Polycrystalline silicon water quenching system

Abstract

The utility model discloses a polycrystalline silicon water quenching system, and particularly relates to the technical field of polycrystalline silicon water quenching, and the water quenching system comprises an integrated control unit, a preheating module, a water quenching module, a temperature adjusting module, an automatic material conveying module, a silicon rod crushing module, a heat energy recovery module and a safety monitoring unit. According to the polycrystalline silicon water quenching system disclosed by the utility model, operation conditions are dynamically adjusted through an intelligent optimization algorithm and real-time data acquisition of the integrated control unit so as to adapt to characteristics of different silicon rods, and the water quenching efficiency and uniformity are improved; the safety monitoring unit monitors temperature, pressure and leakage in real time, abnormal operation is automatically stopped, and the safety accident risk is reduced; the heat energy recovery and water circulation purification assembly effectively reduces energy consumption and resource waste, and the energy management assembly optimizes energy efficiency and reduces cost. The rapid replacement and maintenance design simplifies the maintenance process, reduces the maintenance cost and shortens the downtime; the fault diagnosis system reduces accidental shutdown and guarantees production continuity.

Description

TECHNICAL FIELD

[0001] The utility model relates to polycrystal silicon water quenching technical field, especially polycrystal silicon water quenching system. BACKGROUND

[0002] Polycrystal silicon is a polycrystal material composed of many small crystals, and it is a form of elemental silicon. Under supercooling conditions, when molten elemental silicon solidifies, silicon atoms arrange in diamond lattice form to form many crystal nuclei, which grow into grains with different crystal faces, and combine to form polycrystal silicon. Polycrystal silicon is widely used in photovoltaic, integrated circuit and other fields, and is an important basic material for the photovoltaic industry and electronic information industry.

[0003] Water quenching is an important step in the production process of polycrystal silicon, and its main purpose is to reduce the breakage loss rate of polycrystal silicon. By rapidly cooling the silicon rod after calcination at high temperature, cracks will be generated in the silicon rod, which can reduce the generation of dust and particles in the subsequent crushing process, thereby reducing the breakage loss rate. After water quenching, the silicon rod is crushed by the same crusher, and the silicon material breakage loss can be significantly reduced from 3.5% to about 2%. SUMMARY

[0004] The main purpose of the utility model is to provide a polycrystal silicon water quenching system, which can effectively solve the problems of poor water quenching effect and high breakage loss rate of the existing device.

[0005] To achieve the above purpose, the technical scheme adopted by the utility model is as follows:

[0006] A polycrystal silicon water quenching system, the water quenching system comprises the following modules:

[0007] An integrated control unit for real-time monitoring and adjusting the entire water quenching process;

[0008] A preheating module for preheating the silicon rod to a temperature close to the water quenching temperature to reduce thermal shock and improve water quenching efficiency;

[0009] A water quenching module with a multi-stage spraying system inside for uniformly and rapidly cooling the preheated silicon rod;

[0010] A temperature adjusting module connected to the water quenching module for maintaining the constant temperature of the water quenching liquid to ensure the water quenching effect;

[0011] An automatic material conveying module for conveying the silicon rod from the preheating module to the water quenching module, and then from the water quenching module to the subsequent processing area;

[0012] A silicon rod crushing module located downstream of the water quenching module for crushing the water quenched silicon rod into the required size, and the silicon rod crushing module has a dust suppression function to reduce dust generation.

[0013] A thermal energy recovery module for collecting and reusing the thermal energy and water resources generated during the water quenching process to improve the utilization efficiency of energy and water resources.

[0014] Preferably, the integrated control unit comprises:

[0015] A data acquisition component for collecting system operation parameters in real time;

[0016] An intelligent optimization algorithm that automatically adjusts operating conditions based on collected parameters to optimize water quenching efficiency and quality;

[0017] A human-machine interface that allows operators to monitor system status and manually intervene in control processes;

[0018] A fault diagnosis system for detecting and predicting potential system failures to ensure continuous production and reduce downtime.

