A high-efficiency grading, concentrating and conditioning device for slurry

Abstract

The utility model relates to a kind of mud high-efficiency grading concentration conditioning device, including mud grading unit, conditioning unit, monitoring unit, dosing unit and control unit constitute;Mud grading unit adopts cyclone structure, mud is separated into coarse particle underflow and fine particle overflow by centrifugal force, respectively into independent first, second mixing box, box is equipped with helical fin agitator, and the mixing uniformity of reagent and mud is enhanced;Dosing unit adopts electromagnetic drive metering pump, and dosing amount can be dynamically adjusted according to monitoring data;Monitoring unit is in real time by flow, concentration and pressure sensor Acquisition key parameter, closed-loop control is realized by control unit, and slurry amount, dosing amount and stirring intensity are automatically adjusted;Its advantage shows in: the device cooperates through grading treatment and accurate dosing, compared with traditional process, reagent consumption is reduced, while mud sedimentation efficiency and conditioning quality stability are improved.

Description

Technical Field

[0001] This utility model relates to the field of mud treatment technology, and in particular to a high-efficiency mud grading, concentration and conditioning device. Background Technology

[0002] Dredging, construction, and tunnel boring machine (TBM) projects generate large quantities of engineering mud. Due to its large volume and slow settling time, traditional treatment methods typically involve conditioning the mud using chemical mixing and gravity sedimentation to reduce its volume and lower the burden on subsequent treatment processes. However, the properties of the mud (such as particle size, density, and composition) significantly impact conditioning effectiveness: for example, coarse-particle mud is easier to condition, while fine-particle mud is not only difficult to settle, but also requires 15% more conditioning agents. Furthermore, different particle sizes of mud have varying requirements for reagent selection, mixing methods, mixing intensity, and settling time.

[0003] Traditional techniques treat all types of mud slurry uniformly without considering graded treatment, leading to problems such as large amounts of conditioning materials, poor sedimentation, and low efficiency. This directly affects the feasibility and cost of the entire mud treatment project. Therefore, how to reduce the amount of chemicals added and improve conditioning efficiency and effectiveness has become a key issue that urgently needs to be addressed in the engineering field. Utility Model Content

[0004] The purpose of this invention is to solve the above-mentioned problems in the prior art and to provide a high-efficiency mud grading, concentration and conditioning device.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0006] A high-efficiency mud classification, concentration and conditioning device includes a mud classification unit, a mud conditioning unit, a monitoring unit, a chemical dosing unit and a control unit;

[0007] The mud grading unit is a hydrocyclone structure. Its input end is connected to the mud inlet pump through a mud inlet pipe, and its output end is divided into a coarse particle mud outlet and a fine particle mud outlet. The coarse particle mud outlet is connected to the input end of the first discharge pump, and the fine particle mud outlet is connected to the input end of the second discharge pump.

[0008] The mud conditioning unit includes a first mixing chamber and a second mixing chamber. The input ends of the first mixing chamber and the second mixing chamber are respectively connected to the output ends of the first slurry pump outlet and the second slurry pump outlet via a first mud conveying pipe. The output ends of the first mixing chamber and the second mixing chamber are respectively connected to the input ends of the third slurry pump and the fourth slurry pump. The output ends of the third slurry pump and the fourth slurry pump are connected to the input end of the discharge pump via a second mud conveying pipe.

[0009] The monitoring unit includes: a first flow sensor and a first concentration sensor disposed at the input end of the mud grading unit; a second flow sensor and a second concentration sensor disposed at the input end of the first mixing tank; a third flow sensor and a third concentration sensor disposed at the input end of the second mixing tank; and a pressure sensor disposed at the output end of the third discharge pump and the fourth discharge pump.

[0010] The dosing unit includes: a first dosing pump connected to the first mixing tank and a second dosing pump connected to the second mixing tank;

[0011] The control unit is electrically connected to the monitoring unit, the dosing unit, and the slurry pump.

[0012] Preferably, both the first and second mixing chambers are equipped with spiral finned agitators; the spiral finned agitators are installed vertically along the central axis of the chamber, with the fins extending to the bottom of the chamber, to enhance the uniformity of mixing of the agent and the mud.

