A tar separator anti-blocking and mud scraping system and a control method thereof

Abstract

The present application provides a tar separator anti-blocking and mud scraping system and a control method thereof. The tar separator anti-blocking and mud scraping system comprises: a separator with an inner cavity; a mud scraping machine assembly; a state detection assembly comprising an angle detection unit for detecting the real-time rotation angle of the scraping arm frame relative to a preset reference position, and a load detection unit for detecting the operating load of the driving unit; a regional heat tracing assembly, which is sleeved on the outer wall of the bottom of the separator and is divided into multiple independent heating sectors in the circumferential direction; and a controller, which is configured to: construct a resistance mapping matrix based on the real-time rotation angle and the operating load, determine the corresponding target heating sector according to the current real-time rotation angle when it is determined that there is a blocking trend according to the operating load, and control the opening of the adjusting valve corresponding to the heating sector. The present application realizes the automatic identification, positioning and non-stop self-healing of local blocking during the tar mud scraping process.

Description

Technical Field

[0001] This invention relates to the technical field of coal chemical and coking wastewater treatment equipment, specifically to a primary tar separator anti-jamming scraping system and its control method. Background Technology

[0002] In the coal chemical and coking production process, the primary tar separator is a key piece of equipment for separating tar from ammonia water. Its working principle mainly relies on the density difference between tar and ammonia water. The heavy tar sludge is deposited at the bottom of the separator by gravity settling, and then the sludge scraper assembly scrapes the deposited tar sludge to the slag discharge cone for centralized discharge.

[0003] However, traditional primary tar separators and their sludge scraping systems are extremely passive in their response mechanisms when encountering localized high-viscosity tar residue obstruction during actual operation. Current technology typically only provides a shutdown alarm via the drive motor overload protection, followed by a cleaning operation. This approach is not only labor-intensive and creates a harsh working environment, but also necessitates a complete shutdown of the separator, severely disrupting continuous production and making it impossible to resolve issues without shutting down the system. Therefore, the equipment's operating efficiency and automation level urgently need improvement. Summary of the Invention

[0004] Based on the above background, the purpose of this invention is to provide a primary tar separator anti-jamming scraping system and its control method, so as to realize the automatic identification, positioning and self-healing of local jamming during the tar sludge scraping process without stopping the machine.

[0005] To achieve the above-mentioned objectives, the present invention provides the following technical solution: A primary tar separator anti-jamming and sludge scraping system includes: A separator having an internal cavity, the bottom of which is conical; A sludge scraper assembly includes a drive unit, a central spindle, and a scraper arm frame. The drive unit is located at the bottom of the separator. The bottom end of the central spindle is fixedly connected to the output end of the drive unit. The central spindle extends vertically upward, and its top end is located inside the separator. The scraper arm frame includes a horizontal support arm connected to the top end of the central spindle and an inclined scraper arm parallel to the inner wall of the bottom of the separator. The upper end of the inclined scraper arm is connected to the outer end of the horizontal support arm, and the lower end of the inclined scraper arm is connected to the lower part of the central spindle. A scraper is provided on the inclined scraper arm, and the scraper abuts against the inner wall of the bottom of the separator. The status detection component includes an angle detection unit for detecting the real-time rotation angle of the scraper frame relative to a preset reference position, and a load detection unit for detecting the operating load of the drive unit. A zoned heating component is fitted onto the bottom outer wall of the separator. The zoned heating component is divided into multiple independent heating zones along the circumferential direction. A heat-insulating and sealing baffle is provided between adjacent heating zones. Each heating zone is equipped with an independently controlled regulating valve and a temperature sensor. The controller is electrically connected to the status detection component, the zoned heat tracing component, and the drive unit, respectively. The controller is configured to: construct a resistance mapping matrix based on the real-time rotation angle and the operating load; when a jamming trend is determined based on the operating load, determine the corresponding target heating sector based on the current real-time rotation angle, and control the opening of the regulating valve corresponding to the heating sector.

[0006] Preferably, the separator has a slag discharge cone at the bottom, and the zoned heating assembly is fitted onto the outer wall of the slag discharge cone; the zoned heating assembly includes a heating shell, and an annular cavity is formed between the heating shell and the outer wall of the slag discharge cone; the heat-insulating sealing baffle is arranged radially in the annular cavity along the slag discharge cone and divides the annular cavity into multiple independent heating sectors.

