Summary:: With the increasing requirements for industrial safety, more and more companies are focusing on storage solutions in dust and explosion-proof environments. This paper mainly introduces the special requirements for the operation of the logistics system in the dust and explosion-proof environment, and then analyzes the characteristics and application advantages of the dense storage system, and introduces its practical application in combination with specific project cases, so as to draw the conclusion that the dense storage system can reduce the fire and risk in the dust and explosion-proof environment, and improve the safety of staff and property through rational design and specific explosion-proof measures.
Keywords:Dense storage systems, dust and explosion-proof environments, practical applications
I. Introduction
In the field of industrial production, such as grain, oil, rice and flour, petrochemical, coal and military industries, in the process of production, processing, transportation and storage, a variety of flammable and explosive gases, liquids and various dust and fibers may be leaked or overflowed. With the improvement of industrial safety requirements, more and more companies are beginning to focus on storage solutions in dust and explosion-proof environments, where traditional storage models such as high racks and floor stacks can be unsafe and inefficient. Dense storage systems centrally address these issues and provide a durable, reliable storage solution for these special environments.
In these special environments, dust and explosion-proof environments are common problems, which are of great significance to production safety and environmental protection, and the dense storage technology in logistics automation has a wide range of application value in this environment, which can effectively solve the storage problems in the production process, improve space utilization, reduce costs, and ensure safety and reliability at the same time.
This article will describe the application of dense storage systems in dusty and explosion-proof environments.
Second, the concept of explosion-proof equipment
In the design process of explosion-proof logistics equipment, the selection of conventional mechanical parts is the same as the design of conventional automated production lines, and the corresponding accounting can be carried out according to the requirements of power, load, speed and so on.
Special attention should be paid to the selection of electrical equipment: choose electrical products with explosion-proof characteristics that meet the safety requirements of the site.
1.Introduction to the content of explosion-proof signs
Fig.1 Explosion-proof signs.
Fig.2 Schematic diagram of explosion-proof signs (**For reference only).
The content of the explosion-proof mark, as shown in Figure 1; Explosion-proof signs are schematic, as shown in Figure 2. Where:
ex": China's explosion-proof symbol, indicating that the product is explosion-proof;
d": means that the product adopts the flameproof and explosion-proof type, that is, the shell is used to isolate the possible ignition source;
B": means that the equipment is used in an explosion-proof gas environment outside the mine, and the explosion-proof level is IIB;
t3": indicates that the maximum surface temperature of the device is 200;
GB": indicates that the product is used in a ** dust environment, and the equipment has a "high" protection level.
2.Partitioning of the environment
In accordance with the national standard GB 383614-2014 **Sexual Environment Part 14: Classification of Places The definition of **Sexual Gas Environment, according to the frequency and duration of occurrence of **Sexual gas environment, is mainly divided into the following areas:
Zone 0: Places where the ** gas environment occurs continuously or frequently or for a long time;
Zone 1: During normal operation, there may be occasional ** gas environment;
Zone 2: During normal operation, it is impossible to have a ** gas environment, and if it does, it is only a place that exists for a short time.
3.Explosion-proof form of explosion-proof equipment
For different hazardous places, electrical equipment has different explosion-proof methods, generally speaking, for the most serious gas environment, the main measures are shown in Table 1.
Table 1 Explosion-proof types of explosion-proof equipment.
4.Classification of explosion-proof equipment
Corresponding to the level of hazardous places is the classification of explosion-proof equipment, according to the national standard GB 38361-2010 **Sexual environment Part 1: Equipment General requirements", explosion-proof equipment is mainly divided into Class I, Class II and Class III according to the hazardous area used.
Class I: used in the gas environment of coal mines (generally referring to mines), with an detonation energy of 0280mj。
Class II: used in other ** gas environments other than coal mine gas gas (generally referring to places outside the mine).
Class II A: The representative gas is propane, with an initiation energy of 0180mj；
Class II B: The representative gas is ethylene, with an initiation energy of 0060mj；
II Class C: The representative gas is hydrogen, with an initiation energy of 0019MJ, with the highest explosion-proof rating.
