Energy-saving rubber waste gas intelligent collection method
Patent Information
- Application Number
- CN202611075435.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-07-20
- Publication Date
- 2026-10-27
Smart Images
Figure CN122974665A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of waste gas environmental protection treatment technology, specifically to an energy-saving intelligent collection method for rubber waste gas. Background Technology
[0002] In the rubber products processing industry, microwave vulcanization is widely used in the production of various rubber parts such as sealing strips and hoses due to its rapid heating, uniform vulcanization, and high production efficiency. During the production process, the vulcanizing agents, accelerators, polymers, and other components in the rubber formulation react with heat, releasing harmful gaseous substances such as VOCs, hydrogen sulfide, and sulfur dioxide. If these waste gases are not effectively collected and treated, their direct release into the workshop not only fails to meet environmental protection requirements for air pollution control but also negatively impacts the occupational health of frontline operators.
[0003] Currently, there are generally two common approaches to waste gas collection in production sites. One is the overall ventilation of the entire workshop, which involves enclosing the vulcanization workshop and using a high-volume ventilation system to uniformly extract and purify the air within the workshop. This approach has low implementation barriers and does not require significant modifications to individual equipment, but its actual operational drawbacks are also quite prominent: in order to cover the entire workshop space, the system's design air volume is generally too large. After a large amount of clean air is mixed with the waste gas, the pollutant concentration is significantly diluted, increasing the processing load on subsequent purification equipment. This leads to a corresponding increase in equipment purchase investment and daily operating costs, and the effect on controlling the waste gas concentration at the workshop's work surfaces is also relatively limited.
[0004] Another approach is a point-to-point localized collection mode, where each vulcanizing machine is equipped with a separate gas collection hood and corresponding sealed structure, focusing solely on collecting exhaust gases from the mold opening area of the tank. Theoretically, this method offers higher exhaust gas capture efficiency, but in large-scale production scenarios with dozens or even hundreds of vulcanizing machines, practical management presents several challenges. The production cycles of different vulcanizing machines are not entirely consistent, and the timing of mold opening and exhaust varies. It's difficult to match the operating parameters of valves and fans to the production status in real time, making system control and management complex. Furthermore, most localized collection solutions involve individual equipment with independent gas lines connected to the main pipeline. If a leak occurs and exhaust gases overflow, the escaped gases into the workshop environment are difficult to capture effectively, easily leading to excessive exhaust gas concentrations within the workshop.
[0005] In addition, most current exhaust gas collection systems use constant power continuous operation mode for their fans. During the design and selection process, in order to cope with the extreme working conditions of multiple machines operating simultaneously, a large margin is usually reserved for air volume and air pressure. However, in actual production, the probability of all vulcanizing machines operating simultaneously to exhaust gas is very low. Most of the time, only a few machines are in the state of producing gas by operating the mold. The fans maintain full load operation for a long time, which will cause unnecessary power consumption and increase the long-term operating cost of the system.
[0006] To address this energy consumption issue, some solutions attempt to reduce operating energy consumption by monitoring the main pipeline pressure using pressure sensors and adjusting the fan speed accordingly. While these methods can reduce electricity consumption to some extent, their overall energy-saving potential has not been fully realized. The core problem lies in the fact that these solutions do not coordinate the on / off control of the gas valves with the opening and closing of the vulcanizing machine, nor do they deeply optimize for the intermittent characteristics of the vulcanizing process—"concentrated gas production during mold opening and almost no waste gas during mold closing." Relying solely on passively adjusting the fan speed based on pressure feedback limits the energy-saving effect. Furthermore, these solutions still have room for improvement in terms of pipeline layout rationality, waste gas mixing uniformity, and ease of daily maintenance. Summary of the Invention
[0007] To solve the above-mentioned technical problems, the present invention provides the following technical solution.
[0008] An energy-saving intelligent collection method for rubber waste gas utilizes the intermittent nature of waste gas generation during mold opening and non-generation during mold closing in vulcanizing machines to achieve energy-saving collection. The method includes the following steps:
[0009] S1. A gas collection hood is sealed and installed above the vulcanizing machine, and a first switching valve is installed in the gas outlet passage of the gas collection hood.
[0010] S2. Set up two adjacent vulcanizing machines as a group of collection chambers, and connect the outlets of the two gas collection hoods in the same group through convection pipes.
[0011] S3. Connect two or more collection chambers to each other through a connecting pipe, and then connect the connecting pipe to the buffer pipe; connect the buffer pipe to the waste gas treatment equipment, and the fan of the waste gas treatment equipment adopts frequency conversion speed regulation.
[0012] S4. The waste gas that escapes after the vulcanizing machine opens the mold is adsorbed by the negative pressure inside the buffer tube. At the same time, the waste gas in the buffer tube is drawn in by the fan of the waste gas treatment equipment. The waste gas is discharged after purification treatment.
