Safety auxiliary device for deep well processing of aluminum ingot

Abstract

The utility model discloses a kind of aluminium ingot deep well processing safety auxiliary device, its casting well main body structure adopts double-layer isolation type well wall design, air gap layer being provided with sealed cavity between outer well wall layer and inner well wall layer;It is integrated simultaneously with pressure, image, temperature data acquisition machine, and by the emergency coagulant release device controlled by PLC, wherein PLC judges aluminium liquid leakage risk by multi-sensor signal fusion, and can automatically trigger release coagulant to carry out fast leak point inhibition.This case is combined by air gap layer physical isolation, multi-parameter intelligent monitoring and active emergency response, utilizes inert gas to isolate aluminium liquid and cooling water, physically blocks explosion condition;When leaking, selectively trigger emergency coagulant release mechanism according to air pressure, temperature, image monitoring data, actively and quickly plug leakage, ensure aluminium ingot deep well processing safety.

Description

Technical Field

[0001] This utility model relates to a safety auxiliary device, and more particularly to a safety auxiliary device for deep well processing of aluminum ingots, belonging to the field of deep well processing technology for aluminum ingots. Background Technology

[0002] In the deep well casting process of metallic aluminum, the main types of production safety accidents that are prone to occur include the following: 1) Aluminum liquid leakage or splashing: High-temperature aluminum liquid comes into contact with cooling water and causes a steam explosion (similar to an aluminum liquid explosion when it comes into contact with water); 2) Coffin well collapse or deformation: Failure of the well wall structure leads to aluminum liquid leakage or equipment damage; 3) Equipment mechanical failure: Such as loss of control of the hoisting mechanism, mold jamming, etc.; 4) High temperature burns or fume poisoning: The volatilization of aluminum liquid or improper cooling produces harmful gases (such as hydrogen).

[0003] Among these issues, the low level of automation and inherent safety of deep-well aluminum casting processes mean that explosions caused by molten aluminum contacting water are frequent occurrences in actual production. Therefore, the most serious and urgent accident to be addressed is a steam explosion triggered by the contact of molten aluminum with water. Such accidents are extremely destructive and can easily cause significant casualties and property damage. Therefore, preventing direct contact between molten aluminum and cooling water, and real-time monitoring and control of water level, temperature, and pressure within the casting well are crucial to ensuring the safety of the aluminum solidification process.

[0004] Therefore, it is necessary to further improve the safety measures for deep well processing of aluminum ingots and add safety auxiliary devices to the processing facilities to improve the safety factor of deep well processing of aluminum ingots. Summary of the Invention

[0005] The purpose of this invention is to solve the above-mentioned problems and provide a safety auxiliary device for deep well processing of aluminum ingots.

[0006] The technical solution of this utility model is: a safety auxiliary device for deep well processing of aluminum ingots, including a casting well main structure and a well cover adapted to it. An infrared thermal imager for scanning and monitoring the internal temperature field distribution of the casting well main structure is installed on the inner side of the well cover. The casting well main structure adopts a double-layer isolation design consisting of an outer well wall layer and an inner well wall layer. A sealed air gap layer is provided between the outer well wall layer and the inner well wall layer. The outer well wall layer (made of high-strength metal material) is a sandwich sleeve structure with uniformly distributed cooling water channels inside for circulating external cooling water, thus protecting the casting well. The main structure of the well is indirectly cooled; it also includes: a first temperature sensor for monitoring the heat exchange efficiency of the cooling water channel inside the outer well wall layer, the temperature probe of which is located in the bottom area of ​​the inner well wall layer; a pressure sensor for real-time monitoring of the gas pressure inside the gas gap layer, the probe of which is located inside the gas gap layer; and a second temperature sensor for monitoring the initial temperature of the molten aluminum inside the main structure of the casting well; and at least one emergency solidifying agent release mechanism is provided at the bottom of the main structure of the casting well, the emergency solidifying agent release mechanism including a storage tank and a spray assembly connected to the top of the storage tank.

[0007] Furthermore, in the aforementioned safety auxiliary device for deep well processing of aluminum ingots, an outlet pipe is provided on one side of the main structure of the casting well, and an external temperature monitor is installed on the outlet pipe. The external temperature monitor is a contact-type temperature monitor and can be equipped with an alarm.

[0008] Furthermore, in the aforementioned safety auxiliary device for deep well processing of aluminum ingots, one end of the cooling water channel inside the outer well wall is equipped with an inlet valve, and the other end is equipped with a drain pump and a drain valve.

[0009] Furthermore, in the aforementioned safety auxiliary device for deep well processing of aluminum ingots, at least one inlet valve and at least one outlet valve are provided on the air gap layer. Both the inlet valve and the outlet valve are electrically controlled valves. The inlet valve is connected to an inert gas source through a pipeline. The outlet valve is connected to the external environment or to a gas processing device through a pipeline.

