SNCR (selective non-catalytic reduction) reactor adsorption tower system and control method thereof

Abstract

The invention relates to the technical field of industrial flue gas denitration, and discloses an SNCR (selective non-catalytic reduction) reactor adsorption tower system and a control method thereof. According to the SNCR reactor adsorption tower system, a flue gas inlet pipe provided with a first real-time monitoring unit is arranged on an SNCR reactor, a reducing agent inlet pipe is connected between a reducing agent bin and the SNCR reactor, and a first metering pump, a flow control valve and a pressure regulator are arranged on the reducing agent inlet pipe; the additive bin is connected with an additive inlet pipe, and a second metering pump is mounted on the additive inlet pipe; the control unit is connected with an actuator, the actuator is respectively connected with the first metering pump, the flow control valve, the pressure regulator and the second metering pump, and the first real-time monitoring unit and the reactor pressure sensor are respectively connected to the control unit. Through the integrated sensor technology, the artificial intelligence control algorithm and the efficient adsorbent, the denitration process can be monitored and adjusted in real time, so that higher denitration efficiency and lower operation cost are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of industrial flue gas denitration, in particular to a SNCR reactor adsorption tower system and a control method thereof. Background Art

[0002] With the acceleration of industrialization, flue gas emissions from industrial facilities such as coal-fired power plants, cement plants, and steel plants have become one of the main sources of air pollution. Among these emissions, nitrogen oxides (NOx) are key substances that form acid rain, photochemical smog, and ozone layer depletion, posing a serious threat to human health and the ecological environment. Therefore, reducing NOx emissions in industrial flue gas is an important task for current environmental protection.

[0003] As a mature flue gas denitrification technology, the selective non-catalytic reduction (SNCR) technology has been widely promoted in industrial applications due to its relatively low investment and operating costs. SNCR technology sprays a reducing agent (such as ammonia or urea) into the furnace, which reacts with NOx within a certain temperature range without the need for a catalyst to generate harmless nitrogen and water vapor. However, traditional SNCR technology has some limitations, such as low denitrification efficiency, ammonia slip problems, and sensitivity to reaction conditions (such as temperature and residence time), which limit its widespread application under more stringent environmental standards.

[0004] In order to improve denitrification efficiency and reduce ammonia escape, researchers have been exploring ways to improve SNCR technology. These improvements include developing new reductants, improving injection systems, optimizing reactor design, and developing advanced control systems. Despite some progress, a more intelligent and efficient system is still needed to adapt to changing industrial flue gas conditions and achieve better denitrification performance. Summary of the invention

[0005] The technical problem to be solved by the present invention is to overcome the deficiencies in the prior art and provide an SNCR reactor adsorption tower system and a control method thereof, which can monitor and adjust the denitration process in real time by integrating sensor technology, artificial intelligence control algorithm and efficient adsorbent to achieve higher denitration efficiency and lower operating costs. At the same time, the system also takes into account the simplicity of operation and the convenience of maintenance to meet the strict requirements of modern industry for environmental protection technology.

[0006] The technical solution adopted by the present invention to solve its technical problem is:

[0007] A SNCR reactor adsorption tower system, comprising a SNCR reactor, an adsorption tower, a reducing agent silo, an auxiliary agent silo and a control unit; the SNCR reactor is provided with a flue gas inlet pipe, a first real-time monitoring unit is installed on the flue gas inlet pipe, a reducing agent inlet pipe is connected between the reducing agent silo and the SNCR reactor, a first metering pump, a flow control valve and a pressure regulator are provided on the reducing agent inlet pipe, the reducing agent inlet pipe is connected to an injection unit after extending into the SNCR reactor, and a reactor pressure sensor is installed on the SNCR reactor; the auxiliary agent silo is connected to an auxiliary agent inlet pipe, the auxiliary agent inlet pipe is communicated with the reducing agent inlet pipe, and a second metering pump is installed on the auxiliary agent inlet pipe; an exhaust gas pipeline is connected between the SNCR reactor and the adsorption tower, and a second real-time monitoring unit is installed on the exhaust gas pipeline;

[0008] The control unit is connected to an actuator, which is respectively connected to the first metering pump, the flow control valve, the pressure regulator, and the second metering pump, and the first real-time monitoring unit, the second real-time monitoring unit, and the reactor pressure sensor are respectively connected to the control unit;

[0009] The control unit is also connected to a user interface, an alarm unit and a data recording module.

[0010] Furthermore, the control unit includes a main control unit and a backup control unit which are arranged in parallel.

[0011] Furthermore, the control unit has a built-in machine learning module.

[0012] Furthermore, the reducing agent silo is filled with a reducing agent, and the components and mass percentages of the reducing agent are: 15-40% urea, 40-80% ionized water, 1-10% ammonia water and 1-10% organic amine; preferably 30% urea, 60% ionized water, 5% ammonia water and 5% organic amine.

[0013] Furthermore, the auxiliary agent silo is filled with auxiliary agents, and the components and mass percentages of the auxiliary agents are: 1-20% potassium titanium oxalate, 1-10% tetraethyl silicate, 10-30% sodium ferric ethylenediaminetetraacetate, 5-25% sodium manganese ethylenediaminetetraacetate and 30-60% potassium ferrocyanide; preferably 15% potassium titanium oxalate, 5% tetraethyl silicate, 20% sodium ferric ethylenediaminetetraacetate, 10% sodium manganese ethylenediaminetetraacetate and 50% potassium ferrocyanide.