[0013] In step S4, the intelligent constant pressure control logic is executed: the first switching valve is linked to the mold opening and closing state of the vulcanizing machine. When the mold is closed, the first switching valve is closed, blocking the extraction path of ineffective clean air; when the mold is opened, the first switching valve is opened, opening the exhaust gas collection path; the fan of the exhaust gas treatment equipment automatically adjusts its speed according to the real-time pressure in the buffer pipe, maintaining the pressure in the buffer pipe within the set constant pressure range to achieve on-demand air supply and energy saving.
[0014] As a preferred embodiment of the present invention, the collection system is equipped with a control console, and a pressure sensor is installed inside the buffer pipe; the fan of the exhaust gas treatment equipment is driven by a variable frequency motor; the first switching valve is an electric valve, which is communicatively connected to the control console along with the pressure sensor and the variable frequency motor; the control console automatically controls the opening and closing of the first switching valve according to the mold opening and closing status signal of the vulcanizing machine, and receives real-time wind pressure data collected by the pressure sensor, and adjusts the speed of the variable frequency motor through the frequency converter to form a closed-loop control circuit of "wind pressure acquisition - calculation and adjustment - speed adjustment - wind pressure stabilization".
[0015] As a preferred embodiment of the present invention, the control console supports access to manual operation signals or connection to the production management system to obtain the mold opening and closing plan, which serves as the triggering basis for the linkage opening and closing of the first switch valve; the control console can predict the mold opening density of the next stage based on the mold opening and closing plan, adjust the fan speed in advance, and improve the system response speed.
[0016] As a preferred embodiment of the present invention, the connection between the convection pipe and the two gas collection hoods in the same group is respectively set as a first conical opening and a first expansion opening structure, so that the exhaust gas discharged from the two vulcanizing machines in the same group enters the convection pipe at different flow rates to form an impact mixing, thereby improving the uniformity of the exhaust gas.
[0017] As a preferred embodiment of the present invention, the connection between the connecting pipe and each group of collection chambers is respectively configured as a second conical opening and a second expansion opening structure; a second switching valve is provided at the connection between the connecting pipe and the buffer pipe to control the opening and closing of the corresponding collection chamber and the buffer pipe.
[0018] As a preferred embodiment of the present invention, the opening and closing action of the second switching valve is delayed by one second from the first switching valve in the corresponding collection chamber, and the second switching valve and the corresponding first switching valve maintain the same opening and closing state to avoid the valves operating synchronously and causing drastic fluctuations in pipeline pressure.
[0019] As a preferred embodiment of the present invention, a third switching valve, a temperature sensor, and a concentration sensor are also provided on the wall of the buffer tube; the third switching valve, the temperature sensor, and the concentration sensor are all communicatively connected to the control console; the buffer tube is controllably connected to the vulcanization workshop through the third switching valve, and the temperature sensor and the concentration sensor are used to monitor the exhaust gas parameters in the buffer tube in real time and assist in the early warning of system anomalies.
[0020] As a preferred embodiment of the present invention, a baffle plate is provided inside the connecting pipe between the buffer pipe and the waste gas treatment equipment, and a sewage discharge device is provided on one side of the baffle plate.
[0021] As a preferred embodiment of the present invention, the ratio of mold opening time to mold closing time in a single production cycle of a single vulcanizing machine is 1:3.
[0022] As a preferred embodiment of the present invention, the exhaust gas treatment equipment is set up in series with multiple units. The multiple exhaust gas treatment equipment works together to maintain a constant negative pressure in the exhaust duct. The exhaust gas treatment equipment in the idle state is automatically shut down to reduce energy consumption.
[0023] The beneficial effects of this invention are as follows:
[0024] 1. This invention fully utilizes the intermittent process characteristic of vulcanizing machines, where gas is produced when the mold is open and not when it is closed. By using a first switching valve linked to mold opening and closing to cut off ineffective gas paths, and then cooperating with a variable frequency motor to drive the fan, constant pressure and dynamic speed regulation are achieved, enabling on-demand air supply. The system does not need to operate continuously at full load under the extreme condition of all vulcanizing machines opening simultaneously. The fan output power can be dynamically adjusted according to the actual number of molds opened, effectively reducing the fan's energy consumption and lowering the production line's operating costs.
[0025] 2. This invention provides unified control of all valves, fans, and sensors through a control console, forming a complete closed-loop automatic control circuit. The system can automatically adjust operating parameters according to production status, eliminating the need for frequent manual operation. Simultaneously, the system supports integration with production management systems as well as manual intervention, adapting to different workshop management models. The predictive speed adjustment function based on production plans further enhances the system's response speed and operational stability.
