An integrated anti-caking and drying equipment system for desulfurizer production

Abstract

This invention relates to an integrated anti-caking and drying equipment system for desulfurizing agent production, belonging to the field of chemical production equipment technology. It comprises, in sequence: a reaction system for preparing desulfurizing agent slurry; a vacuum belt filter for maintaining the system vacuum within the range of 0.03 MPa to 0.053 MPa; a dryer with a mechanical dispersing mechanism or vibrating motor at its feed chute; a cooling device connected to a circulating cooling water or refrigerant source; a mixer, which is a high-shear mixer or a static mixer; and an anti-caking agent addition system electrically connected to the vacuum belt filter, dryer, cooling device, anti-caking agent addition system, and online monitoring instruments. This integrated anti-caking and drying equipment system for desulfurizing agent production, by configuring a high-power vacuum pump group to raise the vacuum of the vacuum belt filter to above 0.03 MPa, and cooperating with a high-pressure backwash water pump to clean the filter cloth, reduces the output moisture content from the traditional 26% to below 18% to 20%.

Description

Technical Field

[0001] This invention relates to the field of chemical production equipment technology, specifically to an integrated anti-caking and drying equipment system for desulfurizing agent production. Background Technology

[0002] Sodium bicarbonate (baking soda) is a highly efficient desulfurizing agent for coal-fired power plants and industrial flue gas. The drying, screening, and packaging processes during its production directly affect product quality. In traditional production lines, materials undergo reaction, solid-liquid separation, drying, conveying, mixing, and then packaging. However, in actual production, unreasonable equipment configuration often leads to problems such as high material moisture content, severe agglomeration, and poor production continuity, thus restricting product quality and production capacity.

[0003] The existing desulfurizer production equipment and processes have the following prominent problems: First, the vacuum level of the vacuum belt filter is too low (usually only around 0.02 MPa), resulting in a discharge moisture content of over 26%, which leads to blockage of the subsequent dryer chutes and overload of the stirring motor; the filter cloth is easily clogged by fine powder or accelerator residue, and the backwashing effect is poor. Second, severe product agglomeration: Although the temperature at the packaging machine is controlled below 45℃, due to unstable drying reduction control and excessively fine crystal particle size, the product still agglomerates severely during the stacking of ton bags, affecting pneumatic conveying and user use. Third, lack of effective cooling: The existing process lacks a targeted cooling device, and hot materials generate sweat or decompose due to residual heat during conveying and packaging, exacerbating agglomeration. Fourth, the anti-caking agent is added in a crude manner, and the traditional mixing equipment does not disperse it evenly, resulting in local agglomeration or poor anti-caking effect. Fifth, each unit is controlled independently, lacking linkage, and cannot automatically adjust parameters according to changes in material moisture and temperature.

[0004] Therefore, there is an urgent need for an integrated equipment system capable of achieving efficient vacuum filtration, stepped drying and anti-clogging, pneumatic conveying and cooling, and efficient mixing. This invention aims to provide an integrated anti-caking and drying equipment system that solves problems such as high material moisture content, easy clogging, severe agglomeration, and fragmented process control in existing technologies by optimizing the vacuum system, adding drying and anti-clogging devices, cooling devices, and an intelligent mixing system. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides an integrated anti-caking and drying equipment system for desulfurizing agent production. It features advantages such as low moisture content due to vacuum filtration, stable operation with anti-clogging chutes, triple cooling to eliminate residual heat, uniform mixing of high-shear additives, and DCS intelligent linkage control. This system solves the problems of low vacuum levels leading to high material moisture content, easy clogging of filter cloth and chutes, severe product agglomeration, lack of effective cooling, uneven dispersion of anti-caking agents, and poor production continuity in traditional equipment.

[0006] To achieve the above objectives, the present invention provides the following technical solution: An integrated anti-caking and drying equipment system for desulfurizing agent production includes: The reaction system is used to prepare desulfurizing agent slurry; The vacuum belt filter is equipped with a high-power vacuum pump set to maintain the system vacuum level within the range of 0.03MPa to 0.053MPa; the filter cloth cleaning section of the vacuum belt filter is equipped with a high-pressure backwash water pump. The dryer is equipped with a mechanical dispersing mechanism or a vibrating motor at its feed chute; A cooling device, located between the dryer and the packaging system, includes a fluidized bed cooler or a spiral cooler, connected to a circulating cooling water or a refrigerant source; The mixer, located at the front end of the packaging machine, is a high-shear mixer or a static mixer; Anti-caking agent addition system, including precision metering pump and injector; The DCS control system is electrically connected to the vacuum filter, dryer, cooling device, anti-caking agent addition system, and online monitoring instruments.

[0007] Furthermore, the high-pressure backwash water pump has a water pressure of 0.5MPa to 0.8MPa and uses continuous or pulse cleaning.

