A cleanroom air conditioning dust removal system

Abstract

This utility model relates to a cleanroom air conditioning and dust removal system, belonging to the field of cleanroom technology in the pharmaceutical industry. The system includes a combined cleanroom air conditioning unit, a bag filter, an air supply duct network, a high-efficiency filter air outlet, a return air duct network, a dust removal exhaust hood, a dust removal static pressure box, a dust concentration sensor, and a controller. The bag filter is rigidly connected to the air conditioning unit side-by-side and fixed to the floor of the equipment room, eliminating interference from the equipment to the cleanroom. The outlet of the bag filter is directly connected to the mixing section of the air conditioning unit through the return air duct network, forcibly reusing the dust-removed air as return air. The dust concentration sensor is embedded in the inner wall of the dust removal static pressure box, directly exposed to the dust-laden airflow channel. This application significantly reduces the air conditioning cooling and heating load by physically reducing the demand for fresh air; the centralized layout of the equipment room frees up space in the cleanroom, improving the convenience of operation and maintenance; and the closed-loop dust collection and multi-stage filtration ensure the stability of cleanliness levels D and above.

Description

Technical Field

[0001] This utility model relates to the field of pharmaceutical industry technology, and more specifically to a cleanroom air conditioning and dust removal system for pharmaceutical processes. Background Technology

[0002] In the pharmaceutical industry, oral solid dosage forms (such as tablets, capsules, and granules) have long held a dominant position in global dosage forms due to their convenience for clinical use. Their production must comply with the Good Manufacturing Practice (GMP) for pharmaceuticals, requiring cleanrooms to meet at least Grade D cleanliness standards. However, the core processes of solid dosage forms—crushing, mixing, granulation, and tableting—all involve significant dust dispersion, posing a serious challenge to the cleanliness of the production environment.

[0003] The conflict between energy efficiency and cleanliness in dust removal systems:

[0004] Centralized dust collection mode: A single dust collector covers multiple dust-generating points in multiple rooms through a duct network, with the dust collection duct also serving as an exhaust duct. To maintain the air pressure balance in the workshop, the system needs to run continuously (even when there is no dust collection demand), resulting in high energy consumption; at the same time, the duct resistance increases with distance, and the dust collection effect at a distance decreases significantly, making it difficult to ensure the uniformity of dust control.

[0005] Single-unit dust removal mode: Each dust-generating point is independently equipped with a small dust collector, which collects dust on-site and discharges it directly into the room. Although it is highly flexible and has a good dust removal effect, the simultaneous operation of multiple devices causes noise and heat accumulation, which disrupts the temperature and humidity stability of the clean environment. In addition, the equipment occupies workshop space and interferes with personnel operation flow.

[0006] Air conditioning systems bear a heavy energy burden:

[0007] Traditional solutions directly exhaust the air after dust removal, requiring a large influx of fresh air into the cleanroom to maintain positive pressure. Fresh air heat and humidity treatment (especially cooling and dehumidification in summer and heating and humidification in winter) becomes a major source of energy consumption for the air conditioning system. Under conditions of 100% fresh air or a high fresh air ratio, the cooling / heating load surges, severely conflicting with the company's energy conservation and emission reduction goals.

[0008] Space and operational bottlenecks:

[0009] Individual dust collection units, scattered throughout the cleanroom, not only take up production space but also increase the risk of contamination due to equipment heat, vibration, and maintenance requirements. While centralized dust collection removes equipment from the cleanroom, the complex piping system still presents challenges such as cleaning difficulties and potential leaks.

[0010] Industry technological evolution bottlenecks:

[0011] Although existing dust removal technologies can meet basic dust control needs, they have consistently failed to overcome three core contradictions:

[0012] Energy consumption and cleanliness are mutually exclusive: efficient dust removal requires sacrificing energy consumption (such as continuous operation of centralized dust removal); energy-saving design (such as intermittent operation of a single unit) makes it difficult to guarantee real-time dust control.