[0010] Furthermore, the aforementioned safety auxiliary device for deep well processing of aluminum ingots further includes a PLC. The signal input terminal of the PLC is connected to the signals of a first temperature sensor, a pressure sensor, and a second temperature sensor. The control output terminal of the PLC is connected to the emergency coagulant release mechanism. The PLC is configured to receive and process data from each sensor and data from an infrared thermal imager, and continuously monitor the readings of the pressure sensor. When the reading of the pressure sensor experiences a continuous and irreversible decrease, it is determined that the sealing of the air gap layer of the main structure of the casting well has failed, and a first-level warning signal is generated. When the infrared thermal imager detects an abnormally high temperature area in the inner well wall layer, and the temperature detected by the first temperature sensor exceeds a safety threshold, it is determined that the preset aluminum liquid leakage conditions are met. The PLC outputs a control signal to the emergency coagulant release mechanism, triggering it to instantly blow coagulant powder to the leak point, mix it with the aluminum liquid, and significantly reduce its fluidity, causing it to solidify rapidly, thereby actively plugging the leak.

[0011] Furthermore, in the aforementioned safety auxiliary device for deep well processing of aluminum ingots, the injection assembly includes an injection pipeline connected to the storage tank, a rupture diaphragm and an adjustable nozzle installed at the top of the injection pipeline; the storage tank (filled with titanium powder or aluminum-titanium alloy powder as a solidifying agent) is connected to a high-pressure nitrogen source via a high-pressure gas line, and a normally closed solenoid valve controlled by the PLC is installed on the high-pressure gas line.

[0012] Furthermore, in the aforementioned safety auxiliary device for deep well processing of aluminum ingots, the well cover is provided with a multi-stage pressure relief structure, which includes a rupture disc and a spring-loaded safety valve.

[0013] Compared with existing technologies, the present invention utilizes a double-layer isolation well wall structure to isolate molten aluminum from cooling water using inert gas, physically blocking explosion conditions. It can also provide leak alerts by combining air pressure, temperature, and image monitoring. Furthermore, in the event of a leak, an emergency coagulant release mechanism is automatically triggered to release the coagulant. Compared with traditional passive plugging, the response time is effectively shortened, and the leak can be quickly plugged, greatly improving the safety of the deep well processing of aluminum ingots. Attached Figure Description

[0014] Fig. 1 This is a schematic diagram of the overall structure of this utility model; Fig. 2 This is a schematic diagram illustrating the operational principle of the main structure of the casting well. Fig. 3 This is a schematic diagram of the internal structure of the main structure of the casting well.

[0015] The meanings of the labels in the attached figures are as follows: 1-Main structure of the casting well, 2-Outer well wall layer, 3-Inner well wall layer, 4-Air gap layer, 5-Water inlet valve, 6-Drainage pump, 7-Drainage valve, 8-Air inlet valve, 9-Exhaust valve, 10-First temperature sensor, 11-Air pressure sensor, 12-Second temperature sensor, 13-Emergency coagulant release mechanism, 131-Storage tank, 132-Injection assembly, 14-PLC, 15-Outlet pipe, 16-External temperature monitor, 17-Well cover, 18-Infrared thermal imager. Detailed Implementation

[0016] The technical solution of this utility model will be further described below with reference to the accompanying drawings to make it easier to understand and master. The components involved, such as the temperature sensor, air pressure sensor 11, PLC 14, external temperature monitor 16, and infrared thermal imager 18, are all commonly used by those skilled in the art, and there are no special requirements for them in this application.

[0017] like Figs. 1-3 As shown, this utility model provides a safety auxiliary device for deep well processing of aluminum ingots, including a casting well main structure 1 and a well cover 17 adapted to it. The inner side of the well cover 17 is provided with an infrared thermal imager 18 for scanning and monitoring the internal temperature field distribution of the casting well main structure 1, so as to monitor temperature abnormalities and provide early warning of aluminum liquid leakage.

[0018] According to the technical solution of this utility model, the main structure 1 of the casting well adopts a double-layer isolation well wall design consisting of an outer well wall layer 2 and an inner well wall layer 3. An air gap layer 4, forming a sealed cavity, is provided between the outer well wall layer 2 and the inner well wall layer 3. The outer well wall layer 2 (made of high-strength metal material) is a sandwich sleeve structure with uniformly arranged cooling water channels inside. These cooling water channels circulate external cooling water to indirectly cool the main structure 1 of the casting well. As a safety auxiliary measure, it also includes: 1) a first temperature sensor 10 for monitoring the heat exchange efficiency of the cooling water channels inside the outer well wall layer 2, with its temperature probe located at the bottom of the inner well wall layer 3; 2) a pressure sensor 11 for real-time monitoring of the air pressure inside the air gap layer 4, with its probe located inside the air gap layer 4; and 3) a second temperature sensor 12 for monitoring the initial temperature of the molten aluminum inside the main structure 1 of the casting well. Furthermore, the bottom of the main structure 1 of the casting well is provided with at least one emergency coagulant release mechanism 13, which includes a storage tank 131 and a spraying assembly 132 connected to the top of the storage tank 131.

