High-efficiency and low-consumption deep vanadium removal ultrasonic processor

Abstract

The application discloses a high-efficiency and low-consumption deep vanadium removal ultrasonic processor and relates to the technical field of metal ion impurity removal. The processor comprises an ultrasonic generating unit, an energy conversion unit, a reaction unit, an online monitoring unit and an intelligent control unit. The intelligent control unit is integrated with an ultrasonic parameter self-adaptive optimization algorithm, and is connected with the ultrasonic generating unit and the online monitoring unit of the water quality. According to the real-time fluctuation of the water quality, the intelligent control unit can automatically match and optimize the ultrasonic operation parameters, and realize the effect of accurate 'on-demand energy supply', so that the core function of greatly reducing the unit energy consumption in the treatment process is realized under the premise that the vanadium concentration of the outlet water is stably lower than 1 ppm.

Description

Technical Field

[0001] This invention relates to the field of metal ion impurity removal technology, and more specifically, to a high-efficiency, low-consumption deep vanadium removal ultrasonic processor. Background Technology

[0002] Vanadium is an important metal widely used in steel, chemical, and aerospace industries. However, improper treatment of vanadium-containing wastewater and solutions can cause serious harm to the environment and human health. Countries around the world are increasingly stringent in their requirements for vanadium concentrations in wastewater discharge, often requiring treatment to below 1 ppm.

[0003] Ultrasonic technology, due to its unique cavitation effect, has been proven to significantly enhance the adsorption, precipitation, and reduction reactions of vanadium. However, existing ultrasonic treatment equipment suffers from the following prominent problems in practical applications: 1. Low energy efficiency: Traditional ultrasonic equipment generally has low electroacoustic conversion efficiency, with a large amount of electrical energy lost as heat, resulting in high processing costs. Studies have shown that the energy efficiency of conventional ultrasonic reactors is typically below 50%.

[0004] 2. Uneven distribution of cavitation field: Traditional single-frequency ultrasound is prone to forming standing waves in the reactor, creating dead zones and energy concentration zones, resulting in local overheating and poor treatment effect in other areas, thus reducing the overall energy utilization efficiency.

[0005] 3. Fixed parameters and poor adaptability: Existing equipment mostly adopts a fixed frequency and fixed power design, which cannot optimize ultrasonic parameters in real time according to the fluctuation of influent water quality, resulting in "over-treatment" or "under-treatment". The former wastes energy, while the latter affects the effluent from meeting the standards.

[0006] 4. Lack of intelligent control: Most equipment relies on manual experience to adjust parameters, making precise control and energy consumption optimization difficult. Researchers have proposed some improvement schemes to address these issues. South China University of Technology has disclosed a continuous reverberation ultrasonic field coupled with chemical method for drinking water safety treatment, which enhances the sterilization effect through reverberation ultrasonic fields. However, this device mainly targets the drinking water safety field and does not address the energy consumption optimization issue of heavy metal removal. Shaanxi Normal University has developed a hydraulic acoustic cavitation circulating reactor that utilizes the synergistic effect of hydraulic cavitation and ultrasonic cavitation; however, the equipment structure is complex, and there is still room for energy consumption optimization.

[0007] Therefore, developing an ultrasonic processor specifically designed for deep vanadium removal, with high energy efficiency and low operating costs, has significant practical implications and application value. Summary of the Invention

[0008] The purpose of this invention is to provide a high-efficiency and low-consumption deep vanadium removal ultrasonic processor. By optimizing energy conversion efficiency, enhancing cavitation field uniformity, achieving on-demand energy supply and intelligent control, it significantly reduces the unit energy consumption of the treatment process, while ensuring that the vanadium concentration in the effluent is consistently below 1 ppm.

