Fluidized bed granulation and drying integrated intelligent device

Abstract

This invention discloses an integrated intelligent fluidized bed granulation and drying device, belonging to the field of fluidized bed granulation technology. The device includes a three-section variable-diameter adaptive fluidized bed chamber, an adjustable air distribution plate mechanism, a multispectral online in-situ particle detection module, a controller with a built-in multi-source data fusion algorithm, a gas-solid dual-circulation waste heat recovery system, and a fine powder in-situ agglomeration and regeneration device. The air distribution plate mechanism uses a worm gear-bevel gear transmission to synchronously rotate the fan blades to adjust the air outlet angle, and a second adjustment mechanism to regulate the air volume. The multispectral online detection module integrates near-infrared spectroscopy and high-speed microscopic imaging data, outputs a particle quality evaluation index through a deep learning model, and performs closed-loop control of spray, hot air, and air distribution plate parameters, automatically determining the granulation and drying endpoints. This invention solves the technical problems of uneven particle size distribution, delayed endpoint judgment, high energy consumption, and large fine powder loss, and can be widely used in integrated granulation and drying production in the pharmaceutical, food, and chemical industries.

Description

Technical Field

[0001] This invention relates to the field of fluidized bed granulation technology, specifically to an integrated intelligent equipment for fluidized bed granulation and drying. Background Technology

[0002] Fluidized bed granulation and drying technology is a one-step granulation technology that integrates granulation and drying processes into a single device. Due to its advantage of completing mixing, granulation, and drying in one operation, it has been widely used in the pharmaceutical, food, and chemical industries. Existing fluidized bed granulation and drying equipment typically includes an air inlet chamber, a granulation and drying chamber, an expansion section, and a separation chamber, with an air distribution plate installed between the granulation and drying chamber and the air inlet chamber. However, traditional fluidized bed granulation and drying equipment still has the following prominent problems in practical applications: First, the particle size distribution is uneven and there are serious local dead beds.

[0003] Traditional fluidized beds employ a fixed cavity structure with a single, fixed airflow velocity, making it difficult to adapt to the varying airflow requirements at different stages of granulation and drying. In the initial stage of granulation, the powder is lightweight, and high airflow velocities easily cause dust and powder to fly away. In the middle and later stages of granulation, the particles gradually become heavier, and low airflow velocities cannot guarantee sufficient fluidization and tumbling. Insufficient fluidization of large particles leads to dead beds and agglomeration, while small particles are largely entrained and discharged, resulting in particle size dispersion, low yield, and high material loss. Uneven airflow distribution is also a core issue in existing equipment. If the airflow distribution plate has improperly designed openings or becomes blocked, it can lead to an imbalance in the fluidization state of the material within the bed, with some areas experiencing excessive boiling and agglomeration, while other areas suffer from insufficient fluidization, resulting in dead beds.

[0004] Second, the process parameters rely on manual setting, resulting in a lag in endpoint determination.

[0005] Existing smart devices can only monitor basic parameters such as temperature, wind speed, and humidity. Key quality attributes such as particle moisture content, roundness, porosity, and particle size distribution still require offline sampling and testing. This detection method has significant lag, making it difficult to reflect the true state of particles within the chamber in real time, resulting in large batch-to-batch deviations and significant human error. Although some studies have attempted to apply near-infrared spectroscopy to moisture detection in fluidized bed granulation processes, these are mostly single-parameter monitoring methods, lacking a closed-loop self-tuning control system that integrates multiple parameters.

[0006] Third, it has high energy consumption and insufficient utilization of waste heat.

[0007] Traditional fluidized bed equipment uses a relatively simple waste heat recovery method, only partially recovering the sensible heat from the hot air exhaust gas, while a large amount of humid and hot exhaust gas containing water vapor is directly discharged. The latent heat of condensation contained in the moisture is not utilized, and the high humidity in the exhaust gas leads to a decrease in drying efficiency when the hot air is recycled, creating an industry contradiction of "high energy consumption for high-temperature drying and low efficiency for low-temperature drying".

[0008] Fourth, the loss of fine powder is high and the recycling process is cumbersome.

[0009] During fluidized bed granulation, a large amount of fine powder is carried away with the exhaust gas. Existing equipment requires external dust collection devices (such as bag filters, cyclone separators, etc.) to collect the fine powder before it is manually returned to the machine. This process is not only cumbersome and increases equipment investment and operating costs, but also results in poor integration between the returned fine powder and the finished granules, affecting the density and roundness of the granules.

[0010] To address the aforementioned technical challenges, there is an urgent need to develop an integrated intelligent fluidized bed granulation and drying equipment capable of achieving graded dynamic fluidization, online intelligent detection and closed-loop control, efficient waste heat utilization, and in-situ regeneration of fine powder. Summary of the Invention

[0011] The purpose of this invention is to provide an integrated intelligent fluidized bed granulation and drying device to solve the problems mentioned in the background art.