[0014] Furthermore, the preparation method of the auxiliary agent is: the above-mentioned potassium titanium oxalate, tetraethyl silicate, sodium ferric ethylenediaminetetraacetate, sodium manganese ethylenediaminetetraacetate and potassium ferrocyanide are mixed evenly, the mixed powder is dissolved in deionized water, the solution is aged at 100 to 400° C. to ensure that each component fully reacts and forms a stable reducing agent solution, the aged solution is filtered to remove insoluble matter or precipitation, and the resulting liquid is the finished auxiliary agent.

[0015] Furthermore, the adsorption tower is a detachable structure.

[0016] Furthermore, the adsorption tower is filled with an adsorbent, and the components and mass percentages of the adsorbent are: 15-45% Na-ZSM-5 molecular sieve, 20-40% activated carbon, 10-30% potassium carbonate modified activated carbon, 1-10% metal organic framework and 1-10% silica alumina; preferably 30% Na-ZSM-5 molecular sieve, 30% activated carbon, 20% potassium carbonate modified activated carbon, 10% metal organic framework and 10% silica alumina.

[0017] Furthermore, the adsorbent preparation method is: the above-mentioned Na-ZSM-5 molecular sieve, activated carbon, potassium carbonate modified activated carbon, metal organic framework and silica-alumina gel are mixed evenly, and pressed into target particles, and then activated at high temperature to obtain the finished adsorbent.

[0018] A control method for the SNCR reactor adsorption tower system as described above specifically comprises the following steps:

[0019] Step S1, the first real-time monitoring unit monitors the flue gas condition in real time, the reactor pressure sensor monitors the internal pressure of the SNCR reactor, and transmits the detection data to the control unit;

[0020] Step S2: The control unit processes the monitoring data and provides an operation instruction based on an artificial intelligence algorithm, and then sends the instruction to the actuator, and the actuator automatically adjusts the injection unit, that is, adjusts the injection amount and frequency of the reducing agent;

[0021] Step S3, the machine learning module built into the control unit predicts the optimal operating conditions and optimizes the denitrification efficiency, and then sends instructions to the actuator;

[0022] Step S4: the actuator receives the instruction, accurately measures and delivers the reducing agent in the reducing agent silo;

[0023] Step S5: The actuator receives the instruction, accurately measures and delivers the additive in the additive silo.

[0024] The beneficial effects of the present invention are as follows: the present invention is reasonably designed and has the following advantages:

[0025] (1) The first real-time monitoring unit 3 monitors the flue gas composition in real time, and the reactor pressure sensor monitors the internal pressure of the SNCR reactor and transmits the detection data to the control unit; the control unit processes the monitoring data and provides operation instructions based on the artificial intelligence algorithm, and then sends the instructions to the actuator, and the actuator automatically adjusts the injection unit, that is, adjusts the injection amount and frequency of the reducing agent, so that the denitrification efficiency is increased to more than 90%, which greatly improves the denitrification efficiency;

[0026] (2) The adsorbent built into the adsorption tower has a high specific surface area and high adsorption capacity, which improves the adsorption efficiency of residual NOx, ensuring that the NOx concentration of the gas treated by the adsorption tower is stably controlled at 30mg / Nm 3 the following;

[0027] (3) The reducing agent reacts with NOx at a lower concentration, reducing the escape rate of ammonia to 5 mg / Nm 3 The control unit and actuator cooperate with each other to avoid ammonia slip caused by excessive reducing agent, optimize the injection time and amount, and reduce unnecessary ammonia use;

[0028] (4) The amount of reducing agent used is precisely controlled, reducing the consumption of reducing agent by more than 30%. The adsorbent can be recycled, reducing the replacement frequency and processing costs, extending the adsorbent replacement cycle to more than 5 years, greatly reducing operating costs;

[0029] (5) When the main control unit fails, the backup control unit can take over seamlessly to ensure the continuous and stable operation of the system; the alarm unit can immediately notify the operator when abnormal operating conditions are detected, and take timely measures to avoid potential failures and safety accidents; the user interface enables the operator to easily monitor the system status and perform manual operations when necessary. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0031] Figure 1 It is a structural schematic diagram of the system in the present invention;

[0032] Figure 2 is a flow chart of the control method of the present invention;

[0033] In the figure: 1. SNCR reactor, 2. adsorption tower, 3. first real-time monitoring unit, 4. second real-time monitoring unit, 5. reducing agent silo, 6. first metering pump, 7. flow control valve, 8. pressure regulator, 9. auxiliary agent silo, 10. second metering pump, 11. control unit, 12. actuator, 13. user interface, 14. alarm unit, 15. data recording module, 16. injection unit, 17. reactor pressure sensor. DETAILED DESCRIPTION

[0034] It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present application belongs.