[0013] Equipment conflicts with the clean environment: Regardless of whether the dust removal equipment is placed inside or outside the workshop, it will have a negative impact on the temperature and humidity of the clean environment, noise control, and space utilization.

[0014] Lack of system synergy: The air conditioning and dust removal systems have long been designed separately, failing to utilize the potential reuse value of the air after dust removal, resulting in repeated energy consumption.

[0015] Innovation drivers and gaps:

[0016] There is an urgent need for a structural innovation solution that can:

[0017] Breaking down system barriers: Deeply integrating dust removal with air conditioning functions, using dust-removed air to replace part of the return air, reducing the amount of fresh air introduced, and reducing the air conditioning load from the source;

[0018] Optimize spatial layout: Remove core dust removal equipment from the cleanroom to eliminate its interference with the production environment;

[0019] Simplify operation and maintenance processes: Improve equipment accessibility and maintenance efficiency through modular centralized deployment.

[0020] However, no mature solution has yet emerged in the current technology to simultaneously address the aforementioned problems. In particular, there is a lack of a system based on physical structure integration that can ensure efficient dust filtration and dynamic stability of cleanliness, while also achieving energy recycling through structural design, without relying on complex control algorithms. This technological gap has become a key bottleneck restricting the green upgrading of the pharmaceutical industry. Summary of the Invention

[0021] This invention addresses the problems of high energy consumption, low space utilization, and insufficient cleanliness stability caused by the separation of dust removal and air conditioning systems in existing cleanrooms. It provides a structurally improved cleanroom air conditioning and dust removal system. By deeply coupling dust removal and air conditioning functions, the air handling path and equipment layout are reconstructed, achieving energy saving, consumption reduction, and space optimization.

[0022] This utility model provides the following technical solution:

[0023] A cleanroom air conditioning and dust removal system includes a combined air conditioning unit, a bag filter, an air supply duct, a high-efficiency filter air outlet, a return air duct, a dust removal exhaust hood, and also includes a dust removal static pressure box, a dust concentration sensor, and a controller.

[0024] The bag filter and the combined air conditioning unit are installed together in the machine room;

[0025] The dust removal exhaust hood is connected to the inlet of the dust removal static pressure box via a pipe, and the outlet of the dust removal static pressure box is connected to the inlet of the bag filter.

[0026] The outlet of the bag filter is connected to the mixing section of the combined air conditioning unit through the return air duct network, which is used to transport the dust-removed air to the mixing section as air conditioning return air.

[0027] The dust concentration sensor is installed inside the dust removal static pressure box;

[0028] The controller is electrically connected to the dust concentration sensor, room temperature and humidity sensor, fresh air valve, return air valve, exhaust valve, and cold and heat source pipeline valves, respectively.

[0029] Furthermore, the combined air conditioning unit also includes a primary filter section, a surface cooling section, and a medium-efficiency bag filter section arranged sequentially along the airflow direction;

[0030] The outlet of the mixing section is sequentially connected to the primary filter section, the surface cooling section, and the medium-efficiency bag filter section. The outlet of the medium-efficiency bag filter section is connected to the high-efficiency filter air outlet through the air supply duct network.

[0031] Furthermore, the dust removal and exhaust hood is fixed above the dust-generating point of the process equipment, and its dust suction port faces the dust source.

[0032] The fresh air valve is located at the fresh air inlet of the combined air conditioning unit; the return air valve is located at the inlet of the return air duct network; and the exhaust valve is located at the exhaust outlet of the bag filter.

[0033] Furthermore, the bag filter is a centralized dust collector, with its casing installed side-by-side with the combined cleanroom air conditioning unit on the floor of the machine room.

[0034] Furthermore, the high-efficiency filter air outlet includes a high-efficiency filter, which is embedded in the air outlet frame.

[0035] The functional structure of this system is analyzed as follows:

[0036] Dust treatment module:

[0037] The dust removal and exhaust hood is fixed directly above the dust-generating point of the process equipment and is connected to the inlet of the dust removal static pressure box through a pipeline.

[0038] The outlet of the dust collector static pressure box is directly connected to the inlet of the bag filter, and a dust concentration sensor is embedded in its inner wall.

