A wet dust removal device with inert gas explosion suppression and an explosion suppression control method thereof

Abstract

The application provides a wet dust removal device with inert gas explosion suppression and an explosion suppression control method thereof, and relates to the technical field of dust removal. The wet dust removal device with inert gas explosion suppression comprises a wet dust remover body provided with a dust removal chamber, a hydrogen detection unit, an inert gas supply unit and a control unit; the hydrogen detection unit is arranged in the dust removal chamber; the inert gas supply unit is arranged outside the wet dust remover body and is communicated with the dust removal chamber at an output end; and the control unit is electrically connected with the two units. The control unit is provided with a hydrogen production rate prediction model, can calculate the hydrogen production rate and predict the hydrogen concentration in real time by combining parameters such as dust type, particle size and water temperature, and can start the gas supply unit in advance when the predicted value reaches a pre-inertization threshold value. The application can accurately detect the internal hydrogen concentration, the external gas supply structure is convenient for maintenance and avoids element corrosion, the pre-inertization control places safety protection in the front, and is suitable for the safe and efficient operation requirements of the wet dust removal of active metal dust.

Description

Technical Field

[0001] This invention relates to the field of industrial dust removal and explosion-proof safety technology, specifically to a wet dust removal device with inert gas explosion suppression. Background Technology

[0002] Wet scrubbers are widely used in industrial dust gas treatment due to their high dust collection efficiency. However, in the treatment of reactive metal dust such as aluminum and magnesium powder, the metal dust reacts chemically with the dust collection water, producing hydrogen gas. While the equipment is running, some hydrogen gas can be carried out with the exhaust air, and even after shutdown, residual dust continues to generate hydrogen. Furthermore, because wet scrubbers are semi-enclosed, hydrogen gas easily accumulates within the dust collection chamber. When the concentration reaches the lower explosive limit and encounters an ignition source, it can easily lead to an explosion.

[0003] Existing wet dust collectors mostly rely on externally deployed sensor points for hydrogen monitoring, which makes it difficult to accurately detect the true hydrogen concentration inside the dust collector chamber. This results in large detection errors, delayed risk response, and an inability to promptly detect internal hydrogen accumulation. Furthermore, existing dust collectors with inert gas explosion suppression functions often integrate the inert gas supply structure inside the dust collector body. This not only occupies limited installation space within the dust collector chamber but also poses a risk of corrosion damage to gas supply components due to the high dust and humidity environment inside. Furthermore, traditional wet scrubbing equipment lacks an automated linkage control structure for hydrogen concentration monitoring and inert gas supply. It cannot automatically adjust the inert gas supply and shutdown based on the real-time hydrogen concentration in the dust collector, making it difficult to quickly achieve inerting and explosion suppression when hydrogen accumulation exceeds the limit. The timeliness and accuracy of preventing hydrogen explosion risks are insufficient. At the same time, existing dust collectors with inert gas explosion suppression functions mostly have the gas supply components built-in, occupying limited space in the dust collector and being susceptible to corrosion from the high dust and high humidity environment inside. Later maintenance and gas cylinder replacement are extremely inconvenient. It also cannot achieve fully automated closed-loop linkage control of hydrogen monitoring and inerting gas supply. The level of intelligence in risk handling is low, making it difficult to meet the actual needs of long-term safe operation of wet scrubbing of reactive metal dust.

[0004] Furthermore, the reactivity of different reactive metal dusts (such as aluminum powder, magnesium powder, titanium powder, zinc powder, etc.) with water varies significantly. The hydrogen production rate of aluminum powder reacting with water is much higher than that of magnesium powder. Titanium powder reacts slowly at room temperature, but its hydrogen production rate increases significantly at high temperatures or under specific pH conditions. Existing wet dust collectors generally use uniform alarm thresholds and inerting control parameters, which cannot be specifically adapted to different dust types. This results in both insufficient protection against highly reactive dust and over-protection against low-reactive dust, wasting inert gas resources and making it difficult to ensure safety redundancy. At the same time, existing technologies all adopt a passive response mode that triggers explosion suppression upon detecting excessive hydrogen concentration. They lack the ability to predict the hydrogen generation rate and cannot perform predictive control before the hydrogen concentration reaches the dangerous threshold. For operating conditions with high hydrogen production rates, the hydrogen concentration is often close to or has reached the explosive range when explosion suppression is triggered, resulting in a significant response lag. Summary of the Invention

[0005] To address the problems of existing wet scrubbers' inability to accurately monitor hydrogen concentration inside the dust collector, unreasonable inert gas supply structure layout that cannot form automatic linkage control with hydrogen monitoring, difficulty in effectively preventing the explosion risk caused by hydrogen accumulation inside the dust collector, and the inability of existing technologies to provide targeted safety protection based on the differentiated reactivity of different reactive metal dusts, as well as the lack of hydrogen generation rate prediction capability leading to delayed explosion suppression response, this invention proposes a wet scrubber device with inert gas explosion suppression and its explosion suppression control method, including:

[0006] The wet scrubber body, hydrogen detection unit, inert gas supply unit, and control unit;

[0007] The wet dust collector body is equipped with a dust removal chamber;

[0008] The hydrogen detection unit is installed inside the dust removal chamber and is used to collect the hydrogen concentration signal inside the dust removal chamber;

[0009] The inert gas supply unit is located on the outside of the wet dust collector body, and the output end of the inert gas supply unit is connected to the dust collection chamber for introducing inert gas into the dust collection chamber.

[0010] The control unit is electrically connected to the hydrogen detection unit and the inert gas supply unit respectively, and is used to receive the hydrogen concentration signal and control the on / off state of the inert gas supply unit according to the hydrogen concentration signal.

[0011] The control unit has a built-in hydrogen production rate prediction model. The hydrogen production rate prediction model is used to calculate the hydrogen production rate under the current operating conditions based on the dust type, dust particle size distribution, water temperature, water pH value and dust-water contact area parameters. Based on the hydrogen production rate, dust removal chamber effective volume, current hydrogen concentration and exhaust replacement rate, the hydrogen concentration under the current operating conditions is predicted to obtain the hydrogen concentration prediction value.

[0012] The control unit is also used to activate the inert gas supply unit to perform pre-inertization control when the predicted hydrogen concentration reaches a preset pre-inertization threshold.

[0013] Optionally, the hydrogen detection unit includes a first hydrogen concentration sensor and a second hydrogen concentration sensor;

[0014] The first hydrogen concentration sensor is located in the area where hydrogen tends to accumulate in the dust removal chamber, and the second hydrogen concentration sensor is located at the air outlet of the wet dust collector body.

[0015] Optionally, the inert gas supply unit includes an inert gas high-pressure cylinder, a pressure reducing valve, and a solenoid valve;

[0016] The outlet of the inert gas high-pressure cylinder is connected in sequence to the pressure reducing valve and the solenoid valve, and the outlet of the solenoid valve is connected to the dust removal chamber.

[0017] Optionally, an air inlet pipe is connected between the solenoid valve and the dust removal chamber, and an expansion pipe is connected to one end of the air inlet pipe located inside the dust removal chamber.

[0018] The expansion tube has a single-stage expansion structure, and the nozzle of the expansion tube is inclined downward along the vertical plane.

[0019] Optionally, the nozzle of the expansion tube is directed toward the spray zone of the dust removal chamber.

[0020] Optionally, the wet dust removal device may also include an audible and visual alarm;

[0021] The audible and visual alarm is located on the top of the wet dust collector and is electrically connected to the control unit. It is used to receive the concentration abnormality control signal from the control unit and execute the alarm action.

[0022] Optionally, a sealing gasket is provided at the connection between the hydrogen concentration sensor and the wet dust collector body, and the hydrogen concentration sensor is pressed and fixed to the wet dust collector body by fasteners.

[0023] Optionally, the control unit has built-in hierarchical alarm and interlocking logic;

[0024] When the hydrogen concentration reaches a preset threshold, the control unit controls the inert gas supply unit to turn on and triggers an interlock protection action.

