A device and method for preventing leakage of high-temperature graphite material in a rotary cooler.

Abstract

This invention discloses a device and method for controlling high-temperature graphite material leakage in a rotary cooler, belonging to the field of sealing and environmental protection technology for graphite production equipment. The device includes a machine head, a cooling drum, and a star-shaped ash discharge valve body. A fish-scale seal is installed between the machine head and the drum. Additional components include a high-temperature resistant rubber baffle assembly, a zoned gradient wind pressure vortex fan air seal assembly, a fish-scale blower exhaust channel at the machine head, a hot air closed-loop filter unit at the machine tail, and a multi-parameter variable frequency closed-loop control assembly. The baffle assembly provides a leak-proof seal from the material discharge source. This invention addresses the technical problem of material leakage through layered solutions, significantly extends the lifespan of vulnerable parts, and eliminates condensation, dust, and safety hazards.

Description

Technical Field

[0001] This invention belongs to the technical field of graphite production and processing equipment, specifically relating to a device and method for controlling leakage of high-temperature graphite material in a rotary cooler. Background Technology

[0002] After graphitization, the high-temperature graphite material needs to be cooled by a rotary cooler. The core structure of the rotary cooler includes a fixed head, a rotatable cooling drum, and a star-shaped ash discharge valve in the bottom discharge hopper. The cooling drum and the head are in relative motion, and a 5-8mm annular gap must be reserved between them. This gap is the core channel for the leakage of graphite coke and fine powder.

[0003] Patent document CN98206681.3 discloses a high-efficiency rotary cooler. Its rotor cylindrical shell is a water-cooled spiral jacket structure, with bearings supporting the tube shafts at both ends. The tube shaft ends serve as water inlets and outlets. A cooling spiral heat exchange surface is provided inside the rotor cylinder. The rotor head is equipped with a tangentially fed hopper and a conveying screw, which scoops hot material from the tangentially fed feed box. The cooled material is conveyed from the rotor tail to the discharge funnel via the discharge screw. The tail of the rotor cylindrical shell is driven by a drive device. All the above components are mounted on a frame, forming a horizontal high-efficiency rotary cooler.

[0004] However, in actual use, the inventors found that the high-temperature graphite powder settled downwards due to its own weight, and a large amount of it leaked out from the lower part of the gap, accompanied by continuous dust in the upper part. The traditional fish scale single mechanical seal was affected by high temperature thermal deformation and continuous erosion and wear of powder, resulting in a short seal life, continuous expansion of the gap, and inability to completely solve the problems of material leakage and dust. If only the fish scale clamping force is increased, it will aggravate the friction loss of the roller and increase the drive load of the equipment. Summary of the Invention

[0005] The purpose of this invention is to address the shortcomings of existing technologies by providing a device and method for controlling the leakage of high-temperature graphite material in a rotary cooler. This invention utilizes a four-in-one synergistic structure comprising a high-temperature resistant baffle mechanical seal, a zoned directional hot air seal, a tail-end hot air circulation recovery system, and a multi-parameter variable frequency closed-loop linkage to comprehensively suppress graphite powder leakage from the material feeding end, the head sealing end, the airflow system, and the intelligent control end. This achieves the technical goals of long-term sealing, low maintenance, energy saving, consumption reduction, and automated stable production.

[0006] To address the above technical issues, the following technical solution is adopted: A device for preventing leakage of high-temperature graphite material in a rotary cooler includes a machine head, a cooling drum rotatably connected to the machine head, and a star-shaped ash discharge valve body for the discharge hopper connected to the cooling drum. The connection between the machine head and the cooling drum is sealed by multiple sets of fish-scale seals. It also includes a baffle assembly, an air seal assembly, and a variable frequency closed-loop control assembly; The baffle assembly is installed on the star-shaped ash discharge valve body of the discharge hopper and is used to seal the gap of the ash discharge valve and adjust the discharge amount; The air seal assembly is installed on the outside of the machine head and connected to the machine head. It includes a vortex fan installed next to the rotary cooler and a duct connected at one end to the air outlet of the vortex fan and at the other end to the air duct in the lower part of the machine head. The duct forms an air chamber between the cooling drum and the machine head. The air chamber generates an airflow barrier that blows from the machine head to the tail of the machine. The variable frequency closed-loop control component includes a PLC controller, a WINCC configuration module, and a variable frequency driver. The PLC controller is electrically connected to the rotary cooler current detection unit, the star-shaped ash discharge valve motor, and the vortex fan.