[0013] Preferably, both the first and second dosing pumps are electromagnetically driven metering pumps, and the metering pumps have frequency adjustment and flow display functions.

[0014] Preferably, the hydrocyclone structure, the first mixing chamber, and the second mixing chamber are all made of high-density polyethylene to avoid the influence of metal ions on the mud conditioning effect.

[0015] Preferably, the first flow sensor, the second flow sensor, and the third flow sensor are electromagnetic flow meters; the first concentration sensor, the second concentration sensor, and the third concentration sensor are ultrasonic concentration meters; and the pressure sensor is a diffused silicon pressure transmitter.

[0016] Preferably, the control unit is an integrated PLC controller, which is configured to receive flow rate, concentration and pressure data collected by the monitoring unit and output control signals to the dosing unit and the slurry pump.

[0017] Due to the adoption of the above technical solution, the beneficial effects obtained by this utility model include:

[0018] 1. This utility model uses a hydrocyclone to classify the mud and combines the flow and concentration sensors to monitor data in real time and dynamically adjust the flow rate of the dosing pump to achieve precise dosing of chemicals in stages, which effectively reduces the amount of chemicals used compared with the traditional full particle size mixing and conditioning process.

[0019] 2. This utility model designs conditioning processes for mud with different particle sizes and characteristics, and combines a spiral finned agitator to enhance the mixing effect of the agent and mud, which significantly improves mud sedimentation efficiency and conditioning quality. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the efficient mud grading, concentration and conditioning device of this utility model.

[0021] The attached figures are labeled as follows:

[0022] 1. Slurry pump; 2. Slurry input pipeline; 3. Hydrocyclone;

[0023] 4. First discharge pump; 5. Second discharge pump;

[0024] 6. First mixing chamber; 61. First dosing pump; 62. Spiral finned agitator;

[0025] 7. Second mixing chamber; 71. Second dosing pump;

[0026] 8. First mud conveying pipeline; 9. Third mud discharge pump; 10. Fourth mud discharge pump;

[0027] 11. Second mud conveying pipeline; 12. Slurry discharge pump;

[0028] 13. First flow sensor; 14. First concentration sensor;

[0029] 15. Second flow sensor; 16. Second concentration sensor;

[0030] 17. Third flow sensor; 18. Third concentration sensor;

[0031] 19. Pressure sensor; 20. Control unit. Detailed Implementation

[0032] Please see the appendix Figure 1 As shown, this utility model mainly provides a mud high-efficiency classification, concentration and conditioning device, including a mud classification unit, a mud conditioning unit, a monitoring unit, a chemical dosing unit and a control unit;

[0033] The mud classification unit 1 is a cylindrical-conical hydrocyclone 3 structure. Its input end is sealed to the output end of the mud inlet pump 1 (centrifugal pump) through a mud inlet pipe 2 with a flange. The output end is divided into a coarse particle mud outlet (underflow pipe) at the bottom and a fine particle mud outlet (overflow pipe) at the top along the axial direction. The coarse particle mud outlet can be connected to the input end of the first discharge pump 4 (centrifugal pump) through a flange joint, and the fine particle mud outlet can be connected to the input end of the second discharge pump 5 (centrifugal pump) through a flange joint.

[0034] The mud conditioning unit includes two independent vertical cylindrical mixing chambers (first mixing chamber 6 and second mixing chamber 7). The input end of the first mixing chamber 6 is connected to the output end of the first discharge pump 4 through the mud conveying pipe 2, and the input end of the second mixing chamber 7 is connected to the output end of the second discharge pump 5 through the first mud conveying pipe 8. The output port at the bottom of the first mixing chamber 6 is connected to the input flange of the third discharge pump 9 (centrifugal pump), and the output port at the bottom of the second mixing chamber 7 is connected to the input flange of the fourth discharge pump 10 (centrifugal pump). The output ends of the third discharge pump 9 and the fourth discharge pump 10 are connected to the input end of the discharge pump 12 (centrifugal pump) through the combined second mud conveying pipe 11.

