An emulsion on-line monitoring self-circulation purifier

Abstract

The utility model relates to industrial emulsion treatment equipment technical field discloses an emulsion on -line monitoring self -circulation purification device, including liquid supplementing system, monitoring purification system and emulsion storage tank, liquid supplementing system includes stock solution comprehensive liquid storage tank and acid liquid comprehensive liquid storage tank, and liquid supplementing system communicates with emulsion storage tank through liquid supplementing pipeline to supplement emulsion stock solution and acid liquid comprehensive liquid to emulsion, monitoring purification system includes purification separator, and purification separator communicates with emulsion storage tank through circulation pipeline, and the granule collection bin, waste liquid collection tank and monitoring component are equipped in the purification separator. The utility model through each system cooperation, can realize emulsion recycling, reduce the dangerous waste, reduce the cost, accurate control emulsion performance simultaneously, guarantee product quality stability, satisfy environmental protection and efficient production demand.

Description

Technical Field

[0001] This utility model relates to the technical field of industrial emulsion treatment equipment, specifically to an online monitoring and self-circulating purification device for emulsions. Background Technology

[0002] In industrial production, emulsions play a crucial role as key media. For example, in cold isostatic pressing (COP) processes, they serve as one of the pressure-transmitting media in dual-media pressing, directly affecting the molding quality of the product. In machining, they function to cool and lubricate cutting tools and workpieces. However, in the application scenarios of large-scale COP equipment, due to the large volume of the equipment (e.g., a 1350×4000mm machine requires a large amount of emulsion to achieve uniform pressure transmission), the management of emulsions becomes particularly challenging. Currently, the emulsion used in these large-scale cold isostatic pressing (COP) machines needs to be replaced every quarter, with each replacement involving a huge volume of emulsion. For a manufacturing company with two units of this type of equipment, an average of 50 tons of hazardous waste are generated annually due to emulsion replacement. This hazardous waste not only requires high professional disposal costs but also necessitates the construction of environmentally compliant temporary storage and transfer facilities, increasing the company's economic burden and placing significant pressure on green environmental protection initiatives. Furthermore, during long-term use, the emulsion is prone to deterioration and foul odor due to microbial growth and component degradation. The resulting irritating odor directly harms the respiratory system and skin health of workshop employees, violating occupational health and safety management requirements. More seriously, the pressure transmission performance of the deteriorated emulsion decreases significantly, leading to uneven pressure distribution during cold isostatic pressing, resulting in product density fluctuations, increased internal defects, significantly reduced product pressing quality, and even batch scrap issues. Besides the unique challenges of large-scale cold isostatic pressing (COP) equipment, existing industrial emulsion management suffers from common deficiencies that further exacerbate emulsion losses and performance degradation. On one hand, during recycling, emulsions continuously absorb solid particles (such as wear debris from COP seals and metal shavings from machining), and waste liquid is generated due to water evaporation and chemical oxidation. If these contaminants are not removed promptly, they accelerate emulsion deterioration and significantly shorten its lifespan. On the other hand, current management methods rely heavily on manual, periodic sampling to test emulsion pH, turbidity, and other indicators. This approach is significantly lagging; often, by the time performance abnormalities are detected, the emulsion has already impacted production quality or posed health risks, making real-time control impossible. Furthermore, current emulsion purification devices, monitoring components, and circulation systems are mostly independently configured, lacking an effective linkage mechanism. Purification devices can only remove some solid particles, failing to simultaneously separate waste liquid or dynamically adjust purification intensity or replenishment based on monitoring data, resulting in low emulsion circulation efficiency and significant resource waste. Therefore, there is an urgent need to develop an emulsion treatment device that integrates "real-time monitoring, high-efficiency purification, precise replenishment, and recycling" functions, especially for the needs of large-scale cold isostatic pressing equipment. By optimizing the structural design and system linkage, the device can solve problems such as short emulsion life, large amount of hazardous waste, and lagging monitoring, thereby extending the service life of emulsions, reducing the generation of hazardous waste, and ensuring the occupational health of employees and the quality of product production. Utility Model Content

[0003] The purpose of this invention is to provide an online monitoring and self-circulating purification device for emulsions, capable of real-time monitoring of the emulsion state, efficient separation of pollutants, and precise replenishment, thereby extending the service life of the emulsion and reducing hazardous waste generation. To achieve the above objective, this invention provides the following technical solution: An online monitoring and self-circulating purification device for emulsions includes a replenishment system, a monitoring and purification system, and a storage system. The storage system includes an emulsion storage tank. The monitoring and purification system includes a purification separator for separating impurities in the emulsion and a monitoring component for detecting the purified emulsion. The purification separator includes a purification chamber, the inlet of which is connected to the emulsion storage tank via a feed pipe. The outlet of the purification chamber is connected to the emulsion storage tank via a return pipe. The replenishment system includes a raw liquid integrated storage tank and an acid integrated storage tank, both of which are connected to the emulsion storage tank via replenishment pipes.

