An adsorptive separation device

Abstract

The utility model discloses an adsorption separation device relates to adsorption and analysis control technical field. The method includes: setting the first cleanliness threshold of finished gas and the second cleanliness threshold of analysis gas, according to the current state of the first cleanliness and the second cleanliness, the dynamic adjustment of the regeneration medium flow of analysis process, or when the first cleanliness reaches the first cleanliness threshold, end current adsorption process, make the adsorption tower and the regeneration tower switch operation mode. The utility model discloses through the dynamic adjustment of the dual state of real -time monitoring finished gas and analysis gas, can adaptive response actual working condition fluctuation, while guaranteeing finished gas quality stability, avoided the problem of insufficient or excessive consumption of regeneration medium of regeneration, significantly reduced operating energy consumption.

Description

Technical Field

[0001] This utility model relates to the field of adsorption and desorption control technology, and in particular to an adsorption separation device for compressed air adsorption separation. Background Technology

[0002] Adsorption separation devices utilize the selective adsorption characteristics of adsorbents on different gas components in compressed gas to separate and purify gas components in the air. In the adsorption tower, the adsorbate on the surface of the adsorbent will reach a saturated state. At this time, it is necessary to reduce the pressure of the adsorption tower to desorb the adsorbate on the adsorbent, thereby desorbing the adsorbent and allowing it to be adsorbed again.

[0003] Currently, to ensure seamless switching between adsorption and desorption in the adsorption tower, compressed gas adsorption separation devices typically employ time-sequential control, meaning the device's operation is controlled according to a preset process sequence and corresponding time intervals. However, in actual production, the consumption of purified finished gas at the production end fluctuates, sometimes high and sometimes low. Under these conditions, the time-sequential control method reveals numerous problems.

[0004] Specifically, when the consumption of finished gas is large, the adsorbent in the adsorption device will be in a supersaturated state. Under this state, traditional time-sequential control cannot detect the supersaturation of the adsorbent, which will cause unstable quality of the finished gas. Since traditional time-sequential control cannot detect the supersaturation of the adsorbent, it will still perform the desorption operation according to the predetermined time, resulting in insufficient desorption, which in turn affects the adsorption and separation effect of the next cycle, causing unstable quality of the finished gas.

[0005] When gas consumption is low, the adsorbent is in an unsaturated state, and only a small amount of clean medium or energy is needed to complete the desorption process. However, sequential control still operates according to the preset time and program, continuously inputting clean or energy medium into the regeneration tower even after desorption is complete, resulting in unnecessary resource waste. In summary, sequential control, because it cannot dynamically adjust according to the actual state of the adsorbent, is difficult to adapt to fluctuations in gas consumption during actual production, leading to unstable finished gas quality and resource waste.

[0006] Therefore, to address the problem that adsorption towers relying on time-series adjustments cannot flexibly adjust their operating modes according to the actual state of the adsorbent, leading to a decrease in the quality of the finished gas when the adsorbent is oversaturated and a waste of resources when it is undersaturated, this invention proposes a saturation control mechanism based on real-time monitoring of the cleanliness of both the finished gas and the desorption gas, thereby achieving precise adjustment of the adsorption tower and the regeneration tower. Utility Model Content

[0007] The main purpose of this invention is to provide an adsorption separation device that allows the adsorption tower to switch operating states based on the saturation of the adsorbent, thereby improving the quality of the finished gas and reducing resource waste.

[0008] To achieve the above objectives, this utility model proposes an adsorption separation device, characterized in that it includes at least one A tower body and at least one B tower body capable of alternating as an adsorption tower and a regeneration tower, and a control valve system for controlling the airflow path. The device further includes: The first measuring device is installed on the finished gas outlet pipeline and is used to monitor the real-time first cleanliness of the finished gas; A second measuring device is installed on the desorption gas emission pipeline and is used to monitor the real-time second cleanliness level of the desorption gas; and The controller is electrically connected to the first measuring device, the second measuring device, and the control valve system. The controller is configured to switch the operating modes of the A tower body and the B tower body based on the first cleanliness and the second cleanliness of the first and second measuring devices, and through the control valve system.

[0009] Furthermore, the controller is configured to dynamically adjust the regeneration medium flow rate of the A tower body and the B tower body according to the current state of the first cleanliness and the second cleanliness, and through the control valve system.

[0010] Furthermore, the control valve system includes a regeneration medium regulating valve for increasing or decreasing the supply of regeneration medium. The output terminal of the controller is electrically connected to the control input terminal of the regeneration medium regulating valve. The regeneration medium regulating valve is used to shut off or limit the supply of regeneration medium. The regeneration medium regulating valve is a connecting valve as described in this application; it is a proportional valve, facilitating the increase or decrease of the regeneration medium.

[0011] Furthermore, it also includes a connecting pipe, one end of which is connected to the outlet pipe of the A tower body and the other end of which is connected to the outlet pipe of the B tower body, for supplying a portion of the finished gas from the outlet of the A tower body into the B tower body.

[0012] Furthermore, it also includes: Pressure sensing components are respectively installed on the top of tower body A and tower body B; The controller is electrically connected to the pressure sensing component and is used to determine the completion status of the pressure equalization process of the A tower body and the B tower body.

[0013] Furthermore, the first measuring device and the second measuring device are pressure dew point sensors or gas component content sensors.