[0012] To achieve the above objectives, the present invention provides the following technical solution: an integrated intelligent fluidized bed granulation and drying device, comprising a fluidized bed, an air distribution plate mechanism, an air inlet system, a spray system, and a controller. The fluidized bed is a three-section variable-diameter adaptive fluidized bed, comprising a bottom narrow diameter section, a middle equal diameter section, and a top expanded diameter section from bottom to top, with a smooth transition between the bottom narrow diameter section, the middle equal diameter section, and the top expanded diameter section. The air distribution plate mechanism is located at the bottom of the fluidized bed and corresponds to the output end of the air inlet system, comprising an outer support ring, an inner support cylinder, multiple fan blades, and a first adjustment mechanism. The outer support ring is fixedly connected to the inner wall of the bottom narrow diameter section, and the multiple fan blades are arranged in a ring array and rotatably connected between the outer support ring and the inner support cylinder by a drive rod. The first adjustment mechanism is used to drive the multiple fan blades to rotate synchronously to adjust the air outlet angle.

[0013] Preferably, the surface of the fan blade is provided with a plurality of ventilation holes, and the lower surface of the fan blade is provided with a second adjustment mechanism for adjusting the air volume of the ventilation holes. The second adjustment mechanism includes a plurality of wind caps, a plurality of conical sealing columns, an adjustment bracket and a hydraulic telescopic rod. The plurality of wind caps are fixedly connected to the ventilation holes one by one. The upper end of the wind cap is provided with at least one air outlet, and the lower end of the wind cap is provided with an air cavity communicating with the air outlet. The adjustment bracket is slidably connected to the lower surface of the fan blade through a limiting column. The hydraulic telescopic rod is provided between the adjustment bracket and the lower surface of the fan blade. The plurality of conical sealing columns are all fixedly connected to the surface of the adjustment bracket and correspond to the air cavity.

[0014] Preferably, the first adjustment mechanism includes a servo motor, a transmission worm, a worm wheel, a vertical bevel gear, and multiple horizontal bevel gears. The multiple horizontal bevel gears are rotatably connected to the inner wall of the inner support cylinder and are correspondingly connected to multiple drive rods. The worm wheel is rotatably connected to the bottom of the inner support cylinder. The vertical bevel gear is connected to the rotation shaft of the worm wheel and meshes with the multiple horizontal bevel gears. The transmission worm is rotatably connected to the inner wall of the inner support cylinder and meshes with the worm wheel. The tail of the transmission worm extends to the outside of the fluidization cavity and is connected to the output end of the servo motor.

[0015] Preferably, the system further includes a multispectral online in-situ particle detection module, which comprises a near-infrared spectral sensor and a high-speed microscopic imaging sensor. The near-infrared spectral sensor operates in the wavelength range of 1100–1600 nm and uses diffuse reflectance detection. It collects the spectral information of particles within the cavity without contact through a sapphire window for real-time detection of particle moisture content and porosity. The high-speed microscopic imaging sensor is an industrial-grade high-speed camera with a sampling frequency of 40–80 frames per second. It is used in conjunction with a telecentric lens and an LED ring light source for real-time detection of particle size distribution and sphericity. Two sets of near-infrared spectral sensors and two sets of high-speed microscopic imaging sensors are symmetrically installed on the sidewalls of the equal-diameter section in the middle of the fluidized cavity, and one set of near-infrared spectral sensors is installed on the sidewalls of the expanded-diameter section at the top.

[0016] Preferably, the controller is signal-connected to the multispectral online particle in-situ detection module and is respectively controlled by the servo motors and hydraulic telescopic rods of the spray system, air intake system, and air distribution plate mechanism. The controller has a built-in deep learning-based multi-source data fusion algorithm, and its control logic includes a data acquisition layer, a feature extraction layer, a fusion evaluation layer, and a decision execution layer. The data acquisition layer is used to receive in real time particle moisture content and porosity data from the near-infrared spectral sensor and particle size distribution and roundness data from the high-speed microscopic imaging sensor. The feature extraction layer is used to preprocess the near-infrared spectral data by performing first-order derivative and multivariate scattering correction to obtain features. The absorbance value at a given wavelength is used to perform edge detection and contour recognition on the microscopic image, and to obtain the statistical features of particle size distribution and the roundness coefficient. The fusion evaluation layer is used to input the above absorbance value, statistical features of particle size distribution, and roundness coefficient into the trained deep neural network model and output the comprehensive particle quality evaluation index. The decision execution layer is used to automatically output control commands based on the comprehensive particle quality evaluation index through a composite control algorithm combining PID and fuzzy control, including adjusting the spray rate, atomization pressure, hot air temperature, fluidization velocity, air volume and air outlet angle of the air distribution plate mechanism, and automatically determining the granulation endpoint and drying endpoint based on the particle moisture content.

[0017] Preferably, the system further includes a gas-solid dual-cycle waste heat recovery system, which comprises a primary waste heat recovery unit, a secondary waste heat recovery unit, a tertiary waste heat recovery unit, and a dehumidification recovery module. The primary waste heat recovery unit is installed on the exhaust duct and the fresh air duct, and is a gas-to-gas plate heat exchanger, used to preheat the fresh air using the waste heat exhaust gas in the exhaust duct. The secondary waste heat recovery unit is installed on the exhaust duct and the reagent delivery pipe, and is located downstream of the primary waste heat recovery unit. It is a gas-liquid shell-and-tube heat exchanger, used to preheat the adhesive liquid using the latent heat of condensation of the moisture in the exhaust gas. The tertiary waste heat recovery unit is installed on the outer wall of the fluidization chamber and the feed pipe, and is a jacketed heat exchanger, used to preheat the feed powder using heat dissipation from the chamber.

