Visual unloading system for catalyst

Abstract

The catalyst visual unloading system comprises an instrument air pipe, a vacuum suction pipe, a tube nest, a portable PLC (Programmable Logic Controller), a flow sensor, a vacuum sensor and a visual movable unloading manipulator, one end of the instrument air pipe is wound on a positive and negative rotation electric retractor, and the other end of the instrument air pipe extends into an unloading opening in the tube nest through a lantern ring; a flowmeter sensor and a vacuum sensor are arranged on the vacuum pumping pipe; a plurality of unloading guns are transversely and uniformly distributed at the front end of the visual movable unloading manipulator, and a vacuum pumping pipe is respectively communicated with a pumping port of a gun barrel at the front end of each unloading gun in a one-to-one correspondence manner; the other end of the vacuum pumping pipe extends into the discharging opening in the tube nest; and electromagnetic valves are respectively arranged on an air inlet at one end of the instrument air pipe and a discharge port of the tube nest in a one-to-one correspondence manner. The catalyst visual unloading system solves the problems that the catalyst is difficult to extract after the reactor runs for several years and the efficiency of the existing construction method is low, the labor cost is reduced, and the unloading is dynamic, visual and safe.

Description

TECHNICAL FIELD

[0001] The utility model relates to catalyst unloading device technical field, concretely is a kind of catalyst visual unloading system. BACKGROUND

[0002] In chemical plant, the application of catalyst unloading device is widespread.Our original construction scheme is from the top of ethylene oxide reactor to unload catalyst, uses vacuum to extract catalyst in reactor tube, and each person controls an unloading gun tube to extract catalyst.But, because reactor runs several years, catalyst is difficult to be extracted, and the original construction scheme (for example, 10,000 reactor tubes are unloaded) also has the following problems:

[0003] 1) if 6 people are simultaneously constructed (because construction site is limited space, at most 6 people are constructed in reactor for safety risk consideration), 10,000 tubes are unloaded, and at least 3-4 days are needed to complete (considering in ideal state without stop and abnormal condition), and construction efficiency is low;

[0004] 2) sometimes, catalyst in some tubes is not completely unloaded, and pressure burst is generated when sand blasting, and then multiple safety accidents are caused. CONTENT OF UTILITY MODEL

[0005] In view of the above existing technology, the utility model aims at providing a kind of catalyst visual unloading system, and the problem that catalyst is difficult to be extracted due to reactor running several years and the efficiency of existing construction method is low is preferably solved.

[0006] To solve the above technical problem, the utility model adopts the following technical scheme:

[0007] The utility model provides a kind of catalyst visual unloading system, including instrument air pipe, vacuum pipe, pipe, portable PLC controller, flow sensor, vacuum sensor and visual movable unloading manipulator, the one end of instrument air pipe is wound on positive and negative rotation electric retractor, and the other end is inserted into the unloading port in pipe by ring extension;The vacuum pipe is equipped with flowmeter sensor and vacuum sensor;Visual movable unloading manipulator front end transverse distribution has several unloading agent guns, and the unloading agent gun front end barrel of each is one-to-one correspondence respectively connected with a vacuum pipe;The other end of vacuum pipe is inserted into the unloading port in pipe;The one end of instrument air pipe, pipe unloading port one-to-one correspondence is respectively equipped with an electromagnetic valve;Positive and negative rotation electric retractor, electromagnetic valve are electrically connected with portable PLC controller;Flowmeter sensor, vacuum sensor are electrically connected with portable PLC controller respectively, for the convenience statistics unloading total amount, whole unloading progress and single pipe inventory state can also be shown on the operation display screen of PLC controller in real time, and automatically draw into reactor pipe distribution diagram, all dynamic is directly visualized, simultaneously using the response characteristic of vacuum sensor to vacuum environment, in combination with the low flow alarm of flowmeter sensor, the pipe that can be missed or not unloaded is found in time, and then effectively guarantee production quality safety and personnel construction safety.