[0019] Preferably, in the above structure: one end of the cooling water channel inside the outer well wall layer 2 is provided with an inlet valve 5, and the other end is provided with a drain pump 6 and a drain valve 7. The air gap layer 4 is provided with at least one air inlet valve 8 and at least one air outlet valve 9. Both the air inlet valve 8 and the air outlet valve 9 are electrically controlled valves. The air inlet valve 8 is connected to an inert gas source through a pipeline to replenish the gas. The air outlet valve 9 is connected to the external environment, or connected to a gas treatment device through a pipeline, which can directly discharge the gas into the atmosphere, or it can be connected to the exhaust gas treatment system.

[0020] Preferably, the above structure further includes a PLC14, the signal input terminal of which is connected to the first temperature sensor 10, the air pressure sensor 11, and the second temperature sensor 12, and the control output terminal of the PLC7 is connected to the emergency coagulant release mechanism 13. PLC14 is configured to receive and process data from various sensors and infrared thermal imager 18, and continuously monitor the readings of the pressure sensor 11. When the reading of the pressure sensor 11 experiences a continuous and irreversible decline, it determines that the air gap layer 4 of the main structure 1 of the casting well has failed to seal, and generates a first-level warning signal. It receives the monitoring signal from the infrared thermal imager 18. When the infrared thermal imager 18 detects an abnormally high temperature area in the inner well wall layer 3, and the temperature detected by the first temperature sensor 10 exceeds the safety threshold, it determines that the preset aluminum liquid leakage conditions are met. PLC14 outputs a control signal to the emergency coagulant release mechanism 13, triggering it to instantly blow the coagulant powder to the leak point, mix it with the aluminum liquid, and significantly reduce its fluidity, causing it to solidify rapidly, thereby actively plugging the leak.

[0021] Specifically, in the structure of the above-mentioned safety auxiliary device for deep well processing of aluminum ingots, the injection assembly 132 includes an injection pipeline connected to the storage tank 131, a rupture diaphragm and an adjustable nozzle installed at the top of the injection pipeline. The storage tank 131 (the solidifying agent filled in the storage tank 131 is titanium powder or aluminum-titanium alloy powder) is connected to a high-pressure nitrogen source through a high-pressure gas line. The high-pressure gas line is equipped with a normally closed solenoid valve controlled by the PLC 14.

[0022] More specifically, an outlet pipe 15 is provided on one side of the main structure 1 of the casting well, and an external temperature monitor 16 is installed on the outlet pipe 15. The external temperature monitor 16 is a contact-type temperature monitor and can be equipped with an alarm to remind personnel to stay away from the danger zone. In the event of aluminum molten material leakage, it prevents further flow of aluminum molten material.

[0023] More specifically, the manhole cover 17 is equipped with a multi-stage pressure relief structure, which includes a rupture disc with a set specific burst pressure and a spring-loaded safety valve. This dual design enhances safety protection. In the event of a violent steam explosion in extreme circumstances, the multi-stage pressure relief structure on the manhole cover 17 will rapidly and directionally burst or open, guiding the ultra-high temperature and high pressure steam to a predetermined pressure relief channel (i.e., connecting to an external safe point), preventing the disorderly release of energy inside the manhole and workshop, thus avoiding secondary damage.

[0024] The key technical aspect of this invention lies in the combination of its multi-layered protective structure and proactive emergency response mechanism. Figs. 1-3 The key features showcased are the components and specific structures involved in the multi-layered protective structure and active emergency response mechanism. The air gap layer 4 forms a physical isolation barrier, effectively preventing external cooling water from contacting the internal high-temperature aluminum liquid due to well wall failure. For components such as the temperature sensor, air pressure sensor 11, PLC 14, external temperature monitor 16, and infrared thermal imager 18, those skilled in the art can perform conventional setups based on existing technology; this case does not have special requirements regarding model selection or combination.