[0026] 3. The present invention adopts a fixed-point collection method using a gas collection hood, which, in conjunction with the linkage control of the first switching valve, reduces the mixing of clean air, thereby increasing the pollutant concentration of the collected waste gas and reducing the processing air volume load of subsequent purification equipment. Attached Figure Description
[0027] Figure 1 This is a schematic diagram of the components involved in the energy-saving intelligent collection method for rubber waste gas in Example 1;
[0028] Figure 2 This is a flowchart of the steps in the energy-saving intelligent collection method for rubber waste gas in Example 1;
[0029] Figure 3 This is a schematic diagram of the components involved in the energy-saving intelligent collection method for rubber waste gas in Example 1;
[0030] Figure 4 This is a schematic diagram of the collision state of exhaust gas at different flow rates in Example 1.
[0031] The attached figures are labeled as follows:
[0032] 1. Vulcanizing workshop; 2. Vulcanizing machine; 3. Gas collection hood; 4. Convection pipe; 5. Connecting pipe; 6. Buffer pipe; 7. Baffle plate; 8. Waste gas treatment equipment; 9. Dust collection assembly; 10. Control console; 41. First conical inlet; 42. First expansion port; 43. First switching valve; 51. Second conical inlet; 52. Second expansion port; 53. Second switching valve; 61. Third switching valve; 62. Temperature sensor; 63. Concentration sensor; 64. Pressure sensor; 81. Variable frequency motor; 91. Collection pipe; 92. Telescopic pipe; 93. Conical hopper; 94. Return spring. Detailed Implementation
[0033] To further understand the content of this invention, a detailed description of the invention will be provided in conjunction with the accompanying drawings and embodiments. It should be understood that the embodiments are merely illustrative and not limiting of the invention.
[0034] Example 1, as Figure 1-4 As shown in the figure, this embodiment provides an energy-saving intelligent collection method for rubber waste gas. This method is designed based on the intermittent process characteristics of the vulcanizing machine 2, where waste gas is concentrated during the mold opening stage and virtually no waste gas is generated during the mold closing and vulcanizing stage. It is suitable for rubber production workshops with multiple vulcanizing machines operating in clusters, and can reduce system operating energy consumption while ensuring effective waste gas collection. This method is implemented using a supporting waste gas collection and treatment system, which is deployed throughout the vulcanizing workshop 1. The following describes the system's composition and structure, followed by the specific collection method steps and operating principle.
[0035] Each vulcanizing machine 2 is equipped with a sealed gas collection hood 3 above its tank opening. The hood 3 covers the mold opening area of the vulcanizing machine 2 and can directionally capture the escaping exhaust gas at the moment of mold opening, reducing the diffusion of exhaust gas into the workshop. A first switching valve 43 is connected in series in the exhaust passage at the top of the gas collection hood 3. The first switching valve 43 is an electrically controlled valve used to individually control the opening and closing of the corresponding gas passage of the gas collection hood 3.
[0036] Two adjacent vulcanizing machines 2 are divided into a group of collection chambers. The outlets of the two gas collection hoods 3 in the same group are interconnected by convection pipes 4, so that the exhaust gas collection paths of the two vulcanizing machines 2 in the same group are interconnected. The connection between the convection pipe 4 and the two gas collection hoods 3 in the same group is respectively set as a first conical opening 41 and a first expansion opening 42: the cross section of the first conical opening 41 gradually narrows along the airflow direction, which can increase the exhaust gas velocity flowing through this point; the cross section of the first expansion opening 42 gradually expands along the airflow direction, which will reduce the exhaust gas velocity flowing through this point, so that the exhaust gas discharged from the two vulcanizing machines 2 in the same group enters the interior of the convection pipe 4 at different flow rates.
[0037] Two or more collection chambers are interconnected via connecting pipe 5, enabling parallel airflow through multiple collection chambers. The connection points between connecting pipe 5 and each collection chamber are respectively configured with a second conical opening 51 and a second expansion opening 52, serving the same purpose as the conical and expansion structures of convection pipe 4, allowing the waste gas entering from different collection chambers to form a velocity difference. The outlet end of connecting pipe 5 is connected to buffer pipe 6, and a second switching valve 53 is installed at the connection point between connecting pipe 5 and buffer pipe 6. The second switching valve 53 is also an electric valve, used to control the opening and closing of the airflow between the corresponding collection chamber group and buffer pipe 6. It can cut off the airflow when all corresponding collection chambers are closed, further reducing ineffective air intake.
[0038] The buffer pipe 6 is laid laterally along the length of the vulcanization workshop 1, serving as the main gas collection pipe of the system and playing a role in buffering gas pressure and balancing the air volume of each branch. The buffer pipe 6 is equipped with a third switching valve 61, a temperature sensor 62, a concentration sensor 63, and a pressure sensor 64 in sequence on its wall. The third switching valve 61 is a workshop connection valve, allowing the buffer pipe 6 to be controllably connected to the internal space of the vulcanization workshop 1, enabling the extraction of escaping exhaust gas from the workshop when needed. The temperature sensor 62 is used to monitor the exhaust gas temperature in the buffer pipe 6 in real time, the concentration sensor 63 is used to monitor the concentration of characteristic pollutants in the exhaust gas, and the pressure sensor 64 is used to collect the real-time air pressure value in the buffer pipe 6. The monitoring data from all three types of sensors are uploaded to the control terminal in real time.
