Multi-point detection oil removal reactor
Patent Information
- Application Number
- CN202522114387.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-30
- Publication Date
- 2026-10-27
- Estimated Expiration
- 2035-09-30
AI Technical Summary
[0003]催化氧化式除油器中，为了保持催化剂的催化效果，通常会将催化剂保持在一个固定的温度区间；因此如何监控温度是该除油器的核心问题之一；目前是采用温度传感器进行温度监测，而若是温度传感器出现偏差或失效，则难以对温度进行监控，轻则无法判断除油器是否在最佳除油区间，重则造成含油压缩空气进入特种加工场景，造成安全事故
[0008]作为优选，所述温度保护模块的数据输出端还与所述控制单元的第二信号输入端通信连接；所述控制单元被配置为能够比较来自第一独立测温元件的温度信号和来自温度保护模块的温度数据，当两者差值超出预设范围时，所述控制单元发出传感器故障报警信号；本优选的有益效果是，本方案增加了数据交叉验证功能；控制单元不仅接收自己回路的第一测温元件的信号，还能读取保护回路中第二测温元件经保护模块转换后的数据；通过实时比较这两路本应高度一致的信号，实现对传感器自身工作状态的诊断；通过双路数据比对，可及时发现传感器的精度偏差，为系统校准提供依据，提升了整个系统的温度控制精度和可信度。
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Figure CN224893828U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of compressed air technology, specifically to a multi-point detection oil removal reactor. Background Technology
[0002] In special processing technologies, compressed air is often required, such as in laser cutting. However, the actual application of compressed air requires compressed air with extremely high purity. Therefore, it is necessary to add an oil removal reaction device to the production circuit of compressed air for oil removal. Among them, catalytic oxidation oil removers or heating oil removers are widely used in these scenarios. They work together to achieve extremely high oil removal efficiency, especially to completely eliminate oil, rather than just filtering and separating it.
[0003] In catalytic oxidation oil separators, the catalyst is usually kept within a fixed temperature range to maintain its catalytic effect. Therefore, temperature monitoring is one of the core issues of this oil separator. Currently, temperature sensors are used for temperature monitoring. However, if the temperature sensor deviates or fails, it is difficult to monitor the temperature. At best, it is impossible to determine whether the oil separator is in the optimal oil removal range. At worst, oily compressed air may enter special processing environments, causing safety accidents.
[0004] Therefore, how to better and more accurately monitor the oil separator and ensure its safe operation has become a technical problem that urgently needs to be solved. Utility Model Content
[0005] I. Technical problems to be solved This invention addresses the shortcomings of existing technologies by proposing hardware redundancy and a dual-loop design to achieve ultra-high safety and reliability of the oil removal reactor.
[0006] II. Specific Technical Solutions A multi-point detection oil removal reactor includes a reactor body with an inlet and an outlet, a catalyst bed inside, a heater for heating the gas, and a dual-sensor temperature sensor. The probes of the dual-sensor temperature sensors are in close contact with the outside of the reactor body to collect the heater temperature, and each sensor integrates a first independent temperature sensing element and a second independent temperature sensing element. The device also includes a control unit and a temperature protection module independent of the control unit. The signal output terminal of the first independent temperature sensing element is electrically connected to the first signal input terminal of the control unit, and the control output terminal of the control unit is electrically connected to the heater to form a first temperature control loop. The signal output terminal of the second independent temperature sensing element is electrically connected to the signal input terminal of the temperature protection module, and the protection signal output terminal of the temperature protection module is electrically connected to a safety circuit for cutting off the heater power supply to form a second temperature protection loop independent of the first temperature control loop.
[0007] Implementation and Working Principle: This solution constructs two physically and functionally independent monitoring channels. The first loop (control unit) is responsible for normal temperature regulation, while the second loop (temperature protection module) is dedicated to safety monitoring. The two temperature measuring elements of the dual-sensor collect signals from the same heat source but send them to two independent processing units. Collecting temperatures from the same heat source provides higher accuracy. When the main control loop fails, the protection loop can directly cut off the heater power supply through the safety loop without going through the main control unit, achieving hardware redundancy. This fundamentally solves the risk of temperature control failure due to a single control unit failure (such as system crash, program crash, or data acquisition card damage). Even if the main control system is completely paralyzed, the independent protection module can still perform over-temperature power-off function to prevent equipment burnout or safety accidents. By separating the safety function from the control function and implementing it through dedicated hardware, namely the temperature protection module, the potential risks brought about by software complexity are avoided, making the protection action faster and more reliable.