[0008] Preferably, the visual movable unloading manipulator includes a tracked power moving chassis, a first arm rod, a second arm rod, a third arm rod and an image sensor, a base at a tail of the first arm rod is installed on the tracked power moving chassis by fastening bolts, a tail end of the first arm rod is connected with the base by a first up-down rotary drive connecting piece, a head end of the first arm rod is connected with the second arm rod by a second up-down rotary drive connecting piece, a shell head end of a head end of the second arm rod is connected with a tail end of the third arm rod by a left-right rotary drive connecting piece, and the image sensor is installed on the shell head end of the head end of the second arm rod by bolts; six unloading agent guns are horizontally and evenly distributed on a front end mounting plate of the third arm rod by bolts; one angle displacement sensor is arranged on each of the first up-down rotary drive connecting piece, the second up-down rotary drive connecting piece and the left-right rotary drive connecting piece; the visual movable unloading manipulator, the image sensor and the angle displacement sensor are electrically connected with the portable PLC controller.

[0009] Preferably, an inductive switch is arranged on the unloading agent gun, and the inductive switch is electrically connected with the portable PLC controller.

[0010] Preferably, an interface of the electromagnetic valve on the one end of the instrument air pipe is connected to an instrument air inlet by a gas conveying pipe, so that instrument air enters the instrument air pipe through the gas conveying pipe when the PLC control opens the electromagnetic valve, air is sprayed by the conical nozzle at the top of the instrument air pipe to blow and scatter the catalyst, and the catalyst in the pipe is conveniently unloaded.

[0011] Preferably, the vacuum tube is integrally formed with a collar, and the other end of the instrument air duct passes through the collar and extends into the tube column through the discharge port.

[0012] Preferably, the instrument duct is 12m long and 12mm in diameter; the bottom of the cone-shaped nozzle at the top of the instrument duct has 4 nozzles.

[0013] The beneficial effects of this utility model are as follows: The catalyst visualization unloading system of this utility model, by adding an instrument air duct with a conical nozzle at the top to the vacuum extraction pipe, uses the upward air jet from the conical nozzle to continuously loosen the catalyst in the reactor tubes, solving the problem that the catalyst is difficult to extract after the reactor has been running for several years; combined with a movable vision robot arm with an unloading gun, and using a PLC controller to control the catalyst unloading operation, the work efficiency is improved, the intensity of manual labor is reduced, the labor cost is reduced, and the problem of low efficiency of existing construction methods is solved; at the same time, a flow meter sensor and a vacuum sensor are added to the vacuum extraction pipe to count the total unloading volume, so that the PLC controller can use the data transmitted by the flow meter sensor and the vacuum sensor to display the overall unloading progress and the catalyst storage status of a single tube in real time on the PLC controller's operation display screen interface, and automatically draw a reactor tube distribution diagram, thus making the dynamic unloading process clear at a glance, achieving the purpose of intuitive and visual catalyst unloading process, greatly reducing safety risks, and ensuring construction safety. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 A schematic diagram of the structure of a catalyst visualization unloading system provided in this embodiment of the present invention;

[0016] Figure 2 for Figure 1 A side view;

[0017] Figure 3 A schematic diagram of the structure of a vision-based mobile unloading robot after installing an unloading gun;

[0018] Figure 4 for Figure 3 A side view;

[0019] Figure 5 This is a schematic diagram of the instrument duct structure;

[0020] Figure 6 for Figure 5 side view of the middle conical nozzle;

[0021] Figure 7 for portable PLC controller to operate the reactor tube distribution diagram displayed on the display screen.