[0007] Preferably, the air outlet of the air seal assembly is evenly distributed around the lower part of the machine head, and the air chamber completely covers the entire annular gap between the cooling drum and the machine head.

[0008] Preferably, an airflow equalization plate is installed at the air outlet position of the air duct corresponding to the machine head; The equalization plate is divided into a lower main sealing area, two side auxiliary sealing areas, and an upper weak sealing area along the circumference. The air outlet density and air outlet diameter of the lower main sealing area, two side auxiliary sealing areas, and upper weak sealing area increase sequentially.

[0009] Preferably, the machine head has an air outlet channel circumferentially opened inside. The air inlet of the air outlet channel is connected to the air seal assembly. The air outlet of the air outlet channel is inclined towards the inside of the cooling drum. The airflow washes over the fish scale sealing structure and continuously cools the fish scales to prevent high-temperature graphite powder from accumulating and adhering to the root of the fish scales.

[0010] Preferably, a return air filtration unit is also included, which forms a closed-loop circulating air path with the air seal assembly; The return air filtration unit includes an annular return air hood, a bag filter unit, a return pipe, and a make-up air regulating valve; An annular return air hood is located at the tail of the machine to collect the air seal airflow. The return air duct guides the dust-laden airflow into the bag filter unit to separate and recover the graphite powder. The clean airflow is connected to the air inlet of the vortex blower through the return pipe. A makeup air regulating valve is installed on the return pipe to balance the internal air pressure of the system by supplementing fresh air.

[0011] Preferably, the baffle assembly includes a high-temperature resistant sealing sheet with a thickness of 8-10 mm and a high-temperature resistance of ≥130℃. The sealing sheet is fitted and assembled at the gap between the rotor and the housing of the star-shaped ash discharge valve.

[0012] As a preferred option, the sealing sheet is made from an 8mm thick industrial rubber conveyor belt, cut and shaped to replace the traditional polyurethane baffle.

[0013] Preferably, the star-shaped ash discharge valve adjustment logic of the frequency conversion closed-loop control component is equipped with a quantized current threshold: If the operating current of the main motor of the rotary cooler is ≤15A, it is determined to be a low-load condition of the insulation material. The PLC controls the frequency converter to reduce the operating frequency of the star-shaped ash discharge valve motor to 15~20Hz. If the main motor of the rotary cooler operates at a current ≥25A, it is considered a high-load condition for the particle material. The PLC-controlled frequency converter increases the operating frequency of the star-shaped ash discharge valve motor to 30~35Hz.

[0014] As a preferred option, the vortex blower is synchronously connected to the variable frequency closed-loop control system.

[0015] As a preferred option, a current detection unit, a differential pressure sensor, a dust concentration sensor, and a bag filter recovery powder storage bin are also provided. The entire set of equipment is controlled by a variable frequency closed-loop control component.

[0016] On the other hand, a method for controlling leakage of high-temperature graphite material in a rotary cooler based on the above-mentioned device includes the following steps: Air seal assembly installation and commissioning: Clean up accumulated material and debris at the machine head, measure the annular gap between the cooling drum and the machine head; fix the vortex blower and lay the air duct, adjust the air outlet position to ensure that the air chamber completely covers the annular gap; start the blower and commission it to form a stable directional airflow from the machine head to the machine tail; Closed-loop circulation air path construction: Install an annular return air hood at the tail of the machine, lay return air ducts to connect to the bag filter unit, and filter clean hot air is connected to the vortex blower inlet through the return pipe. Adjust the make-up air regulating valve to match the system air pressure. Variable frequency closed-loop control system construction: PLC is connected to the frequency monitoring of the cooler, the opening detection signal of the ash discharge valve and the frequency feedback signal of the cyclone fan. The control logic is written through the WINCC configuration module, and the corresponding current thresholds of the insulation material and the particle material, the frequency range of the cooler, the frequency range of the ash discharge valve and the frequency conversion linkage parameters of the fan are set to complete the online debugging. Integrated operation and maintenance: Start the rotary cooler and treatment device, monitor the sealing, air seal and material feeding stability in real time; regularly clean the accumulated material at the air outlet, check the air duct sealing, and check the wear condition of the baffle; dynamically fine-tune the air pressure and frequency conversion parameters according to the material characteristics.

