Vertical high temperature and high pressure reaction kettle safety monitoring system and monitoring method

Abstract

The present application belongs to the technical field of industrial safety protection, and discloses a vertical high-temperature and high-pressure reaction kettle safety monitoring system and a monitoring method. The system comprises: a multi-point monitoring unit, which comprises at least five monitoring points arranged at key spatial positions of a reaction kettle body; a monitoring module, which receives and processes temperature and pressure data; a fault diagnosis module, which judges single-point data anomaly, change rate anomaly or signal loss; a warning module, which triggers graded warning according to pressure change rate and absolute value; a pressure control module, which maintains a slightly positive pressure state; and a pressure relief device, which passively opens to release pressure. The method comprises self-checking, data acquisition, fault diagnosis, graded warning, pressure relief starting and ending steps. The present application realizes all-around monitoring, sensor fault self-diagnosis, graded warning linkage and efficient passive pressure relief, and effectively improves the safety of the reaction kettle operation.

Description

Technical Field

[0001] This invention relates to the field of industrial safety protection technology, and in particular to a safety monitoring system and method for vertical high-temperature and high-pressure reactors. Background Technology

[0002] In industrial production, the storage and processing of high-temperature, high-pressure ultrafine toner is widespread. This type of toner typically possesses extremely high temperature characteristics (reaching over 1500℃), and in the special environment of a sealed tank, it is prone to volatilization and decomposition, producing flammable gases such as hydrogen and methane. To prevent outside air from entering the tank and forming an explosive mixture with flammable gases, the tank must be strictly maintained at a slightly positive pressure during normal operation. However, in actual production, various unforeseen factors can cause the pressure inside the tank to rise rapidly in a short period, such as gas accumulation inside the toner, leakage and vaporization due to tank seal failure, and water-gas reaction between toner and water vapor. If the pressure is not released in a timely and effective manner, it can directly lead to serious safety accidents such as tank rupture and explosion, causing significant casualties and property damage.

[0003] Existing explosion venting devices and monitoring systems have many shortcomings and are insufficient to meet the safety protection requirements of high-temperature and high-pressure toner cartridges:

[0004] The monitoring points are deployed in a single way, which can only obtain temperature and pressure data for local locations in the tank. This cannot fully and accurately reflect the overall distribution and changing trend of temperature and pressure inside the tank. As a result, local pressure exceeding the standard may not be detected in time, which may lead to potential safety hazards.

[0005] The lack of a fault diagnosis mechanism means that when monitoring components malfunction, they cannot be identified and maintenance is not prompted in a timely manner, which can easily lead to distorted monitoring data and mislead operators' judgment.

[0006] The early warning and control logic is simplistic, lacking a tiered response mechanism, making it difficult to accurately assess the severity of emergencies based on key parameters such as the rate and magnitude of pressure increases.

[0007] Therefore, developing an integrated safety protection system that can accurately adapt to the characteristics of high-temperature and high-pressure toner canisters and achieve comprehensive and accurate monitoring, rapid fault diagnosis, graded early warning, and efficient and safe explosion relief has become an urgent need to solve the safety hazards in existing technologies and is of great significance to improving the safety and stability of related industrial production. Summary of the Invention

[0008] The present invention aims to provide a safety monitoring system and method for vertical high-temperature and high-pressure reactors to solve the problems of untimely explosion venting, inaccurate monitoring, lack of fault diagnosis, and imperfect early warning mechanism in the prior art.

[0009] To achieve the above objectives, the present invention provides the following technical solution:

[0010] A safety monitoring system for a vertical high-temperature and high-pressure reactor includes:

[0011] The multi-point monitoring unit includes at least 5 monitoring points, which are set at key spatial locations on the reactor body to monitor the status at different heights. Each monitoring point integrates a temperature sensor and a pressure sensor for real-time acquisition of temperature and pressure data.

