A novel automatic alkali preparation device

Abstract

This utility model discloses a novel automatic alkali preparation device, relating to the technical field of alkali preparation equipment. The device includes a storage unit (using an alkali material storage tank to store KOH raw materials, a pure water tank, and an alkali solution tank to store the prepared 30% alkali solution), an automatic feeding unit (using PLC for precise quantity control to automatically feed caustic soda flakes and pure water), a solution preparation unit (using an alkali solution preparation tank and a stirring mechanism as auxiliary structures for alkali preparation), a conveying unit (including pumps, pipes, and valves for material transfer), and a control unit (using PLC for parameter control and monitoring). The PLC controls the quantitative feeding of caustic soda flakes and pure water into the alkali solution preparation tank, preparing a 30% alkali solution according to the monitoring data. The prepared alkali solution is then output to the alkali solution tank for storage. This utility model achieves automated and precise alkali preparation, improves efficiency and quality, reduces labor costs and operational risks, and is suitable for various alkali preparation scenarios, contributing to production optimization and upgrading.

Description

Technical Field

[0001] This utility model relates to the technical field of alkali production equipment, specifically to a novel automatic feeding alkali preparation device, which is used to achieve automated and precise control of the alkali preparation process, thereby improving the efficiency and quality of alkali preparation. Background Technology

[0002] In chemical production and other fields, it is often necessary to prepare alkali solutions of specific concentrations. Traditional alkali preparation methods rely heavily on manual control of the dosage and water volume, which can easily lead to large fluctuations in the concentration of the prepared alkali solution, affecting the subsequent process effect. Moreover, the manual addition and stirring dissolution homogenization process is time-consuming and cannot meet the needs of continuous production. Furthermore, alkali materials (caustic soda flakes) are highly corrosive, and manual addition can easily lead to the risk of burns to personnel, making the safety too low.

[0003] Given that the aforementioned problems make it difficult to meet the requirements of modern production for precision, stability, and safety, there is an urgent need for a highly automated alkali mixing device with precise solution preparation. Utility Model Content

[0004] Purpose of the utility model: Through PLC-based fully automated control, the automatic and precise addition of alkali feed and pure water, and the automatic preparation and delivery of alkali solution are achieved, thereby improving the automation level, solution preparation accuracy, and production efficiency of the alkali preparation process and reducing the risks associated with manual intervention.

[0005] To address the aforementioned problems, this utility model proposes a novel automatic alkali preparation device, aiming to provide an automated, safe, and efficient alkali preparation system that enables the automatic addition, dissolution, and storage of caustic soda flakes. The specific technical solution is as follows:

[0006] A novel automatic alkali feeding device includes:

[0007] The storage unit includes an alkali storage tank, a pure water tank, and an alkali solution tank. The alkali storage tank is equipped with a material level monitoring device, the pure water tank is equipped with a water level monitoring device, and the alkali solution tank is equipped with a liquid level sensor.

[0008] The solution preparation unit includes an alkali preparation tank, which is equipped with a stirring mechanism driven by a motor and a liquid level sensor.

[0009] An automatic feeding unit includes a metering and feeding component for automatically feeding alkali from an alkali storage tank and pure water from a pure water tank into an alkali solution preparation tank, respectively; the metering and feeding component includes an alkali metering and feeding component disposed between the alkali storage tank and the alkali solution tank and a pure water metering and feeding component disposed between the pure water tank and the alkali solution tank.

[0010] The conveying unit includes an alkali output pipe, an output pump, and an alkali tank. The alkali output end of the alkali preparation tank is connected to the alkali tank through the alkali output pipe and the output pump.

[0011] The control unit includes a metering and feeding control system, which receives signals from various sensors and controls the actions of various actuators to achieve precise control of the amount of alkali and pure water fed.

[0012] Preferably, the alkali material is KOH flakes.

[0013] Preferably, the metering and feeding control system is a PLC control system.

[0014] Preferably, in the control unit, the metering and feeding control system automatically controls the feeding timing, feeding amount, stirring start and stop, and conveying and mixing actions according to a preset program, so as to realize the automated closed-loop control of the alkali preparation process.

[0015] The above-mentioned method involves equipping the alkali preparation tank of the solution preparation unit with a stirring mechanism (such as an anchor-type stirring paddle), which is driven by a motor to rotate the stirring paddle, thereby accelerating the dissolution of the alkali solution.

[0016] In this invention, the alkali storage tank of the storage unit includes a material level monitoring device, which can provide real-time feedback on the alkali discharge and remaining amount, facilitating timely replenishment. The alkali storage tank has a certain capacity, allowing for on-demand storage, and is equipped with a corresponding discharge structure to facilitate the orderly discharge of caustic soda flakes, providing a raw material reserve basis for automatic feeding.

[0017] Preferably, the storage unit is also equipped with a temperature sensor and a concentration monitoring sensor, the solution preparation unit is also equipped with a temperature sensor and a concentration monitoring sensor, the metering and feeding control system is equipped with a human-machine interface, and the alkali tank is also equipped with a return branch connected to the alkali preparation tank.

[0018] In this invention, the alkali tank is used to store the prepared 30% alkali solution. The tank is equipped with a liquid level sensor, a temperature sensor, and a concentration monitoring sensor to monitor the liquid level, temperature, and concentration in real time.

[0019] In this invention, the reflux branch can realize the circulation of alkali solution, thereby maintaining the stability of pressure and concentration in the alkali solution preparation tank.

[0020] In this invention, the pure water metering and dispensing component of the metering and dispensing assembly includes a water supply pipeline disposed between the pure water tank and the alkali preparation tank, a solenoid valve and a flow meter respectively disposed on the water supply pipeline and connected to the metering and dispensing control system.