[0017] The beneficial effects of this invention are: (1) In this invention, the partitioned directional hot air seal is combined with the mechanical baffle for double sealing. The airflow blocks the powder from overflowing along the material conveying direction, resulting in high efficiency in preventing material leakage. The fish scale air-cooling structure reduces the wear and tear of the sealing parts due to powder accumulation. The closed-loop hot air eliminates the cause of condensation and material accumulation. There is no continuous dust or material leakage during long-term operation, and the annual labor cost for on-site cleaning is greatly reduced.

[0018] (2) In this invention, the service life of the rubber baffle of the star-shaped ash discharge valve is extended, reducing the frequency of downtime replacement; and with the dual protection of hot air circulation and fish scale air cooling, the wear rate of the fish scale seal is reduced, the purchase of spare parts and downtime losses are greatly reduced, and the annual cost savings are high.

[0019] (3) In this invention, the fan and ash discharge valve are all adaptively frequency-controlled according to the cooler load. The air pressure and discharge speed are automatically reduced under low load conditions to avoid ineffective energy consumption. The hot air circulation at the tail of the machine recovers the waste heat, so there is no need to continuously extract the ambient temperature cold air, thus reducing the overall energy consumption of the fan. The discharge amount is automatically matched with the equipment load to prevent secondary leakage caused by material blockage and overflow.

[0020] (4) In this invention, there is no need to modify the rotary cooler drum and the main load-bearing structure of the head. Only the air seal, return air and electrical control components are added to the outside, and the installation cycle is short. The current, air pressure and frequency parameters can be freely configured and modified to adapt to different specifications and different production capacities of graphitization rotary coolers. The equipment has high value for upgrading, transformation and promotion.

[0021] (5) In this invention, there is no scattered high-temperature graphite powder, avoiding the risk of personnel slipping and being burned by high temperature; the feeding amount is stable and controllable, and there is no equipment jamming failure caused by material blockage and overload, which significantly improves the stability of the production line operation. Attached Figure Description

[0022] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the rotary cooling machine treatment device of the present invention.

[0024] Figure 2 This is a schematic diagram of the structure of the graphite high-temperature material leakage control device for the rotary cooler of the present invention.

[0025] Figure 3 This is a schematic diagram of the airflow equalization plate of the present invention.

[0026] Figure 4 This is a schematic diagram of the structure of the shielding assembly of the present invention.

[0027] Figure 5 This is a schematic diagram of the pipeline layout of the gas sealing assembly of the present invention. Detailed Implementation

[0028] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0029] Example 1 like Figure 1-5 As shown, a device for preventing leakage of high-temperature graphite material in a rotary cooler includes a head 1, a tail 10, a cooling drum 2 rotating between the head 1 and the tail 10, and a star-shaped ash discharge valve body 3 connected to the cooling drum 2. The connection between the head 1 and the cooling drum 2 is sealed by multiple sets of fish scales 4. It also includes a baffle assembly 31, an air seal assembly 5, and a variable frequency closed-loop control assembly; The baffle assembly 31 is installed on the star-shaped ash discharge valve body 3 of the discharge hopper and is used to seal the gap of the ash discharge valve and adjust the discharge amount. The air seal assembly 5 is installed on the outside of the machine head 1 and connected to the machine head 1. It includes a vortex fan 51 installed next to the cooling drum 2 and a duct 52 connected at one end to the air outlet of the vortex fan 51 and at the other end to the lower area of ​​the machine head 1. The duct 52 forms an air chamber between the cooling drum 2 and the machine head 1. The air chamber generates an airflow barrier from the machine head 1 to the machine tail 10. The airflow is uniformly transported from the machine head to the machine tail in a directional manner. The airflow is consistent with the natural flow direction of the powder, preventing the powder from turning back and leaking outward. It should be noted that all duct sections close to the high-temperature machine head and rollers are covered with a ceramic insulation layer to prevent high-temperature deformation and heat loss, while also preventing burns to personnel. The adjustable air pressure feature, with the vortex blower equipped with a frequency converter drive, allows for stepless dynamic adjustment of the output air pressure from 0.3 to 0.5 MPa, adapting to the dust and settling characteristics of different materials such as insulation materials and granular materials.

