Development and development of large-scale ozone generator
2023-04-12 12:13:45
With the wide application of ozone in various industries and fields, ozone generation technology and application technology have been rapidly developed, especially the implementation of the new “Water Quality Standard for Urban Water Supplyâ€, which puts higher requirements on water quality and increases water. Test items and test items for disinfection by-products. The use of ozone-activated carbon technology will be the development trend of water plant disinfection, and ozone advanced treatment technology will be more powerfully developed. There will be more water plants in China that use ozone treatment. Large-volume, high-efficiency ozone generators will have a broad market demand. At present, large-scale ozone generator equipment in China mainly relies on foreign imports. Therefore, the development and development of high-performance, high-yield new generation of large-scale ozone generators to replace imports is the primary task of China's ozone enterprises. It is of great significance to accelerate the realization of the use of ozone-activated carbon technology in China's water industry.
In view of the domestic ozone product market situation, our company's scientific research personnel have successfully developed large-scale high-frequency ozone generators with independent intellectual property rights based on the comparison of the existing equipment and the similar foreign product technology. The design principle and main features are:
Ozone discharge room:
The ozone generating tube adopts an enamel dielectric discharge body, and the single discharge body has a large ozone output, and is suitable for a working condition of 5000HZ and a voltage of 3-5.0kV, and the breakdown strength is greater than 10kV. Each of the two ozone discharge tubes constitutes a discharge unit.
In order to solve the shortcomings of the overall shutdown caused by the damage of the power generation body during the operation of the large-scale ozone generator, each discharge unit is provided with a high-voltage safety device to ensure the reliability of the entire system.
The discharge chamber adopts a horizontal tube water-cooling structure, and the shells are all made of stainless steel sheet by heat fusion welding, which is corrosion resistant and difficult to scale. The outer electrode tube and the generator tube plate adopt automatic control of the cold expansion tube technology to avoid the defects of hot welding deformation.
Development of high-power high-frequency ozone power supply:
The ozone generator power supply is typically designed to match the ozone power source according to the applicable medium and discharge chamber configuration. We adopt high frequency frequency conversion technology with IGBT as power device, the frequency adjustment range is adjustable from 0 to 5000HZ, the inverter output voltage is adjustable, the output voltage is 0-500V, and the high voltage output can reach 5KV. Mainly composed of high frequency inverter power supply main circuit, PWM control circuit, IGBT drive circuit and other parts.
Simplified overall structure of high-power high-frequency high-voltage inverter ozone power supply
After three-phase 380V power frequency AC rectification and filtering, it becomes a single-phase 0-500V adjustable DC voltage, and then the DC voltage is inverted by the inverter circuit, and then boosted by the power transformer. The rectification part of the circuit adopts three-phase full-bridge controllable rectification technology, and the 0-500V DC adjustable voltage is obtained by changing the conduction angle of the thyristor, thereby achieving the purpose of controlling the output power and facilitating debugging.
The performance of ozone power, especially discharge power and stability, directly affects the quality and application of ozone. The traditional ozone generator power supply uses a thyristor as a power switching device. However, the use of thyristors as power switching devices has many drawbacks. Therefore, the ozone power supply designed by the project uses a new power switching device IGBT to replace the traditional thyristor circuit. The quasi-resonant switching characteristics are used to achieve zero voltage, current turn-on and turn-off, and the switching power loss of the switching device is small.
In addition to the perfect overload, automatic current limit, over voltage, under voltage, short circuit and other multiple protection functions, the power supply also specifically designed the power device temperature rise monitoring and protection function. That is, the operating temperature rise of the IGBT can be directly understood by the display on the operating keyboard of the power supply. Thereby effectively ensuring the working stability of the power supply.
The power supply uses digital PI closed-loop control technology. It can realize the comparison of the given amount and the feedback amount, and the closed-loop feedback can effectively stabilize the output current.
The high-frequency power control operation is designed with independent LED display digital control keyboard and 485 communication interface. Field operation and remote communication are possible. The output voltage and output frequency of the ozone power supply can be set in both states. Control accuracy ±1V, ±1Hz.
Development of high frequency step-up transformer:
The development and production of high-power high-frequency high-voltage power supplies must first break through the technical difficulties of high-frequency step-up transformers. The high-power high-frequency step-up transformer is different from the power frequency power transformer due to its own high-frequency characteristics and the specificity of the load. Therefore, the voltage of the primary and secondary windings of the transformer is inaccurate according to the ratio of the voltage on the high voltage side. This theory is not suitable. The design is difficult and difficult to manufacture. At the same time, because there is no professional manufacturer of high-power high-frequency step-up transformers in China. Therefore, many domestic ozone companies have been rejected from large-scale ozone generators. For the ozone generator special transformer working under high frequency conditions, the magnetic core we use manganese-zinc ferrite material. The ferrite core has the advantages of low loss under high frequency conditions, high dynamic permeability, low resistivity and small temperature coefficient. High-power transformers require a large-section magnetic core skeleton. In order to solve the technical problem without large cross-section core material, we use combination technology. This practice, which has been carried out by a large number of customers on-site, proves that this technology is feasible and successful.