[0021] In this invention, the pure water tank of the storage unit contains a water level monitoring device, which can provide real-time feedback on the output and remaining water volume of pure water, facilitating timely water replenishment. The pure water tank supplies pure water to the alkali solution preparation tank through a water supply pipeline. A solenoid valve and a flow meter are installed on the water supply pipeline, and the water supply volume is regulated by a PLC control system.

[0022] In this invention, the alkali metering and dispensing component of the metering and feeding assembly includes an alkali discharge pipe disposed between the alkali storage tank and the alkali preparation tank, and a solenoid valve disposed on the alkali discharge pipe. The alkali in the alkali storage tank is discharged by gravity settling, which utilizes the weight of the alkali itself to allow it to slide out of the alkali discharge pipe and enter the alkali preparation tank. Alternatively, the alkali in the alkali storage tank is discharged by vacuum suction, which utilizes a vacuum suction device disposed on the alkali discharge pipe to draw the alkali from the alkali storage tank into the alkali discharge pipe and into the alkali preparation tank.

[0023] In the above-mentioned metering and feeding components, by setting up a pure water metering and feeding component and an alkali metering and feeding component, the inlet of the alkali preparation tank in the solution preparation unit is connected to the pure water tank, the inlet of the alkali preparation tank is connected to the alkali storage tank, and the outlet of the alkali preparation tank is connected to the alkali tank.

[0024] When the alkali material in the alkali material storage tank is discharged by gravity settling, the bottom surface of the alkali material storage tank is inclined so that the alkali material can naturally settle and slide towards the discharge port inside the alkali material storage tank.

[0025] The outlet of the alkali storage tank is located at the lowest end of the inclined surface. With the help of control devices such as electromagnetic valves, the alkali can flow out automatically under gravity after the valve is opened, thus completing the feeding process.

[0026] In this invention, the alkali tank of the storage unit is used to store the prepared 30% alkali solution. The tank is equipped with a level monitoring device (liquid level sensor), a temperature sensor, and a concentration monitoring sensor to monitor the liquid level, temperature, and alkali concentration in the tank in real time.

[0027] In this invention, the top of the alkali tank is connected to the outlet of the alkali preparation tank via an alkali output pipe, and the bottom outlet of the alkali tank is provided with an alkali delivery pipeline leading to the electrolytic cell.

[0028] Preferably, when the alkali material in the alkali material storage tank is discharged by gravity settling, the alkali material storage tank is placed on the ground, and the alkali solution preparation tank and pure water tank are set on the ground.

[0029] When the alkali material in the above-mentioned alkali material storage tank is discharged by gravity settling, the caustic soda flakes fall with the help of ground potential energy, and pure water is transported from the pure water tank in the settling area to the alkali solution preparation tank in the settling area by a pure water pump. The combination of gravity potential energy and space enables the alkali material and pure water to be fed together, reducing the energy consumption of intermediate transportation links.

[0030] In this invention, the alkaline solution output pipeline of the conveying unit is equipped with a flow regulating valve, which is an electromagnetic valve.

[0031] The above-mentioned method involves installing a flow regulating valve on the alkali output pipeline. Combined with downstream demand, a PLC control system controls the flow and pressure to precisely allocate the alkali delivery volume. If the downstream process does not require a large amount of alkali, a reflux branch can be configured to ensure alkali circulation within the system, maintaining stable pressure and concentration.

[0032] In this invention, an alkali weighing sensor is installed at the lower end of the alkali storage tank, and a pure water weighing sensor is installed at the lower end of the pure water tank.

[0033] This invention, through the aforementioned automatic alkali feeding and mixing device, automates the alkali mixing process, significantly improving mixing accuracy and ensuring stable alkali concentration. Compared to manual operation, it effectively reduces concentration deviation, improves product quality consistency, and meets the stringent quality requirements of the chemical and other industries. It also reduces labor intensity and costs, and lowers the probability of production failures. Furthermore, the entire alkali mixing process is recorded, facilitating traceability, analysis, and optimization, thus helping enterprises continuously improve production processes and enhance production management.

[0034] As a further improvement of this utility model, the stirring mechanism in the solution preparation unit is a magnetic levitation ultrasonic homogenizing and dispersing stirring mechanism. The magnetic levitation ultrasonic homogenizing and dispersing stirring mechanism includes a stirring motor fixed to the alkali preparation tank by a motor mounting flange, a non-contact magnetic levitation coupling connected to the motor shaft of the stirring motor, an ultrasonic transducer connected to the lower end of the magnetic levitation coupling, a stirring shaft fixed to the lower end of the ultrasonic transducer and inserted below the liquid surface of the alkali preparation tank, and an anchor-type stirring paddle set at the lower end of the stirring shaft.

[0035] Preferably, a number of ultrasonic expansion auxiliary fins for expanding and transmitting ultrasonic energy are arranged circumferentially at intervals at the lower end of the stirring shaft near the anchor-type stirring paddle. The ultrasonic expansion auxiliary fins are flat fins perpendicular to the motor shaft.

[0036] When the ultrasonic transducer is working, its ultrasonic vibration energy is transferred through the ultrasonic expansion auxiliary fins to the alkaline solution in the chamber over a large area, which accelerates the diffusion of ultrasonic vibration energy into the alkaline solution. Combined with the stirring of the anchor-type stirring paddle, it greatly improves the speed of homogenization of caustic soda flakes in the alkaline solution and improves production efficiency.

[0037] Preferably, the stirring motor is a dual-shaft extension motor, the lower end of which is provided with a motor mounting flange, the motor shaft of which is a hollow motor shaft, the lower end of which is a long extension shaft extending downward from the motor mounting flange, and the upper end of which is a short output shaft extending upward from the top of the motor housing. The magnetic levitation coupling includes an inner rotor fixed on the long extension shaft, an outer rotor sleeved on the outer circle of the inner rotor and having a circumferential air gap between them, and an axial magnetic levitation assembly disposed between the lower end of the motor mounting flange of the stirring motor and the outer circle of the outer rotor for axially suspending the outer rotor in a magnetic levitation manner. The ultrasonic transducer is connected to the lower end of the outer rotor, and a conductive slip ring is provided at the end of the short output shaft. After the conductive rod of the ultrasonic transducer passes through the hollow motor shaft, the upper end of the conductive rod is connected to the lower end of the conductive slip ring through a section of retractable spring helical wire.