[0008] Preferably, the data output terminal of the temperature protection module is also communicatively connected to the second signal input terminal of the control unit; the control unit is configured to compare the temperature signal from the first independent temperature sensing element and the temperature data from the temperature protection module. When the difference between the two exceeds a preset range, the control unit issues a sensor fault alarm signal. The beneficial effect of this preferred embodiment is that this solution adds a data cross-validation function; the control unit not only receives the signal from the first temperature sensing element in its own circuit, but also reads the data converted by the protection module from the second temperature sensing element in the protection circuit; by comparing these two signals, which should be highly consistent, in real time, the working status of the sensor itself can be diagnosed; through dual-channel data comparison, the accuracy deviation of the sensor can be detected in a timely manner, providing a basis for system calibration and improving the temperature control accuracy and reliability of the entire system.
[0009] Preferably, the outer wall of the reactor body is covered with a heat insulation layer, which extends from the area where the heater is located to the area where the catalyst bed is located. The beneficial effect of this preferred embodiment is that the heat insulation layer reduces heat loss from the reactor body to the environment, thus creating a stable high-temperature zone inside the reactor. This ensures that the heat generated by the heater is efficiently used for gas heating and maintaining the reaction temperature of the catalyst bed, rather than being wasted. At the same time, it significantly reduces the energy consumption of the heater, improves the operating economy of the system, and maintains the stability of the catalyst bed's operating temperature, avoiding a decrease in catalytic reaction efficiency due to excessively low local temperatures, and ensuring the oil removal effect.
[0010] Preferably, a second dual-branch temperature sensor is also installed on the reactor body corresponding to the catalyst bed outlet area. The probe end of the second dual-branch temperature sensor extends into the reactor body, and a third independent temperature measuring element and a fourth independent temperature measuring element are integrated inside. The third independent temperature measuring element is electrically connected to the third signal input terminal of the control unit, and the fourth independent temperature measuring element is electrically connected to the second signal input terminal of the temperature protection module or another temperature protection module. The beneficial effect of this preferred embodiment is that the outlet temperature of the catalyst bed is a key parameter for monitoring whether the reaction is proceeding normally. By setting up a second set of dual-branch sensor systems here, the temperature at the heater location and the temperature at the catalyst bed location can be monitored and protected with high reliability at the same time. By comparing the heater temperature and the reaction chamber temperature, the exothermic situation of the catalytic reaction can be determined, thereby evaluating the catalyst activity and the working status of the equipment, providing data support for optimizing operation. Furthermore, the real-time temperature of the heater is fed back by the second temperature sensor to control the operation of the heater, ensuring that the temperature inside the reactor is maintained at the set value. This also provides a second safety line for the device, greatly enhancing the fault tolerance and safety of the system.
[0011] Preferably, the safety circuit includes a relay or contactor connected in series in the heater power supply circuit, and the protection signal output terminal of the temperature protection module is electrically connected to the coil control terminal of the relay or contactor. The advantages of this preferred embodiment are: it adopts the simplest and most reliable "hard-wiring" method; the output of the temperature protection module directly drives the coil of the relay / contaminator, which in turn switches the high-voltage circuit through its contacts; this circuit is completely independent of the low-voltage control system of the control unit, is safe and reliable, has a fast response speed, and a simple structure.
[0012] Preferably, the control unit is also electrically connected to a programmable valve installed in the outlet pipeline. When the control unit receives an over-temperature alarm signal from the temperature protection module or determines that the temperature is over-temperature, the control unit controls the programmable valve to close. The advantage of this preferred embodiment is that it not only cuts off the power supply at the energy end, i.e., the heater end, but also isolates the airflow path. When over-temperature occurs, the system cuts off the heater power supply on the one hand and closes the outlet programmable valve on the other hand, effectively improving the safety factor. Attached Figure Description
[0013] Figure 1 This is a schematic diagram of the multi-point detection oil removal reactor of this utility model. Detailed Implementation
[0014] The preferred embodiments of this utility model will now be described in detail with reference to the accompanying drawings, so that the advantages and features of this utility model can be more easily understood by those skilled in the art, thereby providing a clearer and more definite definition of the scope of protection of this utility model. All other embodiments obtained by those skilled in the art based on the embodiments of this utility model without inventive effort are within the scope of protection of this utility model.