[0004] Furthermore, the monitoring components include at least a pH meter and a turbidity meter, which are used to detect the pH value and turbidity of the purified emulsion, respectively.

[0005] Furthermore, the purification separator includes a housing and a rotating drum rotatably disposed within the housing; the rotating drum includes a purification chamber and a mandrel coaxially disposed with the purification chamber; a feed inlet is provided at the top of the purification chamber, and the feed pipe is connected to the feed inlet; an emulsion outlet is also provided at the top of the purification chamber, and the return pipe is connected to the emulsion outlet; the mandrel is a hollow shaft, and the feed inlet is connected to the interior of the purification chamber through the hollow channel of the mandrel.

[0006] Furthermore, a disc assembly is fitted onto the lower part of the mandrel, and a disc cover is fitted over the disc assembly; the inner gaps between adjacent discs in the disc assembly form a waste liquid channel, which converges along the mandrel towards the center and sequentially connects to the waste liquid collection tank via the central hole of the disc cover and the upper central area of ​​the drum; the outer gaps between adjacent discs in the disc assembly and the annular space between the disc assembly and the inner wall of the drum form a purified liquid channel, which connects to the discharge port; a slag discharge port is provided below the drum, which connects to the particle collection bin.

[0007] Furthermore, both the pH meter and the turbidity meter are located inside the purified liquid channel near the bottom of the drum.

[0008] Furthermore, the monitoring and purification system also includes a frame and a motor mounted on the frame, the purification separator is fixedly installed on the frame, and the motor is connected to the spindle via a drive connection.

[0009] Furthermore, the replenishment system also includes a stock solution pump and an acid solution pump. One end of the stock solution pump is connected to the stock solution integrated storage tank, and the other end is connected to the replenishment pipeline. One end of the acid solution pump is connected to the acid solution integrated storage tank, and the other end is connected to the replenishment pipeline.

[0010] Furthermore, the raw liquid pump is equipped with a raw liquid motor, and the acid liquid pump is equipped with an acid liquid motor.

[0011] Furthermore, the raw liquid storage tank and the acid liquid storage tank are respectively equipped with raw liquid level gauges and acid liquid level gauges.

[0012] Furthermore, the emulsion storage tank is equipped with a stirring shaft with several stirring blades, and the stirring shaft is driven by a stirring motor.

[0013] The beneficial effects of this utility model are as follows: This utility model integrates the liquid storage, monitoring and purification, and liquid replenishment systems to form a closed-loop cycle. Combined with the purification and separation structure, real-time monitoring components, precise liquid replenishment control, and auxiliary operating components, it can construct a complete treatment system of "real-time monitoring - high-efficiency purification - precise liquid replenishment - recycling". It can reduce emulsion loss and pollution, delay deterioration, and at the same time, real-time monitoring can prevent health and quality problems. It can also stabilize performance and adapt to large equipment and simplify operation and maintenance. Attached Figure Description

[0014] Figure 1 An online monitoring and self-circulating purification device for emulsions provided in this embodiment of the present invention; Figure 2 This is a schematic diagram of the monitoring and purification system according to an embodiment of the present invention; Figure 3 This is a cross-sectional structural diagram of the purification separator according to an embodiment of the present utility model; Figure 4 This is a schematic diagram of the fluid replenishment system according to an embodiment of the present invention; Figure 5 This is a schematic diagram of the emulsion storage tank according to an embodiment of the present invention.