[0019] Preferably, the preheating module comprises:

[0020] A preheating temperature controller for precise control of the preheating temperature of the silicon rod;

[0021] A hot air circulation component to ensure uniform heating of the silicon rod;

[0022] A preheating time controller that adjusts the preheating time based on the size and material properties of the silicon rod.

[0023] Preferably, the water quenching module comprises:

[0024] A pressure controller for controlling the pressure of the spray system to accommodate silicon rods of different sizes and material properties;

[0025] A nozzle cleaning component that automatically removes nozzle blockages to maintain spray efficiency;

[0026] A safety protection component to prevent water quenching liquid from splashing and protect operators' safety.

[0027] Preferably, the temperature regulation module comprises:

[0028] A temperature sensor for real-time monitoring of the temperature of the water quenching liquid;

[0029] A water quenching temperature controller that automatically adjusts the working state of the heat exchanger based on monitoring results;

[0030] A liquid level control component to ensure a constant liquid level of the water quenching liquid in the tank.

[0031] Preferably, the automated material conveying module comprises:

[0032] A sensor detection component for detecting the position and state of the silicon rod;

[0033] Automatic fault recovery system that automatically adjusts the conveyor speed or stops the conveyor when an abnormality in the conveying is detected;

[0034] Emergency stop device for quickly cutting off the power supply of the conveying system in an emergency.

[0035] Preferably, the silicon rod breaking module comprises:

[0036] Vibration frequency controller that adjusts the breaking vibration frequency according to the hardness and brittleness of the silicon rod;

[0037] Breaking effect monitoring component that evaluates the size and shape of the silicon rod after breaking and feeds back to the control system to optimize the breaking parameters;

[0038] Dust collection and filtration component that reduces dust emissions during the breaking process.

[0039] Preferably, the thermal energy recovery module comprises:

[0040] Thermal energy recovery component that collects the heat released during the water quenching process and converts it into usable energy;

[0041] Water circulation purification component that filters and purifies the used water quenching liquid for reuse by the system;

[0042] Energy management component that monitors and optimizes the energy utilization efficiency of the entire thermal energy recovery module.

[0043] Preferably, the water quenching system also includes a safety monitoring unit for monitoring potential safety risks during the entire water quenching process and automatically stopping operation when an abnormality is detected, the safety monitoring unit includes but is not limited to temperature monitoring, pressure monitoring and leakage monitoring.

[0044] Preferably, the water quenching system is designed to allow quick replacement and maintenance of individual components to reduce downtime and maintenance costs, the quick replacement and maintenance design includes modular components and easily accessible maintenance interfaces.

[0045] Compared with the prior art, the utility model has the following beneficial effects:

[0046] 1、The utility model discloses a intelligent optimization algorithm and real -time data acquisition component of integrated control unit, and the system can dynamically adjust operating condition to adapt to the characteristics of different silicon rods, thereby improving the water quenching efficiency and uniformity. The design of multistage shower system makes the water quenching liquid be able to be evenly sprayed on the silicon rod surface, avoids the problem of local overheating or underheating, and ensures the consistency of water quenching effect.

[0047] 2, The utility model discloses through the introduction safety monitoring unit has strengthened the security of system, through real -time monitoring temperature, pressure and leakage situation, system can stop operating automatically when detecting the abnormality, has reduced the probability of the occurrence of equipment damage, explosion and environmental pollution and other safety accidents.

[0048] 3, The utility model discloses through the action of heat energy recovery module and water circulation purification subassembly makes system can recycle and reuse the heat energy and water resources produced in the water quenching process, has reduced energy consumption and resource waste significantly, energy management component has further optimized energy utilization efficiency, has reduced energy cost.

[0049] 4, The utility model discloses through the introduction quick replacement and maintenance design has simplified the maintenance process of system, and has reduced maintenance cost, and modular component and easily accessible maintenance interface make each component can be quickly disassembled and replace, need not complicated operation and professional technical personnel, maintenance time has been shortened greatly.

[0050] 5, The utility model discloses through the fault diagnosis system of integrated control unit setting predicts and diagnoses potential system fault, reduces accidental shutdown, guarantees the continuity of production, while the fault automatic recovery system and emergency stop device of automated material conveying module ensure material safe delivery simultaneously, also improve the reliability of system.