[0008] Furthermore, the cooling device is a spiral cooler, with an internal circulating cooling water coil, and the cooling water temperature is 5℃~20℃.

[0009] Furthermore, the cooling device is a fluidized bed cooler, which has multiple layers of cooling coils inside, and the cooling medium is chilled brine or cooling water at -5℃ to 10℃.

[0010] Furthermore, the anti-caking agent is ultrafine silica powder with a particle size of 1500-2000 mesh, and the amount added is 0.5%-1.0% of the material mass.

[0011] Furthermore, the anti-caking agent is a composite anti-caking agent, composed of 70% by mass of ultrafine silica powder and 30% by mass of calcium stearate.

[0012] Furthermore, the mixer is a high-shear mixer with a rotor speed of 1000 rpm to 2000 rpm and a stator-rotor gap of 0.3 mm to 0.8 mm; the anti-caking agent is added by pneumatic spraying with a spray pressure of 0.3 MPa to 0.5 MPa and an atomized particle size of 30 μm to 80 μm.

[0013] Furthermore, the system also includes an air classifier, which is set between the dryer and the cooling device, for classifying materials according to particle size: fine powder with a particle size of less than 100 mesh is returned to the reaction system, qualified products with a particle size between 100 mesh and 325 mesh enter the subsequent process, and coarse particles with a particle size of more than 325 mesh are crushed by the crusher and then returned.

[0014] Furthermore, the DCS control system is also connected to an online material moisture detector, a material temperature sensor, and a filter cloth permeability monitoring sensor, which are used to monitor key process parameters in real time and execute fuzzy PID control algorithms.

[0015] Furthermore, the system also includes a bag filter, a metal detector, and a weight detector. The bag filter is installed at the dust generation points of the filter press, dryer, and mixer, while the metal detector and weight detector are installed at the packaging machine outlet.

[0016] Compared with the prior art, the present invention provides an integrated anti-caking and drying equipment system for desulfurizing agent production, which has the following beneficial effects: 1. This integrated anti-caking and drying equipment system for desulfurizing agent production increases the vacuum level of the vacuum belt filter to above 0.03MPa by configuring a high-power vacuum pump group. Combined with a high-pressure backwash water pump to clean the filter cloth, the output moisture content is reduced from the traditional 26% to below 18% to 20%. The dryer load is significantly reduced, and the problems of chute blockage and motor overload are fundamentally solved, significantly improving production continuity and equipment service life.

[0017] 2. This integrated anti-caking and drying equipment system for desulfurizing agent production employs a triple anti-caking mechanism: vacuum control to reduce internal moisture, a cooling device to eliminate residual heat, and physical isolation with ultrafine powder or composite anti-caking agents. The cooling device reduces the material temperature from above 50℃ to 30-40℃, eliminating sweating and decomposition caused by residual heat; a high-shear mixer combined with pneumatic spraying ensures the anti-caking agent evenly coats the material surface, forming a physical isolation layer. The product maintains good flowability even after 7 days of storage, fully meeting the requirements for long-distance transportation and on-site pneumatic conveying.

[0018] 3. This integrated anti-caking and drying equipment system for desulfurizing agent production utilizes an integrated DCS control system. Through real-time feedback from online moisture and temperature sensors, it automatically adjusts vacuum levels, cooling intensity, and additive addition ratios, achieving intelligent anti-caking control throughout the entire process. Compared to traditional decentralized control, energy consumption is reduced by 20%, product qualification rate reaches over 99.5%, fewer operators are required, and overall economic benefits are significant. Attached Figure Description

[0019] Figure 1 This is a system block diagram of an integrated anti-caking and drying equipment system for desulfurizing agent production according to the present invention.

[0020] Figure 2 This is a block diagram of the reaction, solid-liquid separation, and drying sections of an integrated anti-caking and drying equipment system for desulfurizing agent production according to the present invention.

[0021] Figure 3 This is a block diagram of the cooling, mixing, and packaging components of an integrated anti-caking and drying equipment system for desulfurizing agent production according to the present invention.

[0022] Figure 4 This is a block diagram of the control system and auxiliary system of an integrated anti-caking and drying equipment system for desulfurizing agent production according to the present invention. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figures 1 to 4 .

[0025] Example 1: Basic Integrated Equipment System This embodiment provides an integrated anti-caking and drying equipment system for desulfurizing agent production, comprising a reaction vessel, a vacuum belt filter, a dryer, a pneumatic conveying system, a cooling chamber, a mixer, and a packaging machine connected in sequence.

[0026] Vacuum Filtration System: The raw material slurry enters the vacuum belt filter. A high-power vacuum pump is started, and the vacuum level is controlled at 0.04 MPa. A high-pressure backwash water pump is started, with the water pressure set to 0.6 MPa, to perform periodic continuous cleaning of the filter cloth. Results: The moisture content of the material exiting the belt filter decreased from 26% to below 20%, the filter cloth's permeability was restored, and no clogging occurred.