[0018] Preferably, the dehumidification and recovery module is installed on the exhaust duct and located downstream of the secondary waste heat recovery unit. It includes a dehumidifier and a return pipe. The input end of the dehumidifier is connected to the output end of the exhaust duct, and the output end of the dehumidifier is connected to the return pipe. The end of the return pipe away from the dehumidifier is connected to the middle of the air inlet duct. It is used to return the dehumidified dry hot air to the air inlet duct and mix it with the preheated fresh air before it re-enters the fluidized chamber.

[0019] Preferably, a fine powder in-situ agglomeration and regeneration device is provided above the top expansion section of the fluidizing cavity. The fine powder in-situ agglomeration and regeneration device includes a low-speed fine powder agglomeration chamber, a micro-atomizing adhesive nozzle, and a low-speed fluidizing gas distribution plate. The low-speed fine powder agglomeration chamber has a cylindrical structure, with its bottom connected to the top expansion section and its top connected to the inlet of the exhaust duct. The micro-atomizing adhesive nozzle is located in the middle of the low-speed fine powder agglomeration chamber and is a dual-fluid atomizing nozzle, connected to the spray duct through a side branch pipe. The low-speed fluidizing gas distribution plate is located at the bottom of the low-speed fine powder agglomeration chamber and has an annular porous plate structure.

[0020] Preferably, the spray volume of the micro-atomizing adhesive nozzle is 15% to 35% of the spray volume of the atomizing nozzle of the spray system; the fluidizing gas velocity introduced into the low-speed fluidizing gas distribution plate is 0.2 to 0.4 times the fluidizing gas velocity of the middle equal diameter section.

[0021] Preferably, the height of the bottom narrow section accounts for 15% to 25% of the total height of the fluidizing cavity, the height of the middle equal-diameter section accounts for 45% to 55% of the total height, and the height of the top widening section accounts for 25% to 35% of the total height.

[0022] Beneficial effects This invention provides an integrated intelligent equipment for fluidized bed granulation and drying, which has the following beneficial effects: 1. This integrated intelligent fluidized bed granulation and drying equipment utilizes a three-section variable-diameter adaptive fluidizing chamber, consisting of a narrow-diameter bottom section, a uniform-diameter middle section, and an expanding-diameter top section, coupled with an adjustable air outlet angle and volume distribution plate mechanism, to achieve staged dynamic fluidization. In the initial stage of granulation, it operates with low air volume, small air outlet angle, and low air velocity to effectively prevent the flying of light powder dust. In the middle stage of granulation, it operates with high air volume, medium tilt angle, and increased air velocity to ensure sufficient tumbling and adhesion of particles, resulting in uniform particle growth. In the later stage of drying, it operates with medium air volume and large tilt angle to ensure uniform dehydration of particles. The three-section variable-diameter chamber, combined with the dynamically adjustable air outlet plate mechanism, achieves precise staged fluidization control throughout the granulation and drying process, significantly improving particle size uniformity and yield.

[0023] 2. This integrated intelligent fluidized bed granulation and drying equipment achieves real-time online detection and closed-loop self-tuning control of particle quality attributes by incorporating a multi-spectral online in-situ particle detection module and a controller with a built-in multi-source data fusion algorithm. Near-infrared spectral sensors detect particle moisture content and porosity in real time, while high-speed microscopic imaging sensors detect particle size distribution and sphericity. Multi-source data is fused via a deep neural network to output a comprehensive particle quality evaluation index. A composite control algorithm combining PID and fuzzy control automatically adjusts spray parameters, hot air parameters, and air distribution plate parameters, and automatically determines the granulation and drying endpoints. This completely changes the traditional lag mode relying on manual settings and offline detection, significantly improving batch consistency and product yield.

[0024] 3. This integrated intelligent fluidized bed granulation and drying equipment achieves efficient tiered utilization of heat through a gas-solid dual-circulation waste heat recovery system. The first-stage waste heat recovery unit uses exhaust waste heat to preheat fresh air; the second-stage unit uses the latent heat of condensation in the exhaust gas to preheat the binder solution; and the third-stage unit uses chamber heat dissipation to preheat the feed powder. A dehumidification module dehumidifies the exhaust gas and recycles it. Through this three-stage tiered utilization of sensible heat recovery, latent heat recovery, and chamber heat dissipation recovery, along with exhaust gas dehumidification and recycling, the overall energy consumption is significantly reduced, resolving the industry contradiction of high energy consumption in high-temperature drying and low efficiency in low-temperature drying.

[0025] 4. This integrated intelligent fluidized bed granulation and drying equipment achieves zero-discharge in-situ regeneration of entrained fine powder by incorporating an in-situ fine powder agglomeration and regeneration device. Fine powder escaping due to airflow enters the low-speed fine powder agglomeration chamber, where it comes into contact with micro-atomized binder droplets under gentle fluidization conditions. The fine powder particles agglomerate into small microparticles, which automatically fall back into the fluidization chamber to participate in secondary granulation. The entire process achieves zero fine powder discharge, eliminating the need for manual recovery and external dust collection and return equipment, significantly reducing equipment investment and operating costs while improving material yield and particle density and roundness. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of an integrated intelligent fluidized bed granulation and drying device proposed in this invention. Figure 2 This is a three-dimensional structural diagram of the air distribution plate mechanism of an integrated intelligent fluidized bed granulation and drying device proposed in this invention; Figure 3 This is a cross-sectional schematic diagram of the air distribution plate mechanism of an integrated intelligent fluidized bed granulation and drying device proposed in this invention. Figure 4 This is a bottom view of the fan blade structure of an integrated intelligent fluidized bed granulation and drying device proposed in this invention. Figure 5 This is a three-dimensional structural diagram of the air cap of an integrated intelligent fluidized bed granulation and drying device proposed in this invention; Figure 6 This is a schematic diagram of the three-dimensional structure of the low-speed fluidizing gas distribution disc of an integrated intelligent fluidized bed granulation and drying device proposed in this invention.