[0030] The variable frequency closed-loop control component includes a PLC controller, a WINCC configuration module, and a variable frequency driver. The PLC controller is electrically connected to the rotary cooler current detection unit, the star-shaped ash discharge valve motor, and the vortex fan 51.

[0031] Specifically, the hardware includes a Siemens S7-300 PLC controller, a WINCC7.5 configuration module, a Siemens G120C frequency converter, a main motor current detection unit for the cooler, a differential pressure sensor for the machine head gap, and a dust concentration sensor; the PLC synchronously collects multiple sets of signals and controls the two sets of frequency converters, namely the star-shaped ash discharge valve and the vortex fan, and sets up quantitative threshold control logic.

[0032] It should be further pointed out that the cooling method of this application adopts water cooling, which is different from the traditional air cooling structure. The high-pressure airflow is prone to reverse stirring of the powder in the cylinder, causing secondary dust; the powder continues to accumulate at the root of the seal, and leakage will still occur after the accumulated material exceeds the air pressure.

[0033] In this embodiment, by setting up a baffle assembly, a vortex fan air seal assembly, an airflow distribution plate, a fish scale blowing air outlet channel, a tail return air filter unit, and a frequency conversion closed-loop control assembly, the components work together to form a composite leak-proof system that combines mechanical sealing, layered hot air sealing, hot air circulation, and intelligent linkage control.

[0034] Furthermore, the directional airflow in this application flows smoothly along the material conveying direction, i.e. from the head to the tail, actively driving the suspended fine powder and settled powder in the head area to be conveyed to the tail end of the drum, avoiding the accumulation and agglomeration of high-temperature graphite powder at the root of the fish scale seal. This application directly reduces the material accumulation at the seal by airflow feeding, reducing leakage pressure from the source, rather than relying solely on wind pressure to block it.

[0035] Furthermore, the directional continuous airflow forms a uniform airtight layer at the annular gap of the machine head, preventing a small amount of unconveyed powder from leaking back outwards. Combined with the zoned gradient air outlet design, the lower main sealing zone concentrates air pressure to suppress settled material, while the upper weak sealing zone avoids dust. Reliable sealing can be achieved with only low air volume and low pressure. The fan power is much lower than that of traditional positive pressure air seals. The directional airflow directly contacts the high-temperature graphite powder, carrying away the heat from the material surface. The auxiliary cooling drum enhances the cooling effect, realizing the multiple functions of sealing, conveying, and cooling, and improving the overall cooling efficiency of the rotary cooler.

[0036] Furthermore, such as Figure 4 As shown, the air outlet of the air duct 52 of the air sealing assembly 5 is evenly distributed around the lower part of the machine head 1, and the air chamber completely covers the annular gap between the cooling drum 2 and the machine head 1. The air pressure can be steplessly adjusted.

[0037] Furthermore, such as Figure 3 As shown, an airflow equalization plate 53 is installed at the air outlet position of the air duct 52 corresponding to the machine head 1; The design is based on the distribution pattern of material leakage: the lower main sealing zone is the core area for material leakage and gravity settling, with the lowest density and diameter of the air outlets and concentrated air pressure; the parameters of the auxiliary sealing zones on both sides are in the middle; the upper weak sealing zone has the highest density and diameter of the air outlets, which disperses the air pressure and avoids high-pressure dust from the upper part.

[0038] The airflow distribution plate 53 is divided into a lower main sealing area 531, two side auxiliary sealing areas 532, and an upper weak sealing area 533 along the circumference. The air outlet density and air outlet diameter of the lower main sealing area 531, the two side auxiliary sealing areas 532, and the upper weak sealing area 533 increase sequentially.

