Intelligent regulation and control device for decomposition circulating water in aluminum oxide production

Abstract

The utility model discloses an aluminum oxide production decomposition circulating water intelligent regulation and control device which comprises a decomposition tank circulating water return pipe, a cooling tower, a circulating water pool, a circulating water feeding pump and a decomposition tank circulating water inlet pipe, a temperature instrument is arranged on the decomposition tank circulating water inlet pipe, and the cooling tower comprises a shell, a water inlet pipe, a water outlet pipe, an air inlet and an air outlet. A humidity monitor is arranged at an air exhaust port of the cooling tower and connected with a control computer through a wireless data transmission module, a circulating water feeding pump is arranged on a circulating water inlet pipe of the decomposition tank, and the circulating water feeding pump, the cooling fan and the temperature meter are electrically connected with the control computer. The humidity in the decomposition circulating water cooling tower is monitored through the hygrometer, the cooling fan and the circulating water feeding pump are controlled and adjusted through the control computer, the air circulation amount in the cooling tower is reduced to the minimum value meeting the process production requirement, the effects of reducing water loss and saving electric energy are achieved, and the production benefits of enterprises are improved.

Description

Technical Field

[0001] This utility model belongs to the field of alumina production technology, and in particular relates to an intelligent control device for circulating water in alumina production decomposition. Background Technology

[0002] The decomposition system in alumina production involves cooling a sodium aluminate solution, adding seed crystals, and stirring to precipitate aluminum hydroxide. This is one of the key steps in alumina production. The decomposition circulating water is the most important cold source in the system. The circulating water circulates in the intermediate cooling system of the decomposition tanks, exchanging heat with the aluminum hydroxide slurry to remove heat generated during decomposition. This creates a stable temperature gradient between the decomposition tanks, forming uniformly sized and well-formed aluminum hydroxide crystals, improving decomposition efficiency and maximizing production efficiency. After heat exchange, the circulating water is transported to the decomposition circulating water cooling tower via a return pipe. After cooling, it enters the circulating water pool to continue participating in the intermediate cooling process of the decomposition tanks.

[0003] Existing decomposition circulating water systems typically use open cooling towers, operating at full capacity in summer and adjusting the number of operations in winter based on water temperature to ensure a stable cooling source between the seed tanks. The cooling tower sprays circulating return water onto the packing material, achieving heat exchange through water-air contact. A cooling fan then drives airflow within the tower, carrying away the heated air, thus achieving cooling. This cooling method carries away a significant amount of water vapor along with the heat, resulting in high water and electricity consumption. Therefore, reducing water vapor consumption is a crucial way to lower decomposition costs. Utility Model Content

[0004] To address the above problems, this invention provides an intelligent control device for circulating water in alumina production decomposition. This invention achieves its purpose as follows: A humidity monitor is installed at the top of the decomposition circulating water cooling tower to collect humidity data in real time. Data such as circulating water temperature, circulating water pump frequency, and cooling tower fan frequency are transmitted to a control computer via a 4G / 5G network. The control computer then aggregates and publishes this data, monitoring the cooling tower's operation in real time. Simultaneously, the control computer automatically adjusts the circulating water pump and cooling tower fan frequencies. This reduces the amount of water evaporated from the cooling tower without affecting water temperature or the intermediate cooling in the seed tank, achieving energy conservation and consumption reduction. Specifically:

[0005] The intelligent control device for circulating water in alumina production decomposition includes a decomposition tank circulating return water pipe, a cooling tower, a circulating water pool, a circulating water supply pump, and a decomposition tank circulating inlet water pipe. The circulating return water from the decomposition tank is sent to the cooling tower for cooling, and the cooled return water is collected in the circulating water pool. The circulating water pool is also connected to a water supply pipe. The water in the circulating water pool enters the decomposition tank through the decomposition tank inlet water pipe to provide a cooling source and complete the circulation. The cooling tower includes a shell, an inlet pipe, an outlet pipe, an air inlet, and an air outlet. The shell contains packing material, and a water collection trough is located below the packing material. The water collection trough is connected to the outlet pipe, which is connected to a circulating water tank. The inlet pipe is connected to the decomposition tank's circulating return water pipe. A thermometer is installed on the decomposition tank's circulating inlet pipe. The circulating water tank is connected to the decomposition tank's circulating inlet pipe. A cooling fan is installed at the air outlet, mounted on a support frame. A humidity monitor, including a wireless data transmission module, is also installed on the support frame. The humidity monitor is connected to a control computer via the wireless data transmission module. A circulating water pump is installed on the decomposition tank's circulating inlet pipe. The cooling fan, circulating water pump, electromagnetic control valve, and thermometer are electrically connected to the control computer. The circulating water pump and cooling fan are equipped with frequency converters.

[0006] This utility model relates to an intelligent control device for circulating water in alumina production. Based on process adjustment requirements, after setting the maximum feedwater temperature (monitored by a temperature gauge on the circulating water inlet pipe of the decomposition tank, e.g., 35℃), and simultaneously based on feedback from the humidity monitor (e.g., humidity ≥ 80%, feedwater temperature ≤ 35℃), the cooling fan and circulating water pump receive control computer commands to begin frequency reduction. The frequency is decreased by 5Hz every 4 hours until the feedwater temperature rises to 35℃, at which point the frequency reduction stops. Then, based on the feedwater temperature, the speed is gradually increased by 2.5Hz every 2 hours. This reduces the air circulation volume within the cooling tower to the minimum required for process production, achieving the effects of reducing water loss and saving energy.

[0007] The beneficial effects of this utility model are: by monitoring the humidity inside the decomposition circulating water cooling tower with a hygrometer, the control computer collects data such as the humidity at the top of the cooling tower, the water temperature of the circulating water inlet pipe of the decomposition tank, and the frequency of the cooling fan and circulating water pump, and controls and adjusts the cooling fan and circulating water pump to achieve the purpose of energy saving and consumption reduction, and improve the production efficiency of enterprises. Attached Figure Description

[0008] Figure 1 This is a schematic diagram of the structure of this utility model;

[0009] Figure 2 This is a schematic diagram of the structure of this utility model when the cooling tower is of type I.

[0010] Figure 3 This is a schematic diagram of the structure of this utility model when the cooling tower is of type II.

[0011] Figure 4 This is a structural diagram of a type I cooling tower;

[0012] Figure 5 This is a structural diagram of a Type II cooling tower;

[0013] Figure 6 This is a schematic diagram of the sensor body structure of the humidity monitoring instrument of this utility model;

[0014] Figure 7 This is a schematic diagram of the sensor mounting bracket structure for the humidity monitoring instrument of this utility model;

[0015] Figure 8 This is a schematic diagram of the sensor fixing bracket and support structure of this utility model;

[0016] Figure 9 This is a schematic diagram of the locking screw structure of the sensor mounting bracket of this utility model;

[0017] In the diagram: 1-Cooling tower, 101-Shell, 102-Inlet pipe, 103-Outlet pipe, 104-Packing, 105-Water distributor, 106-Motor, 107-Cooling fan, 108-Support, 109-Water collection tank, 110-Air inlet, 111-Air outlet, 2-Humidity monitor, 201-Sensor body, 2011-Wireless antenna, 2012-Sensor housing, 2013-Sensor probe, 2014-Connecting cable 2015-Fixing ear, 202-Sensor mounting bracket, 2021-Fixing plate, 2022-Through hole, 2023-Locking buckle, 2024-Moving rod, 2025-Fixing hole, 2026-Clamping plate, 2027-Locking screw, 2028-Slide groove, 2029-Elongated hole, 3-Circulating water tank, 4-Circulating water pump, 5-Decomposition tank circulating return water pipe, 6-Water replenishment pipe, 7-Control computer, 8-Decomposition tank circulating water inlet pipe, 9-Thermometer. Detailed Implementation

[0018] To better understand the technical solution of this utility model, the following description, in conjunction with the accompanying drawings, further illustrates this utility model.