Class III: used in ** dust environments other than coal mines.
III Class A: flammable flocculents;
III Class B: Non-conductive dust;
Class III C: Conductive dust.
5.Temperature rating of explosion-proof equipment
Explosion-proof equipment is divided into different grades according to the highest surface temperature during use:
For Class I explosion-proof equipment, its surface temperature should not exceed:
150 (when coal dust may accumulate on the surface of electrical equipment);
450 (when no coal dust will accumulate on the surface of the electrical equipment).
For Class II explosion-proof equipment, the surface temperature should not exceed the specified temperature group, as shown in Table 2.
Table 2 Temperature levels of explosion-proof equipment.
During use, the maximum surface temperature of the selected explosion-proof equipment shall not exceed the ignition temperature of the most hazardous substances in the environment.
6.The level of protection of explosion-proof equipment
The protection level of the equipment is specified according to the possibility of the equipment becoming an ignition source and the different characteristics of the gas environment, the dust environment and the methane of the coal mine, as shown in Table 3.
Table 3 Protection level of explosion-proof equipment.
3. Introduction to technologies related to dense storage in logistics automation
1.The benefits of dense storage
Dense storage technology is a storage technology based on automation and intelligent control, through the rational use of space, to achieve high-density storage of goods, its core is high-density shelves and matching intelligent logistics handling equipment, such as sub-mother car, four-way car, etc., shelves are used to store goods, intelligent logistics handling equipment is used to move and handle goods between shelves, according to actual needs, dense storage technology can also be used with logistics equipment such as A**, R**, etc., to achieve automated and intelligent storage operations.
(1) The advantage of dense storage in a dusty environment
In dusty environments such as flour mills, wood processing plants, chemical plants, etc., the application of dense storage systems brings the following benefits:
Improve storage capacity: Dense storage technology realizes high-density storage of goods through rational use of space, so as to effectively improve space utilization and meet the storage needs of enterprises;
Dust-proof performance: Shelves and warehouse doors need to have good airtight performance to prevent dust leakage and the impact of the external environment on the inside of the warehouse. The storage area adopts a closed structure and dustproof materials to effectively prevent dust from entering the storage area and reduce the risk of fire and fire. The airtight structure and dust-proof materials effectively reduce the accumulation of dust and reduce the risk of fire and fire;
Improve work efficiency: The dense storage system uses automated equipment and intelligent information systems to make it easy for workers to access stored items. Achieve fast and accurate access to goods, reduce operation time, and improve storage efficiency and operation efficiency.
(2) The advantages of intensive storage in explosion-proof environments
In explosion-proof environments such as chemical plants, mines, military industry, and oil and gas extraction sites, the application of dense storage systems has the following important advantages:
Explosion Protection: Dense storage systems are designed and manufactured with explosion protection standards and requirements in mind. It incorporates explosion-resistant materials and designs to reduce the risk of fire and **, and effectively isolate and control fires in adverse situations. The electrical equipment and lighting equipment in the warehouse need to meet the explosion-proof requirements to prevent the occurrence of dust**;
Safety: Dense storage systems can safely store hazardous chemicals and flammable materials, providing effective management and operation solutions;
Corrosion resistance: The equipment in some chemical warehouses needs to be corrosion-resistant to adapt to the corrosive effect of chemical materials on the equipment.
2.Design principles for dense storage in dust and explosion-proof environments
The design principles of dense storage mainly include the following aspects:
(1) Storage capacity:According to the actual demand, determine the storage capacity of the warehouse to ensure that the warehouse can meet the storage needs of goods in the production process;
(2) Space saving:On the premise of satisfying the storage capacity, save space as much as possible and improve space utilization;
(3) Protection of data:The cargo information in the warehouse needs to be recorded and managed, so it is necessary to establish a complete cargo information management system to ensure the security and reliability of the data;
(4) Safe and reliableThe electrical equipment and lighting equipment in the warehouse need to meet the explosion-proof requirements to prevent the occurrence of dust**; At the same time, shelves and warehouse doors need to have good airtightness to prevent dust leakage and the impact of the external environment on the inside of the warehouse.