[0012] The monitoring module communicates with the multi-point monitoring unit to receive and process temperature and pressure data and output visual status charts.

[0013] The fault diagnosis module communicates with the monitoring module to receive processed temperature and pressure data and execute the following diagnostic logic: determine whether there is a single point of abnormal data while neighboring points are normal, a single point of data change rate is significantly different from that of neighboring points, or a single point has no signal output, and generate prompt information containing the fault location and type when a fault is diagnosed.

[0014] The early warning module, which communicates with the monitoring module, is used to receive processed temperature and pressure data and to issue graded early warnings based on the rate of pressure change and the absolute value of pressure: a first-level early warning is triggered when the rate of pressure change exceeds the first threshold, and a second-level early warning is triggered when the absolute value of pressure reaches the second threshold.

[0015] The pressure control module communicates with the monitoring module, receives processed temperature and pressure data, and controls the inlet and outlet valves of the reactor to adjust the pressure in real time and maintain a slightly positive pressure state inside the reactor.

[0016] The explosion relief device is installed on the top of the reactor body. Its explosion pressure is preset and it is passively activated to relieve pressure when the pressure inside the reactor body reaches the explosion threshold.

[0017] Furthermore, the key spatial locations are located at the top center, upper side, middle side, lower side, and bottom center of the reactor body.

[0018] Furthermore, the first threshold is a pressure rise rate greater than 600 Pa / s that lasts for more than 20 seconds; the first-level warning is to issue a continuous audible and visual alarm signal, with the monitoring module's display interface flashing a warning prompt, and simultaneously pushing warning information to the mobile terminals of relevant operators; the second threshold is a pressure peak rise to 0.1 MPa; the second-level warning is to automatically cut off the feed system and heating system of the reactor.

[0019] Furthermore, the pressure control module maintains a slight positive pressure state inside the reactor at a maximum pressure of 1000 Pa.

[0020] Furthermore, the explosion venting device includes a rupture disc installed at the explosion vent of the reactor body, with a rupture pressure of 0.15 MPa ± 5%; a sealing structure installed at the connection between the rupture disc and the reactor body; an explosion venting pipe installed at the explosion vent of the reactor body, with an explosion venting pressure of 1.5 MPa and an explosion venting pressure of 1 MPa, forming a graded pressure bearing system; and a protective component installed at the outlet end of the explosion venting pipe to block the splashing of high-temperature carbon powder particles and guide the airflow.

[0021] A safety monitoring method for a vertical high-temperature and high-pressure reactor includes the following steps:

[0022] S1. After the system starts up, it sequentially completes the hardware self-test and communication link test of the monitoring module, fault diagnosis module, and early warning module. Each sensor in the multi-point monitoring unit feeds back working status signals. After all signals are normal, it enters standby mode.

[0023] S2. During the operation of the reactor, the multi-point monitoring unit continuously collects temperature and pressure data from each monitoring point and transmits them to the monitoring module. The monitoring module adjusts the opening of the inlet valve and the exhaust valve in real time according to the preset pressure control target to maintain a slightly positive pressure state inside the reactor.

[0024] S3, the fault diagnosis module compares the temperature and pressure data collected from each monitoring point in real time to determine whether there are single-point numerical anomalies, abnormal response speeds, or signal loss, and generates prompt information including the fault location and type when a fault is diagnosed.

[0025] S4. The early warning module dynamically analyzes the overall pressure change rate and absolute pressure value of the pressure data processed by the monitoring module. When the pressure change rate exceeds the first threshold, a first-level early warning is triggered, and when the absolute pressure value reaches the second threshold, a second-level early warning is triggered.

[0026] S5. When the pressure rises to the explosion threshold, the explosion relief device is passively opened to relieve pressure. During the explosion relief process, the multi-point monitoring unit continuously collects temperature and pressure data at each monitoring point, and the monitoring module generates a dynamic curve of the explosion relief process in real time.