[0007] Preferably, each of the heating sectors is provided with a steam inlet and a condensate drain outlet, and the regulating valve is located on the steam inlet pipeline connected to the steam inlet.

[0008] Preferably, the angle detection unit is an absolute encoder mounted on the output shaft of the drive unit, the load detection unit is a high-frequency current transmitter for detecting the current of the drive unit, and the temperature sensor is a patch-type temperature sensor.

[0009] A control method for an anti-jamming and sludge scraping system for a primary tar separator based on the above-mentioned method includes the following steps: S1. Under the normal forward rotation operation of the drive unit, the regulating valves corresponding to each heating sector are all in the closed state; the real-time rotation angle of the scraper frame relative to the preset reference position and the operating load of the drive unit are collected in real time, and a resistance mapping matrix between each angle range and the operating load is established. S2. Calculate the rate of change of the operating load. When the rate of change is greater than the preset dynamic threshold, it is determined that there is a jamming trend, and the corresponding target heating sector is determined according to the current real-time rotation angle. S3. Control the drive unit to stop rotating forward and open the regulating valve corresponding to the target heating sector, while keeping the regulating valves of the other heating sectors closed; S4. The real-time temperature of the target heating sector is obtained through the temperature sensor. After the real-time temperature reaches the preset softening critical temperature, the drive unit is controlled to perform alternating forward and reverse oscillation operation until the operating load of the drive unit during forward operation is less than the preset safety baseline. The safety baseline is the upper limit value of the operating load corresponding to the drive unit when it is in the normal forward operation state. S5. Close the regulating valve of the target heating sector and control the drive unit to resume forward operation.

[0010] Preferably, step S1 involves establishing a resistance mapping matrix between each angle range and the operating load, specifically including: A two-dimensional array or circular queue is constructed inside the controller to divide the 360-degree circumference into multiple angle intervals that correspond one-to-one with the heating sector, and the real-time collected operating load is updated to the angle interval to which the current real-time rotation angle belongs.

[0011] Preferably, step S3 further includes the following before opening the regulating valve corresponding to the target heating sector: The control drive unit reverses the preset angle.

[0012] Preferably, in step S4, controlling the drive unit to perform alternating forward and reverse oscillation operation specifically includes: The drive unit is controlled to reverse at a first frequency and then rotate forward at a second frequency to a second angle; wherein the first frequency is less than the normal operating frequency of the drive unit, and the first angle is less than the second angle; Repeat the above reverse and forward rotation actions.

[0013] Preferably, in step S4, during the period when the drive unit is oscillating between forward and reverse rotation, if it is detected that the operating load of the drive unit during reverse rotation is greater than a preset safety baseline, then the value of the softening critical temperature is increased or the heating time is extended.

[0014] Preferably, the control method further includes: Record and store historical load overload data for each heating sector. If the overload frequency of a certain heating sector within a preset historical time period is found to be greater than the set number, the regulating valve corresponding to that heating sector will be opened in advance when the corresponding time period is reached in subsequent operation.

[0015] Compared with the prior art, the present invention has the following advantages: This invention discloses an anti-jamming sludge scraping system for a primary tar separator. Through a core mechanism of spatial resistance grid mapping and directional thermal and mechanical coordinated intervention, it deeply integrates mechanical structure, sensor detection, thermal control, and intelligent algorithms to achieve automatic identification, location, and self-healing of local jamming during tar sludge scraping without shutting down the system. By setting up a status detection component, it collects the rotation angle of the scraper frame and the operating load of the drive unit in real time, providing a data basis for spatial resistance analysis and jamming trend determination. The regional heating component is divided into multiple independent heating sectors along the circumference, and with independent regulating valves and temperature sensors, it achieves targeted application of heating energy, eliminating thermal convection disturbances from heating the entire bottom of the tank and protecting the gravity settling environment. The controller constructs a resistance mapping matrix based on real-time rotation angle and operating load, associating the drive load with spatial position to identify the physical location of the jamming. It then only locally heats the target heating sector to reduce viscosity. Under normal conditions, all regulating valves remain closed to avoid energy waste and settling disturbances from continuous heating. The regulating valve of the target sector is only opened directionally when jamming occurs, while the other sectors remain closed, maximizing the stability of the internal settling environment. The present invention discloses a control method for an anti-jamming scraping system of a primary tar separator. The method determines the jamming trend by calculating the rate of change of operating load and locks the target heating sector by combining the real-time rotation angle. The method forms a movement of slight backward movement and large forward movement by alternating forward and reverse rotation. The low-frequency slight reverse rotation gradually destroys the slag block structure, and the large forward rotation ensures the net displacement forward, thereby achieving the coordinated extrication of mechanical crushing and thermal softening. Attached Figure Description