[0009] The embodiments of the present invention are implemented as follows: A high-efficiency, low-power deep vanadium removal ultrasonic processor, comprising: An ultrasonic generator unit is used to generate ultrasonic electrical signals; The energy conversion unit, electrically connected to the ultrasonic generator unit, is used to convert ultrasonic electrical signals into mechanical vibrations; The reaction unit is used to contain the vanadium-containing solution to be processed and is acoustically coupled to the energy conversion unit. Online monitoring unit; used to acquire the influent water quality parameters of the vanadium-containing solution entering the reaction unit; The intelligent control unit is connected to both the ultrasonic generator unit and the online influent water quality monitoring unit. The intelligent control unit is configured to execute an adaptive optimization algorithm for ultrasonic parameters, which optimizes and controls the ultrasonic parameters output by the ultrasonic generator unit based on real-time influent water quality parameters.

[0010] Furthermore, in other preferred embodiments of the present invention, the adaptive optimization algorithm for ultrasonic parameters includes the following steps: S1. Based on the online monitoring unit for influent water quality, obtain real-time influent water quality parameters, including at least the influent vanadium concentration; S2. Call the preset energy consumption-removal rate optimization model, with the minimum energy consumption per unit of treatment as the optimization objective and the effluent water quality meeting the standard as the constraint, to calculate the current optimal combination of ultrasonic parameters. The combination of ultrasonic parameters includes at least ultrasonic power density and ultrasonic frequency. S3. Send the optimal combination of ultrasound parameters to the ultrasound generator unit for execution; S4. Obtain effluent water quality data, and adjust the parameters of the energy consumption-removal rate optimization model based on the deviation between the effluent water quality and the target value.

[0011] Furthermore, in other preferred embodiments of the present invention, the energy consumption-removal rate optimization model is a machine learning prediction model trained based on historical operating data, used to establish the mapping relationship between influent water quality parameters, ultrasonic operation parameters and predicted effluent water quality and predicted unit energy consumption.

[0012] Furthermore, in other preferred embodiments of the present invention, the water quality parameters include vanadium concentration, pH, and turbidity.

[0013] Furthermore, in other preferred embodiments of the present invention, the ultrasonic generating unit employs multi-level variable frequency power, including: a low-power standby mode with a power density of 100-200W / L, a medium-power enhancement mode with a power density of 200-400W / L, and a high-power deep processing mode with a power density of 400-600W / L.

[0014] Furthermore, in other preferred embodiments of the present invention, the energy conversion unit comprises an electromechanical coupling coefficient k. eff It is composed of a piezoelectric ceramic array with a strength of ≥0.7.

[0015] Furthermore, in other preferred embodiments of the present invention, the energy conversion unit is a sandwich piezoelectric transducer array, the transducer spacing is arranged in integer multiples of half wavelength, and an acoustic impedance matching layer is provided between the piezoelectric ceramic array and the wall of the reaction unit.

[0016] Furthermore, in other preferred embodiments of the present invention, the reaction unit is a corrosion-resistant cavity, the inner wall of which is provided with a turbulence-enhancing structure, and / or, the interior of which is provided with a standing wave suppressor.

[0017] Furthermore, in other preferred embodiments of the present invention, the turbulence enhancement structure is a spiral guide plate or a wave-shaped reflector fixed to the inner wall of the reaction unit; the standing wave suppressor is an angle-adjustable reflector or a random phase modulator.

[0018] Furthermore, in other preferred embodiments of the present invention, the reaction unit is a continuous tubular reactor or a multi-stage series tank reactor; when a tubular reactor is used, its length-to-diameter ratio is not less than 5:1, and multiple sets of ultrasonic transducers are alternately arranged along the flow direction.

[0019] The beneficial effects of the embodiments of the present invention are: This invention provides a high-efficiency, low-energy-consumption deep vanadium removal ultrasonic processor, comprising an ultrasonic generation unit, an energy conversion unit, a reaction unit, an online monitoring unit, and an intelligent control unit. By setting up an intelligent control unit integrating an ultrasonic parameter adaptive optimization algorithm and connecting it to the ultrasonic generation unit and the influent water quality online monitoring unit, the ultrasonic operating parameters are automatically matched and optimized according to real-time fluctuations in the influent water quality, achieving a precise "on-demand energy supply" effect. This ensures that the vanadium concentration in the effluent remains consistently below 1 ppm while significantly reducing the unit energy consumption of the treatment process. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of the present invention. Example

[0021] This embodiment provides a high-efficiency, low-power deep vanadium removal ultrasonic processor, which includes an ultrasonic generation unit, an energy conversion unit, a reaction unit, an online monitoring unit, and an intelligent control unit.

