VOC emission reduction system and method for color coating production line

Abstract

The invention discloses a VOC emission reduction system and method for a color coating production line. The system comprises an online monitoring module, a preprocessing module, an adsorption concentration module, a catalytic combustion module, a waste heat recovery module, a production equipment control module, a safety protection module, a central control module, a data storage and analysis module and a remote monitoring module. The method comprises the steps of real-time monitoring and strategy making, production equipment adjustment, waste gas pretreatment, adsorption concentration and catalytic combustion, data management and analysis, remote monitoring, emergency treatment and the like. The system has the advantages of high efficiency, emission reduction, energy conservation, consumption reduction, intelligent operation, safety, reliability, convenient management and the like, and effectively solves the VOC emission problem of the color coating production line.

Description

Technical Field

[0001] The present invention relates to the technical field of waste gas treatment, and in particular to a VOC emission reduction system and method for a color coating production line. Background Art

[0002] In modern industrial production, color coating production lines are widely used in many fields such as construction, home appliances, and automobiles, giving various products beautiful and durable coatings. However, color coating production lines will inevitably produce a large amount of waste gas containing volatile organic compounds (VOCs) during operation, and the emission of these waste gases has a serious negative impact on the environment and human health.

[0003] Impact on the environment

[0004] From the perspective of air pollution, VOC is an important precursor to the formation of fine particulate matter (PM2.5) and ozone (O3). When the VOC waste gas emitted by the color coating production line enters the atmosphere, it will undergo a series of complex photochemical reactions with nitrogen oxides under sunlight, thereby accelerating the formation of ozone. High concentrations of ozone near the ground will not only irritate the human respiratory tract, but also damage plant growth and affect the yield and quality of crops. At the same time, VOC will also participate in the formation of secondary organic aerosols, increasing the concentration of fine particulate matter in the atmosphere, leading to frequent smog weather, reducing atmospheric visibility, and seriously affecting air quality and the ecological environment.

[0005] In addition, if VOC waste gas is discharged directly into water bodies without effective treatment, it will damage the aquatic ecosystem. Some difficult-to-degrade VOC substances will accumulate in water bodies, affecting the survival and reproduction of aquatic organisms and destroying the water ecological balance. Moreover, VOCs may also enter the soil environment through soil infiltration and other channels, changing the physical and chemical properties of the soil, affecting the activity of soil microorganisms, and thus having an adverse effect on vegetation growth and soil ecological functions.

[0006] Hazards to human health

[0007] VOC waste gas has many harmful effects on human health. Many VOC substances have pungent odors. When people inhale these waste gases, they will irritate the respiratory mucosa, causing symptoms such as coughing, wheezing, and difficulty breathing. Long-term exposure to an environment containing VOCs may also lead to chronic respiratory diseases such as bronchitis and asthma.

[0008] Some VOC substances are also toxic and carcinogenic. For example, aromatic hydrocarbon VOCs such as benzene, toluene, and xylene are known carcinogens, and long-term exposure may increase the risk of leukemia, lung cancer, and other cancers. In addition, some VOCs can also cause damage to the human nervous system, immune system, and reproductive system, affecting the normal physiological functions of the human body.

[0009] Insufficient processing technology

[0010] At present, although there are many technical means to treat VOC waste gas from color coating production lines, such as adsorption, combustion, catalytic oxidation, etc., these technologies still have many shortcomings in practical applications.

[0011] Although the traditional adsorption method can effectively adsorb VOCs in exhaust gas, the adsorption capacity of the adsorbent is limited and needs to be frequently replaced or regenerated, which increases the operating cost and difficulty of operation. Moreover, if the adsorption process is not handled properly, it may also lead to the secondary release of VOCs after the adsorbent is saturated, causing secondary pollution.

[0012] Although the combustion method can completely decompose VOC into carbon dioxide and water, the combustion process consumes a lot of energy, which is too expensive for large-scale color coating production lines. At the same time, if the combustion process is not properly controlled, other pollutants such as nitrogen oxides may be produced, which will put new pressure on the environment.

[0013] The catalytic oxidation method can reduce the reaction temperature and energy consumption to a certain extent, but the activity and stability of the catalyst are easily affected by impurities and moisture in the exhaust gas, and the exhaust gas needs to be strictly pre-treated. In addition, the service life of the catalyst is limited, and the cost of replacing the catalyst is high, which limits the widespread application of this technology.

[0014] In addition, most existing VOC treatment systems lack effective real-time monitoring and intelligent control methods, and it is difficult to adjust the treatment parameters in real time according to the actual operation of the color coating production line and the characteristics of exhaust gas emissions, resulting in unstable treatment effects and failure to meet increasingly stringent environmental emission standards. Moreover, some treatment systems are deficient in safety protection, and are prone to fire or explosion accidents due to catalytic combustion and other links, posing a serious threat to the production safety of enterprises.

[0015] In summary, there is an urgent practical need to develop an efficient, energy-saving, intelligent, safe and reliable VOC emission reduction system and method for color coating production lines. Summary of the invention

[0016] In order to solve the above problems, especially to address the deficiencies in the prior art, the present invention provides a VOC emission reduction system and method for a color coating production line that can solve the above problems.

