Ultrasonic emulsification reaction kettle for producing wax removal water

Abstract

The utility model discloses an ultrasonic emulsification reaction kettle for wax removal water production, including support subassembly, coaxial nesting's heating component and ultrasonic stirring unit, emulsification subassembly and safety control unit. Through ultrasonic stirring cooperation multidirectional stirring vane and ultrasonic transducer group intensification emulsion dispersion, hot water cavity even heating cooperation precision temperature control, integrated automation control and safety protection function. Solve traditional equipment emulsification uneven, temperature control inaccuracy, automation deficiency and potential safety hazard etc. problem, promote wax removal water production efficiency and quality, be applicable to the large -scale industrial production.

Description

Technical Field

[0001] This utility model relates to the field of fine chemical production equipment, and in particular to an ultrasonic emulsification reactor for producing dewaxing water. Background Technology

[0002] Wax remover is a commonly used fine chemical product in the industrial cleaning field, mainly used for cleaning wax stains on the surfaces of precision machinery, optical components, and metal products. Its production process usually involves steps such as mixing, heating and dissolving, emulsifying and dispersing, and homogenizing raw materials (such as surfactants, co-solvents, and water). Among these steps, the emulsification and dispersion effect directly affects the wax removal efficiency and stability of the wax remover. Currently, traditional wax remover production equipment mostly adopts a step-by-step process using a single stirring tank combined with an external emulsifier, which has the following significant drawbacks: 1. Low mixing and emulsification efficiency: Traditional stirring tanks rely solely on mechanical stirring in one direction, making it difficult to effectively break up the agglomerated structure of wax particles. Uneven wax dispersion easily leads to emulsification and stratification of the final product, resulting in poor stability. 2. Unstable temperature control: Heating methods are mostly jacketed heating or direct heating with electric heating rods, which suffer from uneven heating and low heat transfer efficiency. Localized excessively high or low temperatures can affect the dissolution rate of raw materials and the emulsification reaction rate, leading to fluctuations in product quality. 3. Insufficient automation: Parameters such as raw material feeding, temperature adjustment, stirring speed, and emulsification time rely on manual experience for control, making it difficult to achieve precise production. Especially when processing high-viscosity wax raw materials, over- or under-reaction is likely to occur. 4. Significant safety hazards: Wax raw materials may volatilize flammable vapors at high temperatures. Traditional equipment lacks pressure monitoring and pressure relief protection devices, posing an explosion risk. At the same time, poor sealing of the stirring shaft can easily lead to material leakage, polluting the environment and increasing production costs.

[0003] Therefore, there is an urgent need for a specialized equipment that integrates efficient mixing, precise temperature control, uniform emulsification, and safety protection to meet the needs of large-scale, high-quality production of industrial wax remover. Utility Model Content

[0004] The technical problem to be solved by this utility model is to overcome the defects of the prior art and provide an ultrasonic emulsification reactor for the production of dewaxing water.

[0005] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0006] This utility model discloses an ultrasonic emulsification reactor for producing dewaxing water, comprising: a support assembly consisting of an outer cylinder, a cover plate hinged to the top of the outer cylinder, and a guide plate disposed on one side of the cover plate; a heating assembly coaxially nested within the support assembly, including a heating cylinder fixed to the outer cylinder, a heating control box disposed on the outer wall of the outer cylinder, several heating rods extending into the heating cylinder, a water temperature sensor, and an inlet valve and an outlet valve communicating with the heating cylinder; and an ultrasonic stirring unit coaxially nested within the heating cylinder, comprising: a stirring inner cylinder, with a liquid inlet valve at the top and a discharge valve at the bottom; and a stirring shaft penetrating the cover plate, consisting of a [missing information - likely a component or component] disposed on the cover plate. The system includes: a stirring motor drive; a stirring frame fixed to the bottom of the stirring shaft, with horizontal and vertical stirring blades hinged at its ends; an ultrasonic transducer assembly circumferentially embedded in the outer wall of the inner stirring cylinder; an emulsification assembly comprising: an emulsification homogenizer connected to a discharge valve via a metal pipe; an emulsification drive motor driving the emulsification homogenizer; and a safety control unit comprising a safety valve located at the top of the inner stirring cylinder, and a controller with a signal input terminal connected to a water temperature sensor and a material temperature sensor inside the inner stirring cylinder, and a control terminal connected to a heating control box, the stirring motor, the ultrasonic transducer assembly, the emulsification drive motor, the inlet valve, the outlet valve, and the safety valve.