[0015] like Figure 1 As shown: Example
[0016] refer to Figure 1 This embodiment provides a multi-point detection oil removal reactor, the core of which lies in achieving ultra-high safety and reliability through hardware redundancy and dual-loop design. The device includes a reactor body 1, which is typically a cylindrical pressure vessel with an air inlet 101 on one side and an air outlet 102 on the other side. The reactor body 1 is filled with a catalyst bed 103 for catalytically oxidizing oil and gas into harmless carbon dioxide and water. A heater 2 is installed on the reactor body 1 near the air inlet 101. The heater 2 is used to maintain the reaction temperature in the reaction chamber to reach the optimal reaction temperature required for the catalytic reaction.
[0017] The key improvement of this invention lies in the temperature monitoring and safety protection system: On the reactor body 1, corresponding to the airflow channel behind the heater, a dual-branch temperature sensor 3 is installed. The metal probe of the dual-branch temperature sensor 3 extends into the reactor body 1, and two completely independent first independent temperature sensing elements 301 and second independent temperature sensing elements 302 are integrated inside. As a preferred embodiment, the dual-branch temperature sensor 3 adopts a structure in which the two independent temperature sensing elements are encapsulated in the same stainless steel metal sheath to ensure that the measurement points of the two elements are extremely close.
[0018] In practice, the device also includes a control unit 5, such as a PLC or a dedicated controller, which serves as the main control core, and a temperature protection module 7, such as a dedicated temperature transmitter alarm or safety relay, which is independent of the control unit 5.
[0019] The connection relationship of the first temperature control loop is as follows: the signal output terminal of the first independent temperature measuring element 301 is electrically connected to the first signal input terminal IN1 of the control unit 5 through a wire; the control unit 5 calculates according to the temperature signal and its internal PID algorithm, and then controls the power of the heater 2 through a solid-state relay or contactor through its control output terminal OUT1, thereby stabilizing the temperature at the set value, thus forming the main loop responsible for normal temperature regulation.
[0020] The connection relationship of the second temperature protection circuit is as follows: the signal output terminal of the second independent temperature sensing element 302 is directly electrically connected to the signal input terminal of the independent temperature protection module 7; the temperature protection module 7 has an internal upper limit alarm value; for example, 10°C higher than the main control set temperature. The protection signal output terminal OUT1 of the temperature protection module 7 is usually a relay dry contact directly connected to a safety circuit, which includes a contactor 801 connected in series in the main power supply circuit of the heater 2; when the temperature protection module 7 detects that the temperature exceeds the limit, its internal relay operates, directly disconnecting the coil circuit of the contactor 801, thereby forcibly cutting off the main power supply of the heater 2. This protection circuit is completely independent of the control unit 5, and can still operate effectively even if the control unit 5 is powered off or has a program failure.
[0021] In addition, to enable diagnostics of the sensor itself, the 1-5V data output terminal of the temperature protection module 7 is also connected to the second signal input terminal IN2 of the control unit 5. The program of the control unit 5 is configured to: compare the temperature value T1 from the first independent temperature measuring element 301 and the temperature value T2 from the second independent temperature measuring element 302 converted by the temperature protection module 7 in real time; if the difference between |T1-T2| continues to exceed a preset reasonable range, such as ±2°C, the control unit 5 issues a "sensor abnormality" alarm signal on the human-machine interface, prompting the staff to check and calibrate; in order to improve energy efficiency, the outer wall of the reactor body 1 is also covered with a heat insulation layer 9, such as ceramic fiber felt, which extends from the area where the heater 2 is located and completely covers the catalyst bed 103 area to reduce heat loss.
[0022] The working process of this embodiment is as follows: Oil-containing compressed air enters through inlet 101, is heated by heater 2, and then flows through catalyst bed 103 to undergo catalytic oxidation. The purified gas is discharged through outlet 102. During this process, dual temperature sensors 3 continuously monitor the heater temperature; control unit 5 performs precise temperature control through the first circuit; in the event of abnormal over-temperature or under-temperature, an independent second temperature protection circuit will directly and rigidly cut off the power supply; simultaneously, control unit 5 monitors the health status of the sensors by comparing the two temperature signals. Example
[0023] Based on Example 1, in order to further enhance monitoring and protection, this example adds an outlet temperature monitoring point.
[0024] refer to Figure 1 On the reactor body 1 corresponding to the outlet area of the catalyst bed 103, a second dual-branch temperature sensor 4 is also provided; its probe also extends into the interior of the body and integrates a third independent temperature measuring element 401 and a fourth independent temperature measuring element 402; wherein, the third independent temperature measuring element 401 is connected to the third signal input terminal of the control unit 5 for monitoring the temperature in the reaction chamber, which is specifically the area where the catalyst bed is located, and the operator can use this to evaluate the efficiency of the catalytic reaction.