[0017] To achieve the above purpose, the present invention adopts the following technical means:

[0018] A VOC emission reduction system for a color coating production line, comprising: an online monitoring module, a pretreatment module, an adsorption concentration module, a catalytic combustion module, a waste heat recovery module, a production equipment control module, a safety protection module, a central control module, a data storage and analysis module, and a remote monitoring module;

[0019] The online monitoring module is used to collect VOC-related data in the color coating production line in real time and accurately;

[0020] The pretreatment module is used to create favorable conditions for subsequent adsorption and catalytic combustion processes;

[0021] The adsorption concentration module is used to enrich the VOC in the exhaust gas;

[0022] The catalytic combustion module is used to heat the high-concentration VOC waste gas sent from the adsorption concentration module to a suitable catalytic combustion temperature;

[0023] The waste heat recovery module is used to recover the heat generated during the catalytic combustion process and transfer it to other links of the color coating production line;

[0024] The production equipment control module is used to accurately adjust the production equipment of the color coating production line;

[0025] The safety protection module is used to prevent fire or explosion accidents caused by catalytic combustion and other links;

[0026] The central control module is used to receive various data from various modules, and then analyze and calculate according to the preset program using the built-in intelligent control algorithm to formulate the best operation strategy and send corresponding control instructions to achieve coordinated operation of the entire system and efficient emission reduction;

[0027] The data storage and analysis module is used to manage and mine various types of data during the operation of the system;

[0028] The remote monitoring module is used to monitor the operating status, various parameters and alarm information of the emission reduction system in real time anytime and anywhere, and remotely adjust some control parameters to respond to problems that occur during system operation in a timely manner;

[0029] The online monitoring module, pretreatment module, adsorption concentration module, catalytic combustion module, waste heat recovery module, production equipment control module, safety protection module, data storage and analysis module, and remote monitoring module are respectively connected to the central control module;

[0030] The pretreatment module is connected to the adsorption concentration module, the adsorption concentration module is connected to the catalytic combustion module, and the catalytic combustion module is connected to the waste heat recovery module.

[0031] A further solution of the present invention is that the online monitoring module includes VOC concentration sensors, temperature sensors and flow sensors arranged at key positions of the color coating production line; the VOC concentration sensor adopts the principle of photoionization detection.

[0032] A further solution of the present invention is that the pre-treatment module is an exhaust gas filtering and processing device, which can control the exhaust gas humidity within the range of 30%-60%.

[0033] A further solution of the present invention is that the adsorption concentration module is composed of a plurality of adsorption towers.

[0034] A further solution of the present invention is that the catalytic combustion module is a combustion device equipped with a high-efficiency precious metal catalyst or a transition metal oxide catalyst, which can heat the exhaust gas to a catalytic combustion temperature of 200-500°C.

[0035] A further solution of the present invention is that the waste heat recovery module is a high-efficiency heat exchanger device.

[0036] A further solution of the present invention is that the production equipment control module is a PLC controller, the central control module adopts a high-performance industrial computer with a built-in intelligent control algorithm, the data storage and analysis module is a storage device with a built-in database management system, and the remote monitoring module is an industrial tablet computer with a built-in remote monitoring platform software.

[0037] A further solution of the present invention is that the safety protection module 7 is a fireproof and explosion-proof device.

[0038] A VOC emission reduction method for a color coating production line of a VOC emission reduction system of a color coating production line comprises the following steps:

[0039] The online monitoring module monitors the VOC concentration, gas temperature and flow rate at key locations of the color coating production line in real time, and transmits the collected data to the central control module in a timely manner. After receiving the data from the online monitoring module, the central control module uses the built-in intelligent control algorithm to analyze and calculate according to the preset emission reduction targets and production process requirements, and formulates the best emission reduction strategy;

[0040] For the production process, the production equipment control module makes precise adjustments to the production equipment of the color coating production line according to the instructions issued by the central control module;

[0041] After the exhaust gas is generated, it first enters the pretreatment module, which effectively removes particulate matter and impurities in the exhaust gas and controls the exhaust gas humidity within the range of 30%-60%, creating suitable conditions for subsequent adsorption and catalytic combustion;

[0042] The exhaust gas treated by the pretreatment module enters the adsorption concentration module, which works under the control of the central control module. The high-concentration VOC exhaust gas concentrated by the adsorption concentration module enters the catalytic combustion module;

[0043] After the catalytic combustion module receives high-concentration VOC exhaust gas, it heats the exhaust gas to a catalytic combustion temperature of 200-500°C under the precise control of the central control module. At the same time, the heat generated by the combustion is recycled through the waste heat recovery module.

[0044] During the entire emission reduction process, the data storage and analysis module continuously stores and deeply analyzes the data collected by the online monitoring module, the operating parameters of each module, and the emission reduction effect data through the central control module;

[0045] The remote monitoring module remotely monitors the emission reduction system through the central control module. The management personnel can check the system's operating status, various parameters and alarm information anytime and anywhere through the remote monitoring module, and remotely adjust some control parameters at the same time;

[0046] The safety protection module always ensures the safe operation of the system. When the safety protection module detects a dangerous accident, it will issue an alarm and send a signal to the central control module. The central control module will initiate corresponding emergency response measures to ensure the safety of personnel and equipment.

