A calcium carbide sampling and sample preparation system with safety protection mechanism

Abstract

The application provides a calcium carbide sampling and sample preparation system with a safety protection mechanism. The outlet of the sampler is connected with the inlet of the buffer bin through a first conveying pipe. The outlet of the buffer bin is arranged at the inlet end of the belt conveyor. The outlet end of the belt conveyor is arranged at the inlet of the distribution valve. The outlet channel of the distribution valve is connected with the inlet of the primary crusher through a second conveying pipe. The outlet of the primary crusher is connected with the inlet of the secondary crusher through a third conveying pipe. The outlet of the secondary crusher is connected with the inlet of the drum screening machine through a fourth conveying pipe. At least one of the first conveying pipe, the second conveying pipe, the third conveying pipe and the fourth conveying pipe is connected with a gas detection protection branch pipe. All the gas detection protection branch pipes are connected with a nitrogen main pipe. Each gas detection protection branch pipe is provided with an acetylene concentration monitor and a nitrogen program control valve. The acetylene concentration monitor and the nitrogen program control valve realize loop control, which effectively reduces the safety hazards caused by man-machine crossing and excessive acetylene concentration.

Description

Technical Field

[0001] This application relates to calcium carbide sampling and preparation technology, and more specifically, to a calcium carbide sampling and preparation system with a safety protection mechanism. Background Technology

[0002] Calcium carbide, primarily composed of calcium carbide, is an industrial-grade grayish-black lumpy substance with a purple or gray cross-section. It reacts violently with water, producing acetylene gas and releasing heat. Calcium carbide is an important basic chemical raw material, mainly used to generate acetylene gas and is one of the raw materials for polyvinyl chloride (PVC) production. Before use, it must be crushed into particles of 40-100 mm in size. The quality testing of calcium carbide must be carried out in accordance with the requirements of the "General Rules for Sampling of Chemical Products" and the "General Rules for Sampling of Solid Chemical Products".

[0003] Chinese utility model patent application number 2019201716835 discloses an electrical control system for automatic calcium carbide sampling, including a primary crusher, a primary belt conveyor, a secondary crusher, a secondary belt conveyor, a chute, a main conveyor belt conveyor, a sampling mechanism, a sampling chute, a sampling bucket, an air curtain dust removal device, a storage bin, and a PLC controller. This technology uses automated equipment to replace manual sampling and sample preparation, saving labor, reducing the safety hazards of human-machine interaction, and minimizing health hazards caused by high-dust operations. During the sampling and sample preparation process, sparks are generated. If the acetylene concentration reaches a certain value, it will pose a safety hazard to the production system, creating a risk of combustion and explosion. Therefore, a safety protection mechanism for acetylene gas is essential. Utility Model Content

[0004] The purpose of this application is to provide a calcium carbide sampling and preparation system with a safety protection mechanism, which effectively reduces the safety hazards caused by human-machine interaction and excessive acetylene concentration.

[0005] A calcium carbide sampling and preparation system with a safety protection mechanism includes, from top to bottom, a sampler, a buffer bin, a belt conveyor, a distribution valve, a primary crusher, a secondary crusher, a drum screen, and a collection cylinder;

[0006] A feeding channel is provided at the top of the silo. The telescopic sampling head of the sampler can extend into the feeding channel to take samples. A first conveying pipe is provided between the sampler and the inlet of the buffer silo. The telescopic sampling head of the sampler can retract to the first conveying pipe and flip to deliver samples. The outlet of the buffer silo is located at the feeding end of the belt conveyor. The discharge end of the belt conveyor is located at the inlet of the distribution valve. The distribution valve includes a discharge channel and a bypass channel. The discharge channel is connected to the inlet of the primary crusher through a second conveying pipe. The outlet of the primary crusher is connected to the inlet of the secondary crusher through a third conveying pipe. The outlet of the secondary crusher is connected to the inlet of the drum screen through a fourth conveying pipe. The qualified material outlet of the drum screen is located at the inlet of the collecting cylinder.

[0007] At least one of the first, second, third, and fourth delivery pipes is connected to a gas detection and protection branch pipe. All gas detection and protection branch pipes are connected to the nitrogen main pipe. Each gas detection and protection branch pipe is equipped with an acetylene concentration monitor and a nitrogen programmable valve. The acetylene concentration monitor and the nitrogen programmable valve are connected to the control system to achieve loop control.

