Charge detection optimized and improved ash bucket anti-blocking heat-tracing-free system

Abstract

The utility model provides a charge detection optimized and improved ash bucket anti-blocking heat-tracing-free system, which comprises an ash bucket, a special nano ceramic material coating coated on the inner wall of the ash bucket, a fluidization air pipeline arranged at a position close to the bottom of the ash bucket, an anti-blocking device arranged at an inlet of the fluidization air pipeline, and a charge quantity detection sensor group arranged on the inner wall of the ash bucket, the charge quantity detection sensor group is electrically connected with the distributed control system, and the outer wall of the ash bucket is provided with a blockage clearing device. The system provided by the utility model eliminates detection dead angles, the sensors collect data in real time through the distributed control system, output of the anti-blocking device is dynamically adjusted, the dust dispersing effect is improved, and the system has the advantages of being comprehensive in detection, accurate in control, low in energy consumption, long in service life and the like.

Description

Optimized and improved charge detection ash hopper anti-clogging heat-tracing system Technical Field

[0001] This utility model belongs to the technical field of dust hopper anti-clogging in dust removal systems, specifically involving a charge detection optimized and improved dust hopper anti-clogging system without heat tracing. Background Technology

[0002] To prevent clogging in dust collection systems, steam or electric heating is often used to heat and insulate the outer wall of the dust hopper, maintaining a high temperature and preventing acid dew and water from forming caking.

[0003] In existing dust hopper anti-clogging technologies, charge detection systems typically only install a small number of sensors on one side or in a localized area of ​​the dust hopper, resulting in limited detection range and blind spots. For example, the charge detection system in patent CN109625648A uses a single sensor arrangement, with insufficient number of sensors or unreasonable arrangement, leading to ineffective monitoring of the charge in the top, bottom, and edge areas of the dust hopper. The control accuracy is low, the anti-clogging device output parameters are fixed, making it difficult to adapt to local charge fluctuations. Furthermore, in practice, due to the complex airflow inside the dust hopper, a single sensor may not be able to fully reflect the charge status of different areas, causing the anti-clogging device to adjust lag or deviation, thus affecting the dust dispersion effect.

[0004] Therefore, it is urgent to optimize and improve the existing charge detection system structure and sensor arrangement to increase the detection range, eliminate detection blind spots, and improve response time, thereby improving the anti-blocking effect. Summary of the Invention

[0005] The purpose of this invention is to provide an optimized and improved ash hopper anti-clogging system without heat tracing for charge detection, which solves the problems of low detection accuracy, high energy consumption and slow system response in existing systems.

[0006] The technical solution adopted in this utility model is an optimized and improved ash hopper anti-clogging system without heat tracing, which includes an ash hopper, the inner wall of the ash hopper is coated with a special nano-ceramic material coating, a fluidizing air duct is set near the bottom of the ash hopper, an anti-clogging device is installed at the inlet of the fluidizing air duct, a charge detection sensor group is set on the inner wall of the ash hopper, the charge detection sensor group is electrically connected to the distributed control system, and a blockage clearing device is installed on the outer wall of the ash hopper.

[0007] The features of this utility model also include:

[0008] The thickness of the special nano-ceramic material coating is no more than 0.5 mm.

[0009] The charge detection sensor group includes multiple charge detection sensors arranged in a layered array along the inner wall of the ash hopper.

[0010] Each layer of charge detection sensors consists of 12 individual sensors. Adjacent sensor individuals are evenly arranged in a ring around the inner wall of the ash hopper at 30° intervals, and adjacent sensor individuals are connected by signal lines.

[0011] The inner wall of the ash hopper is provided with a circumferential groove for the signal pipeline, which is embedded in the groove along the circumferential direction of the inner wall.

[0012] The charge detection sensors are arranged in four layers, with two layers each near the top and bottom of the ash hopper.

[0013] The distributed control system includes a multi-channel data acquisition module and a central processing unit.

[0014] The four-layer charge detection sensors are connected in parallel through signal pipelines and then electrically connected to the multi-channel data acquisition module in the distributed control system.

[0015] The unblocking device is located between the sensor layer at the top of the ash hopper and the sensor layer at the bottom of the ash hopper.

[0016] The unblocking device includes an air cannon and a vibrating motor.

