Acetylene Gas Purification Control for Residual Solvent Removal
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Solution Overview
Problem
Existing gas refining systems face challenges in efficiently removing trace impurities, particularly residual solvents, from acetylene gas used in low-pressure/vacuum carburizing processes, which can affect process homogeneity and quality.
Innovation Solution
A gas refining system comprising a system unit with a gas source unit, a purifier unit, and a refining unit, along with a monitoring unit, an evaluation unit, and a control unit, that uses machine learning models to predict and control the purification process, ensuring appropriate removal of residual solvents and maintaining acetylene gas quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If acetylene gas is extracted from storage containers to supply constant flow rate to chamber, then carburizing process can be maintained, but residual solvent concentration increases when residual pressure decreases
Solution Approach 1:
The system performs preliminary evaluation of the solvent removal device status and predicts future solvent concentration trends before the concentration actually becomes problematic. This allows proactive switching between purification modes or replacement of the solvent removal device, preventing harmful solvent accumulation while maintaining continuous acetylene supply.
Solution Approach 2:
The system continuously monitors residual pressure, solvent concentration, and purification device status, then uses this feedback to dynamically adjust the purification strategy. The evaluation unit processes this feedback to determine optimal switching between complete purification, proportional purification, and bypass modes, resolving the contradiction between maintaining supply and controlling solvent levels.
2Object-affected harmful factors
If solvent removal device is used to remove residual solvent from acetylene gas, then solvent concentration is reduced, but device complexity and operational monitoring requirements increase
Solution Approach 1:
The solvent removal device is equipped with self-diagnosis and self-evaluation capabilities through sensors and embedded processing units that automatically monitor its own status, performance, and health. This self-service functionality reduces the need for external complex monitoring systems and manual intervention, making the purification system more manageable despite its complexity.
Solution Approach 2:
The system replaces manual monitoring and decision-making with automated electronic evaluation units that use algorithms to assess device status and determine purification strategies. This substitution of mechanical/manual operations with electronic automation simplifies operational complexity while maintaining effective solvent removal.
3Object-affected harmful factors
If complete purification is applied to all acetylene gas, then solvent concentration is controlled, but energy consumption and processing time increase
Solution Approach 1:
The system applies proportional purification where only a portion of the acetylene gas flow passes through the complete purification process, while the remainder bypasses it. The evaluation unit calculates the optimal proportion based on current solvent concentrations and process requirements, thereby controlling solvent levels while reducing energy consumption compared to purifying 100% of the gas flow.
Solution Approach 2:
The system dynamically changes the purification parameter (purification ratio) based on real-time conditions. When solvent concentration is low or process tolerance is high, the purification ratio is reduced or bypass is increased, lowering energy consumption. When solvent concentration approaches limits, the system increases purification ratio, adapting the energy input to actual needs rather than maintaining constant high-energy operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively removes residual solvents from acetylene gas, allowing for consistent acetylene supply with controlled solvent concentrations, thereby enhancing process homogeneity and quality while optimizing purifier usage and energy efficiency.
Implementation Method 1
solvent removal devices comprising adsorbents
Data Source
AI summary
A gas refining system 1 having: a system unit 11 comprising a gas source unit111 that includes a storage container, a purifier unit 113 for removing residual solvent from the gas, and a refining unit 112 for controlling the purification operations of the purifier unit 113; an evaluation unit 13 for assessing the status of at least the purifier unit 113 by means of rule-based evaluation conditions and/or a machine learning model 131 based on one or more kinds of data from among system parameters 1100, system monitoring data 1200, and user parameters 1300; and a control unit 15 comprising a purifier control unit 152 for controlling the purifier unit 113 based on data assessed by the evaluation unit 13.