[0014] The above technical solution has the following advantages: By real-time monitoring of the primary cleanliness of the finished gas and using its attainment of the primary cleanliness threshold as the main basis for switching operating modes, the problem of product quality degradation under high loads caused by the inability to detect the actual saturation state of the adsorbent in traditional sequential control is fundamentally solved. Introducing monitoring of the secondary cleanliness of the desorption gas allows for precise assessment of the desorption process's completion. When desorption is completed ahead of schedule but adsorption still has a margin, the supply of regeneration media can be stopped or reduced in a timely manner, avoiding the significant energy waste commonly found in existing technologies. This is especially beneficial under medium- and low-load or variable-load conditions, improving energy efficiency. Simultaneously, ensuring that the standby tower has undergone sufficient desorption during each switchover improves the reliability of the unit's operation and avoids continuity issues caused by incomplete desorption.

[0015] This invention, by setting early warning thresholds and combining them with the states of first and second cleanliness levels, can predict and proactively respond to high-load impacts. It ensures the desorption rate keeps pace with the adsorption rate by increasing the regeneration medium flow rate, demonstrating adaptability to different operating conditions. Monitoring the pressure status of the equalization process enhances equipment safety and fault diagnosis capabilities. By introducing an adaptive algorithm to dynamically adjust control thresholds, the device can self-optimize during long-term operation, consistently maintaining a high-efficiency operating range. Long-term tracking and prediction of equipment performance degradation trends help users effectively avoid unplanned downtime and reduce overall lifecycle maintenance costs.

[0016] Compared with existing technologies, this utility model innovatively introduces dual cleanliness monitoring of finished gas and desorption gas, and dynamically adjusts it when the threshold is not reached, realizing an adaptive response to fluctuations in gas consumption and avoiding the problems of insufficient desorption or excessive waste.

[0017] This invention avoids the problem of material waste caused by the increased packing volume required by traditional sequential control to prevent oversaturation of the adsorbent in the adsorption cylinder. Furthermore, a large packing volume increases energy consumption during desorption, wasting energy. In an undersaturated regeneration tower, desorption may only require half the actual time, while traditional sequential control requires the entire process time, resulting in low efficiency. Moreover, the clean finished product compressed air and energy used for desorption are continuously input, leading to further waste. Attached Figure Description

[0018] The present invention will now be described in detail with reference to specific embodiments and accompanying drawings, wherein: Figure 1 This is a schematic diagram of the control system of a traditional adsorption separation and drying device. Figure 2 This is a schematic diagram of the process structure of adsorption in tower A and desorption in tower B of this utility model; Figure 3 This is a schematic diagram of the process structure of adsorption in tower B and desorption in tower A according to this utility model; Figure 4 This is a flowchart illustrating the steps of this utility model. Figure 5 This is a schematic diagram showing the connection between the controller, the first measuring device, and the second measuring device of this utility model.

[0019] In the diagram: 1. Compressed gas inlet pipe; 2. A-tower inlet pipe; 21. A-tower inlet valve; 3. A-tower body; 31. A-tower adsorbent; 32. A-tower pressure sensing component; 4. A-tower outlet pipe; 41. A-tower check valve; 5. Finished gas outlet pipe; 51. First measuring device; 6. B-tower outlet pipe; 61. B-tower check valve; 7. B-tower body; 71. B-tower adsorbent; 72. B-tower pressure sensing component; 8. B-tower inlet pipe; 81. B-tower inlet valve; 9. Desorption exhaust pipe; 91. Second measuring device; 92. Exhaust silencer; 10. Controller; W. Connecting pipe; W1. Connecting valve; Q. Exhaust pipe; Q1. A-tower exhaust valve; Q2. B-tower exhaust valve. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the following specific embodiments are only used to explain this utility model and do not constitute a limitation on this utility model.

[0021] like Figure 1 and Figure 2 As shown, Figure 1 This is a schematic diagram of the control system of a traditional adsorption separation and drying device. The control system is based on... Figure 1 The timing operation is configured with four time parameters: t1, t2, t3, and t4. t1 is the adsorption time, t2 is the regeneration delay, t3 is the regeneration time, and t4 is the pressure equalization time. Four relays YV1 to YV4 are used to control the corresponding functions: YV1: adsorption of tower A (body 3), YV2: regeneration of tower A (body 3), YV3: adsorption of tower B (body 7), and YV4: regeneration of tower B (body 7). These relays operate sequentially according to time and process. Traditionally, YV1 to YV4 correspond to the tower A inlet valve 21, tower A outlet valve Q1, tower B inlet valve 81, and tower B outlet valve Q2, respectively. The manual valve corresponds to the connecting valve W1, which can be a proportional valve used to adjust the opening. The specific process and control actions are as follows: Pressure equalization process: YV1 open, YV2 close, YV3 open, YV4 close, manual valve open, airflow enters the two towers. The pressure equalization time t4 is generally set to 5 seconds or 10 seconds. When the tower volume is large, it will also be set to 30 seconds or 60 seconds to ensure that the pressure of the two towers is consistent. Regeneration delay process: After the equalization process has been completed, the regeneration delay process begins. At this time, YV1 is open, YV2 is closed, YV3 is closed, and YV4 is closed. The compressed airflow no longer enters the B tower body 7 through YV3.