[0025] Optionally, the control unit integrates a fault diagnosis module for collecting the status and operation information of the wet dust collector, identifying the fault type and fault level of the wet dust collector based on the status and operation information, and executing corresponding graded protection actions based on the fault type and fault level.

[0026] The operational status information includes one or more of the following: hydrogen concentration information, inert gas supply pressure, spray water pressure, circulating water flow rate, fan current, and solenoid valve status feedback signal.

[0027] Optionally, the control unit is pre-configured with a dust reactivity level database, which includes one or more of the following: reaction rate constants, activation energies, lower explosive limits of hydrogen, and characteristic hydrogen production rate parameters for various active metal dusts.

[0028] The control unit is also used to automatically match safety control parameters according to the type of dust being processed.

[0029] The safety control parameters include one or more of the following: alarm threshold, inerting trigger threshold, inert gas injection flow rate, pre-inerting threshold, safety index calculation weight, and interlocking protection strategy parameters.

[0030] Based on the same inventive concept, this invention also proposes an explosion suppression control method for a wet dust collector with inert gas explosion suppression, comprising:

[0031] A pre-defined dust reactivity level database is provided, wherein the database contains reaction rate constants, reaction activation energies, hydrogen explosion lower limit, and hydrogen production rate characteristic parameters for various reactive metal dusts.

[0032] The type of reactive metal dust currently being processed is obtained, and corresponding safety control parameters are matched from the dust reactivity level database according to the type of reactive metal dust; wherein, the safety control parameters include: alarm threshold, inerting trigger threshold, inert gas injection flow rate, pre-inerting threshold, and safety index calculation weight;

[0033] The hydrogen concentration signal in the dust removal chamber is collected by the hydrogen detection unit and transmitted to the control unit;

[0034] Based on a pre-established hydrogen production rate prediction model, the hydrogen production rate under the current operating conditions is calculated according to parameters such as dust type, dust particle size distribution, water temperature, water pH value, and dust-water contact area. Based on the hydrogen production rate, effective volume of dust removal chamber, current hydrogen concentration, and exhaust replacement rate, the predicted hydrogen concentration value within a preset time period is predicted.

[0035] When the predicted hydrogen concentration reaches the pre-inertia threshold, the inert gas supply unit is activated for pre-inertia control.

[0036] When the hydrogen concentration signal reaches the alarm threshold, the inert gas supply unit is controlled to introduce inert gas into the dust removal chamber; when the real-time hydrogen concentration signal drops to the safety threshold, the inert gas supply unit is controlled to shut off.

[0037] Optionally, the pre-inerting control of activating the inert gas supply unit includes:

[0038] When the predicted hydrogen concentration reaches the pre-inertization threshold, the inert gas supply unit is controlled to perform pre-inertization at an initial flow rate less than the full flow rate.

[0039] The inert gas injection flow rate is dynamically adjusted based on the rate of increase of the predicted hydrogen concentration.

[0040] If the predicted hydrogen concentration after pre-inertization falls back to the safe range, then the inert gas supply unit is controlled to stop injecting.

[0041] If the real-time hydrogen concentration signal reaches the alarm threshold, the system will switch to full-flow injection and trigger interlock protection.

[0042] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0043] This invention provides a wet scrubbing device with inert gas explosion suppression and its explosion suppression control method, comprising: a wet scrubbing body, a hydrogen detection unit, an inert gas supply unit, and a control unit; the wet scrubbing body has a dust collection chamber inside; the hydrogen detection unit is disposed inside the dust collection chamber and is used to collect the hydrogen concentration signal inside the dust collection chamber; the inert gas supply unit is disposed outside the wet scrubbing body, and the output end of the inert gas supply unit is connected to the dust collection chamber for introducing inert gas into the dust collection chamber; the control unit is connected to the hydrogen detection unit and the inert gas supply unit respectively. The inert gas supply unit is electrically connected and is used to receive the hydrogen concentration signal and control the on / off state of the inert gas supply unit according to the hydrogen concentration signal. The control unit has a built-in hydrogen production rate prediction model, which is used to calculate the hydrogen production rate under the current operating conditions based on dust type, dust particle size distribution, water temperature, water pH value, and dust-water contact area parameters. Based on the hydrogen production rate, effective volume of the dust removal chamber, current hydrogen concentration, and exhaust replacement rate, the control unit predicts the hydrogen concentration under the current operating conditions to obtain a predicted hydrogen concentration value. The control unit is also used to determine the hydrogen concentration when the predicted hydrogen concentration value reaches a preset value. When the pre-inertia threshold is reached, the inert gas supply unit is activated to perform pre-inertia control. This invention places the hydrogen detection unit inside the dust collector chamber, allowing direct acquisition of real hydrogen concentration data, which helps ensure the accuracy and real-time nature of concentration detection. The inert gas supply unit is entirely located outside the wet scrubber body, with only its output end connected to the dust collector chamber. This eliminates the need for internal installation space, facilitating the disassembly, repair, and daily maintenance of components such as high-pressure gas cylinders and valve groups. Simultaneously, it keeps the gas supply components away from the dusty and humid airflow environment of the dust collector chamber, preventing corrosion interference and extending component lifespan. The control unit and hydrogen detection unit... The inert gas supply unit forms an electrical linkage that can automatically adjust the on / off state of the gas supply unit based on the real-time hydrogen concentration signal. When the hydrogen concentration exceeds the standard, inert gas is quickly introduced to achieve inerting and explosion suppression. Once the concentration drops back to the safe threshold, the gas supply is automatically stopped. This not only effectively prevents the risk of explosion caused by hydrogen accumulation under dust removal conditions, but also enables precise on-demand supply of inert gas, reducing media waste and lowering operating energy consumption. Furthermore, this invention can perform pre-inerting control based on a hydrogen production rate prediction model, which can move the safety control point forward to the concentration trend prediction stage, intervene in advance to suppress the rise in hydrogen concentration, and improve the timeliness and reliability of explosion suppression protection. Attached Figure Description

[0044] Figure 1 A schematic diagram of the overall structure of a wet dust removal device with inert gas explosion suppression provided by the present invention;

[0045] Figure 2 A schematic diagram of the structure and installation of a gas cylinder support in a wet dust removal device with inert gas explosion suppression provided by the present invention.

[0046] Figure 3 A schematic diagram of a nitrogen explosion suppression structure in a wet dust collector with inert gas explosion suppression provided by the present invention;

[0047] Figure 4 A schematic diagram of the installation of a nitrogen explosion suppression structure in a wet dust collector with inert gas explosion suppression provided by the present invention;

[0048] Figure 5 A schematic diagram of the air inlet pipeline structure in a wet dust removal device with inert gas explosion suppression provided by the present invention;

[0049] Figure 6 A schematic diagram of the installation of the first hydrogen concentration sensor in a wet dust removal device with inert gas explosion suppression provided by the present invention;

[0050] Figure 7 A schematic diagram of the installation of the second hydrogen concentration sensor in a wet dust removal device with inert gas explosion suppression provided by the present invention;

[0051] Figure 8 A schematic diagram of the installation of a sealing gasket in a wet dust collector with inert gas explosion suppression provided by the present invention;

[0052] Figure 9 A schematic diagram of the explosion suppression control method of a wet dust collector with inert gas explosion suppression provided by the present invention;

[0053] In the diagram: 1-First hydrogen concentration sensor; 2-Wet scrubber body; 3-Second hydrogen concentration sensor; 4-Audible and visual alarm; 5-Inlet pipe; 6-Solenoid valve; 7-Pressure reducing valve; 8-Inert gas high-pressure cylinder; 9-Cylinder support;

[0054] 101 - First hydrogen concentration sensor connecting bolt; 201 - Left side plate of wet dust collector body; 202 - Right side plate of wet dust collector body; 203 - Air outlet of wet dust collector body; 301 - Second hydrogen concentration sensor connecting bolt; 302 - Screw; 303 - Sealing washer; 304 - Nut; 501 - 90° elbow; 502 - First external thread adapter; 503 - Second external thread adapter; 504 - Straight pipe; 505 - 45° elbow; 506 - Conical expansion tube; 901 - Gas cylinder bracket connecting bolt. Detailed Implementation

[0055] This invention proposes a wet dust removal device with inert gas explosion suppression. The specific embodiments of this invention will be further described in detail below with reference to the accompanying drawings.