At the same time, dense storage in dusty and explosion-proof environments has the following advantages:
(1) Improve space utilizationDense storage technology realizes high-density storage of goods through rational use of space, so as to effectively improve space utilization;
(2) Reduce costsThe use of dense storage technology can reduce the warehouse footprint and reduce the cost of land. At the same time, the fast and accurate access of goods can also improve production efficiency and reduce production costs;
(3) Improve safety:Dense storage technology adopts automatic and intelligent control system, which can reduce manual operation, reduce the risk of operation error, improve production safety, and is equipped with safety equipment such as temperature monitoring, smoke detectors and fire alarm systems to detect and prevent potential fires in a timely manner and ensure the safety of workers and property;
(4) Strong adaptability:Dense storage technology can be customized according to actual needs, adapt to different production environments and cargo characteristics, and have a wide range of applicability.
Fourth, the application of dense storage in dust and explosion-proof environment
In order to meet the needs of the market, the logistics equipment industry manufacturers represented by Tianjin Mastercard Logistics Equipment Co., Ltd. have been deeply engaged in the development and innovation of high-density automatic storage and retrieval technology for more than ten years, and have successively launched suitable system solutions for dust explosion-proof environments.
1.A multinational grain and oil group in the southwest of the mother car intensive storage project
A multinational grain and oil group in the southwest region of the mother car intensive storage project mainly stores flour goods (see Figure 3 for the actual scene of the project, see Figure 4 for the layout planning), the use of shuttle type mother and mother car dense storage system, by the mother car and the car to complete the plane of the X-axis and Y-axis of the material handling, through the hoist to achieve the handling of materials in the Z-axis direction, X, Y, Z-axis three directions are operated by independent equipment, each process is independent of each other, do not interfere with each other, can greatly improve the efficiency of the entire dense repository. At the same time, the high-density storage system of the sub-mother vehicle can maximize the space utilization rate in the limited space, and the whole system is also flexible, which can reasonably increase the number of hardware equipment of the sub-mother vehicle according to the future business growth to meet the challenges brought by future business growth.
Fig.3 The real picture of the intensive storage project of the mother and child vehicles in the southwest region of a multinational grain and oil group.
Fig.4 Planning and layout of a multinational grain and oil group's southwest sub-mother vehicle intensive storage project.
Since the main storage material of the project is flour, the challenges of the dust environment to the dense storage system need to be considered in the intensive storage planning, and the scheme is introduced as follows:
1) The warehouse of the whole project is 72m (l) 44m (w) 12m (h), covering an area of about 3168m2, using the intensive storage of the sub-mother car in the re-layering type, with 2 mother car channels on each floor, and 2 fire partition linkages are realized through the mother car channel;
2) The project adopts 1400 1100mm non-standard pallets, equipped with 8 sets of sub-mother cars, 6 sets of cargo hoists, 2 sets of transfer hoists, 1 set of conveyor system and supporting WMS and WCS systems. The overall design of the cargo space is 5562 pallets, which realizes the total efficiency requirement of about 200 pallet hours in and out of the warehouse. It can realize 24-hour uninterrupted cycle operation;
3) Because the storage material is mainly flour, after the finished flour is stacked off the line, the packaging bag will be attached to the flour dust, considering the harm of dust, an air shower device is set up at the storage port, after the stacking is put into storage, all the stacked finished flour stacks will pass through the air shower device in turn, and the dust scattered on the surface of the flour stack will be removed through the dust removal function of the air shower device, which can effectively prevent the dust from entering the storage area. This can reduce the accumulation of dust on the storage equipment, reduce the potential fire and risk of fire, and solve the safety risk brought by dust to the dense storage system to a certain extent;
4) At the same time, a safe charging isolation room is adopted in the charging area of the sub-mother car, and the charging process is physically isolated from the storage area, and the charging isolation room is provided with an integrated alarm of smoke and temperature, and in case of emergency, the alarm can be given in time, so as to ensure the fire safety of the sub-mother vehicle system during charging;
The company has achieved good application results by adopting the high-density storage system of the sub-mother car, which not only greatly improves the storage capacity per unit area, but also solves the potential safety hazards caused by the dust of the flour warehouse; At the same time, through intelligent logistics equipment, the manual working environment is greatly improved, the "goods to person" mode is realized, and the manual moving line is reduced; Combined with the intelligent management and control of informatization, the information docking between the entire production workshop and the warehouse is realized, the information island of the storage system is solved, the point traceability of the whole process of the whole flour from raw materials to finished products is realized, and food safety is also ensured.