[0027] S6. When the monitoring module shows that the temperature and pressure have returned to the normal range and have been running stably for the predetermined time, the explosion relief is determined to be complete, and an explosion relief completion prompt is issued.

[0028] Further, in step S4, the first threshold is that the pressure increases from 1000Pa to 13000Pa within 20s; the second threshold is that the absolute value of the pressure reaches 0.1MPa.

[0029] Furthermore, in step S5, the explosion relief device is passively activated when the pressure reaches 0.15 MPa, and the explosion relief process takes no more than 10 minutes.

[0030] The principles and beneficial effects of the technical solution are as follows:

[0031] The present invention provides a safety monitoring system and method for vertical high-temperature and high-pressure reactors.

[0032] 1. By setting multiple monitoring points at different locations inside the reactor, the temperature and pressure inside the tank can be monitored in all aspects, avoiding blind spots of single-point monitoring. At the same time, the data from each monitoring point are cross-verified to avoid data inaccuracy caused by single-point sensor failure, ensuring the validity of the data and providing complete data support for safety decisions.

[0033] 2. By comparing data between monitoring points, the system uses a triple diagnostic logic to identify abnormal values, abnormal response speeds, and missing signals. This allows for the timely detection of faults such as sensor drift, slow response, and open circuits, and generates precise fault location and type indicators to facilitate subsequent maintenance and ensure the authenticity and reliability of monitoring data.

[0034] 3. Two levels of early warning are set according to the rate of pressure change and the pressure magnitude. The first level of early warning reminds the operator to pay attention, and the second level of early warning automatically cuts off the feeding and heating systems. This provides the staff with sufficient reaction time and ensures the reliability of safety protection, realizing a gradient safety protection from early warning to forced intervention.

[0035] 4. It adopts high-temperature resistant composite ceramic rupture discs and explosion relief pipes with wear-resistant coatings, combined with a graded pressure-bearing design, which can quickly and reliably release pressure under extreme working conditions. At the same time, the protective components effectively prevent secondary accidents caused by high-temperature carbon powder splashing. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the structure and monitoring point layout of the vertical high-temperature and high-pressure reactor in an embodiment of the present invention;

[0037] Figure 2 This is a block diagram showing the module connection of the security monitoring system in an embodiment of the present invention;

[0038] Figure 3 This is a flowchart illustrating the security monitoring method in an embodiment of the present invention; Detailed Implementation

[0039] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments:

[0040] Example 1

[0041] like Figures 1-2As shown, the vertical high-temperature and high-pressure reactor safety monitoring system includes: a reactor body with a volume of 12m³, a vertical structure, used to hold 3000kg of high-temperature ultrafine carbon powder; the carbon powder has a bulk density of 0.6, an average particle size of 15μm, and an average carbon powder temperature of 1500℃ under normal operating conditions; the reactor is filled with inert gas (such as argon, nitrogen, etc.) to isolate it from air, and also contains a small amount of combustible gas (such as hydrogen, methane, etc.) produced by the decomposition of carbon volatiles. During normal operation, the reactor maintains a slightly positive pressure, with the pressure strictly controlled not exceeding 1000Pa.

[0042] The multi-point monitoring unit includes at least five monitoring points, each positioned at a key spatial location on the reactor body to monitor the status at different heights. This ensures the capture of temperature and pressure changes at different heights and in different areas of the vessel. The key spatial locations are the top center (T1), upper side (T2), middle side (T3), lower side (T4), and bottom center (T5) of the reactor body. The origin (0,0,0) is the bottom center (T5) of the reactor body. The coordinates of the remaining monitoring points are as follows: T1 is located at the top center of the vessel body, coordinates (0, 7.677, 0), primarily monitoring the temperature and pressure data of the top area of ​​the vessel; T2 is located at the connection point between the left cylinder and the reactor cover, coordinates (-1.34, 6.827, 0), used to monitor parameters of the key connection point on the upper left side of the vessel; T3 is located at the middle boundary point on the left side of the vessel, (1.34, 3.4135, 0), corresponding to the monitoring of the middle area of ​​the vessel; T4 is located at the bottom boundary point on the left side of the vessel (coordinates -1.34, 3.4135, 0). 1.34, 0, 0), monitoring the temperature and pressure on the lower left side of the tank; T5 is located at the center of the bottom of the tank (coordinates 0, 0, 0), focusing on monitoring parameters in the bottom area of ​​the tank; the sensor probe is in direct contact with the medium inside the tank to ensure the accuracy of the monitoring data.