[0022] Adsorption process of Tower A body 3 and desorption process of Tower B body 7: After the set regeneration delay time, the discharge valve Q2 of Tower B opens, instantly venting the pressure of Tower B body 7 and entering the regeneration time of Tower B body 7. Pure gas enters Tower B body 7 from the connecting pipe W and connecting valve W1, passes through the adsorbent 71 of Tower B and is discharged from YV4, and the adsorbent 71 of Tower B is regenerated and desorbed. Reverse pressurization process: After the set regeneration time t3, YV4 is shut down, and the reverse pressurization time of the regeneration period begins. After the reverse pressurization time of the regeneration period is completed, the regeneration cycle of tower B body 7 is completed, and the adsorption cycle of tower A body 3 is also completed. At this time, the pressure equalization process after switching working modes and the set pressure equalization time begin, specifically: 1. With YV1 open, YV2 closed, YV3 open, and YV4 closed, the airflow enters both towers simultaneously again. The pressure equalization time is generally set to 5 or 10 seconds. When the tower volume is large, it is also set to 30 or 60 seconds to ensure that the pressure of the two towers is consistent. 2. Regeneration delay process and time of Tower B body 7: After the pressure equalization process is completed, the adsorption and desorption process of Tower B body 7 and Tower A body 3 is entered. At this time, YV1 is closed, YV2 is closed, YV3 is open, and YV4 is closed. Compressed gas no longer enters Tower A body 3 through YV1. 3. B Tower Body 7 Adsorption A Tower Body 3 Reprocess: After the set regeneration time delay, YV2 is opened, instantly venting the pressure in A Tower Body 3 and entering the regeneration time of A Tower Body 3. Pure gas enters A Tower Body 3 through the connecting pipe W and the manual valve, passes through A Tower Adsorbent 31 and is discharged from YV2, regenerating and desorbing A Tower Adsorbent 31. 4. Reverse pressurization process and time: After the set regeneration time, YV2 is turned off, and the reverse pressurization time of the regeneration time is entered. After the reverse pressurization time of the regeneration time is completed, the regeneration cycle of tower B body 7 is completed, and the adsorption cycle of tower A body 3 is also completed. Then, the pressure equalization process and the set pressure equalization time are entered again, YV1 is turned on, YV2 is turned off, YV3 is turned on, and YV4 is turned off. The airflow enters the two towers at the same time again, and the cycle repeats.

[0023] The above scheme uses timed adsorption time t1 and regeneration time t3, which means that the switching of working modes is performed according to preset times. This makes it impossible to know the specific states of tower A (3) and tower B (7), easily leading to difficulty in controlling the quality of the produced gas. Therefore, this application proposes a novel control method to overcome this problem, as follows: like Figure 4 As shown, the judgments for reaching the first cleanliness threshold, the second cleanliness threshold, and the warning threshold are all described in terms of being greater than or equal to.

[0024] like Figures 2 to 4 As shown, a real-time monitoring data control method for adsorption separation is applied to at least one adsorption tower capable of alternately performing an adsorption process and at least one regeneration tower capable of performing a desorption process. The method includes setting a first cleanliness threshold for the finished gas and a second cleanliness threshold for the desorbed gas. There is no limit to the number of adsorption towers and regeneration towers, that is, there is no limit to the number of tower body 3 (A tower) and tower body 7 (B tower). This application takes a single adsorption tower and regeneration tower as an example.

[0025] During the adsorption process, the real-time first cleanliness of the finished gas at the adsorption tower outlet and the real-time second cleanliness of the desorbed gas at the regeneration tower outlet are continuously monitored. Based on real-time comparisons of the first cleanliness level with the first cleanliness threshold and the second cleanliness level with the second cleanliness threshold, the following steps are performed: Step a. Before the adsorption process ends, dynamically adjust the regeneration medium flow rate of the desorption process according to the current status of the first and second cleanliness levels. Step b. When the first cleanliness reaches the first cleanliness threshold and the second cleanliness reaches the second cleanliness threshold, end the current adsorption process and switch the working mode; if the second cleanliness does not reach the second cleanliness threshold, execute step a to increase the regeneration medium flow rate until the switching condition is met.

[0026] The specific implementation control process is as follows: This embodiment uses a common dual-tower pressure swing adsorption compressed air dryer as an example for illustration; its structure can be found in [reference needed]. Figure 2 and Figure 3 The process shown can be partially referenced. Figure 1 As shown. The device includes a tower body 3 (A tower body 3) and a tower body 7 (B tower body 7). Tower body 3 and tower body 7 can be used alternately as an adsorption tower and a regeneration tower. When tower body 3 is used as an adsorption tower, tower body 7 is used as a regeneration tower. The raw material compressed gas enters from the compressed gas inlet pipe 1 and enters tower body 3 through the tower inlet valve 21 on the tower inlet pipe 2.

[0027] First, control parameters are set. In this embodiment, the first cleanliness level is the pressure dew point of the finished gas. The first cleanliness threshold is set according to process requirements, for example, -40℃. When the first cleanliness level is higher than -40℃, it has reached the first cleanliness threshold, meaning the adsorption tower is saturated and the subsequent finished gas dryness is unacceptable. The second cleanliness level is the atmospheric pressure dew point of the desorbed gas discharged from the regeneration tower. Its second cleanliness threshold is set empirically, for example, +20℃. When the second cleanliness level is lower than +20℃, it can be considered that the second cleanliness level has decreased and reached the second cleanliness threshold, most of the moisture in the regeneration tower has been purged, and the regeneration process is basically complete.

[0028] like Figure 4 and Figure 5 As shown, the control method is implemented according to the following steps: Assuming the initial state is adsorption in tower A body 3 and regeneration in tower B body 7, the first cleanliness is continuously obtained through the first measuring device 51 set on the finished gas outlet pipe 5, and the second cleanliness is obtained through the second measuring device 91 set on the desorption exhaust pipe 9. The first measuring device 51 can be a pressure dew point meter, and the second measuring device 91 can be an atmospheric pressure dew point meter.

