Electric heater regulation and control device for preheater

Abstract

The electric heater regulation and control device comprises an electric regulation and control mechanism and a mechanical regulation and control mechanism which are coupled, and the mechanical regulation and control mechanism comprises a handle assembly, a transmission assembly, a baffle assembly and an electric heater containing assembly which are sequentially connected. Wherein the handle assembly, the transmission assembly and the baffle assembly are fixedly connected in sequence, and the baffle assembly is movably connected with the electric heater containing assembly. According to the electric heater regulation and control device for the preheater, the electric heater can be stably, conveniently and flexibly regulated and controlled, and energy consumption is reduced.

Description

Technical Field

[0001] This disclosure generally relates to the field of chemical equipment, and more specifically, to an electric heater control device for a preheater. Background Technology

[0002] An electrically heated preheater in chemical equipment is a type of chemical device that uses electric heating technology to preheat the reaction medium. Electrically heated preheaters are widely used in processes such as organic synthesis, polymerization, catalytic reactions, and distillation. Their main function is to heat the reaction medium to the required reaction temperature via electric heating, thereby promoting the chemical reaction.

[0003] The electric heater control device of the preheater is used to control the heating of the reaction medium. It is an important process device in the preheater reactor. In the chemical reaction process, the reaction temperature is a key factor affecting the reaction rate and product quality. The function of the electric heating control device of the preheater is to control the heating temperature and heating rate to achieve precise control of the reaction process, thereby optimizing the chemical reaction effect and improving product quality.

[0004] Existing electric heater control devices typically regulate the operation of the electric heater electrically, that is, by adjusting parameters such as the current, voltage, and resistance of the electric heater to regulate its power. However, this electrical control method is prone to overheating due to the rapid heating and slow heat dissipation of the electric heater, resulting in equipment shutdown for maintenance and seriously affecting production efficiency; the control mode is limited and cannot easily and flexibly adjust process conditions; and the electric heater has a large load and high energy consumption.

[0005] Therefore, how to provide an electric heater control device that can more stably, conveniently, and flexibly control the electric heater and reduce energy consumption is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0006] In view of this, the present disclosure provides an electric heater control device for a preheater, which can stably, conveniently and flexibly control the electric heater and reduce energy consumption.

[0007] Specifically, this disclosure provides an electric heater control device for a preheater, comprising: an electrical control mechanism and a mechanical control mechanism, wherein the electrical control mechanism includes a voltage regulation component, a current regulation component, or a resistance regulation component, and the electrical control mechanism is coupled to the mechanical control mechanism; the mechanical control mechanism includes a handle assembly, a transmission assembly, a baffle assembly, and an electric heater receiving assembly connected in sequence, wherein the handle assembly, the transmission assembly, and the baffle assembly are fixedly connected in sequence, and the baffle assembly is movably connected to the electric heater receiving assembly.

[0008] Optionally, the baffle assembly includes a baffle and a connector and a support rib disposed on the baffle, the support rib being used to connect the baffle and the connector, and the connector being connected to the transmission assembly.

[0009] Optionally, the electric heater housing assembly includes a top-to-bottom diameter reducing pipe, an electric heater funnel, and a perforated plate, wherein the electric heater funnel houses the electric heater, the top-to-bottom diameter reducing pipe is used to input the reaction medium, and the perforated plate is disposed above the electric heater funnel and has small holes arranged thereon to allow the reaction medium to pass through the perforated plate into the electric heater funnel and contact the electric heater for heating.

[0010] Optionally, the electric heater funnel includes a side plate, and the baffle is rotatable relative to the side plate within a specific angular range to form an openable and closable window between the baffle and the side plate.

[0011] Optionally, the handle assembly includes a handle, a ring tube, a pin, and a dial. The handle is fixedly connected to the ring tube, and the ring tube is fixedly connected to the transmission assembly. The handle has a fixing hole, and the dial has several position holes. The pin passes through the fixing hole and is inserted into one of the position holes of the dial, thereby fixing the handle relative to the dial at different positions.