[0056] Example 1:

[0057] This invention provides a wet dust collector with inert gas explosion suppression, the overall assembly structure of which is shown in the schematic diagram below. Figure 1 As shown, it includes:

[0058] 2. Wet dust collector body, hydrogen detection unit, inert gas supply unit and control unit;

[0059] The wet dust collector body 2 is equipped with a dust removal chamber inside;

[0060] The hydrogen detection unit is installed inside the dust removal chamber and is used to collect the hydrogen concentration signal inside the dust removal chamber;

[0061] The inert gas supply unit is located on the outside of the wet scrubber body 2, and the output end of the inert gas supply unit is connected to the dust removal chamber for introducing inert gas into the dust removal chamber; preferably, the inert gas is nitrogen.

[0062] The control unit is electrically connected to the hydrogen detection unit and the inert gas supply unit respectively, and is used to receive the hydrogen concentration signal and control the on / off state of the inert gas supply unit according to the hydrogen concentration signal.

[0063] The control unit has a built-in hydrogen production rate prediction model. The hydrogen production rate prediction model is used to calculate the hydrogen production rate under the current operating conditions based on the dust type, dust particle size distribution, water temperature, water pH value and dust-water contact area parameters. Based on the hydrogen production rate, dust removal chamber effective volume, current hydrogen concentration and exhaust replacement rate, the hydrogen concentration under the current operating conditions is predicted to obtain the hydrogen concentration prediction value.

[0064] The control unit is further configured to activate the inert gas supply unit to perform pre-inertization control when the predicted hydrogen concentration reaches a preset pre-inertization threshold. In one implementation, the hydrogen detection unit includes a first hydrogen concentration sensor 1 and a second hydrogen concentration sensor 3.

[0065] The first hydrogen concentration sensor 1 is located in the area where hydrogen easily accumulates in the dust removal chamber, and the second hydrogen concentration sensor 3 is located at the air outlet of the wet dust collector body 2. This implementation method uses the top sensor to capture the initial accumulation signal of hydrogen in the dust removal chamber in real time, realizing early risk monitoring. At the same time, the air outlet sensor synchronously verifies the hydrogen concentration at the exhaust end to confirm whether the internal hydrogen has been effectively replaced and discharged. The two mutually verify and complement each other, which can effectively eliminate the detection blind spots, local concentration distortion and detection errors caused by single sensor failure that exist in single-point monitoring, which is conducive to improving the accuracy and reliability of hydrogen concentration detection.

[0066] In one implementation, the inert gas supply unit includes an inert gas high-pressure cylinder 8, a pressure reducing valve 7, and a solenoid valve 6.

[0067] The outlet of the inert gas high-pressure cylinder 8 is sequentially communicated with a safety valve, a pressure reducing valve 7 and a solenoid valve 6, and the outlet of the solenoid valve 6 is communicated with the dust removal chamber; the solenoid valve 6 is opened after receiving an electric signal from the control unit, and delivers the decompressed and stabilized nitrogen to the dust removal chamber through an output pipeline; the inert gas high-pressure cylinder 8 is fixed on the outer side of the wet dust remover body 2 through a cylinder bracket 9, and the cylinder bracket 9 comprises a circular ring structure for horizontally fixing the cylinder and a base support structure for vertical positioning;

[0068] The connecting part between the cylinder bracket 9 and the side wall of the wet dust remover body 2 is configured as a several-shaped convex avoiding structure, which is used for preventing the connecting bolt from interfering with the cylinder.

[0069] For example, the outlet of the inert gas high-pressure cylinder 8 may be in threaded connection;

[0070] For example, the specification parameters of the inert gas high-pressure cylinder may include: a volume of 15L, a diameter of 159mm, a height of 1030mm, a wall thickness of ≥3.6mm, a weight of 18kg, an operating ambient temperature of -20 to 60°C, and a working pressure of 15MPa;

[0071] In this implementation, the inert gas high-pressure cylinder is installed externally and stably assembled through the cylinder bracket with a circular ring for horizontal fixing and a base support for vertical positioning, in cooperation with the several-shaped convex avoiding structure at the connecting part between the bracket and the side wall of the dust remover, which can not only avoid the interference between the connecting bolt and the cylinder, improve the assembly convenience and installation stability, but also do not occupy the internal space of the dust removal chamber, meanwhile avoid the corrosion damage to the cylinder and the valve group caused by the indoor high-dust and high-humidity environment, and facilitate the later disassembly, assembly, maintenance and cylinder replacement; the outlet of the cylinder is sequentially communicated with the safety valve, the pressure reducing valve and the solenoid valve, the safety valve can realize overpressure safety protection, the pressure reducing valve stabilizes the output of the working pressure adapted to the working condition, and the solenoid valve receives the electric signal to realize precise on-off control, the three components work together to ensure the safety, stability and controllability of the inert gas supply, and in cooperation with the high-pressure cylinder of standardized specifications, it can be adapted to industrial working conditions in a wide temperature range, and meet the continuous and reliable inertization and explosion suppression gas supply requirements of the wet dust removal device.

[0072] In one implementation, the downstream of the solenoid valve 6 is communicated with the dust removal chamber through an air inlet pipeline 5, and one end of the air inlet pipeline 5 located in the dust removal chamber is connected with an expansion pipe; the air inlet pipeline 5 penetrates from the top of the dust removal chamber and extends into the interior of the dust removal chamber,

[0073] The expansion tube has a single-stage expansion structure, and the nozzle of the expansion tube is inclined downward along the vertical plane, so that the inert gas is injected into the dust removal chamber in an oblique downward manner to dilute the hydrogen in the dust removal chamber and reduce the oxygen concentration. At this time, the control unit triggers an alarm based on the hydrogen concentration signal and controls the solenoid valve to open, so that the inert gas is injected into the dust removal chamber through the expansion tube to suppress the explosion.

[0074] For example, the single-stage expansion structure may include a straight pipe section connected to the intake pipe 5 and an expansion section connected to the straight pipe section, wherein the inner diameter of the expansion section gradually increases along the gas flow direction; preferably, the expansion section is a conical expansion section to achieve diffusion injection.

[0075] Preferably, the nozzle of the expansion tube is oriented toward the spray area of ​​the dust removal chamber to improve the dilution effect of the inert gas on hydrogen and combustible dust cloud.

[0076] In this implementation, the downstream of the solenoid valve uses an air inlet pipe that enters from the top of the dust removal chamber. A single-stage expanding conical expansion tube is installed at the end of the pipe, and the nozzle is set at an angle downwards towards the spray area. This layout can precisely match the characteristics of hydrogen gas, which has a low density and tends to accumulate at the top of the dust removal chamber, allowing the inert gas to diffuse downwards from the hydrogen accumulation source. The single-stage expanding structure can expand the spray coverage of the inert gas, avoiding uneven local dilution caused by direct spraying. The angled downward spray angle can eliminate dead zones for hydrogen accumulation in the dust removal chamber, allowing the inert gas to quickly cover the entire area. At the same time, the nozzle facing the spray area allows the inert gas and the spray water mist to work synergistically, simultaneously completing hydrogen dilution, oxygen content reduction, and suspended dust sedimentation. This is beneficial to improving the speed and effect of inerting and explosion suppression. Moreover, the single-stage expanding structure is easy to process and has low gas flow resistance, ensuring a stable and efficient supply of explosion suppression gas.