[0035] The monitoring unit includes:

[0036] The first flow sensor 13 (electromagnetic flow meter) and the first concentration sensor 14 (ultrasonic concentration meter) are installed at the input end of the mud classification unit (mud input pipe);

[0037] The second flow sensor 15 (electromagnetic flow meter) and the second concentration sensor 16 (ultrasonic concentration meter) are installed at the input end of the first mixing tank 6 (first mud conveying pipeline);

[0038] The third flow sensor 17 (electromagnetic flow meter) and the third concentration sensor 18 (ultrasonic concentration meter) are installed at the input end of the second mixing chamber 7 (first mud conveying pipeline);

[0039] Pressure sensors (diffused silicon pressure transmitters) are installed at the output ends of the third slurry pump 9 and the fourth slurry pump 10 (second mud conveying pipeline);

[0040] The dosing unit includes:

[0041] The first dosing pump 61 (electromagnetic metering pump) is connected to the top side wall of the first mixing tank 6, and its dosing pipeline is connected to the tank through a quick connector;

[0042] The second dosing pump 71 (electromagnetic metering pump) is connected to the top side wall of the second mixing tank 7, and its dosing pipeline is connected to the tank through a quick-connect coupling;

[0043] The control unit 20 (integrated PLC controller, installed in an independent control cabinet) is electrically connected to the monitoring unit (first to third flow sensors, first to third concentration sensors, and pressure sensor), the dosing unit (first dosing pump and second dosing pump), and the slurry pump via cables. For ease of operation, a data display panel and manual adjustment buttons can also be provided on the surface of the control cabinet.

[0044] Furthermore, this invention achieves mud grading by particle size (coarse / fine particle separation) through a cylindrical-conical hydrocyclone. Combined with an integrated structure of an independent mixing chamber, multi-parameter sensors, and a PLC control unit, it enables targeted treatment of graded conditioning. Each unit is connected by flange sealing and standardized piping configuration, improving the overall sealing performance and ease of installation and maintenance. Its multi-sensor real-time monitoring of flow rate, concentration, and pressure data provides a hardware foundation for precise dosing and system protection, effectively solving the problems of reagent waste and low treatment efficiency in traditional full-particle-size mixing conditioning.

[0045] In this embodiment, a spiral finned agitator 62 is coaxially arranged in both the first mixing chamber 6 and the second mixing chamber 7. The agitator includes a stainless steel main shaft, 3-4 sets of rectangular fins spirally distributed along the main shaft, and a drive motor. The agitator is installed vertically along the central axis of the chamber, with the bottom of the fins 50-100mm away from the bottom of the chamber and the top of the fins 200-300mm away from the top of the chamber, which is used to enhance the shear mixing effect of the agent and the mud.

[0046] Furthermore, the spiral finned agitator 62 enhances the shear mixing effect of the agent and the mud through the design of a stainless steel main shaft and spirally distributed rectangular fins, shortening the mixing time compared with traditional paddle agitators; the fins extend to the bottom of the tank and maintain a reasonable distance from the bottom, ensuring full contact between the mud and the agent throughout the entire liquid level range, improving sedimentation efficiency and conditioning quality stability.

[0047] In this embodiment, both the first dosing pump 4 and the second dosing pump 5 are electromagnetically driven diaphragm metering pumps, equipped with an LCD flow display screen and a frequency conversion adjustment knob.

[0048] Furthermore, the electromagnetically driven diaphragm metering pump has frequency conversion regulation and flow display functions, realizing dynamic matching between the dosing flow rate and the treatment load, and reducing chemical waste.

[0049] In this embodiment, the hydrocyclone 3 structure, the first mixing chamber 6 and the second mixing chamber 7 are all made of high-density polyethylene (HDPE) material with a thickness of 10-15mm and are formed by hot melt welding.

[0050] Furthermore, HDPE material is formed through hot-melt welding, avoiding the presence of metal ions (such as Fe) in traditional metal materials. 3+ This disrupts the stability of the mud colloid, ensuring the effective adsorption of conditioning agents.

