repeated descriptions of them will be omitted. Some block diagrams shown in the drawings are functional entities and do not necessarily correspond to physically or logically independent entities. These functional entities can be implemented in software, in one or more hardware modules or integrated circuits, or in different network and / or processor methods and / or microcontroller methods.

[0024] It should be understood that although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are used merely to distinguish one unit from another. For example, without departing from the scope of the exemplary embodiments, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0025] 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 and specific embodiments. The embodiments described are merely illustrative and are not intended to limit the scope of protection of this invention. All equivalent substitutions or improvements made based on the concept of this invention should be included within the scope of protection of this invention.

[0026] Example 1 This embodiment provides a safe and automated industrial wastewater purification process, the process flow of which is as follows: Figure 1-2 As shown. This process is based on a complete automated control system, preferably a programmable logic controller (PLC) or a distributed control system (DCS), used to receive signals, process data and issue execution instructions.

[0027] 1. System Hardware Configuration To implement this process, the following hardware units are configured on the wastewater treatment line, all of which are electrically connected to the central control system: Sensor group: This includes various online monitoring instruments installed in the inlet pipe, equalization tank, neutralization reaction tank, coagulation sedimentation tank, membrane separation module (or advanced oxidation reactor), and final outlet. Specifically, it includes: pH meter, online COD analyzer, suspended solids (SS) concentration meter, online monitor for characteristic heavy metal ions (such as copper, nickel, chromium, etc.), electromagnetic flow meter, ultrasonic level gauge, pressure transmitter, and temperature sensor.

[0028] Actuators include automatic control valves (electric or pneumatic valves) distributed on various pipelines, variable frequency dosing pumps, booster pumps, and start / stop control cabinets for standby processing units.

[0029] Emergency facilities: An emergency regulating pool with sufficient capacity is set up, the inlet of which is connected to the front end pipeline of the pretreatment unit through a controlled valve, for the temporary storage of wastewater exceeding the standard.

[0030] Alarm and communication module: The control system is connected to an audible and visual alarm and is connected to the central control room server and the mobile terminals (such as mobile APP) of on-site maintenance personnel via industrial Ethernet or wireless communication module.

[0031] The safety processing technology of the present invention includes the following specific implementation steps: S1, Data Acquisition After the system starts up, all sensors collect data in real time at a high frequency (e.g., once every 10 seconds). The collected water quality parameters include influent pH value, COD concentration, SS concentration, and characteristic heavy metal ion concentration; equipment operating parameters include influent flow rate, liquid level in each tank, membrane pressure, and water temperature. This real-time data is transmitted to the PLC control system, forming a dynamic real-time data stream.

[0032] S2, Pattern Recognition and Judgment The PLC control system has a preset safety threshold range. In this embodiment, the threshold not only includes static limit values, but also a dynamic update module based on machine learning. The system retrieves historical operating data from the past year (including normal and abnormal data) and uses linear regression or support vector machine (SVM) algorithms to periodically (e.g., weekly) optimize the threshold.

[0033] During real-time assessment, the system compares real-time parameters with the dynamic safety threshold for the current period to intelligently identify the system status. Normal state: All parameters fluctuate smoothly within the safe threshold.

[0034] Abnormal fluctuation state: When any parameter is detected to exceed the dynamic threshold range, or the parameter change rate is abnormal, an anomaly judgment is triggered. In this embodiment, the specific triggering conditions are set as follows: when the influent pH value changes at a rate exceeding 1.5 / minute, the instantaneous COD concentration exceeds 30% of the design load, or the concentration of characteristic heavy metal ions exceeds 90% of the discharge standard, the system determines that it has entered an abnormal fluctuation state.

[0035] S3, Mode Switching and Execution In normal conditions, the system maintains the preset continuous flow treatment mode: wastewater sequentially passes through a screen, equalization tank, neutralization tank (addition of alkali / acid), coagulation sedimentation tank (addition of PAC / PAM), membrane separation / advanced oxidation, and is discharged after meeting the standards.

