CN115212782A - Polycarbonate batching method and automatic control system thereof - Google Patents
Polycarbonate batching method and automatic control system thereof Download PDFInfo
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- CN115212782A CN115212782A CN202110418838.2A CN202110418838A CN115212782A CN 115212782 A CN115212782 A CN 115212782A CN 202110418838 A CN202110418838 A CN 202110418838A CN 115212782 A CN115212782 A CN 115212782A
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- G05—CONTROLLING; REGULATING
- G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
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- G05D7/06—Control of flow characterised by the use of electric means
- G05D7/0617—Control of flow characterised by the use of electric means specially adapted for fluid materials
- G05D7/0629—Control of flow characterised by the use of electric means specially adapted for fluid materials characterised by the type of regulator means
- G05D7/0635—Control of flow characterised by the use of electric means specially adapted for fluid materials characterised by the type of regulator means by action on throttling means
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The utility model provides a batching autonomous system of polycarbonate, and because this autonomous system's batching method, control through autonomous system, the key formula is opened and is stopped bisphenol A, the solvent, the measurement and the feeding equipment of auxiliary agent, polycarbonate's automation has been realized, accurate batching, polycarbonate's batching adopts manual operation more among the prior art has been solved, artifical high-frequency intervention and operation easily lead to the maloperation, it is inaccurate to appear the raw materials measurement, lack the material scheduling problem, greatly reduced operating personnel's intensity of labour, stopped the accident that causes because the misoperation, guarantee batching process safety, it is accurate, high-efficient, very big improvement polycarbonate's production efficiency and degree of automation.
Description
Technical Field
The invention relates to the technical field of chemical equipment and instrument automation, in particular to a polycarbonate batching method and an automatic control system thereof.
Background
At present, along with the popularization and application of polycarbonate products, the demand of the polycarbonate products in markets at home and abroad is larger, but the continuous and automatic degrees of the polycarbonate production line are generally lower. In the production process of polycarbonate, the dust is large, the polycarbonate is inflammable and explosive, the corrosivity is strong, a large amount of harmful and toxic substances are generated, the feeding continuity is poor, the labor intensity of workers is high, and in the batching process of the polycarbonate, manual starting and stopping equipment one by one is adopted for preparing materials and feeding materials. In the operation process, the time change of the reaction and the weight change of the raw materials in the metering hopper need to be monitored, and the rotating equipment, the switch valve and the manual valve opening adjusting valve need to be started and stopped by frequent manual operation and releasing the interlocking. The material preparation and feeding of each reaction kettle can be completed by manual multi-step operation. Automatic control operation staff need operate all kinds of equipment and valves of multifrequency, and high strength manual operation leads to the maloperation easily, often appears preparing heavy material, drawing heavy material, batching time overlength, rotating equipment can not in time stop, a series of abnormal phenomena such as raw materials measurement is inaccurate, lack of material appear even, has not only increased intensity of labour, causes the energy loss, damages equipment when serious, influences production, and has the potential safety hazard. In the present day when information and automation technology are developed abnormally, the backward batching mode in the polycarbonate industry cannot adapt to the rapid development of polycarbonate production and application, and the research and development of a batching automation system of polycarbonate and a batching method based on the batching automation system are urgent.
Disclosure of Invention
The invention provides a polycarbonate batching method and an automatic control system thereof, aiming at the defects that in the prior art, manual operation is mostly adopted for batching polycarbonate, manual high-frequency intervention and operation are easy to cause misoperation, and raw material metering is inaccurate and the raw material is short.
The method is characterized in that: the automatic control system for polycarbonate batching comprises a bisphenol A feeding module, a bisphenol A material supplementing module, a solvent primary feeding module, an auxiliary agent feeding module and a solvent secondary feeding module; the polycarbonate batching method is a method for realizing one-key opening and closing and completing accurate batching in polycarbonate production through the cooperative linkage of all modules based on the automatic control system according to a preset instruction signal; the solvent is one of common solvents such as dichloromethane, dichloroethane and chlorobenzene used for dissolving bisphenol A in the production process of polycarbonate; the auxiliary agent is a catalyst, an end-capping reagent and an iron remover which are added in the production process of the polycarbonate;
the bisphenol A feeding module and the bisphenol A supplementing module are in interactive connection with accurate metering feeding equipment, a DCS or PLC controller and a digital controller through a control loop and are used for finishing accurate metering feeding of a main raw material bisphenol A material used for polycarbonate production; wherein the accurate metering feeding device is a weight-loss feeder or a combined feeder in the prior art; the combined feeder is a feeder which is formed by combining and cooperating a bisphenol A bunker, a weighing hopper, a loss scale and a screw propeller;
the solvent primary feeding module and the solvent secondary feeding module are in interactive connection with a solvent storage tank, a solvent flowmeter, a solvent regulating valve, a solvent stop valve, a DCS or PLC controller and a digital controller through a control loop;
the solvent primary feeding module is connected with a solvent storage tank, a solvent flowmeter, a solvent regulating valve, a solvent stop valve, a DCS or PLC controller and a digital controller in an interactive way by a control loop; when the solvent primary feeding module receives an instruction and starts to add the solvent into the batching kettle, the solvent flow meter starts to meter the adding amount of the solvent, along with the increase of the adding amount, when a set numerical value is reached, the solvent regulating valve starts to work, the opening degree of the valve is reduced, the added solvent amount is further accurately controlled, when the accumulated value of the solvent flow meter is equal to or larger than the preset primary solvent adding amount, the solvent stop valve is triggered to be closed, and the primary adding operation of the solvent is stopped;