[0027] In the diagram: 1. Fluidizing chamber; 2. Air distribution plate mechanism; 3. Bottom narrow diameter section; 4. Middle equal diameter section; 5. Top widening diameter section; 6. Feed pipe; 7. Discharge pipe; 8. Exhaust pipe; 9. Outer support ring; 10. Inner support cylinder; 11. Fan blade; 12. Drive rod; 13. Servo motor; 14. Transmission worm gear; 15. Worm gear; 16. Vertical bevel gear; 17. Horizontal bevel gear; 18. Air cap; 19. Conical sealing column; 20. Adjusting bracket; 21. Hydraulic telescopic rod; 22. Air outlet; 23. Air cavity; 24. Near 25. Infrared spectral sensor; 26. High-speed microscopic imaging sensor; 27. Adhesive storage tank; 28. Chemical delivery pipe; 29. ​​High-pressure spray pump; 30. Atomizing nozzle; 31. Fresh air duct; 32. Preheater; 33. Air supply fan; 34. Air inlet duct; 35. Dehumidification and recovery module; 36. Primary waste heat recovery unit; 37. Secondary waste heat recovery unit; 38. Tertiary waste heat recovery unit; 39. Dehumidifier; 40. Return pipe; 41. Low-speed fine powder agglomeration chamber; 42. Micro-atomizing adhesive filling nozzle; 43. Low-speed fluidizing gas distribution plate. Detailed Implementation

[0028] 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.

[0029] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0030] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0031] Example 1, please refer to Figures 1 to 6 The present invention provides a technical solution: an integrated intelligent equipment for fluidized bed granulation and drying, comprising a fluidized chamber 1, an air distribution plate mechanism 2, an air inlet system, a spray system and a controller.

[0032] The fluidization chamber 1 is a three-section variable-diameter adaptive fluidization chamber, consisting of a bottom narrow diameter section 3, a middle constant diameter section 4, and a top widening diameter section 5 from bottom to top. The bottom narrow diameter section 3, the middle constant diameter section 4, and the top widening diameter section 5 are smoothly connected to avoid particle impact and wear caused by sudden changes in airflow.

[0033] The bottom narrow section 3 accounts for 20% of the total height of the fluidizing cavity 1, the middle constant diameter section 4 accounts for 50% of the total height, and the top widening section 5 accounts for 30% of the total height. The inner diameter of the bottom narrow section 3 is 0.65 times the inner diameter of the middle constant diameter section 4, and the inner diameter of the top widening section 5 is 1.5 times the inner diameter of the middle constant diameter section 4.

[0034] A feed pipe 6 is connected to the side of the equal-diameter section 4 near the top, and a discharge pipe 7 is connected to the middle of the side of the narrow-diameter section 3 at the bottom. The lower end of the narrow-diameter section 3 is connected to the output end of the air inlet system. An exhaust pipe 8 is installed at the upper end of the widened-diameter section 5 at the top.

[0035] Please refer to Example 2 for details. Figures 2 to 5 The air distribution plate mechanism 2 is located at the bottom of the fluidization chamber 1 and corresponds to the output end of the air inlet system.

[0036] The air distribution plate mechanism 2 includes an outer support ring 9, an inner support cylinder 10, multiple fan blades 11, and a first adjustment mechanism. The outer support ring 9 is fixedly connected to the inner wall of the bottom narrow diameter section 3. The multiple fan blades 11 are arranged in a ring array and are rotatably connected between the outer support ring 9 and the inner support cylinder 10 through a drive rod 12.

[0037] The first adjustment mechanism includes a servo motor 13, a transmission worm 14, a worm wheel 15, a vertical bevel gear 16, and multiple horizontal bevel gears 17. The multiple horizontal bevel gears 17 are rotatably connected to the inner wall of the inner support cylinder 10, and the multiple horizontal bevel gears 17 are correspondingly connected to multiple drive rods 12. The worm wheel 15 is rotatably connected to the bottom of the inner support cylinder 10. The vertical bevel gear 16 is connected to the rotating shaft of the worm wheel 15, and the multiple horizontal bevel gears 17 are all meshed with the vertical bevel gear 16. The transmission worm 14 is rotatably connected to the inner wall of the inner support cylinder 10, and the transmission worm 14 is meshed with the worm wheel 15. The tail of the transmission worm 14 extends to the outside of the fluidization cavity 1 and is connected to the output end of the servo motor 13.

[0038] During operation, the servo motor 13 drives the transmission worm gear 14 to rotate. The transmission worm gear 14 and the worm wheel 15 mesh to drive the vertical bevel gear 16 to rotate. The vertical bevel gear 16 and multiple horizontal bevel gears 17 mesh to drive multiple drive rods 12 to rotate synchronously, which in turn drives multiple fan blades 11 to rotate. As the fan blades 11 rotate, air outlet channels with gradually changing angles are formed between adjacent fan blades 11, thereby realizing the adjustment of the air outlet angle of the air distribution plate mechanism 2.