[0077] In one implementation, the moisture removal device further includes an audible and visual alarm 4;

[0078] The audible and visual alarm 4 is located on the top of the wet dust collector and is electrically connected to the control unit. It is used to receive the concentration abnormality control signal from the control unit and execute the alarm action. This implementation method, by placing the audible and visual alarm on the top of the wet dust collector and directly connecting it to the control unit, allows the control unit to trigger the alarm immediately when the hydrogen concentration is abnormal, with no response delay, and can remind personnel to deal with the risk at the first time. At the same time, the top installation position can avoid the erosion and obstruction of the alarm by dust and water mist in the dust collector chamber, which is conducive to ensuring the long-term stable and reliable operation of the alarm device, thereby effectively improving the timeliness and intuitiveness of on-site safety warnings.

[0079] In one implementation, a sealing gasket is provided at the connection between the hydrogen concentration sensor and the wet scrubber body (i.e., the mounting surface of the wet scrubber body), and the hydrogen concentration sensor is pressed and fixed to the wet scrubber body by fasteners to ensure the airtightness of the installation point. This implementation, by setting a sealing gasket on the mounting surface of the hydrogen concentration sensor and the wet scrubber body and pressing the sensor and the scrubber body together with fasteners, can reliably seal the assembly gap at the sensor installation location, preventing hydrogen, dust-laden airflow, and water mist in the dust removal chamber from leaking through the installation gap, eliminating the safety hazards caused by gas leakage, and preventing external air from seeping in and causing distortion of hydrogen concentration detection data. The sealing gasket also plays a buffering and vibration-damping role, preventing the sensor from loosening or shifting due to equipment vibration, which helps to ensure the sensor is installed stably, keeping the detection probe in a stable monitoring position, ensuring the accuracy and continuity of hydrogen concentration acquisition, adapting to the harsh working conditions of high humidity and dust in wet scrubbing, and improving the overall sealing reliability and monitoring stability of the device.

[0080] In one implementation, the control unit has built-in hierarchical alarm and interlocking logic;

[0081] When the hydrogen concentration reaches a preset threshold, the control unit controls the inert gas supply unit to turn on and triggers an interlock protection action.

[0082] For example, the control unit can set graded alarm and interlock logic based on the lower explosive limit of hydrogen. When the hydrogen concentration reaches 25% of the lower explosive limit, an audible and visual alarm is triggered and interlock control is executed. The interlock control can at least include cutting off the power supply to the processing equipment and keeping the induced draft fan and circulating water supply mechanism running continuously.

[0083] This implementation method, through the built-in hierarchical alarm and interlocking logic based on the lower explosive limit of hydrogen in the control unit, can simultaneously trigger visual and audible alarms, activate the inert gas supply, and execute interlocking actions such as cutting off the power supply to the processing equipment and maintaining the operation of the induced draft fan and circulating water supply mechanism when the hydrogen concentration reaches the warning threshold. It can achieve multi-stage linkage and handling in the early stage of hydrogen accumulation, including early warning, cutting off the source of dust and hydrogen production, maintaining ventilation to remove hydrogen, dust suppression by spraying, and inert gas inerting. This is conducive to curbing the continuous generation of hydrogen from the source, rapidly reducing the indoor hydrogen and oxygen concentration, and preventing the hydrogen concentration from rising further to the explosive range. It achieves active and forward-looking safety protection, and significantly improves the risk response speed and explosion-proof reliability of the device.

[0084] In one implementation, the control unit integrates a fault diagnosis module, which is used to collect the status and operation information of the wet dust collector, calculate a comprehensive safety index based on the status and operation information, determine the fault type and fault level of the wet dust collector based on the comprehensive safety index and the status and operation information, and execute corresponding graded protection actions based on the fault type and fault level.

[0085] The operational status information includes one or more of the following: hydrogen concentration information, inert gas supply pressure, spray water pressure, circulating water flow rate, fan current, and solenoid valve status feedback signal; the fault types may include: hydrogen monitoring system fault, inert gas system fault, and dust removal system fault.

[0086] The hydrogen monitoring system can be considered faulty if any of the following conditions are met:

[0087] ;

[0088] in, express Hydrogen concentration at any given time; This represents the threshold for determining sudden changes in hydrogen concentration, i.e., the critical value for the volume change of hydrogen concentration between adjacent sampling times.

[0089] A fault in the inert gas system can be identified when any of the following conditions are met:

[0090] ;

[0091] in, express Constant inert gas intake pressure; express Inert gas outlet pressure at all times

[0092] The dust removal system can be identified as malfunctioning when the following conditions are met:

[0093] ;

[0094] in, express Real-time pressure of water supply for wet scrubber spray; express Real-time flow rate of water sprayed by the dust collector; express Real-time operating current of the dust collector fan; This indicates the rated design flow rate of the dust collector spray system; This indicates the rated operating current of the dust collector fan;

[0095] For example, a fault is determined when any of the following conditions are met: hydrogen concentration information, inert gas supply pressure, spray water pressure, circulating water flow rate, fan current, and solenoid valve status feedback signal:

[0096] Hydrogen sensor output >1%vol;

[0097] The inert gas supply pressure is below 1.5 MPa;

[0098] There is no status feedback for 1 second after the solenoid valve opening command is issued.

[0099] The spray water pressure is below 0.15 MPa;

[0100] The circulating water flow rate is less than 50% of the rated flow rate;

[0101] The fan current exceeds 1.2 times the rated value or there is no current input.

[0102] For example, the above-mentioned fault levels can be divided into three levels: Level I warning (indicating that the parameter is close to the threshold or slightly drifts), Level II abnormal (indicating that the parameter exceeds the limit but does not endanger safety), and Level III danger (indicating critical failure or rapid accumulation of hydrogen). When Level III danger is triggered, the machine should be shut down immediately and inerting should be used to suppress the explosion.

[0103] For example, the formula for calculating the comprehensive safety index mentioned above can be as follows:

[0104] ;

[0105] In the formula, Hydrogen safety sub-index The expression can be as follows:

[0106] ;

[0107] ;

[0108] ;

[0109] in, express The overall safety index of wet dust collection devices at all times; express The real-time hydrogen safety sub-index can be calculated from parameters such as real-time hydrogen concentration and the extent to which the concentration exceeds the standard; express The constant inert gas supply safety sub-index is used to characterize whether the inert gas pressure, gas supply pipeline, valve group working status, etc. are normal. express The safety sub-index of dust removal operation is used to characterize the working safety status of the dust removal system, including dust concentration in the dust removal chamber, spray operation, and fan operation. The weighting coefficients represent the hydrogen operating conditions; The weighting coefficients represent the inert gas supply conditions. This represents the weighting coefficient for dust removal operation. An example weighting coefficient can be set as follows: , , ; express Hydrogen concentration at any given time; Indicates the real-time supply pressure of the inert gas supply pipeline; when When, it is classified into a safety level (i.e., Level I warning), when At that time, attention levels are classified (i.e., Level II abnormalities). When the alert level is determined (i.e., Level III warning), the system will be immediately shut down and inertia will be initiated.

[0110] This implementation integrates a fault diagnosis module into the control unit. By collecting multi-dimensional operational information such as hydrogen concentration, gas supply pressure, spray water pressure, circulating water flow, fan current, and solenoid valve status, and combining this with clearly defined fault judgment thresholds and weighted comprehensive safety index calculations, it can accurately identify the fault types of the three core modules: hydrogen monitoring, inert gas supply, and dust removal system. Furthermore, based on the comprehensive safety index, it classifies the operating status into three levels and corresponding protection strategies. This avoids false alarms and missed diagnoses caused by relying on single parameters, enabling precise fault location and tiered handling. It also allows for immediate shutdown and inerting explosion suppression in hazardous conditions, transforming safety control from passive early warning to proactive quantitative management. This improves the accuracy of fault diagnosis, the scientific nature of safety assessments, and the timeliness of explosion-proof protection, fully meeting the high reliability and high safety requirements of wet dust removal systems for reactive metal dust.

[0111] In one implementation, the control unit may have a preset dust reactivity level database, which may include one or more of the following: reaction rate constants, activation energies, lower explosive limits of hydrogen, and characteristic hydrogen production rate parameters of various reactive metal dusts (such as aluminum powder, magnesium powder, titanium powder, zinc powder, etc.).

