A microwave-assisted sludge drying incineration control system

Abstract

The present application relates to sludge drying incineration automatic control technical field, especially in kind based on microwave auxiliary's sludge drying incineration control system, including data acquisition module gathers the electromagnetic reflection signal of original sludge and generates real-time moisture content data.State determination module compares real-time moisture content data with high viscosity critical interval, generates dynamic intervention instruction when sludge falls into the interval.Mixture adjustment module calculates solid auxiliary material addition amount and controls the feeding motor to drive auxiliary material into mechanical mixing bin to mix.The system controls the real-time proportioning of solid auxiliary material, promotes the sludge to quickly pass through the high sticky plastic stage which is easy to adhere to the equipment.Power matching module adjusts the microwave radiation power of microwave energy generation assembly according to the moisture content of mixed material.The present application effectively prevents the sludge from agglomeration and wall adhesion in the drying process, and realizes the technical effect of reducing the overall energy consumption of the system.

Description

Technical Field

[0001] This invention relates to the field of automatic control technology for sludge drying and incineration, and in particular to a microwave-assisted sludge drying and incineration control system. Background Technology

[0002] In the application of microwave-assisted drying and incineration volume reduction technology for municipal and industrial sludge, the treatment system utilizes microwave heating to reduce the moisture content of the sludge and then incinerates it for volume reduction. During the drying stage, the internal moisture of the sludge continuously evaporates, causing the water content to decrease steadily as the treatment progresses, thus triggering a phased transformation in the sludge's morphology. When the water content decreases to a specific range, the sludge enters a high-viscosity plasticity stage, exhibiting extremely strong surface adhesion characteristics.

[0003] Existing microwave control equipment generally outputs microwave energy at a constant power, and most of them execute drying and incineration processes according to pre-set fixed programs. The control system lacks an adaptive adjustment mechanism to match the sludge state and fails to obtain real-time data on changes in the moisture content of the sludge, causing the microwave control unit to be unable to perform dynamic feedback control based on real-time moisture content.

[0004] Due to the inability to obtain real-time moisture data, microwave control systems struggle to adjust operating parameters such as microwave output power in real time based on the actual state of the sludge. This makes fixed-parameter control methods unsuitable for the treatment requirements when sludge enters a high-viscosity plasticity stage. Objectively, the lack of a dynamic feedback adjustment mechanism based on real-time moisture content presents a technical challenge: sludge severely adheres to equipment during the high-viscosity plasticity stage, leading to a sharp increase in energy consumption. Severe sludge adhesion significantly reduces microwave heat transfer efficiency and causes mechanical failures, while the surge in energy consumption significantly increases the overall operating cost of the treatment process. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a microwave-assisted sludge drying and incineration control system. This invention solves the technical problem that the lack of dynamic feedback adjustment for the real-time moisture content of sludge in the microwave control system causes sludge to adhere to the equipment and energy consumption to increase sharply when it is in a high-viscosity plastic stage.

[0006] To solve the above-mentioned technical problems, the specific contents of the present invention are as follows: The present invention provides a microwave-assisted sludge drying and incineration control system, including equipment and a control device, wherein the control device is communicatively connected to the equipment. The equipment includes: a drying chamber, a mechanical mixing chamber, a moisture detection probe, a feeding motor, a microwave energy generating component, and a microwave radiation antenna. The mechanical mixing chamber is equipped with a discharge port and a power input end; the drying chamber is equipped with a feeding port; the feeding motor is equipped with a drive shaft; and the microwave energy generating component is equipped with an energy output end. The discharge port of the mechanical mixing chamber is connected to the feeding port of the drying chamber; the drive shaft of the feeding motor is connected to the power input end of the mechanical mixing chamber; the moisture detection probe is installed on the inner wall of the drying chamber; the energy output end of the microwave energy generating component is connected to the microwave radiation antenna; and the microwave radiation antenna is placed inside the drying chamber. The control device includes: a data acquisition module, a status determination module, a mixing adjustment module, and a power matching module; The data acquisition module controls the moisture detection probe to collect the electromagnetic reflection signal of the original sludge in the drying chamber, generates real-time moisture content data based on the electromagnetic reflection signal, and sends the real-time moisture content data to the status determination module. The state determination module compares the real-time moisture content data with the preset high viscosity critical range. When the real-time moisture content data falls into the high viscosity critical range, a dynamic intervention command is generated and sent to the mixing adjustment module. The mixing adjustment module obtains the difference between the real-time moisture content data and the preset safe moisture content threshold, calculates the amount of solid additives to be added based on the difference, and generates a speed control signal based on the amount of solid additives to be added and sends it to the feeding motor. The feeding motor drives the solid additives corresponding to the amount of solid additives added into the mechanical mixing chamber. The mechanical mixing chamber mixes the solid additives with the raw sludge to obtain blended sludge. The blended sludge then enters the drying chamber. The data acquisition module collects the current moisture content data of the mixed sludge and sends it to the power matching module; The power matching module generates a power scheduling command based on the current moisture content data and sends it to the microwave energy generating component. The microwave energy generating component receives the power scheduling command and adjusts the output microwave energy.

