A separation system for a production process containing carbon black dust fumes

Abstract

The application relates to the technical field of carbon black production, in particular to a separation system for carbon black dust-containing flue gas in a production process, which comprises a flue gas air supply fan, an inlet of which is used for connecting with dust-containing flue gas; a primary cyclone separator, an inlet of which is communicated with an outlet of the flue gas air supply fan; a secondary cyclone separator, which is arranged at the side of the primary cyclone separator and is arranged in series with the primary cyclone separator, an inlet of which is communicated with a flue gas outlet of the primary cyclone separator; a main discharging pipe, which is installed at a carbon black outlet end of the primary cyclone separator, and an airtight valve is installed on the main discharging pipe; and a secondary discharging pipe, which is installed at a carbon black outlet end of the secondary cyclone separator. The primary and secondary cyclone separators with different diameters are arranged in series, gradient separation of coarse separation first and fine separation later is realized, the secondary separator is used for collecting fine dust carbon black in the flue gas after the primary separation by reducing the cylinder diameter to improve the centrifugal force, and therefore the overall separation efficiency is remarkably improved.

Description

Technical Field

[0001] This application relates to the field of carbon black production technology, and in particular to a separation system for carbon black dust-containing flue gas during the production process. Background Technology

[0002] In the carbon black production process, the separation of carbon black dust-containing flue gas is a crucial step. Existing separation processes mainly rely on pulse-jet bag filters. However, traditional bag filter technology has many drawbacks: First, because the flue gas usually contains corrosive gases and high-temperature particles, it easily leads to corrosion and ablation of the filter bags, resulting in a high breakage rate and huge maintenance costs; second, carbon black dust has high viscosity, which easily causes filter bag clogging or "bag jamming," leading to large fluctuations in system pressure drop and poor process stability; third, bag filters have limited capacity to handle high-concentration dust, and secondary dust is easily generated during the process.

[0003] Although cyclone separators, as traditional separation equipment, have advantages such as simple structure and high temperature resistance, single-stage cyclone separators have limited efficiency in capturing fine carbon black particles. Existing technologies also employ multi-stage cyclone separators, but these often suffer from problems such as difficulty in accurately balancing inter-stage pressure leading to unstable separation conditions, easy blockage of inter-stage feed pipes due to pressure or material characteristics, and high fan energy consumption to maintain system pressure differentials. These issues make it difficult to meet the requirements of modern carbon black production for high efficiency, stability, and low energy consumption. Summary of the Invention

[0004] This application provides a separation system for carbon black dust-containing flue gas in a production process, which solves the problems of high maintenance cost, easy clogging, low separation efficiency and unstable operation of existing carbon black dust-containing flue gas separation systems.

[0005] This application provides a separation system for carbon black dust-containing flue gas in a production process, comprising: The flue gas supply fan has its inlet for receiving dust-laden exhaust gas. A primary cyclone separator, the inlet of which is connected to the outlet of the flue gas blower; A secondary cyclone separator is located beside the primary cyclone separator and connected in series with it. Its inlet is connected to the gas outlet of the primary cyclone separator. The main feed pipe is installed at the solid outlet end of the first-stage cyclone separator, and an airtight valve is installed on the main feed pipe. The secondary feed pipe is installed at the solid outlet end of the secondary cyclone separator, and the lower end of the secondary feed pipe is inserted into the primary cyclone separator or the conveying pipeline.

[0006] Preferably, it also includes the carbon black conveying pipeline and the carbon black conveying fan. The carbon black conveying pipeline is connected to the lower end of the main feed pipe, and the carbon black conveying fan is connected to the carbon black conveying pipeline for conveying the collected carbon black to the next process. A dust removal flue gas duct is installed at the top of the secondary cyclone separator and connected to the gas outlet of the secondary cyclone separator for discharging purified flue gas. A flue gas conveying fan is also installed on the dust removal flue gas duct.

[0007] Preferably, both the carbon black conveying fan and the flue gas conveying fan are suction fans, wherein the carbon black conveying fan is used to create a negative pressure environment within the carbon black conveying pipeline.

[0008] Preferably, both the primary cyclone separator and the secondary cyclone separator are tangential inlet cyclone separators, and the cylinder diameter of the secondary cyclone separator is smaller than that of the primary cyclone separator.

[0009] Preferably, the airtight valve is a star-shaped discharge valve or a double-layer flap valve, whose rotation speed or opening and closing frequency is adjustable to match the solid discharge volume and maintain the negative pressure seal inside the separator. While continuously discharging carbon black particles, it blocks external air from entering the system and maintains the negative pressure environment inside the primary cyclone separator cylinder.

