A full-automatic anti-blocking and slag-cleaning device and method for a cyclone basin suction well

Abstract

The application provides a full-automatic anti-blocking and slag cleaning device and method for a cyclone tank water suction well, and relates to the technical field of metallurgy. The full-automatic anti-blocking and slag cleaning device comprises a slag layer monitoring module, a disturbance module, a slag cleaning module, a slag discharging module and a control module. The slag layer monitoring module is used for monitoring a slag layer thickness parameter at the bottom of the water suction well. The disturbance module is used for applying a disturbance to the bottom of the water suction well to destroy the hardening structure of the slag layer. The slag cleaning module is used for cleaning the destroyed slag layer to separate slag in the slag layer from the bottom of the water suction well. The slag discharging module is used for discharging the separated slag. The control module is electrically connected or communicatively connected with the slag layer monitoring module, the disturbance module, the slag cleaning module and the slag discharging module. The control module controls the start and stop of the disturbance module, the slag cleaning module and the slag discharging module according to the slag layer thickness parameter. The full-automatic anti-blocking and slag cleaning device and method can automatically clean the deposited slag layer at the bottom of the water suction well.

Description

Technical Field

[0001] This invention relates to the field of metallurgical technology, and in particular to a fully automatic anti-clogging and slag-removing device and method for a cyclone pool suction well. Background Technology

[0002] The cyclone separator is a core facility for treating turbid circulating water in metallurgical enterprises. Iron oxide scale generated during steel rolling and continuous casting enters the cyclone separator along with the turbid circulating water. Larger particles settle in the lower sludge storage area; finer iron oxide particles are carried by the water flow into the central cylinder, spiraling downwards to the bottom before turning upwards, overturning the overflow weir, and entering the suction well. A booster pump is installed in the suction well to transport the preliminarily purified water to subsequent treatment equipment. Due to the low flow velocity and minimal turbulence within the suction well, the remaining fine iron oxide particles gradually deposit at the bottom, forming a sludge layer.

[0003] As the sludge layer thickens, some fine iron oxide particles can clog the inlet of the booster pump's suction pipe, leading to insufficient pump flow, equipment wear, and in severe cases, shutdown for maintenance. Therefore, it is necessary to clean the bottom of the suction well.

[0004] For example, patent CN222413397U proposes a structure for removing iron oxide scale from the suction zone of a vortex well. Two holes are opened at the bottom of the suction zone, separated from the well bottom. The pump body pipes of the suction zone pump and the external discharge pump are movably connected to the water pipe. The pumps use hydraulic power to flush the deposited slag from the holes into the external well, combined with a grab bucket for slag removal. However, this structure relies solely on the hydraulic flushing of the pumps, failing to clean the dead corners and hardened slag at the bottom of the well, making it prone to re-deposition of residual slag. It also relies on manual assistance: manual operation of the grab bucket for slag removal is labor-intensive, and the safety risks of working in confined spaces are not eliminated. Furthermore, it lacks real-time monitoring capabilities, making it impossible to determine the thickness of the slag accumulation at the bottom, requiring periodic shutdowns for inspection, which can easily lead to pump blockage accidents due to excessive slag accumulation.

[0005] In view of the shortcomings of existing technologies, such as incomplete cleaning of the bottom of the suction well, high safety risks, reliance on manual labor, lack of real-time monitoring, and impact on continuous production, this invention aims to provide a fully automatic anti-clogging and slag-removing device and method for the suction well of a cyclone pool to solve the deficiencies of the existing technology. Summary of the Invention

[0006] This invention proposes a fully automatic anti-clogging and slag-removing device and method for vortex pool suction wells, which can automatically clean the sediment layer at the bottom of the suction well.

[0007] To achieve the above-mentioned objectives, this invention proposes a fully automatic anti-clogging and slag-removing device for a vortex pool suction well, wherein the fully automatic anti-clogging and slag-removing device for a vortex pool suction well includes: The slag layer monitoring module is used to monitor the slag layer thickness parameters at the bottom of the water intake well. A disturbance module is used to apply disturbance to the slag layer in order to disrupt the slag layer's compacted structure; The slag removal module is used to clean the damaged slag layer, so that the slag material in the slag layer is separated from the bottom of the water intake well; The slag removal module is used to extract the separated slag material; The control module is electrically or communicatively connected to the slag layer monitoring module, the disturbance module, the slag cleaning module, and the slag discharge module, respectively. The control module controls the start and stop of the disturbance module, the slag cleaning module, and the slag discharge module according to the slag layer thickness parameter.

[0008] This invention also proposes a fully automated anti-clogging and slag removal method for a vortex pool suction well, wherein the fully automated anti-clogging and slag removal method includes: Real-time monitoring of the slag layer thickness at the bottom of the suction well; When the thickness of the slag layer reaches a first preset threshold, a disturbance is applied to the slag layer to disrupt its compacted structure. After the slab structure is destroyed, the bottom of the water intake well is cleaned to separate the slag material in the slag layer from the bottom of the water intake well. The separated slag is extracted from the bottom of the suction well. Compared with the prior art, the fully automatic anti-clogging and slag removal device and method for the suction well of the cyclone pool proposed in this invention has the following characteristics and advantages: The fully automatic anti-clogging and slag-removing device and method for vortex pool suction wells proposed in this invention can achieve full coverage and thorough cleaning of sediment at the bottom of the suction well, completely removing hardened slag and dead corner slag; moreover, there is no need to drain the well water or manually go down into the well during slag removal, eliminating the safety risks of working in confined spaces and reducing labor intensity.