[0039] The surface of the fan blade 11 has several ventilation holes. The lower surface of the fan blade 11 is provided with a second adjustment mechanism for adjusting the air volume of the ventilation holes. The second adjustment mechanism includes several wind caps 18, several conical sealing columns 19, an adjustment bracket 20 and a hydraulic telescopic rod 21. Several wind caps 18 are fixedly connected to the ventilation holes one by one, and the upper end of the wind cap 18 has at least one air outlet 22. The lower end of the wind cap 18 has an air cavity 23 that communicates with the air outlet 22. The adjustment bracket 20 is slidably connected to the lower surface of the fan blade 11 through a limiting column. The hydraulic telescopic rod 21 is located between the adjustment bracket 20 and the lower surface of the fan blade 11. Several conical sealing columns 19 are fixedly connected to the surface of the adjustment bracket 20, and the conical sealing columns 19 correspond to the air cavity 23.

[0040] During operation, the hydraulic telescopic rod 21 extends and retracts, which can drive the adjusting bracket 20 to rise and fall, thereby driving multiple conical sealing columns 19 to rise and fall. When the conical sealing column 19 rises to the top, it can completely block the inlet of the air cavity 23. When the conical sealing column 19 descends, it can gradually open the inlet of the air cavity 23, thereby gradually increasing the air volume of the air outlet 22. This allows for adjustment of the air volume of the air distribution plate mechanism 2. Furthermore, the design of multiple air caps 18 makes the air distribution plate mechanism 2 more uniform in its air output.

[0041] Example 3

[0042] An integrated intelligent fluidized bed granulation and drying device further includes a multispectral online in-situ particle detection module, which comprises a near-infrared spectral sensor 24 and a high-speed microscopic imaging sensor 25. The near-infrared spectral sensor 24 operates in the wavelength range of 1100–1600 nm, employing diffuse reflectance detection to non-contactly acquire spectral information of particles within the chamber through a sapphire window. The high-speed microscopic imaging sensor 25 is an industrial-grade high-speed camera with a sampling frequency of 60 frames per second, which, in conjunction with a telecentric lens and an LED ring light source, acquires real-time morphological images of the particles. The near-infrared spectral sensor 24 is used for real-time detection of particle moisture content and porosity, while the high-speed microscopic imaging sensor 25 is used for real-time detection of particle size distribution and sphericity.

[0043] Two sets of near-infrared spectral sensors 24 and two sets of high-speed microscopic imaging sensors 25 are symmetrically installed on the sidewalls of the equal diameter section 4 in the middle of the fluidized cavity 1, and a set of near-infrared spectral sensors 24 is installed on the sidewalls of the top diameter-expanding section 5 to ensure that the detection data has good representativeness and coverage.

[0044] The spraying system includes an adhesive storage tank 26, a chemical delivery pipe 27, a high-pressure spray pump 28, and atomizing nozzles 29. The input end of the high-pressure spray pump 28 is connected to the adhesive storage tank 26 through the chemical delivery pipe 27, and the output end of the high-pressure spray pump 28 is connected to the atomizing nozzles 29 through a spray pipe. The atomizing nozzles 29 are located on both sides of the bottom of the equal diameter section 4 in the middle.

[0045] The air intake system includes a fresh air duct 30, a preheater 31, a blower 32, and an air intake pipe 33. The fresh air duct 30 is connected to the input end of the preheater 31, the input end of the blower 32 is connected to the output end of the preheater 31, the air intake pipe 33 is connected to the output end of the preheater 31, and the air intake pipe 33 is connected to the lower end of the bottom narrow diameter section 3.

[0046] Example 4

[0047] The controller is signal-connected to the multispectral online in-situ particle detection module, and is respectively controlled by the servo motor 13 and hydraulic telescopic rod 21 of the spray system, air intake system, and air distribution plate mechanism 2. The controller has a built-in deep learning-based multi-source data fusion algorithm, and its control logic is as follows: (1) Data acquisition layer: Real-time reception of near-infrared spectral data fed back by near-infrared spectral sensor 24, including: particle moisture content and porosity data; and microscopic images fed back by high-speed microscopic imaging sensor 25, including: particle size distribution and roundness data.

[0048] (2) Feature extraction layer: The near-infrared spectral data are preprocessed with first derivative and multivariate scattering correction to obtain the absorbance value at the characteristic wavelength; edge detection and contour recognition are performed on the microscopic image to obtain the statistical features of particle size distribution and roundness coefficient.

[0049] (3) Fusion evaluation layer: The absorbance value, particle size distribution statistical characteristics and roundness coefficient are input into the trained deep neural network model, and the particle comprehensive quality evaluation index is output.

[0050] (4) Decision execution layer: Based on the particle comprehensive quality evaluation index, the following control instructions are automatically output through a composite control algorithm combining PID and fuzzy control: Adjust the rotation speed of the high-pressure spray pump 28 to control the spray rate; Adjust the supply pressure of the high-pressure spray pump 28 to control the atomization pressure; Adjust the heating power of preheater 31 to control the hot air temperature; Adjust the speed of the blower 32 to control the fluidization velocity; Adjust the rotation angle of the servo motor 13 and the extension length of the hydraulic telescopic rod 21 to control the air volume and air outlet angle of the air distribution plate mechanism 2; The granulation endpoint and drying endpoint are automatically determined based on the particle moisture content.