[0016] 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 embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of an anti-jamming and sludge scraping system for a primary tar separator according to the present invention; Figure 2 This is a schematic diagram of the architecture principle of a primary tar separator anti-jamming and sludge scraping system according to the present invention; Figure 3 This is a schematic diagram of the control method of the anti-jamming and sludge scraping system of the primary tar separator according to the present invention; In the diagram: 10. Separator; 11. Inner cavity; 12. Slag discharge cone; 13. Positioning bracket; 14. Sliding bearing; 20. Sludge scraper assembly; 21. Drive unit; 22. Central spindle; 23. Scraper arm frame; 231. Horizontal support arm; 232. Inclined scraper arm; 233. Scraper; 30. Status detection assembly; 31. Angle detection unit; 32. Load detection unit; 40. Zoned heating assembly; 41. Heating shell; 42. Annular chamber; 43. Insulated sealing baffle; 44. Heating sector; 45. Regulating valve; 46. Steam inlet pipe; 47. Drainage and exhaust port; 48. Temperature sensor; 50. Controller. Detailed Implementation

[0018] The technical solution of the present invention will be further described in detail below through specific embodiments and in conjunction with the accompanying drawings. It should be understood that the implementation of the present invention is not limited to the following embodiments, and any modifications and / or alterations made to the present invention will fall within the protection scope of the present invention.

[0019] In this invention, unless otherwise specified, all parts and percentages are by weight, and the equipment and raw materials used are commercially available or commonly used in the art. Unless otherwise specified, the methods in the following embodiments are conventional methods in the art. Unless otherwise specified, the components or equipment in the following embodiments are general standard parts or components known to those skilled in the art, and their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0020] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings. In this detailed description, numerous specific details are set forth to facilitate explanation and provide a thorough understanding of the embodiments of the present invention. However, one or more embodiments may be practiced by those skilled in the art without these specific details.

[0021] like Figure 1-3 As shown, an embodiment of the present invention discloses a primary tar separator anti-jamming scraping system and its control method. The primary tar separator anti-jamming scraping system includes a separator 10, a scraper assembly 20, a status detection assembly 30, a zoned heating assembly 40, and a controller 50.

[0022] The separator 10 has an inner cavity 11 for containing a mixture of tar and ammonia, with a conical bottom. Specifically, the bottom of the separator 10 is provided with a discharge cone 12 for collecting heavy tar sludge. The conical structure of the discharge cone 12 facilitates the convergence of deposited tar sludge towards the bottom center under gravity, making it easy to discharge. The sludge scraper assembly 20 is located in the bottom region of the separator 10 and includes a drive unit 21, a central spindle 22, and a scraper arm frame 23. The drive unit 21 is located at the very bottom of the separator 10, below the discharge cone 12. The drive unit 21 can be a combination of a geared motor and a transmission mechanism, with its output providing rotational driving force. The bottom end of the central spindle 22 is fixedly connected to the output end of the drive unit 21. The central spindle 22 extends vertically upward through the discharge cone 12 into the inner cavity 11 of the separator 10, with its top end located in the middle region of the inner cavity 11. The bottom inner wall of the separator 10 is also fixed with a positioning bracket 13. The top end of the central spindle 22 is hinged to the middle of the positioning bracket through a sliding bearing 14, thereby limiting the radial swing of the central spindle 22 when it rotates and ensuring the levelness of the scraper frame 23.