[0022] BRIEF DESCRIPTION OF DRAWINGS

[0023] instrument air pipe 1, vacuum pipe 2, tube 3, portable PLC controller 4, flow sensor 5, vacuum sensor 6, visual movable discharge manipulator 7, positive and negative rotation electric retractor 8, discharge gun 9, solenoid valve 10, inductive switch 11, collar 12;

[0024] crawler power mobile chassis 701, first arm rod 702, second arm rod 703, third arm rod 704, image sensor 705. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0026] Example 1, as Figures 1 to 6As shown, a catalyst visualization unloading system includes an instrument air pipe 1, a vacuum pipe 2, a column pipe 3, a portable PLC controller 4, a flow sensor 5, a vacuum sensor 6 and a visual movable unloading manipulator 7. One end of the instrument air pipe 1 is wound on a forward and reverse electric retractor 8, and the other end extends into the unloading port in the column pipe 3 through a collar 12. The vacuum pipe 2 is provided with a flow meter sensor 5 and a vacuum sensor 6. The visual movable unloading manipulator 7 is provided with a plurality of unloading guns 9 at the front end, and the unloading port position of the front gun barrel of each unloading gun 9 is connected to a vacuum pipe 2 one by one. The other end of the vacuum pipe 2 extends into the unloading port in the column pipe 3. An electromagnetic valve 10 is provided on the air inlet of one end of the instrument air pipe 1 and the unloading port of the column pipe 3 one by one. The forward and reverse electric retractor 8 and the electromagnetic valve 10 are electrically connected to the portable PLC controller 4, so as to start and stop the rotation of the forward and reverse electric retractor 8, open or close the instrument air pipe 1, and open or close the unloading port of the column pipe 3 through PLC control. The flow meter sensor 5 and the vacuum sensor 6 are electrically connected to the portable PLC controller 4, which is used for conveniently counting the total unloading amount, and can also display the overall unloading progress and the inventory state of a single pipe on the operation display screen of the PLC controller in real time, and automatically draw a reactor column pipe distribution map, which is intuitive and visual for all dynamic conditions and can be understood at a glance. Among them, it should be noted that the response characteristics of the vacuum sensor to the vacuum environment, combined with the low flow alarm of the flow meter sensor, can timely find the column pipes that are missed or not unloaded, and effectively ensure the production quality safety and personnel construction safety.

[0027] Further, as Figure 1 , Figure 2 and Figure 3 , Figure 4As shown, the visual movable discharging manipulator 7 comprises a tracked power moving chassis 701, a first arm rod 702, a second arm rod 703, a third arm rod 704 and an image sensor 705, the base at the tail of the first arm rod 702 is installed on the tracked power moving chassis 701 through fastening bolts, the tail end of the first arm rod 702 is connected with the base through a first up-down rotary driving connecting piece, the head end of the first arm rod 702 is connected with the second arm rod 703 through a second up-down rotary driving connecting piece, the front end of the shell at the head end of the second arm rod 703 is connected with the tail end of the third arm rod 704 through a left-right rotary driving connecting piece, and the image sensor 705 is installed on the shell at the head end of the second arm rod 703 through bolts; six discharging guns 9 are transversely and evenly arranged on the front end mounting plate of the third arm rod 704 through bolts; one angle displacement sensor is arranged on each of the first up-down rotary driving connecting piece, the second up-down rotary driving connecting piece and the left-right rotary driving connecting piece; the visual movable discharging manipulator 7, the image sensor 705 and the angle displacement sensors are electrically connected with the portable PLC controller 4. It should be noted that the tracked power moving chassis 701 is provided with a displacement sensor electrically connected with the portable PLC controller 4, so as to facilitate the automatic positioning of the visual movable discharging manipulator 7.

[0028] In addition, it should be noted that the up-down rotary driving connecting piece and the left-right driving connecting piece belong to the existing structure, which are both composed of a driving piece and a universal shaft, wherein the driving piece needs to be electrically connected with the rechargeable power source on the tracked power moving chassis through an electric wire, and is used in power-on mode. The specific setting will not be described in detail in this embodiment.

[0029] Further, as shown in Figure 1 , Figure 2 , Figure 3 and Figure 4 , the discharging gun 10 is provided with an inductive switch 11, and the inductive switch 11 is electrically connected with the portable PLC controller 4, so as to control the start and stop of the discharging gun 10 by controlling the inductive switch through the PLC.

[0030] Further, as shown in Figure 1 and Figure 2 , the vacuum suction pipe 2 is integrally formed with a sleeve ring 12, and the other end of the instrument air pipe 1 penetrates through the sleeve ring and enters the tube 3 through the discharging port.