[0051] In this embodiment, the first flow sensor 13, the second flow sensor 15, and the third flow sensor 17 are flange-type electromagnetic flow meters with PTFE lining and 316L stainless steel electrodes; the first concentration sensor 14, the second concentration sensor 16, and the third concentration sensor 18 are insertion-type ultrasonic concentration meters with titanium alloy probes; and the pressure sensor 19 is a threaded diffused silicon pressure transmitter.

[0052] Furthermore, electromagnetic flowmeters and ultrasonic concentration meters are wear-resistant and corrosion-resistant, making them suitable for high-concentration slurry environments; diffused silicon pressure transmitters offer high measurement accuracy, ensuring reliable pressure monitoring data; and the stable output signals of various sensors provide precise data support for the control unit, avoiding the risk of overdosing or system overpressure due to monitoring errors.

[0053] The control unit 20 is an integrated PLC controller. The input module of the PLC controller is connected to the sensor signal output terminal of the monitoring unit, and the output module is connected to the frequency converter driver of the dosing unit and the frequency converter control cabinet of the slurry pump through relays. It transmits the received, processed and stored messages to the terminal through signal transmission (such as Wi-Fi, Bluetooth, etc.) so as to make timely adjustments based on feedback: if the product of the mud flow rate value in the flow sensor and the mud concentration value in the concentration sensor increases, the dosing pump is controlled to increase the amount of agent added; if the product of the mud flow rate value in the flow sensor and the mud concentration value in the concentration sensor decreases, the dosing pump is controlled to decrease the amount of agent added; if the product of the mud flow rate value in the flow sensor and the mud concentration value in the concentration sensor remains unchanged, the dosing pump is controlled to keep the amount of agent added constant.

[0054] The usage method and working principle of this utility model:

[0055] This invention utilizes a synergistic process of graded pretreatment, precise conditioning, and intelligent control to achieve differentiated treatment of slurry based on particle characteristics, thereby improving concentration efficiency and reducing reagent consumption. The specific steps are as follows:

[0056] 1. Mud classification and separation

[0057] Input stage: After being pressurized by the feed pump, the mud to be treated enters the cylindrical-conical hydrocyclone (mud classification unit) through the flanged input pipe.

[0058] Grading principle: Utilizing the centrifugal force generated by high-speed rotation inside the hydrocyclone (acceleration in the cylindrical section and enhanced separation in the conical section), the mud is divided into coarse particle underflow (discharged through the bottom underflow pipe) and fine particle overflow (discharged through the top overflow pipe) according to particle size, thus achieving the initial separation of mud with different particle characteristics.

[0059] 2. Graded conditioning and drug mixing

[0060] Diverted conveying: Coarse-particle slurry is pumped into the first mixing tank via the first discharge pump, while fine-particle slurry is pumped into the second mixing tank (independent conditioning unit) via the second discharge pump.

[0061] Precise dosing: The control unit drives the corresponding dosing pump (electromagnetic flow meter) to inject conditioning agents (such as flocculants and coagulants) into the mixing tank based on the real-time flow rate (electromagnetic flow meter) and concentration (ultrasonic concentration meter) data collected by the monitoring unit. The dosage is dynamically matched with the mud flow rate / concentration.

[0062] High-efficiency mixing: The spiral finned agitator inside the tank rotates at high speed (driven by a 1.5-3kW motor). Through the shearing and propulsion action of the spiral fins, the agent and mud are uniformly mixed in the entire liquid level range, which promotes particle coagulation and improves dewatering performance.

[0063] 3. Data monitoring and intelligent control

[0064] Real-time monitoring: The sensor group (flow rate, concentration, pressure) continuously collects parameters of each key node (such as the flow rate at the hydrocyclone inlet, the concentration at the mixing tank inlet, and the pressure in the confluence pipeline) and transmits the signals to the PLC control unit.

[0065] Closed-loop control: The PLC controller analyzes and monitors data, and automatically adjusts the frequency of the feed pump (controlling the throughput), the flow rate of the dosing pump (controlling the amount of chemicals added), and the speed of the agitator to ensure that the system operates under stable conditions and avoids overload or waste of chemicals.

[0066] 4. Merging and discharging

[0067] The conditioned coarse and fine particle slurries are transported to the confluence pipeline by the third and fourth discharge pumps, respectively, and finally discharged to the subsequent dewatering equipment by the discharge pump, completing the entire graded concentration and conditioning process.

