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首頁 / 解決方案 / 減水劑行業自動化典型解決方案

減水劑行業自動化典型解決方案

減水劑行業自動化典型解決方案

華凌科技專業致力于減水劑行業DCS控制系統設計集成。DCS控制系統在減水劑行業的應用如下:

工藝簡介:

1、磺化工段

將定量的工業萘加入磺化反應釜,并把194℃的蒸汽通入反應釜夾套對反應釜進行升溫,在高溫下萘開始融化,當溫度升到135℃時停止加熱,向反應釜滴加硫酸。之所以采用滴加的方式,是為了防止加入硫酸后釋放大量熱能導致溫度過高。硫酸加入完畢后,繼續通氣加熱,使物料溫度上升到160~165℃,此時硫酸與工業萘開始進行磺化反應,生成α-萘磺酸與β-萘磺酸。此時為了保證化學反應順利進行,必須通過調節蒸汽壓力進行溫度控制。還需要控制加入硫酸量,從而控制物料酸度。反應結束后,向反應釜通入蒸汽,加水稀釋。

2、水解工段

開啟循環水向反應釜內加水,目的是通過水解反應去除α-萘磺酸。水解反應結束后,通入蒸氣將β-萘磺酸壓入縮合反應釜內進行縮合反應。

3、縮合工段

縮合反應的要點是既要盡量縮短反應時間,又要使反應充分,得到長鏈分子。

用冷卻水對物料進行降溫,加入甲醛。甲醛和物料發生反應,生成羰基離子。

為保證甲醛最大限度羰基化,滴加速度要慢,一般控制在2小時左右。羰化反應結束后,通氣加熱,使物料溫度上升到110℃,此時甲醛羰離子與β-萘磺酸開始進行縮合反應,生成萘系磺酸甲醛縮合物,縮合反應歷時約4.5h。反應過程中,為了調節物料粘度,需補充部分稀釋水。縮合反應結束后,將生成物轉移到中和罐內進行中和反應。

3、中和工段

加入堿液中和減水劑的酸度,以達到增強減水劑的水溶性的目的。

控制方案:

磺化反應的控制內容有:萘與硫酸的質量配比;磺化反應的溫度控制以及磺化時間控制;

水解反應控制總酸度在29%左右,加水量一般為2~5克/克萘,用水量多對水解反應有利,但對縮合反應不利,故在控制好酸度的情況下,盡量少加水。

縮合反應的控制要點:萘磺酸和甲醛的配比;縮合溫度、酸度和時間控制

應用效果

山東萬山減水劑生產線應用DCS控制系統后后,大幅提高了生產效率和產品質量,在不增加車間人員情況下,生產線規模得到快速擴建。使得客戶在同行業中快速躍居領先水平。


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