[0112] The control unit is also used to automatically match safety control parameters according to the type of dust being processed.

[0113] The safety control parameters include one or more of the following: alarm threshold, inerting trigger threshold, inert gas injection flow rate, pre-inerting threshold, safety index calculation weight, and interlocking protection strategy parameters.

[0114] In this implementation, a parameter matching mechanism based on the dust reactivity level database can be used to adapt to the reaction characteristics and explosion risk levels of different types of reactive metal dust, so that various safety control parameters accurately correspond to actual working conditions, thereby improving the adaptability and protection rationality of the device in multi-dust treatment scenarios.

[0115] In summary, this invention addresses the safety hazards caused by hydrogen accumulation during wet dust removal of reactive metal dust by proposing a wet dust removal device with inert gas explosion suppression. Through a four-tiered safety mechanism—dual-point hydrogen monitoring, audible and visual alarms, status assessment, and fault diagnosis—it achieves early detection, early warning, and early handling of hydrogen accumulation and equipment anomalies. Combined with comprehensive safety index quantitative assessment, hierarchical interlocking control, and intelligent fault diagnosis, along with an integrated design for nitrogen inerting and explosion suppression, it not only effectively avoids the safety hazards of high-temperature carbon dioxide use but also enhances the device's safety redundancy and operational reliability through full-link fault monitoring, hierarchical safety management, and dynamic adaptive adjustment. This meets the safety operation requirements in reactive metal dust treatment scenarios, prevents safety risks at the source, and ensures long-term stable operation of the equipment.

[0116] Example 2:

[0117] To more clearly illustrate the purpose, technical solution, and advantages of the present invention, the following detailed description of a wet dust removal device with nitrogen inerting and explosion suppression proposed by the present invention is provided in conjunction with the accompanying drawings and specific embodiments.

[0118] The device in this embodiment includes a wet scrubber body 2, an induced draft fan, a nitrogen explosion suppression system (inert gas high-pressure cylinder 8, pressure reducing valve 7, solenoid valve 6, and inlet pipe 5), a control unit, and an alarm unit. The control unit receives monitoring signals and outputs execution control to realize alarm, interlocking, and inerting explosion suppression.

[0119] To address the risk of hydrogen production during wet dust removal of reactive metal dust, where the reaction between dust and water leads to accumulation and potential explosion during shutdown or semi-enclosed conditions, this embodiment employs inert gas for inertization and explosion suppression. Considering both explosion suppression performance and safety under high-temperature conditions, and taking into account the potential reduction reaction of carbon dioxide at high temperatures that could introduce carbon monoxide and other hazards, nitrogen is preferred as the inert gas for explosion suppression in this embodiment.

[0120] The audible and visual alarm 4 is installed on the top of the wet dust collector body 2. When the control unit determines that the hydrogen concentration has reached the preset threshold or an abnormal operating condition occurs, it will trigger the audible and visual alarm to prompt personnel to take timely action and improve operational safety.

[0121] like Figure 2The figure shows the structure and installation schematic of the gas cylinder bracket. The gas cylinder is fixed by the gas cylinder bracket 9. The connection part between the gas cylinder bracket 9 and the left side plate 201 of the wet dust collector body can be designed as a several-shaped outward protruding avoidance structure (the middle protrusion is used to avoid interference between the fastening bolt and the gas cylinder). The gas cylinder bracket 9 is provided with a circular ring for horizontally fixing the gas cylinder, and a bottom bracket is arranged at the bottom for vertical positioning. The gas cylinder bracket 9 and the wet dust collector body 2 are fixed by gas cylinder bracket connecting bolts 901, and a rubber gasket can be added at the connection to improve the sealing and vibration damping effect.

[0122] As Figure 3 The figure shows the schematic diagram of the nitrogen explosion suppression structure. The inert gas high-pressure gas cylinder 8 is fixed on the outer side of the wet dust collector body 2 through a safety valve, a solenoid valve and a pressure reducing valve. The valve set at the top of the inert gas high-pressure gas cylinder 8 is connected with an air inlet pipeline 5, and the pipeline realizes direction change and sealing connection through a 90° elbow 501, a first external thread adapter 502, and a second external thread adapter 503 in sequence, so as to introduce the inert gas into the wet dust collector to achieve explosion suppression protection.

[0123] As Figure 4 The figure shows the installation schematic of the nitrogen explosion suppression structure. The inert gas high-pressure gas cylinder 8 is fixed by an annular hoop, and the gas cylinder bracket 9 supported by the hoop is rigidly fixed on the outer side of the left side plate 201 of the wet dust collector body through gas cylinder bracket connecting bolts 901. The valve set at the top is connected with the air inlet pipeline 5, which extends into the interior of the wet dust collector body 2, so that nitrogen can be introduced into the dust removal chamber to achieve inerting and explosion suppression.

[0124] The gas cylinder outlet is a G5 / 8 threaded interface, and the downstream is connected with the pressure reducing valve 7 and the solenoid valve 6 in sequence. The pressure reducing valve 7 reduces the pressure of the high-pressure nitrogen in the gas cylinder and outputs it at a constant pressure; the solenoid valve 6 is opened after receiving the electric signal from the control unit, and delivers nitrogen to the interior of the wet dust collector body 2 through the output pipeline.

[0125] Preferably, the specification parameters of the nitrogen gas cylinder can be selected as follows: volume 15L, diameter 159 mm, height 1030 mm, wall thickness ≥ 3.6 mm, weight 18kg, operating ambient temperature -20 to 60°C, working pressure 15MPa.

[0126] As Figure 5 The figure shows the structural schematic of the air inlet pipeline 5. The air inlet pipeline 5 penetrates from the top of the dust removal chamber and extends into the interior of the dust removal chamber. The air inlet pipeline can be composed of a 90° elbow 501, a first external thread adapter 502, a second external thread adapter 503, a straight pipe 504, a 45° elbow 505, etc., and the end is connected with a conical expansion pipe 506 for realizing single-stage diameter expansion diffusion injection. The conical expansion pipe 506 has a single-stage diameter expansion, and its injection port is inclined downward relative to the vertical direction, so that nitrogen forms a diffusion-covered mixed state in the dust removal chamber, which can dilute local hydrogen faster and reduce the oxygen concentration.

[0127] In this embodiment, the control unit is set to a graded response based on the lower explosive limit (LEL) of hydrogen: when the hydrogen concentration reaches 25% of the LEL (approximately 1% by volume), the audible and visual alarm system is immediately triggered to automatically execute interlock control, including cutting off the power to the processing equipment and workbench; the exhaust fan continues to run to accelerate internal gas replacement; and the circulating water pump continues to run to continuously generate water mist to capture suspended dust and achieve a certain suppression effect.

[0128] At the same time, when the control unit outputs a control signal to open the solenoid valve 6, the nitrogen gas that has been depressurized and stabilized is injected obliquely downward into the dust removal chamber through the air inlet pipe and the conical expansion pipe to achieve rapid inerting and explosion suppression; when the hydrogen concentration returns to below the safe threshold, the solenoid valve is closed to complete the inerting process.

[0129] Hydrogen has a low density and tends to accumulate at the top of the dust removal chamber. Therefore, a first hydrogen concentration sensor 1 is installed at the top of the dust removal chamber / gas collection area. Simultaneously, to monitor changes in hydrogen concentration on the exhaust side, a second hydrogen concentration sensor 3 is installed at the air outlet or exhaust duct. The monitoring signals from both sensors are connected to a centralized control unit to achieve real-time display, historical data recording, and tiered alarm / interlock functions.

[0130] like Figure 6 The diagram shows the installation of the first hydrogen concentration sensor. The first hydrogen concentration sensor 1 is fixed to the air outlet 203 of the wet dust collector body by the first hydrogen concentration sensor connecting bolt 101. It can monitor the hydrogen concentration at the air outlet and cooperate with the internal sensor to realize multi-point hydrogen concentration monitoring.