[0009] The fully automatic anti-clogging and sludge removal device and method for cyclone pool suction wells proposed in this invention has real-time monitoring of sludge thickness and automatic start-stop cleaning functions, reducing manual intervention and improving cleaning efficiency.

[0010] The fully automatic anti-clogging and slag-removing device and method for the suction well of a cyclone pool proposed in this invention can achieve directional discharge and rapid separation of slag and water, preventing suspended slag from redepositing or clogging subsequent equipment. The fully automatic anti-clogging and slag-removing device for the suction well of a cyclone pool proposed in this invention has a simple structure, is easy to maintain, has low operating costs, is adaptable to the renovation of existing cyclone pools, and does not affect continuous production. Attached Figure Description

[0011] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of the invention in any way. Furthermore, the shapes and proportions of the components in the drawings are merely illustrative to aid in understanding the invention and do not specifically limit the shapes and proportions of the components. Those skilled in the art, guided by the teachings of this invention, can select various possible shapes and proportions to implement the invention according to specific circumstances.

[0012] Figure 1 This is a schematic diagram of the fully automatic anti-clogging and slag removal device proposed in this invention; Figure 2 This is a top view of the fully automatic anti-clogging and slag-removing device proposed in this invention; Figure 3 This is a flowchart illustrating the operation of the fully automatic anti-clogging and slag-removing device proposed in this invention.

[0013] Explanation of reference numerals in the attached figures

[0014] 100. Fully Automatic Anti-Clogging and Slag Removal Device; 20. Slag Layer Monitoring Module; 1. Pressure Detection Unit; 2. Liquid Level Detection Unit; 3. Data Acquisition Unit; 30. Disturbance Module; 5. Main Gas Supply Pipe; 6. Annular Gas Distribution Pipe; 7. Perforated Gas Pipe; 8. Electromagnetic Ball Valve; 40. Slag Removal Module; 9. Slag Flushing Water Pump; 10. Main Slag Flushing Pipe; 11. Annular Slag Flushing Pipe; 12. Nozzle; 50. Slide Valve; 14. Pre-embedded Slag Discharge Pipe; 60. Control Module. Detailed Implementation

[0015] The details of the present invention can be more clearly understood by referring to the accompanying drawings and the description of specific embodiments. However, the specific embodiments of the present invention described herein are for illustrative purposes only and should not be construed as limiting the invention in any way. Under the teachings of this invention, those skilled in the art can conceive of any possible modifications based on the invention, and these should all be considered to fall within the scope of the invention.

[0016] Please refer to Figure 1 , Figure 2 and Figure 3 As shown, this invention proposes a fully automatic anti-clogging and slag-removing device 100 for a cyclone pool suction well, comprising: The slag layer monitoring module 20 is used to monitor the slag layer thickness parameters at the bottom of the water intake well in real time. The disturbance module 30 is used to apply disturbance to the slag layer to disrupt the slag layer's compacted structure. The slag cleaning module 40 is used to clean the damaged slag layer, so that the slag material in the slag layer is separated from the bottom of the suction well; The slag removal module is used to extract the separated slag. The control module 60 is electrically or communicatively connected to the slag layer monitoring module 20, the disturbance module 30, the slag cleaning module 40, and the slag discharge module, respectively. The control module 60 controls the start and stop of the disturbance module 30, the slag cleaning module 40, and the slag discharge module according to the slag layer thickness parameters monitored by the slag layer monitoring module 20.

[0017] The fully automatic anti-clogging and slag removal device 100 for vortex pool suction wells proposed in this invention achieves real-time monitoring of slag layer thickness and automatic triggering and stopping of the cleaning process through the coordinated cooperation of slag layer monitoring module 20 and control module 60. It eliminates the need for manual inspection and operation, significantly reducing the labor intensity of operators and avoiding the safety risks of manual well cleaning.

[0018] The fully automatic anti-clogging and slag-removing device 100 for the suction well of a cyclone pool proposed in this invention first breaks down the compacted structure of the slag layer through a disturbance module 30, loosening the dense slag layer; then, a slag-removing module 40 cleans the slag to separate it from the bottom of the suction well; finally, a slag-discharge module extracts the suspended slag. Through the sequential activation and orderly coordination of the disturbance module 30, the slag-removing module 40, and the slag-discharge module, compared to a single slag-removing method, it can effectively handle severely compacted sediment and thoroughly remove compacted and dead-angle slag from the bottom of the suction well.

[0019] The fully automatic anti-clogging and slag-removing device 100 for the suction well of a cyclone pool proposed in this invention has a simple structure, is easy to maintain, has low operating costs, is suitable for the renovation of existing cyclone pools, and does not affect continuous production.

[0020] This invention also proposes a fully automated anti-clogging and slag removal method for the suction well of a vortex pool, the fully automated anti-clogging and slag removal method comprising: Real-time monitoring of the slag layer thickness at the bottom of the suction well; When the thickness of the slag layer reaches the first preset threshold, a disturbance is applied to the slag layer to disrupt its compacted structure. After the slag layer is destroyed, it is cleaned to separate the slag material in the slag layer from the bottom of the suction well. The separated slag is extracted from the bottom of the suction well.