[0007] Furthermore, the microwave-assisted sludge drying and incineration control system of the present invention includes a data acquisition module comprising: a signal receiving unit, a filtering and noise reduction unit, and a data conversion unit; The signal receiving unit receives the electromagnetic reflection signal sent by the moisture detection probe and sends the electromagnetic reflection signal to the filtering and noise reduction unit; The filtering and noise reduction unit receives the electromagnetic reflection signal, performs filtering and noise reduction processing on the electromagnetic reflection signal, and generates a filtered electromagnetic signal which is then sent to the data conversion unit. The data conversion unit receives the filtered electromagnetic signal and generates real-time moisture content data based on the correspondence between the filtered electromagnetic signal and a preset data mapping table.

[0008] Furthermore, the microwave-assisted sludge drying and incineration control system of the present invention includes a status determination module comprising: a parameter extraction unit, a numerical comparison unit, and an instruction generation unit. The parameter extraction unit receives real-time moisture content data, retrieves the stored moisture content and state mapping model, extracts the high viscosity critical range from the moisture content and state mapping model, and sends the real-time moisture content data and the high viscosity critical range to the numerical comparison unit. The numerical comparison unit receives real-time moisture content data and the high viscosity critical range, determines that the real-time moisture content data is within the high viscosity critical range, generates a moisture content exceeding the limit signal and sends it to the instruction generation unit. The instruction generation unit receives a moisture content exceeding the limit signal and generates a dynamic intervention instruction based on the moisture content exceeding the limit signal, which is then sent to the mixing adjustment module.

[0009] Furthermore, the microwave-assisted sludge drying and incineration control system of the present invention includes a mixing adjustment module comprising: a deviation calculation unit and a parameter mapping unit; The deviation calculation unit receives the dynamic intervention command, extracts the real-time moisture content data and the stored preset safe moisture content threshold, calculates the difference between the real-time moisture content data and the preset safe moisture content threshold, and calculates the amount of solid auxiliary material to be added based on the difference and sends it to the parameter mapping unit. The parameter mapping unit receives the amount of solid additives added, determines the corresponding motor rotation frequency parameters based on the amount of solid additives added, and generates a speed control signal based on the motor rotation frequency parameters and sends it to the feeding motor.

[0010] Furthermore, the microwave-assisted sludge drying and incineration control system of the present invention further includes an auxiliary material metering screw. The auxiliary material metering screw is equipped with a power input end and a discharge channel, and the mechanical mixing bin is equipped with a feeding channel; The power input end of the auxiliary material metering screw is connected to the drive shaft of the feeding motor, and the discharge channel of the auxiliary material metering screw is connected to the feeding channel of the mechanical mixing chamber. The feed motor receives a speed control signal and drives the auxiliary material metering screw to rotate according to the speed control signal. The auxiliary material metering screw conveys the solid auxiliary material into the mechanical mixing chamber.

[0011] Furthermore, the microwave-assisted sludge drying and incineration control system of the present invention includes a power matching module comprising: a variable collection unit and an electrical parameter adjustment unit; The variable collection unit receives the current moisture content data, calculates the difference between the current moisture content data and the preset target moisture content data, and generates a power adjustment amount based on the difference, which is then sent to the electrical parameter adjustment unit. The electrical parameter adjustment unit receives the power adjustment amount, converts the power adjustment amount into current adjustment parameters and voltage adjustment parameters, and generates a power scheduling command based on the current adjustment parameters and voltage adjustment parameters, which is then sent to the microwave energy generating component.