[0031] Further, as shown in Figure 1 , Figure 2 and Figure 5 , the interface of the electromagnetic valve at one end of the instrument air pipe 1 is connected to the instrument air outlet through a gas conveying pipe, so that when the PLC controls the electromagnetic valve to be opened, the instrument air enters the instrument air pipe through the gas conveying pipe, so that the conical nozzle at the top of the instrument air pipe sprays air to blow and loosen the catalyst, facilitating the discharging of the catalyst in the tube.

[0032] Further, as shown in Figure 1 , Figure 2 and Figure 5 , Figure 6 , the instrument air pipe 1 is 12 m long and 12 mm in diameter; the bottom of the conical nozzle at the top of the instrument air pipe 1 is provided with 4 nozzles; when the instrument air pipe is connected to air, the 4 nozzles of the conical nozzle start to spray gas upward; at this time, the conical nozzle moves upward or downward with the instrument air pipe being wound or unwound by the forward and reverse rotation of the winder, thereby continuously blowing and loosening the catalyst in the reactor column pipe; the loosened catalyst is accelerated by gravity and falls to be vacuum extracted by the vacuum pipe. In this way, the movement speed of the catalyst in the column pipe is accelerated, thereby forming a scouring friction force on the bottom wall of the column pipe, and thereby removing the catalyst powder and rust attached to the bottom wall of the column pipe due to the high temperature of the reactor to a certain extent, which improves the work efficiency and optimizes the vacuum extraction effect.

[0033] When the catalyst visual unloading system is used to unload the catalyst from an ethylene oxide reactor (taking the unloading of 10,000 reactor column pipes as an example), a worker pre-connects the flow sensor, vacuum sensor and vacuum pipe of the instrument air pipe at one end of the unloading gun of the visual movable unloading manipulator at the front end one by one; then the worker controls the visual movable unloading manipulator provided with 6 unloading guns to automatically position and move to the corresponding position of the column pipe to be extracted by operating the operation display screen of the PLC controller, and then drives the manipulator by the PLC controller until the other end of the vacuum pipe and the other end of the instrument air pipe on the manipulator are aligned and inserted into the unloading port of the ethylene oxide reactor column pipe, and then controls the inductive switch to make the unloading gun start to work, and controls the electromagnetic valve on the column pipe and the electromagnetic valve on the instrument air pipe to open, and the unloading gun starts to unload the catalyst in the reactor column pipe; at this time, the instrument air pipe inserted into the reactor column pipe at the front end moves upward or downward along the inner wall of the column pipe under the action of the forward and reverse rotation of the forward and reverse rotation electric winder, and the electromagnetic valve on the instrument air pipe is opened to connect the instrument air to make the conical nozzle at the top of the instrument air pipe spray gas, thereby blowing and loosening the catalyst, so that the catalyst can be more easily extracted by the vacuum pipe; after the column pipes where the 6 unloading guns are located are all extracted, the electromagnetic valves on the column pipes and the inductive switches on the unloading guns and the electromagnetic valves on the instrument air pipes are closed, the manipulator is controlled to retract, and the crawler-type power moving chassis is controlled to position and move to the next batch of column pipes to be extracted, and the above unloading operation is repeated until the catalyst in all reactor column pipes is unloaded. In the ideal state without interruption and abnormal conditions, one worker controls the manipulator to unload 10,000 pipes, which can be completed in about 1-2 days, which improves the work efficiency, reduces the labor cost and the work intensity, and greatly guarantees the construction safety and reduces the safety risk.