[0010] Preferably, the inner wall of the cylinder of the primary cyclone separator and / or the secondary cyclone separator is provided with a wear-resistant and corrosion-resistant inner lining, and the cylinder is provided with guide vanes to extend the airflow rotation path and improve the separation efficiency. The inner lining is made of ceramic material or wear-resistant alloy.

[0011] Preferably, the flue gas conveying fan is connected to a frequency converter, which can be used to dynamically adjust the frequency of the flue gas conveying fan to control the pressure in the dust removal flue gas duct.

[0012] Preferably, the system is also equipped with a differential pressure sensor, which is located between the primary cyclone separator cylinder and the secondary cyclone separator cylinder and is interlocked with the flue gas conveying fan.

[0013] Preferably, the main feed pipe is inclined or vertical, and the secondary feed pipe is coaxial with or parallel to the main feed pipe.

[0014] Preferably, the conical portion of the primary cyclone separator and / or the secondary cyclone separator is equipped with a heat preservation device and / or a vibrator to prevent carbon black from adhering to the separator wall.

[0015] The beneficial effects of this application are as follows: The separation system for carbon black dust-containing flue gas in the production process described in this application achieves gradient separation by setting up two-stage cyclone separators with different diameters in series: a primary stage and a secondary stage. The secondary cyclone separator increases centrifugal force by reducing the diameter of the cylinder, specifically capturing the fine carbon black dust after the primary stage separation, thereby significantly improving the overall separation efficiency. This system ensures efficient and stable carbon black dust separation while reducing maintenance costs and preventing blockages. In addition, the system effectively solves the problems of interstage pressure imbalance and material blockage by using airtight valves, dual conveyor fans, and differential pressure closed-loop control, ensuring the continuity and stability of system operation.

[0016] Furthermore, by adopting dual-fan coordinated control, the carbon black conveying fan provides negative pressure suction to the feed pipe, which can effectively prevent carbon black from accumulating and clogging at the airtight valve; the flue gas conveying fan, in conjunction with the frequency converter and differential pressure sensor, dynamically adjusts the system pressure drop to ensure that the separation process is always in the best working condition. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0018] Figure 1 A schematic diagram of the overall structure of the separation system for carbon black dust-containing flue gas in the carbon black production process provided in this application; Figure 2 This is a schematic diagram of the overall structure of another embodiment of the dust-containing flue gas separation system provided in this application during the carbon black production process.

[0019] Figure label: 1. Flue gas supply fan; 2. Primary dust-laden flue gas duct; 3. Primary cyclone separator; 4. Airtight valve; 5. Main feed pipe; 6. Carbon black conveying duct; 7. Carbon black conveying fan; 8. Secondary dust-laden flue gas duct; 9. Secondary cyclone separator; 10. Secondary feed pipe; 11. Dust-removing flue gas duct; 12. Flue gas conveying fan. Detailed Implementation

[0020] The technical solutions of this application will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0021] The following is combined Figure 1-2 This application describes a separation system for carbon black dust-containing flue gas in a production process, as provided in an embodiment of the present application.

[0022] Reference Figure 1 As shown in the embodiment of this application, the separation system for dust-laden flue gas in the carbon black production process mainly includes a flue gas supply fan 1, a primary cyclone separator 3, a secondary cyclone separator 9, a main feed pipe 5, a secondary feed pipe 10, a carbon black conveying pipeline 6, a carbon black conveying fan 7, and a flue gas conveying fan 12.

[0023] The inlet of the flue gas supply fan 1 is used to receive dust-laden flue gas from the carbon black production section, and its outlet is connected to the tangential inlet of the primary cyclone separator 3 via the primary dust-laden flue gas pipeline 2. The dust-laden flue gas is first drawn in by the flue gas supply fan 1, and then, driven by the fan, enters the primary cyclone separator 3 at high speed tangentially. The primary cyclone separator 3 is made of high-temperature and corrosion-resistant alloy steel, such as 304 stainless steel, or lined with a ceramic layer. Its internal structure is optimized, featuring larger cylindrical and conical sections to extend the airflow rotation path and improve separation efficiency. Inside the primary cyclone separator 3, the airflow rotation generates centrifugal force, throwing most of the coarse dust and carbon black in the flue gas towards the separator wall and causing it to settle.