[0012] Optionally, the transmission assembly includes a transmission shaft, one end of which is bolted to the annular tube and the other end of which is screwed to the connector.

[0013] Optionally, the electric heater control device includes two sets of the handle assembly, the transmission assembly, and the baffle assembly.

[0014] Optionally, the gear position includes at least two positions: fully closed and fully open.

[0015] Compared with the prior art, the electric heater control device for preheaters provided in this disclosure has at least the following advantages:

[0016] 1. By combining electrical and mechanical control, dual-dimensional temperature control is achieved by mechanically adjusting the air flow rate using baffle angle, in addition to traditional electric heating power regulation. When upstream process temperature or flow rate fluctuates, the unheated medium can be quickly diverted by adjusting the baffle angle, and the temperature can be balanced by heat conduction. This avoids heating lag or overload problems caused by single electrical regulation, significantly improves temperature stability, and adapts to complex and changing process conditions.

[0017] 2. Mechanical diversion control reduces over-reliance on electric heaters, allowing some media to pass through the window without heating, directly reducing the operating power and energy consumption of the electric heater. Simultaneously, by reducing continuous high-load operation of the electric heater, overheating can be avoided, extending heater life, reducing downtime for maintenance, and improving production efficiency.

[0018] 3. The mechanical adjustment part adopts a linkage design between the handle and the dial. The operator only needs to manually rotate the handle and fix the top to complete the adjustment. There is no need for complicated electrical parameter settings, which makes the operation convenient and reduces the difficulty and cost of daily maintenance and troubleshooting. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of this disclosure, the embodiments of this disclosure will be further explained and described with reference to the following drawings. These drawings are only used to more conveniently and specifically describe the embodiments of this disclosure and are not intended to limit this disclosure. In the drawings:

[0020] Figure 1 This is a front cross-sectional schematic diagram of an electric heater control device for a preheater according to one embodiment of the present disclosure;

[0021] Figure 2 This is a cross-sectional left view of an electric heater control device for a preheater according to one embodiment of the present disclosure;

[0022] Figure 3 This is a top view of an electric heater control device for a preheater according to one embodiment of the present disclosure;

[0023] Figure 4 yes Figure 1 A partially enlarged schematic diagram of box I in the middle;

[0024] Figure 5 This is a schematic diagram of the handle according to one embodiment of the present disclosure;

[0025] Figure 6 This is a schematic diagram of the structure of a dial according to one embodiment of the present disclosure; and

[0026] Figure 7 This is a schematic diagram of the structure of a baffle assembly according to one embodiment of the present disclosure.

[0027] In the diagram: 1-Handle assembly, 11-Handle, 111-Fixing hole, 12-Ring tube, 13-Ejector pin, 14-Dial, 141-Gear hole; 2-Transmission assembly, 21-Transmission shaft; 3-Baffle assembly, 31-Baffle, 32-Connector, 33-Support rib; 4-Electric heater housing assembly, 41-Round-to-square reducing pipe, 42-Electric heater funnel, 43-Perforated plate, 44-Electric heater, 421-Side plate. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, specific embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. These embodiments are provided by way of example only. Obviously, the described embodiments are only a part of the embodiments of this disclosure, and not all of them. Based on the described embodiments of this disclosure, all other embodiments obtained by those skilled in the art without inventive effort are also within the scope of protection claimed by this disclosure.

[0029] In the description of this disclosure, it should be noted that the terms "center," "longitudinal," "transverse," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0030] In the description of this disclosure, unless otherwise expressly specified and limited, the terms "set," "install," "connect," "link," "fix," etc., should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; a mechanical connection; a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this disclosure according to the specific circumstances. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features.