[0023] The scraper frame 23 adopts a truss-type rigid frame structure, including a horizontal support arm 231 fixedly connected to the top of the central main shaft 22, and an inclined scraper arm 232 arranged parallel to the inner wall of the conical bottom of the separator 10. The upper end of the inclined scraper arm 232 is fixedly connected to the outer end of the horizontal support arm 231, and the lower end of the inclined scraper arm 232 is fixedly connected to the lower part of the central main shaft 22, near the bottom of the slag discharge cone 12. The horizontal support arm 231, the inclined scraper arm 232, and the central main shaft 22 form a stable triangular force-bearing truss. This truss structure can effectively withstand the radial and axial forces during the sludge scraping process and evenly transmit the torque to the entire scraper frame 23. The inclined scraper arm 232 is provided with multiple scrapers 233. The edges of the scrapers 233 abut against the inner wall of the conical bottom of the separator 10, and are used to scrape the tar sludge on the inner wall to the slag discharge cone 12 during rotation. The contact pressure between the scraper 233 and the bottom inner wall of the separator 10 can be moderately adjusted by adjusting the installation angle of the scraper 233 or by using an elastic support structure to ensure the sludge scraping effect while avoiding excessive wear.

[0024] The status detection component 30 includes an angle detection unit 31 and a load detection unit 32. The angle detection unit 31 uses an absolute encoder mounted on the output shaft of the drive unit 21. This absolute encoder can detect the real-time rotation angle θ of the scraper frame 23 relative to a preset reference position on the separator 10 housing. This angle information is not lost after the system is powered off, and the current absolute position can be directly read upon power-up without the need for zeroing. The signal output terminal of the absolute encoder is electrically connected to the controller 50, transmitting the real-time rotation angle data to the controller 50 in digital signal form. The load detection unit 32 uses a high-frequency current transmitter. This high-frequency current transmitter characterizes the operating load by collecting the real-time current of the drive unit 21 motor. Since there is a definite correspondence between motor current and output torque, the mechanical resistance experienced by the scraper assembly 20 can be indirectly reflected by monitoring changes in the motor current in real time. The sampling frequency of the high-frequency current transmitter should be sufficient to capture rapid load changes, generally set to hundreds to thousands of times per second, to ensure timely response to sudden jamming.

[0025] A zoned heating assembly 40 is fitted onto the outer wall of the slag discharge cone 12. This assembly includes a heating shell 41, which forms an annular chamber 42 with the outer wall of the slag discharge cone 12. The heating shell 41 can be made of rolled and welded metal sheet, maintaining a uniform gap with the outer wall of the slag discharge cone 12. This gap constitutes the annular chamber 42 for steam flow. Multiple heat-insulating and sealing baffles 43 are arranged radially along the slag discharge cone 12 within the annular chamber 42. These baffles physically divide the annular chamber 42 into multiple independent heating sectors 44 in the circumferential direction. The heat-insulating and sealing baffles 43 can be made of high-temperature resistant heat-insulating material, forming a sealed fit with both the outer wall of the slag discharge cone 12 and the heating shell 41, effectively preventing steam cross-flow between adjacent heating sectors 44. In this embodiment, the heating sector 44 can be set to 4, with each sector corresponding to a central angle of 90 degrees. However, the present invention is not limited to this. Depending on the diameter of the separator 10 and the control precision requirements, it can also be set to 6, 8 or other appropriate numbers.

[0026] Each heating sector 44 is equipped with an independent steam inlet and a drain outlet 47. The steam inlet is connected to a steam inlet pipe 46, which is equipped with an independently controlled proportional-integral (PI) regulating valve 45. This PI regulating valve 45 can accurately adjust the valve opening according to the control signal output by the controller 50, thereby achieving stepless regulation and stable control of the steam flow. Each heating sector 44 is fitted with a patch temperature sensor 48 on its outer wall. The patch temperature sensor 48 is tightly attached to the outer surface of the heat tracing housing 41 and is used to provide feedback on the real-time temperature of the heating sector 44. This temperature can indirectly reflect the temperature status of the corresponding area on the inner wall of the slag discharge cone 12.

[0027] The controller 50 is electrically connected to the absolute encoder, high-frequency current transmitter, surface-mount temperature sensor 48, various proportional-integral control valves 45, and drive unit 21. The controller 50 has built-in data processing and linkage control algorithms. The controller 50 can be a programmable logic controller or an industrial control computer, and its hardware platform has sufficient computing speed and storage capacity to support the real-time construction, updating, and querying of the resistance mapping matrix, as well as the execution of multi-task parallel control algorithms.

[0028] The control method for the primary tar separator's anti-jamming and sludge scraping system constructs a mechanism of spatial resistance grid mapping and directional thermodynamic-assisted mechanical intervention, which specifically includes the following steps.