[0015] Attached reference numerals: 100-Monitoring and purification system, 110-Purification separator, 111-Shell, 112-Drum, 113-Spindle, 114-Disc assembly, 115-Disc cap, 116-Purified liquid discharge channel, 117-Waste liquid discharge channel, 118-Waste residue discharge port, 119-Feed inlet, 120-Frame, 130-Separation motor, 140-Waste liquid storage tank, 200-Storage system, 201-Emulsion storage tank. 202-Stirring motor, 203-Stirring shaft, 204-Stirring blades, 300-Replenishment system, 301-Combined raw liquid storage tank, 302-Combined acid liquid storage tank, 303-Raw liquid pump, 304-Acid pump, 305-Raw liquid level gauge, 306-Acid level gauge, 307-Raw liquid motor, 308-Acid motor, 309-Replenishment pipe, 401-Feed pipe, 402-Return pipe, 403-Circulating pump. Detailed Implementation

[0016] The specific embodiments of this utility model are described below with reference to the accompanying drawings.

[0017] Example 1 like Figures 1 to 5 As shown in the figure, this embodiment discloses an online monitoring and self-circulating device for emulsions, including a replenishment system 300, a monitoring and purification system 100, and a storage system 200. In this embodiment, a PLC control system is also provided, and all systems work collaboratively under the overall coordination of the PLC control system to achieve real-time monitoring, purification, and recycling of the emulsion.

[0018] The replenishment system 300 includes a bulk liquid storage tank 301 and an acid liquid storage tank 302, which are connected to the emulsion storage tank 201 via a replenishment pipe 309. It is used to replenish the emulsion storage tank 201 with both emulsion bulk liquid and acid liquid. The replenishment system 300 also includes a bulk liquid pump 303 and an acid pump 304. One end of the bulk liquid pump 303 is connected to the bulk liquid storage tank 301, and the other end is connected to the replenishment pipe 309. One end of the acid pump 304 is connected to the acid liquid storage tank 302, and the other end is connected to the replenishment pipe 309. The raw material pump 303 is equipped with a raw material motor 307, and the acid pump 304 is equipped with an acid motor 308. The raw material motor 307 provides power to the raw material pump 303 to control the emulsion raw material delivery volume, and the acid motor 308 provides power to the acid pump 304 to control the acid mixed liquid delivery volume, ensuring that both liquids are accurately replenished to the emulsion storage tank 201 as needed. The raw material mixed liquid storage tank 301 and the acid mixed liquid storage tank 302 are respectively equipped with a raw material level gauge 305 and an acid level gauge 306. The raw material level gauge 305 monitors the remaining raw material in the raw material mixed liquid storage tank 301 in real time, and the acid level gauge 306 monitors the remaining acid in the acid mixed liquid storage tank 302 in real time, facilitating timely replenishment of raw materials by operators and avoiding the impact of insufficient raw materials on the continuous operation of the equipment. The emulsion storage tank 201 is equipped with a stirring shaft 203 with several stirring blades 204, and the stirring shaft 203 is driven by a stirring motor 202. When replenished stock solution, acid solution, or returned purified emulsion is injected into the emulsion storage tank 201, the stirring motor 202 drives the stirring shaft 203 to rotate, which drives the stirring blades 204 to uniformly stir the emulsion in the tank, so that the emulsion components are evenly mixed and to prevent uneven local composition from causing a decrease in performance. The monitoring and purification system 100 includes a purification separator 110, which is connected to the emulsion storage tank 201 via a circulation pipe. The purification separator 110 contains a particle collection chamber, a waste liquid collection tank, and monitoring components. The purification separator 110 includes a housing 111 and a rotating drum 112 rotatably disposed within the housing 111. Specifically, the rotating drum 112 is supported and guided by a bearing assembly during high-speed rotation, and a sealing structure isolates the media inside and outside the housing 111 (not shown in the figure). A hollow spindle 113 is coaxially located at the top of the rotating drum 112, and a feed inlet 119 is located at the top of the housing 111 corresponding to the position of the spindle 113. The feed inlet 119 communicates with the interior of the rotating drum 112 through the hollow channel of the spindle 113. The spindle 113 is rotatably connected to the housing 111 via a bearing (not shown in the figure). The top of the shell 111 is also provided with an emulsion outlet; the circulation pipeline includes an inlet pipeline 401 and a return pipeline 402, and a circulation pump 403 is provided on the circulation pipeline. The circulation pump 403 is connected in series with the inlet pipeline 401. Its input end is connected to the emulsion storage tank 201 and its output end is connected to the inlet 119. It is used to provide power for the circulation of emulsion and to stably pump the emulsion to be purified in the emulsion storage tank 201 to the inlet pipeline 401. The inlet 119 is connected to the inlet pipeline 401 and the outlet is connected to the return pipeline 402. Through the drive of the circulation pump 403 and the cooperation of the pipeline, the emulsion is directionally circulated between the emulsion storage tank 201 and the purification separator 110. A disc assembly 114 is fitted onto the lower part of the mandrel 113, and a disc cover 115 is placed on top of the disc assembly 114. The disc cover 115 is used to fix the disc assembly 114, preventing displacement of the disc assembly 114 when the drum 112 rotates, and ensuring stable separation effect. The inner gaps between adjacent discs in the disc assembly 114 form a waste liquid channel, which converges towards the center along the mandrel 113, and communicates with the waste liquid collection tank through the central hole of the disc cover 115 and the upper central area of ​​the drum 112. The outer gaps between adjacent discs in the disc assembly 114 and the annular space between the disc assembly 114 and the inner wall of the drum 112 form a purified liquid channel, which communicates with the discharge port. A slag discharge port is provided below the drum 112, which communicates with the particle collection chamber for collecting solid particles separated from the emulsion. The monitoring and purification system 100 also includes a frame 120 and a motor mounted on the frame 120. The purification separator 110 and the circulating liquid pump 403 are both fixedly installed on the frame 120. The frame 120 provides stable support for the purification separator 110, the circulating liquid pump 403 and the motor. The motor is connected to the spindle 113 and electrically connected to the PLC control system, providing power for the rotation of the drum 112 and controlling its speed. During operation, the circulating pump 403 starts under the command of the PLC control system, drawing the emulsion from the emulsion storage tank 201 into the feed pipe 401. The emulsion then enters the drum 112 through the feed port 119 and the hollow channel of the mandrel 113. At the same time, the motor drives the mandrel 113 to rotate the drum 112 at high speed. Under the action of centrifugal force, the emulsion is separated: the waste liquid with higher density gathers along the waste liquid channel and eventually enters the waste liquid collection tank; the purified emulsion flows along the purified liquid channel and flows back to the emulsion storage tank 201 through the discharge port and the return liquid pipe 402; the solid particles settle under the action of centrifugal force and enter the particle collection bin through the slag discharge port, completing the purification of the emulsion.