[0131] Figure 7 The diagram shows the installation of the second hydrogen concentration sensor 3. The second hydrogen concentration sensor 3 is fixed to the right side plate 202 of the wet dust collector body by the second hydrogen concentration sensor connecting bolt 301. Multiple fixing points are set on both sides of the sensor to ensure its reliable installation on the side plate of the dust collector and to monitor the hydrogen concentration status in the dust collection chamber.

[0132] like Figure 8 As shown in this embodiment, the sensor mounting hole adopts a through-hole structure. The screw 302 passes through the through-hole on the wet dust collector body 2 and cooperates with the hydrogen concentration sensor mounting part. A sealing gasket 303 is set between the sensor and the outer wall / mounting surface of the dust collector body. The screw 302 is locked by the nut 304, so that the sealing gasket 303 is compressed to form a reliable gas seal.

[0133] In addition, this embodiment may also include a fault diagnosis module, which is executed in real time according to the following steps:

[0134] (1) Data acquisition and smoothing

[0135] The control unit collects hydrogen concentration, cylinder pressure, pressure reducing valve outlet pressure, spray water pressure, circulating water flow, fan current, and solenoid valve feedback signals at a frequency of 2Hz, and performs moving average filtering.

[0136] ;

[0137] in, express The optimized data value after three-point moving average smoothing filtering is used to eliminate random fluctuations and instantaneous interference in the sensor-acquired data; express The raw, real-time detection data collected at all times can refer to the original sensor measurements such as hydrogen concentration and gas supply pressure.

[0138] (2) Fault determination conditions

[0139] The control unit will detect the following faults in real time:

[0140] Hydrogen monitoring malfunction: If the hydrogen concentration is 0 for ≥2 seconds, or the concentration jumps by >2%vol, the sensor is considered to be faulty / broken.

[0141] Inert gas supply failure: Cylinder pressure If the pressure is less than 1.5 MPa, it is determined to be insufficient pressure; if there is no feedback within 1 second after the solenoid valve is opened, it is determined to be stuck / open circuit.

[0142] Dust removal system malfunction: Real-time pressure of spray water supply <0.15MPa; Real-time flow rate of spray water Fan operating current or =0 indicates a fan malfunction.

[0143] (3) Fault classification and execution strategy

[0144] Level I (Warning): Parameters are close to the threshold or slightly drifting. The panel will then display a message indicating that the sampling frequency should be increased.

[0145] Level II (Abnormal): Parameters exceed limits but do not reach danger. At this time, an audible and visual warning will be issued, and the fan and water pump should be kept running.

[0146] Level III (Danger): Monitoring failure, gas supply failure, rapid accumulation of hydrogen. In this case, immediately cut off the power to the processing equipment, start nitrogen inerting, and trigger a forced alarm.

[0147] (4) Fault locking and reset

[0148] After a Level III fault is triggered, the system will automatically lock. It can only be restarted after the fault is cleared and the system is manually reset.

[0149] In this embodiment, a status assessment module may also be included to collect multi-dimensional parameters such as hydrogen concentration, inert gas supply pressure, spray water pressure, circulating water flow rate, and fan operating status in real time. Through normalization processing and weighted fusion calculation, a comprehensive safety index is obtained to achieve quantitative assessment, graded early warning, and adaptive control of the device's safety level. The specific implementation steps are as follows:

[0150] (1) Calculation of comprehensive safety index

[0151] The operating parameters of each component in the device are collected at a fixed frequency. After filtering and normalization, the comprehensive safety index is calculated using the following formula:

[0152] ;

[0153] in, express The overall safety index of wet dust collection devices at all times; express The real-time hydrogen safety sub-index can be calculated from parameters such as real-time hydrogen concentration and the extent to which the concentration exceeds the standard; express The constant inert gas supply safety sub-index is used to characterize whether the inert gas pressure, gas supply pipeline, valve group working status, etc. are normal. express The safety sub-index of dust removal operation is used to characterize the working safety status of the dust removal system, including dust concentration in the dust removal chamber, spray operation, and fan operation. The weighting coefficients represent the hydrogen operating conditions; The weighting coefficients represent the inert gas supply conditions. The weighting coefficient represents the dust removal operating conditions;

[0154] (2) Normalization of component states

[0155] Hydrogen concentration is a core indicator determining the system's safety level, and its normalization function is:

[0156] ;

[0157] express Hydrogen concentration at any given time;

[0158] When the hydrogen concentration is below 0.5% vol, it is considered risk-free, and the normalization value is taken as 1.

[0159] When the hydrogen concentration is in the range of 0.5% to 1.2% vol, the safe value decreases linearly with increasing concentration.

[0160] When the hydrogen concentration reaches 1.2% vol (25% of the lower explosive limit), the normalized value drops to 0, and the system determines it to be high risk.

[0161] (2) Normalization of the health status of inert gas explosion suppression system

[0162] ;

[0163] This indicates the real-time gas supply pressure of the inert gas supply pipeline;

[0164] This normalization rule can reflect the nitrogen cylinder pressure margin, pipeline sealing, and actuator reliability in real time, ensuring that the explosion suppression system is always available.

[0165] (3) Normalization of the effectiveness of wet dust collection systems

[0166] ;

[0167] The effectiveness of dust removal is determined by comprehensively considering water pressure, flow rate, and fan status, thus avoiding dust accumulation and accelerated hydrogen release due to localized failures.

[0168] (4) Security level determination and linkage strategy

[0169] The control unit classifies the operating status into three levels based on the comprehensive safety index and executes differentiated control accordingly:

[0170] Safety status: S total ≥0.7;

[0171] All modules of the device are operating normally, with low hydrogen concentration, explosion suppression system on standby, and stable dust removal efficiency. The system is operating in conventional mode and requires no additional intervention.

[0172] Note the state: 0.4≤S total <0.7;

[0173] The system exhibited minor anomalies, such as increased hydrogen concentration, low water pressure, and decreased cylinder pressure, but the risks were within a manageable range. The system automatically increased the monitoring frequency, activated audible and visual warnings to alert maintenance personnel, and slightly increased the spray flow rate to enhance dust and hydrogen suppression.

[0174] Alert status: Total < 0.4;

[0175] The equipment's safety capability has significantly decreased, approaching the danger threshold. The system immediately enters the highest level of interlock protection: automatically cutting off the power to the processing equipment and stopping dust generation; maintaining continuous operation of the induced draft fan and circulating water pump; and simultaneously initiating an inert gas injection program to rapidly reduce the internal oxygen and hydrogen concentrations to prevent combustion and explosion.

[0176] (5) Power-on self-test evaluation logic

[0177] Before the device is started, the control unit automatically performs a full-dimensional safety self-test assessment, completing the following steps in sequence:

[0178] Hydrogen sensor calibration and effectiveness testing, inert gas cylinder pressure testing, solenoid valve operation reliability testing, fan start-up performance testing, spray water pressure and flow rate testing, and comprehensive safety index calculation.

[0179] Only if the self-test result meets S total Normal startup procedure is allowed only when the value is ≥0.7; if the self-test fails, the device will lock startup and display the cause of the fault until the hidden danger is eliminated.

[0180] (6) Dynamic evaluation and adaptive adjustment during operation

[0181] During device operation, the comprehensive safety index is updated every 0.5 seconds to achieve real-time risk tracking.

[0182] When the overall safety index shows a downward trend, preventative adjustments are automatically implemented: valve opening is increased in advance to enhance water mist coverage; fan negative pressure is increased to improve internal gas replacement efficiency; and pre-protection logic is activated in advance to shorten the explosion suppression response time. Through dynamic evaluation and adaptive adjustment, a shift from passive alarm to proactive prevention is achieved.