[0022] The ultrasonic generator unit is primarily used to generate ultrasonic electrical signals. It employs multi-level frequency conversion power regulation technology, with an output frequency covering 20-100kHz. It includes at least three power regulation modes: a low-power standby mode with a power density of 100-200W / L, a medium-power enhancement mode with a power density of 200-400W / L, and a high-power deep treatment mode with a power density of 400-600W / L. The modes can be automatically switched according to the influent water quality and treatment requirements. This multi-level power design avoids the "one-size-fits-all" operation of traditional equipment, using a low-power mode when the influent concentration is low or the treatment requirements are not high, significantly reducing energy consumption.

[0023] The energy conversion unit is electrically connected to the ultrasonic generator unit and is used to convert ultrasonic electrical signals into mechanical vibrations. The energy conversion unit consists of an electromechanical coupling coefficient k. eff Composed of a piezoelectric ceramic array with a strength of ≥0.7, it can efficiently convert electrical energy into mechanical energy.

[0024] Furthermore, the energy conversion unit is a sandwich-type piezoelectric transducer array, with the transducers spaced in integer multiples of half the wavelength to form a coherently reinforced ultrasonic field. An impedance matching layer connects the transducers to the reactor wall. The acoustic impedance of this layer lies between the transducer's acoustic impedance and the liquid's acoustic impedance, effectively reducing sound wave reflection losses at the interface and improving energy transfer efficiency. Calculations show that using an impedance matching layer can improve energy transfer efficiency by more than 30%.

[0025] The reaction unit is used to contain the vanadium-containing solution to be treated and is acoustically coupled to the energy conversion unit. The reaction unit is a closed or open corrosion-resistant reaction chamber, with a turbulence-enhancing structure on its inner wall and / or a standing wave suppressor inside.

[0026] Furthermore, the turbulence-enhancing structure is a spiral guide plate or a corrugated reflector plate fixed to the inner wall of the reaction unit. This structure guides the liquid to form a complex, spiraling flow path within the reaction unit. This breaks the simple plug flow or laminar flow state, significantly extending the effective residence time of the fluid in the reactor, allowing vanadium ions to have more sufficient contact opportunities with reagents and ultrasonic cavitation bubbles. It also reflects and scatters ultrasonic waves, helping to diffuse sound wave energy that might otherwise propagate in a straight line to a wider area, thereby indirectly enhancing the uniformity of the sound field across the reactor cross-section.

[0027] Standing wave suppressors are adjustable reflectors or random phase modulators. Under the action of fixed-frequency ultrasound, stable standing waves easily form inside the reactor, causing the sound pressure energy to be highly concentrated at the antinodes (reverse nodes), resulting in local overheating, while the energy is very weak at the nodes, forming "processing dead zones." Standing wave suppressors effectively disrupt the formation of steady-state standing waves by dynamically or randomly changing the reflection phase and direction of the sound waves.

[0028] Furthermore, the reaction unit is either a continuous tubular reactor or a multi-stage series tank reactor; both reactor types support continuous feeding and discharging, making them suitable for industrial continuous production and solving the problems of low efficiency and instability in batch processing. Optionally, when using a tubular reactor, its length-to-diameter ratio is not less than 5:1, and multiple sets of ultrasonic transducers are alternately arranged along the flow direction. A larger length-to-diameter ratio means that the fluid has a sufficiently long flow path and residence time in the reactor, ensuring that the vanadium-containing solution can be subjected to sufficient and continuous ultrasonic action. Alternating the transducers along the flow direction ensures that ultrasonic energy is injected uniformly along the entire length of the tube, avoiding the "strong start and weak finish" phenomenon where there is strong ultrasound only at the inlet or in a localized area, while the energy at the outlet is insufficient, thus ensuring the consistency of the treatment effect throughout the entire process.

[0029] The online monitoring unit is used to acquire the influent water quality parameters of the vanadium-containing solution entering the reaction unit. These parameters include vanadium concentration, pH, and turbidity. Vanadium concentration can be detected using a vanadium ion selective electrode, an electrochemical sensor that specifically responds to the activity of vanadium ions in the solution and converts it into an electrical signal. pH and turbidity are monitored using a pH meter and a turbidity meter, respectively.