[0047] Beneficial effects of the present invention:

[0048] 1. The present invention can reduce emissions efficiently: With the help of the online monitoring module, the system can monitor the VOC concentration, gas temperature and flow rate at each key position of the color coating production line in real time. Based on these data, the central control module uses the intelligent control algorithm to formulate the best emission reduction strategy in combination with the preset emission reduction targets and production process requirements. The pretreatment module, adsorption concentration module and catalytic combustion module work together to efficiently remove the VOC waste gas generated by the color coating production line, ensure that the emissions meet strict environmental protection standards, and significantly reduce the pollution to the atmospheric environment.

[0049] 2. The present invention can reduce the risk of secondary pollution: the pretreatment module can effectively remove particulate matter and impurities in the exhaust gas, control the exhaust gas humidity within an appropriate range, avoid the impact of these impurities on subsequent treatment modules, reduce the risk of secondary release of VOCs after adsorbent saturation and the generation of other pollutants during catalytic combustion, and ensure the environmental protection of the entire treatment process.

[0050] 3. The present invention can save energy and reduce consumption: the waste heat recovery module recovers the heat generated during the catalytic combustion process and transfers it to other links of the color coating production line, realizing the reuse of energy and reducing the overall energy consumption of the system. This not only reduces the energy expenditure of the enterprise, but also improves the energy utilization efficiency and reduces the production cost.

[0051] 4. The present invention can reduce operating costs: the adsorption concentration module enriches the VOC in the exhaust gas, so that the exhaust gas concentration entering the catalytic combustion module is increased, thereby reducing the energy required for catalytic combustion and also reducing the consumption of catalysts. In addition, the precise adjustment of the production equipment by the production equipment control module helps to optimize the production process and reduce the fines and rectification costs that may be incurred due to non-compliance with exhaust gas emissions.

[0052] 5. The present invention can operate intelligently: the central control module uses a high-performance industrial computer with a built-in intelligent control algorithm, which can automatically receive and analyze the data of each module and adjust the system's operating strategy in real time according to the actual situation. This intelligent operation mode improves the system's automation and operating efficiency, reduces manual intervention, and reduces operational errors caused by human factors.

[0053] 6. The present invention enables convenient management: the remote monitoring module provides a convenient management method for managers. Through the industrial tablet computer with built-in remote monitoring platform software, managers can monitor the operating status, various parameters and alarm information of the emission reduction system in real time anytime and anywhere, and can remotely adjust some control parameters. This enables managers to respond to problems that arise during the operation of the system in a timely manner, improving the timeliness and effectiveness of management.

[0054] 7. The present invention is safe and reliable: the safety protection module is equipped with fire prevention and explosion-proof devices, which can monitor the system operation status in real time. Once a dangerous accident is detected, it will immediately issue an alarm and send a signal to the central control module. The central control module will quickly initiate corresponding emergency response measures to ensure the safety of personnel and equipment, avoid fire or explosion accidents caused by catalytic combustion and other links, and reduce the safety risks of the enterprise.

[0055] 8. The present invention can provide in-depth data analysis and decision support: the data storage and analysis module manages and mines various types of data during the operation of the system. By analyzing historical data, it can predict VOC emission trends and evaluate the impact of each module's operating efficiency on emission reduction effects. These analysis results can provide strong support for the company's production decisions, equipment maintenance, and system optimization, helping the company to continuously improve emission reduction measures and improve production efficiency and environmental protection levels. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1 It is a schematic diagram of a module of the present invention;

[0057] Reference numerals:

[0058] Online monitoring module 1, pretreatment module 2, adsorption concentration module 3, catalytic combustion module 4, waste heat recovery module 5, production equipment control module 6, safety protection module 7, central control module 8, data storage and analysis module 9, remote monitoring module 10. DETAILED DESCRIPTION

[0059] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not 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.

[0060] Example 1

[0061] A VOC emission reduction system for a color coating production line, comprising: an online monitoring module 1, a pretreatment module 2, an adsorption concentration module 3, a catalytic combustion module 4, a waste heat recovery module 5, a production equipment control module 6, a safety protection module 7, a central control module 8, a data storage and analysis module 9, and a remote monitoring module 10;

[0062] The online monitoring module 1 is used to collect VOC-related data in the color coating production line in real time and accurately;

[0063] The pretreatment module 2 is used to create favorable conditions for the subsequent adsorption and catalytic combustion processes;

[0064] The adsorption concentration module 3 is used to enrich the VOC in the exhaust gas;

[0065] The catalytic combustion module 4 is used to heat the high-concentration VOC exhaust gas sent from the adsorption concentration module 3 to a suitable catalytic combustion temperature;

[0066] The waste heat recovery module 5 is used to recover the heat generated during the catalytic combustion process and transfer it to other links of the color coating production line;

[0067] The production equipment control module 6 is used to accurately adjust the production equipment of the color coating production line;

[0068] The safety protection module 7 is used to prevent fire or explosion accidents caused by catalytic combustion and other links;

[0069] The central control module 8 is used to receive various data from various modules, and then analyze and calculate according to the preset program using the built-in intelligent control algorithm, formulate the best operation strategy, and send corresponding control instructions to achieve coordinated operation of the entire system and efficient emission reduction;

