Liquid level switch device suitable for high-temperature conducting medium in caustic soda production

Abstract

The utility model discloses a liquid level switch device suitable for a high-temperature conducting medium in caustic soda production, which is mainly used in the field of industrial process control, particularly in the liquid level measurement and control of a tank body with a conducting medium safety environment, and solves the problems encountered when a traditional pressure transmitter treats a medium containing solid sediments. The device comprises a tank body, a conductive electrode body, a flange for connecting the tank body and the conductive electrode body, a connecting circuit, a safety barrier and the like, wherein the tank body is required to be made of a high-strength and corrosion-resistant conductive material; the conductive electrode body is of a slender rod-shaped structure, the surface is subjected to insulation treatment, and the insertion position and depth are obtained through accurate calculation. The device can be suitable for the fields of various liquids, turbid liquids and high-temperature melting conductive media, and is particularly suitable for being used under complex working conditions with solid sediments.

Description

Technical Field

[0001] This invention is applicable to various liquids, suspensions, and high-temperature molten conductive media, and is particularly suitable for use in complex working conditions where solid sediments exist. Background Technology

[0002] In the production processes of many industrial sectors, such as chemical, pharmaceutical, and food processing, precise control of the liquid level in tanks is always a critical step. The stability of the liquid level directly affects the continuity and stability of the production process, thus decisively influencing the quality of the final product. At the same time, accurate liquid level monitoring is also an important prerequisite for ensuring production safety, preventing dangerous situations such as leaks and overflows caused by abnormal liquid levels.

[0003] For a long time, single-flange pressure transmitters with capillary tubes have been a common method for liquid level measurement. Their working principle is based on measuring the pressure at the bottom of the tank and then indirectly calculating the liquid level based on the correlation between pressure and liquid level. This method typically provides relatively accurate and reliable measurement results when dealing with conventional liquid media.

[0004] However, problems become increasingly apparent when dealing with media containing solid sediments. Solid sediments accumulate at the bottom of the tank, gradually solidifying over time. These solidified sediments possess considerable hardness and irregular shapes, exerting abnormal pressure on the sensitive components of the pressure transmitter.

[0005] The current problem is:

[0006] 1. This compression may directly cause physical damage to sensitive components, disrupting their normal structure and performance.

[0007] 2. The accumulation of solid sediment can also block the connection channel between the pressure transmitter and the bottom of the tank, interfering with the normal transmission of pressure and thus affecting the accuracy of the measurement.

[0008] 3. The chemical properties of solid sediments may also corrode the sensitive components of the pressure transmitter, further weakening its measurement performance.

[0009] 4. The combined effect of these adverse factors leads to a significant decrease in measurement accuracy and a substantial increase in the frequency of malfunctions.

[0010] 5. As a result, the average service life of this type of pressure transmitter is significantly shortened, requiring frequent replacement and maintenance, which undoubtedly increases the company's cost investment in equipment maintenance.

[0011] 6. Due to measurement limitations, abnormal changes in liquid level may not be detected in time, potentially leading to a series of production accidents, such as material spillage causing environmental pollution, equipment damage, or production interruption due to excessively low liquid level, which can affect production efficiency, reduce the company's economic benefits, and pose a significant challenge to the company's normal production and operation. Utility Model Content

[0012] To address the aforementioned problems, this utility model provides a level switch device suitable for high-temperature conductive media in granular alkali production, comprising a tank, a flange, a conductive electrode body, connecting wires, a safety barrier, a power supply device, and a DCS control system. The flange is mounted on the tank, and a sealing gasket is used to seal the flange and the tank. The conductive electrode body is inserted into the tank through the flange, with the insertion depth and position precisely calculated. One end of the conductive electrode body is connected to the DCS control system via the connecting wire and the safety barrier, and the power supply device is connected in series to the safety barrier via the connecting wire. The other end is connected to an insulator via the connecting wire.

[0013] Preferably, the flange is installed on the tank body by welding or bolting. The tank body is made of high-strength, corrosion-resistant conductive material, and its shape and size are customized according to actual application requirements. The flange is firmly installed on the tank body by welding or bolting, and a sealing gasket is used between the flange and the tank body to ensure sealing performance and prevent media leakage.

[0014] Preferably, the conductive electrode body is a slender rod-shaped structure made of a special conductive material, and its surface is insulated to ensure good insulation between it and the flange. The conductive electrode body is inserted into the tank through the flange, and the insertion depth and position are precisely calculated and experimentally verified to ensure the accuracy and reliability of the liquid level measurement.