[0035] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form also includes the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this description, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0036] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0037] like Figure 1 The SNCR reactor adsorption tower system shown in the figure comprises an SNCR reactor 1, an adsorption tower 2, a reducing agent silo 5, an auxiliary agent silo 9 and a control unit 11; a flue gas inlet pipe is provided on the SNCR reactor 1, a first real-time monitoring unit 3 is installed on the flue gas inlet pipe, a reducing agent inlet pipe is connected between the reducing agent silo 5 and the SNCR reactor 1, a first metering pump 6, a flow control valve 7 and a pressure regulator 8 are provided on the reducing agent inlet pipe, an injection unit 16 is connected after the reducing agent inlet pipe extends into the SNCR reactor 1, and a reactor pressure regulator 8 is installed on the SNCR reactor 1. force sensor 17; the additive silo 9 is connected to an additive inlet pipe, the additive inlet pipe is connected to the reducing agent inlet pipe, and a second metering pump 10 is installed on the additive inlet pipe; an exhaust gas pipeline is connected between the SNCR reactor 1 and the adsorption tower 2, and a second real-time monitoring unit 4 is installed on the exhaust gas pipeline; the control unit 11 is connected to an actuator 12, and the actuator 12 is respectively connected to the first metering pump 6, the flow control valve 7, the pressure regulator 8, and the second metering pump 10, and the first real-time monitoring unit 3, the second real-time monitoring unit 4 and the reactor pressure sensor 17 are respectively connected to the control unit 11.

[0038] The control unit 11 is also connected to a user interface 13, an alarm unit 14 and a data recording module 15. The control unit 11 includes a main control unit and a backup control unit arranged in parallel. The control unit 11 has a built-in machine learning module.

[0039] The SNCR reactor 1 is used to receive industrial flue gas and inject reducing agent, wherein the reactor has multiple injection points to achieve uniform mixing of flue gas and reducing agent. The adsorption tower 2 is connected to the SNCR reactor 1 and filled with high-efficiency adsorbent for adsorbing residual NOx, wherein the adsorption tower is designed as a detachable structure to facilitate the replacement of adsorbent.

[0040] The first real-time monitoring unit 3 and the second real-time monitoring unit 4 are used to monitor the conditions of flue gas or tail gas in real time, including but not limited to temperature, pressure, flow rate and NOx concentration; the first real-time monitoring unit 3 and the second real-time monitoring unit 4 are integrated with: a temperature sensor for detecting the temperature of flue gas or tail gas; a flow sensor for detecting the flow rate of flue gas or tail gas; and a NOx concentration sensor for detecting the concentration of NOx in flue gas or tail gas. The reactor pressure sensor 17 is used to detect the pressure inside the SNCR reactor 1.

[0041] The control unit 11 is used to process sensor data and provide operating instructions based on artificial intelligence algorithms. The control unit 11 has self-learning capabilities and can optimize operating parameters based on historical data. The actuator 12 automatically adjusts the injection unit 16 according to the instructions of the control unit 11, that is, adjusts the injection amount and frequency of the reducing agent. The user interface 13 allows the operator to monitor the system status and manually override the automatic control operation when necessary; the data recording module 15 is used to store historical operating data and sensor readings for performance evaluation and fault diagnosis; the alarm unit 14 is used to notify the operator when abnormal operating conditions are detected. The control unit 11 includes a main control unit and a backup control unit arranged in parallel. The main control unit is used in normal status. When the main control unit fails, the backup control unit takes over the control operation to ensure the continuous operation of the system.

[0042] The SNCR reactor 1 is equipped with multiple injection points. The arrangement of the injection points is a key technical point to ensure the denitrification efficiency. The SNCR technology is most suitable for denitrification reaction in the temperature range of 850 to 1100 ° C. The injection points should be arranged in the area where the flue gas temperature is in this range to achieve uniform mixing of the flue gas and the reducing agent. Therefore, it is necessary to arrange the injection points at multiple positions inside the boiler. These injection points should be evenly distributed in the boiler furnace or the inlet of the cyclone separation cylinder to ensure that the reducing agent can cover the entire flue gas cross section. The injection unit 16 includes a spray gun, which is resistant to high temperatures and has self-contained cooling protection measures. The nozzle surface of the spray gun should be perpendicular to the flue gas flow direction so that the atomization cross section of the denitrification spray gun can maximize the mixed flue gas to achieve the best denitrification efficiency. The spray gun spray distance is about the width of the flue at the injection point, and the spray angle is about 60°. The atomization effect of the spray gun is very important, including the spray distance, spray angle, pressure of the mixed liquid, pressure of the compressed air, etc. of the spray gun. The pressure of atomizing compressed air is generally controlled at 0.25-0.35MPa, and the pressure of the mixed liquid is maintained at 0.25-0.35MPa. Regularly conduct spray gun atomization test inspections to ensure that the atomization effect of each spray gun is good during operation. The wear of the spray gun nozzle also needs to be checked regularly and handled accordingly.

[0043] The degree of flue gas mixing refers to the contact between the smoke generated after boiler combustion and the reducing agent (urea solution, mainly ammonia in urea solution), which is mainly judged by two indicators: residence time and contact area. The residence time of flue gas in SCR reactor 1 is 0.1-0.2s. Denitrification efficiency and ammonia escape are important operating parameters of the SNCR system. By optimizing the layout of the injection point, the ammonia escape can be effectively controlled within the environmental protection standard range, and the ammonia escape is usually required to be less than 8mg / Nm 3 The spray volume of the spray gun needs to be adjusted according to the actual NOx concentration and flue gas conditions to ensure that the NOx concentration in the flue gas is stably controlled at 30mg / Nm 3 Below, meet strict emission standards.