[0019] like Figure 1-9 The device shown is an intelligent control device for circulating water in alumina production decomposition, comprising a decomposition tank circulating return water pipe 5, a cooling tower 1, a circulating water pool 3, a circulating water supply pump 4, and a decomposition tank circulating inlet water pipe 8. A thermometer 9 is installed on the decomposition tank circulating inlet water pipe. The overall structure is as follows: Figure 1-3 As shown, Figure 2 and Figure 3 The difference lies in the shape of the cooling tower. Figure 2 The cooling tower is type I. Figure 3The cooling tower is Type II. Type I and Type II cooling towers have similar structures, the main difference being the shape and the location of the cooling fan blades: Type I has the blades below the motor, while Type II has them above the motor. The main functional components are similar. Figure 4 and Figure 5 As shown, the cooling tower includes a housing 101, an inlet pipe 102, an outlet pipe 103, an air inlet 110, and an air outlet 111. The housing contains packing material 104. A water collection trough 109 is located below the packing material in the housing 101. The water collection trough 109 is connected to the outlet pipe 103, which is connected to a circulating water tank 3. The inlet pipe 102 is connected to a circulating return water pipe 5 for the decomposition tank. The circulating water tank 3 is connected to a circulating inlet water pipe 8 for the decomposition tank. A cooling fan 107 is installed at the air outlet 111. The cooling fan 107 is mounted on a support 108. A motor 106 is typically also installed on the support, driving the fan to rotate. The cooling tower generally also includes a water distributor 105. A humidity monitor 2 is also installed on the support 108. The humidity monitor 2 includes a wireless data transmission module and is connected to a control computer 7 via the wireless data transmission module.

[0020] The humidity monitor 2 includes a sensor body 201 and a sensor mounting bracket 202. The sensor body 201 includes a wireless antenna 2011, a sensor housing 2012, and a sensor probe 2013. The sensor probe 2013 is connected to the sensor housing 2012 via a connecting cable 2014. The sensor housing 2012 integrates a wireless data transmission module, a battery, and a control chip. Humidity monitors with wireless transmission capabilities are existing technology and readily available on the market; their internal structure will not be described in detail here. The sensor housing 2012 has a mounting ear 2015 with threaded holes. The mounting bracket 202 includes a fixing plate 2021. One side of the fixing plate 2021 has several fixing holes 2025, which correspond to the fixing ears 2015 on the sensor housing. The other side of the fixing plate 2021 has a through hole 2022. Sliding grooves are provided on both sides of the through hole 2022, and a movable rod 2024 is disposed within each groove. A locking buckle 2023 is provided on one side of the movable rod 2024. A clamping plate 2026 is provided at the bottom of the fixing plate 2021, and the clamping plate 2026 cooperates with the support bracket 108 of the cooling fan. Locking screws 2027 are provided on the clamping plate 2026. In use, first install the sensor mounting plate 202 in a suitable position with the cooling fan bracket 108 via the clamp 2026. Secure the sensor mounting plate 202 with locking screws. Then, fix the sensor body 201 onto the sensor mounting plate 202. During fixing, ensure that the threaded holes of the fixing ears 2015 correspond one-to-one with the fixing holes 2025, and tighten the screws to secure it. The humidity sensor 2 monitors the humidity at the air outlet of the cooling tower 1 in real time and transmits the data wirelessly to the control computer.

[0021] The circulating water inlet pipe 8 of the decomposition tank is equipped with a circulating water pump 4. The circulating water pump 4, the cooling fan 107 and the temperature instrument 7 are electrically connected to the control computer. The circulating water pump 4 and the cooling fan 107 are equipped with a frequency converter. Frequency conversion is an existing technology in the field of electromechanical control, and will not be described in detail here.