[0025] Thus, by adopting the technical solution of this utility model, multi-parameter data such as the pressure of the air gap layer 4, the temperature of the cooling water, the temperature of the inner well wall layer 3, and image information are collected in real time and transmitted to the PLC. The PLC performs state judgment through logic operations: when the water level is abnormal, it controls the cooling water circuit to adjust the temperature to reduce the risk; when a comprehensive judgment (e.g., abnormal pressure in the air gap layer 4 accompanied by local high temperature in the inner well wall layer 3) indicates an aluminum liquid leak, the emergency coagulant release device is immediately triggered. This device uses high-pressure gas to drive the coagulant to be sprayed out instantly and omnidirectionally, covering the entire leak area at the bottom of the well. The coagulant mixes with the leaking high-temperature aluminum liquid, undergoing a violent endothermic reaction and alloying reaction, rapidly reducing the fluidity of the aluminum liquid and causing it to solidify in situ, thereby blocking the leak point and actively suppressing the occurrence of an explosion accident, realizing a safety mode transformation from passively accepting risks to actively eliminating hidden dangers.

[0026] As can be seen from the above description, compared with the prior art, this utility model, through its double-layer isolation well wall structure, can use inert gas to isolate molten aluminum from cooling water, physically blocking the conditions for explosion. It can also combine air pressure, temperature, and image monitoring to provide leakage warnings. Moreover, in the event of a leak, it automatically triggers the emergency coagulant release mechanism to release the coagulant. Compared with traditional passive leak plugging, the response time is effectively shortened, the leak is quickly plugged, and the safety of the deep well processing of aluminum ingots is greatly improved.

[0027] The technical solution, working process and implementation effect of this utility model have been described in detail above. It should be noted that the described example is only a typical example of this utility model. In addition, this utility model may have many other specific implementation methods. All technical solutions formed by equivalent substitution or equivalent transformation fall within the scope of protection claimed by this utility model.

Claims

1. A safety auxiliary device for deep well processing of aluminum ingots, comprising a casting well main structure (1) and a well cover (17) adapted thereto, wherein an infrared thermal imager (18) for scanning and monitoring the internal temperature field distribution of the casting well main structure (1) is provided on the inner side of the well cover (17), characterized in that: The main structure (1) of the cast well adopts a double-layer isolation well wall design consisting of an outer well wall layer (2) and an inner well wall layer (3). A sealed air gap layer (4) is provided between the outer well wall layer (2) and the inner well wall layer (3). The outer well wall layer (2) is a sandwich sleeve structure with uniform cooling water channels inside. It also includes a first temperature sensor (10) for monitoring the heat exchange efficiency of the cooling water channels inside the outer well wall layer (2). Its temperature probe is located in the bottom area of ​​the inner well wall layer (3) for real-time monitoring. A pressure sensor (11) for monitoring the internal pressure of the air gap layer (4) is provided with its probe inside the air gap layer (4), and a second temperature sensor (12) for monitoring the initial temperature of the molten aluminum inside the main structure (1) of the casting well; and at least one emergency coagulant release mechanism (13) is provided at the bottom of the main structure (1) of the casting well, the emergency coagulant release mechanism (13) includes a storage tank (131) and a spray assembly (132) connected to the top of the storage tank (131).

2. The safety auxiliary device for deep well processing of aluminum ingots according to claim 1, characterized in that: The cooling water channel inside the outer well wall layer (2) is provided with an inlet valve (5) at one end and a drain pump (6) and a drain valve (7) at the other end.

3. The safety auxiliary device for deep well processing of aluminum ingots according to claim 1, characterized in that: At least one inlet valve (8) and at least one exhaust valve (9) are provided on the air gap layer (4). Both the inlet valve (8) and the exhaust valve (9) are electrically controlled valves. The inlet valve (8) is connected to an inert gas source through a pipeline. The exhaust valve (9) is connected to the external environment or to a gas processing device through a pipeline.

4. The safety auxiliary device for deep well processing of aluminum ingots according to claim 1, characterized in that: It also includes a PLC (14), the signal input terminal of which is connected to the first temperature sensor (10), the air pressure sensor (11), and the second temperature sensor (12), and the control output terminal of the PLC (7) is connected to the emergency coagulant release mechanism (13).

5. The safety auxiliary device for deep well processing of aluminum ingots according to claim 4, characterized in that: The injection assembly (132) includes an injection pipeline connected to the storage tank (131), a bursting diaphragm installed at the top of the injection pipeline, and an adjustable nozzle. The storage tank (131) is connected to a high-pressure nitrogen source through a high-pressure gas line, and a normally closed solenoid valve controlled by the PLC (14) is provided on the high-pressure gas line.

6. The safety auxiliary device for deep well processing of aluminum ingots according to claim 1, characterized in that: An outlet pipe (15) is provided on one side of the main structure (1) of the casting well, and an external temperature monitor (16) is installed on the outlet pipe (15).

7. The safety auxiliary device for deep well processing of aluminum ingots according to claim 1, characterized in that: The manhole cover (17) is provided with a multi-stage pressure relief structure, which includes a rupture disc and a spring-loaded safety valve.

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