[0051] 6, The utility model discloses through the dust collection and filtration component in silicon rod crushing module effectively reduces the dust emission in the crushing process, reduces the influence to working environment and operator's health. BRIEF DESCRIPTION OF DRAWINGS

[0052] Figure 1 It is the system composition block diagram of the utility model;

[0053] Figure 2 It is the operation flow schematic drawing of the utility model;

[0054] Figure 3 It is the data flow communication flow schematic drawing of the utility model. DETAILED DESCRIPTION

[0055] In order to make the technical means, creative characteristics, achieve purposes and effects of the utility model easy to understand, the following further describes the utility model in combination with specific embodiments.

[0056] As Figure 1 , Figure 2 And Figure 3 Indicated, a polysilicon water quenching system, the water quenching system includes the following modules:

[0057] The integrated control unit serves as the brain of the system, monitoring and adjusting the entire water quenching process in real time. By monitoring the operating status of each module and adjusting operating parameters based on feedback data, the system ensures high efficiency and stability of the water quenching process.

[0058] The preheating module is used to preheat the silicon rod to a temperature close to the water quenching temperature, reducing thermal shock and improving water quenching efficiency.

[0059] The water quenching module is equipped with a multi-stage spraying system for uniform and rapid cooling of the preheated silicon rod.

[0060] The temperature regulation module is connected to the water quenching module to maintain a constant temperature of the water quenching liquid, ensuring the effectiveness of water quenching.

[0061] The automated material conveying module is used to transport the silicon rod from the preheating module to the water quenching module and then to the subsequent processing area, achieving seamless connection between the modules and improving production efficiency.

[0062] The silicon rod crushing module is located downstream of the water quenching module and is used to crush the water-quenched silicon rod into the required size. The silicon rod crushing module has a dust suppression function to reduce dust generation and environmental pollution.

[0063] The heat energy recovery module is used to collect and reuse the heat energy and water resources generated during the water quenching process, improving the utilization efficiency of energy and water resources, reducing production costs, and achieving green production.

[0064] Further, the integrated control unit includes:

[0065] The data acquisition component is used to collect system operating parameters in real time.

[0066] The high-precision sensor collects key parameters of the system in real time, including but not limited to temperature, pressure, and flow rate, providing data support for intelligent optimization of the system.

[0067] The intelligent optimization algorithm automatically adjusts operating conditions based on collected parameters to optimize water quenching efficiency and quality, dynamically adjusting operating conditions such as preheating temperature of the preheating module and spraying pressure of the water quenching module to improve water quenching effectiveness and energy efficiency ratio, and reduce excessive differences in finished product quality caused by minor differences in raw material quality.

[0068] The human-machine interface provides an intuitive operation platform, allowing operators to monitor system status and manually intervene in control processes when necessary, improving system flexibility and reliability.

[0069] The fault diagnosis system is used for detecting and predicting potential system faults by continuously monitoring system performance, ensuring continuous production and reducing downtime, ensuring the continuity of production, and reducing maintenance costs.

[0070] Further, the preheating module comprises:

[0071] A preheating temperature controller uses advanced temperature control technology to accurately control the preheating temperature of the silicon rod, ensuring that the silicon rod reaches the appropriate temperature before entering the water quenching process, reducing thermal shock and improving water quenching efficiency.

[0072] A hot air circulation assembly ensures uniform heating of the silicon rod by uniformly distributing hot air, avoiding local overheating or underheating, and improving the uniformity and efficiency of preheating.

[0073] A preheating time controller adjusts the preheating time according to the size and material properties of the silicon rod, ensuring uniform preheating of the silicon rod and laying a good foundation for the subsequent water quenching process.

[0074] Preferably, the water quenching module comprises:

[0075] A pressure controller is used to control the pressure of the spray system to accommodate silicon rods of different sizes and material properties, ensuring uniform spraying of the water quenching liquid on the surface of the silicon rod, achieving rapid and uniform cooling.