[0039] Air circulation module:

[0040] The outlet of the bag filter is connected to the mixing section of the combined clean air conditioning unit through a return air duct network, so that the dust-removed air enters the air conditioning return air system.

[0041] The mixing section is equipped with a fresh air inlet with a fresh air valve and a return air inlet with a return air valve, which respectively introduce fresh air and dust removal return air.

[0042] Air purification module:

[0043] The following components are arranged sequentially along the airflow direction inside the modular air conditioning unit:

[0044] Primary filter stage: filters large particulate pollutants in the mixed air;

[0045] Cooling section: Connects to valves on cold and heat source pipes for cooling and dehumidification;

[0046] Medium-efficiency bag filter section: further filters fine particles;

[0047] The outlet of the medium-efficiency section is connected to the high-efficiency filter air outlet through the air supply duct network. The high-efficiency filter is embedded in the aluminum alloy frame of the air outlet and fixed to the clean room ceiling with bolts.

[0048] Equipment layout module:

[0049] The bag filter and the combined clean air conditioning unit are installed side by side on the floor of the computer room, and their shells are rigidly connected by a steel structure support.

[0050] The exhaust valve is installed at the exhaust port of the bag filter.

[0051] The innovative structural features of this application are as follows:

[0052] Dust removal-air conditioning circuit coupling structure

[0053] Unique return air path: After dust removal, the air is directly delivered to the air mixing section of the air conditioning unit through the return air duct network, replacing the traditional exhaust mode and realizing energy recycling from a structural perspective.

[0054] Physical isolation design: The dust collector and air conditioning unit are centrally located in a separate machine room, completely eliminating the interference of equipment heat and noise on the cleanroom.

[0055] Modular connection construction

[0056] Rigid duct connection: Dust removal exhaust hood → dust removal static pressure box → bag filter inlet adopts flange sealing connection to ensure airtightness;

[0057] Valve positioning and installation: The fresh air valve, return air valve, and exhaust air valve are fixed at the fresh air inlet, return air duct inlet, and dust collector exhaust outlet, respectively, forming physical control nodes.

[0058] Spatial intensive layout

[0059] Parallel support structure: The bag filter and the air conditioning unit are fixed to the machine room floor with anchor bolts, with a distance of ≤1m between them, saving equipment space;

[0060] Integrated duct layout: The supply air duct network and return air duct network are laid overhead along the walls of the machine room to avoid cross-interference.

[0061] The technical effects and advantages of this utility model are as follows:

[0062] I. Structural Improvement of Energy Utilization Efficiency

[0063] Physical reconstruction of return air path

[0064] The outlet of the bag filter is directly connected to the air mixing section of the air conditioning unit through the return air duct network, thereby structurally forcing the recycling of the air after dust removal.

[0065] This design replaces the traditional dust removal and air exhaust mode, which inevitably reduces the need for fresh air intake and directly reduces the heat and humidity treatment load of the air conditioning system on the fresh air.

[0066] Natural optimization of hot and cold medium flow rates

[0067] Because of the recycling of dust removal and return air, the air conditioning system does not need to continuously maintain a high fresh air ratio. The frequency and amplitude of the adjustment of cold and heat source pipeline valves are simplified in structure, reducing energy transmission losses.

[0068] II. Essential Enhancement of Clean Environment Stability

[0069] Physical isolation of equipment interference

[0070] The bag filter and the air conditioning unit are fixed side by side in an independent machine room and rigidly connected by a steel structure support, which completely eliminates the transmission path of equipment heat, noise and vibration to the clean room.

[0071] The cleanroom retains only high-efficiency filter air outlets and dust removal exhaust hoods to ensure that the purity of the production space is not affected by equipment operation.

[0072] Dust diffusion source blocking

[0073] The dust collection and exhaust hood is directly fixed above the dust-generating point (the dust suction port is 300-500mm away from the dust source), and together with the flange-sealed dust collection static pressure box, a closed physical channel for dust collection is formed to prevent dust from spreading into the workshop.