[0038] Preferably, the inner rotor is sleeved on the outer circle of the long extension shaft at the lower end of the dual-shaft extension motor, and axial positioning is achieved by elastic retaining rings or nuts. The long extension shaft and the inner rotor are connected by a key to achieve circumferential torque transmission.

[0039] In this invention, the outer circumference of the inner rotor facing the outer rotor is provided with N-pole permanent magnets and S-pole permanent magnets arranged alternately along the circumference, and the inner wall of the outer rotor facing the inner rotor is provided with N-pole permanent magnets and S-pole permanent magnets arranged alternately along the circumference.

[0040] By setting N-pole permanent magnets and S-pole permanent magnets alternately arranged along the circumference on the inner and outer rotors, the magnetic driving force of the inner rotor on the outer rotor can be realized when the inner rotor rotates, thereby driving the rotation of the outer rotor.

[0041] Preferably, the axial magnetic levitation assembly includes an upper annular magnet, a middle annular magnet, and a lower annular magnet arranged around the outer rotor and spaced apart in a top-to-bottom order. The upper annular magnet is fixed to the lower end of the motor mounting flange, the middle annular magnet is fixedly connected to the outer circle of the outer rotor, and the lower annular magnet is disposed on a magnet bracket, which is fixedly connected to the lower end of the motor mounting flange.

[0042] Preferably, the intermediate annular magnet is sleeved on the outer circle of the step on the upper part of the outer rotor and is axially fixed by an elastic retaining ring.

[0043] Preferably, the axial magnetic levitation assembly is a self-centering axial magnetic levitation assembly capable of automatic centering, and the self-centering axial magnetic levitation assembly includes an upper V-shaped gap fitting pair disposed between the upper annular magnet and the middle annular magnet.

[0044] Preferably, the self-centering axial magnetic levitation assembly further includes a lower V-shaped gap fitting pair disposed between the lower annular magnet and the middle annular magnet.

[0045] The aforementioned upper V-shaped gap fit pair is formed by setting the gap fit between the upper annular magnet and the middle annular magnet as one of the V-shaped protrusions and the other of the V-shaped concave.

[0046] The aforementioned lower V-shaped gap fit pair is formed by setting one of the gap fit parts between the lower annular magnet and the middle annular magnet as a V-shaped protrusion and the other as a V-shaped concave.

[0047] In this design, the lower V-shaped magnetic pole of the intermediate annular magnet and the V-shaped magnetic pole of the lower annular magnet that cooperate with it repel each other, while the upper V-shaped magnetic pole of the intermediate annular magnet and the V-shaped magnetic pole of the upper annular magnet that cooperate with it attract each other. The sum of their upward magnetic forces balances the downward gravity of the outer rotor components (including the ultrasonic transducer and the anchor-type stirring paddle suspended below), thereby forming axial suspension and achieving automatic centering through the V-shaped gap fit pair.

[0048] The advantages of mounting the ultrasonic transducer on the magnetic levitation coupling are: the ultrasonic transducer does not contact the motor shaft or the alkali preparation tank, and all its ultrasonic energy is applied to the alkali solution, thus overcoming the large loss of ultrasonic energy caused by the traditional ultrasonic transducer needing to be fixed to the tank wall. This further improves the ultrasonic homogenization effect of KOH caustic soda in the alkali solution, greatly shortens the time for alkali dissolution and homogenization, and further improves production efficiency.

[0049] A novel alkali preparation method for an automated alkali feeding device includes the following steps:

[0050] (1) Pure water addition: The metering and feeding control system adds pure water to the alkali preparation tank through the pure water metering and addition component in the automatic feeding unit, and first uses the liquid level sensor on the alkali preparation tank to make the pure water reach the specified liquid level according to the preset alkali concentration and total amount of solution.

[0051] (2) Alkali addition: After the pure water is added, the metering and feeding control system adds alkali to the alkali preparation tank through the alkali metering and feeding component in the automatic feeding unit, and calculates and accurately adds alkali with the help of the weighing sensor set on the alkali storage tank.

[0052] The alkali material in the alkali storage tank is discharged by gravity settling or by vacuum suction.

[0053] The alkali preparation method of the novel automatic feeding alkali preparation device of this utility model also includes the following steps after the alkali feeding in step (2):

[0054] (3) Alkali stirring and homogenization: Turn on the magnetic levitation ultrasonic homogenization and dispersion stirring mechanism on the alkali preparation box. The ultrasonic vibration energy of the ultrasonic transducer is transmitted to the alkali in the box through the ultrasonic extension auxiliary fins set on the stirring shaft, which are in large-area contact with the alkali. This accelerates the diffusion of ultrasonic vibration energy into the alkali. Combined with the stirring of the anchor-type stirring paddle, the caustic soda flakes in the alkali are dissolved and homogenized more quickly.

[0055] Preferably, the metering and feeding control system uses a PLC to control the pump drive and uses a solenoid valve to adjust the quantitative delivery of caustic soda flakes and pure water. The delivery volume is adjusted by the PLC control system according to the required caustic soda concentration.

[0056] Preferably, the metering and feeding control system acquires the state parameters of the alkali solution in the alkali solution preparation tank in real time through the liquid level sensor, temperature sensor and concentration monitoring sensor of the solution preparation unit, and dynamically adjusts the preparation process.