[0029] The switching logic in step b above is as follows: During the adsorption process, the adsorbent 31 in tower A body 3 continuously adsorbs moisture. The dried finished gas flows out from tower A outlet pipe 4, passes through tower A one-way valve 41 to prevent backflow, and then flows into finished gas outlet pipe 5. During this process, the first cleanliness value will slowly rise from a very low initial value, which can be selected as -60℃. When the first cleanliness is detected to rise and reach the first cleanliness threshold, such as -40℃, it indicates that the adsorbent 31 in tower A is saturated and can no longer guarantee the quality of the finished gas. At this time, the external controller 10 does not immediately switch the working mode, but first judges the regeneration status of tower B body 7. Only when the second cleanliness also reaches the second cleanliness threshold will the controller 10 trigger the program to switch the working mode. If the regeneration of tower B body 7 has not yet been completed at this time, the controller 10 will gradually increase the opening of the connecting valve W1, prioritize the execution of the command to increase the flow rate of the regeneration medium, and accelerate the desorption process of tower B body 7. After it is completed, the working mode will be switched. This is the key benchmark to ensure the continuous, stable and reliable operation of the finished gas quality.

[0030] The switching logic of step a above is as follows: During the process where the first cleanliness level has not yet reached the first cleanliness threshold, tower A body 3 is in an unsaturated adsorption state. The core of this step is to reduce energy consumption. Specifically, at the start of desorption, tower B body 7 will discharge very humid gas with a high second cleanliness value, such as +30°C. This gas passes through tower B inlet pipe 8, tower B discharge valve Q2 on discharge pipe Q, and is finally discharged through desorption exhaust pipe 9. As the regeneration medium continues to purge, the second cleanliness level will gradually decrease. When the second measuring device 91 detects that the second cleanliness level has dropped below the second cleanliness threshold, such as +20°C, while the first cleanliness level is still far superior to the first cleanliness threshold, for example, -55°C, this indicates that the regeneration of tower B body 7 is complete, but the adsorption capacity of tower A body 3 still has a large margin. At this point, continuing to supply regeneration medium to tower B body 7 would be a waste. Therefore, dynamic adjustment operations are performed. For example, the controller 10 sends a command to the connecting valve W1, which is typically a proportional valve or a regulating valve, located on the connecting pipe W, to reduce its opening or even close it completely, thereby reducing or stopping the supply of regeneration medium to the B tower body 7. While ensuring normal adsorption in the A tower body 3, dynamic savings in regeneration gas consumption are achieved. When the subsequent first cleanliness level approaches the first cleanliness threshold, the controller 10 reopens the connecting valve W1 to equalize and reverse pressurize the B tower body 7, preparing for the switching of operating modes.

[0031] When the first cleanliness level at the outlet of tower A body 3 is lower than the first cleanliness threshold and the second cleanliness level at the outlet of tower B body 7 is higher than the second cleanliness threshold, it indicates that the adsorption capacity of tower A body 3 still has a large margin, and tower B body 7 also needs to continue to complete the desorption. At this time, the adsorption of tower A body 3 and the desorption of tower B body 7 continue, and the first and second cleanliness levels are continuously monitored.

[0032] Based on the above embodiments, this embodiment adds an additional warning threshold for the finished gas, which is better than the first cleanliness threshold. For example, the warning threshold is set to -45°C and the first cleanliness threshold is -40°C.

[0033] Under high-load conditions, a large flow rate or high moisture content of compressed air entering the adsorption tower can cause the first cleanliness value to rise very rapidly. The first measuring device 51 detected that the first cleanliness deteriorated and exceeded the warning threshold in a short period of time. At the same time, monitoring by the second measuring device 91 revealed that due to the short switching time, the regeneration process of the regeneration tower was not yet complete, and the second cleanliness was still much higher than the second cleanliness threshold. This indicates that the adsorbent saturation rate is faster than the regeneration rate. If the high-load conditions continue, in the next cycle, the regeneration tower is prone to incomplete desorption and will be unable to perform the adsorption task, resulting in the finished gas quality continuously failing to meet standards.

[0034] To address the aforementioned issues with the regeneration tower, the method further includes the following steps: When both the first cleanliness level and the second cleanliness level are detected to be above the first cleanliness threshold and above the second cleanliness threshold, the flow rate of the medium used for regeneration is proactively increased. Specifically, the connecting valve W1 is adjusted to increase its opening, supplying more dry gas to the regeneration tower to forcibly accelerate the regeneration process, ensuring that tower B 7 can complete regeneration and restore its adsorption capacity before tower A 3 becomes completely saturated. This proactive and predictive adjustment based on dual monitoring data significantly improves the adaptability and reliability of the unit under load fluctuations.

[0035] When the first cleanliness level has not reached the first cleanliness threshold and the second cleanliness level has reached the second cleanliness threshold, the supply of regeneration media for the analysis process is reduced or stopped to save energy.

[0036] In a typical low-load application scenario, since the required gas consumption is very small, tower A body 3 performs the adsorption process, tower B body 7 performs the desorption process, the first cleanliness threshold is set to -40℃, and the second cleanliness threshold is set to +20℃.

[0037] After adsorption begins, due to the low load, the first cleanliness value of tower A body 3 remains at an excellent level below -60℃ for a long time. Since the amount of gas entering tower A body 3 is small, the amount of regeneration gas diverted to tower B body 7 is relatively sufficient. The regeneration process of tower B body 7 proceeds very quickly. It is possible that within one-third of the time after the start of the entire working cycle, the second measuring device 91 will detect that the second cleanliness of tower B body 7 has decreased and reached the second cleanliness threshold requirement.