[0017] The beneficial effects of this invention are as follows: First, the charge detection system adopts a combination of a ring array and vertical layering, arranged at 30° intervals along the circumference of the inner wall of the ash hopper, forming a monitoring network that covers the entire space. This improves the detection coverage and completely eliminates the blind spots caused by insufficient sensor quantity or single sensor placement in traditional solutions. Second, the distributed control system dynamically adjusts the negative ion output intensity of the anti-clogging device through multi-channel data acquisition and adaptive algorithms. It can precisely enhance the negative ion beam in the zone within 0.5 seconds, homogenizing the electrostatic repulsion between dust particles and further reducing anti-clogging energy consumption. Furthermore, the system significantly improves emergency response capabilities and cleaning efficiency through charge detection and a linked cleaning mechanism, minimizing downtime risks. Attached Figure Description

[0018] Figure 1 is a schematic diagram of the structure of the optimized and improved charge detection ash hopper anti-clogging and heat-tracing system of this utility model.

[0019] In the figure, 1. Nano-ceramic material coating, 2. Charge detection sensor, 3. Unblocking device, 4. Anti-blocking device, 5. Signal line. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this utility model.

[0021] The charge detection optimized and improved ash hopper anti-clogging system provided by this utility model achieves efficient anti-clogging through multi-dimensional collaborative design. As shown in Figure 1, it includes an ash hopper (1). The inner wall of the ash hopper (1) is coated with a special nano-ceramic material coating with a thickness controlled within 0.5 mm and a surface friction coefficient of less than 0.1, which significantly reduces the probability of dust adhesion. The high temperature resistance of the coating makes it stable within the flue gas temperature fluctuation range, while resisting the corrosion of acid and alkaline media. A fluidizing air duct is set near the bottom of the ash hopper (1). Its function is to keep the ash and other materials in the ash hopper in a fluidized state by introducing fluidizing air into the ash hopper, so as to prevent them from accumulating and clogging. An anti-blocking device (4) is installed at the inlet of the fluidizing air duct to prevent duct blockage and ensure the normal supply of fluidizing air, thereby ensuring the fluidization effect in the ash hopper. The anti-blocking device (4) adopts high-frequency high-voltage pulse technology and can adjust the intensity of the negative ion beam according to the real-time charge data to ensure that the dust particles are uniformly charged. A charge detection sensor group is installed on the inner wall of the ash hopper (1), and the charge detection sensor group is electrically connected to the distributed control system. A blockage clearing device (3) is installed on the outer wall of the ash hopper. The blockage clearing device (4) is composed of an air cannon and a vibrating motor and is installed at a key position in the middle of the outer wall of the ash hopper. The control system automatically determines whether to start the blockage clearing by monitoring the frequency of abnormal charge and the change of ash hopper pressure in real time. For example, when abnormal charge is detected three times in a row in the same area and accompanied by an increase in the pressure inside the ash hopper, the system will trigger the air cannon to make directional impact and start the vibrating motor to apply high-frequency vibration to the ash hopper wall, eliminating the risk of arching by working together. If the impact and vibration effects are not ideal, relevant technicians can adjust the impact direction of the air cannon or the vibration position of the vibrating motor according to the detection data of the charge detection sensor group to ensure efficient blockage removal. After the blockage removal operation is completed, the system will automatically return to the normal monitoring state and generate a maintenance log for subsequent analysis.

[0022] The charge detection and control system uses AC charge coupling technology and digital signal processing technology to measure the charge of dust in the dust collector, which is used to control the operation of the anti-clogging device.

[0023] The charge detection sensor group includes multiple charge detection sensors (2), which are arranged in a layered array along the inner wall of the ash hopper. Each layer of charge detection sensors (2) has 12 individual sensors. Adjacent sensor individuals are evenly arranged in a ring with a 30° interval between each other along the circumference of the inner wall of the ash hopper. Adjacent sensor individuals are connected by signal lines (5). A wire groove can be opened in the circumference of the inner wall of the ash hopper. The signal lines (5) are embedded in the wire groove in the circumference of the inner wall to avoid ash accumulation interference. The signal lines (5) are covered with a high-temperature resistant silicone sleeve. The surface of the wire groove and the nano-ceramic material coating are smoothly transitioned. The charge detection sensors (2) are arranged in 4 layers and symmetrically set near the top and bottom of the ash hopper. In order to further improve the detection density, the charge detection sensors (2) can be set in more layers. It can be adjusted according to the needs of on-site construction. The core improvement of the charge detection system lies in the arrangement of the sensors and the data processing logic. In the circumferential direction of the inner wall of the ash hopper, a charge detection sensor (2) is installed every 30°. The charge detection sensors (2) are arranged in layers to form a ring array to monitor the charge status of the top settling area and the bottom ash outlet respectively. The air cannon and vibrating motor of the unblocking device (3) are set on the outer wall between the sensor layer at the top of the ash hopper and the sensor layer at the bottom of the ash hopper to avoid damage to the sensors and pipelines during the unblocking work.