[0031] One embodiment of this disclosure provides an electric heater control device for a preheater. The electric heater control device includes an electrical control mechanism (not shown) and a mechanical control mechanism. The electrical control mechanism is a conventional electrical control unit in the art, such as a voltage, current, or resistance control structure, used to control the voltage, current, resistance, etc., input to the electric heater, thereby electrically regulating its power. The electrical control mechanism may also include information acquisition components such as sensors, used to acquire the operating parameters of the electric heater and adjust the operation of the electric heater accordingly. The structure and principle of the electrical control mechanism are conventional technology in the art and will not be described in detail here. In some embodiments, the electrical control mechanism and the mechanical control mechanism are coupled; for example, both the electrical control mechanism and the mechanical control mechanism are simultaneously connected to a controller, and the three are communicatively connected. The controller controls the electrical control mechanism and the mechanical control mechanism to work together to regulate the operation of the electric heater.

[0032] like Figures 1 to 3 As shown, the mechanical control mechanism includes a handle assembly 1, a transmission assembly 2, a baffle assembly 3, and an electric heater housing assembly 4 connected in sequence. The handle assembly 1, the transmission assembly 2, and the baffle assembly 3 are fixedly connected in sequence, and the baffle assembly 3 is movably connected to the electric heater housing assembly 4. Figures 1 to 3 The diagram shows two sets of handle assemblies 1, transmission assemblies 2, and baffle assemblies 3. In other embodiments, the mechanical control mechanism may include only one set or two or more sets of handle assemblies 1, transmission assemblies 2, and baffle assemblies 3, and this disclosure does not impose specific limitations in this regard. For example, the mechanical control mechanism can be configured with multiple independent assemblies depending on the size of the preheater: in a large preheater with a diameter exceeding 2 meters, four sets of handle-transmission-baffle assemblies are symmetrically arranged along the circumference, each set controlling a 90° fan-shaped area, thereby balancing the heat field distribution through zoned adjustment and avoiding local overheating.

[0033] The electric heater housing assembly 4 includes a variable diameter pipe 41 (round top to square bottom), an electric heater funnel 42, and a perforated plate 43. The upper end of the variable diameter pipe 41 is welded to the inner wall of the equipment, and the lower end is welded to the electric heater funnel 42, for inputting the reaction medium. The electric heater funnel 42 houses the electric heater 44. The perforated plate 43 covers the electric heater funnel 42 and has an array of small holes 431 arranged on it, allowing the reaction medium to pass through the perforated plate 43 into the electric heater funnel 42 and contact the electric heater 44 for heating, thereby reaching the required reaction temperature. Optionally, the small holes 431 of the perforated plate 43 can be optimized with a gradually changing aperture design: the inlet side aperture is 3mm, and the outlet side is enlarged to 5mm, utilizing the Venturi effect to accelerate medium flow and reduce pressure drop. Furthermore, the perforated plate 43 can integrate a fiber optic temperature sensor array to monitor the medium temperature distribution in each area in real time and transmit the data to the electrical control mechanism via a data bus (such as RS485) to achieve dynamic power distribution. The electric heater funnel 42 includes two side plates 421 and a bottom plate. The electric heater 43 is housed in the cavity formed by the perforated plate 43, the side plates 421, and the bottom plate. Optionally, the side plates 421 of the electric heater funnel 42 may be provided with fin structures to increase the heat dissipation area, reduce the surface temperature, and avoid high-temperature deformation.

[0034] like Figure 7 As shown, the baffle assembly 3 includes a baffle 31, a connector 32 and a support rib 33 disposed on the baffle 31, and the connector 32 is connected to the transmission assembly 33. The support rib 33 is used to connect the baffle 31 and the connector 32 to reinforce the baffle assembly 3. The baffle 31 can rotate relative to the side plate 421 within a certain angle range to form an openable and closable window between the baffle 31 and the side plate 421 for the reaction medium to pass through. Figures 1 to 3 The window shown is rectangular, but it can be other shapes depending on the specific process requirements, and this disclosure does not impose any specific limitations on this. The rotation angle range of the baffle 31 can also be set as needed. Optionally, the geometry of the baffle 31 can be adjusted according to the characteristics of the medium: for low-viscosity gases, an arc-shaped baffle is used to guide the medium to form a swirling flow to enhance heat exchange; for high-viscosity liquids, a flat baffle is used with guide grooves at the edges to reduce flow dead zones. The surface of the baffle 31 can be sprayed with a superhydrophobic nano-coating (such as fluorosilane-modified silica) to significantly reduce the medium adhesion rate and reduce the risk of coking. In scenarios with strict sealing requirements, a graphite sealing ring can be embedded in the contact surface between the baffle 31 and the side plate 421 to achieve zero leakage when the baffle is fully closed.