[0038] At this point, the conditions are met: the first cleanliness level has not yet reached the first cleanliness threshold, and the second cleanliness level has reached the second cleanliness threshold. At this time, the connecting valve W1 needs to stop supplying the regeneration medium to the B tower body 7. In the following cycle, the A tower body 3 continues its adsorption operation until the first cleanliness level slowly rises to the first cleanliness threshold to trigger the switch, or reaches a maximum protection time. In this way, under low load conditions, the regeneration gas consumption is zero most of the time, and the energy saving effect is very significant.

[0039] like Figure 4 As shown, dynamic adjustment includes: When the first cleanliness level has exceeded the warning threshold but has not yet reached the first cleanliness level threshold, and the second cleanliness level has not reached the second cleanliness level threshold, the supply of regeneration media for the analysis process is increased to accelerate the analysis process; wherein, the value of the warning threshold is better than the first cleanliness level threshold.

[0040] This embodiment demonstrates how, when faced with high load impacts, the system can anticipate potential risks of insufficient regeneration by using a combination of first and second cleanliness levels, and proactively increase the regeneration medium flow rate to ensure stable system operation. This is an important adjustment method to guarantee system stability.

[0041] The regeneration medium is a portion of the finished product gas drawn from the outlet of the adsorption tower.

[0042] exist Figure 2 In the illustrated apparatus structure, when tower A (3) functions as an adsorption tower, most of the dried finished gas from its outlet is supplied to the user through finished gas outlet pipe 5. A small portion, however, flows in the opposite direction through connecting pipe W and connecting valve W1 into the outlet end of tower B (7), which serves as a regeneration tower, i.e., tower B outlet pipe 6. This gas then passes through the adsorbent 71 in tower B and is discharged from tower B inlet pipe 8 via tower B outlet valve Q2 on outlet pipe Q. This portion is the dried finished gas used for regeneration, which is the regeneration medium defined in this application. This method of regeneration using its own product is common in pressure swing adsorption (PSA) and is a standard method in heatless and micro-thermal regeneration equipment.

[0043] The method of this application also includes monitoring the completion status of the process through a pressure sensor after switching the working mode, and outputting a fault signal if the process is not completed within a preset time.

[0044] Pressure sensing components 32 for tower A and 72 for tower B are respectively installed on tower A body 3 and tower B body 7. When the working mode is switched, the pressure equalization process will be executed.

[0045] The specific operation is as follows: Open the valves connecting tower A (body 3) and tower B (body 7), namely the connecting valve W1, as well as the tower A inlet valve 21 and tower B inlet valve 81, allowing the high-pressure adsorption tower to supply gas to the low-pressure regeneration tower. During this process, the controller 10 monitors the pressure signals from the tower A pressure sensing component 32 and the tower B pressure sensing component 72 in real time. When the absolute value of the difference between the readings of the two pressure sensors is less than a preset very small pressure difference, such as 0.02 MPa, the controller 10 determines that the pressure equalization process is complete, and then proceeds to the next step of switching operating modes.

[0046] Meanwhile, the controller 10 is equipped with an internal pressure equalization timer, for example, 15 seconds. If the pressures of the two towers have not reached equilibrium 15 seconds after the pressure equalization process is started, the controller 10 determines that a system fault has occurred. For example, the connecting valve W1 may be stuck and not operating correctly, or there may be a leak in the pipeline. At this time, the controller 10 will immediately stop the switching process, put the equipment into a safe state, and display an alarm message of "pressure equalization fault" on the human-machine interface to prompt maintenance personnel to check.

[0047] The first cleanliness threshold and / or the second cleanliness threshold are variables that the control system dynamically adjusts based on historical operating data and adaptive algorithms.

[0048] The above method achieves optimal operating efficiency, and the values ​​of the first and second cleanliness thresholds can be adjusted and changed according to different scenarios. The controller 10 integrates an adaptive adjustment module that continuously records and analyzes historical operating data, such as the duration of each cycle, the specific time points when the first and second cleanliness thresholds are reached, ambient temperature, system pressure, etc.

[0049] Based on this big data, the controller 10 can perform self-optimization. For example, the adaptive adjustment module detects that in summer, when the ambient temperature and humidity are high, the regeneration process becomes more difficult. Even if the second cleanliness level reaches +20°C, the initial first cleanliness value of the new adsorption tower after switching is still poor. After learning, the controller 10 will automatically lower the second cleanliness threshold to +15°C under summer conditions, requiring deeper regeneration to ensure the quality of the finished gas. Conversely, in winter, when the dry conditions are favorable, the adaptive adjustment module detects that regeneration is easy and will appropriately relax the second cleanliness threshold to +23°C to save more regeneration gas.

[0050] Similarly, for the first cleanliness threshold, if the performance of adsorbent 31 in tower A and adsorbent 71 in tower B degrades after long-term operation, the controller 10 will find that the time to reach -40℃ is getting shorter and shorter. In order to extend the adsorbent replacement cycle, in some non-core applications, the first cleanliness threshold can be automatically adjusted slightly to -38℃ after the performance degrades to a certain extent, according to a preset strategy. This sacrifices a small amount of quality margin in exchange for a longer operating time. At the same time, the user will be prompted that the performance of adsorbent 31 in tower A and adsorbent 71 in tower B has degraded and maintenance is recommended. Through its adaptive capability, it can maintain a near-optimal operating state throughout its entire cycle.