[0012] Furthermore, in the microwave-assisted sludge drying and incineration control system of the present invention, the microwave energy generating component includes a solid-state microwave power supply module. The solid-state microwave power supply module is equipped with a control terminal, and the control device is equipped with a communication port; The control terminal of the solid-state microwave power module is connected to the communication port of the control device, and the energy output terminal of the solid-state microwave power module is connected to the microwave radiation antenna as the energy output terminal of the microwave energy generating component. The solid-state microwave power module receives power scheduling commands, parses the commands to obtain current and voltage adjustment parameters, adjusts the DC power output based on the current and voltage adjustment parameters and converts it into radio frequency power, and transmits the radio frequency power to the microwave radiating antenna using a coaxial cable.

[0013] Furthermore, the microwave-assisted sludge drying and incineration control system of the present invention further includes an efficiency evaluation module. The performance evaluation module acquires multiple sets of real-time moisture content data and corresponding sampling times within a preset time window, and calculates the rate of moisture content decrease based on the multiple sets of real-time moisture content data and sampling times. When the rate of decrease in moisture content is less than the preset rate threshold, the performance evaluation module generates a compensation correction signal and sends it to the mixing adjustment module. The mixing adjustment module receives a compensation correction signal and increases the amount of solid additives added based on the compensation correction signal.

[0014] Furthermore, the microwave-assisted sludge drying and incineration control system of the present invention further includes a safety protection module. The safety protection module continuously receives output current feedback data and continuous operating time data transmitted back from the microwave energy generating component. When the output current feedback data is greater than the preset current safety threshold and the continuous running time data reaches the preset time threshold, the safety protection module generates a blocking command and sends it to the microwave energy generating component. The microwave energy generating component receives a blocking command and cuts off the radio frequency power transmitted to the microwave radiating antenna.

[0015] Furthermore, the microwave-assisted sludge drying and incineration control system of the present invention further includes a bus communication structure in the control device. The data acquisition module has an output terminal, and the status determination module has an input terminal; The bus communication structure connects the output of the data acquisition module and the input of the status determination module respectively; The data acquisition module collects electromagnetic reflection signals according to a preset sampling period and periodically sends the generated real-time moisture content data to the status determination module through a bus communication structure.

[0016] Beneficial effects of this invention: This invention provides a microwave-assisted sludge drying and incineration control system. A data acquisition module collects electromagnetic reflection signals from the raw sludge inside the drying chamber and transmits the generated real-time moisture content data to a state determination module. The state determination module compares the real-time moisture content data with a preset high-viscosity critical range. When the real-time moisture content falls within the high-viscosity critical range, a dynamic intervention command is generated and sent to a mixing adjustment module. The mixing adjustment module calculates the amount of solid additives to be added based on the difference between the real-time moisture content data and a preset safe moisture threshold. Based on the amount of solid additives added, it generates a speed control signal and sends it to the feed motor. The feed motor receives the speed control signal and drives the corresponding amount of solid additives into the mechanical mixing chamber, where the solid additives and raw sludge are mechanically mixed. The data acquisition module, state determination module, and mixing adjustment module work collaboratively through data flow. Relying on objective data signals, they identify the boundary conditions of the sludge in a viscous physical state and reduce the overall moisture content of the mixture by adding a quantitative amount of solid additives. Mechanical mixing combined with data feedback logic promotes the physical transformation of the mixed sludge away from the high-viscosity plasticity stage where surface adhesion easily occurs. After the mixing step is completed, the power matching module receives the current moisture content data of the mixed sludge and dynamically adjusts the microwave energy output intensity of the microwave energy generating component based on this data. This closed-loop data flow and dynamic feedback intervention mechanism constructed by the above multiple modules overcomes the shortcomings of existing microwave control equipment that operates according to preset fixed programs and constant power, resulting in a control method that cannot match the needs of sludge physical transformation. The collaborative operation of the technical features of this invention avoids sludge clumping and adhesion to the equipment inside the drying chamber, maintains stable microwave heat transfer efficiency, and reduces the increased power consumption when processing high-viscosity materials. Attached Figure Description

[0017] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, those skilled in the art can obtain other drawings based on the accompanying drawings without creative effort.

[0018] Figure 1 This is a system architecture diagram of a microwave-assisted sludge drying and incineration control system according to the present invention. Detailed Implementation

[0019] To make the technical solution of the present invention clearer, the present invention will be clearly and completely described below with reference to specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. 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.