[0039] The outlet of the buffer pipe 6 is connected to the exhaust gas treatment equipment 8 via a connecting pipe. A baffle plate 7 is installed inside the connecting pipe. The baffle plate 7 bends the airflow path, causing large dust particles and droplets entrained in the exhaust gas to impact the plate wall and settle under inertia, thus achieving pretreatment of the exhaust gas. A sewage discharge device is installed on one side of the baffle plate 7 to periodically discharge the settled sludge.
[0040] The waste gas treatment equipment 8 has a built-in fan that serves as the negative pressure power source for the system. The fan is driven by a variable frequency motor 81, and the air volume can be changed by adjusting the motor speed. In this embodiment, multiple waste gas treatment equipment 8 units can be connected in series according to treatment needs. Multiple units work together to maintain a constant negative pressure in the exhaust duct, and idle units can be automatically shut down to further reduce energy consumption.
[0041] The system is equipped with a control console 10 as the control center. The aforementioned first switching valve 43, second switching valve 53, third switching valve 61, temperature sensor 62, concentration sensor 63, pressure sensor 64, and variable frequency motor 81 are all communicatively connected to the control console 10. The control console 10 can receive the mold opening and closing status signals of the vulcanizing machine 2 and the monitoring data of various sensors, and output control commands for valve opening and closing and motor speed adjustment to realize the automated operation of the system.
[0042] Dust collection components 9 are installed below both the convection pipe 4 and the connecting pipe 5 to collect dust settled within the pipelines and to assist in locating leaks. Each dust collection component 9 includes a collection pipe 91, the top of which connects to the bottom of the convection pipe 4 / connecting pipe 5 and communicates with the main pipeline. A telescopic pipe 92 is slidably installed inside the collection pipe 91, allowing it to slide up and down along its inner wall. A conical hopper 93 is located above the inside of the telescopic pipe 92 to guide the dust flow and prevent it from flowing back into the main pipeline. A return spring 94 is installed between the bottom of the telescopic pipe 92 and the inner bottom of the collection pipe 91, providing an upward return force. A sensor, such as a displacement sensor, is installed on the surface of the return spring 94 to detect its extension or retraction, thereby determining the airtightness of the corresponding pipe section.
[0043] The energy-saving intelligent collection method for rubber waste gas in this embodiment specifically includes the following steps:
[0044] S1. Front-end gas collection device layout: A corresponding sealed gas collection hood 3 is installed above each vulcanizing machine 2, and a first switching valve 43 is installed in the gas outlet passage of each gas collection hood 3 to complete the gas collection unit configuration of a single vulcanizing machine.
[0045] S2. Group connection of collection chambers: Two adjacent vulcanizing machines 2 are divided into a group of collection chambers. The gas outlets of two gas collection hoods 3 in the same group are connected to each other through the convection pipe 4. At the same time, the first conical port 41 and the first expansion port 42 are machined at both ends of the convection pipe 4 to complete the gas path connection of a single group of collection chambers.
[0046] S3. Main pipeline connection: Connect two or more collection chambers to each other through the connecting pipe 5. Process the second conical port 51 and the second expansion port 52 at the docking point of the connecting pipe 5 and each collection chamber. Then, unify the air outlets of all the connecting pipes 5 into the buffer pipe 6. Install the second switch valve 53 at the connection point of the connecting pipe 5 and the buffer pipe 6. Finally, connect the air outlet of the buffer pipe 6 to the waste gas treatment equipment 8 to complete the layout of the entire pipeline. The fan of the waste gas treatment equipment 8 is driven by a variable frequency motor 81 and supports speed regulation operation.
[0047] S4. Intelligent constant pressure exhaust gas collection: Start the exhaust gas treatment equipment 8, and use the fan to draw in the buffer pipe 6 and the front-end pipeline to form a negative pressure. Use the negative pressure inside the buffer pipe 6 to adsorb the exhaust gas that escapes after the vulcanizing machine 2 opens the mold. The exhaust gas flows along the gas collection hood 3, convection pipe 4, and connecting pipe 5 into the buffer pipe 6, and then enters the exhaust gas treatment equipment 8 after pretreatment by the baffle plate 7. After purification and meeting the standards, it is discharged.
[0048] During the execution of step S4, the system synchronously executes intelligent constant voltage control logic, which is specifically divided into two parts:
[0049] First, the valve is linked to the mold opening and closing control: the first switch valve 43 is linked to the mold opening and closing state of the vulcanizing machine 2. When the vulcanizing machine 2 enters the mold closing vulcanization stage, the first switch valve 43 corresponding to the gas collection hood 3 closes synchronously to block the gas path and avoid drawing clean air without waste gas; when the vulcanizing machine 2 completes vulcanization and enters the mold opening stage, the first switch valve 43 opens synchronously to open the waste gas collection path and capture the escaped waste gas in time.