the auxiliary agent feeding module is connected with an auxiliary agent storage tank, an auxiliary agent flowmeter, an auxiliary agent regulating valve, an auxiliary agent stop valve, a DCS or PLC controller and a digital controller in an interactive way by a control loop; when the auxiliary agent feeding module receives an instruction and starts to add auxiliary agents into the batching kettle, the auxiliary agent flowmeter starts to meter the addition amount of the auxiliary agents, when the addition amount increases and reaches a set numerical value, the auxiliary agent regulating valve starts to work, the opening degree of the valve is reduced, the added auxiliary agent amount is further accurately controlled, when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset addition amount of the auxiliary agents, the auxiliary agent stop valve is triggered to close, and the addition operation of the auxiliary agents is stopped; the auxiliary agents are catalysts, end-capping agents and iron-removing agents which are added in the production process of the polycarbonate and are sequentially added according to the process requirements;
the solvent secondary feeding module is connected with a solvent storage tank, a solvent flowmeter, a solvent regulating valve, a solvent stop valve, a DCS or PLC controller and a digital controller by a control loop in an interactive way; when the solvent secondary feeding module receives an instruction and begins to add a secondary solvent into the batching kettle, the solvent flow meter begins to meter the addition amount of the solvent, along with the increase of the addition amount, when a set numerical value is reached, the solvent regulating valve begins to work, the opening degree of the valve is reduced, the amount of the added solvent is further accurately controlled, when the accumulated value of the solvent flow meter is equal to or greater than the preset addition amount of the secondary solvent, the solvent stop valve is triggered to be closed, and the secondary adding operation of the solvent is stopped;
the polycarbonate batching method comprises the following specific steps:
step 1: setting a start-stop signal; according to the formula of the production process of the polycarbonate, calculating the amount of bisphenol A, the amount of the solvent added for the first time, the amount of the solvent added for the second time and the amount of the auxiliary agent added; setting start-stop signal values of the accurate metering feeding equipment, the solvent storage tank and the auxiliary agent storage tank according to the required feeding amount of different raw materials;
step 2: calibrating accurate metering charging equipment; in the preparation stage of batching, the bisphenol A material supplementing module and the feeding module are started in sequence, so that the precise metering feeding equipment is filled with bisphenol A materials, the fed bisphenol A materials are prevented from deviating or fluctuating due to material shortage of an empty bin of a weightless type feeding machine or a screw propeller of a combined type feeder when the batching operation is started, and the precise feeding is realized;
and 3, step 3: adding the solvent at one time; calling a solvent primary feeding module according to a preset program to complete the primary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset one-time adding amount of the solvent, triggering the one-time adding operation of the solvent to stop;
and 4, step 4: adding bisphenol A; calling a bisphenol A feeding module to finish the quantitative feeding of the bisphenol A; when the difference between the two times of weighing of the accurate metering feeding equipment is equal to or greater than the preset formula demand of the bisphenol A, triggering the operation of adding the bisphenol A to stop;
and 5: adding an auxiliary agent; the auxiliary agent feeding module is called to complete the addition of the auxiliary agent; adding a catalyst, a blocking agent and an iron removing agent according to the process requirements and a preset program; when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset auxiliary agent formula demand, triggering the operation of adding the auxiliary agent to stop;
step 6: dissolving and stirring; starting a stirrer, and after the bisphenol A is fully dissolved in the primary solvent and the auxiliary agent, uniformly mixing the primary solvent, the bisphenol A and the auxiliary agent added into the batching kettle to complete primary batching, so as to obtain a mixed solution; opening a discharge valve, and adding the mixed solution in the batching kettle into the reaction kettle;
and 7: adding the solvent for the second time; calling a solvent secondary feeding module to finish secondary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset secondary solvent adding amount, triggering the secondary solvent adding operation to stop;
and 8: washing; starting the stirrer, washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, ensuring that the material loss is not caused in the batching process, after the preset washing time is reached, completely washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, opening a discharge valve, adding the solvent added secondarily in the batching kettle, the bisphenol A and the auxiliary agent which are washed down from the kettle wall into the reaction kettle together, and finishing the batching operation of the polycarbonate.
Has the beneficial effects that:
according to the automatic control system for polycarbonate batching and the batching method based on the automatic control system, automatic and accurate batching of polycarbonate is realized by starting and stopping the metering and feeding equipment of bisphenol A, a solvent and an auxiliary agent by one key under the control of the automatic control system, the problems that in the prior art, the batching of polycarbonate is mostly manually operated, manual high-frequency intervention and operation easily cause misoperation, raw material metering is inaccurate, material shortage and the like are caused are solved, the labor intensity of operators is greatly reduced, accidents caused by misoperation are avoided, the safety, accuracy and high efficiency of the batching process are ensured, and the production efficiency and the automation degree of the polycarbonate are greatly improved.
Drawings
FIG. 1 is a block diagram of the process flow of the present invention.
FIG. 2 is an apparatus layout of a combination feeder in example 1 of the present invention;
in the figure: 1. a bisphenol A bunker; 2. a first-stage screw propeller; 3. a discharge valve A;4. weighing a hopper; 5. weighing the loss; 6. a secondary screw propeller; 7. a discharge valve B;8. a solvent storage tank; 9. a solvent flow meter; 10. a solvent regulating valve; 11. a solvent stop valve; 12. a stirrer; 13. a batching kettle; 14. an auxiliary agent storage tank; 15. an auxiliary flow meter; 16. an auxiliary agent regulating valve; 17. an auxiliary agent stop valve; 18. a discharge valve.