[0025] In practice, the fourth independent temperature sensing element 402 can be connected to the second input channel IN2 of the temperature protection module 7, or to another independent temperature protection module; in this way, the system not only provides dual protection for the inlet temperature, but also provides dual monitoring for the outlet temperature; in particular, when the abnormal reaction of the catalyst causes the bed temperature to rise or fall sharply, the temperature sensor in the area where the catalyst bed is located will detect the temperature rise or fall before the temperature sensor at the heater, thereby triggering the protection action in advance and forming a defense-in-depth system.
[0026] In addition, a normally closed programmable valve 6 is installed in series on the connecting pipe of the air inlet 101 or the air outlet 102. The programmable valve 6 is one of a pneumatic shut-off valve, an electric shut-off valve, or a solenoid valve. The programmable valve 6 is electrically connected to the control unit 5. When the control unit 5 determines that the temperature is too high or receives an alarm signal of over-temperature or under-temperature from any temperature protection module, in addition to cutting off the power supply to the heater 2, it will also control the programmable valve 6 to close the gas pipeline to isolate the device and prevent abnormal gas from entering the downstream pipeline network.
[0027] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims.
Claims
1. A multi-point detection oil removal reactor, comprising a reactor body (1), wherein the reactor body (1) is provided with an inlet (101) and an outlet (102), and a catalyst bed (103) is provided inside the reactor body (1), and a heater (2) for heating the gas is provided on the reactor body (1), characterized in that: The reactor body (1) is equipped with a dual-branch temperature sensor (3). The probe end of the dual-branch temperature sensor (3) is in close contact with the outside of the reactor body (1) to collect the heater temperature. It integrates a first independent temperature measuring element (301) and a second independent temperature measuring element (302). The reactor body (1) also includes a control unit (5) and a temperature protection module (7) independent of the control unit (5). The signal output end of the first independent temperature measuring element (301) is electrically connected to the first signal input end of the control unit (5). The control output end of the control unit (5) is electrically connected to the heater (2) to form a first temperature control loop. The signal output end of the second independent temperature measuring element (302) is electrically connected to the signal input end of the temperature protection module (7). The protection signal output end of the temperature protection module (7) is electrically connected to a safety circuit for cutting off the power supply of the heater (2) to form a second temperature protection loop independent of the first temperature control loop.
2. The multi-point detection oil removal reactor according to claim 1, characterized in that: The data output terminal of the temperature protection module (7) is also connected to the second signal input terminal of the control unit (5); the control unit (5) is configured to compare the temperature signal from the first independent temperature measuring element (301) and the temperature data from the temperature protection module (7), and when the difference between the two exceeds the preset range, the control unit (5) issues a sensor fault alarm signal.
3. The multi-point detection oil removal reactor according to claim 2, characterized in that: The outer wall of the reactor body (1) is covered with a heat insulation layer (9), which extends from the area where the heater (2) is located to the area where the catalyst bed (103) is located.
4. The multi-point detection oil removal reactor according to claim 3, characterized in that: A second dual-branch temperature sensor (4) is also provided on the reactor body (1) corresponding to the catalyst bed (103) region. The probe end of the second dual-branch temperature sensor (4) extends into the reactor body (1) to monitor the reaction temperature. It also integrates a third independent temperature measuring element (401) and a fourth independent temperature measuring element (402). The third independent temperature measuring element (401) is electrically connected to the third signal input terminal of the control unit (5), and the fourth independent temperature measuring element (402) is electrically connected to the second signal input terminal of the temperature protection module (7) or another temperature protection module (7).
5. The multi-point detection oil removal reactor according to claim 3, characterized in that: The safety circuit includes a relay or contactor (801) connected in series in the power supply circuit of the heater (2), and the protection signal output terminal of the temperature protection module (7) is electrically connected to the coil control terminal of the relay or contactor (801).
6. The multi-point detection oil removal reactor according to claim 1, characterized in that: A programmable valve (6) is installed on one or both ends of the gas pipeline at the inlet (101) and outlet (102). The programmable valve (6) is one of a pneumatic shut-off valve, an electric shut-off valve, or a solenoid valve. When the control unit (5) receives an over-temperature alarm signal from the temperature protection module (7) or determines that the temperature is over-temperature, the control unit (5) controls the programmable valve (6) to operate to shut off the gas pipeline.