[0050] Secondly, the fan automatically adjusts its speed based on pressure: the fan in the exhaust gas treatment equipment 8 automatically adjusts its speed according to the real-time pressure in the buffer pipe 6, maintaining the pressure in the buffer pipe 6 within a set constant pressure range. When the number of vulcanizing machines 2 operating simultaneously increases, and the number of first switch valves 43 opened increases, the total flow area of the pipeline increases, and the negative pressure value in the buffer pipe 6 decreases. At this time, the fan automatically increases its speed to increase the air volume to compensate for the negative pressure. When the number of vulcanizing machines 2 operating simultaneously decreases, and the first switch valves 43 are closed successively, the total flow area of the pipeline decreases, and the negative pressure value in the buffer pipe 6 rises. At this time, the fan automatically decreases its speed to reduce the air volume and reduce energy consumption. Dynamic speed regulation achieves on-demand air supply, reducing operating energy consumption while ensuring the exhaust gas collection effect.
[0051] In this embodiment, based on the conventional production cycle of rubber microwave vulcanization, the ratio of mold opening time to mold closing time in a single production cycle of a single vulcanizing machine 2 is approximately 1:2. This time ratio can also be adjusted according to the actual production process. The opening and closing action of the second switching valve 53 lags behind the first switching valve 43 in the corresponding collection chamber by one second, and the second switching valve 53 and the corresponding first switching valve 43 maintain the same opening and closing state. By delaying the control, the pressure fluctuations in the pipeline are smoothed out, avoiding the air pressure shock caused by the synchronous opening and closing of the valves.
[0052] Meanwhile, the control console 10 supports the input of manual operation signals and can also connect to the workshop's production management system to obtain the vulcanizing machine's mold opening and closing plan, which serves as the trigger for the linkage opening and closing of the first switching valve 43. Based on the mold opening and closing plan data, the control console 10 can predict the mold opening density of the next stage, adjust the fan speed in advance, shorten the system's pressure response time, and further improve the system's response speed and operational stability.
[0053] The core control logic of this system is designed around the intermittent gas production characteristics of the vulcanization process. The control console 10 can obtain the opening and closing status of the vulcanizing machine 2 in two ways: one is to directly connect to the control system of the vulcanizing machine 2 itself and read the opening and closing action signals of the equipment; the other is to connect to the production plan of the production management system or receive start and stop instructions from manual operation.
[0054] When the vulcanizing machine 2 is detected to be in the mold-closing vulcanization stage, the rubber reacts in the sealed tank and almost no waste gas escapes outward. The control console 10 then outputs a shutdown command to control the corresponding first switch valve 43 to close, cutting off the gas path of this branch and preventing the blower from continuously drawing clean air and causing ineffective energy consumption. When the vulcanizing machine 2 is detected to be about to open the mold or has already opened the mold, the control console 10 controls the first switch valve 43 to open, opening the gas collection path and using the negative pressure of the pipeline to collect the large amount of waste gas that escapes at the moment of mold opening.
[0055] The second switching valve 53 corresponding to the collection bin group adopts a delayed linkage logic, which opens and closes synchronously one second after the first switching valve 43 in the same group. By staggering the switching of valves, the simultaneous operation of multiple groups of valves avoids drastic fluctuations in the main pipeline pressure and improves the stability of the negative pressure in the buffer pipe 6.
[0056] The system uses the set negative pressure value in the buffer tube 6 as the control target, and collects wind pressure data in real time through the pressure sensor 64 to form feedback and construct a closed-loop control loop. The pressure sensor 64 transmits the real-time wind pressure value to the control console 10. The control module in the control console 10 compares the real-time value with the set value and outputs a speed regulation signal to the frequency converter. The frequency converter adjusts the output speed of the variable frequency motor 81, thereby changing the air volume of the fan.
[0057] As the number of vulcanizing machines 2 on the production line increases, the number of first switch valves 43 that are opened also increases, increasing the total air intake area of the pipeline. With the fan speed remaining constant, the negative pressure in the buffer pipe 6 will decrease. If the negative pressure is insufficient, the collection velocity at the gas collection hood 3 will decrease, making it easier for waste gas to escape. At this time, the control panel 10 controls the variable frequency motor 81 to increase its speed, increasing the fan's suction volume and restoring the negative pressure in the buffer pipe 6 to the set range to ensure effective collection.
[0058] Conversely, when the number of vulcanizing machines 2 decreases, most of the first switching valves 43 are closed, reducing the total air intake area of the pipeline. This causes the negative pressure in the buffer pipe 6 to continuously rise. Excessive negative pressure not only increases energy consumption but also easily draws a large amount of clean air from the workshop into the system, diluting the exhaust gas concentration. At this time, the control panel 10 controls the variable frequency motor 81 to reduce its speed and ventilation volume, maintaining the negative pressure within the set range and minimizing energy consumption while ensuring effective collection.