[0057] In this invention, the metering and feeding control system realizes automated closed-loop control of the alkali preparation process through PLC. It collects data in real time through concentration monitoring sensors, liquid level sensors, and temperature sensors installed on the alkali preparation tank and alkali tank. It also sets parameters, monitors operating status, records production data, and alarms faults through a human-machine interface.

[0058] Preferably, the metering and feeding control system sets upper and lower limit alarm thresholds for parameters such as concentration, liquid level, and temperature, and automatically interlocks to start and stop the equipment when the alarm thresholds are exceeded.

[0059] In this invention, the metering and feeding control system is used to control the amount of material fed, the amount of water fed, the speed of the agitator, the start and stop of the pump, and the flow rate.

[0060] The beneficial effects of this utility model are:

[0061] First, it has a high degree of automation: the entire process is controlled by PLC, which reduces manual operation, lowers labor intensity, improves production efficiency, and enables continuous and stable alkali preparation.

[0062] Second, high solution preparation accuracy: By accurately metering and feeding materials, monitoring solution parameters in real time and providing feedback for adjustment, the concentration of alkali solution is ensured to be accurate, meeting the strict requirements of the production process for the quality of alkali solution.

[0063] Third, it has good safety: it reduces the number of manual contacts with alkali materials and alkali solutions, thereby reducing the safety risks such as chemical burns. In addition, the system's operating status is monitored in real time, and abnormal situations can be automatically alarmed and intervened.

[0064] Fourth, data-driven management: By using the control system to record production data, production traceability and process optimization are facilitated, helping enterprises achieve refined management.

[0065] Fifth, clean, environmentally friendly and energy-saving: closed conveying reduces dust from alkali materials and pollution to the environment; the inclined design of the alkali material storage tank and the ground potential energy allow the caustic soda flakes to slide down naturally, resulting in good energy efficiency.

[0066] Sixth, reduced energy consumption: The alkali storage tank is placed on the ground, utilizing the gravitational potential energy generated by its own height, combined with the inclined bottom design, to naturally transport caustic soda flakes to the alkali solution preparation tank below, requiring no additional power, simplifying the caustic soda flake feeding process and saving energy; the pure water tank and alkali solution preparation tank are submerged, reducing the ground space occupied, suitable for scenarios with limited space, and facilitating connection with other underground pipelines. The submerged design can utilize the liquid level difference to assist water intake; when water is replenished from the outside, it can flow into the water tank by gravity, reducing pumping energy consumption.

[0067] Seventh, high production efficiency: The stirring mechanism in the solution preparation unit adopts a specially designed magnetic levitation ultrasonic homogenization and dispersion stirring mechanism. Through the special structure of the self-centering axial magnetic levitation component, it can be ensured that the outer rotor does not contact the inner rotor when rotating, realizing the non-contact suspension of the ultrasonic transducer and the anchor-type stirring paddle at the lower end of the motor shaft. This allows the ultrasonic energy to be fully applied to the alkali solution, avoiding the ineffective consumption of ultrasonic energy, which is conducive to accelerating the dissolution and homogenization of caustic soda flakes in the solution, thereby greatly improving the quality and efficiency of caustic soda flakes dissolving and homogenizing in the alkali solution. Attached Figure Description

[0068] Figure 1 This is a schematic diagram of the structure of a novel automatic feeding alkali preparation device according to this utility model;

[0069] Figure 2 This is a schematic diagram of the structure of a magnetic levitation ultrasonic homogenization and dispersion stirring mechanism;

[0070] Figure 3 yes Figure 2 A magnified view of a portion of the view;

[0071] Figure 4 yes Figure 3 The image shows a cross-sectional view (top view) of the inner and outer rotor sections.

[0072] In the diagram: 1. Alkali storage tank; 2. Pure water tank; 3. Alkali solution tank; 4. Material level monitoring device; 5. Water level monitoring device; 6. Liquid level sensor; 7. Alkali solution preparation tank; 8. Alkali solution output pipeline; 9. Output pump; 10. Anchor-type stirring paddle; 11. Temperature sensor; 12. Concentration monitoring sensor; 13. Return branch; 14. Water supply pipeline; 15. Solenoid valve; 16. Flow meter; 17. Alkali discharge pipe; 18. Alkali solution delivery pipeline; 19. Flow regulating valve; 20. Alkali weighing sensor; 21. Pure water weighing sensor; 22. Pure water pump; 23. Stirring mechanism; 24. Stirring motor; 25. Motor shaft; 26. 27. Magnetic levitation coupling; 28. Ultrasonic transducer; 29. ​​Stirring shaft; 30. Anchor-type stirring paddle; 31. Ultrasonic extended auxiliary fins; 32. Long extension shaft; 33. Short output shaft; 34. Inner rotor; 35. Circumferential air gap; 36. Outer rotor; 37. Motor mounting flange; 38. Axial magnetic levitation assembly; 39. Conductive slip ring; 40. Conductive rod; 41. Upper annular magnet; 42. Middle annular magnet; 43. Lower annular magnet; 44. Magnet bracket; 45. Upper V-type clearance fit pair; 46. Lower V-type clearance fit pair; 47. Motor mounting flange; 48. Slip ring bracket; 49. Telescopic spring helical wire.

[0073] In the diagram: A represents the N-pole permanent magnets and S-pole permanent magnets arranged alternately along the circumference at the outer circumference of the inner rotor; B represents the N-pole permanent magnets and S-pole permanent magnets arranged alternately along the circumference at the inner wall of the outer rotor. Detailed Implementation

[0074] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings and examples. The following examples are only used to more clearly illustrate the technical solution of this utility model and should not be construed as limiting the scope of protection of this utility model.