[0044] The reducing agent silo 5 is filled with a reducing agent, and the components and mass percentages of the reducing agent are: 30% urea, 60% ionized water, 5% ammonia water and 5% organic amine. The reduction efficiency of the reducing agent is more than 20% higher than that of the traditional reducing agent, which means that the amount of reducing agent used can be reduced while achieving the same denitration effect. The reducing agent also significantly reduces the escape of ammonia. In traditional SNCR technology, ammonia escape is a common problem that causes secondary pollution. However, using the reducing agent of the present invention, the escape rate of ammonia is reduced by 50%, effectively controlling environmental pollution, while also reducing the health risks caused by ammonia escape. Environmental friendliness is another significant feature of the reducing agent of the present invention. This reducing agent has less impact on the environment and is easy to store and transport, providing a safer and more environmentally friendly denitration solution. This is particularly important for industrial facilities because they usually need to handle a large amount of flue gas, and traditional reducing agents may bring safety and environmental challenges. Economic benefits are also an advantage that cannot be ignored for the reducing agent of the present invention. Due to its high efficiency and low dosage, the improved reducing agent helps to reduce the overall cost of the denitration process. This not only saves operating expenses for enterprises, but also improves the economic efficiency of the denitrification system, making environmental protection investment more attractive. The use of improved reducing agents simplifies the operating process, improves the reliability of the system, and reduces the difficulty and cost of maintenance. This reducing agent is suitable for a variety of industrial flue gas denitrification occasions, including coal-fired power plants, cement kilns, steel mills, etc., and has broad market application prospects.

[0045] The reductant supply system is a key component in the SNCR denitrification technology, specifically including the reductant inlet pipe, the first metering pump 6, the flow control valve 7 and the pressure regulator 8. It optimizes the injection of the reductant by accurately controlling the metering and delivery of the reductant (i.e., urea solution). Specifically including. The first metering pump 6 can control the delivery amount of the urea solution within an error range of ±3%, ensuring the accurate supply of the reductant. The flow control valve 7 adjusts the flow of the urea solution according to the instructions of the ECU to meet the denitrification requirements under different working conditions. The pressure regulator 8 can maintain a constant pressure of the urea solution during the transportation process, usually between 4 and 10 bar, to ensure the uniformity and reliability of the injection. The urea solution is injected through a special nozzle, which is designed to achieve atomization in high-temperature flue gas to optimize the mixing of the urea solution and the flue gas and improve the reduction efficiency. In order to ensure that the urea solution can flow and inject normally in a low-temperature environment, the reductant silo 5 and the first metering pump 6 are heated by engine circulating water to prevent the freezing of the urea solution in cold conditions.

[0046] The additive silo 9 is filled with additives, and the components and mass percentages of the additives are: 15% potassium titanium oxalate, 5% tetraethyl silicate, 20% sodium ferric ethylenediaminetetraacetate, 10% sodium manganese ethylenediaminetetraacetate and 50% potassium ferrocyanide. The additive preparation method is: 15% potassium titanium oxalate, 5% tetraethyl silicate, 20% sodium ferric ethylenediaminetetraacetate, 10% sodium manganese ethylenediaminetetraacetate and 50% potassium ferrocyanide are mixed evenly, the mixed powder is dissolved in deionized water, the solution is aged at 100-400°C to ensure that each component fully reacts and forms a stable reducing agent solution, the aged solution is filtered to remove insoluble matter or precipitation, and the resulting liquid is the finished additive.

[0047] By adding the additive to the reducing agent (i.e. urea solution) and spraying it into the furnace together with the urea solution, the additive can increase the denitrification efficiency of SNCR to more than 55%, which is significantly better than the traditional SNCR technology. The optimal reaction temperature window for the additive to work is 800°C to 900°C, and the contact time with the flue gas is roughly between 4 and 7 seconds. These conditions can maximize the effect of the additive. When using the additive, the ammonia nitrogen ratio (i.e. the molar ratio of ammonia to NOx) can be controlled in the range of 0.2 to 5, which helps to reduce the amount of ammonia escape and improve the denitrification efficiency compared with the traditional SNCR technology. The high-efficiency additive has good resistance to fly ash interference and sulfur dioxide poisoning, making it effective in furnaces containing fly ash and SO 2 High efficiency can be maintained even in flue gas environments. This feature is particularly important for industrial flue gas treatment, because these flue gases usually contain a variety of pollutants that may affect the performance of the denitrifier. Since the additive can improve the denitrification efficiency and reduce the amount of reducing agent, it helps to reduce the operating costs of the enterprise while improving the environmental protection effect. This makes the additive of the present invention not only technologically advanced, but also economically feasible, and has a high market application value. The additive is suitable for various industrial flue gas denitrification occasions using SNCR technology, including coal-fired power plants, cement kilns, steel mills, etc., and has broad market application prospects.

[0048] The adsorption tower 2 is a detachable structure, which is convenient for replacing the adsorbent.

[0049] The adsorption tower 2 is filled with an adsorbent, and the components and mass percentages of the adsorbent are: 30% Na-ZSM-5 molecular sieve, 30% activated carbon, 20% potassium carbonate modified activated carbon, 10% metal organic framework and 10% silica alumina. The adsorbent preparation method is: 30% Na-ZSM-5 molecular sieve, 30% activated carbon, 20% potassium carbonate modified activated carbon, 10% metal organic framework and 10% silica alumina are mixed evenly, pressed into target particles, and then activated at high temperature to obtain a finished adsorbent.