[0021] This invention proposes a fully automated anti-clogging and slag-removing method for cyclone pool suction wells. Through the coordinated action of four steps—monitoring, disturbance, cleaning, and extraction—it achieves fully automated slag removal while efficiently and thoroughly cleaning hardened slag layers. The entire process requires no manual inspection, judgment, or operation, eliminating the safety risks associated with personnel working in confined spaces.

[0022] The slag removal method for vortex pool suction wells proposed in this invention involves a disturbance step before the cleaning step. This disturbance effect is applied to the compacted slag layer, causing its structure to change from dense and compacted to a loose state. After the compacted structure is sufficiently broken down, cleaning and extraction are then carried out. This not only improves cleaning efficiency but also avoids cleaning dead zones caused by the inability to effectively disperse the compacted slag layer.

[0023] The slag removal method for the vortex pool suction well proposed in this invention uses extraction as the final step, so that the separated slag is completely removed from the bottom of the suction well, rather than simply breaking up the slag layer and letting it settle naturally. Through directional discharge and rapid separation of slag and water, the suspended slag is prevented from redepositing or clogging subsequent equipment.

[0024] In an optional embodiment of the present invention, the control module 60 has a built-in first preset threshold and a second preset threshold. When the slag layer thickness detected by the slag layer monitoring module 20 reaches the first preset threshold, the control module 60 sequentially activates the disturbance module 30, the slag cleaning module 40, and the slag discharge module. When the slag layer thickness drops below the second preset threshold, the control module 60 sequentially shuts down the slag cleaning module 40, the slag discharge module, and the disturbance module 30. By setting the first preset threshold as the start value and the second preset threshold as the stop value, the fully automatic anti-clogging slag cleaning device 100 is ensured to only start when the slag layer thickness reaches the level that truly needs cleaning (the first preset threshold), and immediately stops after cleaning reaches the standard (the second preset threshold), thus achieving fully automatic on-demand operation without the need for manual intervention.

[0025] In an optional embodiment of the present invention, the slag layer monitoring module 20 includes: Multiple pressure detection units 1 are installed at the bottom of the suction well to detect the pressure on the bottom of the slag layer; Liquid level detection unit 2 is installed at the top of the suction well and is used to detect the liquid level height inside the suction well; The data acquisition unit 3 acquires the pressure data detected by each pressure detection unit 1 and the height data detected by the liquid level detection unit 2, and transmits the pressure data and height data to the control module 60.

[0026] In this embodiment, the slag layer thickness parameters include the bottom pressure of the slag layer and the liquid level in the suction well. The pressure at the top of the slag layer can be calculated based on the liquid level and the liquid density in the suction well. The thickness of the slag layer can be calculated based on the difference between the pressure at the top and bottom of the slag layer and the density of the slag layer.

[0027] In one optional example, the calculation accuracy for the slag layer thickness can reach ±5mm.

[0028] In an optional example of this implementation, the pressure detection unit 1 is a pressure sensor and the liquid level detection unit 2 is an ultrasonic liquid level gauge.

[0029] Furthermore, multiple pressure sensors are evenly embedded in the bottom plate of the suction well. An ultrasonic level gauge is installed at the top of the suction well.

[0030] In an optional embodiment of the present invention, the disturbance module 30 includes: The gas supply main pipe 5 has one end connected to a compressed air source and the other end extending to the bottom of the water intake well; An air distribution component is installed at the bottom of the water intake well and connected to the air supply main pipe 5. The air distribution component sprays compressed air into the slag layer to disturb the slag layer. A control valve is installed on the main gas supply pipe 5 and controls the connection and disconnection of the main gas supply pipe 5. The control valve is electrically or communicatively connected to the control module 60.

[0031] With the above structure, the compressed air source flows into the air distribution component through the air supply pipe 5 and then flows out through the air distribution component to form a bubble flow, which in turn disturbs the slag layer deposited at the bottom of the water intake well and breaks the hardened structure of the slag layer.

[0032] In one optional example of this implementation, the compressed air source is a 0.4~0.6 MPa compressed air source.

[0033] In an optional example of this implementation, the air distribution assembly includes: An annular air distribution pipe 6 is located at the bottom of the water intake well and is arranged around the central axis of the water intake well; Multiple perforated air pipes 7 are evenly distributed along the circumference of the annular air distribution pipe 6. One end of each perforated air pipe 7 is connected to the annular air distribution pipe 6, and the other end of each perforated air pipe 7 extends outward along the radial direction of the water intake well. Multiple air outlet holes are opened on the pipe wall of each perforated air pipe 7.

[0034] In one optional example of this embodiment, the air distribution assembly includes 4 to 6 perforated air pipes 7, each with a diameter of 50 mm, evenly distributed at the bottom of the water intake well, and each perforated air pipe 7 has an air outlet hole with a diameter of 8 mm on its pipe wall, with a spacing of 100 mm between adjacent air outlet holes.

[0035] In one optional example of this embodiment, the diameter of the annular air distribution pipe 6 is 80 mm, and the annular air distribution pipe 6 is welded to the end of each perforated air pipe 7 to form an annular air distribution network.

[0036] In an optional example, the annular air distribution pipe 6 also has multiple air outlets on its pipe wall.