[0029] Under normal system operation, the drive unit 21 drives the scraper frame 23 to rotate forward at a set normal speed. At this time, the proportional-integral regulating valves 45 corresponding to each heating sector 44 are all closed, and no form of heating is applied to the separator 10. This design is based on the following technical considerations: Under normal operating conditions, the tar sludge still has a certain degree of fluidity, and the scraper 233 can smoothly complete the scraping operation. If the entire bottom of the tank is blindly heated, it will not only cause unnecessary consumption of steam energy, but also generate continuous heat convection, which will disrupt the gravity sedimentation separation process of tar and ammonia water, resulting in a decline in the quality of the effluent. Therefore, keeping the regulating valves 45 of the heating sector 44 normally closed can maintain a stable gravity sedimentation environment for the medium in the inner cavity 11 and reduce operating energy consumption.

[0030] During normal forward rotation, the controller 50 acquires the real-time rotation angle of the absolute encoder. And the operating load of the high-frequency current transmitter, i.e., the current value. The controller 50 internally employs a data structure in the form of a two-dimensional array or a circular queue, dividing the 360° circumference into N angular intervals corresponding one-to-one with the heating sectors 44. Angle interval indices are defined. satisfy: ; The controller 50 dynamically updates the real-time rotation angle based on the real-time collected operating load. Within the corresponding angle range, a resistance mapping matrix is ​​established. The matrix is A dimensional data structure, in which, The number of heating sectors 44, The number of historical sampling points retained within each angle interval. Matrix elements. Indicates the first Within the angular interval, the _th The runtime load value at each sampling time. This matrix is ​​updated using a sliding window weighted average algorithm; specifically, for the current sampling time... , No. Equivalent resistance value for each angle range The calculation formula is: ; in, The forgetting factor, with a value ranging from 0.7 to 0.95, is used to balance the weights of historical data and current data. This represents the current value acquired by the high-frequency current transmitter at the current moment. This weighted averaging algorithm effectively eliminates accidental fluctuations from single sampling, improving data reliability. Simultaneously, it assigns higher weights to recent data, making the matrix better reflect the current resistance distribution. As the scraper frame 23 continues to rotate, the resistance mapping matrix... It is constantly refreshed, dynamically reflecting the resistance distribution in the circumferential direction at the bottom of the separator 10.

[0031] The controller 50 calculates the rate of change of the operating load in real time, that is, the increment of the current value per unit time, denoted as... When the rate of change exceeds a preset dynamic threshold... This indicates that the resistance experienced by scraper 233 has increased sharply in a short period of time. Based on this, controller 50 determines that scraper 233 has encountered high-viscosity hard slag and is prone to jamming. Dynamic threshold The setting adopts a dynamic adjustment sliding mode variable structure control strategy, and its calculation formula is: ; in, The base threshold is determined based on the normal viscosity fluctuation range of the tar sludge and the response characteristics of the drive unit 21. To dynamically adjust the gain coefficient; Let be the sliding modal surface function, defined as ,in, For current deviation, , This is the reference current under normal operating conditions. This is the differential coefficient. This dynamic threshold adjustment mechanism can dynamically adjust the judgment sensitivity according to the current operating state of the system. It maintains high sensitivity for identifying jams when normal fluctuations are small, and appropriately relaxes the threshold when operating conditions fluctuate drastically to avoid false triggering, significantly improving the system's anti-interference capability and judgment accuracy.

[0032] Once a jamming tendency is detected, the controller 50 will adjust the current real-time rotation angle accordingly. Retrieve the resistance mapping matrix To lock the current angle interval index where the resistance anomaly is occurring. And determine the corresponding physical target heating sector 44. The accuracy of this spatial positioning depends on the granularity of the angle interval division. In this embodiment, when At that time, the positioning accuracy is 90°; when a finer division is used, such as... or At the same time, the positioning accuracy can be improved to 45° or 30°.

[0033] After identifying the target heating sector 44, the controller 50 first controls the drive unit 21 to stop rotating forward, and then performs a yielding and unloading action. Specifically, the controller 50 controls the drive unit 21 to reverse by a preset angle. The preset angle can generally be set to 5°-10°, allowing the scraper 233 to slightly disengage from the hard slag obstruction surface, releasing the mechanical stress between the scraper 233 and the hard slag. The significance of this yielding action is twofold: firstly, it prevents the scraper 233 from maintaining a rigid compression state with the hard slag during subsequent heating and softening, preventing the hard slag from being further compacted due to continuous force before softening, and even causing mechanical damage to the scraper 233 or the drive mechanism 21; secondly, it creates the necessary space conditions for the effective penetration of steam heat to the contact surface between the hard slag and the scraper 233, which is beneficial to improving the efficiency of subsequent thermal softening.