[0050] Na-ZSM-5 molecular sieve has a high specific surface area and uniform pore size, which can effectively adsorb NOx, while activated carbon is widely used in gas adsorption due to its rich pore structure. The adsorbent not only has a high specific surface area of ​​more than 1500 square meters per gram, but also maintains stable physical and chemical properties in an environment up to 300°C. Its saturated adsorption capacity reaches more than 0.18g / g, which can reduce the concentration of NOx in flue gas to 30mg / Nm 3 The following meet strict environmental emission standards. The adsorbent is easy to regenerate, and its adsorption performance can be restored by simple heat treatment or pressure change, further improving its efficiency and economy.

[0051] like Figure 2 A control method for the SNCR reactor adsorption tower system as shown above specifically comprises the following steps:

[0052] Step S1, the first real-time monitoring unit 3 monitors the flue gas composition in real time, the reactor pressure sensor 17 monitors the internal pressure of the SNCR reactor 1, and transmits the detection data to the control unit 11;

[0053] Step S2, the control unit 11 processes the monitoring data and provides an operation instruction based on an artificial intelligence algorithm, and then sends the instruction to the actuator 12, and the actuator 12 automatically adjusts the injection unit 16, that is, adjusts the injection amount and frequency of the reducing agent;

[0054] Step S3, the machine learning module built into the control unit 11 predicts the optimal operating conditions and optimizes the denitrification efficiency, and then sends instructions to the actuator 12;

[0055] Step S4, the actuator 12 receives the instruction, accurately measures and delivers the reducing agent in the reducing agent silo 5;

[0056] Step S5 : the actuator 12 receives the instruction, and accurately measures and delivers the additive in the additive silo 9 .

[0057] Step S1 is specifically as follows: real-time monitoring, the first real-time monitoring unit 3 monitors the NOx concentration in the flue gas in real time with an accuracy of ±0.1% of the full scale, as well as the temperature (range 850°C to 1100°C) and flow rate (0 to 100m / s) of the flue gas; the reactor pressure sensor 17 monitors the internal pressure of the SNCR reactor 1 (0 to 2bar); these data are transmitted to the control unit 11 in real time via a 4 to 20mA signal or Modbus TCP protocol to ensure the accurate execution of the control strategy.

[0058] Step S2 is as follows: the control unit 11 processes the monitoring data and provides operation instructions based on the artificial intelligence algorithm, and the actuator 12 automatically adjusts the injection amount of the reducing agent with an accuracy within ±2%, and the injection frequency, ranging from 1Hz to 10Hz; these adjustments are based on the preset control strategy to ensure that the NOx concentration in the flue gas is stably controlled at 30mg / Nm under different working conditions. 3 Below, meet strict emission standards.

[0059] Step S3 is specifically as follows: the machine learning module built into the control unit 11 implements optimization. The machine learning module uses historical operation data and real-time data to predict the optimal operating conditions through algorithms, such as the temperature window of 900°C to 950°C and the optimal injection point of the urea solution located 4 to 6 meters inside the furnace; the system continuously optimizes these parameters through self-learning, improves denitrification efficiency, and reduces the use of reducing agents. The control unit 11 uses advanced artificial intelligence algorithms, such as neural networks or fuzzy logic control, to process monitoring data and provide operating instructions, which are then sent to the actuator 12. The computing power of the control unit 11 reaches millions of floating-point operations per second to ensure real-time data analysis and response.

[0060] Step S4 specifically includes: accurately metering the reducing agent (ie, urea solution). The urea supply system accurately meters the urea solution through the first metering pump 6, and the metering accuracy reaches ±0.5%; the flow control valve 7 and the pressure regulator 8 ensure that the urea solution is stably delivered to the injection point at a pressure of 2 to 8 bar.

[0061] Step S5 specifically includes: using a high-efficiency additive, SNCR high-efficiency additive is added to the urea solution at a mass percentage of 1% to 3%, and this additive can improve the denitrification efficiency by 5% to 10%. The additive is added by the second metering pump 10 to ensure that it is fully mixed with the urea solution.

[0062] As an energy efficiency analysis tool, the SNCR reactor adsorption tower system is a real-time energy monitoring and optimization system designed specifically for the SNCR reactor adsorption tower system. The system is provided with a first metering pump 6, a flow control valve 7, a pressure regulator 8, a second metering pump 10, a first real-time monitoring unit 3, a second real-time monitoring unit 4, a reactor pressure sensor 17 and a control unit 11, which realizes continuous tracking and data analysis of the system energy consumption, and can provide key energy consumption indicators, such as the use of electricity, heat and fuel, to ensure the optimization of energy efficiency. The control unit 11 adopts advanced data analysis algorithms, which can identify energy consumption patterns, find out energy saving potential points, and provide specific optimization suggestions. The user interface 13 is intuitive, displaying key energy consumption indicators and optimization suggestions, so that operators can easily understand and take action. In addition, the system can automatically generate detailed energy consumption reports, including energy consumption statistics, cost analysis and energy saving effect evaluation, to provide decision support for management.