[0020] Please see Figure 1 The present invention provides a microwave-assisted sludge drying and incineration control system, which includes equipment and a control device, wherein the control device is communicatively connected to the equipment. The equipment includes: a drying chamber, a mechanical mixing chamber, a moisture detection probe, a feeding motor, a microwave energy generating component, and a microwave radiation antenna. The mechanical mixing chamber is equipped with a discharge port and a power input end; the drying chamber is equipped with a feeding port; the feeding motor is equipped with a drive shaft; and the microwave energy generating component is equipped with an energy output end. The discharge port of the mechanical mixing chamber is connected to the feeding port of the drying chamber; the drive shaft of the feeding motor is connected to the power input end of the mechanical mixing chamber; the moisture detection probe is installed on the inner wall of the drying chamber; the energy output end of the microwave energy generating component is connected to the microwave radiation antenna; and the microwave radiation antenna is placed inside the drying chamber. The control device includes: a data acquisition module, a status determination module, a mixing adjustment module, and a power matching module; The data acquisition module controls the moisture detection probe to collect the electromagnetic reflection signal of the original sludge in the drying chamber, generates real-time moisture content data based on the electromagnetic reflection signal, and sends the real-time moisture content data to the status determination module. The state determination module compares the real-time moisture content data with the preset high viscosity critical range. When the real-time moisture content data falls into the high viscosity critical range, a dynamic intervention command is generated and sent to the mixing adjustment module. The mixing adjustment module obtains the difference between the real-time moisture content data and the preset safe moisture content threshold, calculates the amount of solid additives to be added based on the difference, and generates a speed control signal based on the amount of solid additives to be added and sends it to the feeding motor. The feeding motor drives the solid additives corresponding to the amount of solid additives added into the mechanical mixing chamber. The mechanical mixing chamber mixes the solid additives with the raw sludge to obtain blended sludge. The blended sludge then enters the drying chamber. The data acquisition module collects the current moisture content data of the mixed sludge and sends it to the power matching module; The power matching module generates a power scheduling command based on the current moisture content data and sends it to the microwave energy generating component. The microwave energy generating component receives the power scheduling command and adjusts the output microwave energy.

[0021] The equipment includes a drying chamber, a mechanical mixing chamber, a moisture detection probe, a feeding motor, a microwave energy generating component, a microwave radiation antenna, and an auxiliary material metering screw. The mechanical mixing chamber is equipped with a discharge port, a power input end, and a feeding channel. The drying chamber is equipped with a feeding port. The feeding motor is equipped with a drive shaft. The microwave energy generating component has an energy output end. The auxiliary material metering screw is equipped with a power input end and a discharge channel.

[0022] Specifically, the mechanical structure connections are as follows: the discharge port of the mechanical mixing chamber is connected to the inlet of the drying chamber; simultaneously, the power input end of the auxiliary material metering screw is connected to the drive shaft of the feeding motor, and the discharge channel of the auxiliary material metering screw is connected to the inlet channel of the mechanical mixing chamber, allowing the drive shaft of the feeding motor to indirectly drive the mechanical mixing chamber through the auxiliary material metering screw. Furthermore, a moisture detection probe is fixedly installed on the inner wall of the drying chamber; the energy output end of the microwave energy generating component is connected to a microwave radiation antenna, which is placed inside the drying chamber.

[0023] The control device mainly includes a data acquisition module, a status determination module, a mixing adjustment module, a power matching module, an efficiency evaluation module, a safety protection module, and a bus communication structure. The data acquisition module has an output terminal, the status determination module has an input terminal, and the bus communication structure connects the output terminal of the data acquisition module and the input terminal of the status determination module.

[0024] In the initial stage of this invention, the data acquisition module controls the moisture detection probe to collect electromagnetic reflection signals from the raw sludge inside the drying chamber. The signal receiving unit within the data acquisition module receives the electromagnetic reflection signal from the moisture detection probe and transmits it to the filtering and noise reduction unit. The filtering and noise reduction unit performs filtering and noise reduction processing on the received electromagnetic reflection signal to remove electromagnetic noise, generating a filtered electromagnetic signal, which is then sent to the data conversion unit. Subsequently, the data conversion unit performs parsing and conversion based on the correspondence between the filtered electromagnetic signal and a preset data mapping table, generating real-time moisture content data. The data acquisition module then periodically sends the generated real-time moisture content data to the status determination module via a bus communication structure according to a preset sampling period.

[0025] Upon receiving real-time moisture content data, the parameter extraction unit within the state determination module retrieves the stored moisture content-state mapping model, extracts the preset high-viscosity critical range from the model, and simultaneously sends the real-time moisture content data and the high-viscosity critical range to the numerical comparison unit. The numerical comparison unit compares the real-time moisture content data with the high-viscosity critical range. When the real-time moisture content data falls within the high-viscosity critical range, it confirms that the original sludge has entered a sticky, high-energy-consuming state and generates a moisture content exceeding the limit signal, which is sent to the instruction generation unit. After receiving the moisture content exceeding the limit signal, the instruction generation unit generates a dynamic intervention instruction based on the signal and sends it to the mixing adjustment module.