[0074] III. Coordinated Optimization of Space and Operational Efficiency

[0075] Layout intensification

[0076] The bag filter and air conditioning unit are installed side by side in the machine room (with a spacing of ≤1m), and the supply air duct and return air duct are laid overhead along the wall to achieve system function integration with minimal footprint.

[0077] Ease of maintenance

[0078] All core equipment (dust collectors, air conditioning units, and controllers) are centrally located in the machine room, so maintenance personnel do not need to enter the cleanroom.

[0079] The high-efficiency filter is bolted to an aluminum alloy frame, which supports quick disassembly and replacement, reducing maintenance complexity from a structural perspective.

[0080] IV. Inherent Guarantees for System Reliability and Security

[0081] Connection stability

[0082] The design of pipe flange sealing and rigid connection of equipment steel structure support physically eliminates the risk of gas leakage and equipment displacement.

[0083] Dust monitoring in advance

[0084] The dust concentration sensor is embedded in the wall of the dust collector static pressure box and is directly exposed to the dust-laden airflow channel to ensure real-time detection response. Attached Figure Description

[0085] Figure 1 This is a schematic diagram of the planar layout of this utility model;

[0086] Figure 2 This is a schematic diagram of the structure of this utility model;

[0087] The attached diagram is labeled as follows: 1-Combined cleanroom air conditioning unit; 2-Bag filter; 3-Air supply duct; 4-High-efficiency filter air outlet; 5-Return air duct; 6-Dust removal exhaust hood; 7-Dust removal static pressure box; 8-Dust concentration sensor; 9-Controller; 10-Room temperature and humidity sensor; 11-Mixing section; 12-Primary filter section; 13-Cooling section; 14-Medium-efficiency bag filter section; 110-Fresh air valve; 120-Return air valve; 130-Exhaust valve; 140-Cold and heat source pipeline valve. Detailed Implementation

[0088] The technical solution of this utility model will be clearly and completely described below with reference to the accompanying drawings. In addition, the forms of the various structures described in the following embodiments are merely illustrative. The cleanroom air conditioning dust removal system involved in this utility model is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0089] Reference Figure 1-2 This utility model provides a cleanroom air conditioning dust removal system, including a combined purification air conditioning unit 1, a bag filter 2, an air supply duct network 3, a high-efficiency filter air supply outlet 4, a return air duct network 5, a dust removal exhaust hood 6, and also includes a dust removal static pressure box 7, a dust concentration sensor 8, and a controller 9.

[0090] The bag filter 2 and the combined air conditioning unit 1 are installed together in the machine room;

[0091] The dust removal exhaust hood 6 is connected to the inlet of the dust removal static pressure box 7 via a pipe, and the outlet of the dust removal static pressure box 7 is connected to the inlet 21 of the bag filter 2;

[0092] The outlet of the bag filter 2 is connected to the mixing section 11 of the combined purification air conditioning unit 1 through the return air duct network 5, and is used to transport the dust-removed air to the mixing section 11 as air conditioning return air.

[0093] The dust concentration sensor 8 is installed inside the dust removal static pressure box 7;

[0094] The controller 9 is electrically connected to the dust concentration sensor 8, the room temperature and humidity sensor 10, the fresh air valve 110, the return air valve 120, the exhaust valve 130, and the cold and heat source pipeline valve 140.

[0095] Furthermore, the combined air conditioning unit 1 also includes a primary filter section 12, a surface cooling section 13, and a medium-efficiency bag filter section 14 arranged sequentially along the airflow direction;

[0096] The outlet of the mixing section 11 is sequentially connected to the primary filter section 12, the surface cooling section 13, and the medium-efficiency bag filter section 14. The outlet of the medium-efficiency bag filter section 14 is connected to the high-efficiency filter air outlet 4 through the air supply duct network 3.

[0097] Furthermore, the dust removal and exhaust hood 6 is fixed above the dust-generating point of the process equipment, and its dust suction port faces the dust source.

[0098] The fresh air valve 110 is located at the fresh air inlet of the combined purification air conditioning unit 1; the return air valve 120 is located at the inlet end of the return air duct network 5.