[0059] In addition, the console 10 can predict changes in the number of molds to be opened in advance through the production plan and adjust the fan speed in advance. Compared with simple pressure feedback control, it can further reduce pressure fluctuations and improve the system's response speed.
[0060] The structure of the first conical opening 41 and the first expansion opening 42 at both ends of the convection pipe 4 changes the airflow velocity by altering the cross-section, creating a significant velocity difference between the exhaust gases discharged from the two vulcanizing machines 2 in the same group: the exhaust gas entering through the first conical opening 41 has a faster velocity due to the narrowing of the pipe, while the exhaust gas entering through the first expansion opening 42 has a slower velocity due to the widening of the pipe. The two airflows with different velocities form a collision zone in the middle of the convection pipe 4. This zone is offset from the interface of the connecting pipe 5, which reduces the interference of the negative pressure in the main pipeline on the settling process.
[0061] The airflow collision can, on the one hand, fully mix the components in the two exhaust gases, making the concentration and temperature of the exhaust gases more uniform, which is conducive to the subsequent exhaust gas treatment equipment 8 to carry out stable purification treatment and improve the consistency of treatment effect; on the other hand, the dust, rubber particles and other particles carried in the exhaust gases will lose kinetic energy during the collision process, and the larger particles will settle under the action of gravity and fall into the dust collection component 9 below the pipeline.
[0062] The second conical opening 51 and the second expansion opening 52 at the connecting pipe 5 have the same structure, which can play the same role in mixing and aiding sedimentation of the exhaust gas entering from different collection chambers. By achieving pre-sedimentation of particulate matter through the pipeline structure, the particulate matter content entering the baffle plate 7 and the exhaust gas treatment equipment 8 can be reduced, the load on subsequent treatment units can be reduced, and the cleaning and maintenance cycle of the equipment can be extended.
[0063] After the settled dust falls into the collection pipe 91, it is guided by the conical hopper 93 and collects at the bottom of the collection pipe 91. It will not flow back into the main pipeline with the airflow. Maintenance personnel can disassemble and clean the dust inside the collection pipe 91 regularly.
[0064] In addition to collecting settled dust, the dust collection component 9 can also assist in detecting the airtightness of the corresponding pipe section, facilitating rapid location of leaks. Its detection principle is based on the suction effect of vacuum negative pressure on the telescopic pipe 92.
[0065] When the first switch valve 43 is closed, the negative pressure on the buffer tube 6 side will act on the collecting tube 91 through the connecting tube 5, generating an upward suction force on the telescopic tube 92, causing the telescopic tube 92 to slide upward along the inner wall of the collecting tube 91, and the return spring 94 will be compressed simultaneously; one second later, the second switch valve 53 is closed. At this time, the pipe section between the first switch valve 43 and the second switch valve 53 forms a sealed independent space. Under the action of negative pressure, the space maintains a vacuum state, and the telescopic tube 92 and the return spring 94 continue to remain in a contracted state.
[0066] If a leak occurs in this section of the pipeline, outside air will continuously seep into the pipe, causing the vacuum negative pressure state inside the pipe to be unable to be maintained. Consequently, the collecting pipe 91 loses its suction force on the telescopic pipe 92. At this time, the return spring 94 will rebound under its own elastic force, pushing the telescopic pipe 92 downwards to reset. The displacement sensor on the surface of the return spring 94 can detect the spring's extension and retraction displacement in real time. When the spring abnormally resets or the displacement exceeds a set threshold, the control console 10 can determine that there is a leak in the corresponding pipe section and pinpoint the exact location of the leak. This eliminates the need for maintenance personnel to check each section individually, improving the efficiency of pipeline maintenance.
[0067] Temperature sensor 62 and concentration sensor 63 on buffer pipe 6 can monitor the parameters of the exhaust gas inside the pipe in real time, and the monitoring data is synchronously uploaded to control console 10. When the exhaust gas concentration rises abnormally, it can help determine whether there is abnormal emission of exhaust gas from the vulcanizing machine or a decrease in the collection effect at the front end of the pipeline; when the temperature rises abnormally, it can help investigate whether there is an abnormality in the vulcanizing process. The data from these two types of sensors can help maintenance personnel to detect abnormalities in system operation in a timely manner, take proactive measures, and avoid environmental risks.
[0068] The third switch valve 61 enables controllable connection between the buffer pipe 6 and the internal space of the vulcanizing workshop 1, serving as a supplementary means for local gas collection. During normal production, the third switch valve 61 is closed, and the system only collects waste gas at fixed points through the gas collection hood 3. When waste gas accumulates and the overall concentration is too high in the workshop, the third switch valve 61 can be opened to use the negative pressure of the buffer pipe 6 to extract air from the workshop, replenish the escaped waste gas, and improve the working environment in the workshop. In addition, during shift changes and equipment shutdowns, the third switch valve 61 can also be opened to ventilate the entire workshop.