[0026] After receiving a dynamic intervention command, the mixing adjustment module extracts real-time moisture content data and a stored preset safe moisture content threshold through its internal deviation calculation unit, and calculates the difference between the real-time moisture content data and the safe moisture content threshold. The deviation calculation unit determines the amount of solid additive to be added based on the calculated difference, and then transmits the amount of solid additive to the parameter mapping unit. The parameter mapping unit determines the corresponding motor rotation frequency parameter based on the received amount of solid additive, and generates a speed control signal based on the motor rotation frequency parameter, which is then sent to the feeding motor.

[0027] During the execution phase, the feed motor receives a speed control signal and drives the auxiliary material metering screw to rotate, causing the screw to deliver a fixed amount of solid auxiliary material into the mechanical mixing chamber. The mechanical mixing chamber mechanically mixes the solid auxiliary material with the raw sludge to obtain blended sludge. After mixing, the overall moisture content of the blended sludge changes, causing its morphology to deviate from the high-viscosity plasticity parameter range. The blended sludge then enters the drying chamber through the connecting pipe between the discharge port and the feed port.

[0028] Furthermore, the data acquisition module collects the current moisture content data of the mixed sludge and sends it to the power matching module. The variable aggregation unit within the power matching module receives the current moisture content data, calculates the difference between the current moisture content data and the preset target moisture content data, generates a power adjustment amount based on the difference, and transmits it to the electrical parameter adjustment unit. The electrical parameter adjustment unit converts the power adjustment amount into current adjustment parameters and voltage adjustment parameters, generates a power scheduling command based on the current adjustment parameters and voltage adjustment parameters, and sends the power scheduling command to the microwave energy generating component.

[0029] The microwave energy generating component includes a solid-state microwave power supply module with a control terminal, which is connected to the communication port of the control device. After receiving a power scheduling command, the solid-state microwave power supply module parses the command to obtain current and voltage adjustment parameters. Based on these parameters, it adjusts the DC power output and converts it into radio frequency (RF) power. Then, it transmits the RF power to the microwave radiating antenna via a coaxial cable, thereby achieving dynamic adjustment of the microwave energy output intensity.

[0030] In the dynamic adjustment and correction phase, the performance evaluation module acquires multiple sets of real-time moisture content data and corresponding sampling times within a preset time window, and calculates the moisture content decrease rate based on these data. When the performance evaluation module determines that the moisture content decrease rate is less than a preset rate threshold, it determines that the material state adjustment has not met the predetermined parameter standards, and then generates a compensation correction signal and sends it to the mixing adjustment module. After receiving the compensation correction signal, the mixing adjustment module increases the corresponding amount of solid additives according to the signal, thereby enhancing the surface de-adhesion effect of the mixed sludge.

[0031] The safety protection module continuously receives output current feedback data and continuous operating time data from the microwave energy generating component, and executes hardware overload protection logic. When the safety protection module determines that the output current feedback data exceeds a preset current safety threshold and the continuous operating time data reaches a preset time threshold, it determines that the microwave operating parameters have experienced an overload. The safety protection module then generates a blocking command and sends it to the microwave energy generating component. Upon receiving the blocking command, the microwave energy generating component cuts off the radio frequency power transmitted to the microwave radiating antenna and stops microwave output to maintain the stability of the equipment.

[0032] In this invention embodiment: In the application scenario of sludge reduction in municipal wastewater treatment plants, the moisture content of untreated raw municipal sludge is typically around 80%. The microwave-assisted sludge drying and incineration control system controls the mechanical equipment and microwave source through dynamic closed-loop data flow control, enabling the high-moisture-content sludge to cross the high-viscosity plasticity stage, which is characterized by high energy consumption and equipment adhesion, during the drying and incineration process.