[0037] In an optional example of this implementation, the control valve is a solenoid ball valve 8, which is connected to the control module 60 and controls the connection and disconnection of the gas supply main pipe 5 according to the instructions of the control module 60.

[0038] In an optional example of this embodiment, the disturbance module 30 further includes an air source processing unit disposed on the air supply main pipe 5. The air source processing unit is used to filter impurities and moisture in the compressed air to prevent the air outlet from becoming blocked.

[0039] In another optional embodiment of the present invention, the disturbance module 30 includes: Multiple ultrasonic transducers are installed at the bottom of the water intake well. Each ultrasonic transducer can generate ultrasonic vibration and disturb the slag layer. The power supply is electrically connected to each ultrasonic transducer. The controller is connected to the power supply and sends frequency adjustment commands and power adjustment commands to the power supply. The controller is also electrically or communicatively connected to the control module 60.

[0040] In an optional example of this implementation, the disturbance module 30 includes 4 to 6 ultrasonic transducers.

[0041] In one optional example of this implementation, the ultrasonic transducer can generate ultrasonic vibrations of 20-40 kHz, which disturb the deposited slag and thus break up the slag layer's compacted structure. The ultrasonic transducer eliminates the risk of pore blockage, simplifies maintenance, produces more uniform vibration disturbances, has a better destructive effect on the slag layer's compacted structure, and consumes less energy. It is suitable for operating conditions where the slag layer is hard, severely compacted, and where the compressed air supply is unstable.

[0042] In one optional example of this implementation, the power supply in the disturbance module 30 is a high-frequency power supply with an AC signal frequency above 80kHz.

[0043] In an optional embodiment of the present invention, the slag removal module 40 includes: Slag flushing pump 9 is installed above the suction well; The slag flushing main pipe 10 is connected at one end to the slag flushing water pump 9, and at the other end extends into the bottom of the suction well; The annular flushing pipe 11 is located at the bottom of the suction well and is arranged around the central axis of the suction well; Multiple nozzles 12 are installed on the annular flushing pipe 11 and are evenly distributed along the circumference of the annular flushing pipe 11. Each nozzle 12 sprays flushing water into the slag layer.

[0044] In one optional example of this implementation, the slag flushing pump 9 is a high-pressure water pump with a flow rate of 50~80m³ / h and a pressure of 10~15MPa, and the slag flushing pump is installed outside the suction well.

[0045] In one optional example of this implementation, the diameter of the slag flushing main pipe 10 is 65 mm.

[0046] In an optional example of this embodiment, the diameter of the annular slag flushing pipe 11 is 80 mm, and the annular slag flushing pipe 11 is located 200 mm above the annular gas distribution pipe 6.

[0047] In an optional example of this embodiment, 12 to 16 nozzles 12 are provided on the annular slag flushing pipe 11, and the diameter of the nozzles 12 is 15 mm.

[0048] In one alternative example, the nozzle 12 is directed at a 45° angle to the bottom of the well to directionally impact the deposited slag.

[0049] In one alternative embodiment, a pressure regulating valve is installed on the slag flushing main pipe 10, which can adjust the pressure of the nozzle 12 to accommodate slag deposits of different hardness.

[0050] In another optional embodiment of the present invention, the slag removal module 40 includes at least one slag scraper and a drive motor. The slag scraper is disposed at the bottom of the suction well, and the drive motor drives the slag scraper to move relative to the bottom of the suction well (the bottom plate of the suction well) so as to separate the slag from the bottom of the suction well.

[0051] In one optional embodiment of this implementation, a guide rail is provided on the bottom plate of the suction well, and a scraper blade slides in cooperation with the guide rail and moves back and forth along the guide rail under the drive of a drive motor to scrape the slag off the bottom plate.

[0052] In an optional embodiment of the present invention, the slag discharge module includes: A slag-water separator is installed above the suction well; The slag discharge pipe is located at the bottom of the suction well at one end and connected to the inlet of the slag-water separator at the other end. The slag discharge pump is located at the outlet of the slag-water separator. The slag material at the bottom of the suction well is pumped into the slag-water separator through the slag discharge pipe via the slag discharge pump.

[0053] In this embodiment, the slag separated from the bottom of the suction well forms a suspended slag-water mixture with the well water in the suction well. After the slag discharge pump installed on the slag discharge pipe is started, the slag-water mixture enters the slag discharge pipe under the suction of the slag discharge pump, and is then transported to the slag-water separator through the slag discharge pipe. The slag-water separator separates the slag from the clean water. The separated dry slag is transported to the next sewage treatment equipment by the slag discharge pump to complete the cleaning; the separated clean water can be returned to the suction well through the return pipe to realize the recycling of water resources.

[0054] In one optional embodiment of this implementation, the slag discharge pipe is provided with a rotating slag discharge port at one end at the bottom of the water intake well. The rotating slag discharge port can rotate relative to the bottom of the water intake well to align with slag accumulation areas in different directions.

[0055] In one alternative example, the rotating slag discharge port can rotate 360 ​​degrees relative to the bottom of the suction well.

[0056] In one optional example, the diameter of the slag discharge pipe is 150 mm.

[0057] In one alternative example, the sludge-water separator is a hydrocyclone separator.

[0058] In one alternative example, the slag pump is a wear-resistant slurry pump with a flow rate of 30~50 m³ / h.