[0070] The data storage and analysis module 9 is used to manage and mine various types of data during the operation of the system;

[0071] The remote monitoring module 10 is used to monitor the operating status, various parameters and alarm information of the emission reduction system in real time anytime and anywhere, and remotely adjust some control parameters to respond to problems that occur during the operation of the system in a timely manner;

[0072] The online monitoring module 1, the pretreatment module 2, the adsorption concentration module 3, the catalytic combustion module 4, the waste heat recovery module 5, the production equipment control module 6, the safety protection module 7, the data storage and analysis module 9, and the remote monitoring module 10 are respectively connected to the central control module 8;

[0073] The pretreatment module 2 is connected to the adsorption concentration module 3 , the adsorption concentration module 3 is connected to the catalytic combustion module 4 , and the catalytic combustion module 4 is connected to the waste heat recovery module 5 .

[0074] The online monitoring module 1 includes VOC concentration sensors, temperature sensors and flow sensors arranged at key positions of the color coating production line; the VOC concentration sensor adopts the principle of photoionization detection.

[0075] The advantages of the above settings are:

[0076] For VOC concentration sensors

[0077] High-precision detection

[0078] The principle of photoionization detection is based on the fact that gas molecules are ionized after absorbing photons of specific energy, and the gas concentration is determined by detecting the ion current. This principle can detect a variety of volatile organic compounds with high precision, and can detect VOC concentrations at the ppm or even ppb level. In the color coating production line, even if the VOC emission concentration is low, it can be accurately detected, which helps to timely discover potential exhaust gas leaks or excessive emissions.

[0079] Quick response

[0080] PID sensors respond very quickly to changes in VOC concentration and can provide test results in a short time. During the color coating production process, the generation and emission of waste gas may change rapidly with factors such as production process and equipment operation status. Fast-responding VOC concentration sensors can capture these changes in real time, allowing the central control module to obtain the latest VOC emission information in a timely manner, thereby quickly adjusting emission reduction strategies.

[0081] Wide applicability

[0082] PID sensors can detect various types of VOCs, including benzene, toluene, xylene, esters, ketones and other organic compounds commonly found in color coating production lines. This enables the sensor to meet the needs of exhaust gas detection generated by different color coating processes and coating formulations, and has strong versatility and adaptability.

[0083] Non-destructive testing

[0084] Photoionization detection is a non-destructive detection method that does not change the composition and properties of the gas being tested during the detection process. This means that the exhaust gas can be monitored continuously and in real time without affecting the subsequent treatment process, ensuring the authenticity and validity of the monitoring data.

[0085] For temperature sensors and flow sensors

[0086] Optimizing the process

[0087] Temperature is an important factor affecting VOC adsorption, catalytic combustion and other treatment processes. By monitoring the exhaust gas temperature in real time through the temperature sensor, the central control module can adjust the heating power of the catalytic combustion module according to the temperature change to ensure that the exhaust gas is catalytically burned at a suitable temperature, thereby improving the treatment efficiency and effect. At the same time, during the adsorption process, the temperature will also affect the adsorption performance of the adsorbent. By monitoring the temperature, timely measures can be taken to optimize the adsorption process.

[0088] Accurately calculate emissions

[0089] The flow sensor can accurately measure the flow of exhaust gas, and combined with the concentration data measured by the VOC concentration sensor, the total amount of VOC emissions can be accurately calculated. This is very important for enterprises to carry out environmental management and emission compliance accounting, and it also helps to evaluate the actual effect of the emission reduction system. In addition, according to the changes in the exhaust gas flow, the central control module can adjust the operating parameters of the adsorption concentration module and the catalytic combustion module to achieve efficient operation of the system.

[0090] Ensure system security

[0091] During the catalytic combustion process, if the exhaust gas temperature is too high or the flow rate is too large, it may cause a safety accident. The temperature sensor and flow sensor can monitor these parameters in real time. Once the safety threshold is exceeded, the safety protection module will immediately initiate corresponding protection measures, such as reducing the heating power, adjusting the exhaust gas flow, etc., to ensure the safe operation of the system.

[0092] Overall Advantages

[0093] Provide comprehensive data support

[0094] The combination of VOC concentration sensors, temperature sensors and flow sensors can provide the central control module with comprehensive information about exhaust gas. Based on these multi-dimensional data, the central control module can use intelligent control algorithms for comprehensive analysis and calculation to develop more accurate and effective emission reduction strategies, thus achieving coordinated operation and efficient emission reduction of the entire emission reduction system.

[0095] Realize intelligent control

[0096] The data collected in real time by the online monitoring module 1 provides a basis for the intelligent control of the system. The central control module 8 can automatically adjust the operating parameters of the production equipment control module 6, the adsorption concentration module 3, the catalytic combustion module 4, etc. according to the monitoring data, so that the emission reduction system can dynamically optimize the operation according to the actual production situation, and improve the intelligence level and operation efficiency of the system.

[0097] The pre-treatment module 2 is an exhaust gas filtering and processing device, which can control the exhaust gas humidity within the range of 30%-60%.