[0063] The integrated intelligent fault diagnosis function is a significant feature of the present invention, which can predict and identify potential energy waste and equipment failures, thereby reducing unplanned downtime and maintenance costs. By continuously monitoring system performance, the energy efficiency analysis tool helps prevent failures and extend equipment life. The energy efficiency analysis tool supports remote access, and managers can monitor and control energy use from any location via the Internet, which improves the flexibility and convenience of the system. The design of the tool takes into account the compatibility with other industrial automation systems, and can be easily integrated into existing industrial control systems, ensuring its wide application potential in different industrial environments. The energy efficiency analysis tool of the present invention significantly improves the energy efficiency and operational efficiency of the SNCR system through real-time monitoring, intelligent analysis and optimization suggestions, reduces operating costs, and supports industrial enterprises to achieve the goals of green production and sustainable operation. The energy efficiency analysis tool mainly relies on the control unit 11, the first metering pump 6, the flow control valve 7, the pressure regulator 8, the second metering pump 10, the first real-time monitoring unit 3, the second real-time monitoring unit 4 and the reactor pressure sensor 17 in the SNCR reactor adsorption tower system to realize the intelligent fault diagnosis function. These components work together to collect various data of system operation and provide basic support for fault diagnosis. The specific working principle is as follows:

[0064] Data collection: The first real-time monitoring unit 3 and the second real-time monitoring unit 4 monitor the flue gas or exhaust gas in real time, including parameters such as temperature, pressure, flow rate and NOx concentration, and the reactor pressure sensor 17 monitors the internal pressure of the SNCR reactor 1. These monitoring data are transmitted to the control unit 11 in real time via 4 to 20mA signal or Modbus TCP protocol; at the same time, the working status data of the first metering pump 6, flow control valve 7, pressure regulator 8 and the second metering pump 10 will also be collected to the control unit 11;

[0065] Intelligent analysis: The control unit 11 has built-in advanced data analysis algorithms, such as neural networks or fuzzy logic control algorithms. It receives and processes data from various sensors and devices, and uses historical operation data and real-time data for in-depth analysis. By establishing a system operation model and a fault feature library, the real-time data is compared with the model and feature library to identify abnormal changes in energy consumption patterns and potential signs of equipment failure. For example, if the reductant flow and pressure are monitored to fluctuate abnormally and exceed the normal threshold range, combined with similar fluctuations in historical data that cause failures, it is judged that there may be problems such as pipeline blockage or pump failure; if the flue gas temperature and flow rate deviate too much from the standard values ​​under normal denitrification conditions, analyze whether it is caused by unreasonable layout of injection points in the reactor or deterioration of the atomization effect of the spray gun;

[0066] Fault prediction and diagnosis: Based on data analysis results, predict potential energy waste and equipment fault types, locations and severity. For example, early warning of reduced denitration efficiency and energy waste caused by decreased atomization effect due to long-term use and wear of the spray gun, or predicting the unstable reductant delivery and chain effects on the entire denitration system caused by pressure regulator failure, so as to take maintenance measures in time to prevent the fault from expanding into an unplanned downtime event, thereby reducing maintenance costs and downtime and extending equipment life;

[0067] Remote access and control: With the help of network communication technology, the energy efficiency analysis tool supports remote access function. Managers can use terminal devices (such as computers, mobile phones, etc.) to connect to the control unit 11 of the system through the Internet, view the real-time operation data of the system at any time, receive fault alarm information, and remotely adjust the operating parameters of the first metering pump 6, flow control valve 7, pressure regulator 8 and second metering pump 10 and other equipment, so as to achieve real-time monitoring and flexible control of energy use, improve the convenience of application of the system in different industrial environments and overall operational efficiency, and strongly support industrial enterprises to achieve green production and sustainable operation goals.

[0068] Example 1: Application in a coal-fired power plant

[0069] Configuration of flue gas denitrification system: An SNCR reactor adsorption tower system is installed in a coal-fired power plant. The SNCR reactor 1 is designed with multiple injection points, which are evenly distributed at appropriate positions in the boiler furnace to ensure that the flue gas and the reducing agent are fully mixed in the ideal temperature range of 850-1100°C. The adsorption tower 2 is a detachable structure, filled with self-made adsorbent (30% Na-ZSM-5 molecular sieve, 30% activated carbon, 20% potassium carbonate modified activated carbon, 10% metal organic framework and 10% silica alumina), the reducing agent silo (5) stores a specific proportion of reducing agent (30% urea, 60% ion water, 5% ammonia water and 5% organic amine), and the auxiliary agent silo 9 is equipped with corresponding auxiliary agents (15% potassium titanium oxalate, 5% tetraethyl silicate, 20% sodium iron ethylenediaminetetraacetate, 10% sodium manganese ethylenediaminetetraacetate and 50% potassium ferrocyanide).

[0070] Control unit operation: The control unit 11 receives the flue gas NOx concentration (e.g. 500 mg / Nm 3 ), temperature (950℃), flow rate (50m / s) and pressure value (0.8bar) of reactor pressure sensor 17 are processed by artificial intelligence algorithm and predicted by machine learning module, and then instructions are issued to actuator 12. Actuator 12 accurately controls the flow rate of reducing agent delivered by first metering pump 6 to a suitable value (such as 10L / min), adjusts the injection frequency (3Hz), and controls second metering pump 10 to add additive to reducing agent at a mass ratio of 2%, so that denitration efficiency reaches 92% and ammonia escape rate is reduced to 4mg / Nm3 After the flue gas passes through the adsorption tower, the NOx concentration is stabilized at 25mg / Nm 3 the following.