[0024] The distributed control system includes a multi-channel data acquisition module and a central processing unit (CPU) for real-time analysis of the charge data from each sensor and dynamic adjustment of the negative ion output intensity of the anti-blocking device. Each layer of charge detection sensors (2) is connected in parallel via signal lines (5) to the multi-channel data acquisition module in the distributed control system. This parallel connection allows the data from each layer's charge detection sensors (2) to be centrally transmitted to the multi-channel data acquisition module, facilitating data acquisition and processing and improving system efficiency and stability. The multi-channel data acquisition module employs an independent signal channel design, with each sensor corresponding to a dedicated channel, ensuring the synchronization and independence of data acquisition and avoiding signal crosstalk. The CPU integrates an adaptive algorithm, enabling it to receive charge data from each channel in real-time and perform comparative analysis based on preset thresholds. When the charge in a certain area falls below the threshold, the processor immediately generates an adjustment command, which is sent to the corresponding partition control unit of the anti-blocking device via a digital signal interface. For example, if the sensor on the left side of the bottom of the dust hopper detects insufficient charge, the central processing unit will directionally enhance the intensity of the negative ion beam in that area, thereby increasing the negative ion output intensity in that area. This will increase the repulsive force between dust particles, preventing local agglomeration, while other areas maintain the baseline output. This dynamic adjustment mechanism not only relies on real-time changes in charge, but also automatically verifies the charge recovery status after each adjustment, ensuring control accuracy.

[0025] The anti-blocking device uses high-frequency high-voltage pulse technology to adjust the negative ion beam according to the difference in charge distribution. Specifically, the anti-blocking device is equipped with multiple independently controlled zone electrode groups. Each group of electrodes is connected to a high-frequency pulse generator, and the pulse width and frequency of each zone electrode can be dynamically adjusted according to the difference in charge distribution.

[0026] Example 1

[0027] The charge detection optimized and improved ash hopper anti-clogging and heat-free system provided in Embodiment 1 includes an ash hopper. The inner wall of the ash hopper is coated with a special nano-ceramic material coating. A fluidizing air duct is set near the bottom of the ash hopper to keep the ash material in the ash hopper in a fluidized state. An anti-clogging device is installed at the inlet of the fluidizing air duct to prevent external debris from entering the fluidizing air duct. A charge detection sensor group is set on the inner wall of the ash hopper and is electrically connected to a distributed control system. A blockage removal device is installed on the outer wall of the ash hopper. The thickness of the special nano-ceramic material coating is 0.5 mm.

[0028] Example 2

[0029] The optimized and improved charge detection ash hopper anti-clogging system provided in Embodiment 2 includes an ash hopper. The inner wall of the ash hopper is coated with a special nano-ceramic material. A fluidizing air duct is installed near the bottom of the ash hopper to keep the ash material in a fluidized state. An anti-clogging device is installed at the inlet of the fluidizing air duct to prevent external debris from entering the duct. A charge detection sensor group is installed on the inner wall of the ash hopper. The charge detection sensor group includes multiple charge detection sensors arranged in a layered array along the inner wall of the ash hopper. This arrangement aims to more comprehensively detect the charge at different locations on the inner wall of the ash hopper, improving the accuracy and reliability of the detection. The charge detection sensor group is electrically connected to a distributed control system. A clearing device is installed on the outer wall of the ash hopper. The thickness of the special nano-ceramic material coating is 0.3 mm.

[0030] Example 3

[0031] The optimized and improved charge detection ash hopper anti-clogging system without heat tracing provided in Embodiment 3 includes an ash hopper. The inner wall of the ash hopper is coated with a special nano-ceramic material. A fluidizing air duct is installed near the bottom of the ash hopper to keep the ash material in the hopper in a fluidized state. An anti-clogging device is installed at the inlet of the fluidizing air duct to prevent external debris from entering the fluidizing air duct. A charge detection sensor group is installed on the inner wall of the ash hopper. The charge detection sensor group includes multiple charge detection sensors arranged in a layered array along the inner wall of the ash hopper. Each layer of charge detection sensors has 12 individual sensors. Adjacent sensor individuals are evenly arranged in a ring around the circumference of the inner wall of the ash hopper at 30° intervals. Adjacent sensor individuals are connected by signal lines. The charge detection sensor group is electrically connected to a distributed control system. This uniform arrangement can ensure comprehensive detection of the inner wall of the ash hopper and avoid detection blind spots. At the same time, the signal line connection facilitates the transmission of data from each sensor to the distributed control system. A clearing device is installed on the outer wall of the ash hopper. The thickness of the special nano-ceramic material coating is 0.1 mm.