Another key point of the transformer is the choice of coil wire material. High-power transformers must have large operating currents. In addition to the high-voltage, high-frequency current skin effect, the selection of wire materials and manufacturing processes have put forward higher requirements. On the basis of a large number of comparative tests, the wires are made of synthetic high-frequency wires. It can adapt to the requirements of high frequency working conditions and reduce the skin effect of high frequency power supply. Reduce the working temperature rise of the wire, avoid overheating and overload, affect the service life and stability and reliability of the system. And the high-voltage transformer design capacity has ample capacity, generally up to 15-30%.
Based on the application of these two technologies, the high-frequency step-up transformer has the advantages of small size, light weight and low working temperature rise. In the absence of cooling and cooling measures, natural cooling can also meet the job requirements.
Automatic Control System:
System control uses an advanced HMI human-machine interface. It can set, monitor, alarm and protect the various operating conditions of the ozone generator. (Ozone generator intake, outlet temperature, inlet water, outlet temperature, gas source dew point, pressure, flow rate, ozone concentration can be detected and adjusted online, and remote, short-range control and touch screen display are implemented. Online detection and automatic Adjustment.) The ozone power supply can also be controlled via the 485 interface. At the same time, an intelligent integrated electric energy monitoring instrument is installed to monitor nearly 30 parameters such as working current, ozone power and power factor when the ozone generator is working.
For the field of water treatment applications, there is a new breakthrough in the online monitoring technology for ozone concentration in water. The principle of using a specific correspondence relationship between the ORP (oxidation reduction potential) value and the ozone concentration in water is used. Developed ORP online monitoring ozone concentration monitor in water. The change of the ORP value reflects the change of the residual ozone concentration of the water and ozone, so that the feedback ozone generator control system realizes the automatic adjustment and the closed-loop control technology of automatically adding ozone. ORP closed-loop control technology is the domestic advanced level in both hardware and software, and fills the blank of the automatic adjustment function of ozone in the water treatment application place.
The key to the ozone water treatment process is the water dissolved ozone concentration, which is the fundamental condition for ensuring sterilization and removing chemical pollutants. In this respect, foreign countries use polarographic electrode instruments for testing, but because of the high price, the country is basically unable to apply. Only a few companies use the ORP principle to detect water-soluble ozone concentration in swimming pool water and ozone treatment, and the technology is confidential. On-line detection of water-soluble ozone concentrations on ORP technology on large-scale ozone generators is almost non-existent. It has strong practicality and has a wide range of promotional value. The application of ORP control technology can raise the technical level of ozone water treatment engineering in China to a new height.
The successful development of this product marks a breakthrough in the manufacture and application of ozone generator equipment in China. It has changed the backwardness of our domestic ozone equipment technology. It will also promote the rapid development of China's ozone technology in the fields of chemical, pharmaceutical and water treatment!
In view of the domestic ozone product market situation, our company's scientific research personnel have successfully developed large-scale high-frequency ozone generators with independent intellectual property rights based on the comparison of the existing equipment and the similar foreign product technology. The design principle and main features are:
Ozone discharge room:
The ozone generating tube adopts an enamel dielectric discharge body, and the single discharge body has a large ozone output, and is suitable for a working condition of 5000HZ and a voltage of 3-5.0kV, and the breakdown strength is greater than 10kV. Each of the two ozone discharge tubes constitutes a discharge unit.
In order to solve the shortcomings of the overall shutdown caused by the damage of the power generation body during the operation of the large-scale ozone generator, each discharge unit is provided with a high-voltage safety device to ensure the reliability of the entire system.
The discharge chamber adopts a horizontal tube water-cooling structure, and the shells are all made of stainless steel sheet by heat fusion welding, which is corrosion resistant and difficult to scale. The outer electrode tube and the generator tube plate adopt automatic control of the cold expansion tube technology to avoid the defects of hot welding deformation.
Development of high-power high-frequency ozone power supply:
The ozone generator power supply is typically designed to match the ozone power source according to the applicable medium and discharge chamber configuration. We adopt high frequency frequency conversion technology with IGBT as power device, the frequency adjustment range is adjustable from 0 to 5000HZ, the inverter output voltage is adjustable, the output voltage is 0-500V, and the high voltage output can reach 5KV. Mainly composed of high frequency inverter power supply main circuit, PWM control circuit, IGBT drive circuit and other parts.
Simplified overall structure of high-power high-frequency high-voltage inverter ozone power supply
After three-phase 380V power frequency AC rectification and filtering, it becomes a single-phase 0-500V adjustable DC voltage, and then the DC voltage is inverted by the inverter circuit, and then boosted by the power transformer. The rectification part of the circuit adopts three-phase full-bridge controllable rectification technology, and the 0-500V DC adjustable voltage is obtained by changing the conduction angle of the thyristor, thereby achieving the purpose of controlling the output power and facilitating debugging.