[0059] In one alternative example, the next wastewater treatment unit is a sludge storage area in a cyclone tank.

[0060] In another optional embodiment of the present invention, the slag discharge module includes a slide valve 50 and a pre-embedded slag discharge pipe 14. The pre-embedded slag discharge pipe 14 is pre-embedded in the concrete at the bottom of the water intake well and connects the water intake well and the central cylinder. The slide valve 50 is connected to the pre-embedded slag discharge pipe 14. When slag discharge is required, the valve plate of the slide valve 50 is opened, and the steel slag is discharged from the pre-embedded slag discharge pipe 14 to the central cylinder, thereby realizing the slag removal at the water intake well.

[0061] In an optional example of this implementation, the switching component of the slide valve 50 is located above the suction well for easy maintenance and replacement.

[0062] In one optional example of this implementation, the pre-embedded slag discharge pipe 14 is a steel pipe.

[0063] In one optional embodiment of this implementation, a plurality of pre-embedded slag discharge pipes 14 are provided along the circumference of the water intake well, and each pre-embedded slag discharge pipe 14 is respectively provided with a slide valve 50.

[0064] In another optional embodiment of the present invention, the slag discharge module includes: A vacuum generator, installed outside the suction well, is used to generate negative pressure; The negative pressure pipeline is connected to a vacuum generator at one end and extends into the bottom of the suction well at the other end. Under the action of negative pressure, the negative pressure pipeline extracts the mixture of slag and well water. The slag box, connected to the negative pressure pipeline, is used to collect the extracted slag. The slag box is equipped with a filter element to separate the slag from the well water.

[0065] In this embodiment, the vacuum generator produces negative pressure, which draws the scraped slag into the negative pressure pipeline and transports it to the slag box. The entire process does not require slag-water separation, and the dry slag is collected directly, making subsequent processing simpler.

[0066] In an optional embodiment of the present invention, the slag layer monitoring module 20, disturbance module 30, slag cleaning module 40, slag discharge module, and control module 60 are integrated into a single frame to form an integral structure. On-site, the fully automatic anti-clogging slag cleaning device 100 for use in cyclone pool suction wells can be put into operation simply by hoisting the frame to the bottom of the suction well and connecting the power supply, air supply, and slag discharge pipe. This structure effectively shortens on-site installation time, eliminates the need for complex construction such as welding and drilling, and allows for complete disassembly and maintenance without affecting the use of the suction well during repairs. Furthermore, this structure is adaptable to suction wells of different sizes, offering greater versatility and suitability for cyclone pool suction wells requiring rapid modification, frequent maintenance, or temporary additional cleaning needs.

[0067] In an optional embodiment of the present invention, the control module 60 includes a PLC controller, a touch screen, a wireless communication unit, and an alarm unit. The PLC controller receives parameter data monitored by the slag layer monitoring module 20 for calculating the slag layer thickness, and the PLC controller has a built-in control program: when the slag layer thickness is ≥100mm, the PLC controller automatically starts the disturbance module 30 (runs for 5~10 minutes), and then starts the slag cleaning module 40 and the slag discharge module; when the slag layer thickness is ≤30mm, the PLC controller automatically stops the disturbance module 30, the slag cleaning module 40, and the slag discharge module; the touch screen in the control module 60 is used for parameter setting, real-time data display, and manual / automatic mode switching; the wireless communication unit is used to connect to the plant's DC system to realize remote monitoring and operation; the alarm unit issues an audible and visual alarm when equipment malfunctions or the slag layer is too thick.

[0068] The working principle and process of the fully automatic anti-clogging and slag-removing device 100 and method proposed in this invention are as follows: Real-time monitoring: The slag layer monitoring module 20 collects slag layer pressure and well water level data at the bottom of the suction well in real time, and the PLC controller of the control module 60 calculates the slag layer thickness and dynamically monitors the siltation situation.

[0069] Automatic disturbance: When the thickness of the slag layer reaches the first preset threshold (100mm), the PLC controller of the control module 60 turns on the disturbance module 30, and compressed air is ejected from the air outlet of the perforated air pipe 7 to form a bubble flow, which disturbs the slag layer deposited at the bottom of the water intake well, breaks the hardened structure of the slag layer, and makes the slag material in the slag layer mix with the well water to form a suspended slag-water mixture.

[0070] High-pressure slag flushing: After 5-10 minutes of compressed air disturbance, the PLC controller starts the slag flushing water pump 9. High-pressure water is sprayed out through the annular slag flushing pipe 11 and the inclined nozzle 12, which directionally impacts the dead corners and residual slab structures at the bottom of the water intake well, completely dispersing the slag layer and suspending the slag in the water; at the same time, the rotating slag discharge port is aimed at the high-concentration suspended slag area to improve the slag discharge efficiency.

[0071] Directional slag discharge and separation: Under the combined action of the impact of high-pressure water flow and the suction of the slag discharge pump, the suspended slag-water mixture enters the slag discharge main pipe through the rotary slag discharge port and is then transported to the slag-water separator. The slag-water separator uses cyclone centrifugal force to separate the slag from the clean water. The clean water is returned to the suction well through the return pipe, realizing the recycling of water resources. The separated dry slag is transported to the sludge storage area of ​​the cyclone pool by the slag discharge pump to complete the cleaning.