[0007] As a preferred technical solution of this utility model, the outer cylinder is a cylindrical body with openings at the top and bottom. The cover plate is rotatably connected to the top edge of the outer cylinder by a hinge. The guide plate is installed obliquely on one side of the cover plate, with an angle of 30°~60° with the cover plate, to assist the solid raw material in automatically sliding into the top opening of the stirring inner cylinder along the guide plate.

[0008] As a preferred embodiment of this utility model, a hot water cavity is formed between the heating cylinder and the stirring inner cylinder, and is welded and fixed to the bottom of the outer cylinder; the heating control box is fixed to the bottom of the outer wall of the outer cylinder; the heating rods are evenly distributed along the circumference of the outer cylinder, and each heating rod is sealed to the outer cylinder wall through a flange, with the heating end extending into the hot water cavity; the water temperature sensor is fixed to the middle of the inner wall of the heating cylinder, and the signal output end is electrically connected to the controller input end; the inlet valve and the outlet valve are both ball valves.

[0009] As a preferred technical solution of this utility model, the stirring shaft is a solid stainless steel shaft, and its top is fixedly connected to the output shaft of the stirring motor through a coupling; the stirring frame is a rectangular bracket, fixed to the bottom of the stirring shaft, and its two ends are respectively hinged to the roots of the horizontal stirring blade and the vertical stirring blade; the ultrasonic transducer assembly is fixed to the outer wall of the stirring inner cylinder through a mounting flange, and the transducer surface is flush with the inner wall of the stirring inner cylinder.

[0010] As a preferred embodiment of this utility model, the rotor of the emulsifying homogenizer is fixedly connected to the output shaft of the emulsifying drive motor via a coupling; the emulsifying drive motor is an explosion-proof motor, fixed to one side of the emulsifying homogenizer; both ends of the metal pipe are respectively sealed to the discharge valve and the emulsifying homogenizer via flanges.

[0011] As a preferred technical solution of this utility model, the safety valve is a spring-loaded safety valve, installed on the top of the inner stirring cylinder, which automatically opens to release pressure when the pressure inside the inner stirring cylinder exceeds the set value; the controller is fixed to the outer wall of the outer cylinder, used to receive signals from the water temperature sensor and the material temperature sensor, and to control the working status of the heating control box, stirring motor, ultrasonic transducer group, emulsification drive motor, water inlet valve, water outlet valve and safety valve, so as to realize the automated control of the reactor.

[0012] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0013] 1. Through the synergistic effect of the multi-directional stirring blades and ultrasonic transducer group of the ultrasonic stirring unit: the horizontal stirring blades realize the radial circulation mixing of materials, the vertical stirring blades enhance the axial shear dispersion, and the high-frequency cavitation effect generated by the ultrasonic transducer group can destroy the agglomeration structure of wax particles, so that the tiny wax particles are evenly dispersed in the aqueous phase, the emulsion particle size is smaller and the distribution is narrower, which greatly improves the stability and dewaxing efficiency of the dewaxing water.

[0014] 2. The heating component adopts an indirect heating method with a "hot water chamber". The heating rods are evenly distributed in the chamber between the outer cylinder and the inner stirring cylinder. Uniform heating is achieved through heat conduction of the medium (such as water). With the real-time feedback of the water temperature sensor and controller, the temperature of the reaction system can be controlled within ±1℃ to avoid the decomposition or emulsification failure of raw materials caused by local overheating, and to ensure the stability of the production process and the consistency of product quality.

