Method for monitoring a fluidized bed reactor and fluidized bed

Abstract

The application discloses a kind of fluidized bed reactor monitoring method, comprising the following steps: S1, a window is arranged on the top of reactor body;S2, an infrared camera is fixed on the window;S3, the fluidization state of particles in the reactor body is monitored by the infrared camera in real time, image data is generated and sent to the controller, and the working state of the stirring air inlet mechanism at the bottom of the reactor body is adjusted according to the received image data.The fluidized bed reactor of the application can accurately monitor the fluidization state of the internal particles, and provide a reference for temperature regulation and gas flow control during the reaction process, thereby improving the stability of the product and better meeting the needs of the material for the battery end.

Description

Technical Field

[0001] This invention belongs to the field of silicon carbide material equipment technology, specifically relating to a monitoring method for a fluidized bed reactor and a fluidized bed. Background Technology

[0002] Silicon-carbon CVD (chemical vapor deposition) fluidized bed deposition is a type of fluidized bed. As a multiphase flow reactor, it exhibits complex hydrodynamic behavior, posing significant challenges to the detection of relevant fluidized bed parameters, such as particle size distribution, fluidizing gas velocity, and fluidization morphology. Effective detection of certain parameters and states within the fluidized bed plays a crucial role in the stable operation of the system; failure to detect them in a timely manner may lead to malfunctions and affect normal production. Agglomeration and agglomeration within the reactor is one of the main problems encountered during fluidized bed CVD deposition.

[0003] Silicon-carbon CVD deposition uses porous carbon powder as the substrate, with a particle size of 5-10 μm. These particles are affected by intermolecular forces and electrostatic fields. Because the reaction environment inside a fluidized bed reactor is relatively dry, collisions and friction between particles and the reactor wall, as well as between particles themselves, create an electrostatic field. When excessive static electricity accumulates, small particles agglomerate and adsorb onto the reactor wall. Furthermore, intermolecular forces cause these particles to agglomerate further, forming larger clumps. Finally, due to gravity, these clumps fall onto the distribution plate, disrupting the normal fluidization state within the fluidized bed reactor and necessitating equipment shutdown. In severe cases, this can lead to safety accidents.

[0004] To monitor the fluidization state of porous carbon powder, a cold-state model is typically used to observe the particle fluidization state. However, this method differs significantly from the fluidization state during hot deposition and cannot fully reflect the actual fluidization state. Currently, in silicon-carbon CVD fluidized bed deposition production, process parameters such as temperature and process gas flow rate need to be adjusted during the reaction. Without accurately capturing the internal particle fluidization state, inconsistencies in the stability of different batches of products may arise, potentially failing to meet the material requirements of battery cells.

[0005] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to provide a monitoring method for fluidized bed reactors, which improves the ability to obtain the fluidization state of particles within the reactor.

[0007] To achieve the above objectives, a specific embodiment of the present invention provides a monitoring method for a fluidized bed reactor, comprising the following steps:

[0008] S1. A viewing window is installed at the top of the reactor body;

[0009] S2. Fix an infrared camera on the viewing window;

[0010] S3. An infrared camera monitors the fluidization state of particles inside the reactor body in real time, generates and sends image data to the controller, and the controller adjusts the working state of the stirring and air intake mechanism at the bottom of the reactor body according to the received image data.

[0011] In one or more embodiments of the present invention, step S3 includes: the controller is set with a normal temperature range value; after the reaction enters the constant temperature stage, the camera monitors the temperature inside the reactor body through images, generates and sends corresponding image data to the controller; when the received internal temperature of the reactor body is higher or lower than the normal temperature range value, the controller adjusts the heating power of the external heating furnace of the reactor body to lower or higher.

[0012] In one or more embodiments of the present invention, step S3 includes: after the reaction is completed and the material is discharged, the infrared camera monitors whether there are particles remaining on the inner wall of the reactor body. When particles are detected, the corresponding image is sent to the controller, and the controller issues a prompt through a buzzer.

[0013] In one or more embodiments of the present invention, step S3 includes: when the infrared camera detects the formation of particle agglomerates in the reactor body, it sends the corresponding image to the controller, and the controller controls the carrier gas flow rate and increases the stirring speed to gradually reduce the particle agglomerates until they disappear completely.

[0014] In one or more embodiments of the present invention, a temperature difference is generated between adjacent particles, the infrared camera captures the temperature difference generated between adjacent particles, and displays a blocky area with a significantly different color from the surrounding area as particle agglomeration on the generated image.

[0015] The present invention also provides a fluidized bed reactor, comprising a reactor body, a heating furnace, a stirring and air inlet mechanism, an infrared camera, and a controller. The reactor body includes a reaction zone and a cooling zone disposed above and communicating with the reaction zone. A viewing window is provided at the top of the reaction zone. The heating furnace is disposed outside the reaction zone and is used to heat the reaction zone. The stirring and air inlet mechanism is disposed at the bottom of the reaction zone and is used to supply carrier gas and process gas to the reaction zone and to stir it. The infrared camera is fixed to the viewing window and is used to monitor the fluidization state of particles in the reaction zone and the cooling zone. The controller is communicatively connected to the infrared camera, the heating furnace, and the stirring and air inlet mechanism.