[0033] The state determination module is equipped with a moisture content and state mapping model. The input to this model receives historical experimental data as a training sample set. This training sample set includes the measured moisture content of different types of sludge during the heating process, the real-time torque resistance data of the stirring shaft in the mechanical mixing chamber at the corresponding moment, and the cumulative power consumption data of the microwave energy generator at the corresponding moment. The system uses a support vector machine regression algorithm to perform machine learning on the training sample set and constructs a nonlinear function mapping relationship between the moisture content independent variable and the stirring torque and energy consumption dependent variables within the moisture content and state mapping model. After model training, it outputs a feature determination boundary, corresponding to the range of moisture content values ​​when the stirring torque change rate and energy consumption derivative reach preset thresholds. In the municipal sludge treatment scenario, the high viscosity critical range formed by the feature determination boundary is set to a moisture content range of 60% to 40%. In actual operation, the moisture content and state mapping model receives the current sludge category label and real-time moisture content data transmitted by the data acquisition module. Then, through table lookup and interpolation calculations, it outputs a Boolean value determination result indicating that the current sludge falls within the 60% to 40% high viscosity critical range.

[0034] During data acquisition, the moisture detection probe emits a microwave signal at a 2.45 GHz operating frequency into the sludge within the drying chamber. Utilizing the absorption and reflection of the microwave signal by water molecules within the sludge, the signal receiving unit acquires an electromagnetic reflection signal containing parameters for amplitude attenuation and phase delay. The data conversion unit's built-in preset data mapping table stores multivariate relationships between amplitude attenuation parameters, phase delay parameters, relative permittivity, and absolute moisture content percentage. The data conversion unit extracts the amplitude attenuation and phase delay parameters from the electromagnetic reflection signal, then performs interpolation addressing in the preset data mapping table, ultimately outputting real-time moisture content data with an accuracy of 0.1%.

[0035] Based on the numerical comparison results from the state determination module, if the real-time moisture content data decreases to 62% and meets the preset conditions of approaching the high viscosity critical range, the state determination module synchronously generates a moisture content exceeding the limit signal. The instruction generation unit converts the moisture content exceeding the limit signal into a dynamic intervention instruction and sends it to the mixing adjustment module.

[0036] The mixing and adjustment module initiates the anti-sticking batching calculation and mechanical control program. The deviation calculation unit extracts the safe moisture content threshold stored in the system and sets the safe moisture content threshold to 38%, which is below the lower limit of high viscoplasticity. After obtaining the current real-time moisture content data of 62% and the safe moisture content threshold of 38%, the deviation calculation unit uses the lever cross-mixing formula and combines it with the pre-calibrated dry powder sludge moisture content of less than 5% to calculate the amount of solid additives required to reduce the overall moisture content of the mixed sludge to 38%. Next, the parameter mapping unit maps the amount of solid additives added corresponding to the mass flow rate value to AC variable frequency drive parameters from 0 to 50 Hz, generating a speed control signal. The feed motor, which acts as a variable frequency geared motor, receives the speed control signal and drives the additive metering screw to rotate according to the speed limit set by the speed control signal, conveying the predetermined amount of dry powder sludge to the mechanical mixing chamber. The high-speed rotating blades in the mechanical mixing chamber perform the mixing action between dry powder sludge and raw sludge. Under the action of mechanical stirring force, the dry powder sludge particles act as crystal nuclei, causing the raw sludge with high water content to coat the surface of the dry powder sludge particles in a thin layer, generating a blended sludge with a water content of less than 38%. Because the state of the blended sludge is outside the adhesive phase range, it effectively avoids scaling on the inner wall of the drying chamber and surface hardening due to residual moisture.

[0037] As the mixed sludge is transported to the drying chamber, the power matching module receives data indicating the current moisture content of 38% and the target moisture content of 25% via the variable collection unit. The electrical parameter adjustment unit generates a power adjustment value based on the enthalpy corresponding to the remaining moisture after evaporation, and then converts this power adjustment value into a 0-10 volt analog control signal suitable for the solid-state microwave power supply module. Based on the received analog control signal, the solid-state microwave power supply module linearly adjusts the 0-50 volt DC output voltage and 0-100 ampere DC output current of its built-in switching power supply. Subsequently, the solid-state microwave power supply module generates radio frequency microwave energy with a corresponding power value based on the adjusted DC parameters, and radiates microwaves into the mixed sludge within the drying chamber via a microwave radiating antenna, thereby reducing microwave energy consumption.

[0038] In addition, the performance evaluation module assesses the drying rate based on a time series, extracting multiple sets of real-time moisture content data sampled within the past 5-minute time window. The percentage decrease in moisture content per minute is calculated using the least squares method as the moisture content decrease rate. Taking a preset rate threshold of 1.5% per minute as an example, if the actual calculated moisture content decrease rate is measured to be 0.8% per minute, the performance evaluation module immediately sends a compensation correction signal to the mixing adjustment module. Based on the compensation correction signal, the mixing adjustment module increases the dry powder delivery ratio by 10% on top of the originally set solid additive amount, utilizing the increased number of dry material crystal nuclei to expand the sludge's heated surface area, thereby improving microwave absorption and moisture evaporation efficiency.