[0030] The intelligent control unit is connected to both the ultrasonic generator unit and the online influent water quality monitoring unit. The intelligent control unit is configured to execute an adaptive optimization algorithm for ultrasonic parameters, which optimizes and controls the ultrasonic parameters output by the ultrasonic generator unit based on real-time influent water quality parameters.

[0031] Furthermore, in other preferred embodiments of the present invention, the ultrasonic parameter adaptive optimization algorithm is a hybrid intelligent control system based on model predictive control and data-driven decision-making. Its core consists of an offline-trained initial prediction model (energy consumption-removal rate optimization model) and an online-running feedback optimizer.

[0032] It includes the following steps: S1. Based on the online influent water quality monitoring unit, obtain real-time influent water quality parameters, including at least the influent vanadium concentration.

[0033] S2. Call the preset energy consumption-removal rate optimization model, with the minimum energy consumption per unit of treatment as the optimization objective and the effluent water quality meeting the standard as the constraint, to calculate the current optimal combination of ultrasonic parameters. The combination of ultrasonic parameters includes at least ultrasonic power density and ultrasonic frequency.

[0034] S3. Send the optimal combination of ultrasound parameters to the ultrasound generator unit for execution.

[0035] S4. Obtain effluent water quality data, and adjust the parameters of the energy consumption-removal rate optimization model based on the deviation between the effluent water quality and the target value.

[0036] Furthermore, the energy consumption-removal rate optimization model is a machine learning prediction model trained based on historical operating data. It is used to establish the mapping relationship between influent water quality parameters, ultrasonic operation parameters, predicted effluent water quality, and predicted unit energy consumption. The model can employ gradient boosting decision trees or feedforward neural networks, using corresponding influent water quality parameters (influent vanadium concentration, influent pH, influent turbidity, feed flow rate, reaction temperature, etc.) and ultrasonic operation parameters (ultrasonic power density, ultrasonic frequency, main frequency, auxiliary frequency, main-auxiliary frequency power ratio, target reaction time, etc.) from historical operating data as input features. The objective function is constructed using effluent vanadium concentration and specific energy consumption (i.e., energy consumption to remove each gram of vanadium) as output targets. The core optimization objective of the objective function is set as minimizing specific energy consumption, while satisfying the following constraints: 1. Effluent vanadium concentration ≤ 1 ppm; 2. Safe operating range of the equipment (maximum power does not exceed the safety limit, maximum temperature does not exceed the temperature limit). Before training the model, the relevant data is cleaned, outliers are removed, and features are standardized or normalized to eliminate the influence of dimensions and accelerate model convergence.

[0037] Application Example 1 This application example uses the deep vanadium removal ultrasonic processor provided in Example 1 to treat wastewater from a vanadium smelter.

[0038] The water quality parameters are as follows: Vanadium concentration: 35 ppm, pH: 6.8, daily processing capacity: 100 m³ 3 .

[0039] The operating parameters are: Feed flow rate: 5m 3 / h, with a stay time of approximately 60min; pH adjustment: Add dilute sulfuric acid to adjust the pH to 4.0; Vanadium removal agent: ferrous sulfate, dosage 0.5 g / L; The intelligent control unit of the deep vanadium removal ultrasonic processor automatically matches the ultrasonic parameters according to the influent water quality: The incoming water quality was stable on the day of the test. The medium-power enhancement mode was adopted with a power density of 300W / L, a main frequency of 28kHz, an auxiliary frequency of 70kHz, and a main-auxiliary frequency power ratio of 70%:30%. The temperature was controlled at 45℃.

[0040] After 30 days of continuous operation using this deep vanadium removal ultrasonic processor, the effluent, analyzed by ICP-MS, showed an average vanadium concentration of 0.65 ppm, consistently below 1 ppm. The unit energy consumption was 0.85 kWh / m³. 3 .