[0075] Example 1:

[0076] like Figures 1 to 4 The image shows an embodiment of a novel automatic alkali feeding device according to this utility model, comprising:

[0077] The storage unit is equipped with an alkali storage tank 1, a pure water tank 2 and an alkali solution tank 3. The alkali storage tank 1 is equipped with a material level monitoring device 4, the pure water tank 2 is equipped with a water level monitoring device 5, and the alkali solution tank 3 is equipped with a liquid level sensor 6.

[0078] The solution preparation unit is equipped with an alkali preparation tank 7, which is equipped with a stirring mechanism 23 driven by a motor and a liquid level sensor 6.

[0079] An automatic feeding unit includes a metering feeding component for automatically feeding alkali from the alkali storage tank 1 and pure water from the pure water tank 2 into the alkali solution preparation tank 7, respectively; the metering feeding component includes an alkali metering feeding component disposed between the alkali storage tank 1 and the alkali solution tank 3 and a pure water metering feeding component disposed between the pure water tank 2 and the alkali solution tank 3.

[0080] The conveying unit includes an alkali output pipe 8, an output pump 9, and an alkali tank 3. The alkali output end of the alkali preparation tank 7 is connected to the alkali tank 3 through the alkali output pipe 8 and the output pump 9.

[0081] The control unit includes a metering and feeding control system, which receives signals from various sensors and controls the actions of various actuators to achieve precise control of the amount of alkali and pure water fed.

[0082] Preferably, the alkali material is KOH flakes.

[0083] Preferably, the metering and feeding control system is a PLC control system.

[0084] Preferably, in the control unit, the metering and feeding control system automatically controls the feeding timing, feeding amount, stirring start and stop, and conveying and mixing actions according to a preset program, so as to realize the automated closed-loop control of the alkali preparation process.

[0085] The above-mentioned method uses a stirring mechanism (such as an anchor-type stirring paddle 10) in the alkali preparation tank of the solution preparation unit to accelerate the dissolution of alkali. The stirring paddle is driven by a motor to rotate.

[0086] In this embodiment, the alkali storage tank 1 of the storage unit includes a material level monitoring device 4, which can provide real-time feedback on the alkali discharge and remaining amount, facilitating timely replenishment. The alkali storage tank 1 has a certain capacity, allowing for storage as needed, and is equipped with a corresponding discharge structure to facilitate the orderly discharge of caustic soda flakes, providing a raw material reserve basis for automatic feeding.

[0087] Preferably, the storage unit is also equipped with a temperature sensor 11 and a concentration monitoring sensor 12, the solution preparation unit is also equipped with a temperature sensor 11 and a concentration monitoring sensor 12, the metering and feeding control system is equipped with a human-machine interface, and the alkali tank 3 is also equipped with a return branch 13 connected to the alkali preparation tank 7.

[0088] In this embodiment, the alkali tank 3 is used to store the prepared 30% alkali solution. The tank is equipped with a liquid level sensor 6, a temperature sensor 11, and a concentration monitoring sensor 12 to monitor the liquid level, temperature, and concentration in real time.

[0089] In this embodiment, the reflux branch 13 can realize the circulation of alkali solution, thereby maintaining the stability of pressure and concentration in the alkali solution preparation tank.

[0090] In this embodiment, the pure water metering and dispensing component in the metering and dispensing assembly includes a water supply pipeline 14 disposed between the pure water tank 2 and the alkali preparation tank 7, a solenoid valve 15 disposed on the water supply pipeline 14 and connected to the metering and dispensing control system, and a flow meter 16.

[0091] In this embodiment, the pure water tank 2 of the storage unit contains a water level monitoring device 5, which can provide real-time feedback on the pure water output and remaining water volume, facilitating timely water replenishment. The pure water tank 2 supplies pure water to the alkali solution preparation tank 7 through a water supply pipeline 14. A solenoid valve 15 and a flow meter 16 are installed on the water supply pipeline 14, and the water supply volume is regulated by a PLC control system.

[0092] In this embodiment, the alkali metering and dispensing component of the metering and feeding assembly includes an alkali discharge pipe 17 disposed between the alkali storage tank 1 and the alkali preparation tank 7, and a solenoid valve 15 disposed on the alkali discharge pipe 17. The alkali in the alkali storage tank 1 is discharged by gravity settling, which uses the weight of the alkali itself to make it slide out of the alkali discharge pipe 17 and enter the alkali preparation tank 7. Alternatively, the alkali in the alkali storage tank 1 is discharged by vacuum suction, which uses a vacuum suction device (not shown in the figure) disposed on the alkali discharge pipe 17 to suck the alkali from the alkali storage tank 1 into the alkali discharge pipe 17 and into the alkali preparation tank 7.

[0093] In the above-mentioned metering and feeding components, by setting up a pure water metering and feeding component and an alkali metering and feeding component, the inlet of the alkali preparation tank 7 in the solution preparation unit is connected to the pure water tank 2, the inlet of the alkali preparation tank 7 is connected to the alkali storage tank 1, and the outlet of the alkali preparation tank 7 is connected to the alkali tank 3.

[0094] When the alkali material in the alkali material storage tank 1 is discharged by gravity settling, the bottom surface of the alkali material storage tank 1 is inclined so that the alkali material can naturally settle and slide towards the discharge port in the alkali material storage tank 1.

[0095] The outlet of the alkali storage tank 1 is located at the lowest end of the inclined surface. With the help of control devices such as electromagnetic valves, the alkali can flow out automatically under gravity after the valve is opened, thus completing the feeding process.

[0096] In this embodiment, the alkali tank 3 of the storage unit is used to store the prepared 30% alkali solution. A level monitoring device (liquid level sensor 6), a temperature sensor 11, and a concentration monitoring sensor 12 are installed inside the tank to monitor the liquid level, temperature, and alkali concentration in the alkali tank 3 in real time.

[0097] In this embodiment, the top of the alkali tank 3 is connected to the outlet of the alkali preparation tank 7 via an alkali output pipe 8, and the bottom outlet of the alkali tank 3 is provided with an alkali delivery pipe 18 leading to the electrolytic cell.