[0019] The monitoring components include at least a pH meter and a turbidity meter. The pH meter is used to monitor the pH value of the emulsion in real time, and the turbidity meter is used to monitor the turbidity of the emulsion in real time. Both are located on the bottom side of the purified liquid channel near the rotating drum 112. The monitoring data from both devices can be used to promptly grasp the state of the emulsion, providing a basis for adjusting the replenishment system 300 and controlling the purification process, ensuring that the emulsion always meets the usage requirements.

[0020] Its specific working principle is as follows: After the device is started, the PLC control system coordinates all components to operate according to preset process parameters. First, the raw material level data is transmitted to the PLC through the raw liquid level gauge 305 and the acid liquid level gauge 306. After confirming that the raw material is sufficient, the PLC commands the circulating pump 403 to start, pumping the emulsion in the emulsion storage tank 201 to the purification separator 110. At the same time, the motor drives the drum 112 to rotate at high speed, so that the emulsion undergoes centrifugal motion in the drum 112. Due to the different specific gravities of the waste liquid (containing oil phase impurities), the purified emulsion and solid particles, they gradually separate under the action of centrifugal force: the solid particles, due to their maximum density, settle to the bottom of the drum 112 and enter the particle collection bin through the slag discharge port for recycling; the waste liquid (containing oil phase) gathers along the gap on the inner side of the disc to the waste liquid collection tank for centralized treatment as hazardous waste; the purified emulsion flows back to the emulsion storage tank 201 through the return liquid pipe 402 along the outer channel, realizing recycling.