[0041] In contrast, replacing the aforementioned deep vanadium removal ultrasonic processor with a traditional single-frequency ultrasonic device (fixed frequency 28kHz, no intelligent control, no impedance matching) resulted in a vanadium concentration of 2.3 ppm in the effluent at the same power density of 300 W / L, failing to meet the target of 1 ppm. Increasing the power density to 500 W / L reduced the vanadium concentration to 0.9 ppm, but increased the energy consumption per unit area to 4.2 kWh / m³. 3 .

[0042] Application Example 2 This application example uses the deep vanadium removal ultrasonic processor provided in Example 1 to treat wastewater from a vanadium-containing wastewater treatment plant.

[0043] The water quality parameters are as follows: The vanadium concentration fluctuates between 10 and 80 ppm.

[0044] The operating parameters are: Feed flow rate: 5m 3 / h, with a stay time of approximately 60min; pH adjustment: Add dilute sulfuric acid to adjust the pH to 4.0; Vanadium removal agent: ferrous sulfate, dosage 0.5 g / L; The preset target vanadium concentration in the effluent is ≤0.8ppm. The intelligent control unit of the deep vanadium removal ultrasonic processor automatically and dynamically matches the ultrasonic parameters according to the influent water quality. After 7 days of continuous operation, the monitored influent vanadium concentrations were 12ppm, 25ppm, 48ppm, 65ppm, 72ppm, 38ppm, and 22ppm, respectively. The ultrasonic parameters automatically matched by the intelligent control unit are shown in Table 1. Table 1. Ultrasonic parameters automatically matched by the intelligent control unit Influent concentration (ppm) Power mode Power density (W / L) Clock speed (kHz) Reaction time (min) Effluent concentration (ppm) Energy consumption per unit (kWh / m³) 12 Low power standby 150 25 40 0.4 0.42 25 Medium power efficiency 280 28 50 0.5 0.68 48 Medium power efficiency 320 28 55 0.6 0.79 65 High power depth 450 28 60 0.7 1.12 72 High power depth 480 28 60 0.8 1.25 38 Medium power efficiency 300 28 50 0.5 0.71 22 Medium power efficiency 260 28 45 0.5 0.58 As shown in Table 1, the effluent consistently met the standards throughout all time periods, with an average energy consumption of only 0.79 kWh / m³. 3 Compared to traditional fixed-parameter operation (which always uses high-power mode to cope with high concentrations), it reduces energy consumption by about 50%.

[0045] Experimental Example 1 This experimental example uses the deep vanadium removal ultrasonic processor provided in Example 1 to verify its standing wave suppression effect. The experiment employs a sound field distribution testing system to test the sound field distribution within the reaction unit with and without a standing wave suppressor. The test results are as follows: No standing wave suppressor: The sound pressure distribution is extremely uneven, with the ratio of the maximum sound pressure to the minimum sound pressure reaching 8.5:1, resulting in obvious processing dead zones.

[0046] With a standing wave suppressor: the uniformity of sound pressure distribution is significantly improved, the ratio of maximum sound pressure to minimum sound pressure is reduced to 2.1:1, and the dead zone is basically eliminated.

[0047] Results: The cavitation volume fraction increased from 45% to 85%, resulting in a significant improvement in energy utilization efficiency.

[0048] Experimental Example 2 This experimental example uses the deep vanadium removal ultrasonic processor provided in Example 1 to verify the effect of its impedance matching layer. The energy transfer efficiency with and without the impedance matching layer is compared in the experiment. The test results are as follows: No impedance matching layer: The transducer outputs 1000 W of acoustic power, and the actual acoustic power entering the liquid is about 520 W, with an energy transfer efficiency of 52%.

[0049] With an impedance matching layer: the transducer outputs 1000 W of acoustic power, and the actual acoustic power entering the liquid is about 820 W, with an energy transfer efficiency of 82%, which is 30 percentage points higher.

[0050] In summary, this invention provides a high-efficiency, low-energy-consumption deep vanadium removal ultrasonic processor, comprising an ultrasonic generation unit, an energy conversion unit, a reaction unit, an online monitoring unit, and an intelligent control unit. By incorporating an intelligent control unit with an integrated ultrasonic parameter adaptive optimization algorithm and connecting it to the ultrasonic generation unit and the influent water quality online monitoring unit, the ultrasonic operating parameters are automatically matched and optimized based on real-time fluctuations in the influent water quality, achieving precise "on-demand energy supply." This ensures that the vanadium concentration in the effluent remains consistently below 1 ppm while significantly reducing the unit energy consumption of the treatment process.