[0043] Each monitoring point integrates temperature and pressure sensors for real-time acquisition of temperature and pressure data. All sensors at monitoring points T1-T5 employ a through-type installation, inserting from the outside of the tank wall to a specified depth inside the reactor to directly measure the internal medium's state and ensure the accuracy of the monitoring data. The temperature sensor's measurement range is from room temperature to 2000℃, with a measurement accuracy of ±1℃. The pressure sensor's measurement range is from -500Pa to 2MPa, with a measurement accuracy of ±1Pa. The sensors possess anti-interference and anti-vibration properties, and the data transmission delay does not exceed 10ms.

[0044] The monitoring module employs industrial-grade computer equipment, equipped with a high-performance processor, large-capacity storage unit, and dedicated data acquisition card. It establishes a stable connection with multiple monitoring units via wired or wireless communication, receiving real-time temperature and pressure data from each monitoring point. The module performs preprocessing such as filtering and noise reduction on the raw data, eliminating abnormal data to ensure reliability. Simultaneously, it stores the processed, valid data in real-time to a local database and a cloud server for at least one year, facilitating subsequent data traceability, analysis, and equipment operation status assessment. It can also dynamically analyze real-time data, generating visual charts such as temperature and pressure change curves and thermal maps of parameter distribution in different areas of the tank, intuitively displaying the working status inside the reactor. Operators can view relevant data and charts in real-time through the monitoring module's display interface to quickly determine whether the equipment is operating normally.

[0045] The fault diagnosis module communicates with the monitoring module and performs fault diagnosis on temperature and pressure sensing elements by real-time monitoring of temperature, pressure data, and sensor operating status signals at each monitoring point. It incorporates the following diagnostic logic:

[0046] Numerical anomaly diagnosis: When the temperature or pressure data of a certain measuring point is abnormally displayed as too low or too high, and exceeds the preset normal value range, while the temperature and pressure data of other measuring points on the same side are normal, it is determined that the temperature and pressure detection element of the measuring point has problems such as parameter drift or damage. The fault diagnosis module immediately generates fault prompt information, which clarifies the location of the fault measuring point and the fault type.

[0047] The abnormal response speed diagnosis compares the rate of temperature and pressure change at each measuring point on the same side. When the temperature or pressure change at a certain measuring point is abnormally slow, and there is a significant difference in the change trend with other measuring points, and the response time exceeds the preset threshold, it is determined that the response capability of the temperature and pressure detection element at that measuring point has decreased or failed, and the fault diagnosis module issues a corresponding fault prompt.

[0048] Signal loss diagnosis: When a certain measuring point has no signal output at all, while other measuring points on the same side have normal signal output and the communication link is normal, it is determined that the temperature and pressure detection element of the measuring point has a fault such as open circuit or short circuit, and the fault diagnosis module will issue the corresponding fault prompt in a timely manner.

[0049] The fault message is displayed on the control and monitoring module's screen, with a corresponding fault pop-up window appearing and the screen edge flashing red. It sends relevant information to the maintenance personnel's mobile device and provides a detailed fault handling guide (including troubleshooting steps, required tools, replacement component models and specifications, etc.) to guide maintenance personnel to quickly and accurately troubleshoot and repair the fault.