[0051] Example 5

[0052] A fluidized bed granulation and drying integrated intelligent equipment also includes a gas-solid dual-circulation waste heat recovery system, comprising a primary waste heat recovery unit 35, a secondary waste heat recovery unit 36, a tertiary waste heat recovery unit 37, and a dehumidification recovery module 34.

[0053] The primary waste heat recovery unit 35 is installed on the exhaust duct 8 and the fresh air duct 30. It is a gas-to-gas plate heat exchanger that uses the waste heat exhaust gas with a temperature of about 70 to 90°C in the exhaust duct 8 to preheat the fresh air entering the preheater 31 from the fresh air duct 30. It can preheat the fresh air from room temperature (about 20°C) to 45 to 55°C.

[0054] The secondary waste heat recovery unit 36 ​​is installed on the exhaust duct 8 and the agent delivery pipe 27 and is located downstream of the primary waste heat recovery unit 35. It is a gas-liquid shell-and-tube heat exchanger that uses the latent heat of condensation of the moisture in the exhaust gas to preheat the adhesive liquid in the agent delivery pipe 27, which can preheat the liquid from room temperature to 35-45°C.

[0055] The three-stage waste heat recovery unit 37 is installed on the outer wall of the fluidizing chamber 1 and the feed pipe 6. It is a jacketed heat exchanger that fits into the outer wall of the chamber. It uses the heat dissipation of the chamber to preheat the initial feed powder in the feed pipe 6, and can preheat the initial feed powder to 30-40°C.

[0056] The dehumidification and recovery module 34 is located on the exhaust duct 8 and downstream of the secondary waste heat recovery unit 36. It includes a dehumidifier 38 and a return pipe 39. The input end of the dehumidifier 38 is connected to the output end of the exhaust duct 8, and the output end of the dehumidifier 38 is connected to the return pipe 39. The end of the return pipe 39 furthest from the dehumidifier 38 is connected to the middle of the air inlet duct 33. The fluidized dry exhaust gas (temperature about 60-80℃, relative humidity about 70%-90%) in the exhaust duct 8 enters the dehumidifier 38. The dehumidified dry hot air (relative humidity reduced to 30%-50%) is returned to the air inlet duct 33 through the return pipe 39. After mixing with the preheated fresh air, it re-enters the fluidized chamber 1, realizing the recycling of hot air.

[0057] Example 6

[0058] A fine powder in-situ agglomeration and regeneration device is provided above the top expansion section 5 of the fluidization chamber 1. The fine powder in-situ agglomeration and regeneration device includes a low-speed fine powder agglomeration chamber 40, a micro-atomizing glue filling nozzle 41, and a low-speed fluidizing gas distribution plate 42.

[0059] The low-speed fine powder agglomeration chamber 40 has a cylindrical structure, with the bottom and top expansion section 5 connected, and the top connected to the inlet of the exhaust duct 8.

[0060] The micro-atomizing adhesive nozzle 41 is located in the middle of the low-speed fine powder agglomeration chamber 40. It is a dual-fluid atomizing nozzle used to form nanoscale spray. The micro-atomizing adhesive nozzle 41 is connected to the spray pipeline through a side branch pipeline. The spray volume of the micro-atomizing adhesive nozzle 41 is 25% of the spray volume of the atomizing nozzle 29.

[0061] The low-speed fluidizing gas distribution plate 42 is located at the bottom of the low-speed fine powder agglomeration cavity 40. It has an annular porous plate structure, and the fluidizing gas velocity introduced is 0.3 times that of the fluidizing gas velocity in the middle constant diameter section 4.

[0062] During operation, fine powder escaped by the airflow enters the low-speed fine powder agglomeration chamber 40, where it comes into contact with micro-atomized binder droplets under gentle fluidization conditions. The fine powder particles agglomerate together to form small microparticles. When the agglomerated microparticles grow to a certain size, they overcome the carrying force of the rising airflow and automatically fall back to the top expansion section 5, then enter the middle equal-diameter section 4 to participate in secondary granulation. Throughout the entire process, there is zero discharge of fine powder, eliminating the need for manual collection and external dust collection and return equipment.

[0063] Example 7

[0064] The working process of the device of the present invention is as follows: (I) Initial Granulation Stage. Based on the initial powder state fed back by the multispectral online particle in-situ detection module, the controller controls the servo motor 13 and hydraulic telescopic rod 21 to adjust the air distribution plate mechanism 2 to a small air volume and small air outlet angle (approximately 0-5°), controls the blower 32 to operate at a low wind speed, and controls the spray system to start at a low liquid spray rate. The powder is initially fluidized by the airflow in the narrow diameter section 3 at the bottom, and comes into contact with the atomized binder droplets in the equal diameter section 4 in the middle, beginning to form initial particle nuclei. The low wind speed at this stage effectively prevents the lightweight powder from flying and creating dust.

[0065] (II) Mid-stage of granulation. As the particles gradually increase in weight, the multispectral online particle in-situ detection module detects changes in particle size and moisture content in real time. The controller automatically adjusts the air distribution plate mechanism 2 to a high air volume and a medium tilt angle (about 8 to 15°) to increase the wind speed and liquid spraying rate, ensuring that the particles fully tumble and bond and grow uniformly in the equal diameter section 4 in the middle.