[0098] The advantages of the above settings are:

[0099] Positive impact on adsorption concentration module 3

[0100] Improve adsorption efficiency: Most adsorbents used to adsorb VOCs, such as activated carbon and molecular sieves, are affected by the humidity of the exhaust gas. When the humidity is appropriate, the microporous structure of the adsorbent can play a better role, making it easier for VOC molecules to adhere. When the exhaust gas humidity is in the range of 30%-60%, it can prevent the adsorbent micropores from being occupied by water molecules due to excessive humidity, thereby reducing the adsorption capacity of VOCs. It can also prevent the adsorption effect from being poor due to low humidity, thereby ensuring the efficient enrichment of VOCs by the adsorption concentration module.

[0101] Extend the service life of the adsorbent: Too high humidity will cause a water film to form on the surface of the adsorbent, which will not only hinder the contact between VOC molecules and the adsorbent, but may also cause problems such as hydrolysis and expansion of the adsorbent, accelerating the aging and failure of the adsorbent. Controlling the humidity within an appropriate range can reduce the damage of moisture to the adsorbent, extend the replacement cycle of the adsorbent, and reduce operating costs.

[0102] Promoting effect on catalytic combustion module 4

[0103] Ensure catalyst activity: The catalyst in the catalytic combustion module 4 is sensitive to humidity. Excessive humidity will cause hydrates to form on the catalyst surface, covering the active sites, reducing the activity and selectivity of the catalyst, and affecting the catalytic combustion effect of VOC. Controlling the exhaust gas humidity at 30%-60% can keep the catalyst surface dry and active, ensure the efficient catalytic combustion reaction, and enable VOC to be quickly decomposed at a lower temperature.

[0104] Reduce equipment corrosion: Water combined with certain substances produced during the combustion process may form corrosive substances that damage catalytic combustion equipment. The appropriate humidity range can reduce the occurrence of such corrosion, extend the service life of catalytic combustion equipment, and reduce equipment maintenance costs.

[0105] Ensure the overall stability of the system

[0106] Prevent pipe blockage: The moisture in the exhaust gas may cause particles to stick together, resulting in pipe blockage and affecting the normal flow of exhaust gas. Controlling the humidity at 30%-60% can reduce the possibility of particle sticking, ensure the smooth transmission of exhaust gas in the system, and reduce failures and downtime caused by pipe blockage.

[0107] Improve system reliability: A stable humidity environment helps the stable operation of each module and reduces the impact of humidity fluctuations on the system. This enables the entire VOC emission reduction system to work more reliably, improves the overall performance and operating efficiency of the system, and ensures continuous and effective control of VOC emissions from the color coating production line.

[0108] The adsorption concentration module 3 is composed of a plurality of adsorption towers.

[0109] The advantages of the above settings are:

[0110] Improve processing power and efficiency

[0111] Increase adsorption area: Multiple adsorption towers work simultaneously or alternately, which is equivalent to greatly increasing the contact area between the exhaust gas and the adsorbent. When the color coating production line produces a large amount of VOC-containing exhaust gas, it can more efficiently adsorb the VOC in the exhaust gas, increase the exhaust gas treatment volume per unit time, ensure that the system can meet the exhaust gas treatment needs of the production line, and avoid affecting the production progress due to untimely exhaust gas treatment.

[0112] Realize continuous processing: By rationally arranging the working order of multiple adsorption towers, the continuity of the adsorption process can be achieved. When one adsorption tower reaches adsorption saturation, it can be switched to another adsorption tower to continue the adsorption operation, and the saturated adsorption tower can be desorbed and regenerated at the same time. In this way, the entire adsorption concentration module can operate uninterruptedly, greatly improving the processing efficiency of the system and ensuring the stable operation of the color coating production line.

[0113] Enhance system stability and reliability

[0114] Reduce the impact of failures: If the adsorption concentration module consists of only one adsorption tower, once the adsorption tower fails, the entire module will not work properly, resulting in interruption of waste gas treatment. The setting of multiple adsorption towers provides redundancy. When one adsorption tower fails, the other adsorption towers can continue to work, maintaining the basic processing capacity of the system, reducing the impact of equipment failure on production and environmental protection, and improving the reliability and stability of the system.

[0115] Adapt to changes in working conditions: The production conditions of the color coating production line may change due to factors such as product type, production process, and production load, which may cause the flow rate, concentration and other parameters of the exhaust gas to change accordingly. Multiple adsorption towers can flexibly adjust the number of working and operation modes according to actual working conditions. For example, when the exhaust gas flow rate is large or the concentration is high, the number of adsorption towers invested can be increased to ensure effective adsorption of VOCs; when the working conditions are relatively stable and the exhaust gas volume is small, the number of adsorption towers in operation can be reduced to reduce energy consumption and operating costs.

[0116] Easy to maintain and manage

[0117] Simplified maintenance operations: The design of multiple adsorption towers makes maintenance work more convenient. Regular inspection, maintenance and adsorbent replacement can be performed on a single adsorption tower without affecting the normal operation of other adsorption towers. This can reasonably arrange maintenance time and resources, reduce maintenance difficulty and cost, and improve maintenance efficiency.