[0036] If an abnormal fluctuation is detected, the control system immediately and automatically interrupts the normal process and switches to "safety handling mode." This mode includes the following coordinated actions: S31. Wastewater Diversion: The control system immediately issues a command to close the inlet valve to the regular neutralization tank and simultaneously open the valve to the emergency regulating tank. The high-impact wastewater causing the abnormal fluctuation is entirely diverted to the emergency regulating tank for temporary storage, and homogenized and regulated by pre-aeration or stirring devices installed in the tank to prevent sedimentation or further deterioration of its properties during temporary storage.

[0037] S32. Dynamic Dosing Adjustment: For small amounts of wastewater still in the treatment path but not yet entering the advanced treatment unit, the system initiates a dynamic dosing procedure. Based on real-time monitored abnormal parameters (e.g., pH suddenly dropping to 3.0), the PLC invokes the built-in fuzzy control algorithm. This algorithm takes the pH deviation and flow rate as input, and outputs a compensation value for the alkali dosage after fuzzy inference. It also instructs the alkali pump in the neutralization tank to increase its operating frequency to ensure that the effluent pH returns to neutral before entering subsequent units.

[0038] S33. Deep Treatment Load Control: To prevent abnormal water quality from impacting the core treatment unit, the control system automatically reduces the operating flux of the primary membrane module (e.g., reducing the permeate flow from 100% to 50% of the rated flow) and simultaneously activates the backup membrane module. This "load reduction + backup" approach ensures that even if a small amount of abnormal water quality penetrates the pretreatment process, the overall water quality entering the deep treatment unit remains within the membrane module's tolerance range, effectively preventing membrane fouling or irreversible blockage.

[0039] At the same time, the system sends an audible and visual alarm to the central control room and pushes fault diagnosis information to the mobile phones of maintenance personnel, indicating "the pH of the influent has changed suddenly, and we have switched to safe mode".

[0040] S4, Recovery and Switching The online monitoring system continuously monitors the water quality at the outlet of the emergency regulating tank (or the front end of the conventional process). When key water quality parameters (pH, COD) are detected to have continuously and stably returned to the preset safety threshold range (e.g., pH stabilized between 6 and 9 for more than 30 minutes), the control system determines that the abnormal shock has been eliminated.

[0041] At this point, the system enters the recovery phase: First, the process flow is switched from "safe treatment mode" back to "normal treatment mode." Second, the wastewater temporarily stored in the emergency equalization tank begins to be treated. The control system dynamically calculates the back-pumping ratio based on the current influent flow rate and the water quality in the emergency equalization tank. For example, if the current influent flow rate is 100 m³ / h, and the COD in the emergency tank, although homogenized, is still relatively high, the system is set to pump the wastewater from the emergency tank into the equalization tank evenly and slowly via a variable frequency pump at a flow rate of 10 m³ / h (10% of the total influent), mixing it with the fresh influent before it re-enters the treatment process. This ratio is dynamically adjusted by a PID controller to ensure that the mixed water quality does not cause a secondary impact on the system, ultimately achieving safe treatment of all wastewater.

[0042] In an application example at a chemical fiber plant, before adopting the process of this invention, an accidental discharge from an upstream workshop caused a sudden change in the pH of the influent, resulting in severe fouling of the subsequent membrane system, requiring a three-day shutdown for cleaning. After adopting the process described in this embodiment, when a similar accident occurred again, the system automatically identified the anomaly within 5 seconds and switched to a safe mode, successfully isolating the wastewater exceeding the standards. The membrane system operating pressure did not rise abnormally, the entire system operated smoothly, and no equipment damage or environmental penalties were incurred, significantly improving the plant's environmental safety level.

[0043] Example 2 This embodiment further optimizes the dynamic dosing adjustment in step S32 based on embodiment 1.

[0044] Unlike Example 1, this example uses a feedforward-feedback composite control algorithm for dosing control.

[0045] Feedforward control: Before the wastewater enters the neutralization tank, a pH meter on the inlet pipe measures the pH value of the raw water in real time. Based on the inlet flow rate and the raw water pH value, the feedforward controller pre-calculates a basic dosage and instructs the dosing pump to operate in advance, overcoming the lag caused by the neutralization reaction time.

[0046] Feedback control: Another pH meter is installed at the outlet of the neutralization tank to compare the measured pH value of the effluent with the target set value (e.g., 7.0). The deviation signal is used as feedback to finely correct the basic dosage calculated by the feedforward.