[0076] A nozzle cleaning assembly automatically removes nozzle blockages to maintain spray efficiency and prevent uneven water quenching caused by nozzle blockages.

[0077] A safety protection assembly prevents water quenching liquid from splashing and protects the safety of operating personnel, reducing safety hazards in the work environment.

[0078] Further, the temperature adjustment module comprises:

[0079] A temperature sensor monitors the temperature of the water quenching liquid in real time to ensure the accuracy of temperature control.

[0080] A water quenching temperature controller automatically adjusts the working state of the heat exchanger based on the monitoring results of the temperature sensor to maintain a constant temperature of the water quenching liquid, ensuring the consistency of the water quenching effect.

[0081] A liquid level control assembly ensures a constant liquid level of the water quenching liquid in the water tank, avoiding fluctuations in the liquid level caused by evaporation and extraction of the water quenching liquid, which affects the water quenching effect, ensuring stable operation of the system.

[0082] Further, the automated material conveying module comprises a sensor detection assembly for detecting the position and state of the silicon rod to ensure accurate and error-free delivery of the silicon rod to the next processing stage.

[0083] Automatic fault recovery system that automatically adjusts the conveyor belt speed or stops the conveyor when an abnormality in the delivery is detected, reducing production downtime and material loss due to conveyor failures.

[0084] Emergency stop device for quickly cutting off the power supply of the conveying system in emergency situations, ensuring the safety of personnel and equipment, and reducing the risk of accidents.

[0085] Further, the silicon rod breaking module includes:

[0086] Vibration frequency controller that adjusts the breaking vibration frequency according to the hardness and brittleness of the silicon rod, improving breaking efficiency and yield;

[0087] Breaking effect monitoring component that evaluates the size and shape of the silicon rod after breaking, feeding back to the control system to optimize breaking parameters and ensure product quality;

[0088] Dust collection and filtration component that reduces dust emissions during the breaking process, reducing the impact on the working environment and the health of operating personnel.

[0089] Further, the thermal energy recovery module includes:

[0090] Thermal energy recovery component that collects the heat released during the water quenching process and converts it into usable energy, supplying thermal energy or converted electrical energy to other parts of the system;

[0091] Water circulation purification component that filters and purifies used water quenching liquid to meet the reuse standard, reducing water resource consumption;

[0092] Energy management component that monitors and optimizes the energy utilization efficiency of the entire thermal energy recovery module, ensuring efficient use of energy and reducing energy waste.

[0093] Further, the water quenching system also includes a safety monitoring unit for monitoring potential safety risks during the entire water quenching process and automatically stopping operation when an abnormality is detected, the safety monitoring unit includes but is not limited to temperature monitoring, pressure monitoring and leakage monitoring.

[0094] Temperature monitoring that monitors the temperature of each part of the system in real time to prevent overheating and equipment damage and safety accidents; pressure monitoring that monitors the system pressure to prevent high pressure and safety accidents such as explosions; leakage monitoring that monitors system leakage, responds in time to prevent environmental pollution and equipment damage, and ensures the safety of the production environment.

[0095] Further, the design of the water quenching system allows for quick replacement and maintenance of individual components to reduce downtime and maintenance costs, the quick replacement and maintenance design includes modular components and easily accessible maintenance interfaces.

[0096] The maintenance time and cost of the system are significantly reduced through the modular components and the easily accessible maintenance interface; meanwhile, the modular design enables the individual components to be quickly disassembled and replaced without complex operations and professional technicians, greatly shortening the maintenance time;

[0097] The easily accessible maintenance interface design enables the maintenance personnel to easily reach the key components for maintenance and replacement, improving the maintenance efficiency; this design not only reduces the maintenance cost, but also improves the reliability and stability of the system, ensuring the continuity of production.