[0032] Example 4

[0033] The optimized and improved charge detection ash hopper anti-clogging and heat-free system provided in Embodiment 4 includes an ash hopper. The inner wall of the ash hopper is coated with a special nano-ceramic material. A fluidizing air duct is installed near the bottom of the ash hopper to keep the ash material in the ash hopper in a fluidized state. An anti-clogging device is installed at the inlet of the fluidizing air duct to prevent external debris from entering the fluidizing air duct. A charge detection sensor group is installed on the inner wall of the ash hopper. The charge detection sensor group includes multiple charge detection sensors arranged in a layered array along the inner wall of the ash hopper. The charge detection sensors are arranged in 4 layers, with 2 layers symmetrically arranged near the top and bottom of the ash hopper, respectively. Layered detection is performed at dead corners such as the top and bottom of the ash hopper to more accurately understand the charge status at different height levels in the ash hopper, avoid detection blind spots, and support the control system to perform targeted dynamic control. Each layer of charge detection sensors consists of 12 individual sensors, arranged in a 30° interval in a ring along the circumference of the ash hopper's inner wall. Adjacent sensors are connected via signal lines. The charge detection sensor group is electrically connected to the distributed control system. This uniform arrangement ensures comprehensive detection of the ash hopper's inner wall, avoiding blind spots. The signal line connections facilitate data transmission from each sensor to the distributed control system. A blockage-clearing device is installed on the outer wall of the ash hopper, with a 0.5 mm thick coating of specialized nano-ceramic material.

[0034] Example 5

[0035] The optimized and improved charge detection ash hopper anti-clogging and heat-free system provided in Embodiment 5 includes an ash hopper. The inner wall of the ash hopper is coated with a special nano-ceramic material. A fluidizing air duct is installed near the bottom of the ash hopper to keep the ash material in the ash hopper in a fluidized state. An anti-clogging device is installed at the inlet of the fluidizing air duct to prevent external debris from entering the fluidizing air duct. A charge detection sensor group is installed on the inner wall of the ash hopper. The charge detection sensor group includes multiple charge detection sensors arranged in a layered array along the inner wall of the ash hopper. The charge detection sensors are arranged in 4 layers, with 2 layers symmetrically arranged near the top and bottom of the ash hopper, respectively. Layered detection is performed at dead corners such as the top and bottom of the ash hopper to more accurately understand the charge status at different heights in the ash hopper, avoid detection blind spots, and support the control system to perform targeted dynamic control. Each layer of charge detection sensors consists of 12 individual sensors, arranged in a 30° ring around the inner wall of the ash hopper. Adjacent sensors are connected via signal lines. The charge detection sensor group is electrically connected to the distributed control system. This uniform arrangement ensures comprehensive detection of the ash hopper's inner wall, avoiding blind spots. The signal lines also facilitate data transmission from each sensor to the distributed control system. A blockage-clearing device is installed on the outer wall of the ash hopper, with a 0.2 mm thick coating of specialized nano-ceramic material.

[0036] The distributed control system includes a multi-channel data acquisition module and a central processing unit. Each layer of charge detection sensors is connected in parallel via signal lines and electrically connected to the multi-channel data acquisition module in the distributed control system. The charge detection and control system employs AC charge coupling technology and digital signal processing technology to measure the charge of dust particles in the dust collector, which is used to control the operation of the anti-clogging device. The anti-clogging device uses high-frequency, high-voltage pulse technology to adjust the negative ion beam current according to the differences in charge distribution.