[0051] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A high-efficiency, low-power deep vanadium removal ultrasonic processor, characterized in that, include: An ultrasonic generator unit is used to generate ultrasonic electrical signals; An energy conversion unit, electrically connected to the ultrasonic generator unit, is used to convert ultrasonic electrical signals into mechanical vibrations; A reaction unit is used to contain the vanadium-containing solution to be processed and to be acoustically coupled to the energy conversion unit; Online monitoring unit; Used to obtain the influent water quality parameters of the vanadium-containing solution entering the reaction unit; The intelligent control unit is connected to both the ultrasonic generating unit and the online influent water quality monitoring unit. The intelligent control unit is configured to execute an adaptive optimization algorithm for ultrasonic parameters, which optimizes and controls the ultrasonic parameters output by the ultrasonic generating unit based on the real-time influent water quality parameters.

2. The deep vanadium removal ultrasonic processor according to claim 1, characterized in that, The adaptive optimization algorithm for ultrasound parameters includes the following steps: S1. Based on the online monitoring unit for influent water quality, obtain real-time influent water quality parameters, including at least the influent vanadium concentration; S2. Call the preset energy consumption-removal rate optimization model, with the minimum unit treatment energy consumption as the optimization objective and the effluent water quality meeting the standard as the constraint, to calculate the current optimal combination of ultrasonic parameters. The combination of ultrasonic parameters includes at least ultrasonic power density and ultrasonic frequency. S3. The optimal combination of ultrasound parameters is sent to the ultrasound generating unit for execution; S4. Obtain effluent water quality data, and adjust the parameters of the energy consumption-removal rate optimization model based on the deviation between the effluent water quality and the target value.

3. The deep vanadium removal ultrasonic processor according to claim 2, characterized in that, The energy consumption-removal rate optimization model is a machine learning prediction model trained based on historical operating data. It is used to establish the mapping relationship between influent water quality parameters, ultrasonic operation parameters, predicted effluent water quality, and predicted unit energy consumption.

4. The deep vanadium removal ultrasonic processor according to claim 3, characterized in that, The water quality parameters include vanadium concentration, pH, and turbidity.

5. The deep vanadium removal ultrasonic processor according to claim 4, characterized in that, The ultrasonic generating unit adopts multi-level variable frequency power, including: a low-power standby mode with a power density of 100-200W / L, a medium-power enhancement mode with a power density of 200-400W / L, and a high-power deep processing mode with a power density of 400-600W / L.

6. The deep vanadium removal ultrasonic processor according to claim 5, characterized in that, The energy conversion unit has an electromechanical coupling coefficient k. eff It is composed of a piezoelectric ceramic array with a strength of ≥0.

7.

7. The deep vanadium removal ultrasonic processor according to claim 6, characterized in that, The energy conversion unit is a sandwich piezoelectric transducer array, with the transducer spacing arranged in integer multiples of half the wavelength, and an acoustic impedance matching layer is provided between the piezoelectric ceramic array and the wall of the reaction unit.

8. The deep vanadium removal ultrasonic processor according to claim 7, characterized in that, The reaction unit is a corrosion-resistant cavity, with a turbulence-enhancing structure on its inner wall and / or a standing wave suppressor inside.

9. The deep vanadium removal ultrasonic processor according to claim 8, characterized in that, The turbulence enhancement structure is a spiral guide plate or a wave-shaped reflector plate fixed to the inner wall of the reaction unit; the standing wave suppressor is an angle-adjustable reflector plate or a random phase modulator.

10. The deep vanadium removal ultrasonic processor according to claim 9, characterized in that, The reaction unit is a continuous tubular reactor or a multi-stage series tank reactor; when a tubular reactor is used, its length-to-diameter ratio is not less than 5:1, and multiple sets of ultrasonic transducers are alternately arranged along the flow direction.