[0098] Preferably, when the alkali material in the alkali material storage tank 1 is discharged by gravity settling, the alkali material storage tank 1 is placed on the ground, and the alkali solution preparation tank 7 and the pure water tank 2 are set on the ground.

[0099] When the alkali material in the alkali storage tank 1 is discharged by gravity settling, the caustic soda flakes fall with the help of ground potential energy, and pure water is transported from the pure water tank 2 on the ground to the alkali solution preparation tank 7 on the ground by the pure water pump 22. The combination of gravity potential energy and space realizes the coordinated feeding of alkali material and pure water, reducing the energy consumption of intermediate transportation links.

[0100] In this embodiment, a flow regulating valve 19 is provided on the alkali output pipeline 8 of the conveying unit, and the flow regulating valve 19 is an electromagnetic valve.

[0101] The above-mentioned flow regulating valve 19 is installed on the alkali output pipeline 8. Combined with the downstream demand, the flow rate and pressure are controlled by the PLC control system to accurately adjust the alkali delivery volume. If the downstream does not require a large amount of alkali, a return branch 13 can be configured to ensure the circulation of alkali within the system and maintain stable pressure and concentration.

[0102] In this embodiment, an alkali weighing sensor 20 is provided at the lower end of the alkali storage tank 1, and a pure water weighing sensor 21 is provided at the lower end of the pure water tank 2.

[0103] This embodiment automates the alkali preparation process using the aforementioned automatic feeding and mixing device, significantly improving batching accuracy and ensuring stable alkali concentration. Compared to manual operation, it effectively reduces concentration deviations, enhances product quality consistency, and meets the stringent quality requirements of the chemical and other industries. It also reduces labor intensity and costs, and lowers the probability of production failures. Furthermore, the entire alkali preparation process is recorded, facilitating traceability, analysis, and optimization, thus helping companies continuously improve their production processes and enhance production management.

[0104] As a further improvement of this embodiment, the stirring mechanism 23 in the solution preparation unit is a magnetic levitation ultrasonic homogenizing and dispersing stirring mechanism. The magnetic levitation ultrasonic homogenizing and dispersing stirring mechanism includes a stirring motor 24 fixed to the alkali preparation tank 7 via a motor mounting flange 36, a non-contact magnetic levitation coupling 26 connected to the motor shaft 25 of the stirring motor 24, an ultrasonic transducer 27 connected to the lower end of the magnetic levitation coupling 26, a stirring shaft 28 fixed to the lower end of the ultrasonic transducer 27 and inserted below the liquid surface of the alkali preparation tank 7, and an anchor-type stirring paddle 29 disposed at the lower end of the stirring shaft 28.

[0105] Preferably, a number of ultrasonic expansion auxiliary fins 30 for expanding and transmitting ultrasonic energy are arranged circumferentially at intervals at the lower end of the stirring shaft 28 near the anchor-type stirring paddle 29. The ultrasonic expansion auxiliary fins 30 are flat fins perpendicular to the motor shaft 25.

[0106] When the ultrasonic transducer 27 is working, its ultrasonic vibration energy is transferred to the alkaline solution in the chamber through the ultrasonic extension auxiliary fins 30, which makes large-area contact with the alkaline solution. This accelerates the diffusion of ultrasonic vibration energy into the alkaline solution. Combined with the stirring of the anchor-type stirring paddle 29, it greatly improves the speed of homogenization of caustic soda flakes in the alkaline solution and improves production efficiency.

[0107] Preferably, the stirring motor 24 is a dual-shaft extension motor, with a motor mounting flange 36 at its lower end. The motor shaft 25 of the dual-shaft extension motor is a hollow motor shaft, with a long extension shaft 31 extending downward from the motor mounting flange 36 at its lower end and a short output shaft 32 extending upward from the top of the motor housing at its upper end. The magnetic levitation coupling 26 includes an inner rotor 33 fixed on the long extension shaft 31 and an outer rotor 33 sleeved on the outer circle of the inner rotor 33, with a circumferential air gap between the outer circle of the inner rotor 33 and the outer circle of the inner rotor 33. 5. An axial magnetic levitation assembly 37 is provided between the lower end of the motor mounting flange 36 of the stirring motor 24 and the outer circle of the outer rotor 35 for axially suspending the outer rotor 35 in a magnetic levitation manner. The ultrasonic transducer 27 is connected to the lower end of the outer rotor 35. A conductive slip ring 38 is provided at the end of the short output shaft 32. After the conductive rod 39 of the ultrasonic transducer 27 passes through the hollow motor shaft 25, the upper end of the conductive rod 39 is connected to the lower end of the conductive slip ring 38 through a section of retractable spring spiral wire 48.

[0108] Preferably, the inner rotor 33 is sleeved on the outer circle of the long extension shaft 31 at the lower end of the dual-shaft extension motor, and axial positioning is achieved by elastic retaining rings or nuts. The long extension shaft 31 and the inner rotor 33 are connected by a key to achieve circumferential torque transmission.

[0109] In this embodiment, the outer circumference of the inner rotor 33 facing the outer rotor 35 is provided with N-pole permanent magnets and S-pole permanent magnets A arranged alternately in the circumferential direction, and the inner wall of the outer rotor 35 facing the inner rotor 33 is provided with N-pole permanent magnets and S-pole permanent magnets B arranged alternately in the circumferential direction.

[0110] By setting N-pole permanent magnets and S-pole permanent magnets alternately arranged along the circumference on the inner rotor 33 and the outer rotor 35, the magnetic driving effect of the inner rotor 33 on the outer rotor 35 can be realized when the inner rotor 33 rotates, thereby driving the rotation of the outer rotor 35.