[0072] Automatic stop and standby: The sludge monitoring module provides real-time feedback on the sludge layer thickness. When the thickness drops below the second preset threshold (30mm), the PLC controller sequentially shuts down the sludge cleaning module 40, the sludge discharge module, and the disturbance module 30. The fully automatic anti-clogging sludge cleaning device 100 enters standby mode, waiting for the next cleaning trigger.

[0073] Please refer to Figure 1 , Figure 2 and Figure 3 The following detailed description of the fully automatic anti-clogging and slag-removing device and method for vortex pool suction wells proposed in this invention will be provided in conjunction with specific embodiments.

[0074] Example 1

[0075] This embodiment is applicable to conventional working conditions with a slag layer thickness of 100mm. In this embodiment, the diameter of the suction well is 6m and the depth is 4m. The slag layer monitoring module 20 includes five pressure detection units 1, which are pressure sensors embedded in the bottom plate of the suction well. The liquid level detection unit 2 is an ultrasonic liquid level gauge installed at the top of the suction well. The disturbance module 30 includes four perforated air pipes 7, which are arranged radially. The bottom of each perforated air pipe 7 is welded with an annular air distribution pipe 6. The annular flushing pipe 11 of the slag cleaning module 40 is located on the outer ring of the suction well, and the annular air distribution pipe 6 is located on the inner ring of the suction well. The height of the annular flushing pipe 11 is 200mm higher than the height of the annular air distribution pipe 6, and the diameter of the annular flushing pipe 11 is larger than the diameter of the annular air distribution pipe 6. Twelve nozzles 12 are evenly arranged on the annular flushing pipe 11, and each nozzle 12 is inclined to the bottom plate of the suction well. The slag discharge module has a slag discharge pipe diameter of 150mm, the slag-water separator is a cyclone slag-water separator, and the slag discharge pump is a wear-resistant slurry pump. The disturbance module 30, the slag cleaning module 40, and the slag discharge module are also adaptably connected to the compressed air source (0.5MPa) and power supply within the plant area.

[0076] In this first embodiment, the slag layer monitoring module 20, the disturbance module 30, the slag cleaning module 40, and the slag discharge module are electrically or communicatively connected to the control module 60. The control module 60 includes a PLC controller. The PLC controller has built-in upper limit of 100mm (first preset threshold) and lower limit of 30mm (second preset threshold) for the slag layer thickness; the disturbance module 30 uses compressed air for 8 minutes of disturbance; the slag cleaning module 40 has a high-pressure water pump with a pressure of 12MPa and a flow rate of 60m³ / h; and a slag discharge pump with a flow rate of 40m³ / h.

[0077] During operation, the cleaning process is triggered when the pressure sensor detects that the slag layer thickness is 150mm. First, the compressed air control valve is opened to agitate for 8 minutes to fully suspend the slag layer. Then, the flushing water pump 9 and the slag discharge pump are started to flush the slag with high-pressure water and rotate the slag discharge port to align with the high siltation area. The slag-water mixture is separated by the separator, the clean water is returned, and the dry slag is transported to the sludge storage area. After continuous monitoring until the slag layer thickness reaches 25mm, the machine automatically stops and resets.

[0078] The implementation results of this first embodiment are as follows: the cleaning time is only 15 minutes, and there is no need to drain the well water or go down into the well manually; there is no residual slag at the bottom of the well, and the dead corners are thoroughly cleaned; the slag-water separation efficiency is 95%, and the return of clean water does not affect the normal water intake of the suction well; no safety accidents occur, and the cleaning efficiency is 5 times higher than that of manual cleaning.

[0079] Example 2

[0080] In this second embodiment, the thickness of the slag layer at the bottom of the suction well is 300mm, which is a case of severe compaction.

[0081] First, the structure of the fully automatic anti-clogging and slag-removing device 100 is adjusted: based on the first embodiment, one perforated air pipe 7 is added, and the diameter of the air outlet of the annular air distribution pipe 6 is increased to 10mm; the pressure of the slag flushing water pump 9 is adjusted to 15MPa, and the number of inclined nozzles 12 is increased to 16; the slag-water separator model is upgraded, and the processing flow rate is increased to 60m³ / h.

[0082] Set the parameters as follows: extend the compressed air disturbance time to 12 minutes; increase the high-pressure slag flushing time to 20 minutes; and set the other parameters as in Example 1.

[0083] During operation: a slag layer thickness of 280mm was detected and severely compacted, triggering cleaning; compressed air agitation for 12 minutes broke up the compacted layer; slag flushing pump 9 used 15MPa pressure to flush the slag for 20 minutes, completely breaking up the stubborn slag blocks; the slag discharge pump continued to run, quickly discharging the high-concentration slag-water mixture; after separation, the dry slag was transported to the sludge storage area, the slag layer thickness dropped to 28mm, and the machine automatically stopped.

[0084] The implementation effect of this second embodiment is as follows: the cleaning time is 28 minutes, the slag layer is thoroughly cleaned and there is no residue; no manual assistance is required to break up the slag, and the labor intensity is zero; the equipment operates stably without jamming or blockage, and is suitable for harsh working conditions.

[0085] Example 3

[0086] First, the fully automatic anti-clogging and slag removal device 100 is adjusted: Based on the first embodiment, the PLC controller is connected to the plant's DCS system through the wireless communication unit; the touch screen is set with remote operation permissions, which can remotely start and stop the device and adjust parameters; the alarm unit is connected to the plant's audible and visual alarm system, and fault information is pushed to the mobile phones of maintenance personnel in real time.