[0022] The control computer adjusts the frequency of the cooling fan 107 and the circulating water pump 4 based on the data monitored by the temperature instrument 7 on the circulating water inlet pipe of the decomposition tank. This allows control over the rotation speed of the cooling fan 107 and the water supply of the circulating water pump 4, reducing the air circulation volume in the cooling tower 1 to the minimum required to meet the process production needs, thereby reducing water loss and saving energy.

[0023] The circulating water tank 3 is connected to the water supply pipe 6, which can replenish the circulating water system of the decomposition tank.

[0024] Benefit calculation:

[0025] Before the improvement, the decomposition circulating water required 40t / h of water replenishment due to the loss of water vapor in the cooling tower. After the improvement, this was reduced to 20t / h, which can save water costs of (40-20)t / h*24h*365 days*4 yuan / t=700800 yuan per year.

[0026] The applicant's workshop currently has two production lines with four circulating water pumps, each with a power of 450kW. The actual power is approximately 86% of the rated power. After the technical upgrade, approximately 3% of electricity can be saved, resulting in an annual electricity cost saving of 450kW / unit * 86% * 4 units * 24h * 365 days * 3% (energy saving rate) * 0.4 yuan / (kW*h) = 162725.76 yuan.

[0027] In summary, this project can save 700,800 + 162,725.76 = 863,525.76 yuan annually.

[0028] The above description is only a preferred embodiment of the present utility model. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present utility model patent application are included in the scope of the present utility model patent application.

Claims

1. A smart control device for circulating water in alumina production decomposition, characterized in that, The system includes a decomposition tank circulating return water pipe, a cooling tower, a circulating water pool, a circulating water supply pump, and a decomposition tank circulating inlet water pipe. A thermometer is installed on the decomposition tank circulating inlet water pipe. The cooling tower includes a shell, an inlet water pipe, an outlet water pipe, an air inlet, and an air outlet. Packing material is installed inside the shell, and a water collection tank is located below the packing material. The water collection tank is connected to the outlet water pipe, which is connected to the circulating water pool. The inlet water pipe is connected to the decomposition tank circulating return water pipe, and the circulating water pool is connected to the decomposition tank circulating inlet water pipe. A cooling fan is installed at the air outlet, mounted on a support frame. A humidity monitor is also installed on the support frame, and the humidity monitor includes a wireless data transmission module connected to a control computer via the wireless data transmission module. A circulating water supply pump is installed on the decomposition tank circulating inlet water pipe. The circulating water supply pump, cooling fan, and thermometer are electrically connected to the control computer. The circulating water supply pump and cooling fan are equipped with frequency converters.

2. The intelligent control device for circulating water in alumina production decomposition according to claim 1, characterized in that, The humidity monitor includes a sensor body and a sensor mounting bracket.

3. The intelligent control device for circulating water in alumina production decomposition according to claim 2, characterized in that, The sensor body includes a wireless antenna, a sensor housing, and a sensor probe. The sensor probe is connected via a connecting cable. The sensor housing integrates a wireless data transmission module, a battery, and a control chip. The sensor housing has mounting ears with threaded holes on its exterior. The sensor mounting bracket includes a mounting plate with several mounting holes on one side, corresponding to the mounting ears on the sensor housing. The mounting plate has a through hole on the other side, with sliding grooves on both sides. A movable rod is installed in each sliding groove, and a locking buckle is installed on one side of the movable rod. A clamping plate is installed at the bottom of the mounting plate, and the clamping plate cooperates with the support of the cooling fan.

4. The intelligent control device for circulating water in alumina production decomposition according to claim 3, characterized in that, Locking screws are provided on the clamping plate.

5. The intelligent control device for circulating water in alumina production decomposition according to claim 1, characterized in that, The circulating water tank is connected to a water supply pipe.

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