[0008] Furthermore, the calcium carbide sampling and preparation system also includes a bucket elevator, which is located on one side of the silo. The feed end of the bucket elevator is located at the waste outlet of the drum screen, and the discharge end of the bucket elevator is located at the waste recovery port of the silo.

[0009] Furthermore, a magnetic separator is installed above the belt conveyor.

[0010] Furthermore, both the primary and secondary crushers are jaw crushers.

[0011] Furthermore, the feed distribution valve, primary crusher, secondary crusher, drum screen and collecting cylinder are installed layer by layer from top to bottom through the frame, and the frame is equipped with steps.

[0012] Compared with the prior art, the embodiments of this application have at least the following advantages or beneficial effects:

[0013] This system solves the problems of high labor consumption, high human-machine cross-contamination safety hazards, and health hazards to workers caused by high dust operations in manual sampling and sample preparation. Through the linkage mechanism of acetylene concentration monitoring and nitrogen protection, it solves the safety hazards caused by sparks generated during calcium carbide sampling and sample preparation and the possibility that the acetylene concentration may reach the ignition and explosion value, effectively reducing the risks. Attached Figure Description

[0014] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0015] Figure 1 This is a schematic diagram of the overall structure of the calcium carbide sampling and preparation system with a safety protection mechanism provided in Embodiment 1 of this application;

[0016] Icons: 1-Sampler, 2-Buffer bin, 3-Belt conveyor, 4-Distribution valve, 5-Discharge channel, 6-Bypass channel, 7-Primary crusher, 8-Secondary crusher, 9-Drum screen, 10-Qualified material outlet, 11-Discard material outlet, 12-Collection cylinder, 13-First conveying pipe, 14-Second conveying pipe, 15-Third conveying pipe, 16-Fourth conveying pipe, 17-Gas detection and protection branch pipe, 18-Nitrogen main pipe, 19-Acetylene concentration monitor, 20-Nitrogen programmable valve, 21-Bucket elevator, 22-Hopper, 23-Discard material recovery port, 24-Iron separator, 25-Frame, 26-Step ladder, 27-Feed channel. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0018] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0019] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0020] In the description of the embodiments of this application, it should be noted that if terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," or "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use, they are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this application. In addition, terms such as "first," "second," and "third" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0021] In the description of the embodiments of this application, "a plurality of" means at least two.

[0022] In the description of the embodiments of this application, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0023] Example 1

[0024] Reference Figure 1 This embodiment provides a calcium carbide sampling and preparation system with a safety protection mechanism. The system can realize the sampling and preparation of calcium carbide and reduce the risk of combustion and explosion caused by acetylene gas through an effective safety protection mechanism.

[0025] The calcium carbide sampling and preparation system includes a silo 22 and, from top to bottom, a sampler 1, a buffer silo 2, a belt conveyor 3, a distribution valve 4, a primary crusher 7, a secondary crusher 8, a drum screen 9, and a collection cylinder 12. The silo 22 has a feed channel 27 at its top, into which calcium carbide is fed by a belt conveyor (not shown). The sampler 1 is a commercially available electric telescopic sampler. The body of the sampler 1 is installed outside the feed channel 27, and its telescopic sampling head can extend into the feed channel 27 to catch falling material and collect samples. A first conveying pipe 13 is installed between the sampler 1 and the inlet of the buffer silo 2. The telescopic sampling head of the sampler 1 can retract into the first conveying pipe 13 and flip to deliver the sample. The sampler 1 is connected to the inlet of the buffer silo 2 via the first conveying pipe 13. The buffer silo 2 serves to temporarily store samples, balance the feed rate of subsequent equipment, and prevent calcium carbide from falling directly and causing collisions. The outlet of the buffer bin 2 is located at the feed end of the belt conveyor 3, which is responsible for transporting the sample to the next stage. A magnetic separator 24 is installed above the belt conveyor 3, which can effectively remove ferromagnetic impurities that may be mixed in the calcium carbide sample, prevent these impurities from entering the subsequent crushing equipment and causing equipment damage, and ensure the stable progress of the sample preparation process.