[0066] (III) Post-drying stage. Once the particles reach the target particle size, the controller automatically stops spraying, adjusts the air distribution plate mechanism 2 to a medium airflow and a large tilt angle (approximately 15–20°), and controls the hot air temperature and fluidization velocity to enter the drying mode. The low wind speed of the top expansion section 5 effectively suppresses the entrainment of fine particles, while the stable fluidization of the middle equal-diameter section 4 ensures uniform dehydration of the particles. When the multispectral online particle in-situ detection module detects that the particle moisture content has reached the target value, the controller automatically determines the drying endpoint and opens the discharge pipe 7 to stop the machine and discharge the material.

[0067] Throughout the granulation and drying process, the gas-solid dual-circulation waste heat recovery system operates continuously. The first-stage waste heat recovery unit 35 preheats the fresh air, the second-stage waste heat recovery unit 36 ​​preheats the binder solution, and the third-stage waste heat recovery unit 37 preheats the feed powder. The dehumidification and recovery module 34 dehumidifies the exhaust gas and returns it for recycling. The fine powder in-situ agglomeration and regeneration device operates continuously, agglomerating the escaped fine powder in situ and returning it to the fluidized chamber 1 to participate in granulation.

[0068] Actual production verification has shown that the particle size uniformity and material yield of the equipment using this invention are significantly improved, the overall energy consumption is significantly reduced, and the batch consistency error is effectively controlled.

[0069] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of the invention. Any person skilled in the art can make modifications or alterations to the disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications or equivalent substitutions made to the above embodiments based on the technical essence of the present invention, without departing from the scope of the present invention, should be included within the protection scope of the present invention.

Claims

1. A fluidized bed granulation and drying integrated intelligent device, comprising a fluidized bed cavity (1), an air distribution plate mechanism (2), an air inlet system, a spray system, and a controller, characterized in that: The fluidizing cavity (1) is a three-section variable diameter adaptive fluidizing cavity, which includes a bottom narrow diameter section (3), a middle equal diameter section (4) and a top expanded diameter section (5) from bottom to top. The bottom narrow diameter section (3), the middle equal diameter section (4) and the top expanded diameter section (5) are smoothly connected. The air distribution plate mechanism (2) is set at the bottom of the fluidizing cavity (1) and corresponds to the output end of the air inlet system. It includes an outer support ring (9), an inner support cylinder (10), multiple fan blades (11) and a first adjustment mechanism. The outer support ring (9) is fixedly connected to the inner wall of the bottom narrow diameter section (3). The multiple fan blades (11) are arranged in a ring array and are rotatably connected between the outer support ring (9) and the inner support cylinder (10) through a drive rod (12). The first adjustment mechanism is used to drive the multiple fan blades (11) to rotate synchronously to adjust the air outlet angle.

2. The integrated intelligent equipment for fluidized bed granulation and drying according to claim 1, characterized in that: The surface of the fan blade (11) is provided with several ventilation holes. The lower surface of the fan blade (11) is provided with a second adjustment mechanism for adjusting the air volume of the ventilation holes. The second adjustment mechanism includes several wind caps (18), several conical sealing columns (19), an adjustment bracket (20) and a hydraulic telescopic rod (21). Several wind caps (18) are fixedly connected to the ventilation holes one by one. At least one air outlet (22) is opened at the upper end of the wind cap (18). The lower end of the wind cap (18) is provided with an air cavity (23) that communicates with the air outlet (22). The adjustment bracket (20) is slidably connected to the lower surface of the fan blade (11) through a limiting column. The hydraulic telescopic rod (21) is set between the adjustment bracket (20) and the lower surface of the fan blade (11). Several conical sealing columns (19) are fixedly connected to the surface of the adjustment bracket (20) and correspond to the air cavity (23).

3. The integrated intelligent equipment for fluidized bed granulation and drying according to claim 1, characterized in that: The first adjustment mechanism includes a servo motor (13), a transmission worm (14), a worm wheel (15), a vertical bevel gear (16), and multiple horizontal bevel gears (17). The multiple horizontal bevel gears (17) are rotatably connected to the inner wall of the inner support cylinder (10) and are connected to multiple drive rods (12) in a one-to-one transmission connection. The worm wheel (15) is rotatably connected to the bottom of the inner support cylinder (10). The vertical bevel gear (16) is connected to the rotating shaft of the worm wheel (15) and meshes with the multiple horizontal bevel gears (17). The transmission worm (14) is rotatably connected to the inner wall of the inner support cylinder (10) and meshes with the worm wheel (15). The tail of the transmission worm (14) extends to the outside of the fluidization cavity (1) and is connected to the output end of the servo motor (13).

4. The integrated intelligent equipment for fluidized bed granulation and drying according to claim 1, characterized in that: It also includes a multispectral online particle in-situ detection module, which includes a near-infrared spectral sensor (24) and a high-speed microscopic imaging sensor (25). The near-infrared spectral sensor (24) operates in the wavelength range of 1100-1600nm and adopts a diffuse reflection detection method. It collects the spectral information of particles in the cavity without contact through a sapphire window and is used to detect the moisture content and porosity of particles in real time. The high-speed microscopic imaging sensor (25) is an industrial-grade high-speed camera with a sampling frequency of 40-80 frames / second. It is used with a telecentric lens and an LED ring light source to detect the particle size distribution and roundness of particles in real time. Two sets of near-infrared spectral sensors (24) and two sets of high-speed microscopic imaging sensors (25) are symmetrically installed on the side wall of the equal diameter section (4) in the middle of the fluidized cavity (1), and one set of near-infrared spectral sensors (24) is installed on the side wall of the top diameter expansion section (5).