[0051] The first and second cleanliness levels are based on pressure dew point, or measurements of the content of specific gas components.

[0052] As can be seen from the above embodiments, in compressed air drying applications, the first and second cleanliness levels are typically measured based on pressure dew point and atmospheric dew point, which are direct indicators of the water vapor content in the air. However, the method of this invention is also applicable to other gas separation applications. For example, in a pressure swing adsorption (PSA) nitrogen generator, the purpose is to separate nitrogen from compressed air. In this case, the first cleanliness level measures the purity of the finished nitrogen gas, which can be specifically achieved by measuring the oxygen content of impurities in the finished gas. The measuring device is a trace oxygen analyzer, and the first cleanliness threshold may be set to an oxygen content below 10 ppm. The second cleanliness level can be characterized by measuring the oxygen concentration in the exhaust gas discharged from the regeneration tower. When the oxygen concentration in the discharged exhaust gas decreases significantly, it indicates that a large amount of oxygen adsorbed on the adsorbent has been released, and the regeneration process is nearing completion.

[0053] like Figures 2 to 4 As shown, an adsorption separation device includes an adsorption tower, a regeneration tower, and a control valve system, and further includes: The first measuring device 51 is used to monitor the real-time first cleanliness of the finished gas; The second measuring device 91 is used to monitor the real-time second cleanliness of the desorbed gas; and Controller 10 is configured to perform the above-described real-time monitoring data control method for adsorption separation.

[0054] The device includes tower A body 3 and tower B body 7, as well as a control valve system consisting of tower A inlet valve 21, tower B inlet valve 81, tower A discharge valve Q1, tower B discharge valve Q2, and connecting valve W1. The adsorption tower and regeneration tower are tower A body 3 and tower B body 7, respectively. Of course, they will be switched when switching working modes. The control valve system includes all the valves mentioned above, which are used to control the gas flow direction.

[0055] The compressed gas inlet pipe 1 can be independently installed on the A-tower inlet pipe 2 and the B-tower inlet pipe 8. Preferably, the compressed gas inlet pipe 1 is divided into two branches, one connected to the A-tower inlet pipe 2 and the other connected to the B-tower inlet pipe 8. The A-tower inlet pipe 2 is equipped with an A-tower inlet valve 21, and the B-tower inlet pipe 8 is equipped with a B-tower inlet valve 81. When the A-tower body 3 is used as an adsorption tower and the B-tower body 7 is used as a regeneration tower, the A-tower inlet valve 21 is opened, allowing compressed air to flow into the A-tower inlet pipe 2, thus introducing compressed gas. The compressed gas is filled into the A tower body 3, which contains an A tower adsorbent 31. The A tower adsorbent 31 adsorbs the compressed gas, causing impurities in the compressed gas to be adsorbed into the A tower adsorbent 31. The adsorbed compressed gas flows out from the A tower outlet pipe 4 and finally flows to the first measuring device 51, so that the first measuring device 51 can obtain the first cleanliness of the finished gas from the A tower outlet pipe 4 in real time. The finished gas after passing through the first measuring device 51 flows to the finished gas outlet pipe 5 to supply the gas consumption end.

[0056] When the connecting valve W1 is opened, a portion of the finished gas from the outlet pipe 4 of tower A flows from the connecting pipe W and the outlet pipe 6 of tower B to the body 7 of tower B. This also serves to equalize the pressure between the body 3 of tower A and the body 7 of tower B. The finished gas participates in the desorption of the adsorbent 71 in tower B. The impurity gas in the body 7 of tower B flows from the inlet pipe 8 of tower B to the outlet pipe Q. The second cleanliness of the desorbed gas is obtained at the second measuring device 91 at the outlet pipe Q, and finally flows out through the desorption exhaust pipe 9 at the second measuring device 91. The above scheme connects the body 3 of tower A and the body 7 of tower B, and installs the first measuring device 51 and the second measuring device 91 on the finished gas outlet pipe 5 and the desorption exhaust pipe 9, respectively. This allows for continuous acquisition of the first cleanliness of the finished gas and the second cleanliness of the desorbed gas, enabling real-time monitoring of the status of the body 3 of tower A and the body 7 of tower B, facilitating the switching of operation between the body 3 of tower A and the body 7 of tower B. At the same time, the first measuring device 51 and the second measuring device 91 of this invention can continuously measure the status of the finished gas and the desorbed gas, continuously detecting the quality at the gas consumption end.

[0057] like Figure 2 and Figure 3 As shown, the discharge pipe Q can be independently connected to the inlet pipe 2 of tower A and the inlet pipe 8 of tower B, so that both the inlet pipe 2 of tower A and the inlet pipe 8 of tower B are equipped with discharge pipe Q. Preferably, the discharge pipe Q connects the inlet pipe 2 of tower A and the inlet pipe 8 of tower B. An outlet valve Q1 for tower A and an outlet valve Q2 for tower B are installed on the discharge pipe Q. A second measuring device 91 is placed between the outlet valves Q1 and Q2 of tower B, and an exhaust pipe 9 is connected to the second measuring device 91. When tower A 3 is used as a regeneration tower, opening the outlet valve Q1 allows the desorbed gas from tower A 3 to flow out through the inlet pipe 2, the discharge pipe Q, and the exhaust pipe 9. Because the outlet valve Q2 of tower B is closed, gas cannot flow out of the outlet pipe Q of tower B 7. The same applies when tower B 7 is used as a regeneration tower. To reduce the noise of the desorbed gas discharge, an outlet silencer 92 is installed on the exhaust pipe 9.