[0068] It should be noted that this utility model uses a hydrocyclone to classify the mud before mud conditioning, and then adjusts the amount of chemicals added according to the mud flow rate and concentration, thereby achieving graded mud conditioning, reducing the amount of chemicals used in the mud conditioning process, and improving the efficiency and effect of mud conditioning; and by setting a pressure sensor to monitor the pressure in the pipeline and transmit the information to the control unit, the control unit can control the slurry pump, etc., according to the pressure in the pipeline. If the pressure exceeds the warning line, the control unit will shut down the slurry pump until the pressure in the pipeline returns to below the safe warning value to ensure safety.

[0069] The foregoing descriptions and embodiments are provided to enable those skilled in the art to understand and apply this invention. Those skilled in the art will readily make various modifications to these contents and apply the general principles described herein to other embodiments without inventive effort. Therefore, this invention is not limited to the foregoing descriptions and embodiments. Improvements and modifications made by those skilled in the art based on the disclosure of this invention without departing from its scope should be within the protection scope of this invention.

Claims

1. A high-efficiency mud grading, concentration, and conditioning device, characterized in that, It includes a mud grading unit, a mud conditioning unit, a monitoring unit, a chemical dosing unit, and a control unit; The mud grading unit is a hydrocyclone structure. Its input end is connected to the mud inlet pump through a mud inlet pipe, and its output end is divided into a coarse particle mud outlet and a fine particle mud outlet. The coarse particle mud outlet is connected to the input end of the first discharge pump, and the fine particle mud outlet is connected to the input end of the second discharge pump. The mud conditioning unit includes a first mixing chamber and a second mixing chamber. The input ends of the first mixing chamber and the second mixing chamber are respectively connected to the output ends of the first slurry pump outlet and the second slurry pump outlet via a first mud conveying pipe. The output ends of the first mixing chamber and the second mixing chamber are respectively connected to the input ends of the third slurry pump and the fourth slurry pump. The output ends of the third slurry pump and the fourth slurry pump are connected to the input end of the discharge pump via a second mud conveying pipe. The monitoring unit includes: a first flow sensor and a first concentration sensor disposed at the input end of the mud grading unit; a second flow sensor and a second concentration sensor disposed at the input end of the first mixing tank; a third flow sensor and a third concentration sensor disposed at the input end of the second mixing tank; and a pressure sensor disposed at the output end of the third discharge pump and the fourth discharge pump. The dosing unit includes: a first dosing pump connected to the first mixing tank and a second dosing pump connected to the second mixing tank; The control unit is electrically connected to the monitoring unit, the dosing unit, and the slurry pump.

2. The high-efficiency mud classification, concentration, and conditioning device according to claim 1, characterized in that, Both the first and second mixing chambers are equipped with spiral finned agitators; the spiral finned agitators are installed vertically along the central axis of the chamber, with the fins extending to the bottom of the chamber, to enhance the uniformity of mixing of the agent and the mud.

3. The high-efficiency mud classification, concentration, and conditioning device according to claim 1, characterized in that, Both the first and second dosing pumps are electromagnetically driven metering pumps, and the metering pumps have frequency adjustment and flow display functions.

4. The high-efficiency mud classification, concentration, and conditioning device according to claim 1, characterized in that, The hydrocyclone structure, the first mixing chamber, and the second mixing chamber are all made of high-density polyethylene to avoid the influence of metal ions on the mud conditioning effect.

5. The high-efficiency mud classification, concentration, and conditioning device according to claim 1, characterized in that, The first flow sensor, the second flow sensor, and the third flow sensor are electromagnetic flow meters; the first concentration sensor, the second concentration sensor, and the third concentration sensor are ultrasonic concentration meters; and the pressure sensor is a diffused silicon pressure transmitter.

6. The high-efficiency mud classification, concentration, and conditioning device according to claim 1, characterized in that, The control unit is an integrated PLC controller, which is configured to receive flow rate, concentration and pressure data collected by the monitoring unit and output control signals to the dosing unit and the slurry pump.

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