5. The integrated intelligent equipment for fluidized bed granulation and drying according to claim 4, characterized in that: The controller is connected to the multispectral online particle in-situ detection module and is controlled by the servo motor (13) and hydraulic telescopic rod (21) of the spray system, air intake system, and air distribution plate mechanism (2), respectively. The controller has a built-in multi-source data fusion algorithm based on deep learning. Its control logic includes a data acquisition layer, a feature extraction layer, a fusion evaluation layer, and a decision execution layer. The data acquisition layer is used to receive in real time the particle moisture content and porosity data fed back by the near-infrared spectral sensor (24) and the particle size distribution and roundness data fed back by the high-speed microscopic imaging sensor (25). The feature extraction layer is used to preprocess the near-infrared spectral data by performing first derivative and multivariate scattering correction. The absorbance value at the characteristic wavelength is obtained, and the microscopic image is subjected to edge detection and contour recognition to obtain the particle size distribution statistical features and roundness coefficient. The fusion evaluation layer is used to input the above absorbance value, particle size distribution statistical features and roundness coefficient into the trained deep neural network model and output the particle comprehensive quality evaluation index. The decision execution layer is used to automatically output control commands according to the particle comprehensive quality evaluation index through a composite control algorithm combining PID and fuzzy control, including adjusting the spraying rate, atomization pressure, hot air temperature, fluidization wind speed, air volume and air outlet angle of the air distribution plate mechanism (2), and automatically determining the granulation endpoint and drying endpoint according to the particle moisture content.

6. The fluidized bed granulation and drying integrated intelligent equipment according to claim 1, characterized in that: It also includes a gas-solid dual-cycle waste heat recovery system, which includes a primary waste heat recovery unit (35), a secondary waste heat recovery unit (36), a tertiary waste heat recovery unit (37), and a dehumidification recovery module (34). The primary waste heat recovery unit (35) is installed on the exhaust duct (8) and the fresh air duct (30) and is a gas-gas plate heat exchanger, used to preheat the fresh air using the waste heat exhaust gas in the exhaust duct (8). The secondary waste heat recovery unit (36) is installed on the exhaust duct (8) and the agent delivery pipe (27) and is located downstream of the primary waste heat recovery unit (35). It is a gas-liquid shell-and-tube heat exchanger, used to preheat the adhesive liquid using the latent heat of condensation of the moisture in the exhaust gas. The tertiary waste heat recovery unit (37) is installed on the outer wall of the fluidization chamber (1) and the feed pipe (6) and is a jacketed heat exchanger, used to preheat the feed powder using the heat dissipation of the chamber.

7. The integrated intelligent equipment for fluidized bed granulation and drying according to claim 6, characterized in that: The dehumidification and recovery module (34) is located on the exhaust duct (8) and downstream of the secondary waste heat recovery unit (36). It includes a dehumidifier (38) and a return pipe (39). The input end of the dehumidifier (38) is connected to the output end of the exhaust duct (8), and the output end of the dehumidifier (38) is connected to the return pipe (39). The end of the return pipe (39) away from the dehumidifier (38) is connected to the middle of the air inlet duct (33). It is used to return the dehumidified dry hot air to the air inlet duct (33) and mix it with the preheated fresh air before it re-enters the fluidized cavity (1).

8. The integrated intelligent equipment for fluidized bed granulation and drying according to claim 1, characterized in that: A fine powder in-situ agglomeration and regeneration device is provided above the top expansion section (5) of the fluidizing cavity (1). The fine powder in-situ agglomeration and regeneration device includes a low-speed fine powder agglomeration cavity (40), a micro-atomizing glue nozzle (41), and a low-speed fluidizing gas distribution plate (42). The low-speed fine powder agglomeration cavity (40) is a cylindrical structure, with its bottom connected to the top expansion section (5) and its top connected to the inlet of the exhaust pipe (8). The micro-atomizing glue nozzle (41) is located in the middle of the low-speed fine powder agglomeration cavity (40) and is a dual-fluid atomizing nozzle, which is connected to the spray pipe through a side branch pipe. The low-speed fluidizing gas distribution plate (42) is located at the bottom of the low-speed fine powder agglomeration cavity (40) and is an annular porous plate structure.

9. The integrated intelligent equipment for fluidized bed granulation and drying according to claim 8, characterized in that: The spray volume of the micro-atomizing glue nozzle (41) is 15% to 35% of the spray volume of the atomizing nozzle (29) of the spray system; the fluidizing gas velocity introduced into the low-speed fluidizing gas distribution plate (42) is 0.2 to 0.4 times that of the fluidizing gas velocity in the middle equal diameter section (4).

10. The integrated intelligent equipment for fluidized bed granulation and drying according to claim 1, characterized in that: The height of the bottom narrow section (3) accounts for 15% to 25% of the total height of the fluidizing cavity (1), the height of the middle equal diameter section (4) accounts for 45% to 55% of the total height, and the height of the top widening section (5) accounts for 25% to 35% of the total height.

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