2.Four-way vehicle intensive storage project of a grain and oil enterprise in South China
In recent years, the four-way pallet shuttle has been well applied in the food, medicine, cold chain, chemical and other industries, the four-way car is an upgraded version of the shuttle board (sub-car), with X-axis, Y-axis material handling capacity, high flexibility, especially suitable for special-shaped warehouse layout, while the four-way car also belongs to high-density storage, but also belongs to one of the dense storage systems.
The operation of multiple four-way pallet shuttles on the same floor is the basic operation mode of the high-density storage system of four-way pallet shuttles, and the perfect level of cargo location management (WMS) and equipment scheduling capability (WCS) can ensure the stable and efficient operation of the overall system. In order to avoid the waiting of the four-way pallet shuttle and the hoist, a buffer conveyor line is designed between the hoist and the shelf, and the four-way pallet shuttle and hoist are handed over to the buffer conveyor line for transfer operation, so as to improve the operation efficiency.
In the overall planning, the advantages of the four-way pallet shuttle can be fully utilized, and the various storage areas can be connected by opening up the walls and corridors, and the four-way pallet shuttle can enter any storage area through system scheduling to achieve the purpose of equipment sharing.
According to the unique characteristics of four-way vehicles, a grain and oil enterprise in South China adopts a four-way vehicle intensive storage system, and plans to have two storage areas, namely rice storage and flour storage. Among them, the flour warehouse also needs to solve the potential safety hazards caused by the dust environment to the dense storage system of four-way vehicles.
Based on the successful application case of the previous sub-mother vehicle dense storage system in the flour warehouse, this four-way vehicle dense storage system also adopts the same treatment method to solve the dust problem in the flour warehouse. An air shower device is designed at each inlet to remove the dust scattered on the surface of the flour stack through the dust removal function of the air shower device, reduce the potential safety hazards caused by the accumulation of dust entering the storage area, and solve the safety risk brought by dust to the dense storage system to a certain extent. At the same time, it also ensures the cleanliness and tidiness of the flour warehouse environment and improves the safety of grain, oil and food. The project planning layout diagram is shown in Figure 5.
Fig.5 Planning and layout of a four-way vehicle intensive storage project of a grain and oil enterprise in South China.
At the same time, according to the characteristics of the shelf structure, cancel the shelf first layer track support rear beam connecting rod, facilitate manual entry into the shelf area for cleaning, clean up the dust accumulated in the shelf area, reduce the safety risk of the dust environment as much as possible, and the shelf structure is shown in Figure 6.
Fig.6. Schematic diagram of shelf structure.
3.Four-way vehicle intensive storage project of a chemical group in North China
In the explosion-proof environment, the application of dense storage technology is equally important: firstly, the dense storage system adopts electrical equipment, lighting equipment, etc. that meet the explosion-proof requirements to prevent the occurrence of dust; Secondly, shelves and warehouse doors need to have good airtightness to prevent dust leakage and the impact of the external environment on the inside of the warehouse; In addition, the dense storage system can further improve the safety and stability of the warehouse by taking other explosion-proof measures, such as installing explosion-proof air conditioning, using explosion-proof lighting, and using safety explosion-proof motors for equipment.
Taking the four-way vehicle intensive storage project of a chemical group in North China implemented by Tianjin Mastercard Logistics Equipment as an example (project planning layout diagram, see Figure 7), the materials stored in the project are chemicals, and the state is dust particles, and at the same time, in the early stage of scheme design, the owner clearly requires that the storage environment needs to have certain explosion-proof measures, and the explosion-proof level is required to be EXDIIBT4.