[0016] In one or more embodiments of the present invention, a cooling tank with built-in cooling water is also connected between the infrared camera and the viewing window.

[0017] In one or more embodiments of the present invention, a pneumatic hammer is provided on the sidewall of the cooling zone for shaking off particles adhering to the inner wall of the cooling zone.

[0018] Compared with existing technologies, the fluidized bed reactor of the present invention can accurately monitor the fluidization state of internal particles and provide a reference for temperature regulation and gas flow control during the reaction process, thereby improving product stability and better meeting the material requirements of battery cells. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of a fluidized bed reactor according to one embodiment of the present invention;

[0021] Figure 2 This is a flowchart of a fluidized bed reactor monitoring method according to an embodiment of the present invention.

[0022] Explanation of key figure labels:

[0023] 100-Fluidized bed reactor, 10-Reactor body, 11-Reaction zone, 12-Cooling zone, 121-Viewing window, 20-Heating furnace, 30-Stirring and air inlet mechanism, 40-Infrared camera, 50-Cooling tank, 60-Air hammer. Detailed Implementation

[0024] To enable those skilled in the art to better understand the technical solutions in this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this disclosure.

[0025] like Figure 2 As shown, one embodiment of the present invention provides a monitoring method for a fluidized bed reactor. By acquiring the internal particle fluidization state, the equipment parameters are precisely adjusted to ensure that the particles are in a stable fluidized state and to improve the uniformity of material deposition. The monitoring method specifically includes the following steps:

[0026] S1. A viewing window is installed at the top of the reactor body.

[0027] Specifically, a viewing window is installed at the top of the reactor body, allowing direct observation of the reactor's interior. For example, a section at the top of the reactor body is cut, and a flange sight glass is fixed at the cut location to create a viewing area.

[0028] S2. Fix an infrared camera on the viewing window.

[0029] Specifically, an infrared camera is installed on the top of the reactor body, with its lens fixed to a viewing window (on the flange sight glass) to obtain information about the fluid inside the reactor body.

[0030] S3. An infrared camera monitors the fluidization state of particles inside the reactor body in real time, generates and sends image data to the controller, and the controller adjusts the working state of the stirring and air intake mechanism at the bottom of the reactor body according to the received image data.

[0031] Specifically, during the reaction process, an infrared camera monitors the fluidization state of the particles within the reactor body in real time, generating and sending image data to the fluidized bed reactor's controller. An external heating furnace heats the reactor body during deposition, and the continuous flow of particles creates temperature differences at different locations within the reactor body. The infrared camera captures these temperature differences and presents them as images. The fluidized bed reactor's controller receives the image data generated by the infrared camera, determines the internal particle flow state based on the images, and adjusts the operating status of the stirring and air intake mechanism at the bottom of the reactor body in real time, such as carrier gas flow rate and stirring speed, thereby ensuring that the particles are in a stable fluidized state and thus guaranteeing the uniformity of material deposition.

[0032] When particle agglomerates form, a temperature difference arises between them and adjacent particles due to their different volumes. An infrared camera can capture this temperature difference and display it in the generated image. The blocky areas with a distinctly different color from the surrounding area in the generated image are the formed particle agglomerates. When particle agglomerates are detected inside the reactor body, the controller gradually reduces the size of the particle agglomerates until they disappear completely by controlling the carrier gas flow rate and increasing the stirring speed.

[0033] Preferably, in addition to monitoring the fluidization state of the internal particles, the infrared camera is also used to monitor the uniformity of the internal temperature of the reactor body after the reaction enters the isothermal stage. The controller controls the internal temperature within the normal range by adjusting the power of the heating furnace.

[0034] Specifically, the controller is set with a normal temperature range. After entering the constant temperature stage, an infrared camera monitors and sends real-time temperature data of the reactor body to the controller. When the internal temperature is detected to be higher than the normal range, the controller reduces the heating power of the furnace to suppress overheating and overpressure. Simultaneously, it adjusts the gas partial pressure to prevent internal overheating due to exothermic reactions during deposition. Conversely, when the internal temperature is detected to be lower than the normal range, the controller increases the heating power of the furnace to restore the internal temperature of the reactor body to normal.

[0035] Furthermore, after each deposition reaction, the infrared camera also monitors whether the reactor body has been completely discharged. When material clumps are detected on the reactor wall or bottom in the generated image, the controller can prompt the operator to clean the reactor body in time through devices such as buzzers.