[0027] Drying and anti-clogging device: The material enters the dryer through a chute equipped with a vibrating motor (2mm amplitude, 50Hz frequency) to prevent material accumulation. The dryer outlet temperature is controlled to maintain an outlet temperature of approximately 50℃.

[0028] Cooling and Mixing System: The material enters the pneumatic conveying system and passes through a screw cooler, where it is cooled by 15°C circulating water to a temperature of 40°C. The cooled material then enters the mixer, where ultrafine silica powder (1500 mesh) is added at a ratio of 0.5% via a metering screw. The high-shear mixer operates at 1200 rpm for 5 minutes to ensure uniform dispersion of the additive.

[0029] Packaging: The mixed materials are then packaged in a ton bag machine.

[0030] Results: After 72 hours of storage, the product showed no obvious clumping and good fluidity.

[0031] Example 2: Vacuum System Optimization Based on Example 1, the vacuum system was optimized. A two-stage vacuum pump system was adopted, with the first-stage vacuum pump raising the vacuum level to 0.03 MPa and the second-stage vacuum pump further raising the vacuum level to 0.05 MPa. The backwashing system adopted a pulse cleaning method, performing a pulse cleaning every 30 minutes, each lasting 2 minutes, with a water pressure of 0.8 MPa.

[0032] Results: The moisture content of the filter output was further reduced to below 18%, and the service life of the filter cloth was extended by 30%. The vibration frequency of the dryer chute was adjusted to 60Hz and the amplitude was adjusted to 2.5mm, further improving the anti-clogging effect.

[0033] Example 3: Improved cooling device (fluidized bed cooler) Based on Example 1, the convection cooling device was improved. A fluidized bed cooling device was used instead of a spiral cooler, and -5°C chilled brine was used as the cooling medium. Multiple cooling coils were installed within the fluidized bed, ensuring full contact between the material and the cooling coils in the fluidized state, thus increasing cooling efficiency by 40%.

[0034] Results: Material temperature can be reduced to 35℃, and the temperature distribution is more uniform. A temperature sensor is installed at the fluidized bed outlet to achieve closed-loop control of the cooling temperature, further reducing product agglomeration.

[0035] Example 4: Hybrid System Optimization (High Shear + Pneumatic Spray) Based on Example 1, the mixing system was optimized. A high-shear mixer was used, with a rotor speed of 1500 rpm and a stator-rotor gap controlled at 0.5 mm. The anti-caking agent was added via pneumatic spraying at a pressure of 0.4 MPa, with the atomized particle size controlled below 50 μm.

[0036] Results: The anti-caking agent forms a uniform nanoscale coating on the material surface, significantly improving the anti-caking effect. The product maintains good flowability even after being stacked for 7 days.

[0037] Example 5: Adding a hierarchical system Based on Example 1, a screening system is added. An air classifier is added between the dryer and the pneumatic conveying system to classify the material according to particle size. Fine powder with a particle size less than 100 mesh is returned to the reactor for recrystallization, qualified products with a particle size between 100 and 325 mesh enter the subsequent process, and coarse particles with a particle size greater than 325 mesh are crushed in the crusher and then returned to the system.

[0038] Results: The product has a more uniform particle size distribution, with the average particle size controlled at 200 mesh, reducing agglomeration caused by particle size differences and improving raw material utilization.

[0039] Example 6: Upgrade of Intelligent Control System Based on Example 1, the intelligent control system is upgraded. An online material moisture detector (near-infrared moisture detection technology) is added to monitor the moisture content of the filter output in real time. Material temperature detection points are also added, with temperature sensors installed at the dryer outlet, cooling device outlet, and mixer outlet.

[0040] The control system employs a fuzzy PID control algorithm to automatically adjust the vacuum level, drying temperature, cooling intensity, and additive dosage based on real-time data on moisture content and temperature. When the detected moisture content exceeds 22%, the vacuum level is automatically increased to 0.05 MPa, and the cooling intensity is increased; when the moisture content is below 18%, the vacuum level is appropriately reduced to save energy.

[0041] Results: Product moisture fluctuations are controlled within ±1%, clumping rate is reduced by 80%, and energy consumption is reduced by 15%.

[0042] Example 7: Application of Composite Anti-caking Agent Based on Example 1, the anti-caking agent was improved. A composite anti-caking agent was adopted, consisting of 70% ultrafine silica powder and 30% calcium stearate. The composite anti-caking agent was added to the mixer at a ratio of 1.0% using a twin-screw feeder.