Detailed Description
The invention is further described with reference to the following figures and specific examples.
Example 1:
the invention provides a polycarbonate batching method and an automatic control system thereof.
The method is characterized in that: the automatic control system for polycarbonate batching comprises a bisphenol A feeding module, a bisphenol A material supplementing module, a solvent primary feeding module, an auxiliary agent feeding module and a solvent secondary feeding module; the polycarbonate batching method is based on the automatic control system, and the one-click opening and closing of each device controlled by the automatic control system is realized through the cooperative linkage of each module according to a preset instruction signal, so that the accurate batching method for polycarbonate production is completed;
the solvent is one of common solvents such as methylene dichloride, dichloroethane and chlorobenzene which are used for dissolving bisphenol A in the production process of polycarbonate; the auxiliary agent is a catalyst, an end-capping reagent and an iron remover which are added in the production process of the polycarbonate; in this example, the solvent is dichloromethane; the catalyst is triethylamine, the end-capping reagent is phenol, and the iron remover is sodium glutamate;
the bisphenol A feeding module and the bisphenol A supplementing module are in interactive connection with accurate metering feeding equipment, a DCS or PLC controller and a digital controller through a control loop and are used for finishing accurate metering feeding of a main raw material bisphenol A material used for polycarbonate production;
the precise metering feeding equipment in the embodiment is a combined feeder; the combined feeder is a feeder which is formed by combining and cooperating a bisphenol A storage bin, a weighing hopper, a loss weigher and a screw propeller;
the screw rod propeller is divided into a first-stage screw rod propeller and a second-stage screw rod propeller, is respectively connected to the bottoms of the bisphenol A storage bin and the weighing hopper and is used for conveying main raw material bisphenol A into the weighing hopper and the batching kettle;
the bisphenol A feed bin is provided with a material level meter, high and low material level values are set in the bisphenol A feed supplement module according to the capacity of the bisphenol A feed bin, and when the indication value of the material level meter of the bisphenol A feed bin reaches the low material level value, the bisphenol A feed bin is fed; stopping feeding the bisphenol A stock bin when the indicating value of the level indicator of the bisphenol A stock bin reaches a high level value; the bottom of the bisphenol A bin is connected with a primary screw propeller and used for conveying main raw material bisphenol A into the weighing hopper, and a blanking valve A is arranged at the joint of the primary screw propeller and the weighing hopper and used for cutting off the primary screw propeller to feed materials into the weighing hopper;
the weighing hopper and the loss scale work cooperatively to complete the real-time weighing of the bisphenol A material added into the weighing hopper; the bottom of the weighing hopper is connected with a secondary screw propeller for conveying main raw material bisphenol A into the batching kettle, and a blanking valve B is arranged at the joint of the secondary screw propeller and the batching kettle and used for cutting off the secondary screw propeller to feed materials into the batching kettle;
the bisphenol A feeding module is in interactive connection with the weighing hopper, the loss scale, the secondary screw propeller, the discharging valve B, the DCS or PLC controller and the digital controller through a control loop and is used for finishing the accurate metering of the weighing hopper into the batching kettle and adding the bisphenol A material; when the bisphenol A feeding module receives an instruction, the blanking valve B is opened, the secondary screw propeller works, the bisphenol A is started to be added into the batching kettle, when the difference value of two times of weighing before and after the loss weighing is equal to or larger than the preset formula demand amount of the bisphenol A, the blanking valve B is triggered to be closed immediately, and the bisphenol A feeding operation is stopped;
the bisphenol A feed supplement module is in interactive connection with a bisphenol A bin, a primary screw propeller, a blanking valve A, a DCS or PLC controller and a digital controller through a control loop and is used for completing the supplement of bisphenol A materials from the bisphenol A bin to the weighing hopper and the supplement of the materials in the bisphenol A bin; when the material level of the weighing hopper reaches the low material level value of the weighing hopper, triggering the blanking valve B to be immediately closed, receiving an instruction by the bisphenol A material supplementing module, opening the blanking valve A, starting the primary screw propeller to work, supplementing bisphenol A into the weighing hopper, and when the material level of the weighing hopper reaches the high material level value of the weighing hopper, triggering the blanking valve A to be immediately closed, and stopping the bisphenol A material supplementing operation; when the material level of the bisphenol A bin reaches the low material level value of the bisphenol A bin, the bisphenol A feed supplement module gives an instruction to start feeding the bisphenol A bin until the material level reaches the high material level value of the bisphenol A bin, and the feed supplement action of the bisphenol A bin is stopped;
the solvent primary feeding module is connected with a solvent storage tank, a solvent flowmeter, a solvent regulating valve, a solvent stop valve, a DCS or PLC controller and a digital controller in an interactive way by a control loop; when the solvent primary feeding module receives an instruction and starts to add a primary solvent into the batching kettle, the solvent flowmeter starts to measure the addition amount of the solvent, along with the increase of the addition amount, when a set numerical value is reached, the solvent regulating valve starts to work, the opening of the valve is reduced, the amount of the added solvent is further accurately controlled, when the cumulative value of the solvent flowmeter is equal to or more than the preset solvent primary addition amount, the solvent stop valve is triggered to be closed, and the primary adding operation of the solvent is stopped;