[0050] The early warning module, communicating with the monitoring module, receives processed temperature and pressure data. Based on the data analysis results from the monitoring module, it performs real-time monitoring of the data and establishes a tiered early warning mechanism. Depending on the severity of the emergency, it issues different levels of warning signals. Level 1 warning: If the pressure rises from 1000Pa to 13000Pa within 20 seconds, it is determined to be a sudden pressure increase event (including scenarios such as gas accumulation inside the toner, water leakage and vaporization, and water-gas reaction). The early warning mechanism is immediately activated, issuing continuous audible and visual alarm signals. The monitoring module's display interface flashes warning prompts, and warning information is pushed to the mobile terminals of relevant operators, reminding them to closely monitor the equipment status and prepare for emergencies. Level 2 warning: When the pressure continues to rise to 0.1MPa (66.7% of the rupture disc opening pressure), it is determined to be an emergency. In addition to continuous audible and visual alarms, the monitoring module automatically cuts off the reactor's feeding system, heating system, and other related auxiliary systems to prevent further escalation of the danger, and activates emergency lighting, ventilation, and other auxiliary facilities to provide a safe environment for operators to handle emergencies.

[0051] The pressure control module communicates with the monitoring module, receives processed temperature and pressure data, and controls the inlet valve, exhaust valve and other actuators of the reactor to actively adjust the pressure inside the tank, ensuring that the tank always maintains a slight positive pressure and does not exceed 1000Pa under normal operating conditions, thus maintaining the stable operation of the equipment.

[0052] The explosion relief device is installed on the top of the reactor body. Its explosion pressure is preset. When the pressure inside the reactor body reaches the explosion threshold, it is passively opened to relieve pressure. It includes a rupture disc, a sealing structure, an explosion relief pipe and protective components.

[0053] Rupture disc: Installed at the explosion vent on the top of the reactor body, it is made of composite ceramic and metal base material that is resistant to high temperature, wear, and impact. Its temperature resistance is not lower than 1800 degrees Celsius. It can maintain structural stability and performance consistency under the long-term action of high-temperature carbon powder medium. The burst pressure is set at 0.15MPa, and the burst pressure error is strictly controlled within ±5%. This ensures that it opens accurately and quickly when the pressure reaches the set threshold, avoiding untimely or accidental explosion due to burst pressure deviation.

[0054] Sealing structure: Made of high-temperature sealing material, it is installed at the connection between the rupture disc and the tank body to ensure the sealing of the tank during normal operation and prevent gas leakage. At the same time, it does not affect the unobstructed flow of the explosion relief channel when the rupture disc is opened.

[0055] Explosion relief pipeline: Installed at the explosion relief port, it is made of a special alloy composite material resistant to high temperature and pressure. The inner wall of the pipeline is treated with a wear-resistant coating, which can effectively resist the erosion and wear of high-temperature carbon powder and extend its service life. The pipe diameter is precisely designed according to the tank volume, maximum relief volume and relief time requirements to ensure the safe relief of the high-temperature gas and carbon powder mixture within 10 minutes, avoiding blockage of the explosion relief channel. The explosion relief pressure of the explosion relief pipeline is designed to be 1.5MPa, and the explosion relief pressure of the explosion relief port is designed to be 1MPa, forming a graded pressure-bearing protection to further improve the safety of the explosion relief process.

[0056] Protective Components: Located at the outlet end of the explosion venting pipe, these components employ a three-dimensional interception structure composed of multiple layers of stainless steel precision mesh. When the mixture of high-temperature gas and carbon powder enters the protective components through the explosion venting pipe, the components rapidly cool the high-temperature flame through heat exchange, quenching the combustion reaction. Simultaneously, the three-dimensional mesh structure intercepts and traps splashing carbon powder particles, preventing them from escaping into the surrounding environment. The intercepted gas is then orderly guided out through the gaps in the protective components, achieving flameless venting. This prevents the splashing of high-temperature carbon powder particles during the venting process, avoiding damage to surrounding equipment or fire accidents. Furthermore, it provides initial guidance for the venting gas, reducing the impact force during gas venting.