[0111] Preferably, the axial magnetic levitation assembly 37 includes an upper annular magnet 40, a middle annular magnet 41, and a lower annular magnet 42 arranged around the outer rotor 35 in a top-to-bottom order. The upper annular magnet 40 is fixed to the lower end of the motor mounting flange 36. The middle annular magnet 41 is fixedly connected to the outer circle of the outer rotor 35. The lower annular magnet 42 is disposed on a magnet bracket 43, which is fixedly connected to the lower end of the motor mounting flange 36.

[0112] Preferably, the intermediate annular magnet 41 is sleeved on the outer circle of the step on the upper part of the outer rotor 35 and is axially fixed by an elastic retaining ring.

[0113] Preferably, the axial magnetic levitation assembly 37 is a self-centering axial magnetic levitation assembly capable of automatic centering, and the self-centering axial magnetic levitation assembly 37 includes an upper V-shaped gap fit pair 44 disposed between the upper annular magnet 40 and the middle annular magnet 41.

[0114] Preferably, the self-centering axial magnetic levitation assembly 37 further includes a lower V-shaped gap fitting pair 45 disposed between the lower annular magnet 42 and the middle annular magnet 41.

[0115] The aforementioned upper V-shaped gap fit pair 44 is formed by setting the gap fit portion between the upper annular magnet 40 and the middle annular magnet 41 as one of the V-shaped protrusions and the other of the V-shaped concave.

[0116] The aforementioned lower V-shaped gap fit pair 45 is formed by setting the gap fit between the lower annular magnet 42 and the middle annular magnet 41 as one of the V-shaped protrusions and the other of the V-shaped concave.

[0117] In this configuration, the lower V-shaped magnetic pole of the intermediate annular magnet 41 and the V-shaped magnetic pole of the lower annular magnet 42 that cooperate with it repel each other due to their similar polarities. The upper V-shaped magnetic pole of the intermediate annular magnet 41 and the V-shaped magnetic pole of the upper annular magnet 40 that cooperate with it due to their opposite polarities attract each other. The sum of their upward magnetic forces balances the downward gravity of the outer rotor 35 component (including the ultrasonic transducer 27 and the anchor-type stirring paddle 29 suspended below), thereby forming axial suspension and achieving automatic centering through the V-shaped gap fitting pairs 44 and 45.

[0118] The technical advantage of mounting the ultrasonic transducer 27 on the magnetic levitation coupling 26 is that the ultrasonic transducer 27 does not contact the motor shaft 25 or the alkali preparation tank 7. All of its ultrasonic energy is applied to the alkali solution, thus overcoming the large loss of ultrasonic energy caused by the traditional ultrasonic transducer 27 needing to be fixed to the tank wall. This further improves the ultrasonic homogenization effect of KOH caustic soda in the alkali solution, greatly shortens the time for alkali dissolution and homogenization, and further improves production efficiency.

[0119] Example 2:

[0120] A method for preparing alkali using a novel automatic feeding alkali preparation device according to Example 1 includes the following steps:

[0121] (1) Pure water addition: The metering and feeding control system adds pure water to the alkali preparation tank 7 through the pure water metering and addition component in the automatic feeding unit, and first uses the liquid level sensor 6 on the alkali preparation tank 7 to make the pure water reach the specified liquid level according to the preset alkali concentration and total liquid volume.

[0122] (2) Alkali feeding: After the pure water is fed, the metering and feeding control system feeds alkali into the alkali preparation tank 7 through the alkali metering and feeding component in the automatic feeding unit, and calculates and accurately feeds alkali with the help of the weighing sensor set on the alkali storage tank 1.

[0123] The alkali material in the alkali storage tank 1 is discharged by gravity settling or by vacuum suction.

[0124] The alkali preparation method of the novel automatic feeding alkali preparation device in this embodiment also includes the following steps after the alkali feeding in step (2):

[0125] (3) Alkali solution stirring and homogenization: Turn on the magnetic levitation ultrasonic homogenization and dispersion stirring mechanism 23 on the alkali solution preparation box 7, and transfer the ultrasonic vibration energy of the ultrasonic transducer 27 to the alkali solution in the box through the ultrasonic extension auxiliary fins 30 set on the stirring shaft 28, thereby accelerating the diffusion of ultrasonic vibration energy into the alkali solution. Combined with the stirring of the anchor stirring paddle 29, the caustic soda flakes in the alkali solution are dissolved and homogenized more quickly.

[0126] Preferably, the metering and feeding control system uses a PLC to control the pump drive and adjusts the solenoid valve 15 to achieve quantitative delivery of caustic soda flakes and pure water. The delivery amount is adjusted by the PLC control system according to the required caustic soda concentration.

[0127] Preferably, the metering and feeding control system obtains the state parameters of the alkali solution in the alkali solution preparation tank 7 in real time through the liquid level sensor 6, temperature sensor 11 and concentration monitoring sensor 12 of the solution preparation unit, and dynamically adjusts the preparation process.

[0128] In this embodiment, the metering and feeding control system realizes automated closed-loop control of the alkali preparation process through PLC. The concentration monitoring sensor 12, liquid level sensor 6, and temperature sensor 11 installed on the alkali preparation tank 7 and alkali tank 3 collect data in real time. The system also sets parameters, monitors operating status, records production data, and alarms faults through a human-machine interface.

[0129] Preferably, the metering and feeding control system sets upper and lower limit alarm thresholds for parameters such as concentration, liquid level, and temperature, and automatically interlocks to start and stop the equipment when the alarm thresholds are exceeded.

[0130] In this embodiment, the metering and feeding control system is used to control the feeding amount, water intake, agitator speed, pump start / stop and flow rate.