the auxiliary agent feeding module is interactively connected with an auxiliary agent storage tank, an auxiliary agent flowmeter, an auxiliary agent regulating valve, an auxiliary agent stop valve, a DCS or PLC controller and a digital controller through a control loop; when the auxiliary agent feeding module receives an instruction and starts to add auxiliary agents into the batching kettle, the auxiliary agent flowmeter starts to meter the addition amount of the auxiliary agents, when the addition amount increases and reaches a set numerical value, the auxiliary agent regulating valve starts to work, the opening degree of the valve is reduced, the added auxiliary agent amount is further accurately controlled, when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset addition amount of the auxiliary agents, the auxiliary agent stop valve is triggered to close, and the addition operation of the auxiliary agents is stopped; the auxiliary agents are catalysts triethylamine, end-capping reagent phenol and iron removing reagent sodium glutamate which are added in the production process of polycarbonate, and are added in sequence according to the process requirements;
the solvent secondary feeding module is in interactive connection with a solvent storage tank, a solvent flowmeter, a solvent regulating valve, a solvent stop valve, a DCS or PLC controller and a digital controller through a control loop; when the solvent secondary feeding module receives an instruction and starts to add a secondary solvent into the batching kettle, the solvent flowmeter starts to measure the addition amount of the solvent, along with the increase of the addition amount, when a set numerical value is reached, the solvent regulating valve starts to work, the opening of the valve is reduced, the amount of the added solvent is further accurately controlled, when the accumulated value of the solvent flowmeter is equal to or greater than the preset secondary addition amount of the solvent, the solvent stop valve is triggered to close, and the secondary addition operation of the solvent is stopped;
the polycarbonate batching method comprises the following specific processes:
step 1: setting a start-stop signal; according to the formula of the production process of the polycarbonate, calculating the amount of bisphenol A, the amount of the solvent added for the first time, the amount of the solvent added for the second time and the amount of the auxiliary agent added; setting start-stop signal values of the combined feeder, the solvent storage tank and the auxiliary agent storage tank according to the required adding amount of different raw materials;
and 2, step: calibrating the combined feeder; in the preparation stage of batching, the bisphenol A material supplementing module and the feeding module are sequentially started, so that the combined feeder is filled with bisphenol A materials, the fed bisphenol A materials are prevented from deviating or fluctuating due to material shortage of the first-stage screw propeller and the second-stage screw propeller of the combined feeder when the batching operation is started, and accurate feeding is realized;
and step 3: adding the solvent at one time; calling a solvent primary feeding module according to a preset program to complete the primary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset once adding amount of the solvent, triggering the solvent stop valve to close, and stopping the once adding operation of the solvent;
and 4, step 4: adding bisphenol A; calling a bisphenol A feeding module to finish the quantitative feeding of the bisphenol A; when the difference between the two weighing processes before and after the weight loss is equal to or larger than the preset formula demand of the bisphenol A, triggering a blanking valve B to be immediately closed, and stopping the operation of adding the bisphenol A;
and 5: adding an auxiliary agent; the auxiliary agent feeding module is called to complete the addition of the auxiliary agent; according to the process requirements, adding a catalyst triethylamine, a blocking agent phenol and an iron removing agent sodium glutamate according to a preset program; when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset formula demand of the catalyst, the blocking agent and the iron remover, triggering the auxiliary agent stop valve to close, and stopping the operation of adding the auxiliary agent;
and 6: dissolving and stirring; starting a stirrer, and after the bisphenol A is fully dissolved in the primary solvent and the auxiliary agent, uniformly mixing the primary solvent, the bisphenol A and the auxiliary agent added into the batching kettle to complete primary batching to obtain a mixed solution; opening a discharge valve, and adding the mixed solution in the batching kettle into the reaction kettle;
and 7: adding the solvent for the second time; calling a solvent secondary feeding module to finish secondary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset secondary solvent addition amount, triggering the solvent stop valve to close, and stopping the secondary solvent addition operation;
and 8: flushing; the stirrer is started, bisphenol A and auxiliaries adhered to the wall of the batching kettle are washed, material loss caused by the batching process is avoided, after the preset washing time is reached, the bisphenol A and the auxiliaries adhered to the wall of the batching kettle are completely washed, the discharge valve is opened, a solvent added for the second time in the batching kettle and the bisphenol A, the catalyst, the end-capping agent and the iron removing agent which are washed from the wall of the batching kettle are added into the reaction kettle together, and the batching operation of the polycarbonate is completed.
Claims (9)
1. An automatic control system for polycarbonate batching, which is characterized in that,
the system comprises a bisphenol A feeding module, a bisphenol A supplementing module, a solvent primary feeding module, an auxiliary agent feeding module and a solvent secondary feeding module;
the bisphenol A feeding module and the bisphenol A supplementing module are in interactive connection with accurate metering feeding equipment, a DCS or PLC controller and a digital controller through a control loop and are used for finishing accurate metering feeding of a main raw material bisphenol A material used for polycarbonate production;
the solvent primary feeding module and the solvent secondary feeding module are connected with a solvent storage tank, a solvent flowmeter, a solvent regulating valve, a solvent stop valve, a DCS or PLC controller and a digital controller by a control loop in an interactive mode and are used for completing feeding of a solvent used for polycarbonate production;
the additive feeding module is interactively connected with an additive storage tank, an additive flowmeter, an additive regulating valve, an additive stop valve, a DCS or PLC controller and a digital controller through a control loop and is used for feeding additives used for producing polycarbonate;
the solvent is one of common solvents such as dichloromethane, dichloroethane and chlorobenzene used for dissolving bisphenol A in the production process of polycarbonate; the auxiliary agent is a catalyst, an end-capping agent and an iron remover which are added in the production process of the polycarbonate.