[0035] like Figure 4 , Figure 5 and Figure 6As shown, the handle assembly 1 includes a handle 11, a ring tube 12, a pin 13, and a dial 14. The handle 11 is welded to the ring tube 12, which is fixed to the transmission assembly 2 by hexagonal bolts. The handle 11 has a fixing hole 111, and the dial 14 has several position holes 141. The pin 13 passes through the fixing hole 111 and is inserted into one of the position holes of the dial 14, fixing the handle 11 relative to the dial 14 in different positions. The positions include at least two positions: fully closed and fully open. Figure 6 The dial 14 shown includes three gear position holes 141, thus including three gear positions. The dial 14 may also include fewer or more gear positions; this disclosure does not specifically limit this. Optionally, the gear position holes 141 of the dial 14 can be upgraded to a magnetic encoder structure, using a Hall sensor to detect the rotation angle of the handle 11 and transmitting the signal to the PLC controller to achieve digital display of the gear position. The handle 11 may integrate a haptic feedback module: when the baffle 31 reaches its maximum opening, a micro motor inside the handle vibrates to alert the operator. The transmission assembly 2 includes a drive shaft 21, one end of which is bolted to the ring tube 12, and the other end is screwed to the connector 32 of the baffle assembly 3. The dial 14 is welded to the bushing of the drive shaft 21 by reinforcing ribs 15.

[0036] If it is necessary to change the temperature of the process medium during equipment operation, the handle 11 should be held to pull the ejector pin 13 out of the hole in the dial 14, and then the handle 11 should be rotated to adjust to the required angle before inserting the ejector pin 13 into the hole in the dial 14. As the handle 11 is rotated, the drive shaft 21 also rotates. The rotation of the drive shaft 21 drives the rotation of the baffle assembly 3, so that the baffle 31 and the two side plates 421 of the electric heater funnel 42 form a certain angle. The process medium, which previously passed entirely through the perforated plate 43, now passes only partially. The other part of the medium passes directly through the window area of ​​the electric heater funnel 42. This part of the medium will not be heated by the electric heater. There is a temperature difference between the heated and unheated process gas, which will conduct heat and change the temperature of the process gas. That is, by adjusting the angle of the baffle 31, the amount of gas passing through the window is changed, thereby adjusting the amount of gas passing through the electric heater 44 to achieve the purpose of regulating the temperature of the process medium. This ensures that the temperature of the process medium after passing through the device remains stable and meets the process requirements even when the upstream process temperature and flow rate change. This provides qualified process gas for subsequent processes, ensures the stable operation of subsequent processes, and provides a guarantee for the stable production of the target product.

[0037] For the coordination of electrical and mechanical control mechanisms, a fuzzy PID algorithm can be used: when a fluctuation in the medium inlet temperature is detected, the system prioritizes adjusting the flow ratio by adjusting the opening of baffle 31. If the temperature deviation continues to exceed the set threshold, the power compensation of the electric heater 44 is activated, forming a dual-layer control mode of "mechanical coarse adjustment + electrical fine adjustment". The safety interlock mechanism can be expanded to a multi-level response: when the surface temperature of the electric heater 44 exceeds the threshold, baffle 31 automatically switches to the fully open position, triggering an audible and visual alarm and sending a shutdown signal to the central control system.