[0015] 3. The safety control unit integrates temperature sensors, pressure sensors, and controllers, which can automatically complete the entire process of raw material feeding (through the liquid inlet valve), heating temperature adjustment (heating control box), stirring speed control (stirring motor), emulsification time setting (emulsification drive motor), and pressure relief protection (safety valve), reducing human intervention errors and realizing continuous and standardized production, with a capacity increase of more than 30% compared to traditional equipment.

[0016] 4. A spring-loaded safety valve is installed to monitor the pressure inside the mixing cylinder in real time. When the pressure exceeds the set value (e.g., 0.3MPa), it automatically releases pressure to avoid the risk of explosion caused by material decomposition or gas accumulation. The mixing shaft adopts a sealed connection design, combined with the rigid fixing structure of the outer cylinder and the mixing inner cylinder, to effectively prevent wax leakage. The application of the explosion-proof motor further reduces electrical safety hazards in flammable vapor environments and complies with industrial safety production standards. Attached Figure Description

[0017] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings:

[0018] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0019] Figure 2 This is the front view of this utility model;

[0020] Figure 3 This is a side view of the present invention;

[0021] Figure 4 This is a cross-sectional structural schematic diagram of the present invention;

[0022] In the diagram: 1. Support assembly; 2. Heating assembly; 3. Ultrasonic stirring unit; 4. Emulsification assembly; 5. Safety valve; 6. Controller; 11. Outer cylinder; 12. Cover plate; 13. Guide plate; 21. Heating cylinder; 22. Heating control box; 23. Heating rod; 24. Water temperature sensor; 25. Inlet valve; 26. Outlet valve; 31. Inner stirring cylinder; 32. Stirring shaft; 33. Stirring frame; 34. Horizontal stirring blade; 35. Vertical stirring blade; 36. Stirring motor; 37. Ultrasonic transducer assembly; 38. Material temperature sensor; 39. Liquid inlet valve; 40. Discharge valve; 41. Emulsifying homogenizer; 42. Emulsification drive motor; 43. Metal pipe. Detailed Implementation

[0023] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0024] In the attached diagram, all identical reference numerals refer to the same components.

[0025] Example 1: Basic Ultrasonic Emulsification Reactor

[0026] like Figure 1-4 As shown, this embodiment provides a basic reactor suitable for small- to medium-scale industrial dewaxing water production. Its core consists of a support assembly 1, a heating assembly 2, an ultrasonic stirring unit 3, an emulsification assembly 4, and a safety control unit. The structure and connection relationship of each component are as follows:

[0027] The support assembly 1 consists of an outer cylinder 11, a cover plate 12, and a guide plate 13. The outer cylinder 11 is a cylindrical body with openings at the top and bottom, and is vertically fixed to the ground foundation. The cover plate 12 is rotatably connected to the top edge of the outer cylinder 11 via a hinge, and can be lifted upwards or closed downwards to form a closed space. The guide plate 13 is installed at an angle of 30° to 60° to the cover plate 12 on one side, and its surface is polished. It is used to assist solid raw materials (such as wax particles and surfactants) to automatically slide into the top opening of the ultrasonic stirring unit 3 along the guide plate.

[0028] The heating assembly 2 is coaxially nested inside the outer cylinder 11 and includes a heating cylinder 21, a heating control box 22, heating rods 23, a water temperature sensor 24, an inlet valve 25, and an outlet valve 26. The heating cylinder 21 is a cylindrical body, welded and fixed to the bottom of the outer cylinder 11, forming a closed hot water cavity together with the inner wall of the outer cylinder 11. The heating control box 22 is fixed to the bottom of the outer wall of the outer cylinder 11 and integrates a temperature controller and a power module. Several heating rods 23 are evenly distributed around the circumference of the outer cylinder 11 (the number is adjusted according to production capacity). Each heating rod 23 is sealed to the wall of the outer cylinder 11 through a flange, and the heating end extends into the hot water cavity. The water temperature sensor 24 is fixed in the middle of the inner wall of the heating cylinder 21 for real-time monitoring of the temperature of the hot water cavity. The inlet valve 25 and the outlet valve 26 are both ball valves, installed at the end of the inlet pipe and the outlet pipe at the bottom of the heating cylinder 21, respectively, for controlling the circulation of the medium (such as water) in the hot water cavity.