2. The system of claim 1, wherein the polycarbonate batch is self-contained,
the accurate metering feeding equipment is a weightless feeding machine or a combined feeder in the prior art; the combined feeder is a feeder which is formed by combining and cooperating a bisphenol A bunker, a weighing hopper, a loss scale and a screw propeller; the screw rod propeller is divided into a first-stage screw rod propeller and a second-stage screw rod propeller, which are respectively connected to the bottoms of the bisphenol A bin and the weighing hopper and used for conveying main raw material bisphenol A to the weighing hopper and the batching kettle.
3. An automated system for the compounding of polycarbonate as claimed in claim 1 or 2,
when the solvent primary feeding module receives an instruction and starts to add the solvent into the batching kettle, the solvent flowmeter starts to measure the addition amount of the solvent, along with the increase of the addition amount, when the set value is reached, the solvent regulating valve starts to work, the opening of the valve is reduced, the amount of the added solvent is further accurately controlled, when the cumulative value of the solvent flowmeter is equal to or more than the preset primary solvent addition amount, the solvent stop valve is triggered to be closed, and the primary solvent adding operation is stopped;
when the auxiliary agent feeding module receives an instruction and starts to add auxiliary agents into the batching kettle, the auxiliary agent flowmeter starts to meter the addition amount of the auxiliary agents, the auxiliary agent regulating valve starts to work along with the increase of the addition amount when a set numerical value is reached, the opening degree of the valve is reduced, the added auxiliary agent amount is further accurately controlled, when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset addition amount of the auxiliary agents, the auxiliary agent stop valve is triggered to close, and the addition operation of the auxiliary agents is stopped; the auxiliary agents are catalysts, end-capping agents and iron-removing agents which are added in the production process of the polycarbonate and are sequentially added according to the process requirements;
when the solvent secondary feeding module receives an instruction and begins to add a secondary solvent into the batching kettle, the solvent flow meter begins to meter the adding amount of the solvent, along with the increase of the adding amount, when a set numerical value is reached, the solvent regulating valve begins to work, the opening degree of the valve is reduced, the adding amount of the solvent is further accurately controlled, when the cumulative value of the solvent flow meter is equal to or larger than the preset adding amount of the secondary solvent, the solvent stop valve is triggered to be closed, and the secondary adding operation of the solvent is stopped.
4. An automated system for the compounding of polycarbonate of claim 2,
the bisphenol A feed bin is provided with a level meter, high and low level values are set in the bisphenol A feed supplement module according to the capacity of the bisphenol A feed bin, and when the level meter indication value of the bisphenol A feed bin reaches the low level value, the bisphenol A feed bin is supplemented; stopping feeding the bisphenol A stock bin when the indicating value of the level indicator of the bisphenol A stock bin reaches a high level value; the bottom of the bisphenol A bin is connected with a primary screw propeller and used for conveying main raw material bisphenol A into the weighing hopper, and a blanking valve A is arranged at the joint of the primary screw propeller and the weighing hopper and used for cutting off the primary screw propeller to feed materials into the weighing hopper;
the weighing hopper and the loss scale work cooperatively to complete the real-time weighing of the bisphenol A material added into the weighing hopper; the bottom of the weighing hopper is connected with a secondary screw propeller for conveying main raw material bisphenol A into the batching kettle, and a discharge valve B is arranged at the joint of the secondary screw propeller and the batching kettle and used for cutting off the secondary screw propeller to feed materials into the batching kettle;
the bisphenol A feeding module is interactively connected with the weighing hopper, the loss scale, the secondary screw propeller, the blanking valve B, the DCS or PLC controller and the digital controller through a control loop and is used for finishing the accurate metering of the weighing hopper into the batching kettle to feed bisphenol A materials; when the bisphenol A feeding module receives an instruction, the blanking valve B is opened, the secondary screw propeller works, the bisphenol A is started to be added into the batching kettle, when the difference value of two times of weighing before and after the loss weighing is equal to or larger than the preset formula demand amount of the bisphenol A, the blanking valve B is triggered to be closed immediately, and the bisphenol A feeding operation is stopped;
the bisphenol A feed supplement module is in interactive connection with a bisphenol A bin, a primary screw propeller, a blanking valve A, a DCS or PLC controller and a digital controller through a control loop and is used for completing the supplement of bisphenol A materials from the bisphenol A bin to the weighing hopper and the supplement of the materials in the bisphenol A bin; when the material level of the weighing hopper reaches the low material level value of the weighing hopper, triggering the blanking valve B to be immediately closed, receiving an instruction by the bisphenol A material supplementing module, opening the blanking valve A, starting the primary screw propeller to work, supplementing bisphenol A into the weighing hopper, and when the material level of the weighing hopper reaches the high material level value of the weighing hopper, triggering the blanking valve A to be immediately closed, and stopping the bisphenol A material supplementing operation; when the material level of the bisphenol A bin reaches the low material level value of the bisphenol A bin, the bisphenol A feed supplement module gives an instruction to start feeding the bisphenol A bin until the material level reaches the high material level value of the bisphenol A bin, and the feed supplement action of the bisphenol A bin is stopped.