[0034] After the unloading is completed, the controller 50 performs directional heating. The controller 50 only opens the proportional-integral regulating valve 45 corresponding to the target heating sector 44 to introduce steam, while the regulating valves 45 of the other non-blocking sectors remain strictly closed. After the steam enters the annular chamber 42 of the target heating sector 44, it transfers heat to the tar residue at the blockage point through the local wall of the slag discharge cone 12 via thermal conduction, causing its temperature to rise, viscosity to decrease, and hardness to weaken. The advantages of this directional heating strategy are that energy input is highly concentrated, heating response is rapid, and large-area thermal disturbance caused by heating the entire bottom of the tank is avoided; at the same time, because only a local area is heated, heat loss to the surrounding medium is significantly reduced, improving energy utilization efficiency.

[0035] During the directional heating process, the controller 50 obtains the real-time temperature of the target heating sector 44 through the patch temperature sensor 48. And monitor whether the temperature reaches the preset critical temperature for tar softening. The softening critical temperature The softening critical temperature is determined based on the specific physical properties of the tar being processed. Generally, it can be determined experimentally by measuring the hardness or viscosity changes of tar residue at different temperatures, and selecting the critical temperature value with a significant softening effect as the control target. Typically, the preset softening critical temperature is limited to 70℃~90℃. This temperature range is chosen because the mud-like material at the bottom of the discharge cone is a thermoplastic amorphous mixture formed by the mutual binding of heavy coal tar, asphaltene, and free carbon. The melting and softening temperature range of this mixture is approximately 65℃~75℃. When the controller activates the local heating sector to raise the temperature to 70℃~90℃, the coal tar and asphaltene, acting as binders, rapidly melt and liquefy, resulting in a rapid decrease in viscosity. Furthermore, because the discharge cone is in a closed environment, strictly limiting the upper temperature to below 90℃ ensures sufficient liquefaction of the tar components and prevents the vaporization and boiling of trace amounts of moisture or light components in the medium due to local overheating. This eliminates the side effects of moisture loss leading to evaporation and drying of the mud residue and secondary hardening and coking. When the real-time temperature... Reaching the preset softening critical temperature Then, the controller 50 controls the drive unit 21 to perform alternating forward and reverse oscillation operation.

[0036] The specific control parameters for the oscillating operation are as follows: the controller 50 controls the drive unit 21 to operate at a first frequency. Reverse the first angle Then at the second frequency Second angle of forward rotation Among them, the first frequency Less than the frequency at which the drive unit 21 operates normally This forms a low-frequency reversal; first angle Less than the second angle This results in a displacement characteristic of slight backward movement and significant forward movement. The above reverse and forward rotation actions are repeated cyclically. In this embodiment, typical parameters are set as follows: , , , The specific values ​​can be optimized and adjusted according to the actual working conditions.

[0037] The significance of low-frequency micro-oscillation lies in the fact that the lower frequency reduces the impact load on the drive unit 21, protecting the motor and transmission mechanism; the smaller reverse angle ensures that the scraper 233 does not completely exit the jammed area, but instead performs local shearing and squeezing within the hard slag, gradually destroying its internal structure; the larger forward angle ensures that the net displacement is forward in each oscillation cycle, allowing the sludge scraping operation to continue advancing during the unblocking process and avoiding repeated idle spinning. During the oscillation process, the tar slag softened by heat gradually breaks and peels off under the repeated action of mechanical force, and is eventually carried away from the jammed area by the scraper 233.