[0131] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. A novel automatic feeding of alkali device, characterized in that, include: The storage unit includes an alkali storage tank, a pure water tank, and an alkali solution tank. The alkali storage tank is equipped with a material level monitoring device, the pure water tank is equipped with a water level monitoring device, and the alkali solution tank is equipped with a liquid level sensor. The solution preparation unit includes an alkali preparation tank, which is equipped with a stirring mechanism driven by a motor and a liquid level sensor. An automatic feeding unit includes a metering and feeding component for automatically feeding alkali from an alkali storage tank and pure water from a pure water tank into an alkali solution preparation tank, respectively; the metering and feeding component includes an alkali metering and feeding component disposed between the alkali storage tank and the alkali solution tank and a pure water metering and feeding component disposed between the pure water tank and the alkali solution tank. The conveying unit includes an alkali output pipe, an output pump, and an alkali tank. The alkali output end of the alkali preparation tank is connected to the alkali tank through the alkali output pipe and the output pump. The control unit includes a metering and feeding control system, which receives signals from various sensors and controls the actions of various actuators to achieve precise control of the amount of alkali and pure water fed.

2. A novel automatic feeding of alkali device according to claim 1, characterized in that, The storage unit is also equipped with a temperature sensor and a concentration monitoring sensor, the solution preparation unit is also equipped with a temperature sensor and a concentration monitoring sensor, the metering and feeding control system is equipped with a human-machine interface, and the alkali tank is also equipped with a return branch connected to the alkali preparation tank.

3. The novel automatic alkali feeding device according to claim 1, characterized in that, The pure water metering and dispensing component of the metering and dispensing assembly includes a water supply pipeline installed between the pure water tank and the alkali preparation tank, a solenoid valve and a flow meter respectively installed on the water supply pipeline and connected to the metering and dispensing control system.

4. A novel automatic feeding of alkali device according to claim 1, characterized in that, The metering and feeding assembly includes an alkali metering and feeding component, which is located between the alkali storage tank and the alkali preparation tank, and an alkali discharge pipe and a solenoid valve on the alkali discharge pipe. The alkali in the alkali storage tank is discharged by gravity settling, which uses the weight of the alkali itself to slide out of the alkali discharge pipe and into the alkali preparation tank. Alternatively, the alkali in the alkali storage tank is discharged by vacuum suction, which uses a vacuum suction device on the alkali discharge pipe to suck the alkali from the alkali storage tank into the alkali discharge pipe and into the alkali preparation tank.

5. A novel automatic feeding of alkali device according to claim 4, characterized in that, When the alkali material in the alkali material storage tank is discharged by gravity settling, the bottom surface of the alkali material storage tank is inclined so that the alkali material can naturally settle and slide towards the discharge port inside the alkali material storage tank.

6. A novel automatic feeding of alkali device according to claim 5, characterized in that, When the alkali material in the alkali material storage tank is discharged by gravity settling, the alkali material storage tank is placed on the ground, and the alkali solution preparation tank and pure water tank are set on the ground.

7. A novel automatic feeding of alkali device according to claim 1 characterized in that, The alkaline solution output pipeline of the conveying unit is equipped with a flow regulating valve, which is an electromagnetic valve.

8. A novel automatic feeding of alkali device according to claim 1, characterized in that, An alkali weighing sensor is installed at the lower end of the alkali storage tank, and a pure water weighing sensor is installed at the lower end of the pure water tank.

9. A novel automatic feeding of alkali device according to claim 1, characterized in that, The stirring mechanism in the solution preparation unit is a magnetic levitation ultrasonic homogenizing and dispersing stirring mechanism. The magnetic levitation ultrasonic homogenizing and dispersing stirring mechanism includes a stirring motor fixed to the alkali preparation tank by a motor mounting flange, a non-contact magnetic levitation coupling connected to the motor shaft of the stirring motor, an ultrasonic transducer connected to the lower end of the magnetic levitation coupling, a stirring shaft fixed to the lower end of the ultrasonic transducer and inserted below the liquid surface of the alkali preparation tank, and an anchor-type stirring paddle set at the lower end of the stirring shaft.

10. A novel automatic feeding of alkali device according to claim 9, characterized in that, At the lower end of the stirring shaft, near the anchor-type stirring paddle, a number of ultrasonic expansion auxiliary fins are arranged circumferentially at intervals for expanding the transmission of ultrasonic energy. The ultrasonic expansion auxiliary fins are flat fins perpendicular to the motor shaft.

11. A novel automatic feeding of alkali device according to claim 10, characterized in that, The stirring motor is a dual-shaft extension motor. The lower end of the dual-shaft extension motor is provided with a motor mounting flange. The motor shaft of the dual-shaft extension motor is a hollow motor shaft. The lower end of the hollow motor shaft is a long extension shaft extending downward from the motor mounting flange, and the upper end is a short output shaft extending upward from the top of the motor housing. The magnetic levitation coupling includes an inner rotor fixed on the long extension shaft, an outer rotor sleeved on the outer circle of the inner rotor and having a circumferential air gap between the outer circle of the inner rotor, and an axial magnetic levitation assembly disposed between the lower end of the motor mounting flange of the stirring motor and the outer circle of the outer rotor for axially suspending the outer rotor in a magnetic levitation manner. The ultrasonic transducer is connected to the lower end of the outer rotor. The end of the short output shaft is provided with a conductive slip ring. After the conductive rod of the ultrasonic transducer passes through the hollow motor shaft, the upper end of the conductive rod is connected to the lower end of the conductive slip ring through a section of retractable spring helical wire.

12. A novel automatic feeding of alkali device according to claim 11, characterized in that, The axial magnetic levitation assembly includes an upper annular magnet, a middle annular magnet, and a lower annular magnet arranged around the outer rotor in a top-to-bottom order. The upper annular magnet is fixed to the lower end of the motor mounting flange. The middle annular magnet is fixedly connected to the outer circle of the outer rotor. The lower annular magnet is mounted on a magnet bracket, which is fixedly connected to the lower end of the motor mounting flange.

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