[0029] Please see Figure 4 The ultrasonic stirring unit 3 is coaxially nested inside the heating cylinder 21, with the stirring inner cylinder 31 as its core. The stirring inner cylinder 31 has a liquid inlet valve 39 at the top (for injecting liquid raw materials or deionized water) and a discharge valve 40 at the bottom (for discharging emulsified materials). The stirring shaft 32 is a solid stainless steel shaft that vertically passes through the center of the cover plate 12. Its top is fixedly connected to the output shaft of the stirring motor 36 on the cover plate 12 via a coupling (the stirring motor 36 is fixed above the cover plate). A rectangular stirring frame 33 is fixed at the bottom of the stirring shaft 32. The two ends of the stirring frame 33 are respectively hinged to the roots of the horizontal stirring blade 34 and the vertical stirring blade 35 (the horizontal stirring blade extends radially along the stirring shaft, and the vertical stirring blade extends axially along the stirring shaft), forming a multi-directional stirring structure. The ultrasonic transducer assembly 37, which is circumferentially embedded in the outer wall of the stirring inner cylinder 31, is fixed by a mounting flange. Its transducer surface is flush with the inner wall of the stirring inner cylinder 31 and is used to emit high-frequency ultrasonic waves.

[0030] The emulsification assembly 4 includes an emulsification homogenizer 41 and an emulsification drive motor 42. The emulsification homogenizer 41 is connected to the discharge valve 40 at the bottom of the mixing inner cylinder 31 via a metal pipe 43 (both ends of the metal pipe are sealed by flanges). Its rotor is fixedly connected to the output shaft of the emulsification drive motor 42 (the emulsification drive motor 42 is an explosion-proof motor, fixed to one side of the emulsification homogenizer 41), and is used to perform high-speed shear homogenization on the material after ultrasonic mixing.

[0031] The safety control unit includes a spring-loaded safety valve 5 (which automatically releases pressure when the internal pressure exceeds a set value) and a controller 6 installed on the top of the inner mixing cylinder 31. The controller 6 is fixed to the outer wall of the outer cylinder 11. Its input end is connected to a water temperature sensor 24 (monitoring the temperature of the hot water chamber) and a material temperature sensor 38 (monitoring the temperature of the material inside the inner mixing cylinder). Its output end controls the heating control box 22 (adjusting the power of the heating rod 23), the stirring motor 36 (adjusting the speed), the ultrasonic transducer group 37 (adjusting the ultrasonic frequency), the emulsification drive motor 42 (adjusting the shear rate), the inlet valve 25, and the outlet valve 26 (controlling the hot water circulation flow rate), realizing fully automated control of the entire process.

[0032] Workflow: Solid raw materials slide into the mixing inner cylinder 31 via the guide plate 13 → the cover plate 12 is closed, and liquid raw materials are injected through the liquid inlet valve 39 → the heating rod 23 is started to heat the hot water chamber (the water temperature sensor 24 feeds back to the controller 6 to regulate the temperature) → the stirring motor 36 drives the stirring shaft 32 to rotate, the horizontal stirring blades 34 mix radially, and the vertical stirring blades 35 shear axially → the ultrasonic transducer group 37 emits ultrasonic waves to break up wax agglomerates → the material enters the emulsifying homogenizer 41 through the discharge valve 40, and the emulsification drive motor 42 shears and refines it at high speed → the final emulsion is output, completing the production.

[0033] Example 2: High-efficiency heated ultrasonic emulsification reactor

[0034] The difference between this embodiment and Embodiment 1 is that the structure of the heating component 2 has been optimized, making it suitable for industrial scenarios with higher requirements for heating efficiency.