[0026] The discharge end of the belt conveyor 3 is located at the inlet of the distribution valve 4. The distribution valve 4 is a commercially available conventional pneumatic three-way valve, including a discharge channel 5 and a bypass channel 6. The discharge channel 5 is connected to the inlet of the primary crusher 7 via the second conveying pipe 14, and the bypass channel 6 is connected to a bypass pipe extending to the lower part of the frame. The distribution valve 4 makes the system more flexible during operation. When it is necessary to divert or discard some samples, or when downstream equipment such as the primary crusher 7 and the secondary crusher 8 malfunction and require maintenance, the samples can be processed through the bypass channel 6 to ensure that the upstream sampling process is not interrupted. Both the primary crusher 7 and the secondary crusher 8 are jaw crushers. The outlet of the primary crusher 7 is connected to the inlet of the secondary crusher 8 via the third conveying pipe 15. The calcium carbide that has been initially crushed by the primary crusher 7 will enter the secondary crusher 8 for further crushing to meet the particle size requirements for subsequent use. The outlet of the secondary crusher 8 is connected to the inlet of the drum screen 9 through the fourth conveying pipe 16. The drum screen 9 is used to screen the crushed calcium carbide according to the particle size. Its qualified material outlet 10 is set at the inlet of the collection cylinder 12. Qualified calcium carbide samples will enter the collection cylinder 12 for collection, further reduction, and sample bottling, while unqualified samples will be discharged from the waste material outlet 11 of the drum screen 9.

[0027] In addition, in this embodiment, the calcium carbide sampling and preparation system also includes a bucket elevator 21, which is located on one side of the silo 22. Its feed end is located at the waste outlet 11 of the drum screen 9, and its discharge end is located at the waste recovery port 23 at the top of the silo 22. This design enables the recycling of unqualified samples, reduces material waste, and improves resource utilization. The feed valve 4, primary crusher 7, secondary crusher 8, drum screen 9, and collection cylinder 12 are installed layer by layer from top to bottom via the frame 25. The frame 25 is equipped with a ladder 26 to facilitate equipment inspection and maintenance by operators. It should be noted that in this embodiment, the sampler 1, buffer bin 2, and belt conveyor 3 are also installed in specific locations (not shown) via conventional auxiliary mechanisms.

[0028] In terms of safety protection, at least one of the first delivery pipe 13, the second delivery pipe 14, the third delivery pipe 15, and the fourth delivery pipe 16 is connected to a gas detection and protection branch pipe 17. Each delivery pipe is connected to one corresponding gas detection and protection branch pipe 17. All gas detection and protection branch pipes 17 are connected to the nitrogen main pipe 18. Each gas detection and protection branch pipe 17 is equipped with an acetylene concentration monitor 19 and a nitrogen programmable valve 20. The acetylene concentration monitor 19 and the nitrogen programmable valve 20 are connected to the control system to achieve loop control. Figure 1As shown in the figure, in this application, the first delivery pipe 13, the second delivery pipe 14, and the third delivery pipe 15 are connected to the gas detection and protection branch pipe 17. The control system can adopt a DCS system, that is, a distributed control system, which is an automated control system with a computer as its core, integrating communication, control, display and other technologies. By using a DCS system with control algorithms, a decentralized control and centralized management approach can be achieved, realizing precise monitoring and efficient management of the production process. The DCS system is installed in a cabinet and has a power module and a communication module. The specific structure and connection method of the system are omitted in the attached figure, which does not affect the implementation of the overall technical solution.

[0029] The working principle of the system is as follows: First, the sampling head of the telescopic head sampler 1 enters the feed channel 27 to collect the calcium carbide sample, which then enters the buffer bin 2 through the first conveyor pipe 13. The sample in the buffer bin 2 enters the belt conveyor 3, where the iron remover 24 removes ferromagnetic impurities from the sample during the conveying process. The sample is then conveyed by the belt conveyor 3 to the distribution valve 4. If the equipment is operating normally and no diversion is required, the sample enters the primary crusher 7 through the discharge channel 5 and the second conveyor pipe 14 of the distribution valve 4 for preliminary crushing. The sample after preliminary crushing enters the secondary crusher 8 through the third conveyor pipe 15 for further crushing. The crushed sample then enters the drum screen 9 through the fourth conveyor pipe 16 for further crushing. Machine 9 screens the samples. Qualified samples enter the collection cylinder 12, while unqualified samples are discharged from the waste outlet 11 and transported by the bucket elevator 21 to the waste recovery port 23 of the return silo 22 for recycling. Throughout the process, the acetylene concentration monitor 19 on the gas detection and protection branch pipe 17 monitors the acetylene concentration in each conveying pipe in real time. When the acetylene concentration reaches the set threshold, the control system controls the corresponding nitrogen programmable valve 20 to open. Nitrogen in the nitrogen main pipe 18 enters the corresponding conveying pipe through the gas detection and protection branch pipe 17 to reduce the acetylene concentration and prevent combustion and explosion accidents. When the acetylene concentration is detected to be lower than the set threshold, the nitrogen programmable valve 20 is immediately closed, which can effectively control nitrogen consumption.