[0038] This invention also incorporates a dynamic correction mechanism to handle special slag blocks with extremely high hardness that are difficult to soften. During oscillating operation, the controller 50 continuously monitors the operating load of the drive unit 21, collected by the high-frequency current transmitter. In particular, the controller 50 focuses on the operating load of the drive unit 21 during reverse operation. If the load is still greater than the preset safety baseline This indicates that even after reaching the softening critical temperature Despite heating, the slag still possesses extremely high hardness, resulting in immense resistance to retraction. The current softening level is insufficient for effective escape. At this point, the controller 50 executes a softening level correction algorithm, which includes two strategies: first, increasing the softening critical temperature setpoint, i.e. ,in The temperature increment step size is generally taken as... Secondly, extend the heating time, that is, extend the current heating time. Duration of heat preservation at temperature ,Right now ,in This is the time increment step. This dynamic correction process can be executed cyclically until the operating load during the reversal is completed. Reduced to a safe baseline Within a certain range, ensure that the system still has a high success rate of getting out of trouble when facing extreme working conditions.

[0039] When the drive unit 21 is in forward rotation, the operating load Continuously below the preset safety baseline At that time, this safety baseline Assuming the load is at its maximum under normal forward operation, controller 50 determines that the stuck slag has been softened by heat and crushed by mechanical vibration, thus releasing the obstruction. At this point, controller 50 performs a state reset operation, closing the proportional-integral regulating valve 45 of the target heating sector 44 and stopping steam supply; control drive unit 21 resumes normal forward operation, and the system continues to perform normal sludge scraping operations.

[0040] Furthermore, the controller 50 of this invention also incorporates a predictive heat preservation mechanism, which enables predictive maintenance of faults based on the accumulation and analysis of large amounts of operational data. The controller 50 continuously records and stores historical overload data for each heating sector 44, including the time, frequency, duration of the overload, and the operating parameters at that time. (Definition of the first...) 44 heating sectors during the time period The overload frequency count within is: ; in, This is an indicator function that takes the value 1 when the condition is true and 0 otherwise. This is the overload threshold. Through statistical analysis of this data, if it is found that the overload frequency of a certain heating sector 44 exceeds a set number within a preset historical time period... ,Right now Thus, the controller 50 forms a dual memory of space and time. Before the corresponding time period is reached in subsequent operation, the controller 50 slightly opens the proportional-integral regulating valve 45 corresponding to the heating sector 44 for local preheating. The preheating opening is generally set to a fraction of the normal heating opening. The preheating duration is calculated based on the ambient temperature and target temperature rise, ensuring that the tar residue in the area is in a relatively fluid state before the peak period of jamming arrives, thus nipping the potential for jamming in the bud. This predictive insulation mechanism transforms the traditional passive response into proactive prevention, significantly reducing the probability of sudden jamming, extending the continuous trouble-free operation time of the equipment, and further improving the system's intelligence level and operational economy.

[0041] This invention, through the aforementioned spatial resistance grid mapping and directional thermal and mechanical coordinated intervention control mechanism, deeply integrates the mechanical operation of the sludge scraper assembly 20, the thermal output of the regional heating assembly 40, and the decision-making of the controller 50. Under normal operating conditions, the system maintains operation with low energy consumption to protect the settling process; under abnormal operating conditions, the system can quickly identify and accurately locate the problem, and coordinate intervention to achieve non-stop self-healing and extrication from local blockages during the tar sludge scraping process.

[0042] This article uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A primary tar separator anti-jamming and sludge scraping system, characterized in that: The primary tar separator's anti-jamming and sludge scraping system includes: A separator having an internal cavity, the bottom of which is conical; A sludge scraper assembly includes a drive unit, a central spindle, and a scraper arm frame. The drive unit is located at the bottom of the separator. The bottom end of the central spindle is fixedly connected to the output end of the drive unit. The central spindle extends vertically upward, and its top end is located inside the separator. The scraper arm frame includes a horizontal support arm connected to the top end of the central spindle and an inclined scraper arm parallel to the inner wall of the bottom of the separator. The upper end of the inclined scraper arm is connected to the outer end of the horizontal support arm, and the lower end of the inclined scraper arm is connected to the lower part of the central spindle. A scraper is provided on the inclined scraper arm, and the scraper abuts against the inner wall of the bottom of the separator. The status detection component includes an angle detection unit for detecting the real-time rotation angle of the scraper frame relative to a preset reference position, and a load detection unit for detecting the operating load of the drive unit. A zoned heating component is fitted onto the bottom outer wall of the separator. The zoned heating component is divided into multiple independent heating zones along the circumferential direction. A heat-insulating and sealing baffle is provided between adjacent heating zones. Each heating zone is equipped with an independently controlled regulating valve and a temperature sensor. The controller is electrically connected to the status detection component, the zoned heat tracing component, and the drive unit, respectively. The controller is configured to: construct a resistance mapping matrix based on the real-time rotation angle and the operating load; when a jamming trend is determined based on the operating load, determine the corresponding target heating sector based on the current real-time rotation angle, and control the opening of the regulating valve corresponding to the heating sector.