[0035] Improvements to heating component 2: The heating cylinder 21 is still welded to the bottom of the outer cylinder 11, but the heating rods 23 adopt a non-uniform distribution pattern of "dense at the top and sparse at the bottom" (the density of heating rods 23 in the top 1 / 3 area is 1.5 times that at the bottom), and a spiral guide plate is added to the hot water cavity (welded along the inner wall of the outer cylinder 11). The spiral guide plate can guide the hot water to rise spirally along the inner wall of the outer cylinder 11, making full contact with the heating rods 23 and improving heat transfer efficiency; at the same time, the heating control box 22 integrates a temperature control module, which can adjust the power of the heating rods 23 in real time according to the feedback of the material temperature sensor 38, achieving precise temperature control of ±0.5℃.

[0036] Other components: The structure of support component 1, ultrasonic stirring unit 3, emulsification component 4 and safety control unit is the same as in embodiment 1, except that controller 6 adds signal interaction with temperature control module to further optimize heating response speed.

[0037] Advantages: The spiral guide plate, combined with the non-uniformly distributed heating rod 23, solves the problem of "overheating at the edges and insufficient heating in the center" in traditional heating chambers, improving heating efficiency by more than 20%, and is suitable for the rapid dissolution of high-viscosity wax raw materials.

[0038] Example 3: Large-capacity ultrasonic emulsification reactor

[0039] This embodiment focuses on optimizing the stirring efficiency of the ultrasonic stirring unit 3 to meet the needs of large-scale industrial production:

[0040] Improvements to the ultrasonic stirring unit 3: The size of the stirring inner cylinder 31 is increased (the diameter to height ratio is adjusted to 1:1.5), and the diameter of the stirring shaft 32 is correspondingly thickened to enhance rigidity; the stirring frame 33 is changed from a rectangular support to a hollow frame structure (to reduce material adhesion), and the number of horizontal stirring blades 34 hinged at its end is increased to 4 (2 in Example 1), and the height of the vertical stirring blades 35 is increased by 30% (to enhance axial shear force); the ultrasonic transducer group 37 is arranged in two rows along the circumference of the outer wall of the stirring inner cylinder 31 (single row in Example 1), the transducer surface is flush with the inner wall of the stirring inner cylinder 31, and the ultrasonic frequency is adjusted to 28kHz (20kHz in Example 1), taking into account both the cavitation effect intensity and the material penetration depth.

[0041] Other components: The diameter of the outer cylinder 11 of the support component 1 is increased synchronously, and the length of the guide plate 13 is extended to accommodate a larger feed volume; the emulsification homogenizer 41 of the emulsification component 4 is equipped with a more powerful explosion-proof motor (matching the mixing capacity); the controller 6 of the safety control unit is equipped with multiple sensor interfaces (to monitor the material temperature at different heights) to ensure the uniformity of temperature for large-capacity materials.

[0042] Advantages: By increasing the size of the inner mixing cylinder 31 and optimizing the mixing blade structure, the single batch processing capacity is increased by more than 50%. Combined with the high-frequency cavitation effect of the double-row ultrasonic transducer group 37, the emulsion particle size is smaller (down to the micron level), making it suitable for large-scale continuous production of dewaxing water.

[0043] This utility model is an ultrasonic emulsification reactor for the production of wax remover. Through structural innovation and functional integration, it effectively solves the problems of uneven emulsification, inaccurate temperature control, low degree of automation and safety hazards in traditional wax remover production equipment, and provides reliable equipment support for the high-quality and large-scale production of industrial wax remover.