5. The system of claim 2, wherein the polycarbonate batch is self-contained,
the bisphenol A feed bin is provided with a level meter, high and low level values are set in the bisphenol A feed supplement module according to the capacity of the bisphenol A feed bin, and when the level meter indication value of the bisphenol A feed bin reaches the low level value, the bisphenol A feed bin is supplemented; stopping feeding the bisphenol A stock bin when the indicating value of the level indicator of the bisphenol A stock bin reaches a high level value; the bottom of the bisphenol A bin is connected with a primary screw propeller and used for conveying main raw material bisphenol A into the weighing hopper, and a blanking valve A is arranged at the joint of the primary screw propeller and the weighing hopper and used for cutting off the primary screw propeller to feed materials into the weighing hopper;
the weighing hopper and the loss scale work cooperatively to complete the real-time weighing of the bisphenol A material added into the weighing hopper; the bottom of the weighing hopper is connected with a secondary screw propeller for conveying main raw material bisphenol A into the batching kettle, and a blanking valve B is arranged at the joint of the secondary screw propeller and the batching kettle and used for cutting off the secondary screw propeller to feed materials into the batching kettle;
the bisphenol A feeding module is interactively connected with the weighing hopper, the loss scale, the secondary screw propeller, the blanking valve B, the DCS or PLC controller and the digital controller through a control loop and is used for finishing the accurate metering of the weighing hopper into the batching kettle to feed bisphenol A materials; when the bisphenol A feeding module receives an instruction, the blanking valve B is opened, the secondary screw propeller works, the bisphenol A is started to be added into the batching kettle, when the difference value of two times of weighing before and after the loss weighing is equal to or larger than the preset formula demand amount of the bisphenol A, the blanking valve B is triggered to be closed immediately, and the bisphenol A feeding operation is stopped;
the bisphenol A feed supplement module is in interactive connection with a bisphenol A bin, a primary screw propeller, a blanking valve A, a DCS or PLC controller and a digital controller through a control loop and is used for completing the supplement of bisphenol A materials from the bisphenol A bin to the weighing hopper and the supplement of the materials in the bisphenol A bin; when the material level of the weighing hopper reaches the low material level value of the weighing hopper, triggering the blanking valve B to be immediately closed, receiving an instruction by the bisphenol A material supplementing module, opening the blanking valve A, starting the primary screw propeller to work, supplementing bisphenol A into the weighing hopper, and when the material level of the weighing hopper reaches the high material level value of the weighing hopper, triggering the blanking valve A to be immediately closed, and stopping the bisphenol A material supplementing operation; when the material level of the bisphenol A bin reaches the low material level value of the bisphenol A bin, the bisphenol A feed supplement module gives an instruction to start feeding the bisphenol A bin until the material level reaches the high material level value of the bisphenol A bin, and the feed supplement action of the bisphenol A bin is stopped;
when the solvent one-time feeding module receives an instruction and starts to add the solvent into the batching kettle, the solvent flow meter starts to measure the addition amount of the solvent, along with the increase of the addition amount, when a set numerical value is reached, the solvent regulating valve starts to work, the opening degree of the valve is reduced, the amount of the added solvent is further accurately controlled, when the accumulated value of the solvent flow meter is equal to or more than the preset solvent addition amount for one time, the solvent stop valve is triggered to be closed, and the operation of one-time adding of the solvent is stopped;
when the auxiliary agent feeding module receives an instruction and begins to add auxiliary agents into the batching kettle, the auxiliary agent flow meter begins to meter the addition amount of the auxiliary agents, the auxiliary agent regulating valve begins to work along with the increase of the addition amount when a set numerical value is reached, the opening degree of the valve is reduced, the added auxiliary agent amount is further accurately controlled, when the cumulative value of the auxiliary agent flow meter is equal to or more than the preset auxiliary agent addition amount, the auxiliary agent stop valve is triggered to close, and the addition operation of the auxiliary agents is stopped; the auxiliary agents are catalysts, end-capping agents and iron-removing agents which are added in the production process of the polycarbonate and are sequentially added according to the process requirements;
when the solvent secondary feeding module receives an instruction and begins to add a secondary solvent into the batching kettle, the solvent flow meter begins to meter the adding amount of the solvent, along with the increase of the adding amount, when a set numerical value is reached, the solvent regulating valve begins to work, the opening degree of the valve is reduced, the adding amount of the solvent is further accurately controlled, when the cumulative value of the solvent flow meter is equal to or larger than the preset adding amount of the secondary solvent, the solvent stop valve is triggered to be closed, and the secondary adding operation of the solvent is stopped.