[0183] This embodiment illustrates the wet dust collector with nitrogen inerting and explosion suppression proposed in this invention. It achieves precise monitoring of hydrogen concentration across the entire area through multi-point deployment of hydrogen sensors, adapts to operational needs with an external nitrogen supply layout while avoiding the potential hazards of harmful gases derived from high-temperature carbon dioxide. Combined with data smoothing filtering, multi-dimensional intelligent fault diagnosis and graded handling, and a comprehensive safety index quantitative assessment mechanism, along with graded interlocking protection, start-up self-testing, and dynamic adaptive control capabilities, it can proactively identify, provide graded early warnings, and rapidly inertate and suppress explosion interlocking protection for hydrogen accumulation and potential equipment malfunctions during the removal of reactive metal dust. This enhances the device's operational safety redundancy and intelligent risk control level, effectively preventing explosions caused by hydrogen accumulation in the dust collector chamber from the source, and ensuring stable and safe operation of the equipment under all operating conditions.

[0184] Furthermore, this embodiment can achieve pre-inertization control through a hydrogen production rate prediction model, and combine it with a dust reactivity level database to achieve differentiated parameter configuration, forming a complete safety protection system. It can accurately adapt to different active metal dust conditions, upgrading from passive early warning to active quantitative control, thereby improving the intrinsic safety level and intelligence of the device.

[0185] In this embodiment, a hydrogen production rate prediction and pre-inertization control module may also be included, which is implemented as follows:

[0186] (1) Construction of hydrogen production rate prediction model:

[0187] Based on parameters such as dust type (aluminum powder, magnesium powder, titanium powder, and other reactive metals), dust particle size distribution (D10, D50, D90), water temperature T, water pH value, and effective contact area A between dust and water, the hydrogen production reaction kinetic equation can be constructed as follows:

[0188] ;

[0189] in, express Hydrogen production rate at any time (mol / s); The reaction rate constant is related to the type of dust, aluminum powder magnesium powder Titanium powder (normal temperature); As a particle size influence function, the smaller the dust particle size, the larger the specific surface area. The larger the value; This is a temperature correction function; As a pH correction function, the reaction is accelerated in both acidic and alkaline environments; The effective contact area between dust and water (m²); for Constant concentration of suspended dust in the dust removal room (g / m³);

[0190] In the formula,

[0191] ;

[0192] in, For reference particle size, This is the actual particle size. It is an experience index;

[0193] ;

[0194] in, The activation energy of the reaction is expressed in J / mol. It is the molar gas constant (8.314 J / (mol·K)). The absolute temperature (K) is the current operating temperature. The reference temperature is K. The higher the water temperature, the faster the reaction rate. The specific forms and parameter values ​​of the correction functions in the above calculation formulas are for illustrative purposes only. In practical applications, they can be determined through experimental calibration based on the specific dust type.

[0195] (2) Hydrogen concentration prediction calculation:

[0196] Based on hydrogen production rate Effective volume of dust removal chamber Current hydrogen concentration and exhaust air replacement rate For example, the process can be calculated using the following formula. Predicted hydrogen concentration after time:

[0197] ;

[0198] in, for Predicted hydrogen concentration at any given time (%vol). for Current hydrogen concentration (%vol) at any given time. for Hydrogen production rate at any given time (mol / s) For predicting the time step (s). Effective volume of the dust removal chamber (m³) 3 ), exhaust air replacement rate (m 3 / s), which can be flexibly set according to the dust reactivity level and on-site safety assessment results in practical applications.

[0199] (3) Pre-inertia triggering and dynamic adjustment:

[0200] Pre-inertia threshold It can be set to 15%-20% of the lower explosive limit, which is lower than the conventional alarm threshold, ensuring that protection is activated before the hydrogen concentration enters the dangerous range.

[0201] when At that time, the inert gas supply unit is activated in advance for pre-inertization before the actual concentration reaches the conventional alarm threshold.

[0202] The control unit based on the predicted rate of increase in hydrogen concentration For example, the inert gas injection flow rate can be dynamically adjusted using the following formula:

[0203] ;

[0204] in, Real-time injection flow rate (L / min) of inert gas; Inject traffic based on the foundation; This is the flow rate regulation coefficient; The above flow rate regulation formula and parameters are illustrative examples describing the predicted rate of increase in hydrogen concentration. and The specific value can be determined through experimental calibration based on the volume of the dust removal chamber, the type of inert gas, and the dust reactivity level.

[0205] (4) Synergistic control strategy of pre-inertization and conventional explosion suppression:

[0206] Pre-inertization control and conventional threshold-triggered explosion suppression control operate in parallel, forming a three-tiered progressive safety protection:

[0207] First stage (pre-inertization): When the predicted concentration reaches the pre-inertization threshold, inert gas is injected in advance at a small flow rate to suppress the hydrogen concentration from continuing to rise. At this time, the device operates normally and does not trigger a shutdown.

[0208] Level 2 (Conventional Explosion Suppression): If the actual concentration still reaches the explosion protection threshold, immediately switch to full flow injection and trigger interlock shutdown to cut off the power to the processing equipment;

[0209] Level 3 (Resumption of Monitoring): If the predicted hydrogen concentration falls back to the safe range after pre-inertization, the inert gas injection will be automatically stopped, and the normal monitoring status will be restored.

[0210] Example 3:

[0211] Based on the same inventive concept, this invention also provides an explosion suppression control method for a wet dust collector with inert gas explosion suppression, as shown in the flowchart below. Figure 9 As shown, it includes:

[0212] Step 1: Collect the hydrogen concentration signal in the dust removal chamber inside the wet scrubber body through the hydrogen detection unit, and transmit the hydrogen concentration signal to the control unit;

[0213] Step 2: When the hydrogen concentration signal reaches a preset threshold, the inert gas supply unit is activated by the control unit to introduce inert gas into the dust removal chamber to suppress explosion.

[0214] Step 3: When the hydrogen concentration signal drops to a safe threshold, the inert gas supply unit is shut off by the control unit.

[0215] In this embodiment, the hydrogen detection unit may include a first hydrogen concentration sensor deployed in the hydrogen accumulation area of ​​the dust removal chamber and a second hydrogen concentration sensor in the exhaust section of the dust collector outlet. It can simultaneously collect hydrogen concentration signals from the entire dust removal chamber and the exhaust end, which helps to avoid detection blind spots and data deviations caused by single-point monitoring.

[0216] The preset threshold can be set to 25% of the lower explosive limit of hydrogen, and the safety threshold can be set to a safe concentration far below the lower explosive limit of hydrogen. The threshold parameters can be flexibly calibrated according to the actual needs of the dust removal operation of active metal dust.

[0217] While performing explosion suppression control, the control unit can simultaneously trigger the light and sound alarm unit to issue graded warnings, interlocking to maintain the normal operation of the dust removal induced draft fan and the spray water circulation system. In conjunction with the introduced inert gas, it can quickly dilute the accumulated hydrogen and reduce the oxygen content in the dust removal chamber, thereby enhancing the inerting explosion suppression effect. At the same time, the control unit can simultaneously collect operating parameters such as inert gas supply pressure, spray water pressure, and fan operating current, and complete system fault diagnosis and comprehensive safety status assessment in real time. If a dangerous fault interlock condition is triggered, the inert gas supply will be maintained until the fault hazard is completely eliminated and the hydrogen concentration stabilizes and falls back to a safe range before the shutdown action is performed, ensuring the stability and safety of the entire explosion suppression control process.

[0218] In this embodiment, the explosion suppression control method further includes a pre-inerting control step based on hydrogen production rate prediction:

[0219] The hydrogen production rate prediction model built into the control unit calculates the hydrogen production rate under the current operating conditions in real time based on parameters such as dust type, dust particle size distribution, water temperature, water pH value, and dust-water contact area. ;

[0220] Based on hydrogen production rate Effective volume of dust removal chamber Current hydrogen concentration and exhaust air replacement rate Calculate the predicted hydrogen concentration for a future preset time period. ;

[0221] When the predicted value When the preset pre-inerting threshold is reached, the inert gas supply unit is started in advance to perform pre-inerting at a small flow rate before the actual hydrogen concentration reaches the alarm threshold. The inert gas injection flow rate is dynamically adjusted according to the predicted hydrogen concentration rise rate. If the predicted concentration falls back to the safe range after pre-inerting, the pre-inerting injection is automatically stopped. If the actual concentration still reaches the normal alarm threshold, the injection is switched to full flow and the interlock shutdown is triggered.