[0044] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An ultrasonic emulsification reactor for producing dewaxing solution, characterized in that, include: The support assembly (1) consists of an outer cylinder (11), a cover plate (12) hinged to the top of the outer cylinder (11), and a guide plate (13) on one side of the cover plate (12); the heating assembly (2) is coaxially nested in the support assembly (1), including a heating cylinder (21) fixed to the outer cylinder (11), a heating control box (22) located on the outer wall of the outer cylinder (11), several heating rods (23) extending into the heating cylinder (21), a water temperature sensor (24), and a water inlet valve (25) and a water outlet valve (26) connecting the heating cylinder (21); the ultrasonic stirring unit (3) is coaxially nested in the heating cylinder (21), including: a stirring inner cylinder (31) with a liquid inlet valve (39) at the top and a discharge valve (40) at the bottom; a stirring shaft (32) penetrating the cover plate (12) and driven by a stirring motor (36) located on the cover plate (12); A stirring frame (33) is fixed at the bottom of the stirring shaft (32), with a horizontal stirring blade (34) and a vertical stirring blade (35) hinged at its end; an ultrasonic transducer assembly (37) is circumferentially embedded in the outer wall of the stirring inner cylinder (31); an emulsification assembly (4) includes: an emulsification homogenizer (41) connected to a discharge valve (40) via a metal pipe (43); an emulsification drive motor (42) for driving the emulsification homogenizer (41); and a safety control unit including a safety valve (5) located at the top of the stirring inner cylinder (31), and a controller (6) whose signal input terminal is connected to a water temperature sensor (24) and a material temperature sensor (38) inside the stirring inner cylinder (31), and whose control terminal is connected to a heating control box (22), a stirring motor (36), an ultrasonic transducer assembly (37), an emulsification drive motor (42), a water inlet valve (25), a water outlet valve (26), and a safety valve (5).

2. The ultrasonic emulsification reactor for producing dewaxing water according to claim 1, characterized in that, The outer cylinder (11) is a cylindrical body with openings at the top and bottom. The cover plate (12) is rotatably connected to the top edge of the outer cylinder (11) via a hinge. The guide plate (13) is installed obliquely on one side of the cover plate (12) at an angle of 30° to 60° with the cover plate (12) to assist solid raw materials in automatically sliding into the top opening of the stirring inner cylinder (31) along the guide plate (13).

3. The ultrasonic emulsifying reactor for producing dewaxing water according to claim 2, characterized in that, The heating cylinder (21) and the stirring inner cylinder (31) form a hot water cavity, which is welded and fixed to the bottom of the outer cylinder (11); the heating control box (22) is fixed to the bottom of the outer wall of the outer cylinder (11); the heating rods (23) are evenly distributed along the circumference of the outer cylinder (11), and each heating rod (23) is sealed to the outer cylinder (11) wall through a flange, with the heating end extending into the hot water cavity; the water temperature sensor (24) is fixed to the middle of the inner wall of the heating cylinder (21), and the signal output end is electrically connected to the input end of the controller (6); the inlet valve (25) and the outlet valve (26) are both ball valves.

4. The ultrasonic emulsification reactor for producing dewaxing water according to claim 3, characterized in that, The stirring shaft (32) is a solid stainless steel shaft, and its top is fixedly connected to the output shaft of the stirring motor (36) through a coupling; the stirring frame (33) is a rectangular bracket, fixed to the bottom of the stirring shaft (32), and its two ends are respectively hinged to the roots of the horizontal stirring blade (34) and the vertical stirring blade (35); the ultrasonic transducer assembly (37) is fixed to the outer wall of the stirring inner cylinder (31) through a mounting flange, and the transducer surface is flush with the inner wall of the stirring inner cylinder (31).

5. The ultrasonic emulsifying reactor for producing dewaxing water according to claim 4, characterized in that, The rotor of the emulsifying homogenizer (41) is fixedly connected to the output shaft of the emulsifying drive motor (42) via a coupling; the emulsifying drive motor (42) is an explosion-proof motor and is fixed to one side of the emulsifying homogenizer (41); the two ends of the metal pipe (43) are respectively sealed to the discharge valve (40) and the emulsifying homogenizer (41) via flanges.

6. The ultrasonic emulsification reactor for producing dewaxing water according to claim 5, characterized in that, The safety valve (5) is a spring-loaded safety valve installed on the top of the stirring inner cylinder (31). It automatically opens to release pressure when the pressure inside the stirring inner cylinder (31) exceeds the set value. The controller (6) is fixed to the outer wall of the outer cylinder (11) and is used to receive signals from the water temperature sensor (24) and the material temperature sensor (38), and to control the working status of the heating control box (22), stirring motor (36), ultrasonic transducer group (37), emulsification drive motor (42), water inlet valve (25), water outlet valve (26) and safety valve (5) to realize the automated control of the reactor.

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