[0057] Example 2

[0058] This embodiment provides a safety monitoring method for a vertical high-temperature and high-pressure reactor based on the system of Embodiment 1, such as... Figure 3 As shown, it includes the following steps:

[0059] Step S1: System Initialization and Self-Test: Start the monitoring system and related equipment of the reactor. The system enters the initialization phase, sequentially completing hardware self-tests and communication link tests for the monitoring module, fault diagnosis module, and early warning module. Each sensor in the multi-point monitoring unit initiates its self-test program, feeding back its own operating status signal to the monitoring module. If all components are normal, the system issues an initialization completion signal and enters standby mode. If an abnormality is detected, the system immediately issues a fault alarm, identifying the abnormal component and type. Initialization is performed again after the fault is resolved.

[0060] Step S2, Normal State Monitoring and Active Pressure Control: After system initialization, the reactor starts running. The monitoring module controls the pressure control module to activate the active pressure control function. The sensors of the multi-point monitoring unit continuously collect temperature and pressure data at their corresponding locations and transmit them to the monitoring module in real time. According to the preset pressure control target (≤1000Pa), the pressure control module actively adjusts the pressure inside the tank by controlling the opening of the inlet and outlet valves of the actuator to ensure that the tank always maintains a slightly positive pressure state. At the same time, the monitoring module processes and analyzes the collected temperature and pressure data in real time, generates temperature and pressure change curves, and displays them in real time through the computer display interface, intuitively showing the status inside the reactor. Operators can monitor the equipment's operating status in real time through the display interface. The data is synchronously stored in the local database and cloud server for subsequent traceability.

[0061] Step S3, Fault Diagnosis and Maintenance Tips: During system operation, the fault diagnosis module continuously analyzes the data transmitted from the sensors at each monitoring point to the monitoring module. When a fault is detected in the temperature or pressure sensing element at a certain measuring point, such as abnormal values, abnormal response speed, or signal loss, the fault diagnosis module immediately generates fault information and notifies maintenance personnel through the monitoring module's display interface, audible and visual alarm devices, and mobile terminal push notifications, providing detailed fault handling guidelines. After receiving the fault tip, maintenance personnel, ensuring equipment safety, promptly repair or replace the sensing element at the faulty measuring point. After repair, the fault diagnosis module re-inspects the sensing element at that measuring point. Once the fault is confirmed to be eliminated, the system returns to normal monitoring status.

[0062] Step S4, Emergency Situation Judgment and Graded Early Warning: The monitoring module performs real-time dynamic analysis of the collected pressure data. The early warning module determines whether a sudden pressure increase event has occurred based on the pressure change rate and pressure value. When the early warning module detects that the pressure rises from 1000Pa to 13000Pa within 20 seconds, it is determined to be a sudden pressure increase event. The early warning module immediately activates the first-level early warning, issuing a continuous audible and visual alarm signal. The monitoring module's display interface flashes the early warning prompt, and at the same time, early warning information is pushed to the mobile terminals of relevant operators, reminding them to pay close attention to the equipment status and prepare for emergencies. The monitoring module continues to monitor pressure changes. If the pressure stops rising and gradually returns to the normal range, the system maintains the first-level early warning until the pressure stabilizes and is then deactivated. If the pressure continues to rise, when it reaches 0.1MPa, the early warning module upgrades to a second-level early warning, automatically cutting off the reactor's feeding system, heating system, and other auxiliary systems, and activating emergency lighting and ventilation facilities to provide a safe environment for operators to handle emergencies.