[0039] The matching material leakage layer distribution pattern is as follows: the lower part of the gap is the core area of ​​gravity settling material leakage, which adopts small-diameter, high-density air outlets, and the air pressure is concentrated to form a high-pressure sealing layer to suppress the falling powder; the leakage amount on both sides is moderate, and the air outlet parameters are in the middle; the upper part has only a small amount of suspended dust, which adopts large-diameter, low-density air outlets to disperse the air pressure and avoid the high-pressure airflow from stirring the powder in the cylinder in the opposite direction, thus avoiding secondary dust generation. This solves the defects of insufficient air pressure at the lower part and excessive air pressure at the upper part in the traditional uniform air outlet, improves the air pressure utilization rate, significantly enhances the sealing effect under the same fan power, and generates no additional dust.

[0040] Furthermore, such as Figure 5 As shown, the machine head 1 has an air outlet channel 54 circumferentially opened inside. The air inlet of the air outlet channel 54 is connected to the air seal assembly 5. The air outlet of the air outlet channel 54 is inclined towards the inside of the cooling drum 2. The airflow washes the sealing structure of the fish scale sheet 4. On the one hand, the airflow continuously washes the root of the fish scale sheet, carrying away the high-temperature graphite powder that adheres and accumulates, preventing agglomeration and avoiding the accumulation of material which increases the frictional resistance of the drum. On the other hand, the low-temperature airflow continuously carries away the heat of the fish scale sheet metal, reducing the long-term working temperature of the fish scale sheet, slowing down the high-temperature creep and oxidation wear of the metal, and extending the replacement cycle of the fish scale sheet.

[0041] Furthermore, such as Figure 1 As shown, it also includes a return air filter unit 6 that forms a closed-loop circulating air path with the air seal assembly 5; The return air filtration unit 6 includes an annular return air hood, a bag filter unit, a return pipe, and a make-up air regulating valve; An annular return air hood is arranged at the tail of the machine 10 to collect the air seal airflow. The return air duct 52 guides the dust-laden airflow into the bag filter unit to separate and recover the graphite powder. The clean airflow is connected to the air inlet of the vortex fan 51 through the return pipe. A makeup air regulating valve is installed on the return pipe to balance the internal air pressure of the system by supplementing fresh air.

[0042] The circulating hot air system utilizes waste heat to eliminate the temperature difference between the ambient temperature air and the high-temperature blower head, preventing condensation and material adhesion on the inner wall. Simultaneously, powder recovery and reuse, along with hot air circulation, reduce the blower's thermal energy consumption, resulting in dual energy savings. Specifically, dust-laden hot air is recovered at the tail-end return air filtration unit. The filtered, clean hot air is returned to the blower inlet, with only a small amount of fresh air added through the make-up air regulating valve to balance the air pressure. This not only recovers graphite powder but also maintains stable system air temperature, avoiding condensation and material adhesion problems caused by the introduction of ambient temperature air, thus ensuring long-term operational stability.

[0043] Furthermore, the baffle assembly 31 includes a high-temperature resistant sealing sheet with a thickness of 8-10 mm and a high-temperature resistance of ≥130℃; The sealing sheet is fitted and assembled at the gap between the rotary valve rotor and the housing of the rotary valve body 3.

[0044] It should be noted that the sealing strip fits the gap, which on the one hand prevents the powder from leaking out of the bottom of the ash discharge valve, and on the other hand, works with frequency conversion control to accurately and stably control the discharge amount; the rubber material has excellent wear resistance, and there is no obvious deformation or wear after several months of continuous operation, which greatly reduces the frequency of replacement.

[0045] Compared to traditional polyurethane baffles, the rubber conveyor belt has an added wear-resistant carbon black reinforcing layer, which is not easy to harden and crack at high temperatures, and can operate continuously and stably for 3-4 months without significant wear and deformation. After the sealing sheet is attached to the outer wall of the rotor, the sealing gap can be controlled to ≤0.5mm, blocking the downward leakage of powder from the unloading source. In conjunction with the frequency conversion closed-loop system, the feeding speed is adaptively adjusted to avoid the overflow of material in the drum caused by a large instantaneous feeding volume, thus reducing the cause of material leakage from the head gap from the source.