[0087] During operation: The fully automatic anti-clogging and slag removal device 100 is automatically monitored and cleaned daily. Maintenance personnel can view the slag layer thickness, equipment operating status, and cleaning records in real time through the DCS system. When the fully automatic anti-clogging and slag removal device 100 experiences pore blockage or abnormal pressure, an alarm is immediately triggered, and maintenance personnel can remotely investigate and perform rapid on-site maintenance if necessary. Cleaning reports are automatically generated periodically, and statistics on cleaning frequency, slag volume, and energy consumption are compiled to provide data support for equipment maintenance and production optimization.

[0088] The implementation effects of this third embodiment are as follows: unattended operation is achieved, and the operation and maintenance efficiency is improved by 80%; fault early warning is timely, and maintenance time is shortened by 60%; data management facilitates the optimization and cleaning of parameters, and reduces energy consumption and operating costs.

[0089] Compared with the prior art, the fully automatic anti-clogging and slag removal device 100 and method for cyclone pool suction wells proposed in this invention have the following technical advantages: The fully automatic anti-clogging and slag-removing device 100 and method for cyclone pool suction wells proposed in this invention cleans the bottom of the suction well more thoroughly and without any dead corners. First, compressed air is used to break up the slabs, and then high-pressure inclined nozzles are used to directionally impact the dead corners. At the same time, a rotating slag discharge port that can rotate 360° is used to achieve full coverage cleaning of the bottom of the suction well, with a residual slag amount of ≤5%, which completely solves the problem of dead corner residue in traditional technology.

[0090] The fully automatic anti-clogging and slag-removing device 100 and method for vortex pool suction wells proposed in this invention are safe and efficient, requiring no manual labor. The fully automatic anti-clogging and slag-removing device 100 can operate in full automation, without the need to drain the well water or allow personnel to enter the well, eliminating the risk of poisoning and drowning in confined spaces. Moreover, the cleaning time of the fully automatic anti-clogging and slag-removing device 100 can be shortened to 15-30 minutes, which is 5 times more efficient than manual labor, and does not affect continuous production.

[0091] The fully automatic anti-clogging and slag-removing device 100 and method for cyclone pool suction wells proposed in this invention can monitor the slag layer at the bottom of the suction well in real time and intelligently control the start and stop of the cleaning operation. The slag layer monitoring module 20 accurately detects the slag layer thickness, and the PLC controller of the control module 60 automatically starts and stops the cleaning process without manual intervention. The control module 60 also has remote monitoring and alarm functions, enabling unattended operation and improving maintenance efficiency by 80%.

[0092] The fully automatic anti-clogging and slag-removing device 100 and method for the suction well of a cyclone pool proposed in this invention separates slag and water for recycling. The slag discharge module works in conjunction with the cyclone separator to achieve a slag-water separation efficiency of 95%. The clean water is returned to the suction well for recycling, reducing water waste. The separated dry slag is directly transported to the sludge storage area to avoid clogging of subsequent equipment by suspended slag.

[0093] The fully automatic anti-clogging and slag removal device 100 for the suction well of the cyclone pool proposed in this invention has a simple structure and is easy to maintain. Through modular design, it can be adapted to the renovation of existing cyclone pools without the need for large-scale well construction. The key components of the fully automatic anti-clogging and slag removal device 100 are made of wear-resistant materials and have an air hole anti-clogging design, which reduces the maintenance frequency by 70% and the operating cost is lower.

[0094] The fully automatic anti-clogging and slag-removing device 100 and method for cyclone pool suction wells proposed in this invention have a wide range of applications and strong adaptability. They can be adapted to suction wells of different diameters and depths and can efficiently clean both conventional slag layers and hardened slag layers. During operation, the pressure and flow rate are adjustable to adapt to sediment slag of different hardness and concentration, making it highly versatile.

[0095] The detailed explanations of the above embodiments are intended only to explain the present invention so as to facilitate a better understanding of the present invention. However, these descriptions should not be construed as limiting the present invention for any reason. In particular, the various features described in different embodiments can be arbitrarily combined with each other to form other embodiments. Unless there is an explicit description to the contrary, these features should be understood to be applicable to any embodiment, and not limited to the described embodiments.

Claims

1. A fully automatic anti-clogging and slag-removing device for a cyclone pool suction well, characterized in that, The fully automatic anti-clogging and slag-removing device includes: The slag layer monitoring module is used to monitor the slag layer thickness parameters at the bottom of the water intake well. A disturbance module is used to apply disturbance to the bottom of the water intake well in order to disrupt the hardened structure of the slag layer; The slag removal module is used to clean the damaged slag layer, so that the slag material in the slag layer is separated from the bottom of the water intake well; The slag removal module is used to extract the separated slag material; The control module is electrically or communicatively connected to the slag layer monitoring module, the disturbance module, the slag cleaning module, and the slag discharge module, respectively. The control module controls the start and stop of the disturbance module, the slag cleaning module, and the slag discharge module according to the slag layer thickness parameter.