[0058] The present invention preferably connects the gas outlet pipe 5 of tower A and the gas outlet pipe 6 of tower B, and a first measuring device 51 is arranged at the junction of the three, and / or, a tower A pressure sensing component 32 is arranged at the connection between tower A gas outlet pipe 4 and tower A body 3, and a tower B pressure sensing component 72 is arranged at the connection between tower B gas outlet pipe 6 and tower B body 7.

[0059] Specifically, one-way valves 41 for tower A and 61 for tower B are installed on the outlet pipe 4 and outlet pipe 6 of tower B, respectively. This allows the finished gas flowing out of tower A 3 to flow from outlet pipe 4 to outlet pipe 5. During this flow, the first measuring device 51 obtains the first cleanliness level of the finished gas, preventing it from flowing into outlet pipe 61 of tower B, thus increasing the discharge flow rate of the finished gas. Pressure sensing components 32 for tower A and 72 for tower B obtain the pressure values ​​of outlet pipe 4 for tower A and outlet pipe 6 for tower B, respectively, to ensure real-time measurement of pressure equalization and regulation of tower A 3 and tower B 7. This also prevents the effective adsorption area and adsorption performance of the adsorbent from being reduced during the desorption process of the compressed finished gas.

[0060] like Figure 4 and Figure 5 As shown, the above scheme will now be explained in detail: The first measuring device 51 preferably employs a high-precision digital dew point transmitter, which is installed on the finished gas outlet pipe 5 to accurately measure the pressure dew point and first cleanliness of the finished gas.

[0061] The second measuring device 91 preferably employs an economical atmospheric dew point or humidity sensor, installed on the desorption exhaust pipe 9, to measure the dew point and second cleanliness of the desorption gas. The end of the desorption exhaust pipe 9 is typically also equipped with an exhaust muffler 92 to reduce noise generated during exhaust.

[0062] The controller 10 can be a programmable logic controller (PLC) or an embedded industrial computer with rich input / output interfaces. The controller 10 connects to the first measuring device 51 and the second measuring device 91 via analog or digital input ports to receive real-time data on the first and second cleanliness levels. Its output ports connect to the solenoid pilot valves of each pneumatic valve in the control valve system to control the valve's opening and closing actions. The controller 10 internally contains the logic program for the aforementioned control method. When the controller 10 is powered on, it automatically collects the first and second cleanliness data and, based on the built-in logic algorithm, dynamically controls the entire valve system in real-time, thereby achieving intelligent regulation of the adsorption and desorption processes. The controller 10 also includes a human-machine interface (HMI) for setting parameters such as the first and second cleanliness thresholds and displaying the real-time operating status and alarm information of the equipment.

[0063] The controller 10 is configured to send an instruction to reduce or stop the supply of regeneration media in the analysis process when it receives a first cleanliness level that has not yet reached a first cleanliness threshold and a second cleanliness level that has reached a second cleanliness threshold.

[0064] When the controller 10 determines that the first cleanliness level is lower than the first cleanliness threshold and the second cleanliness level is lower than the second cleanliness threshold, the controller 10 controls the output port of the connecting valve W1 and sends an execution signal to close or reduce the opening. If the connecting valve W1 is an electric regulating valve controlled by a 4-20mA signal, the controller 10 will adjust the output current, such as reducing it from 12mA to 4mA to fully close the connecting valve W1, or reducing it from 12mA to 8mA to reduce the opening of the connecting valve W1, thereby achieving precise control of the regeneration medium supply.

[0065] The controller 10 is configured to send a command to increase the supply of regeneration media in the adsorption process when it receives a first cleanliness level that has exceeded the warning threshold but has not yet reached the first cleanliness threshold, and a second cleanliness level that has not yet reached the second cleanliness threshold.

[0066] When the controller 10 program determines that the first cleanliness exceeds the warning threshold, the first cleanliness is lower than the first cleanliness threshold, and the second cleanliness is higher than the second cleanliness threshold, the controller 10 will send an execution command to the connecting valve W1 to increase the opening degree. For example, the 4-20mA control signal will be increased from 12mA to 18mA to increase the flow rate of the regeneration medium and accelerate the analysis process.

[0067] In addition to real-time control, the controller 10 will record the effective adsorption time in its internal memory for a long time, that is, the time from when the A tower body 3 is switched to an adsorption tower until its first cleanliness value reaches the first cleanliness threshold.

[0068] Over the months or even years of equipment operation, controller 10 records data points on the effective adsorption time during operation. Under normal circumstances, the effective adsorption time will fluctuate around an average value. However, as the adsorbent 31 in tower A and the adsorbent 71 in tower B age, become contaminated, or pulverize, their adsorption capacity will permanently decrease, resulting in a slow and continuous downward trend in the effective adsorption time.

[0069] The built-in algorithm of controller 10 fits and extrapolates this trend to predict future trends. When the algorithm predicts that, based on the current decay rate, the effective adsorption time will fall below a preset minimum cycle time necessary to maintain normal production within a future time window, controller 10 will not wait for equipment failure but will proactively display a message on the human-machine interface indicating adsorbent performance degradation and suggesting replacement. This signal can also be transmitted to the central control room. This not only elevates the system to a more intelligent and efficient predictive maintenance stage but also helps users avoid significant losses caused by unplanned downtime.