6. A method for manufacturing a precise polycarbonate formulation based on the automated system for polycarbonate formulation of claim 1 or 2, comprising the steps of:
step 1: setting a start-stop signal; according to the formula of the production process of the polycarbonate, calculating the amount of bisphenol A, the primary addition of the solvent, the secondary addition of the solvent and the addition of the auxiliary agent; setting start-stop signal values of the accurate metering feeding equipment, the solvent storage tank and the auxiliary agent storage tank according to the required feeding amount of different raw materials;
and 2, step: calibrating accurate metering charging equipment; in the preparation stage of batching, the bisphenol A material supplementing module and the feeding module are started in sequence, so that the precise metering feeding equipment is filled with bisphenol A materials, the fed bisphenol A materials are prevented from deviating or fluctuating due to material shortage of an empty bin of a weightless type feeding machine or a screw propeller of a combined type feeder when the batching operation is started, and the precise feeding is realized;
and step 3: adding the solvent at one time; calling a solvent primary feeding module according to a preset program to complete the primary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset one-time adding amount of the solvent, triggering the one-time adding operation of the solvent to stop;
and 4, step 4: adding bisphenol A; calling a bisphenol A feeding module to finish the quantitative feeding of the bisphenol A; when the difference between the two times of weighing of the accurate metering feeding equipment is equal to or greater than the preset formula demand of the bisphenol A, triggering the operation of adding the bisphenol A to stop;
and 5: adding an auxiliary agent; the auxiliary agent feeding module is called to complete the addition of the auxiliary agent; adding a catalyst, a blocking agent and an iron removing agent according to the process requirement and a preset program; when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset auxiliary agent formula demand, triggering the operation of adding the auxiliary agent to stop;
step 6: dissolving and stirring; starting a stirrer, and after the bisphenol A is fully dissolved in the primary solvent and the auxiliary agent, uniformly mixing the primary solvent, the bisphenol A and the auxiliary agent added into the batching kettle to complete primary batching, so as to obtain a mixed solution; opening a discharge valve, and adding the mixed solution in the batching kettle into the reaction kettle;
and 7: adding the solvent for the second time; calling a solvent secondary feeding module to finish secondary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset secondary solvent adding amount, triggering the secondary solvent adding operation to stop;
and step 8: washing; starting stirring, washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, ensuring that the material loss is not caused in the batching process, after the preset washing time is reached, completely washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, opening a discharge valve, adding the solvent added for the second time in the batching kettle, the bisphenol A and the auxiliary agent flushed from the wall of the batching kettle into the reaction kettle together, and finishing the batching operation of the polycarbonate.
7. A method for accurate dosing of polycarbonate production based on the robotic system for polycarbonate dosing of claim 3, comprising the steps of:
step 1: setting a start-stop signal; according to the formula of the production process of the polycarbonate, calculating the amount of bisphenol A, the amount of the solvent added for the first time, the amount of the solvent added for the second time and the amount of the auxiliary agent added; setting start-stop signal values of the accurate metering feeding equipment, the solvent storage tank and the auxiliary agent storage tank according to the required feeding amount of different raw materials;
and 2, step: calibrating accurate metering charging equipment; in the preparation stage of batching, the bisphenol A material supplementing module and the feeding module are started in sequence, so that the precise metering feeding equipment is filled with bisphenol A materials, the fed bisphenol A materials are prevented from deviation or fluctuation caused by empty bin of a weightlessness type feeding machine or material shortage of a screw propeller of a combined feeder when the batching operation is started, and precise feeding is realized;
and step 3: adding the solvent at one time; calling a solvent primary feeding module according to a preset program to complete the primary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset once adding amount of the solvent, triggering the once adding operation of the solvent to stop;
and 4, step 4: adding bisphenol A; calling a bisphenol A feeding module to finish the quantitative feeding of the bisphenol A; when the difference between the two times of weighing of the accurate metering feeding equipment is equal to or greater than the preset formula demand of the bisphenol A, triggering the operation of adding the bisphenol A to stop;
and 5: adding an auxiliary agent; the auxiliary agent feeding module is called to complete the addition of the auxiliary agent; adding a catalyst, a blocking agent and an iron removing agent according to the process requirements and a preset program; when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset auxiliary agent formula demand, triggering the operation of adding the auxiliary agent to stop;
step 6: dissolving and stirring; starting a stirrer, and after the bisphenol A is fully dissolved in the primary solvent and the auxiliary agent, uniformly mixing the primary solvent, the bisphenol A and the auxiliary agent added into the batching kettle to complete primary batching to obtain a mixed solution; opening a discharge valve, and adding the mixed solution in the batching kettle into the reaction kettle;
and 7: adding the solvent for the second time; calling a solvent secondary feeding module to finish secondary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset secondary solvent adding amount, triggering the secondary solvent adding operation to stop;
and step 8: flushing; starting stirring, washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, ensuring that the material loss is not caused in the batching process, after the preset washing time is reached, completely washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, opening a discharge valve, adding the solvent added for the second time in the batching kettle, the bisphenol A and the auxiliary agent flushed from the wall of the batching kettle into the reaction kettle together, and finishing the batching operation of the polycarbonate.