[0024] The solid outlet end of the first-stage cyclone separator 3 is equipped with a main discharge pipe 5, and an airtight valve 4 is provided on the main discharge pipe 5. The airtight valve 4 is preferably a star-shaped discharge valve or a double-layer flap valve. Its rotation speed or opening and closing frequency is adjustable so as to block the entry of external air while continuously discharging carbon black and maintain the negative pressure sealing environment inside the separator.

[0025] The dust-laden flue gas, after primary separation, enters the secondary cyclone separator 9 for secondary purification. The secondary cyclone separator 9 is connected in series with the primary cyclone separator 3. Specifically, the gas outlet of the primary cyclone separator 3 is connected to the tangential inlet of the secondary cyclone separator 9 via the secondary dust-laden flue gas duct 8. Notably, the diameter of the secondary cyclone separator 9 is designed to be smaller than that of the primary cyclone separator 3.

[0026] Specifically, after primary separation, the concentration of carbon black dust in the flue gas decreases, and the dust aggregates become smaller, requiring higher centrifugal force to capture these fine carbon black dust particles. With a constant airflow rate, a smaller cylinder diameter increases the rotational speed of the airflow per unit time, increasing the linear velocity of the airflow rotation, thereby significantly increasing the centrifugal force on the fine carbon black dust. This adapts to the reduced carbon black dust concentration and fine carbon black dust in the flue gas after primary separation, ensuring efficient capture of the fine carbon black dust. Specifically, by employing a primary cyclone separator 3, powered directly by the flue gas blower 1, to handle the high-load conditions of high-concentration, coarse carbon black dust, the operating load of the secondary cyclone separator 9 is reduced, making the division of labor between the two stages more rational.

[0027] By setting up two-stage cyclone separators 3 and 9 with different diameters in series, a gradient separation is achieved, first coarsely separating and then finely separating. The secondary cyclone separator 9, by reducing its cylinder diameter to increase centrifugal force, specifically captures the fine dust and carbon black particles separated in the primary stage, thus significantly improving the overall separation efficiency. The primary cyclone separator 3 first handles the separation of high-concentration coarse dust and carbon black, and then the secondary cyclone separator 9, with its reduced cylinder diameter, increases centrifugal force to specifically capture the fine dust and carbon black, achieving gradient separation and further improving overall separation efficiency. Furthermore, the system effectively solves the problems of inter-stage pressure imbalance and material blockage through airtight valve 4, dual conveyor fan linkage, and differential pressure closed-loop control, ensuring the continuity and stability of system operation.

[0028] A secondary feed pipe 10 is installed at the bottom solid outlet end of the secondary cyclone separator 9. In this embodiment, the secondary feed pipe 10 is arranged side by side with the main feed pipe 5, and its end is inserted directly into the carbon black conveying pipe 6 located below it. An airtight valve 4 is also provided on the secondary feed pipe 10 to maintain the negative pressure sealing environment inside the secondary cyclone separator 9.

[0029] As another implementation of the embodiments of this application, such as Figure 2 As shown, the secondary cyclone separator 9 can also be positioned above the primary cyclone separator, and the lower end of the secondary feed pipe 10 can be inserted into the cylinder of the primary cyclone separator 3. Specifically, the lower end of the secondary feed pipe 10 is inserted into the lower part of the cone of the primary cyclone separator 3, and its outlet is located in the powder collection chamber located above the airtight valve 4. The fine carbon black dust collected by the secondary cyclone separator 9 flows into the powder collection chamber through the secondary feed pipe 10, mixes with the coarse carbon black dust, and is discharged together through the main feed pipe 5; at this time, the airtight valve 4 may not be installed in the secondary feed pipe 10.

[0030] In some specific embodiments, the carbon black conveying pipe 6 is connected to the lower end of the main discharge pipe 5, and the carbon black conveying fan 7 is connected to the carbon black conveying pipe 6. Its outlet is used to send the collected carbon black to the next process, such as a storage silo or packaging section. The carbon black conveying fan 7 is a suction fan, which, while conveying the collected carbon black to the next process, can also create a negative pressure environment within the carbon black conveying pipe 6 and the main discharge pipe 5 or secondary discharge pipe 10, providing a certain negative pressure suction at the outlet of the main discharge pipe 5 or secondary discharge pipe 10. This negative pressure is transmitted through the main discharge pipe 5 or secondary discharge pipe 10 to the area below the corresponding airtight valve 4, helping to smoothly draw the carbon black dust discharged from the airtight valve into the carbon black conveying pipe 6, preventing carbon black from accumulating at the airtight valve 4 and ensuring smooth discharge.