[0039] When dealing with equipment overload, the safety protection module executes a hardware protection program. A Hall current sensor installed inside the solid-state microwave power module sends output current feedback data to the safety protection module at millisecond frequencies. The system sets the current safety threshold to 120% of the rated current and the time threshold to 3 seconds. If localized material accumulation in the drying chamber causes microwave impedance mismatch, resulting in the output current feedback data rising to 130 amps and remaining there for 3 seconds, the safety protection module determines that an abnormal standing wave reflection has occurred in the microwave transmission line. The microcontroller pin built into the safety protection module then outputs a low-level blocking command to the enable pin of the solid-state microwave power module, causing the IGBT switch in the solid-state microwave power module to shut down upon receiving the low-level signal, cutting off the RF power output and preventing overheating damage to the core microwave components.

Claims

1. A microwave-assisted sludge drying and incineration control system, characterized in that, It includes equipment and control devices, with the control devices communicating with the equipment. The equipment includes: a drying chamber, a mechanical mixing chamber, a moisture detection probe, a feeding motor, a microwave energy generating component, and a microwave radiation antenna. The mechanical mixing chamber is equipped with a discharge port and a power input end; the drying chamber is equipped with a feeding port; the feeding motor is equipped with a drive shaft; and the microwave energy generating component is equipped with an energy output end. The discharge port of the mechanical mixing chamber is connected to the feeding port of the drying chamber; the drive shaft of the feeding motor is connected to the power input end of the mechanical mixing chamber; the moisture detection probe is installed on the inner wall of the drying chamber; the energy output end of the microwave energy generating component is connected to the microwave radiation antenna; and the microwave radiation antenna is placed inside the drying chamber. The control device includes: a data acquisition module, a status determination module, a mixing adjustment module, and a power matching module; The data acquisition module controls the moisture detection probe to collect the electromagnetic reflection signal of the original sludge in the drying chamber, generates real-time moisture content data based on the electromagnetic reflection signal, and sends the real-time moisture content data to the status determination module. The state determination module compares the real-time moisture content data with the preset high viscosity critical range. When the real-time moisture content data falls into the high viscosity critical range, a dynamic intervention command is generated and sent to the mixing adjustment module. The mixing adjustment module obtains the difference between the real-time moisture content data and the preset safe moisture content threshold, calculates the amount of solid additives to be added based on the difference, and generates a speed control signal based on the amount of solid additives to be added and sends it to the feeding motor. The feeding motor drives the solid additives corresponding to the amount of solid additives added into the mechanical mixing chamber. The mechanical mixing chamber mixes the solid additives with the raw sludge to obtain blended sludge. The blended sludge then enters the drying chamber. The data acquisition module collects the current moisture content data of the mixed sludge and sends it to the power matching module; The power matching module generates a power scheduling command based on the current moisture content data and sends it to the microwave energy generating component. The microwave energy generating component receives the power scheduling command and adjusts the output microwave energy.

2. The microwave-assisted sludge drying and incineration control system according to claim 1, characterized in that, The data acquisition module includes: a signal receiving unit, a filtering and noise reduction unit, and a data conversion unit; The signal receiving unit receives the electromagnetic reflection signal sent by the moisture detection probe and sends the electromagnetic reflection signal to the filtering and noise reduction unit; The filtering and noise reduction unit receives the electromagnetic reflection signal, performs filtering and noise reduction processing on the electromagnetic reflection signal, and generates a filtered electromagnetic signal which is then sent to the data conversion unit. The data conversion unit receives the filtered electromagnetic signal and generates real-time moisture content data based on the correspondence between the filtered electromagnetic signal and a preset data mapping table.

3. The microwave-assisted sludge drying and incineration control system according to claim 2, characterized in that, The status determination module includes: a parameter extraction unit, a numerical comparison unit, and an instruction generation unit; The parameter extraction unit receives real-time moisture content data, retrieves the stored moisture content and state mapping model, extracts the high viscosity critical range from the moisture content and state mapping model, and sends the real-time moisture content data and the high viscosity critical range to the numerical comparison unit. The numerical comparison unit receives real-time moisture content data and the high viscosity critical range, determines that the real-time moisture content data is within the high viscosity critical range, generates a moisture content exceeding the limit signal and sends it to the instruction generation unit. The instruction generation unit receives a moisture content exceeding the limit signal and generates a dynamic intervention instruction based on the moisture content exceeding the limit signal, which is then sent to the mixing adjustment module.