[0222] This approach transforms explosion suppression control from a passive response to an active prediction through a hydrogen production rate prediction model. It initiates pre-inerting treatment before the hydrogen concentration reaches the alarm threshold, effectively avoiding response lag caused by the rapid increase in hydrogen concentration and eliminating the risk of explosion at its source.

[0223] In this embodiment, the explosion suppression control method further includes a dust type differentiation parameter configuration step, comprising:

[0224] The control unit is pre-loaded with a dust reactivity level database containing the reaction rate constants, activation energies, lower explosive limits, and hydrogen production rate characteristics of different reactive metal dusts;

[0225] Before the device is put into operation, the type of dust to be processed can be selected or automatically identified through the human-machine interface;

[0226] The control unit automatically matches the corresponding alarm threshold, inerting trigger threshold, pre-inerting threshold, inert gas injection flow rate, safety index calculation weight, and interlocking protection strategy parameters according to the selected dust type.

[0227] When the dust type changes, a safety verification process is automatically executed, including parameter updates and power-on self-test assessment. The system can only switch to operation after the self-test passes.

[0228] This approach achieves differentiated safety protection for different reactive metal dusts by matching a dust reactivity level database with automatic parameters. It avoids the safety risks caused by insufficient protection against highly reactive dusts, as well as the waste of inert gas caused by excessive protection against low-reactive dusts. This significantly improves the adaptability of the device to various reactive metal dust treatment conditions and the accuracy of safety protection.

[0229] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0230] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0231] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0232] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0233] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit its protection scope. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that after reading the present invention, they can still make various changes, modifications or equivalent substitutions to the specific implementation of the present application, but these changes, modifications or equivalent substitutions are all within the protection scope of the claims of the present application.

Claims

1. A wet dust collector with inert gas explosion suppression, characterized in that, include: The wet scrubber body, hydrogen detection unit, inert gas supply unit, and control unit; The wet dust collector body is equipped with a dust removal chamber; The hydrogen detection unit is installed inside the dust removal chamber and is used to collect the hydrogen concentration signal inside the dust removal chamber; The inert gas supply unit is located on the outside of the wet dust collector body, and the output end of the inert gas supply unit is connected to the dust collection chamber for introducing inert gas into the dust collection chamber. The control unit is electrically connected to the hydrogen detection unit and the inert gas supply unit respectively, and is used to receive the hydrogen concentration signal and control the on / off state of the inert gas supply unit according to the hydrogen concentration signal. The control unit has a built-in hydrogen production rate prediction model. The hydrogen production rate prediction model is used to calculate the hydrogen production rate under the current operating conditions based on the dust type, dust particle size distribution, water temperature, water pH value and dust-water contact area parameters. Based on the hydrogen production rate, dust removal chamber effective volume, current hydrogen concentration and exhaust replacement rate, the hydrogen concentration under the current operating conditions is predicted to obtain the hydrogen concentration prediction value. The control unit is also used to activate the inert gas supply unit to perform pre-inertization control when the predicted hydrogen concentration reaches a preset pre-inertization threshold.

2. The apparatus as claimed in claim 1, characterized in that, The hydrogen detection unit includes a first hydrogen concentration sensor and a second hydrogen concentration sensor. The first hydrogen concentration sensor is located in the area where hydrogen tends to accumulate in the dust removal chamber, and the second hydrogen concentration sensor is located at the air outlet of the wet dust collector body.

3. The apparatus as described in claim 1, characterized in that, The inert gas supply unit includes an inert gas high-pressure cylinder, a pressure reducing valve, and a solenoid valve; The outlet of the inert gas high-pressure cylinder is connected in sequence to the pressure reducing valve and the solenoid valve, and the outlet of the solenoid valve is connected to the dust removal chamber. An air inlet pipe is connected between the solenoid valve and the dust removal chamber, and an expansion pipe is connected to one end of the air inlet pipe located inside the dust removal chamber. The expansion tube is a single-stage expansion structure, and the nozzle of the expansion tube is inclined downward along the vertical plane. The nozzle of the expansion tube faces the spray area of ​​the dust removal chamber.

4. The apparatus as claimed in claim 1, characterized in that, It also includes audible and visual alarms; The audible and visual alarm is located on the top of the wet dust collector and is electrically connected to the control unit. It is used to receive the concentration abnormality control signal from the control unit and execute the alarm action.

5. The apparatus as claimed in claim 1, characterized in that, A sealing gasket is provided at the connection between the hydrogen concentration sensor and the wet dust collector body, and the hydrogen concentration sensor is pressed and fixed to the wet dust collector body by fasteners.

6. The apparatus as claimed in claim 1, characterized in that, The control unit has built-in hierarchical alarm and interlocking logic; When the hydrogen concentration reaches a preset threshold, the control unit controls the inert gas supply unit to turn on and triggers an interlock protection action.

7. The apparatus as claimed in claim 1, characterized in that, The control unit integrates a fault diagnosis module, which is used to collect the status and operation information of the wet dust collector, identify the fault type and fault level of the wet dust collector based on the status and operation information, and execute corresponding graded protection actions based on the fault type and fault level. The operational status information includes one or more of the following: hydrogen concentration information, inert gas supply pressure, spray water pressure, circulating water flow rate, fan current, and solenoid valve status feedback signal.

8. The apparatus as claimed in claim 1, characterized in that, The control unit is pre-set with a dust reactivity level database, which includes one or more of the following: reaction rate constants, activation energies, lower explosive limits of hydrogen, and characteristic hydrogen production rate parameters for various active metal dusts. The control unit is also used to automatically match safety control parameters according to the type of dust being processed. The safety control parameters include one or more of the following: alarm threshold, inerting trigger threshold, inert gas injection flow rate, pre-inerting threshold, safety index calculation weight, and interlocking protection strategy parameters.

9. A method for explosion suppression control using a wet dust collector with inert gas explosion suppression as described in any one of claims 1-8, characterized in that, include: A pre-defined dust reactivity level database is provided, wherein the database contains reaction rate constants, reaction activation energies, hydrogen explosion lower limit, and hydrogen production rate characteristic parameters for various reactive metal dusts. The type of reactive metal dust currently being processed is obtained, and corresponding safety control parameters are matched from the dust reactivity level database according to the type of reactive metal dust; wherein, the safety control parameters include: alarm threshold, inerting trigger threshold, inert gas injection flow rate, pre-inerting threshold, and safety index calculation weight; The hydrogen concentration signal in the dust removal chamber is collected by the hydrogen detection unit and transmitted to the control unit; Based on a pre-established hydrogen production rate prediction model, the hydrogen production rate under the current operating conditions is calculated according to parameters such as dust type, dust particle size distribution, water temperature, water pH value, and dust-water contact area. Based on the hydrogen production rate, effective volume of dust removal chamber, current hydrogen concentration, and exhaust replacement rate, the predicted hydrogen concentration value within a preset time period is predicted. When the predicted hydrogen concentration reaches the pre-inertia threshold, the inert gas supply unit is activated for pre-inertia control. When the hydrogen concentration signal reaches the alarm threshold, the inert gas supply unit is controlled to introduce inert gas into the dust removal chamber; when the real-time hydrogen concentration signal drops to the safety threshold, the inert gas supply unit is controlled to shut off.

10. The method as described in claim 9, characterized in that, The pre-inerting control of starting the inert gas supply unit includes: When the predicted hydrogen concentration reaches the pre-inertization threshold, the inert gas supply unit is controlled to perform pre-inertization at an initial flow rate less than the full flow rate. The inert gas injection flow rate is dynamically adjusted based on the rate of increase of the predicted hydrogen concentration. If the predicted hydrogen concentration after pre-inertization falls back to the safe range, then the inert gas supply unit is controlled to stop injecting. If the real-time hydrogen concentration signal reaches the alarm threshold, the system will switch to full-flow injection and trigger interlock protection.

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