[0098] The above shows and describes the basic principle and main features of the present application and the advantages of the present application. Those skilled in the art should understand that the present application is not limited by the above examples, and the above examples and descriptions in the specification are only to illustrate the principles of the present application. Without departing from the spirit and scope of the present application, various changes and improvements can be made to the present application, and these changes and improvements all fall within the scope of the claimed present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A polysilicon water quench system, characterized by, The water quenching system comprises the following modules: An integrated control unit for real-time monitoring and adjustment of the entire water quenching process; A preheating module for preheating the silicon rods to near water quenching temperature to reduce thermal shock and improve water quenching efficiency; A water quenching module with multiple-stage spraying system inside for uniform and rapid cooling of preheated silicon rods; A temperature regulation module connected to the water quenching module for maintaining constant temperature of the water quenching liquid to ensure water quenching effect; An automated material conveying module for conveying silicon rods from the preheating module to the water quenching module and then to the subsequent processing area; A silicon rod crushing module downstream of the water quenching module for crushing the water quenched silicon rods into the required size, and the silicon rod crushing module has a dust suppression function to reduce dust generation; A heat energy recovery module for collecting and recycling heat energy and water resources generated during the water quenching process to improve the utilization efficiency of energy and water resources.

2. The polycrystalline silicon water quenching system according to claim 1, wherein: The integrated control unit comprises: A data acquisition component for real-time collection of system operating parameters; An intelligent optimization algorithm automatically adjusts operating conditions based on collected parameters to optimize water quenching efficiency and quality; A human-machine interface allows operators to monitor system status and manually intervene in control process; A fault diagnosis system for detecting and predicting potential system failures to ensure continuous production and reduce downtime.

3. The polycrystalline silicon water quenching system according to claim 1, wherein: The preheating module comprises: A preheating temperature controller for precise control of the preheating temperature of the silicon rods; A hot air circulation component to ensure uniform heating of the silicon rods; A preheating time controller adjusts the preheating time according to the size and material properties of the silicon rods.

4. The polycrystalline silicon water quenching system according to claim 1, wherein: The water quenching module comprises: A pressure controller for controlling the pressure of the spraying system to accommodate silicon rods of different sizes and material properties; A nozzle cleaning component automatically removes nozzle blockages to maintain spraying efficiency; A safety protection component prevents water quenching liquid from splashing and protects the safety of operators.

5. The polycrystalline silicon water quenching system according to claim 1, wherein: The temperature regulation module comprises: A temperature sensor for real-time monitoring of the temperature of the water quenching liquid; A water quenching temperature controller automatically adjusts the working state of the heat exchanger based on monitoring results; A liquid level control component ensures constant liquid level of the water quenching liquid in the tank.

6. The polycrystalline silicon water quenching system according to claim 1, wherein: The automated material conveying module comprises: A sensor detection component for detecting the position and status of the silicon rods; A fault automatic recovery system automatically adjusts the conveying belt speed or stops the conveying when conveying abnormalities are detected; An emergency stop device for quickly cutting off the power supply of the conveying system in emergency situations.

7. The polycrystalline silicon water quenching system according to claim 1, wherein: The silicon rod crushing module comprises: A vibration frequency controller adjusts the crushing vibration frequency according to the hardness and brittleness of the silicon rods; A crushing effect monitoring component evaluates the size and shape of the crushed silicon rods and feeds back to the control system to optimize crushing parameters; Dust collection and filtration assembly to reduce dust emissions during the crushing process.

8. A polysilicon water quench system as claimed in claim 1, wherein: The thermal energy recovery module includes: A thermal energy recovery assembly to collect and convert the heat released during the water quench process into usable energy; A water recycling and purification assembly to filter and purify the used water quench liquid for reuse by the system; An energy management assembly to monitor and optimize the energy utilization efficiency of the entire thermal energy recovery module.

9. A polysilicon water quench system as claimed in claim 1, wherein: The water quench system further includes a safety monitoring unit to monitor potential safety risks during the entire water quench process and automatically stop operation when an anomaly is detected, the safety monitoring unit includes but is not limited to temperature monitoring, pressure monitoring, and leakage monitoring.

10. A polysilicon water quench system as claimed in claim 1, wherein: The water quench system is designed to allow for quick replacement and maintenance of individual components to reduce downtime and maintenance costs, the quick replacement and maintenance design includes modular components and easily accessible maintenance interfaces.

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