[0015] Preferably, when the liquid level in the tank rises or falls to the preset position of the conductive electrode body, the conductive electrode body forms a conductive contact with the tank or medium, thereby changing the conduction state of the circuit. This state change is monitored by the DCS control system and triggers corresponding control actions.

[0016] Preferably, the conductive electrode body is connected to the DCS control system via two wear-resistant and corrosion-resistant 24-volt power lines. A safety barrier conforming to relevant standards is connected in series in the power lines. The safety barrier can effectively limit the energy in the circuit and prevent damage to the system from abnormal conditions such as overcurrent and overvoltage, ensuring that the entire liquid level measurement system meets intrinsic safety requirements and protecting the safety of personnel and equipment at the production site.

[0017] The working principle of this invention is based on the electrical conduction and disconnection mechanism: when the liquid level in the tank rises or falls to the preset position of the conductive electrode, the conductive electrode forms conductive contact with the tank or medium, thereby changing the conduction state of the circuit. This state change is monitored in real time by the DCS control system and triggers corresponding control actions, such as issuing a liquid level alarm signal, controlling the start and stop of the pump, and adjusting the valve opening, to achieve precise control of the liquid level.

[0018] The liquid level switch device of this invention has the following advantages compared with the traditional pressure transmitter for detecting liquid level.

[0019] 1. Durability: The unique structural design effectively avoids direct damage to the measuring components by solid sediments, greatly extending the service life of the equipment, which is expected to reach more than five years, significantly reducing the cost of equipment replacement and maintenance.

[0020] 2. Simplified maintenance process: The liquid level switch device has a simple structure and clear function. It only requires periodic inspection of the working status and wiring of the conductive electrode body. There is no need for complicated pressure calibration and calculation, which reduces the difficulty and workload of maintenance.

[0021] 3. Excellent media adaptability: It is optimized for complex working conditions such as solid sediments and corrosive media, and can maintain stable performance in harsh environments to ensure the accuracy and reliability of liquid level measurement.

[0022] 4. Applicable to various types of liquids, suspensions, and high-temperature molten conductive media in industrial production processes; integrates high-precision measurement technology and intelligent control algorithms, enabling real-time monitoring and automatic control of liquid level, effectively preventing abnormal situations such as overflow, undercurrent, and leakage.

[0023] 5. It possesses excellent stability and reliability. Its design aims to provide an efficient, reliable, and highly adaptable integrated liquid level control solution, which is intended to meet the urgent needs of modern industrial production for precise control and intelligent management of tank liquid levels. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the device of this utility model.

[0025] In the diagram: 1. Conductive medium, 2. Conductive electrode body, 3. Tank, 4. Flange, 5. Safety barrier, 6. DCS control system, 7. Power supply equipment, 8. Connecting wire, 9. Insulator. Detailed Implementation

[0026] To enable those skilled in the art to more clearly and accurately understand the technical solution of this utility model, a detailed explanation is provided below using embodiments. Obviously, the accompanying drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without any creative effort. Example

[0027] This utility model provides a liquid level switch device suitable for high-temperature conductive media in granular alkali production, including a tank body 3, a flange 4, a conductive electrode body 1, a connecting line 8, a safety barrier 5, a power supply device 7, and a DCS control system 6. The flange 4 is installed on the tank body 3, and a sealing gasket is used to seal the flange 4 and the tank body 3. The conductive electrode body 1 is inserted into the tank body 3 through the flange 4, and the insertion depth and position are precisely calculated. One end of the conductive electrode body 1 is connected to the DCS control system 6 through the safety barrier 5 via the connecting line, and the power supply device 7 is connected in series to the safety barrier 5 via the connecting line. The other end is connected to an insulator 9 via the connecting line.

[0028] Preferably, the flange 4 is installed on the tank body 3 by welding or bolting. The tank body 3 is made of high-strength, corrosion-resistant conductive material to ensure good physical properties and chemical stability even under long-term contact with corrosive media. Its shape and size are customized according to actual application requirements. The flange 4 is firmly installed on the tank body 3 by welding or bolting, and a sealing gasket is used between the flange 4 and the tank body 3 to ensure sealing performance and prevent media leakage.

[0029] Preferably, the conductive electrode body 2 is a slender rod-shaped structure made of a special conductive material, and its surface is insulated to ensure good insulation between it and the flange 4. The conductive electrode body 2 is inserted into the tank through the flange, and the insertion depth and position are precisely calculated and experimentally verified to ensure the accuracy and reliability of the liquid level measurement.

[0030] Preferably, when the liquid level in the tank 3 rises or falls to the preset position of the conductive electrode body 2, the conductive electrode body 2 forms a conductive contact with the tank 3 or the conductive medium 1, thereby changing the conduction state of the circuit. This state change is monitored by the DCS control system and triggers the corresponding control action.