[0043] Effects: The composite anti-caking agent forms a double protective layer on the material surface, providing not only physical isolation but also lubrication, further improving the product's flowability. The product's stability under high temperature and high humidity environments is significantly enhanced.

[0044] Example 8: Adding a dust removal and metal detection system Based on Example 1, a dust removal system is added. Bag filters are installed at dust-generating points such as belt filters, dryers, and mixers, achieving a dust removal efficiency of 99.9%. The collected dust is returned to the production process through a closed conveyor system, achieving zero dust emissions.

[0045] Metal detectors and weight detectors are installed at the packaging machine exit to ensure that there are no metal impurities in the products and that the weight error of each bag of products is controlled within ±0.5%.

[0046] Results: The production line meets environmental standards, resulting in higher product quality.

[0047] Example 9: Intelligent Production System for the Entire Process Based on Example 1, a complete intelligent production system is constructed, including: Automatic raw material batching system: loss-in-weight feeder, error ±0.2%; Reaction process control system: The reactor is equipped with a pH meter, thermometer, and pressure sensor; Online quality inspection system: particle size analyzer, moisture analyzer, whiteness analyzer; Energy management system: Real-time monitoring and optimization of water, electricity, and steam consumption; Remote monitoring and fault diagnosis system: Industrial Internet technology.

[0048] Results: The production line achieves an automation level of over 95%, a product qualification rate of 99.5%, energy consumption is reduced by 20%, and production efficiency is increased by 30%.

[0049] Comparative example: The same desulfurizing agent was produced using conventional equipment (0.02 MPa vacuum, no dedicated cooling device, and no additives). Result: The product developed severe hardening after 72 hours of storage, and the energy consumption for crushing was high.

[0050] Summary of effect comparison: Under the same conditions, the products of each embodiment of the present invention showed no obvious clumping after being stacked for 72 hours, and had good fluidity, fully meeting the requirements of long-distance transportation and on-site pneumatic conveying.

[0051] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0052] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An integrated anti-caking and drying equipment system for desulfurizing agent production, characterized in that, Including those connected sequentially: The reaction system is used to prepare desulfurizing agent slurry; The vacuum belt filter is equipped with a high-power vacuum pump set to maintain the system vacuum level within the range of 0.03MPa to 0.053MPa; the filter cloth cleaning section of the vacuum belt filter is equipped with a high-pressure backwash water pump. The dryer is equipped with a mechanical dispersing mechanism or a vibrating motor at its feed chute; A cooling device, located between the dryer and the packaging system, includes a fluidized bed cooler or a spiral cooler, connected to a circulating cooling water or a refrigerant source; The mixer, located at the front end of the packaging machine, is a high-shear mixer or a static mixer; Anti-caking agent addition system, including precision metering pump and injector; The DCS control system is electrically connected to the vacuum filter, dryer, cooling device, anti-caking agent addition system, and online monitoring instruments.

2. The integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The high-pressure backwash water pump has a water pressure of 0.5MPa to 0.8MPa and uses continuous or pulse cleaning.

3. The integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The cooling device is a spiral cooler, which has a circulating cooling water coil inside, and the cooling water temperature is 5℃~20℃.

4. The integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The cooling device is a fluidized bed cooler, which has multiple cooling coils inside, and the cooling medium is chilled brine or cooling water at -5℃ to 10℃.

5. An integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The anti-caking agent is ultrafine silica powder with a particle size of 1500-2000 mesh, and the addition amount is 0.5%-1.0% of the material mass.

6. An integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The anti-caking agent is a composite anti-caking agent, composed of 70% by mass of ultrafine silica powder and 30% by mass of calcium stearate.

7. An integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The mixer is a high-shear mixer with a rotor speed of 1000 rpm to 2000 rpm and a stator-rotor gap of 0.3 mm to 0.8 mm. The anti-caking agent is added by pneumatic spraying with a spray pressure of 0.3 MPa to 0.5 MPa and an atomized particle size of 30 μm to 80 μm.

8. An integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The system also includes an air classifier, which is set between the dryer and the cooling device, and is used to classify materials according to particle size: fine powder with a particle size of less than 100 mesh is returned to the reaction system, qualified products with a particle size between 100 mesh and 325 mesh enter the subsequent process, and coarse particles with a particle size of more than 325 mesh are crushed by the crusher and then returned.

9. An integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The DCS control system is also connected to an online material moisture detector, a material temperature sensor, and a filter cloth air permeability monitoring sensor, which are used to monitor key process parameters in real time and execute fuzzy PID control algorithms.

10. An integrated anti-caking and drying equipment system for desulfurizing agent production according to claim 1, characterized in that, The system also includes a bag filter, a metal detector, and a weight detector. The bag filter is installed at the dust generation points of the filter press, dryer, and mixer, while the metal detector and weight detector are installed at the packaging machine outlet.

Images