[0118] Prolong the service life of adsorbent: By alternating the use of adsorption towers, the use of adsorbent can be more uniform, avoiding premature failure of adsorbent in a single adsorption tower due to excessive use. At the same time, when desorbing and regenerating the adsorption tower, more optimized regeneration processes and parameters can be used to improve the regeneration effect of the adsorbent, prolong the service life of the adsorbent, and further reduce operating costs.

[0119] Optimize adsorption effect

[0120] Achieve graded adsorption: According to the concentration and composition characteristics of VOC in the exhaust gas, multiple adsorption towers can be reasonably configured to achieve graded adsorption. For example, the exhaust gas is first passed through an adsorption tower with a better adsorption effect on low-concentration VOC to remove most of the VOC, and then passed through an adsorption tower with a stronger adsorption capacity for high-concentration VOC for deep treatment. This graded adsorption method can improve the adsorption efficiency of VOCs of different concentrations and components, and further improve the treatment effect of the entire adsorption concentration module.

[0121] The catalytic combustion module 4 is a combustion device equipped with a high-efficiency precious metal catalyst or a transition metal oxide catalyst, which can heat the exhaust gas to a catalytic combustion temperature of 200-500°C.

[0122] The advantages of the above settings are:

[0123] Highly efficient VOC degradation

[0124] Lowering the reaction temperature: Precious metal catalysts and transition metal oxide catalysts have good catalytic activity and can significantly reduce the temperature required for VOC oxidation and decomposition. Compared with the traditional direct combustion method, catalytic combustion can be carried out at a lower temperature of 200-500°C. In this temperature range, the catalyst can cause VOC molecules to react with oxygen, converting them into carbon dioxide and water, achieving efficient degradation while reducing energy consumption.

[0125] Accelerate the reaction rate: The catalyst can reduce the activation energy of the reaction and accelerate the rate of VOC oxidation reaction. In the exhaust gas generated by the color coating production line, the VOC components are complex and the concentration may be high. Efficient catalysts can make a large number of VOC molecules react in a short time, improve the processing efficiency of the catalytic combustion module, and ensure that the exhaust gas can be purified quickly and effectively.

[0126] Save energy consumption

[0127] Low-temperature combustion energy saving: Since catalytic combustion is carried out at a relatively low temperature, compared to direct combustion, which requires a higher temperature to completely burn VOC, the catalytic combustion module can significantly reduce the energy required to heat the exhaust gas. This not only reduces the amount of fuel used and reduces operating costs, but also meets the environmental protection requirements of energy conservation and emission reduction.

[0128] Waste heat recovery: A certain amount of heat is released during catalytic combustion, and the process of heating the exhaust gas to 200-500°C also generates usable waste heat. This waste heat can be recovered through the waste heat recovery module and used to preheat the exhaust gas entering the system, heat other links of the color coating production line, etc., further improving the comprehensive utilization efficiency of energy.

[0129] Reduce secondary pollution

[0130] Complete oxidation products: Under the action of the catalyst, VOC can be more fully oxidized to produce harmless substances such as carbon dioxide and water. Compared with some incomplete combustion situations, catalytic combustion can effectively reduce the generation of incomplete combustion products such as carbon monoxide and hydrocarbons, reduce the risk of secondary pollution, and make exhaust emissions more environmentally friendly.

[0131] Inhibit the formation of nitrogen oxides: Lower combustion temperature can reduce the formation of nitrogen oxides. During high-temperature combustion, nitrogen and oxygen in the air easily react to form nitrogen oxides. The catalytic combustion module works in the temperature range of 200-500°C, which can effectively inhibit the occurrence of this reaction, thereby reducing the pollution of nitrogen oxides to the atmospheric environment.

[0132] Catalyst performance advantages

[0133] Precious metal catalysts: They have the characteristics of high activity, high selectivity and good stability. They can maintain high catalytic performance in a wide range of temperature and concentration, and have a good degradation effect on a variety of VOCs. Even in the case of complex exhaust gas components, they can ensure the stability of the catalytic combustion process, ensuring the treatment effect and reliability of the system.

[0134] Transition metal oxide catalysts: relatively low cost and widely available. Some transition metal oxide catalysts have good catalytic activity for specific VOCs and have a certain resistance to poisoning. In practical applications, appropriate transition metal oxide catalysts can be selected according to the specific composition and characteristics of the exhaust gas to achieve economical and efficient treatment effects.

[0135] The waste heat recovery module 5 is a high-efficiency heat exchanger device.

[0136] The advantages of the above settings are:

[0137] Energy utilization and cost savings

[0138] Energy recovery and reuse: When the catalytic combustion module treats high-concentration VOC exhaust gas, a large amount of heat is released. The high-efficiency heat exchanger can effectively capture and recycle this heat that would otherwise be wasted, and transfer it to other links of the color coating production line, such as preheating the exhaust gas entering the system, heating the paint, and providing heat energy for the drying process. This realizes the secondary use of energy and improves the energy utilization efficiency of the entire production process.

[0139] Reduce energy costs: By recycling waste heat and using it in other parts of the production line, companies can reduce their reliance on external energy. In the long-term production process, this will significantly reduce energy procurement costs and bring considerable economic benefits to companies. Especially for large-scale color coating production lines, where energy costs account for a large proportion, the energy-saving effect of waste heat recovery is more obvious.