[0063] Step S5, Explosion Relief Initiation and Process Monitoring: When the monitoring module detects that the pressure inside the reactor has increased to 0.15 MPa, the rupture disc of the explosion relief device opens precisely under pressure, and the high-temperature gas and carbon powder mixture is released outward through the explosion relief pipe. The protective components play a blocking and guiding role, preventing carbon powder splashing and gas impact from causing secondary accidents. During the explosion relief process, the multi-point monitoring unit continuously collects temperature and pressure data from each monitoring point and transmits them to the monitoring module in real time. The monitoring module analyzes the pressure drop rate and temperature changes inside the reactor based on the data change trend, and generates a dynamic curve of the explosion relief process. The operator can monitor the explosion relief progress in real time through the display interface.

[0064] Step S6, Explosion Relief Completion and Equipment Maintenance: The explosion relief process lasts approximately 10 minutes. When the monitoring module detects that the pressure inside the reactor has returned to the normal slightly positive pressure range (≤1000Pa) and has been running stably for at least 30 minutes, and the temperature has also returned to the normal operating range, the explosion relief is considered complete. The monitoring module issues an explosion relief completion signal, and the early warning module deactivates the alarm. Simultaneously, the monitoring module generates equipment maintenance prompts, specifying the components requiring maintenance (such as rupture discs, sealing structures, explosion relief pipes, sensors, etc.). Operators, ensuring the equipment is completely stopped and the site environment is safe, inspect the explosion relief device according to the maintenance prompts, replace damaged rupture discs and seals, and clean residual carbon powder from the explosion relief pipes. The sensors in the multi-point monitoring unit are calibrated and tested to ensure normal operation. A comprehensive inspection of the reactor's tank structure and sealing performance is conducted to eliminate potential safety hazards. After maintenance is completed, the operator submits maintenance completion confirmation information through the monitoring module. The system re-initializes and performs a self-test. Only after the self-test is passed can the equipment be restarted to resume normal operation.

[0065] Example 3

[0066] During the design verification phase, to assess the pressure distribution and venting requirements under the most unfavorable explosion conditions, this system defined two key ignition locations through simulation:

[0067] First ignition position: 0.425m below the top of the vertical axis of the reactor;

[0068] Second ignition location: located at the lower left of the bottom area of ​​the reactor.

[0069] Two ignition locations were used to simulate the explosion pressure development process of carbon powder and the combustible gases such as CH4 and CO2 generated by its reaction with water vapor under different initial conditions. Based on the simulation results, the optimal layout of the five monitoring points and key parameters such as the explosion pressure and venting area of ​​the explosion relief device were determined to ensure that the explosion can be detected and effectively vented in a timely manner, regardless of whether it occurs in the top or bottom region.

[0070] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific technical solutions or characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the technical solutions of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.

Claims

1. A safety monitoring system for a vertical high-temperature and high-pressure reactor, characterized in that, include: The multi-point monitoring unit includes at least 5 monitoring points, which are respectively set at key spatial locations of the reactor body to monitor the status at different heights. Each monitoring point integrates a temperature sensor and a pressure sensor to collect temperature and pressure data in real time. The monitoring module is communicatively connected to the multi-point monitoring unit and is used to receive and process temperature and pressure data and output a visual status chart. The fault diagnosis module is communicatively connected to the monitoring module and is used to receive processed temperature and pressure data and execute the following diagnostic logic: determine whether there is a situation where the data at a single point is abnormal while the neighboring points are normal, a situation where the rate of change of the data at a single point is significantly different from that of the neighboring points, or a situation where there is no signal output at a single point, and generate prompt information containing the fault location and type when a fault is diagnosed. The early warning module is communicatively connected to the monitoring module and is used to receive processed temperature and pressure data, and to provide graded early warnings based on the pressure change rate and pressure absolute value: when the pressure change rate exceeds the first threshold, a first-level early warning is triggered, and when the pressure absolute value reaches the second threshold, a second-level early warning is triggered. The pressure control module is communicatively connected to the monitoring module, receives the processed temperature and pressure data, and controls the inlet valve and outlet valve of the reactor to adjust the pressure in real time and maintain a slightly positive pressure state inside the reactor. The explosion relief device is installed on the top of the reactor body. Its explosion pressure is preset and it is passively activated to relieve pressure when the pressure inside the reactor body reaches the explosion threshold.