[0070] This invention obtains the actual working state of the adsorption tower and regeneration tower based on the first cleanliness of the finished gas and the second cleanliness of the desorbed gas. It then adjusts the working state of the adsorption tower and regeneration tower in real time according to the first and second cleanliness thresholds. This allows for real-time application in various scenarios, such as fluctuations in finished gas consumption, or issues with excessive or insufficient finished gas consumption. It also reduces the idle working time of the adsorption tower and regeneration tower, preventing the adsorption tower from becoming oversaturated. Furthermore, this invention adjusts strategies based on the quality of the finished gas, improving the stability of the finished air quality and reducing production defects caused by medium quality issues.

[0071] In this application, the first cleanliness and the second cleanliness are measured based on pressure dew point, nitrogen, carbon dioxide, or oxygen content. The corresponding parameters can be selected according to different needs. Furthermore, the first cleanliness threshold and the second cleanliness threshold can be numerical values ​​or range values; no limitation is made here. The first cleanliness can refer to section 7.2 "Humidity and Liquid Water" in GB-13277.1-2008.

[0072] Table 1: Example data of batch measurements for first and second cleanliness levels

[0073] Referring to the data in Table 1, the specific execution process of the control method of this utility model is as follows: like Figure 4 As shown, corresponding to data 1-10, with data 9 as the first and second cleanliness thresholds, in the initial stage: during the initial and middle stages of the adsorption process, the pressure dew point of the finished gas is -58°C, far below the first cleanliness threshold of -40°C, indicating good finished gas quality. Simultaneously, the pressure dew point of the regeneration gas is 22°C to 24.2°C, also far above the second cleanliness threshold of 12°C, indicating that the regeneration process is in progress but not yet complete. During this stage, controller 10 maintains the current adsorption and regeneration operations without switching.

[0074] Switching operating mode phase: Assume that at minute T of operation, the pressure dew point of the finished product gas is monitored to be -40.0°C, which has reached the first cleanliness threshold, while the pressure dew point of the regenerated gas is monitored to be 12.0°C, which has reached the second cleanliness threshold. At this time, controller 10 determines that both conditions are met and immediately executes step b above to switch operating modes; Dynamic Adjustment Phase: At minute T of operation, the pressure dew point of the finished gas was monitored to be -40.0°C, reaching the first cleanliness threshold. However, the pressure dew point of the regenerated gas was monitored to be 15.0°C, not yet reaching the second cleanliness threshold of 12.0°C. This indicates that the adsorption tower is saturated, while the regeneration tower is not yet ready. According to the control method of this invention, the controller 10 will not switch immediately, but will send a command to the connecting valve W1 to increase the opening, increase the supply of regeneration medium, and accelerate the desorption process of tower B 7. The controller 10 will continue this accelerated regeneration process until the data from the second measuring device 91 shows that the pressure dew point of the regenerated gas drops to 12.0°C. At the instant this condition is met, the controller 10 will officially execute the switching operation mode, switching tower A 3 to the regeneration process and tower B 7 to the adsorption process. This ensures that tower B 7 is always in a fully regenerated state, thereby guaranteeing the stability of the finished gas quality after the switch.

[0075] Through the above-described implementation method that combines specific data, this invention can perform precise closed-loop feedback control based on dual real-time data. This not only ensures the constant quality of the finished gas, maintaining it below -40°C, but also avoids the waste of regeneration medium caused by fixed timing control, achieving intelligent, adaptive, energy-saving, and efficient operation.

[0076] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. All equivalent structural transformations made under the inventive concept of the present utility model using the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present utility model.

Claims

1. An adsorption separation device, characterized in that, The apparatus includes at least one A tower body (3) and at least one B tower body (7) that can alternately serve as an adsorption tower and a regeneration tower, and a control valve system for controlling the airflow path. The apparatus also includes: The first measuring device (51) is installed on the finished gas outlet pipeline (5) and is used to monitor the real-time first cleanliness of the finished gas; A second measuring device (91) is installed on the desorption gas discharge pipeline (9) and is used to monitor the real-time second cleanliness of the desorption gas; and The controller (10) is electrically connected to the first measuring device (51), the second measuring device (91), and the control valve system; The controller (10) is configured to switch the operating modes of the A tower body (3) and the B tower body (7) based on the first cleanliness and the second cleanliness of the first measuring device (51) and the second measuring device (91), and through the control valve system.

2. The adsorption separation device as described in claim 1, characterized in that, The controller (10) is configured to dynamically adjust the regeneration medium flow rate of the A tower body (3) and the B tower body (7) according to the current state of the first cleanliness and the second cleanliness, through the control valve system.

3. The adsorption separation device as described in claim 2, characterized in that, The control valve system includes a regeneration medium regulating valve for increasing or decreasing the supply of regeneration medium. The output of the controller is electrically connected to the control input of the regeneration medium regulating valve. The regeneration medium regulating valve is used to shut off or limit the supply of regeneration medium.

4. The adsorption separation device as described in claim 1, characterized in that, It also includes a connecting pipe (W), one end of which is connected to the outlet pipe (4) of the A tower body (3) and the other end is connected to the outlet pipe (6) of the B tower body (7), for supplying part of the finished gas from the outlet of the A tower body (3) into the B tower body (7).

5. The adsorption separation device as described in claim 1, characterized in that, Also includes: Pressure sensing components (32, 72) are respectively installed on the top of the A tower body (3) and the B tower body (7); The controller (10) is electrically connected to the pressure sensing components (32, 72) and is used to determine the completion status of the pressure equalization process of the A tower body (3) and the B tower body (7).

6. The adsorption separation device as described in claim 1, characterized in that, The first measuring device (51) and the second measuring device (91) are pressure dew point sensors or gas component content sensors.

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