[0034] In addition, during the entire unloading process, the flow meter and the vacuum sensor can assist in counting the total amount of the unloading agent, and transmit the dose information signal to the portable PLC controller. The operation display screen of the portable PLC controller can display the information such as the total amount of the catalyst unloading agent and the unloading agent in real time, as shown in Figure 7 The operation display screen displays the overall unloading progress and the inventory state of the single tube, and automatically fills in the drawing of the reactor tube distribution map, which intuitively visualizes all the dynamics and is easy to understand. The vacuum sensor and the low flow alarm can timely find the missed or not unloaded tubes. It should be noted that ① in the reactor tube distribution map, the positions of the unloaded and unloaded agents are marked with red and green colors respectively; ② the display of the single tube extraction progress bar is realized according to the proportion of the vacuum sensor VS signal, and the total amount of the unloaded catalyst and the amount of the single tube are displayed and counted according to the cumulative amount and the instantaneous amount of the flow meter. When the vacuum sensor signal and the flow meter flow meet the set empty tube marking, it is marked that the catalyst of the tube is unloaded, and the inductive switch on the unloading gun is closed. When the vacuum sensor signal and the flow meter sensor signal do not meet the empty tube requirement within a certain time, it is considered that the tube is not unloaded after 1 minute, and the tube number is marked as red. The unloaded completion is marked as green, and the red quantity is recorded. The tube number changes with the batch accumulation.

[0035] Obviously, the above-described embodiments are only used to illustrate the technical solutions of the present application, but not to limit them; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that they can modify the technical solutions recorded in the foregoing embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application. Therefore, if the modifications and variations of the present application are within the scope of the claims of the present application and the equivalent technology, the present application also intends to include these modifications and variations.

Claims

1. A catalyst visualized unloading system characterized by: The device comprises an instrument air pipe, a vacuum pipe, a column, a portable PLC controller, a flow sensor, a vacuum sensor and a visual movable discharging manipulator, one end of the instrument air pipe is wound on a forward and reverse electric retractor, and the other end extends into a discharging port in the column through a sleeve ring; the vacuum pipe is provided with a flow meter sensor and a vacuum sensor; the visual movable discharging manipulator is provided with a plurality of discharging guns at the front end in a transverse and uniform manner, and the discharging port position of the front end of each discharging gun is connected to a vacuum pipe; the other end of the vacuum pipe extends into the discharging port in the column; the inlet of one end of the instrument air pipe and the discharging port of the column are provided with one electromagnetic valve respectively; the flow meter sensor, the vacuum sensor, the forward and reverse electric retractor and the electromagnetic valve are electrically connected with the portable PLC controller.

2. A catalyst visualisation offloading system as claimed in claim 1, characterised in that: The visual movable discharging manipulator comprises a tracked power moving chassis, a first arm rod, a second arm rod, a third arm rod and an image sensor, the base at the tail of the first arm rod is installed on the tracked power moving chassis through fastening bolts, the tail end of the first arm rod is connected with the base through a first up-down rotary driving connecting piece, the head end of the first arm rod is connected with the second arm rod through a second up-down rotary driving connecting piece, the head end of the second arm rod is connected with the tail end of the third arm rod through a left-right rotary driving connecting piece, and the image sensor is installed on the shell at the head end of the second arm rod through bolts; six discharging guns are transversely and uniformly arranged on the front end mounting plate of the third arm rod through bolts; one angle displacement sensor is arranged on each of the first up-down rotary driving connecting piece, the second up-down rotary driving connecting piece and the left-right rotary driving connecting piece; the visual movable discharging manipulator, the image sensor and the angle displacement sensor are electrically connected with the portable PLC controller.

3. A catalyst visualisation offloading system as claimed in claim 2, wherein: The discharging gun is provided with an inductive switch, and the inductive switch is electrically connected with the portable PLC controller.

4. A catalyst visualization offloading system as in claim 1, wherein: The sleeve ring is integrally formed on the vacuum pipe, and the other end of the instrument air pipe penetrates through the sleeve ring and extends into the column through the discharging port.

5. A catalyst visualization offloading system as in claim 1, wherein: The interface of the electromagnetic valve on one end of the instrument air pipe is connected to the instrument air inlet through a gas conveying pipe.

6. A catalyst visualization offloading system as in claim 1, wherein: The instrument air pipe has a length of 12 m and a diameter of 12 mm; and the bottom of the conical nozzle at the top of the instrument air pipe is provided with four nozzles.

Images