8. A method for accurate dosing of polycarbonate production based on the robotic system for polycarbonate dosing of claim 4, comprising the steps of:
step 1: setting a start-stop signal; according to the formula of the production process of the polycarbonate, calculating the amount of bisphenol A, the amount of the solvent added for the first time, the amount of the solvent added for the second time and the amount of the auxiliary agent added; setting start-stop signal values of the accurate metering feeding equipment, the solvent storage tank and the auxiliary agent storage tank according to the required feeding amount of different raw materials;
step 2: calibrating accurate metering and feeding equipment; in the preparation stage of batching, the bisphenol A material supplementing module and the feeding module are started in sequence, so that the precise metering feeding equipment is filled with bisphenol A materials, the fed bisphenol A materials are prevented from deviation or fluctuation caused by empty bin of a weightlessness type feeding machine or material shortage of a screw propeller of a combined feeder when the batching operation is started, and precise feeding is realized;
and step 3: adding the solvent at one time; calling a solvent primary feeding module according to a preset program to complete the primary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset once adding amount of the solvent, triggering the once adding operation of the solvent to stop;
and 4, step 4: adding bisphenol A; calling a bisphenol A feeding module to finish the quantitative feeding of the bisphenol A; when the difference value of the two times of weighing of the accurate metering feeding equipment is equal to or more than the preset formula demand of the bisphenol A, triggering the operation of adding the bisphenol A to stop;
and 5: adding an auxiliary agent; the auxiliary agent feeding module is called to complete the addition of the auxiliary agent; adding a catalyst, a blocking agent and an iron removing agent according to the process requirements and a preset program; when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset auxiliary agent formula demand, triggering the operation of adding the auxiliary agent to stop;
step 6: dissolving and stirring; starting a stirrer, and after the bisphenol A is fully dissolved in the primary solvent and the auxiliary agent, uniformly mixing the primary solvent, the bisphenol A and the auxiliary agent added into the batching kettle to complete primary batching, so as to obtain a mixed solution; opening a discharge valve, and adding the mixed solution in the batching kettle into the reaction kettle;
and 7: adding the solvent for the second time; calling a solvent secondary feeding module to finish secondary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset secondary solvent adding amount, triggering the secondary solvent adding operation to stop;
and step 8: washing; starting stirring, washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, ensuring that the material loss is not caused in the batching process, after the preset washing time is reached, completely washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, opening a discharge valve, adding the solvent added for the second time in the batching kettle, the bisphenol A and the auxiliary agent flushed from the wall of the batching kettle into the reaction kettle together, and finishing the batching operation of the polycarbonate.
9. A method for manufacturing accurate polycarbonate based on the automated system for manufacturing polycarbonate as defined in claim 5, comprising the steps of:
step 1: setting a start-stop signal; according to the formula of the production process of the polycarbonate, calculating the amount of bisphenol A, the amount of the solvent added for the first time, the amount of the solvent added for the second time and the amount of the auxiliary agent added; setting start-stop signal values of the accurate metering feeding equipment, the solvent storage tank and the auxiliary agent storage tank according to the required feeding amount of different raw materials;
and 2, step: calibrating accurate metering charging equipment; in the preparation stage of batching, the bisphenol A material supplementing module and the feeding module are started in sequence, so that the precise metering feeding equipment is filled with bisphenol A materials, the fed bisphenol A materials are prevented from deviating or fluctuating due to material shortage of an empty bin of a weightless type feeding machine or a screw propeller of a combined type feeder when the batching operation is started, and the precise feeding is realized;
and step 3: adding the solvent at one time; calling a solvent primary feeding module according to a preset program to complete the primary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset one-time adding amount of the solvent, triggering the one-time adding operation of the solvent to stop;
and 4, step 4: adding bisphenol A; calling a bisphenol A feeding module to finish the quantitative feeding of the bisphenol A; when the difference between the two times of weighing of the accurate metering feeding equipment is equal to or greater than the preset formula demand of the bisphenol A, triggering the operation of adding the bisphenol A to stop;
and 5: adding an auxiliary agent; the auxiliary agent feeding module is called to complete the addition of the auxiliary agent; adding a catalyst, a blocking agent and an iron removing agent according to the process requirements and a preset program; when the accumulated value of the auxiliary agent flowmeter is equal to or larger than the preset auxiliary agent formula demand, triggering the operation of adding the auxiliary agent to stop;
step 6: dissolving and stirring; starting a stirrer, and after the bisphenol A is fully dissolved in the primary solvent and the auxiliary agent, uniformly mixing the primary solvent, the bisphenol A and the auxiliary agent added into the batching kettle to complete primary batching to obtain a mixed solution; opening a discharge valve, and adding the mixed solution in the batching kettle into the reaction kettle;
and 7: adding the solvent for the second time; calling a solvent secondary feeding module to finish secondary feeding of the solvent in the batching kettle; when the accumulated value of the solvent flowmeter is equal to or larger than the preset secondary solvent adding amount, triggering the secondary solvent adding operation to stop;
and 8: washing; starting stirring, washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, ensuring that no material loss is caused in the batching process, after the preset washing time is reached, completely washing the bisphenol A and the auxiliary agent adhered to the wall of the batching kettle, opening a discharge valve, adding the solvent added secondarily in the batching kettle, the bisphenol A and the auxiliary agent which are washed down from the kettle wall into the reaction kettle together, and finishing the batching operation of the polycarbonate.
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| EP0306838A2 (en) * | 1987-09-05 | 1989-03-15 | Idemitsu Petrochemical Co. Ltd. | Process of preparing polycarbonates |
| US20120041158A1 (en) * | 2009-03-24 | 2012-02-16 | Chauvel Jr Jean | Method for Monitoring Monomer Concentration In Interfacial Polycarbonate Manufacturing Process |
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| CN108946204A (en) * | 2018-07-27 | 2018-12-07 | 珠海市盛西源机电设备有限公司 | A kind of DCS system that intelligent auxiliary agent adds automatically |
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|---|---|---|---|---|
| EP0306838A2 (en) * | 1987-09-05 | 1989-03-15 | Idemitsu Petrochemical Co. Ltd. | Process of preparing polycarbonates |
| US20120041158A1 (en) * | 2009-03-24 | 2012-02-16 | Chauvel Jr Jean | Method for Monitoring Monomer Concentration In Interfacial Polycarbonate Manufacturing Process |
| CN205023524U (en) * | 2015-09-01 | 2016-02-10 | 北京燕山粉研精机有限公司 | Continuous powder weigh feeder of high accuracy |
| CN108946204A (en) * | 2018-07-27 | 2018-12-07 | 珠海市盛西源机电设备有限公司 | A kind of DCS system that intelligent auxiliary agent adds automatically |
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