[0031] The top of the secondary cyclone separator 9 cylinder is equipped with a dust removal flue gas duct 11, on which a flue gas conveying fan 12 is installed to discharge the purified gas. The flue gas conveying fan 12 is also a suction fan, and a frequency converter is connected to it. Specifically, its function is twofold: firstly, to provide a stable negative pressure outlet for the secondary cyclone separator 9, assisting in the smooth discharge of flue gas; secondly, by dynamically adjusting its frequency through the frequency converter, the pressure within the dust removal flue gas duct 11 can be controlled, thereby balancing the pressure drop between the primary cyclone separator 3 and the secondary cyclone separator 9, preventing a decrease in secondary separation efficiency due to excessive pressure drop.

[0032] Since the efficiency of a cyclone separator is closely related to its internal pressure distribution, a differential pressure sensor can be installed in the system to further enhance its intelligence. The differential pressure sensor is located between the primary cyclone separator 3 and the secondary cyclone separator 9, and is connected to the frequency converter of the flue gas conveying fan 12. During system operation, the differential pressure sensor monitors the pressure difference between the gas outlet of the primary cyclone separator 3 and the gas inlet of the secondary cyclone separator 9 (or between their cylinders) in real time. When the detected differential pressure is lower than the set range, it indicates insufficient pressure at the inlet of the secondary separator, and the airflow velocity may decrease. At this time, the frequency converter increases the frequency of the flue gas conveying fan 12 to enhance the suction force, thereby improving the airflow velocity and separation efficiency within the secondary separator. Conversely, when the differential pressure is too high, the frequency is reduced to prevent excessive energy consumption and maintain system stability. Through this closed-loop control, the two separators always work collaboratively under optimized differential pressure conditions, achieving automatic closed-loop adjustment of the system pressure, making the system pressure drop distribution more reasonable and uniform, and ensuring that the two separators always operate under optimal conditions.

[0033] Specifically, during system operation, the pressure difference between the two-stage separators is monitored in real time by a differential pressure sensor. When the pressure difference is too large, it indicates that the pressure drop after passing through the first-stage cyclone separator is too large, which may lead to insufficient airflow speed and reduced efficiency in the second-stage cyclone separator 9. At this time, the frequency of the flue gas conveying fan 12 can be dynamically adjusted by the frequency converter to adjust the exhaust volume, thereby balancing the pressure drop between the first-stage cyclone separator 3 and the second-stage cyclone separator 9, increasing the airflow speed in the cylinder of the second-stage cyclone separator 9, and preventing the separation efficiency from decreasing due to excessive pressure drop.

[0034] Preferably, the operating power of both the carbon black conveying fan 7 and the flue gas conveying fan 12 is adjustable to adapt to different working conditions.

[0035] In some specific embodiments, to prevent carbon black from adhering to the inner wall of the separator, a heat preservation device (such as electric heat tracing) and / or a vibrator can be installed in the conical part of the primary cyclone separator 3 and / or the secondary cyclone separator 9. The heat preservation device prevents the collected carbon black particles from condensing and adhering to water vapor due to excessively low temperatures; the vibrator further accelerates the downward movement of carbon black dust, preventing it from adhering to the inner wall of the cyclone separator, or shakes away any potential adhesion, ensuring long-term stable operation of the system.

[0036] Furthermore, to further improve separation efficiency and address the unique properties of carbon black flue gas, guide vanes can be installed inside the cyclone separator cylinder to extend the airflow rotation path. The inner wall of the cylinder can be lined with a wear-resistant and corrosion-resistant layer, such as ceramic materials or wear-resistant alloys, to enhance equipment durability.

[0037] In some specific embodiments, the main discharge pipe 5 is arranged vertically or at an angle, and when the secondary discharge pipe 10 is inserted into the primary cyclone separator 3, it is preferably arranged coaxially with the main discharge pipe 5 to avoid airflow interference and ensure smooth discharge.