[0021] During the circulating purification process, the PLC control system presets the upper and lower limit thresholds for the pH meter and turbidity meter. When the liquid parameters are detected to exceed the range preset by the operator, the PLC triggers the alarm module to issue a warning, indicating that the liquid is abnormal. If the pH value exceeds the limit alkalinity value, the PLC automatically sends a command to the acid motor 308 to drive the acid pump 304 to run, calculates the required flow rate based on the emulsion volume, and accurately controls the replenishment amount of the acid solution based on the real-time level data fed back by the acid level gauge 306. If the turbidity meter detects that the emulsion concentration is lower than the set value, the PLC sends a command to the raw liquid motor 307 to drive the raw liquid pump 303 to extract the raw solution and transport it to the emulsion storage tank 201 through the replenishment pipeline 309. At the same time, the stirring motor 202 is started to drive the stirring blades 204 to rotate, so that the replenishment liquid is fully mixed with the original emulsion. In summary, this embodiment utilizes a PLC control system to coordinate the various systems, employing the centrifugal force of the drum 112 combined with the disc assembly 114 to separate particles, waste liquid, and purified liquid from the emulsion. A pH meter and turbidity meter provide real-time monitoring. When parameters exceed thresholds, the PLC automatically adjusts the start / stop and flow rate of the raw material pump 303 and acid pump 304, working in conjunction with the stirring motor 202 to mix the liquid, and monitoring the raw materials via a level gauge. This method enables the recycling of the emulsion, reducing hazardous waste and lowering costs, while precisely controlling emulsion performance to ensure stable product quality and meet the demands of environmental protection and efficient production.

[0022] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An emulsion online monitoring self-circulation purifier device, characterized in that, Includes a replenishment system, a monitoring and purification system, and a storage system; The liquid storage system includes an emulsion storage tank; The monitoring and purification system includes a purification separator for separating impurities in the emulsion, and a monitoring component for detecting the purified emulsion; the purification separator includes a purification chamber, the inlet of which is connected to the emulsion storage tank via a feed pipe; the outlet of which is connected to the emulsion storage tank via a return pipe. The replenishment system includes a raw liquid storage tank and an acid liquid storage tank, both of which are connected to the emulsion storage tank via replenishment pipes.

2. The online monitoring and self-cleaning device for emulsion according to claim 1, characterized in that, The monitoring components include at least a pH meter and a turbidity meter, which are used to detect the pH value and turbidity of the purified emulsion, respectively.

3. The online monitoring and self-circulating purification device for emulsions according to claim 2, characterized in that, The purification separator includes a housing and a rotating drum rotatably disposed within the housing; The drum includes a purification chamber and a spindle coaxially arranged with the purification chamber; a feed inlet is provided at the top of the purification chamber, and the feed pipe is connected to the feed inlet. The top of the purification chamber is also provided with an emulsion outlet, and the return pipe is connected to the emulsion outlet; The mandrel is a hollow shaft, and the feed inlet is connected to the interior of the purification chamber through the hollow channel of the mandrel.

4. The online monitoring and self-cleaning device for emulsion according to claim 3, characterized in that, The lower part of the spindle is fitted with a disc assembly, and the top of the disc assembly is covered with a disc cover; The inner gaps between adjacent discs in the disc group form a waste liquid channel. The waste liquid channel converges along the center of the core axis and connects to the waste liquid collection box through the central hole of the disc cover and the central area of ​​the upper part of the drum in sequence. The outer gap between adjacent discs in the disc group and the annular space between the disc group and the inner wall of the drum constitute the purified liquid channel, which is connected to the discharge port. The drum is provided with a slag discharge port below it, which is connected to the particle collection chamber.

5. An on-line monitoring and self-cleaning device for emulsion according to claim 4, characterized in that, Both the pH meter and the turbidity meter are located inside the purified liquid channel near the bottom of the drum.

6. An on-line monitoring and self-cleaning device for emulsion according to claim 3, characterized in that, The monitoring and purification system also includes a frame and a motor mounted on the frame. The purification separator is fixedly installed on the frame, and the motor is connected to the spindle via a drive.

7. The online monitoring and self-cleaning device for emulsion according to claim 1, characterized in that, The replenishment system also includes a stock solution pump and an acid solution pump. One end of the stock solution pump is connected to the stock solution storage tank, and the other end is connected to the replenishment pipeline. One end of the acid solution pump is connected to the acid solution storage tank, and the other end is connected to the replenishment pipeline.

8. An online monitoring self-cleaning device for emulsion according to claim 7, characterized in that, The raw liquid pump is equipped with a raw liquid motor, and the acid liquid pump is equipped with an acid liquid motor.

9. The online monitoring self-cleaning device for emulsion according to claim 1, characterized in that, The raw liquid storage tank and the acid liquid storage tank are respectively equipped with raw liquid level gauges and acid liquid level gauges.

10. The online monitoring and self-circulating purification device for emulsions according to claim 1, characterized in that, The emulsion storage tank is equipped with a stirring shaft with several stirring blades, and the stirring shaft is driven by a stirring motor.

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