2. The primary tar separator anti-jamming and sludge scraping system according to claim 1, characterized in that: The separator is provided with a slag discharge cone at the bottom, and the zoned heating assembly is sleeved on the outer wall of the slag discharge cone; the zoned heating assembly includes a heating shell, and an annular cavity is formed between the heating shell and the outer wall of the slag discharge cone; the heat insulation and sealing baffle is arranged radially in the annular cavity and divides the annular cavity into multiple independent heating sectors.

3. The primary tar separator anti-jamming and sludge scraping system according to claim 2, characterized in that: Each of the heating sectors is provided with a steam inlet and a condensate drain outlet, and the regulating valve is located on the steam inlet pipe connected to the steam inlet.

4. The primary tar separator anti-jamming and sludge scraping system according to claim 1, characterized in that: The angle detection unit is an absolute encoder mounted on the output shaft of the drive unit, the load detection unit is a high-frequency current transmitter for detecting the current of the drive unit, and the temperature sensor is a surface-mount temperature sensor.

5. A control method for an anti-jamming and sludge scraping system of a primary tar separator based on any one of claims 1-4, characterized in that: The control method includes the following steps: S1. Under the normal forward rotation operation of the drive unit, the regulating valves corresponding to each heating sector are all in the closed state; the real-time rotation angle of the scraper frame relative to the preset reference position and the operating load of the drive unit are collected in real time, and a resistance mapping matrix between each angle range and the operating load is established. S2. Calculate the rate of change of the operating load. When the rate of change is greater than the preset dynamic threshold, it is determined that there is a jamming trend, and the corresponding target heating sector is determined according to the current real-time rotation angle. S3. Control the drive unit to stop rotating forward and open the regulating valve corresponding to the target heating sector, while keeping the regulating valves of the other heating sectors closed; S4. The real-time temperature of the target heating sector is obtained through the temperature sensor. After the real-time temperature reaches the preset softening critical temperature, the drive unit is controlled to perform alternating forward and reverse oscillation operation until the operating load of the drive unit during forward operation is less than the preset safety baseline. The safety baseline is the upper limit value of the operating load corresponding to the drive unit when it is in the normal forward operation state. S5. Close the regulating valve of the target heating sector and control the drive unit to resume forward operation.

6. The control method for the anti-jamming and sludge scraping system of a primary tar separator according to claim 5, characterized in that: In step S1, establishing the resistance mapping matrix between each angle interval and the operating load specifically includes: A two-dimensional array or circular queue is constructed inside the controller to divide the 360-degree circumference into multiple angle intervals that correspond one-to-one with the heating sector, and the real-time collected operating load is updated to the angle interval to which the current real-time rotation angle belongs.

7. The control method for the anti-jamming and sludge scraping system of a primary tar separator according to claim 5, characterized in that: In step S3, before opening the regulating valve corresponding to the target heating sector, the method further includes: The control drive unit reverses the preset angle.

8. The control method for the anti-jamming and sludge scraping system of a primary tar separator according to claim 5, characterized in that: In step S4, the control drive unit performs alternating forward and reverse oscillation operation, specifically including: The drive unit is controlled to reverse at a first frequency and then rotate forward at a second frequency to a second angle; wherein the first frequency is less than the normal operating frequency of the drive unit, and the first angle is less than the second angle; Repeat the above reverse and forward rotation actions.

9. The control method for the anti-jamming and sludge scraping system of a primary tar separator according to claim 5, characterized in that: In step S4, during the period when the control drive unit is oscillating between forward and reverse rotation, if it is detected that the operating load of the drive unit during reverse rotation is greater than the preset safety baseline, then the value of the softening critical temperature is increased or the heating time is extended.

10. The control method for the anti-jamming and sludge scraping system of a primary tar separator according to claim 5, characterized in that: The control method also includes: Record and store historical load overload data for each heating sector. If the overload frequency of a certain heating sector within a preset historical time period is found to be greater than the set number, the regulating valve corresponding to that heating sector will be opened in advance when the corresponding time period is reached in subsequent operation.

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