[0046] Furthermore, the star-shaped ash discharge valve adjustment logic of the frequency conversion closed-loop control component is equipped with a quantized current threshold: If the main motor of the rotary cooler operates at a current ≤15A, it is determined to be a low-load condition for the insulation material. The PLC-controlled frequency converter reduces the operating frequency of the star-type ash discharge valve motor to 15~20Hz to reduce the material discharge. If the main motor of the rotary cooler operates at a current ≥25A, it is considered a high-load condition for particle materials. The PLC-controlled frequency converter increases the operating frequency of the star-shaped ash discharge valve motor to 30~35Hz to match the large material handling load.

[0047] When the insulation material is in low-current condition, the operating frequency of the vortex blower is reduced to decrease the air pressure and energy consumption; when the particle material is in high-current condition, the blower frequency is increased to enhance the airflow barrier; when the head pressure difference / dust concentration exceeds the standard, the blower air pressure is temporarily increased to dynamically strengthen the seal and eliminate instantaneous leakage.

[0048] Furthermore, the vortex blower 51 is synchronously connected to the variable frequency closed-loop control system.

[0049] Furthermore, it is equipped with a current detection unit, differential pressure sensor, dust concentration sensor, and bag filter recovery powder storage bin. The entire set of equipment is controlled by a variable frequency closed-loop control component to realize remote parameter modification, operation data recording, and automatic alarm for leakage faults.

[0050] Detailed description: The variable frequency closed-loop control component adopts a Siemens S7-300 PLC controller, WINCC7.5 configuration monitoring module, Siemens G120C variable frequency drive, cooling machine main motor current detection unit, machine head gap differential pressure sensor, dust concentration sensor, and audible and visual fault alarm module; the PLC controller is electrically connected to the star-shaped ash discharge valve drive motor, vortex fan variable frequency drive, and various detection sensors.

[0051] The PLC collects real-time data from the head gap pressure difference and dust concentration sensor signals. When the detected values ​​exceed the preset leakage threshold, the operating frequency of the vortex blower is temporarily increased, regardless of the material load, to briefly increase the air seal pressure and quickly suppress the instantaneous leakage. After the detected parameters return to normal, the blower automatically returns to the load matching reference frequency.

[0052] Supporting functions: The WINCC configuration interface displays real-time current, wind pressure, dust concentration, and fan / ash discharge valve operating frequency. It supports remote parameter modification, operation data storage, and audible and visual alarms for leakage faults, enabling unattended automated control.

[0053] It should be noted that this embodiment constructs an automated management system that includes source control of material discharge, intermediate air seal unblocking, tail-end return air recovery, and full-parameter frequency conversion linkage. Through the frequency conversion coordination of the star-shaped unloading valve and the blower, the dynamic balance of the entire system is achieved.

[0054] Example 2 Components that are the same as or corresponding to those in Embodiment 1 are referred to using the same reference numerals as in Embodiment 1. For simplicity, only the differences from Embodiment 1 are described below. The difference between Embodiment 2 and Embodiment 1 is as follows: A method for controlling leakage of high-temperature graphite material in a rotary cooler based on the above-described device includes the following steps: Installation and commissioning of the air seal assembly: Clean the accumulated material and debris from the head 1, and measure the annular gap between the cooling roller 2 and the head 1; fix the vortex blower 51 and lay the air duct 52, and adjust the position of the air outlet so that the air chamber completely covers the annular gap; start the blower and commission it to form a stable directional airflow from the head 1 to the tail 10. Among them, the output air pressure is adjusted to 0.3~0.5MPa, and the airflow is observed to be delivered to the tail of the machine without any dead corners of outward spillage; Closed-loop circulation air path construction: Install a ring-shaped return air cover at the tail 10, lay return air duct 52 to connect the bag filter unit, and the filtered clean hot air is connected to the air inlet of the vortex fan 51 through the return pipe. Adjust the make-up air regulating valve to match the system air pressure. Among them, the unloaded test of the circulating air path and the adjustment of the make-up air valve are used to ensure that the internal air pressure of the system is stable with no negative pressure and no positive pressure exceeding the limit. Variable frequency closed-loop control system construction: PLC is connected to the frequency monitoring of the cooler, the opening detection signal of the ash discharge valve and the frequency feedback signal of the cyclone fan. The control logic is written through the WINCC configuration module, and the corresponding current thresholds of the insulation material and the particle material, the frequency range of the cooler, the frequency range of the ash discharge valve and the frequency conversion linkage parameters of the fan are set to complete the online debugging. Among them, online testing was conducted under two working conditions: simulating thermal insulation material and particle material, to verify the response speed and accuracy of automatic frequency and wind pressure adjustment. Integrated operation and maintenance: Start the rotary cooler and treatment device, monitor the sealing, air seal and material feeding stability in real time; regularly clean the accumulated material at the air outlet, check the air duct 52 sealing, check the wear condition of the baffle, and dynamically fine-tune the air pressure and frequency conversion parameters according to the material characteristics.