[0030] This system automates calcium carbide sampling and preparation, saving labor, reducing human-machine cross-contamination safety hazards, and mitigating the health risks of high-dust operations. Through effective safety mechanisms, real-time monitoring of acetylene concentration and timely nitrogen injection significantly reduce the risk of combustion and explosion, improving production safety. The iron separator 24 protects downstream equipment and ensures the stability of the sample preparation process. The bypass channel 6 of the feed valve 4 and the design of the bucket elevator 21 enhance the system's flexibility and resource utilization. The frame 25 and ladder 26 facilitate equipment inspection and maintenance, improving the system's operability.

[0031] The above are merely preferred embodiments of this application and are not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A calcium carbide sampling and preparation system with a safety protection mechanism, characterized in that: It includes a hopper (22), and a sampler (1), a buffer hopper (2), a belt conveyor (3), a distribution valve (4), a primary crusher (7), a secondary crusher (8), a drum screen (9), and a collection cylinder (12) arranged from top to bottom; The top of the silo (22) is provided with a feeding channel (27). The telescopic sampling head of the sampler (1) can extend into the feeding channel (27) to take a sample. A first conveying pipe (13) is provided between the sampler (1) and the inlet of the buffer silo (2). The telescopic sampling head of the sampler (1) can retract to the first conveying pipe (13) and flip to deliver the sample. The outlet of the buffer silo (2) is located at the feeding end of the belt conveyor (3), and the discharge end of the belt conveyor (3) is located at the inlet of the distribution valve (4). The material distribution valve (4) includes a discharge channel (5) and a bypass channel (6). The discharge channel (5) is connected to the inlet of the primary crusher (7) through a second conveying pipe (14). The outlet of the primary crusher (7) is connected to the inlet of the secondary crusher (8) through a third conveying pipe (15). The outlet of the secondary crusher (8) is connected to the inlet of the drum screen (9) through a fourth conveying pipe (16). The qualified material outlet (10) of the drum screen (9) is located at the inlet of the collecting cylinder (12). At least one of the first delivery pipe (13), the second delivery pipe (14), the third delivery pipe (15), and the fourth delivery pipe (16) is connected to a gas detection and protection branch pipe (17). All of the gas detection and protection branch pipes (17) are connected to the nitrogen main pipe (18). Each of the gas detection and protection branch pipes (17) is equipped with an acetylene concentration monitor (19) and a nitrogen programmable valve (20). The acetylene concentration monitor (19) and the nitrogen programmable valve (20) are connected to the control system to realize loop control.

2. The calcium carbide sampling and preparation system with safety protection mechanism according to claim 1, characterized in that: The calcium carbide sampling and preparation system also includes a bucket elevator (21), which is located on one side of the silo (22). The feed end of the bucket elevator (21) is located at the waste outlet (11) of the drum screen (9), and the discharge end of the bucket elevator (21) is located at the waste recovery port (23) of the silo (22).

3. The calcium carbide sampling and preparation system with safety protection mechanism according to claim 1, characterized in that: A magnetic separator (24) is installed above the belt conveyor (3).

4. The calcium carbide sampling and preparation system with safety protection mechanism according to claim 1, characterized in that: Both the primary crusher (7) and the secondary crusher (8) are jaw crushers.

5. The calcium carbide sampling and preparation system with a safety protection mechanism according to any one of claims 1-4, characterized in that: The feed valve (4), primary crusher (7), secondary crusher (8), drum screen (9) and collecting cylinder (12) are installed layer by layer from top to bottom through the frame (25), and the frame (25) is provided with a ladder (26).

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