[0071] Example 2: Cement kiln flue gas denitrification

[0072] System adjustment and configuration: In the cement kiln flue gas denitrification scenario, the SNCR reactor adsorption tower system is fine-tuned according to the characteristics of the cement kiln flue gas. The injection point is optimized to be arranged near the entrance of the cyclone separation cylinder to adapt to the flue gas temperature and flow field distribution characteristics. The reducing agent formula is adjusted to 35% urea, 55% ionized water, 7% ammonia water and 3% organic amine, and the auxiliary agent formula is adjusted to 18% potassium titanium oxalate, 8% tetraethyl silicate, 25% sodium iron ethylenediaminetetraacetate, 12% sodium manganese ethylenediaminetetraacetate and 37% potassium ferrocyanide, so as to improve the system's adaptability to the complex flue gas composition and working conditions of the cement kiln.

[0073] Operation effect monitoring: During operation, the control unit 11 is adjusted according to the monitoring data. When the first real-time monitoring unit 3 detects that the flue gas NOx concentration reaches 800 mg / Nm 3 When the temperature is 1000°C, the flow rate is 40m / s and the pressure of the reactor pressure sensor 17 is 1.2bar, the actuator 12 controls the first metering pump 6 to make the reducing agent flow rate to 15L / min and the injection frequency to 4Hz, and the second metering pump 10 adds the auxiliary agent at a mass ratio of 2.5%, achieving a denitration efficiency of 93% and an ammonia escape rate of 3mg / Nm 3 , NOx concentration after treatment in adsorption tower is 20mg / Nm 3 The amount of reducing agent used is reduced by 35% compared with the traditional method, and the performance of the adsorbent is stable within the 5-year replacement cycle, ensuring the efficient and economical operation of the system.

[0074] Example 3: Denitrification of flue gas from sintering machine in steel plant

[0075] Customized system settings: Customized SNCR reactor adsorption tower system for the flue gas working conditions of sintering machines in steel plants. Because the flue gas of sintering machines contains high-concentration dust and multiple complex components, the reactor structure is optimized to enhance the anti-blocking performance, and a pre-pretreatment device is added for preliminary dust removal and desulfurization; the adsorbent in adsorption tower 2 is replaced with a large-particle, high-mechanical strength formula (Na-ZSM-5 molecular sieve 40%, activated carbon 35%, potassium carbonate modified activated carbon 15%, metal organic framework 5% and silica-alumina gel 5%) to enhance the wear resistance and anti-pollution capabilities; the reductant in reductant silo 5 is adjusted to 25% urea, 65% ionized water, 6% ammonia water and 4% organic amine, and the additive in additive silo 9 is optimized to 12% potassium titanium oxalate, 6% tetraethyl silicate, 28% sodium iron ethylenediaminetetraacetate, 14% sodium manganese ethylenediaminetetraacetate and 40% potassium ferrocyanide to enhance the selectivity and stability of denitrification of sintering flue gas.

[0076] Denitrification process and effect: In actual operation, the control unit 11 makes decisions based on real-time monitoring data. For example, if the flue gas NOx concentration is 600mg / Nm 3 , temperature 900℃, flow rate 60m / s, reactor pressure 0.6bar, actuator 12 controls the first metering pump 6 to deliver the reducing agent at a flow rate of 12L / min and an injection frequency of 3.5Hz, and the second metering pump 10 adds the additive at a mass ratio of 1.8%, achieving a denitration efficiency of 91% and an ammonia escape rate of 4.5mg / Nm 3 After the adsorption tower, the NOx concentration dropped to 28mg / Nm 3 The system operates stably, meeting the strict environmental protection requirements of the steel plant and reducing costs and increasing efficiency. The adsorbent has been in service for more than 5 years, and the amount of reducing agent used has been reduced by 32%, which strongly supports the green and sustainable development of steel production.

[0077] In summary, the present invention is reasonably designed and has the following advantages:

[0078] (1) The first real-time monitoring unit 3 monitors the flue gas composition in real time, and the reactor pressure sensor 17 monitors the internal pressure of the SNCR reactor 1 and transmits the detection data to the control unit 11; the control unit 11 processes the monitoring data and provides an operation instruction based on the artificial intelligence algorithm, and then sends the instruction to the actuator 12, and the actuator 12 automatically adjusts the injection unit 16, that is, adjusts the injection amount and frequency of the reducing agent, so that the denitration efficiency is increased to more than 90%, which greatly improves the denitration efficiency;

[0079] (2) The adsorbent built into the adsorption tower 2 has a high specific surface area and high adsorption capacity, which improves the adsorption efficiency of residual NOx, ensuring that the NOx concentration of the gas treated by the adsorption tower 2 is stably controlled at 30 mg / Nm 3 the following;

[0080] (3) The reducing agent reacts with NOx at a lower concentration, reducing the escape rate of ammonia to 5 mg / Nm 3 The control unit 11 and the actuator 12 cooperate with each other to avoid ammonia slip caused by excessive reducing agent, optimize the injection time and amount, and reduce unnecessary ammonia use;

[0081] (4) The amount of reducing agent used is precisely controlled, reducing the consumption of reducing agent by more than 30%. The adsorbent can be recycled, reducing the replacement frequency and processing costs, extending the adsorbent replacement cycle to more than 5 years, greatly reducing operating costs;

[0082] (5) When the main control unit fails, the backup control unit can take over seamlessly to ensure the continuous and stable operation of the system; the alarm unit 14 can immediately notify the operator when abnormal operating conditions are detected, and take timely measures to avoid potential failures and safety accidents; the user interface 13 enables the operator to easily monitor the system status and perform manual operations when necessary.