[0069] The technical solution of this embodiment can achieve the following beneficial effects:
[0070] 1. The technical solution of this embodiment fully utilizes the intermittent process characteristics of the vulcanizing machine 2, which produces gas when the mold is open and not when the mold is closed. The first switching valve 43, linked to the mold opening and closing, cuts off ineffective gas paths. Furthermore, the variable frequency motor 81 drives the fan to achieve constant pressure and dynamic speed regulation, enabling on-demand air supply. The system does not need to operate continuously at full load under the extreme condition of all vulcanizing machines 2 opening simultaneously. The fan output power can be dynamically adjusted according to the actual number of molds opened, effectively reducing the fan's energy consumption and lowering the production line's operating costs. Simultaneously, the reduced actual operating air volume of the system can correspondingly reduce the design processing capacity of the subsequent waste gas treatment equipment 8, lowering the initial equipment investment cost of the project.
[0071] 2. The technical solution in this embodiment uses the control console 10 to uniformly manage all valves, fans, and sensors, forming a complete closed-loop automatic control circuit. The system can automatically adjust operating parameters according to production status, eliminating the need for frequent manual operation. Simultaneously, the system supports integration with production management systems as well as manual intervention, adapting to different workshop management models. The predictive speed adjustment function based on production plans further enhances the system's response speed and operational stability. In large-scale production scenarios with multiple vulcanizing machines clustered together, it effectively reduces management difficulty and improves operational efficiency.
[0072] 3. The technical solution of this embodiment adopts a fixed-point collection method using the gas collection hood 3, which, in conjunction with the linkage control of the first switching valve 43, reduces the mixing of clean air, thereby increasing the pollutant concentration of the collected waste gas and reducing the processing air volume load of subsequent purification equipment. Simultaneously, the differentiated structural design of the first conical port 41 and the first expansion port 42 on the convection pipe 4, and the second conical port 51 and the second expansion port 52 on the connecting pipe 5, allows for thorough and uniform mixing of waste gas from different branches, improving the stability of waste gas concentration and helping the waste gas treatment equipment 8 maintain a stable treatment effect. Furthermore, this structure can also assist in the early settling of particulate matter, working in conjunction with the dust collection component 9 to pre-collect most dust particles, reducing the particulate matter content entering subsequent treatment equipment. This not only reduces the load on pretreatment units such as the baffle plate 7 but also extends the cleaning and maintenance cycle of the environmental protection equipment.
[0073] 4. The technical solution in this embodiment adopts a modular pipeline layout with interconnected groups. Combined with the airtightness detection function of the dust collection component 9, the location of leaking pipe sections can be quickly located without the need for maintenance personnel to check each section, thus improving the efficiency of pipeline leak troubleshooting and repair. At the same time, the dust collection component 9 can pre-sediment and collect most of the accumulated dust in the pipeline, reducing the amount of dust in the main pipeline and also reducing the frequency and workload of pipeline cleaning.
[0074] Example 2, taking a set of 100 vulcanizing machines 2 as an example, before the process improvement, the traditional process requires an air volume of 600 cubic meters per hour for one vulcanizing machine, and 60,000 cubic meters per hour for 100 machines. At this time, a 75KW fan is needed to maintain the pressure in the pipeline (about 2000Pa). If the operating rate is insufficient, such as 50 machines or 1 machine, they will operate at full power to maintain the pressure in the pipeline.
[0075] After adopting the method in Example 1, with all 100 devices running, the required airflow is only 60,000 × 25% cubic meters per hour (preferably 1:3 based on the mold opening / closing time ratio in this example). This requires only one 18.5KW fan, significantly reducing equipment purchase costs and achieving approximately 75% energy savings compared to traditional methods. With insufficient operation, running 50 devices requires an airflow of 30,000 × 25% cubic meters per hour, with a power output between 50-60% of the 18.5KW, resulting in 85%-88% energy savings compared to traditional methods. Running only one device requires an airflow of 600 × 25% cubic meters per hour, with a power output between 1-2% of the 18.5KW, achieving over 95% energy savings compared to traditional methods. Under full load, energy savings are approximately 75%. However, with insufficient operation, the less the machines are used, the higher the energy savings.
[0076] In summary, the above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the present invention.