2. The safety monitoring system for a vertical high-temperature and high-pressure reactor according to claim 1, characterized in that: The key spatial locations are located at the top center, upper side, middle side, lower side, and bottom center of the reactor body.

3. The safety monitoring system for a vertical high-temperature and high-pressure reactor according to claim 1, characterized in that: The first threshold is a pressure rise rate greater than 600 Pa / s and lasting for more than 20 seconds; the first-level warning is to issue a continuous audible and visual alarm signal, the display interface of the monitoring module flashes the warning prompt, and at the same time push the warning information to the mobile terminal of the relevant operator. The second threshold is when the pressure peak rises to 0.1 MPa; the secondary warning is to automatically shut off the feed system and heating system of the reactor.

4. The safety monitoring system for a vertical high-temperature and high-pressure reactor according to claim 1, characterized in that: The pressure control module maintains a slightly positive pressure state inside the reactor at a maximum pressure of 1000 Pa.

5. The safety monitoring system for a vertical high-temperature and high-pressure reactor according to claim 1, characterized in that: The explosion relief device includes a rupture disc, which is installed at the explosion relief port of the reactor body, and the explosion pressure is 0.15MPa±5%; A sealing structure is provided at the connection between the rupture disc and the reactor body; a venting pipe is provided at the venting port of the reactor body, with a venting pressure of 1.5 MPa for the venting pipe and 1 MPa for the venting port, forming a graded pressure bearing; a protective component is provided at the outlet end of the venting pipe to block the splashing of high-temperature carbon powder particles and guide the airflow.

6. A safety monitoring method for a vertical high-temperature and high-pressure reactor, characterized in that, Includes the following steps: S1. After the system starts up, it sequentially completes the hardware self-test and communication link test of the monitoring module, fault diagnosis module, and early warning module. Each sensor in the multi-point monitoring unit feeds back working status signals. After all signals are normal, it enters standby mode. S2. During the operation of the reactor, the multi-point monitoring unit continuously collects temperature and pressure data from each monitoring point and transmits them to the monitoring module. The monitoring module adjusts the opening of the inlet valve and the exhaust valve in real time according to the preset pressure control target to maintain a slightly positive pressure state inside the reactor. S3, the fault diagnosis module compares the temperature and pressure data collected from each monitoring point in real time to determine whether there are single-point numerical anomalies, abnormal response speeds, or signal loss, and generates prompt information including the fault location and type when a fault is diagnosed. S4. The early warning module dynamically analyzes the overall pressure change rate and absolute pressure value of the pressure data processed by the monitoring module. When the pressure change rate exceeds the first threshold, a first-level early warning is triggered, and when the absolute pressure value reaches the second threshold, a second-level early warning is triggered. S5. When the pressure rises to the explosion threshold, the explosion relief device is passively opened to relieve pressure. During the explosion relief process, the multi-point monitoring unit continuously collects temperature and pressure data at each monitoring point, and the monitoring module generates a dynamic curve of the explosion relief process in real time. S6. When the monitoring module shows that the temperature and pressure have returned to the normal range and have been running stably for the predetermined time, the explosion relief is determined to be complete, and an explosion relief completion prompt is issued.

7. The safety monitoring method for a vertical high-temperature and high-pressure reactor according to claim 6, characterized in that: In step S4, the first threshold is when the pressure rises from 1000 Pa to 13000 Pa within 20 seconds; the second threshold is when the absolute value of the pressure reaches 0.1 MPa.

8. The safety monitoring method for a vertical high-temperature and high-pressure reactor according to claim 6, characterized in that: In step S5, the explosion relief device is passively activated when the pressure reaches 0.15 MPa, and the explosion relief process takes no more than 10 minutes.

Images