[0055] Furthermore, this also includes shutting down the production line for the baffle assembly modification, disassembling the star-shaped ash discharge valve, removing internal accumulated material, and removing the original polyurethane soft rubber sheet; cutting and drilling the 8mm rubber conveyor belt according to the internal dimensions of the ash discharge valve, and using stainless steel bolts to attach and fix it to the gap between the rotor and the housing; manually turning the rotor to confirm that there is no jamming, and controlling the sealing gap to ≤0.5mm.

[0056] Actual test results: No cracking or wear of the rubber baffle within a 3-month period; no powder leakage from the annular gap of the machine head, and no dust on site; the current fluctuation of the cooler is ≤±2A, with no material blockage or overflow; the fan saves an average of 30% of electricity, saving a total of RMB 62,000 in labor, spare parts, and downtime losses per year, and completely eliminating on-site safety hazards caused by material leakage.

[0057] In the description of this invention, it should be understood that the terms "front and back", "left and right", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention.

[0058] Of course, those skilled in the art should understand that the term "a" should be understood as "at least one" or "one or more". That is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple. The term "a" should not be understood as a limitation on the number.

[0059] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art under the technical guidance of the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A device for preventing leakage of high-temperature graphite material in a rotary cooler, comprising a head, a tail, a cooling drum rotating between the head and the tail, and a star-shaped ash discharge valve body of a discharge hopper connected to the cooling drum, wherein the connection between the head and the cooling drum is sealed by multiple sets of fish scales. Its features are, It also includes a baffle assembly, an air seal assembly, and a variable frequency closed-loop control assembly; The baffle assembly is installed on the star-shaped ash discharge valve body of the discharge hopper and is used to seal the gap of the ash discharge valve and adjust the discharge amount; The air seal assembly is installed on the outside of the machine head and connected to the machine head. It includes a vortex fan installed next to the cooling drum and a duct connected at one end to the air outlet of the vortex fan and at the other end to the air duct in the lower part of the machine head. The air duct encloses the cooling drum and the machine head to form an air chamber. The air chamber generates an airflow barrier that blows from the machine head to the tail of the machine. The variable frequency closed-loop control component includes a PLC controller, a WINCC configuration module, and a variable frequency driver. The PLC controller is electrically connected to the rotary cooler current detection unit, the star-shaped ash discharge valve motor, and the vortex fan.

2. The device for preventing leakage of high-temperature graphite material in a rotary cooler according to claim 1, characterized in that: The air outlet of the air seal assembly is evenly distributed around the lower part of the machine head, and the air chamber covers the annular gap between the cooling drum and the machine head.

3. The device for preventing leakage of high-temperature graphite material in a rotary cooler according to claim 2, characterized in that: An airflow equalization plate is installed at the air outlet position of the air duct corresponding to the machine head; The airflow distribution plate is divided into a lower main sealing area, two side auxiliary sealing areas, and an upper weak sealing area along the circumference. The air outlet density and air outlet diameter of the lower main sealing area, two side auxiliary sealing areas, and upper weak sealing area increase sequentially.