Claims
1. An energy-saving intelligent collection method for rubber waste gas, utilizing the intermittent characteristic of a vulcanizing machine that generates waste gas when the mold is opened and does not generate waste gas when the mold is closed to achieve energy-saving collection, comprising the following steps: S1. A gas collection hood (3) is sealed and installed above the vulcanizing machine (2), and a first switch valve (43) is set in the gas outlet passage of the gas collection hood (3). S2. Two adjacent vulcanizing machines (2) are set up as a group of collection chambers, and the outlet ends of the two gas collection hoods (3) in the same group are connected to each other through convection pipes (4). S3. Connect two or more collection chambers to each other through a connecting pipe (5), and then connect the connecting pipe (5) to the buffer pipe (6); connect the buffer pipe (6) to the waste gas treatment equipment (8), and the fan of the waste gas treatment equipment (8) adopts frequency conversion speed regulation. S4. The waste gas that escapes after the vulcanizing machine (2) opens the mold is adsorbed by the negative pressure inside the buffer pipe (6), and the waste gas inside the buffer pipe (6) is drawn by the fan of the waste gas treatment equipment (8). The waste gas is discharged after purification treatment. In step S4, the intelligent constant pressure control logic is executed: the first switch valve (43) is linked to the mold opening and closing state of the vulcanizing machine (2). When the mold is closed, the first switch valve (43) is closed, blocking the extraction path of ineffective clean air; when the mold is opened, the first switch valve (43) is opened, opening the waste gas collection path; the fan of the waste gas treatment equipment (8) automatically adjusts its speed according to the real-time pressure in the buffer pipe (6), and maintains the pressure in the buffer pipe (6) within the set constant pressure range to achieve on-demand air supply and energy saving.
2. The energy-saving intelligent collection method for rubber waste gas according to claim 1, characterized in that: The collection system is equipped with a control console (10) and a pressure sensor (64) is installed in the buffer tube (6); the fan of the exhaust gas treatment equipment (8) is driven by a variable frequency motor (81); the first switch valve (43) is an electric valve, which is connected to the control console (10) in communication with the pressure sensor (64) and the variable frequency motor (81); the control console (10) automatically controls the opening and closing of the first switch valve (43) according to the opening and closing status signal of the vulcanizing machine (2), and receives the real-time wind pressure data collected by the pressure sensor (64), and adjusts the speed of the variable frequency motor (81) through the frequency converter to form a closed-loop control loop of "wind pressure collection-calculation adjustment-speed adjustment-wind pressure stabilization".
3. The energy-saving intelligent collection method for rubber waste gas according to claim 2, characterized in that: The console (10) supports access to manual operation signals or connection to the production management system to obtain the mold opening and closing plan, which serves as the trigger basis for the linkage opening and closing of the first switch valve (43); the console (10) can predict the mold opening density of the next stage according to the mold opening and closing plan, adjust the fan speed in advance, and improve the system response speed.
4. The energy-saving intelligent collection method for rubber waste gas according to claim 1, characterized in that: The connection between the convection pipe (4) and the two gas collection hoods (3) in the same group is respectively set as the first conical port (41) and the first expansion port (42) structure, so that the exhaust gas discharged from the two vulcanizing machines in the same group enters the convection pipe (4) at different flow rates to form collision mixing and improve the uniformity of exhaust gas.
5. The energy-saving intelligent collection method for rubber waste gas according to claim 1, characterized in that: The connection between the connecting pipe (5) and each group of collection chambers is respectively set as a second conical port (51) and a second expansion port (52); the connection between the connecting pipe (5) and the buffer pipe (6) is provided with a second switch valve (53) to control the opening and closing of the corresponding collection chamber and the buffer pipe (6).
6. The energy-saving intelligent collection method for rubber waste gas according to claim 5, characterized in that: The opening and closing action of the second switching valve (53) is delayed by one second from the first switching valve (43) in the corresponding collection chamber, and the second switching valve (53) and the corresponding first switching valve (43) maintain the same opening and closing state to avoid the valves from moving synchronously and causing drastic fluctuations in pipeline pressure.
7. The energy-saving intelligent collection method for rubber waste gas according to claim 2, characterized in that: The buffer pipe (6) is also equipped with a third switch valve (61), a temperature sensor (62) and a concentration sensor (63); the third switch valve (61), the temperature sensor (62) and the concentration sensor (63) are all connected to the control console (10); the buffer pipe (6) is controllably connected to the vulcanization workshop (1) through the third switch valve (61), and the temperature sensor (62) and the concentration sensor (63) are used to monitor the waste gas parameters in the buffer pipe (6) in real time and assist the system in abnormal early warning.
8. The energy-saving intelligent collection method for rubber waste gas according to claim 1, characterized in that: A baffle plate (7) is installed inside the connecting pipe between the buffer pipe (6) and the waste gas treatment equipment (8), and a sewage discharge device is installed on one side of the baffle plate (7).
9. The energy-saving intelligent collection method for rubber waste gas according to claim 1, characterized in that: In a single production cycle of a single vulcanizing machine, the ratio of mold opening time to mold closing time is 1:
3.
10. The energy-saving intelligent collection method for rubber waste gas according to claim 1, characterized in that: The exhaust gas treatment equipment (8) is set up in series with multiple units. The multiple exhaust gas treatment equipment (8) work together to maintain a constant negative pressure in the exhaust duct. The exhaust gas treatment equipment (8) in the idle state is automatically shut down to reduce energy consumption.