[0038] It should be understood that the accompanying drawings in the embodiments of this disclosure only relate to structures relevant to the embodiments of this disclosure, while other structures can be referenced to conventional designs. The devices and / or structures in the various embodiments provided in this disclosure can be combined, modified, and / or changed to form new technical solutions. Without inventive effort, these technical solutions should also be included within the scope of protection claimed in this disclosure.

[0039] It should be understood that the specific examples provided in the embodiments described herein are for the purpose of illustrating the embodiments of this disclosure in detail and are not intended to limit the scope of this disclosure. The embodiments in this disclosure can be practiced without these specific examples. In some embodiments, structures and / or techniques well known to those skilled in the art have not been shown in detail so as not to obscure the understanding of this disclosure.

[0040] While preferred embodiments of the present disclosure have been shown and described herein, it will be readily understood by those skilled in the art that these embodiments are provided by way of example only. Various variations, modifications, and substitutions will occur to those skilled in the art without departing from the present disclosure. It should be understood that various alternatives to the embodiments of the present disclosure described herein are optionally used to implement the present disclosure. The scope of the present disclosure is intended to be defined by the appended claims, and thereby covers apparatuses, structures, and their equivalents within the scope of those claims.

Claims

1. An electric heater control device for a preheater, characterized in that, include: An electrical control mechanism and a mechanical control mechanism, wherein the electrical control mechanism includes a voltage regulation component, a current regulation component or a resistance regulation component, and the electrical control mechanism is coupled to the mechanical control mechanism; the mechanical control mechanism includes a handle assembly (1), a transmission assembly (2), a baffle assembly (3) and an electric heater housing assembly (4) connected in sequence, wherein the handle assembly (1), the transmission assembly (2) and the baffle assembly (3) are fixedly connected in sequence, and the baffle assembly (3) is movably connected to the electric heater housing assembly (4).

2. The electric heater control device for a preheater according to claim 1, characterized in that, The baffle assembly (3) includes a baffle (31) and a connector (32) and a support rib (33) disposed on the baffle (31), wherein the support rib (33) is used to connect the baffle (31) and the connector (32), and the connector (32) is connected to the transmission assembly (2).

3. The electric heater control device for a preheater according to claim 1, characterized in that, The electric heater housing assembly (4) includes a top-to-bottom diameter reducer (41), an electric heater funnel (42), and a perforated plate (43). The top-to-bottom diameter reducer (41) is used to input the reaction medium. The electric heater funnel (42) contains an electric heater (44). The perforated plate (43) is placed over the electric heater funnel (42) and has small holes arranged on it so that the reaction medium can pass through the perforated plate (43) into the electric heater funnel (42) and contact the electric heater (44) for heating.

4. The electric heater control device for a preheater according to claim 3, characterized in that, The electric heater funnel (42) includes a side plate (421), and the baffle (31) of the baffle assembly (3) is rotatable relative to the side plate (421) within a specific angular range to form an openable and closable window between the baffle (31) and the side plate (421).

5. The electric heater control device for a preheater according to claim 1, characterized in that, The handle assembly (1) includes a handle (11), a ring tube (12), a pin (13), and a dial (14). The handle (11) is fixedly connected to the ring tube (12), and the ring tube (12) is fixedly connected to the transmission assembly (2). The handle (11) is provided with a fixing hole (111), and the dial (14) is provided with a plurality of gear holes (141). The pin (13) passes through the fixing hole (111) and is inserted into one of the gear holes (141) of the dial (14), thereby fixing the handle (11) relative to the dial (14) at different gear positions.

6. The electric heater control device for a preheater according to claim 5, characterized in that, The transmission assembly (2) includes a transmission shaft (21), one end of which is bolted to the ring tube (12) and the other end is screwed to the connector (32).

7. The electric heater control device for a preheater according to any one of claims 1 to 6, characterized in that, The electric heater control device includes two sets of the handle assembly (1), the transmission assembly (2), and the baffle assembly (3).

8. The electric heater control device for a preheater according to claim 5, characterized in that, The gear positions include at least two positions: fully closed and fully open.

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