4. The microwave-assisted sludge drying and incineration control system according to claim 3, characterized in that, The mixing adjustment module includes: a deviation calculation unit and a parameter mapping unit; The deviation calculation unit receives the dynamic intervention command, extracts the real-time moisture content data and the stored preset safe moisture content threshold, calculates the difference between the real-time moisture content data and the preset safe moisture content threshold, and calculates the amount of solid auxiliary material to be added based on the difference and sends it to the parameter mapping unit. The parameter mapping unit receives the amount of solid additives added, determines the corresponding motor rotation frequency parameters based on the amount of solid additives added, and generates a speed control signal based on the motor rotation frequency parameters and sends it to the feeding motor.

5. The microwave-assisted sludge drying and incineration control system according to claim 4, characterized in that, The equipment also includes an auxiliary material metering screw; The auxiliary material metering screw is equipped with a power input end and a discharge channel, and the mechanical mixing bin is equipped with a feeding channel; The power input end of the auxiliary material metering screw is connected to the drive shaft of the feeding motor, and the discharge channel of the auxiliary material metering screw is connected to the feeding channel of the mechanical mixing chamber. The feed motor receives a speed control signal and drives the auxiliary material metering screw to rotate according to the speed control signal. The auxiliary material metering screw conveys the solid auxiliary material into the mechanical mixing chamber.

6. The microwave-assisted sludge drying and incineration control system according to claim 5, characterized in that, The power matching module includes: a variable collection unit and an electrical parameter adjustment unit; The variable collection unit receives the current moisture content data, calculates the difference between the current moisture content data and the preset target moisture content data, and generates a power adjustment amount based on the difference, which is then sent to the electrical parameter adjustment unit. The electrical parameter adjustment unit receives the power adjustment amount, converts the power adjustment amount into current adjustment parameters and voltage adjustment parameters, and generates a power scheduling command based on the current adjustment parameters and voltage adjustment parameters, which is then sent to the microwave energy generating component.

7. The microwave-assisted sludge drying and incineration control system according to claim 6, characterized in that, The microwave energy generating components include a solid-state microwave power supply module; The solid-state microwave power supply module is equipped with a control terminal, and the control device is equipped with a communication port; The control terminal of the solid-state microwave power module is connected to the communication port of the control device, and the energy output terminal of the solid-state microwave power module is connected to the microwave radiation antenna as the energy output terminal of the microwave energy generating component. The solid-state microwave power module receives power scheduling commands, parses the commands to obtain current and voltage adjustment parameters, adjusts the DC power output based on the current and voltage adjustment parameters and converts it into radio frequency power, and transmits the radio frequency power to the microwave radiating antenna using a coaxial cable.

8. The microwave-assisted sludge drying and incineration control system according to claim 7, characterized in that, The control device also includes a performance evaluation module; The performance evaluation module acquires multiple sets of real-time moisture content data and corresponding sampling times within a preset time window, and calculates the rate of moisture content decrease based on the multiple sets of real-time moisture content data and sampling times. When the rate of decrease in moisture content is less than the preset rate threshold, the performance evaluation module generates a compensation correction signal and sends it to the mixing adjustment module. The mixing adjustment module receives a compensation correction signal and increases the amount of solid additives added based on the compensation correction signal.

9. The microwave-assisted sludge drying and incineration control system according to claim 8, characterized in that, The control device also includes a safety protection module; The safety protection module continuously receives output current feedback data and continuous operating time data transmitted back from the microwave energy generating component. When the output current feedback data is greater than the preset current safety threshold and the continuous running time data reaches the preset time threshold, the safety protection module generates a blocking command and sends it to the microwave energy generating component. The microwave energy generating component receives a blocking command and cuts off the radio frequency power transmitted to the microwave radiating antenna.

10. The microwave-assisted sludge drying and incineration control system according to claim 9, characterized in that, The control device also includes a bus communication structure; The data acquisition module has an output terminal, and the status determination module has an input terminal; The bus communication structure connects the output of the data acquisition module and the input of the status determination module respectively; The data acquisition module collects electromagnetic reflection signals according to a preset sampling period and periodically sends the generated real-time moisture content data to the status determination module through a bus communication structure.

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