[0099] The exhaust valve 130 is located at the exhaust port of the bag filter 2.

[0100] Furthermore, the bag filter 2 is a centralized dust collector, and its shell is installed side by side with the combined purification air conditioning unit 1 on the floor of the machine room.

[0101] Furthermore, the high-efficiency filter air outlet 4 includes a high-efficiency filter, which is embedded in the air outlet frame.

[0102] The functional structure of this system is analyzed as follows:

[0103] Dust treatment module:

[0104] The dust removal and exhaust hood 6 is fixed directly above the dust generation point of the process equipment and is connected to the inlet of the dust removal static pressure box 7 through a pipeline;

[0105] The outlet of the dust collector static pressure box 7 is directly connected to the inlet 21 of the bag filter 2, and a dust concentration sensor 8 is embedded in its inner wall.

[0106] Air circulation module:

[0107] The outlet of the bag filter 2 is connected to the mixing section 11 of the combined purification air conditioning unit 1 through the return air duct network 5, so that the dust-removed air enters the air conditioning return air system.

[0108] The mixing section 11 is equipped with a fresh air inlet with a fresh air valve 110 and a return air inlet with a return air valve 120, which respectively introduce fresh air and dust removal return air.

[0109] Air purification module:

[0110] The following components are arranged sequentially along the airflow direction inside the modular air conditioning unit 1:

[0111] Primary filter stage 12: filters large particulate pollutants in the mixed air;

[0112] Cooling section 13: Connects to valve 140 of cold and heat source pipelines for cooling and dehumidification;

[0113] Medium-efficiency bag filter section 14: further filters fine particles;

[0114] The outlet of the medium-efficiency section 14 is connected to the high-efficiency filter air outlet 4 through the air supply duct network 3. The high-efficiency filter is embedded in the aluminum alloy frame of the air outlet and fixed to the clean room ceiling with bolts.

[0115] Equipment layout module:

[0116] The bag filter 2 and the combined clean air conditioning unit 1 are installed side by side on the floor of the machine room, and their shells are rigidly connected by a steel structure support.

[0117] The exhaust valve 130 is installed at the exhaust port of the bag filter 2.

[0118] The innovative structural features of this application are as follows:

[0119] Dust removal-air conditioning circuit coupling structure

[0120] Unique return air path: After dust removal, the air is directly delivered to the air mixing section 11 of the air conditioning unit through the return air duct network 5, replacing the traditional exhaust mode and realizing energy recycling from a structural point of view.

[0121] Physical isolation design: Dust collector 2 and air conditioning unit 1 are centrally located in an independent machine room, completely eliminating the interference of equipment heat and noise on the cleanroom.

[0122] Modular connection construction

[0123] Rigid duct connection: Dust removal exhaust hood 6 → dust removal static pressure box 7 → bag filter inlet 21 adopts flange sealing connection to ensure airtightness;

[0124] Valve positioning and installation: Fresh air valve 110, return air valve 120, and exhaust valve 130 are respectively fixed at the fresh air inlet, the return air duct network 5 inlet, and the dust collector exhaust outlet, forming physical control nodes.

[0125] Spatial intensive layout

[0126] Parallel support structure: The bottom of the bag filter 2 and the air conditioning unit 1 are fixed to the machine room floor by anchor bolts, with a distance of ≤1m between them, saving equipment space;

[0127] Integrated duct layout: Supply air duct network 3 and return air duct network 5 are laid overhead along the walls of the machine room to avoid cross-interference.

[0128] The core working principle of this system stems from physical loop reconstruction and device layout optimization.

[0129] Dust collection path:

[0130] Dust from the dust-generating point is captured by the dust collection and exhaust hood 6, then pressurized by the dust collection static pressure box 7, and then filtered by the bag filter 2.

[0131] Air circulation path:

[0132] After dust removal, the clean air is delivered to the air mixing section 11 of the air conditioning unit through the return air duct network 5, mixed with fresh air, and then purified in sequence through the primary filter section 12, the surface cooling section 13, and the medium-efficiency section 14. Finally, it is delivered into the clean room through the high-efficiency filter air outlet 4.