[0037] Example 6

[0038] The optimized and improved charge detection ash hopper anti-clogging and heat-free system provided in Embodiment 6 includes an ash hopper. The inner wall of the ash hopper is coated with a special nano-ceramic material. A fluidizing air duct is installed near the bottom of the ash hopper to keep the ash material in the ash hopper in a fluidized state. An anti-clogging device is installed at the inlet of the fluidizing air duct to prevent external debris from entering the fluidizing air duct. A charge detection sensor group is installed on the inner wall of the ash hopper. The charge detection sensor group includes multiple charge detection sensors arranged in a layered array along the inner wall of the ash hopper. The charge detection sensors are arranged in 4 layers, with 2 layers symmetrically arranged near the top and bottom of the ash hopper, respectively. Layered detection is performed at dead corners such as the top and bottom of the ash hopper to more accurately understand the charge status at different heights in the ash hopper, avoid detection blind spots, and support the control system to perform targeted dynamic control. Each layer of charge detection sensors consists of 12 individual sensors, arranged in a 30° ring around the inner wall of the ash hopper. Adjacent sensors are connected via signal lines. The charge detection sensor group is electrically connected to the distributed control system. This uniform arrangement ensures comprehensive detection of the ash hopper's inner wall, avoiding blind spots. The signal line connection facilitates data transmission from each sensor to the distributed control system. The inner wall of the ash hopper has circumferential grooves, with the signal lines embedded in these grooves. A blockage removal device is installed on the outer wall of the ash hopper, located between the top and bottom sensor layers. This device includes an air cannon and a vibrating motor. The air cannon releases high-pressure gas to impact blockages within the ash hopper, while the vibrating motor shakes the hopper to dislodge the blockages. The coating of the special nano-ceramic material is 0.5 mm thick.

[0039] The distributed control system includes a multi-channel data acquisition module and a central processing unit. Each layer of charge detection sensors is connected in parallel through signal pipelines and then electrically connected to the multi-channel data acquisition module in the distributed control system.

[0040] According to the charge detection data of the system provided in Example 6, the charge fluctuation in the top area of ​​the ash hopper is reduced by 70% compared with before the modification, and the charge stability of the bottom ash outlet is improved to 98%. During continuous operation, the control system can trigger local negative ion intensity adjustment, which successfully avoids the formation of agglomerates. When triggered, the system detects the charge abnormality within 0.3 seconds, automatically starts the air cannon to clear the blockage, and restores the smooth flow of ash within 5 seconds. In addition, the system energy consumption is significantly reduced, and the energy saving effect is significant.

Claims

1. An optimized and improved charge detection-based anti-clogging, heat-tracing-free ash hopper system, characterized in that: The hopper includes a hopper (1), the inner wall of which is coated with a special nano-ceramic material coating. A fluidizing air duct is provided near the bottom of the hopper (1), and an anti-blocking device (4) is installed at the inlet of the fluidizing air duct. A charge detection sensor group is provided on the inner wall of the hopper (1), and the charge detection sensor group is electrically connected to the distributed control system. A blockage clearing device (3) is installed on the outer wall of the hopper.

2. The optimized and improved charge detection ash hopper anti-clogging system without heat tracing as described in claim 1, characterized in that, The thickness of the special nano-ceramic material coating is no more than 0.5 mm.

3. The optimized and improved charge detection ash hopper anti-clogging system without heat tracing as described in claim 1, characterized in that, The charge detection sensor group includes multiple charge detection sensors (2) arranged in a layered array along the inner wall of the ash hopper.

4. The optimized and improved charge detection ash hopper anti-clogging system without heat tracing as described in claim 3, characterized in that, Each layer of the charge detection sensor (2) is equipped with 12 individual sensors. Adjacent sensor individuals are evenly arranged in a ring with a 30° interval between each other along the inner circumference of the ash hopper. Adjacent sensor individuals are connected by signal lines (5).

5. The charge detection optimized improved hopper anti-jamming non-heat tracing system of claim 4, wherein, The ash hopper (1) has a circumferential groove on its inner wall, and the signal pipeline (5) is embedded in the circumferential groove along the inner wall.

6. The optimized and improved charge detection ash hopper anti-clogging system without heat tracing as described in claim 5, characterized in that, The charge detection sensor (2) is arranged in 4 layers, with 2 layers arranged at the corresponding positions near the top and bottom of the ash hopper.

7. The optimized and improved charge detection ash hopper anti-clogging system without heat tracing according to claim 6, characterized in that, The distributed control system includes a multi-channel data acquisition module and a central processing unit.

8. The optimized and improved charge detection ash hopper anti-clogging system without heat tracing according to claim 7, characterized in that, The charge detection sensor (2) in layer 4 is connected in parallel with the multi-channel data acquisition module in the distributed control system via the signal pipeline (5).

9. The optimized and improved charge detection ash hopper anti-clogging system without heat tracing according to claim 8, characterized in that, The unblocking device (3) is located between the top sensor layer and the bottom sensor layer of the ash hopper.

10. The charge detection optimized improved hopper anti-jamming non-heat tracing system of claim 9, wherein, The unblocking device (3) includes an air cannon and a vibrating motor.

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