[0038] Specifically, the workflow of a dust-containing flue gas separation system in the carbon black production process provided in this application embodiment is as follows: Dust-laden flue gas enters the cylinder of the primary cyclone separator 3 under the action of flue gas fan 1, and coarse dust and carbon black are separated and fall into the main feed pipe 5 through the airtight valve 4. The flue gas after primary separation enters the cylinder of secondary cyclone separator 9, where fine dust and carbon black are captured for the second time and fed into main feed pipe 5 through secondary feed pipe 10. The carbon black conveying fan 7 creates negative pressure in the conveying pipe 6 to continuously extract carbon black dust from the main discharge pipe 5 or the secondary discharge pipe and convey it to the next process. The flue gas conveying fan 12 provides auxiliary suction in the dust removal flue gas duct 11, and at the same time adjusts the fan frequency according to the feedback of the differential pressure sensor to balance the pressure drop of the two-stage separator and ensure efficient separation. The purified flue gas is discharged in compliance with standards through the dust removal flue gas duct 11.

[0039] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0040] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0041] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between components; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0042] In this application, the terms "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., refer to a specific feature, structure, material, or characteristic described in connection with that embodiment or example, which is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0043] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A separation system for carbon black dust-containing flue gas in a production process, characterized in that, include: Flue gas supply fan (1), whose inlet is used to receive dust-laden exhaust gas; The inlet of the primary cyclone separator (3) is connected to the outlet of the flue gas blower (1); A secondary cyclone separator (9) is located beside the primary cyclone separator (3) and is connected in series with the primary cyclone separator (3). Its inlet is connected to the gas outlet of the primary cyclone separator (3). The main feed pipe (5) is installed at the solid outlet end of the first-stage cyclone separator (3), and an airtight valve (4) is installed on the main feed pipe (5). The secondary feed pipe (10) is installed at the solid outlet end of the secondary cyclone separator (9), and the lower end of the secondary feed pipe (10) is inserted into the primary cyclone separator (3) or the carbon black conveying pipe (6).

2. The separation system for carbon black dust-containing flue gas in the production process according to claim 1, characterized in that, It also includes the carbon black conveying pipe (6) and the carbon black conveying fan (7). The carbon black conveying pipe (6) is connected to the lower end of the main feed pipe (5), and the carbon black conveying fan (7) is connected to the carbon black conveying pipe (6) to send the collected carbon black to the next process. The dust removal flue gas duct (11) is located at the top of the secondary cyclone separator (9) and is connected to the gas outlet of the secondary cyclone separator (9) for discharging purified gas. The dust removal flue gas duct (11) is also equipped with a flue gas conveying fan (12).

3. The separation system for carbon black dust-containing flue gas in the production process according to claim 2, characterized in that, Both the carbon black conveying fan (7) and the flue gas conveying fan (12) are suction fans. The carbon black conveying fan (7) is used to create a negative pressure environment in the carbon black conveying pipeline (6).

4. The separation system for carbon black dust-containing flue gas in the production process according to claim 1, characterized in that, Both the primary cyclone separator (3) and the secondary cyclone separator (9) are cyclone separators with tangential inlets, and the cylinder diameter of the secondary cyclone separator (9) is smaller than that of the primary cyclone separator (3).

5. The separation system for carbon black dust-containing flue gas in the production process according to claim 1, characterized in that, The airtight valve (4) is a star-shaped unloading valve or a double-layer flap valve, and its rotation speed or opening and closing frequency is adjustable.

6. The separation system for carbon black dust-containing flue gas in the production process according to claim 4, characterized in that, The inner wall of the cylinder of the primary cyclone separator (3) and / or the secondary cyclone separator (9) is provided with a wear-resistant and corrosion-resistant inner lining, and the cylinder is provided with guide vanes. The inner lining is made of ceramic material or wear-resistant alloy.

7. The separation system for carbon black dust-containing flue gas in the production process according to claim 3, characterized in that, The flue gas conveying fan (12) is connected to a frequency converter, which can be used to dynamically adjust the frequency of the flue gas conveying fan (12) to control the pressure in the dust removal flue gas duct (11).

8. The separation system for carbon black dust-containing flue gas in the production process according to claim 7, characterized in that, The system is also equipped with a differential pressure sensor, which is located between the cylinder of the first-stage cyclone separator (3) and the cylinder of the second-stage cyclone separator (9), and is interlocked with the flue gas conveying fan (12).

9. The separation system for carbon black dust-containing flue gas in the production process according to claim 2, characterized in that, The main feed pipe (5) is inclined or vertical, and the secondary feed pipe (10) is coaxial or parallel to the main feed pipe (5).

10. The separation system for carbon black dust-containing flue gas in the production process according to claim 1, characterized in that, The conical portion of the primary cyclone separator (3) and / or the secondary cyclone separator (9) is equipped with a heat preservation device and / or a vibrator to prevent carbon black from adhering to the wall of the separator.

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