Fig.7 Planning and layout diagram of a four-way vehicle dense storage project of a chemical group in North China.
The project adopts a four-way vehicle dense storage system, and the whole scheme is briefly described as follows:
1) The warehouse building of the whole project is 53m(l) 55m(w) 55m (h), covering an area of about 2915m2, using pallet four-way car intensive storage, the warehouse area is divided into two areas, the left area storage pallet material specification is 1200 1200 1650mm, and the right area storage pallet material is planned to be 1750 920 1090mm.
2) Each storage area is designed with one main channel on each floor to realize the efficient and flexible handling of four-way vehicles in the entire storage area.
3) According to the characteristics of the storage materials, mainly chemical dust particles, the main inlet is designed with an air shower device to reduce the dust particles into the storage area, and at the same time the storage of materials has the highest risk, according to the relevant requirements of explosion-proof, the entire storage of all equipment is forbidden to use copper and zinc and other materials, and from the shelves, four-way vehicles, hoists, conveying systems and other equipment are equipped with explosion-proof measures, especially the electrical control part, the use of explosion-proof motors, explosion-proof three-color lights, sensors with explosion-proof functions, etc. Design and install related logistics equipment in strict accordance with the requirements of explosion-proof equipment.
4) The whole storage area of the reservoir area adopts the integrated sensor of smoke temperature, and at the same time, a charging isolation room is designed in the charging area of the four-way vehicle and a set of fire safety measures are cleverly designed, as follows:
Charging isolation room: the smoke and temperature integrated alarm is docked through the PLC dry point, the temperature alarm value is 60°, the smoke alarm is according to the shading rate, the built-in infrared sensor, and the smoke particles can be alarmed when the sensor is covered. See Figure 8.
Fig.8 A charging isolation room is designed in the charging area of the four-way vehicle.
Fire extinguishing ball: The charging pile installation area is provided with a fire extinguishing ball, in the event of an emergency, the fire extinguishing ball burns the fire extinguishing lead wound around the surface after encountering an open flame, and then drives the core burst device to automatically spray dry powder to achieve the effect of automatic fire extinguishing and ensure fire safety. See Figure 9.
Figure 9 Fire extinguishing balls are set up in the installation area of the charging pile.
The chemical enterprise uses a dense storage system for cargo storage and management, and the effect is remarkable, through the dust removal treatment of stored materials and the adoption of relevant explosion-proof measures for logistics equipment, it solves the safety risks faced by customers in actual production and ensures the safety of life and property of operators; At the same time, through the advanced dense storage management system, the goods can be automated, quickly accessed and accurately positioned. In practical application, the system not only improves the space utilization rate of the warehouse, reduces the inventory backlog of goods, but also reduces the risk of manual operation and improves production safety. At the same time, the intelligent control system of the system can also intelligently manage the goods according to the production needs, which improves the production efficiency and quality.
V. Conclusion
The application of dense storage systems in dusty and explosion-proof environments provides enterprises with safe, reliable, efficient and space-saving storage solutions. By rationalizing the design and taking specific explosion-proof measures, the dense storage system reduces the risk of fire and fire in dusty and explosion-proof environments, and improves the safety of workers and property.
With the development of automation and intelligent technology, dense storage technology will continue to improve and perfect, and the application of dense storage in dust and explosion-proof environments has a wide range of application prospects, which can improve space utilization, reduce costs, improve production safety and environmental protection level, and provide more efficient and reliable storage solutions for industrial production. Enterprises should fully recognize the advantages of dense storage systems and choose the right solution for their needs to ensure the safe and efficient operation of their production environment.
In the future, the dense storage system will further strengthen the intelligent management of goods to achieve more accurate, fast and efficient cargo access and management. At the same time, with the continuous innovation and upgrading of technology, the dense storage system will also strengthen the perception and protection ability of the environment, improve the safety and stability of the warehouse, and provide more reliable support for industrial production.
This article is from:Logistics Technology and Application, Issue 11, 2023
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