[0140] Production process optimization

[0141] Stabilize the production process: In color coating production, many processes have strict requirements on temperature, such as curing and drying of coatings. The waste heat recovered by the efficient heat exchanger can provide a stable heat source for these processes, which helps to maintain the temperature stability in the production process. A stable temperature environment can improve the consistency of product quality, reduce the defective rate caused by temperature fluctuations, and improve the production efficiency of the enterprise.

[0142] Accelerate the production process: Using the recovered waste heat to preheat the exhaust gas entering the system can make the exhaust gas reach the temperature required for catalytic combustion more quickly, shorten the reaction time of catalytic combustion, and improve the exhaust gas treatment efficiency. At the same time, in the drying process, sufficient waste heat supply can speed up the drying speed, thereby improving the production efficiency of the entire production line and increasing the company's production capacity.

[0143] Environmental benefits

[0144] Reduce emissions from energy consumption: Reducing the demand for external energy means reducing pollutant emissions generated during energy production and use, such as carbon dioxide, sulfur dioxide, nitrogen oxides, etc. generated by burning fossil fuels. This helps companies reduce their own carbon emissions, comply with environmental protection policy requirements, and enhance the company's environmental image.

[0145] Synergistic emission reduction effect: The waste heat recovery module works in conjunction with the entire VOC emission reduction system, which not only achieves energy recovery and utilization, but also promotes efficient treatment of VOC. Stable production processes and efficient waste gas treatment can further reduce VOC emissions, enhance the environmental protection effect of the entire emission reduction system, and contribute to improving the quality of the atmospheric environment.

[0146] Equipment operation and maintenance level

[0147] Reduce equipment burden: After the high-efficiency heat exchanger recovers the waste heat, it reduces the workload of other heating equipment. This not only reduces the energy consumption of these equipment, but also extends their service life, reduces the probability of equipment failure, and reduces equipment maintenance and replacement costs.

[0148] Improve system stability: As part of the entire emission reduction system, the stable operation of the waste heat recovery module helps improve the stability of the entire system. The heat exchanger can effectively adjust the heat distribution within the system, avoid equipment damage or abnormal operation caused by heat accumulation or lack of heat, and ensure that the system can operate continuously and reliably.

[0149] The production equipment control module 6 is a PLC controller.

[0150] The advantages of the above settings are:

[0151] High reliability: PLC controller has strong anti-interference ability and can operate stably in the complex industrial environment of color coating production line. Environmental conditions such as high temperature, humidity, strong electromagnetic interference will not easily affect its normal operation. This ensures stable and reliable control of production equipment and reduces the risk of production interruption due to equipment failure.

[0152] Good flexibility: The programming of the PLC controller is flexible and convenient, and the control program can be easily modified according to the control requirements of different color coating production processes and equipment. Whether it is the speed adjustment of the coating machine or the precise control of the oven temperature, the control strategy can be quickly adjusted to meet the diverse production needs.

[0153] Easy to maintain: The PLC controller has a complete fault diagnosis function. When the equipment fails, it can quickly locate the fault point, which is convenient for maintenance personnel to repair in time. Its modular design also makes it easier to replace the faulty module, reducing maintenance time and cost.

[0154] The safety protection module 7 is a fire-proof and explosion-proof device.

[0155] The advantages of the above settings are:

[0156] Ensure the safety of personnel

[0157] Prevent fire and explosion accidents: In the VOC emission reduction process of the color coating production line, catalytic combustion and other links involve high temperature, open flames and high concentrations of VOC waste gas, which significantly increase the risk of fire and explosion. Fire and explosion-proof devices can effectively control potential fire sources and explosion hazards. For example, by installing fire dampers, explosion-proof doors and other equipment, the spread of flames and explosion shock waves can be prevented to avoid the expansion of accidents, thereby providing a safe working environment for on-site workers and minimizing the possibility of casualties.

[0158] Timely warning and emergency response: Fire and explosion-proof devices are usually equipped with advanced monitoring and alarm systems that can monitor key parameters such as temperature and combustible gas concentration in the environment in real time. Once an abnormal situation is detected, such as combustible gas leakage or excessive temperature, the system will immediately sound an alarm to remind staff to take timely measures. At the same time, these devices can also be connected to the central control module. When danger occurs, the central control module can quickly start the corresponding emergency handling procedures, such as cutting off power supply, stopping equipment operation, etc., to ensure that personnel have enough time to evacuate the dangerous area.

[0159] Protecting equipment and facilities

[0160] Prevent equipment damage: Fire and explosion accidents may cause serious damage to various equipment and facilities in the emission reduction system, such as adsorption towers, catalytic combustion equipment, heat exchangers, etc. Fire and explosion-proof devices can effectively reduce the degree of damage to equipment caused by accidents and extend the service life of equipment. For example, explosion-proof electrical equipment can operate normally in an explosive environment, avoiding explosions caused by electrical faults, and also protecting itself from the impact of explosions.

[0161] Ensure stable operation of the system: By preventing fire and explosion accidents, fire and explosion-proof devices help maintain the stable operation of the emission reduction system. Once an accident occurs, the system may be forced to shut down for maintenance and rectification, which will not only affect the production schedule, but also increase the company's operating costs. The existence of the safety protection module can reduce the occurrence of such accidents, ensure that the system can operate continuously and efficiently, and achieve stable treatment of VOC exhaust gas.