[0047] Through this composite control, even in the face of drastic water quality fluctuations, the pH of the neutralization tank effluent can be precisely controlled within the target range, with a fluctuation range of less than ±0.3. This provides extremely stable water quality conditions for subsequent coagulation sedimentation and advanced treatment, further ensuring the safety of the core treatment unit.

[0048] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

[0049] For example, the characteristic heavy metal ions are not limited to copper, nickel, and chromium, but may also include lead, zinc, arsenic, etc., depending on the specific type of industrial wastewater. The advanced treatment unit is not limited to membrane separation or advanced oxidation, but may also be an activated carbon adsorption or ion exchange unit. The wastewater back-pumping ratio in the emergency regulating tank can be dynamically calculated or set to a safe fixed ratio value (e.g., 5%-15%) in the control system. Any simple modifications or substitutions based on the scope of protection of the claims of this invention are within the scope of protection of this invention.

[0050] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features of the invention herein.

Claims

1. A safe and automated treatment process for industrial wastewater purification, characterized in that, Includes the following steps: S1. Data Acquisition: Through multiple sensors installed in the inlet pipe, equalization tank, each treatment unit and outlet, the wastewater quality parameters and equipment operating parameters are collected in real time. S2. Pattern Recognition and Judgment: The collected real-time parameters are compared with the safety threshold range preset in the control system to determine whether the system is currently in a normal processing state or an abnormal fluctuation state. S3. Mode Switching and Execution: If the system is determined to be in a normal processing state, it will operate according to the preset normal processing mode; if the system is determined to be in an abnormal fluctuation state, the control system will automatically switch the process flow to a safe processing mode, which includes: S31. Wastewater diversion: By controlling the valve, the wastewater that causes abnormal fluctuations is diverted to the emergency regulating tank for temporary storage and homogenization. S32. Dynamic dosing adjustment: Based on the abnormal parameters monitored in real time, dynamically adjust the type and amount of chemicals added to the pretreatment unit; S33. Deep treatment load regulation: Reduce the treatment load of subsequent deep treatment units or start standby treatment units to ensure that the wastewater quality entering the deep treatment units is within its design tolerance range. S4. Recovery and Switching: When the online monitoring system reports that the key water quality parameters have recovered to the preset safety threshold range, the control system automatically switches the process flow from the safe treatment mode back to the normal treatment mode, and pumps the wastewater in the emergency regulating tank into the front end in a certain proportion for re-treatment.

2. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, The water quality parameters in step S2 include at least one or more of pH value, chemical oxygen demand, suspended solids concentration, and characteristic heavy metal ion concentration; the equipment operating parameters include at least one or more of flow rate, liquid level, pressure, and temperature.

3. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, The safety threshold range in step S2 is a dynamically updated threshold range. The control system periodically optimizes and updates the safety threshold based on historical operating data and using machine learning algorithms.

4. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, In step S3, the abnormal fluctuation states that trigger the safety treatment mode include, but are not limited to: the sudden change in influent pH value exceeding 1.5 / min, the instantaneous peak value of COD concentration exceeding 30% of the design load, or the concentration of characteristic heavy metal ions exceeding the standard.

5. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, The dynamic dosing adjustment in step S32 is specifically based on a fuzzy control algorithm or a feedforward-feedback composite control algorithm. The required dosing compensation value is calculated according to the degree of deviation of the abnormal parameters, and the dosing pump is instructed to execute it.

6. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, The pretreatment unit includes at least a neutralization reaction tank and a coagulation sedimentation tank.

7. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, The advanced processing unit includes at least a membrane separation component or an advanced oxidation reactor.

8. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, In safe operation mode, the system also simultaneously sends audible and visual alarm messages and fault diagnosis prompts to the mobile terminals of the central control room and on-site maintenance personnel.

9. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, In step S4, the wastewater in the emergency regulating tank is pumped into the front end in a certain proportion. The proportion is dynamically calculated by the control system based on the current influent flow rate and water quality to avoid secondary impact on the conventional treatment process.

10. The safe treatment process for automated purification of industrial wastewater according to claim 1, characterized in that, The control system is a programmable logic controller or a distributed control system.

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