4. The device for preventing leakage of high-temperature graphite material in a rotary cooler according to claim 1, characterized in that: The machine head has an air outlet channel circumferentially opened inside. The air inlet of the air outlet channel is connected to the air seal assembly. The air outlet of the air outlet channel is inclined towards the inside of the cooling drum. The airflow washes over the fish scale sealing structure and continuously cools the fish scales to prevent high-temperature graphite powder from accumulating and adhering to the base of the fish scales.

5. The device for preventing leakage of high-temperature graphite material in a rotary cooler according to claim 1, characterized in that: It also includes a return air filtration unit that forms a closed-loop circulating air path with the air seal assembly; The return air filtration unit includes an annular return air hood, a bag filter unit, a return pipe, and a make-up air regulating valve; An annular return air hood is located at the tail of the machine to collect the air seal airflow. The return air duct guides the dust-laden airflow into the bag filter unit to separate and recover the graphite powder. The clean airflow is connected to the air inlet of the vortex blower through the return pipe. A makeup air regulating valve is installed on the return pipe to balance the internal air pressure of the system by supplementing fresh air.

6. The device for preventing leakage of high-temperature graphite material in a rotary cooler according to claim 1, characterized in that: The baffle assembly includes a high-temperature resistant sealing sheet with a thickness of 8-10 mm and a high-temperature resistance of ≥130℃. The sealing sheet is fitted and assembled into the gap between the rotor of the star-shaped ash discharge valve and the housing of the star-shaped ash discharge valve body.

7. The device for preventing leakage of high-temperature graphite material in a rotary cooler according to claim 1, characterized in that: The variable frequency closed-loop control component's star-shaped ash discharge valve adjustment logic is equipped with a quantized current threshold: If the operating current of the main motor of the rotary cooler is ≤15A, it is determined to be a low-load condition of the insulation material. The PLC controls the frequency converter to reduce the operating frequency of the star-shaped ash discharge valve motor to 15~20Hz. If the main motor of the rotary cooler operates at a current ≥25A, it is considered a high-load condition for the particle material. The PLC-controlled frequency converter increases the operating frequency of the star-shaped ash discharge valve motor to 30~35Hz.

8. The device for preventing leakage of high-temperature graphite material in a rotary cooler according to claim 7, characterized in that: The vortex blower is synchronously connected to the variable frequency closed-loop control system.

9. A device for controlling leakage of high-temperature graphite material in a rotary cooler, characterized in that: It is also equipped with a current detection unit, a differential pressure sensor, a dust concentration sensor, and a bag filter recovery powder storage bin. The entire set of equipment is controlled by a variable frequency closed-loop control component.

10. A method for controlling leakage of high-temperature graphite material in a rotary cooler based on the device described in any one of claims 1 to 9, characterized in that, It includes the following steps: Air seal assembly installation and commissioning: Clean up accumulated material and debris at the machine head, measure the annular gap between the cooling drum and the machine head; fix the vortex blower and lay the air duct, adjust the air outlet position to ensure that the air chamber completely covers the annular gap; start the blower and commission it to form a stable directional airflow from the machine head to the machine tail; Closed-loop circulation air path construction: Install an annular return air hood at the tail of the machine, lay return air ducts to connect to the bag filter unit, and filter clean hot air is connected to the vortex blower inlet through the return pipe. Adjust the make-up air regulating valve to match the system air pressure. Variable frequency closed-loop control system construction: PLC is connected to the frequency monitoring of the cooler, the opening detection signal of the ash discharge valve and the frequency feedback signal of the cyclone fan. The control logic is written through the WINCC configuration module, and the corresponding current thresholds of the insulation material and the particle material, the frequency range of the cooler, the frequency range of the ash discharge valve and the frequency conversion linkage parameters of the fan are set to complete the online debugging. Integrated operation and maintenance: Start the rotary cooler and treatment device, monitor the sealing, air seal and material feeding stability in real time; regularly clean the accumulated material at the air outlet, check the air duct sealing, and check the wear condition of the baffle; dynamically fine-tune the air pressure and frequency conversion parameters according to the material characteristics.

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