[0031] Preferably, the conductive electrode body 2 is connected to the DCS control system 6 via two wear-resistant and corrosion-resistant 24-volt power lines. A safety barrier 5 conforming to relevant standards is connected in series in the power lines. The safety barrier can effectively limit the energy in the circuit and prevent abnormal conditions such as overcurrent and overvoltage from damaging the system, ensuring that the entire liquid level measurement system meets the intrinsic safety requirements and protecting the safety of personnel and equipment at the production site.

[0032] Figure 1 The conductive electrode body 2 is tightly inserted into the tank 3 through the flange 4, ensuring a certain distance between it and the medium inside the tank. As the liquid level in the tank 3 rises or falls, the conductive electrode body 2 senses the change in liquid level. When the liquid level reaches a preset position, the conductive electrode body 2 comes into contact with the tank 3 or the conductive medium 1, triggering a change in the conduction state of the circuit. This change in state is monitored in real time by the DCS control system, which triggers corresponding control actions, such as issuing a liquid level alarm signal, controlling the start and stop of the pump, and adjusting the valve opening, thereby achieving precise control of the liquid level inside the tank 3.

[0033] This invention is applied to the granulated alkali production process in a large chemical plant. Two level switches are installed on the top of each molten salt tank, including alkali and molten salt tanks, to accurately monitor high and low liquid levels, ensuring the safe storage and use of the molten salt. After long-term operation, these level switches have demonstrated extremely high stability and reliability, effectively reducing production interruptions and equipment maintenance frequency caused by level measurement failures, thereby improving production efficiency and reducing production costs.

[0034] 1. This liquid level switch device not only successfully achieves precise measurement and control of the liquid level in the tank, but also effectively avoids problems such as wear, blockage and chemical corrosion that may occur when traditional pressure transmitters handle similar working conditions by using special conductive materials and sophisticated process design.

[0035] 2. This device also boasts high interchangeability and versatility, its design and construction allowing it to easily adapt to various types of storage tanks and process conditions. Through standardized interfaces and modular design, the device can be quickly and easily installed and disassembled, significantly reducing maintenance costs and operational complexity.

[0036] 3. In terms of safety and reliability, the device also performs exceptionally well. Its corrosion resistance, high temperature resistance, and high pressure resistance enable it to operate normally under various extreme conditions, effectively ensuring the safety and continuity of the production process.

[0037] 4. The device also has a self-diagnostic function, which can promptly detect and warn of potential faults, further improving the reliability and stability of the system.

[0038] 5. With its unique structural design, material selection, and process innovation, this device provides a more accurate, stable, and safe solution for liquid level measurement and control in chemical production processes such as tanks, and provides strong technical support for the sustainable development of related industries and environmental protection.

[0039] This invention features a device with significant innovation and practicality in structural design, performance, and application. It solves many problems faced by traditional liquid level measuring devices in complex media environments, providing a more reliable, efficient, and economical solution for liquid level measurement and control in industrial production.

[0040] The above description is merely a preferred embodiment of this utility model, but the protection scope of this utility model is not limited thereto. Any person skilled in the art can apply this utility model to any specific embodiment.

[0041] Within the scope of the technology disclosed in this utility model, any equivalent substitutions or modifications made based on the technical solution and inventive concept of this utility model shall be covered within the protection scope of this utility model.

Claims

1. A level switch device suitable for high-temperature conductive media in granular alkali production, characterized in that, The device includes a tank, a flange, a conductive electrode body, connecting wires, a safety barrier, a power supply device, and a DCS control system. The flange is installed on the tank and sealed with a gasket between the flange and the tank. The conductive electrode body is inserted into the tank through the flange, and the insertion depth and position are precisely calculated. One end of the conductive electrode body is connected to the DCS control system via the safety barrier through a connecting wire. The power supply device is connected in series to the safety barrier through a connecting wire. The other end is connected to an insulator through a connecting wire.

2. The liquid level switch device for high-temperature conductive media in granular alkali production according to claim 1, characterized in that, The flange is installed on the tank body by welding or bolting, and the tank body is made of conductive material.

3. A level switch device for high-temperature conductive media in granular alkali production according to claim 1, characterized in that, The conductive electrode body is a slender rod-shaped structure made of conductive material, and its surface is treated with insulation.

4. A level switch device for high-temperature conductive media in granular alkali production according to claim 1, characterized in that, When the liquid level in the tank rises or falls to the preset position of the conductive electrode body, the conductive electrode body forms a conductive contact with the tank or medium, thereby changing the conduction state of the circuit. This state change is monitored by the DCS control system and triggers the corresponding control action.

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