[0083] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A SNCR reactor adsorption tower system, characterized in that: The invention comprises an SNCR reactor (1), an adsorption tower (2), a reducing agent silo (5), an auxiliary agent silo (9) and a control unit (11); the SNCR reactor (1) is provided with a flue gas inlet pipe, on which a first real-time monitoring unit (3) is installed; a reducing agent inlet pipe is connected between the reducing agent silo (5) and the SNCR reactor (1), on which a first metering pump (6), a flow control valve (7) and a pressure regulator (8) are installed; the reducing agent inlet pipe is connected to the SNCR reactor (1) and then connected to an injection unit (16); and a reactor pressure sensor (17) is installed on the SNCR reactor (1); the auxiliary agent silo (9) is connected to the auxiliary agent inlet pipe, the auxiliary agent inlet pipe is in communication with the reducing agent inlet pipe, and a second metering pump (10) is installed on the auxiliary agent inlet pipe; an exhaust gas pipeline is connected between the SNCR reactor (1) and the adsorption tower (2), on which a second real-time monitoring unit (4) is installed; The control unit (11) is connected to an actuator (12), the actuator (12) is respectively connected to the first metering pump (6), the flow control valve (7), the pressure regulator (8), and the second metering pump (10), and the first real-time monitoring unit (3), the second real-time monitoring unit (4), and the reactor pressure sensor (17) are respectively connected to the control unit (11); The control unit (11) is also connected to a user interface (13), an alarm unit (14) and a data recording module (15).

2. The SNCR reactor adsorption tower system according to claim 1, characterized in that: The control unit (11) comprises a main control unit and a backup control unit which are arranged in parallel.

3. The SNCR reactor adsorption tower system according to claim 1, characterized in that: The control unit (11) has a built-in machine learning module.

4. The SNCR reactor adsorption tower system according to claim 1, characterized in that: The reducing agent silo (5) is filled with reducing agent, and the components and mass percentages of the reducing agent are: 15-40% urea, 40-80% ionized water, 1-10% ammonia water and 1-10% organic amine.

5. The SNCR reactor adsorption tower system according to claim 1, characterized in that: The auxiliary agent silo (9) is filled with auxiliary agents, and the components and mass percentages of the auxiliary agents are: 1-20% potassium titanium oxalate, 1-10% tetraethyl silicate, 10-30% sodium ferric ethylenediaminetetraacetate, 5-25% sodium manganese ethylenediaminetetraacetate and 30-60% potassium ferrocyanide.

6. The SNCR reactor adsorption tower system according to claim 5, characterized in that: The preparation method of the auxiliary agent comprises the following steps: uniformly mixing 1-20% potassium titanium oxalate, 1-10% tetraethyl silicate, 10-30% sodium ferric ethylenediaminetetraacetate, 5-25% sodium manganese ethylenediaminetetraacetate and 30-60% potassium ferrocyanide; dissolving the mixed powder in deionized water; aging the solution at 100-400° C. to ensure that each component fully reacts and forms a stable reducing agent solution; filtering the aged solution to remove insoluble matter or precipitation, and obtaining a liquid that is a finished auxiliary agent.

7. The SNCR reactor adsorption tower system according to claim 1, characterized in that: The adsorption tower (2) is a detachable structure.

8. The SNCR reactor adsorption tower system according to claim 7, characterized in that: The adsorption tower (2) is filled with an adsorbent, the components and mass percentages of the adsorbent are: 15-45% Na-ZSM-5 molecular sieve, 20-40% activated carbon, 10-30% potassium carbonate modified activated carbon, 1-10% metal organic framework and 1-10% silica-alumina gel.

9. The SNCR reactor adsorption tower system according to claim 8, characterized in that: The adsorbent preparation method comprises the following steps: evenly mixing 15-45% of Na-ZSM-5 molecular sieve, 20-40% of activated carbon, 10-30% of potassium carbonate modified activated carbon, 1-10% of metal organic framework and 1-10% of silica-alumina gel, pressing the mixture into target particles, and then performing activation treatment at high temperature to obtain a finished adsorbent.

10. A control method for an SNCR reactor adsorption tower system according to any one of claims 1 to 9, characterized in that: The specific steps include: Step S1, the first real-time monitoring unit (3) monitors the flue gas condition in real time, the reactor pressure sensor (17) monitors the internal pressure of the SNCR reactor (1), and transmits the monitoring data to the control unit (11); Step S2, the control unit (11) processes the monitoring data and provides an operation instruction based on an artificial intelligence algorithm, and then sends the instruction to the actuator (12), and the actuator (12) automatically adjusts the injection unit (16), that is, adjusts the injection amount and frequency of the reducing agent; Step S3, the machine learning module built into the control unit (11) predicts the optimal operating conditions and optimizes the denitrification efficiency, and then sends instructions to the actuator (12); Step S4, the actuator (12) receives the instruction, accurately measures and delivers the reducing agent in the reducing agent silo (5); Step S5: The actuator (12) receives the instruction, accurately measures and delivers the additive in the additive silo (9).

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