The performance of ozone power, especially discharge power and stability, directly affects the quality and application of ozone. The traditional ozone generator power supply uses a thyristor as a power switching device. However, the use of thyristors as power switching devices has many drawbacks. Therefore, the ozone power supply designed by the project uses a new power switching device IGBT to replace the traditional thyristor circuit. The quasi-resonant switching characteristics are used to achieve zero voltage, current turn-on and turn-off, and the switching power loss of the switching device is small.
In addition to the perfect overload, automatic current limit, over voltage, under voltage, short circuit and other multiple protection functions, the power supply also specifically designed the power device temperature rise monitoring and protection function. That is, the operating temperature rise of the IGBT can be directly understood by the display on the operating keyboard of the power supply. Thereby effectively ensuring the working stability of the power supply.
The power supply uses digital PI closed-loop control technology. It can realize the comparison of the given amount and the feedback amount, and the closed-loop feedback can effectively stabilize the output current.
The high-frequency power control operation is designed with independent LED display digital control keyboard and 485 communication interface. Field operation and remote communication are possible. The output voltage and output frequency of the ozone power supply can be set in both states. Control accuracy ±1V, ±1Hz.
Development of high frequency step-up transformer:
The development and production of high-power high-frequency high-voltage power supplies must first break through the technical difficulties of high-frequency step-up transformers. The high-power high-frequency step-up transformer is different from the power frequency power transformer due to its own high-frequency characteristics and the specificity of the load. Therefore, the voltage of the primary and secondary windings of the transformer is inaccurate according to the ratio of the voltage on the high voltage side. This theory is not suitable. The design is difficult and difficult to manufacture. At the same time, because there is no professional manufacturer of high-power high-frequency step-up transformers in China. Therefore, many domestic ozone companies have been rejected from large-scale ozone generators. For the ozone generator special transformer working under high frequency conditions, the magnetic core we use manganese-zinc ferrite material. The ferrite core has the advantages of low loss under high frequency conditions, high dynamic permeability, low resistivity and small temperature coefficient. High-power transformers require a large-section magnetic core skeleton. In order to solve the technical problem without large cross-section core material, we use combination technology. This practice, which has been carried out by a large number of customers on-site, proves that this technology is feasible and successful.
Another key point of the transformer is the choice of coil wire material. High-power transformers must have large operating currents. In addition to the high-voltage, high-frequency current skin effect, the selection of wire materials and manufacturing processes have put forward higher requirements. On the basis of a large number of comparative tests, the wires are made of synthetic high-frequency wires. It can adapt to the requirements of high frequency working conditions and reduce the skin effect of high frequency power supply. Reduce the working temperature rise of the wire, avoid overheating and overload, affect the service life and stability and reliability of the system. And the high-voltage transformer design capacity has ample capacity, generally up to 15-30%.
Based on the application of these two technologies, the high-frequency step-up transformer has the advantages of small size, light weight and low working temperature rise. In the absence of cooling and cooling measures, natural cooling can also meet the job requirements.
Automatic Control System:
System control uses an advanced HMI human-machine interface. It can set, monitor, alarm and protect the various operating conditions of the ozone generator. (Ozone generator intake, outlet temperature, inlet water, outlet temperature, gas source dew point, pressure, flow rate, ozone concentration can be detected and adjusted online, and remote, short-range control and touch screen display are implemented. Online detection and automatic Adjustment.) The ozone power supply can also be controlled via the 485 interface. At the same time, an intelligent integrated electric energy monitoring instrument is installed to monitor nearly 30 parameters such as working current, ozone power and power factor when the ozone generator is working.
For the field of water treatment applications, there is a new breakthrough in the online monitoring technology for ozone concentration in water. The principle of using a specific correspondence relationship between the ORP (oxidation reduction potential) value and the ozone concentration in water is used. Developed ORP online monitoring ozone concentration monitor in water. The change of the ORP value reflects the change of the residual ozone concentration of the water and ozone, so that the feedback ozone generator control system realizes the automatic adjustment and the closed-loop control technology of automatically adding ozone. ORP closed-loop control technology is the domestic advanced level in both hardware and software, and fills the blank of the automatic adjustment function of ozone in the water treatment application place.
The key to the ozone water treatment process is the water dissolved ozone concentration, which is the fundamental condition for ensuring sterilization and removing chemical pollutants. In this respect, foreign countries use polarographic electrode instruments for testing, but because of the high price, the country is basically unable to apply. Only a few companies use the ORP principle to detect water-soluble ozone concentration in swimming pool water and ozone treatment, and the technology is confidential. On-line detection of water-soluble ozone concentrations on ORP technology on large-scale ozone generators is almost non-existent. It has strong practicality and has a wide range of promotional value. The application of ORP control technology can raise the technical level of ozone water treatment engineering in China to a new height.
The successful development of this product marks a breakthrough in the manufacture and application of ozone generator equipment in China. It has changed the backwardness of our domestic ozone equipment technology. It will also promote the rapid development of China's ozone technology in the fields of chemical, pharmaceutical and water treatment!
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