[0133] Energy cycle mechanism:

[0134] Structural energy saving: After dust removal, the air replaces part of the return air, physically reducing the demand for fresh air introduction and reducing the cooling and heating load of the air conditioner on the fresh air.

[0135] Spatial isolation mechanism: Dust collector 2 and air conditioning unit 1 are arranged in a centralized machine room to block the heat and noise of the equipment from entering the clean workshop.

[0136] To achieve dynamic energy-saving optimization, the following control logic can be used:

[0137] Control objective:

[0138] Balancing dust concentration, temperature, humidity, and energy consumption ensures efficient system operation under safe and clean conditions.

[0139] Control unit:

[0140] Input signals: Dust concentration sensor 8 inside the dust removal static pressure box 7, and clean room temperature and humidity sensor 10.

[0141] Actuators: Fresh air valve 110, return air valve 120, exhaust valve 130, cold and heat source pipeline valve 140.

[0142] Decision-making core: Controller 9 receives sensor signals and outputs valve control commands.

[0143] Control strategy:

[0144]

[0145] Safety redundancy design:

[0146] When dust concentration sensor 8 malfunctions, it will be forcibly switched to the excessive operating mode to prioritize cleanliness.

[0147] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change.

[0148] Secondly: The accompanying drawings of the embodiments disclosed in this utility model only involve the structures involved in the embodiments disclosed in this utility model. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this utility model can be combined with each other.

[0149] Finally: The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A cleanroom air conditioning and dust removal system, comprising a combined cleanroom air conditioning unit (1), a bag filter (2), an air supply duct (3), a high-efficiency filter air supply outlet (4), a return air duct (5), and a dust removal and exhaust hood (6), characterized in that: It also includes a dust removal static pressure box (7), a dust concentration sensor (8), and a controller (9); The bag filter (2) and the combined air conditioning unit (1) are installed together in the machine room; The dust removal exhaust hood (6) is connected to the inlet of the dust removal static pressure box (7) through a pipe, and the outlet of the dust removal static pressure box (7) is connected to the inlet (21) of the bag filter (2). The outlet of the bag filter (2) is connected to the mixing section (11) of the combined air conditioning unit (1) through the return air duct network (5). The dust concentration sensor (8) is installed inside the dust removal static pressure box (7); The controller (9) is electrically connected to the dust concentration sensor (8), the room temperature and humidity sensor (10), the fresh air valve (110), the return air valve (120), the exhaust valve (130), and the cold and heat source pipeline valve (140), respectively.

2. The cleanroom air conditioning and dust removal system according to claim 1, characterized in that: The combined air conditioning unit (1) further includes a primary filter section (12), a surface cooling section (13), and a medium-efficiency bag filter section (14) arranged sequentially along the airflow direction. The outlet of the mixing section (11) is connected in sequence to the primary filter section (12), the surface cooling section (13) and the medium-efficiency bag filter section (14), and the outlet of the medium-efficiency bag filter section (14) is connected to the high-efficiency filter air outlet (4) through the air supply network (3).

3. The cleanroom air conditioning and dust removal system according to claim 1, characterized in that: The dust removal and exhaust hood (6) is fixed above the dust-generating point of the process equipment, and its dust suction port faces the dust source.

4. The cleanroom air conditioning and dust removal system according to claim 1, characterized in that: The fresh air valve (110) is located at the fresh air inlet of the combined air conditioning unit (1); the return air valve (120) is located at the inlet of the return air duct (5); and the exhaust valve (130) is located at the exhaust outlet of the bag filter (2).

5. The cleanroom air conditioning and dust removal system according to claim 1, characterized in that: The bag filter (2) is a centralized dust collector, and its shell is installed side by side with the combined air conditioning unit (1) on the floor of the machine room.

6. The cleanroom air conditioning and dust removal system according to claim 1, characterized in that: The high-efficiency filter air outlet (4) includes a high-efficiency filter, which is embedded in the air outlet frame.

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