[0036] This invention also provides an improved fluidized bed reactor 100, which can at least effectively monitor the internal particle fluidization state to provide data reference for reactor decision-making and reaction process control. The fluidized bed reactor 100 includes a reactor body 10, a heater 20, a stirring and air-inlet mechanism 30, an infrared camera 40, and a controller (not shown). The reactor body 10 is two-sectioned, including a reaction zone 11 and a cooling zone 12, which are interconnected. The cooling zone 12 is located above the reaction zone 11, and a viewing window 121 is provided at the top of the cooling zone 12. The heater 20 surrounds the reaction zone 11 and is used to heat the reaction zone 11. The stirring and air-inlet mechanism 30 is located at the bottom of the reaction zone 11 and is used to input carrier gas and process gas into the reaction zone 11 and to perform stirring. The infrared camera 40 is fixed to the viewing window 121 and is used to monitor the particle fluidization state in the reaction zone 11 and the cooling zone 12, and to generate feedback signals. The controller is communicatively connected to the infrared camera 40, the heating furnace 20, and the stirring and air intake mechanism 30. It receives feedback signals from the infrared camera 40 and adjusts the heating power of the heating furnace 20 and the air intake and stirring rate of the stirring and air intake mechanism 30 to ensure overall safe operation and the stability of material deposition.

[0037] In one embodiment, the infrared camera 40 is an infrared camera used not only to monitor the fluidization state of internal particles but also to monitor for overheating and overpressure phenomena during the isothermal stage. Since the infrared camera 40 itself generally has limited high-temperature resistance, if directly connected to the viewing window 121, the heat generated by the reactor body 10 may affect the infrared camera 40, thus impacting the monitoring effect. Therefore, preferably, a cooling tank 50 is also connected between the infrared camera 40 and the viewing window 121. This cooling tank 50 contains cooling water to eliminate the impact of heat on the infrared camera 40, thereby improving detection accuracy.

[0038] Furthermore, to facilitate cleaning of the reactor body 10 after discharge, an air hammer 60 is installed on the side wall of the cooling zone 12 to shake off particles adhering to the inner wall of the cooling zone 12. It is conceivable that the air hammer 60 can also be installed on the side wall of the reaction zone 11.

[0039] It will be apparent to those skilled in the art that this disclosure is not limited to the details of the exemplary embodiments described above, and that this disclosure can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of this disclosure is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this disclosure. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0040] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A monitoring method for a fluidized bed reactor, characterized in that, Includes the following steps: S1. A viewing window is installed at the top of the reactor body; S2. Fix an infrared camera on the viewing window; S3. An infrared camera monitors the fluidization state of particles inside the reactor body in real time, generates and sends image data to the controller, and the controller adjusts the working state of the stirring and air intake mechanism at the bottom of the reactor body according to the received image data.

2. The monitoring method according to claim 1, characterized in that, Step S3 includes: the controller is set with a normal temperature range value; after the reaction enters the constant temperature stage, the camera monitors the temperature inside the reactor body through images, generates and sends corresponding image data to the controller; when the received internal temperature of the reactor body is higher or lower than the normal temperature range value, the controller adjusts the heating power of the external heating furnace of the reactor body to lower or higher.

3. The monitoring method according to claim 1, characterized in that, Step S3 includes: after the reaction is completed and the material is discharged, the infrared camera monitors whether there are particles remaining on the inner wall of the reactor body. When particles are detected, the corresponding image is sent to the controller, and the controller issues a prompt through a buzzer.

4. The monitoring method according to claim 1, characterized in that, Step S3 includes: when the infrared camera detects the formation of particle agglomerates in the reactor body, it sends the corresponding image to the controller, and the controller controls the carrier gas flow rate and increases the stirring speed to gradually reduce the particle agglomerates until they disappear completely.

5. The monitoring method according to claim 4, characterized in that, A temperature difference is generated between adjacent particles. The infrared camera captures the temperature difference between adjacent particles and displays a blocky area with a significantly different color from the surrounding area on the generated image, which is the particle agglomeration.

6. A fluidized bed reactor, characterized in that, include: The reactor body includes a reaction zone and a cooling zone disposed above and connected to the reaction zone, wherein a viewing window is provided at the top of the reaction zone; A heating furnace, which is located outside the reaction zone and is used to heat the reaction zone; A stirring and air intake mechanism is located at the bottom of the reaction zone. The stirring and air intake mechanism is used to supply carrier gas and process gas to the reaction zone and to stir them. An infrared camera, fixed to the viewing window, is used to monitor the fluidization state of particles in the reaction zone and cooling zone; The controller is communicatively connected to the infrared camera, the heating furnace, and the stirring and air intake mechanism.

7. The fluidized bed reactor according to claim 6, characterized in that, A cooling tank with built-in cooling water is also connected between the infrared camera and the viewing window.

8. The fluidized bed reactor according to claim 6, characterized in that, The sidewall of the cooling zone is equipped with an air hammer for shaking off particles adhering to the inner wall of the cooling zone.

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