2. The fully automatic anti-clogging and slag-removing device for the suction well of a cyclone pool as described in claim 1, characterized in that, The control module has a first preset threshold and a second preset threshold. When the slag layer thickness detected by the slag layer monitoring module reaches the first preset threshold, the control module sequentially activates the disturbance module, the slag cleaning module, and the slag discharge module. When the slag layer thickness drops below the second preset threshold, the control module sequentially shuts down the slag cleaning module, the slag discharge module, and the disturbance module.

3. The fully automatic anti-clogging and slag-removing device for the suction well of a cyclone pool as described in claim 1, characterized in that, The slag layer monitoring module includes: A pressure detection unit is installed at the bottom of the suction well to detect the pressure at the bottom of the slag layer; A liquid level detection unit is installed at the top of the water intake well to detect the liquid level height inside the water intake well.

4. The fully automatic anti-clogging and slag-removing device for the suction well of a cyclone pool as described in claim 3, characterized in that, The slag layer monitoring module also includes: The data acquisition unit calculates the thickness of the slag layer based on the pressure at the bottom of the slag layer and the liquid level.

5. The fully automatic anti-clogging and slag-removing device for a cyclone pool suction well as described in claim 1, characterized in that, The disturbance module includes: The main gas supply pipe has one end connected to a compressed air source and the other end extending to the bottom of the water intake well. An air distribution assembly is installed at the bottom of the water intake well and connected to the air supply main pipe. The air distribution assembly sprays compressed air into the slag layer to disturb the slag layer. A control valve is installed on the main gas supply pipe and controls the connection and disconnection of the main gas supply pipe.

6. The fully automatic anti-clogging and slag-removing device for a cyclone pool suction well as described in claim 5, characterized in that, The air distribution assembly includes: An annular air distribution pipe is located at the bottom of the water intake well and is arranged around the central axis of the water intake well; Multiple perforated air pipes are evenly distributed along the circumference of the annular air distribution pipe. One end of each perforated air pipe is connected to the annular air distribution pipe, and the other end of each perforated air pipe extends outward along the radial direction of the water intake well. Multiple air outlet holes are opened on the pipe wall of each perforated air pipe.

7. The fully automatic anti-clogging and slag-removing device for a cyclone pool suction well as described in claim 1, characterized in that, The disturbance module includes: Multiple ultrasonic transducers are installed at the bottom of the water intake well, and each ultrasonic transducer generates ultrasonic vibrations and disturbs the slag layer. A power supply is electrically connected to each of the ultrasonic transducers. The controller is connected to the power supply and sends frequency adjustment commands and power adjustment commands to the power supply.

8. The fully automatic anti-clogging and slag-removing device for a cyclone pool suction well as described in claim 1, characterized in that, The slag removal module includes: A slag flushing water pump is installed outside the suction well; The slag flushing main pipe has one end connected to the water pump and the other end extending into the bottom of the suction well; An annular flushing pipe is located at the bottom of the suction well and is arranged around the central axis of the suction well; Multiple nozzles are installed on the annular flushing pipe and evenly distributed along the circumference of the annular flushing pipe, and each nozzle sprays flushing water into the slag layer.

9. The fully automatic anti-clogging and slag-removing device for a cyclone pool suction well as described in claim 1, characterized in that, The slag removal module includes at least one slag scraper and a drive motor. The slag scraper is disposed at the bottom of the water intake well, and the drive motor drives the slag scraper to move relative to the bottom of the water intake well so as to separate the slag from the bottom of the water intake well.

10. The fully automatic anti-clogging and slag-removing device for a cyclone pool suction well as described in claim 1, characterized in that, The slag removal module includes: A slag-water separator is installed outside the suction well; A slag discharge pipe, one end of which is located at the bottom of the water intake well, and the other end of which is connected to the inlet of the slag-water separator; A slag discharge pump is installed on the slag discharge pipe, and the slag material at the bottom of the water intake well is pumped into the slag-water separator by the slag discharge pump.

11. The fully automatic anti-clogging and slag-removing device for a cyclone pool suction well as described in claim 10, characterized in that, The slag discharge pipe is provided with a rotating slag discharge port at one end at the bottom of the water intake well. The rotating slag discharge port can rotate relative to the bottom of the water intake well and is used to align with the slag accumulation area in different directions.

12. The fully automatic anti-clogging and slag-removing device for a cyclone pool suction well as described in claim 1, characterized in that, The slag removal module includes: A vacuum generator, installed outside the water intake well, is used to generate negative pressure; A negative pressure pipeline, one end of which is connected to the vacuum generator and the other end extends into the bottom of the water intake well, the negative pressure pipeline extracts the mixture of slag and well water under negative pressure; A slag box, connected to the negative pressure pipeline, is used to collect the extracted slag. The slag box is equipped with a filter element to separate the slag from the well water.

13. A fully automated anti-clogging and slag-removing method for a vortex pool suction well, characterized in that, The fully automatic anti-clogging and slag removal method includes: Real-time monitoring of the slag layer thickness at the bottom of the suction well; When the thickness of the slag layer reaches a first preset threshold, a disturbance is applied to the slag layer to disrupt its compacted structure. After the slab structure is destroyed, the bottom of the water intake well is cleaned to separate the slag material in the slag layer from the bottom of the water intake well. The separated slag is extracted from the bottom of the suction well.

14. The fully automatic anti-clogging and slag removal method as described in claim 13, characterized in that, When the thickness of the slag layer drops below the second preset threshold, the cleaning, extraction, and disturbance of the slag layer are stopped sequentially.

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