[0162] Comply with regulations and standards

[0163] Comply with environmental protection and safety regulations: Today, as environmental protection and safe production are increasingly valued, companies must comply with relevant laws and standards. Installing fire and explosion-proof devices is an important measure for companies to meet these regulatory requirements, which can avoid fines, suspension of production and other penalties for violating regulations. At the same time, this also helps companies establish a good social image and enhance their sense of social responsibility.

[0164] Improve enterprise competitiveness: Having comprehensive safety protection measures is an advantage for enterprises in market competition. Customers and partners prefer to cooperate with enterprises that focus on production safety, because this means that product quality and supply stability are more guaranteed. Therefore, the setting of safety protection module 7 can improve the competitiveness of enterprises and lay the foundation for their long-term development.

[0165] Reduce economic losses

[0166] Reduce accident losses: Fire and explosion accidents often bring huge economic losses to enterprises, including equipment damage, production stagnation, compensation for casualties, etc. The application of fire and explosion prevention devices can effectively reduce the probability of accidents and the degree of losses, saving enterprises a lot of money. In addition, by timely discovering and dealing with potential safety hazards, it can also avoid major accidents caused by small problems, further reducing economic losses.

[0167] Guaranteeing production benefits: A stable production environment is the basis for enterprises to achieve economic benefits. Safety protection module 7 can ensure the normal operation of the emission reduction system and ensure that the production of the color coating production line is not disturbed by safety accidents, thereby ensuring the production benefits of the enterprise. At the same time, by reducing energy consumption and improving waste gas treatment efficiency, the economic benefits of the enterprise can be further improved.

[0168] The central control module 8 adopts a high-performance industrial computer with built-in intelligent control algorithm.

[0169] The advantages of the above settings are:

[0170] Powerful data processing capability: High-performance industrial computers can quickly process large amounts of data from multiple modules such as online monitoring modules and production equipment control modules. Through built-in intelligent control algorithms, these data are analyzed and calculated in real time to develop the best operation strategy. For example, the operating parameters of the adsorption concentration module and the catalytic combustion module can be accurately adjusted based on data such as VOC concentration, exhaust gas flow and temperature.

[0171] Intelligent decision-making and optimization: The intelligent control algorithm can automatically optimize the operation of the system according to the preset emission reduction targets and production process requirements. It can monitor the operating status of the system in real time, identify potential problems in time and make adjustments to improve the overall operating efficiency and emission reduction effect of the system. For example, when the production load changes, the operating parameters of the production equipment are automatically adjusted to achieve the best balance of energy saving and emission reduction.

[0172] System integration and coordination: The central control module can organically integrate various modules together to achieve the coordinated operation of the entire emission reduction system. It can coordinate the production equipment control module to adjust the production equipment, and at the same time control the working status of the adsorption concentration module, catalytic combustion module, etc., to ensure accurate and efficient coordination between various modules.

[0173] The data storage and analysis module 9 is a storage device with a built-in database management system.

[0174] The advantages of the above settings are:

[0175] Safe and reliable data storage: The storage device with built-in database management system can store various data in the system operation process for a long time and safely. These data include VOC concentration, temperature, flow rate and other data collected by the online monitoring module, as well as the operating parameters and emission reduction effect data of each module. The database management system has functions such as data backup, recovery and encryption to ensure the integrity and security of the data.

[0176] In-depth data analysis: With the powerful data analysis function of the database management system, the stored data can be deeply mined and analyzed. By analyzing historical data, the laws and trends of system operation can be discovered, VOC emissions can be predicted, and strong support can be provided for system optimization and decision-making. For example, by analyzing VOC emission data in different time periods, the peak emission periods and causes can be found so that targeted measures can be taken.

[0177] Data sharing and query: It is convenient for different departments and personnel to share and query data. Managers can view the system's operating data and emission reduction effects at any time, and technicians can perform system fault diagnosis and performance evaluation based on the data, providing data basis for the company's management and technical improvements.

[0178] The remote monitoring module 10 is an industrial tablet computer with built-in remote monitoring platform software.

[0179] The advantages of the above settings are:

[0180] Real-time remote monitoring: Managers can use the remote monitoring platform software on the industrial tablet computer to monitor the operating status, various parameters and alarm information of the emission reduction system in real time anytime and anywhere. No matter where they are, they can understand the operation of the system in a timely manner, detect abnormalities in time and respond.

[0181] Convenient parameter adjustment: The remote monitoring module supports remote adjustment of some control parameters. When there is a problem with the system operation or adjustments are needed according to production conditions, managers can modify the relevant parameters directly on the tablet computer without having to go to the site for operation, which improves the convenience and timeliness of management.

[0182] Improve emergency response capabilities: Once a system failure or alarm occurs, managers can quickly understand the situation through the remote monitoring module and remotely initiate corresponding emergency response measures to reduce the impact of the failure on production and the environment, thereby improving the system's emergency response capabilities and safety.

[0183] A VOC emission reduction method for a color coating production line of a VOC emission reduction system of a color coating production line comprises the following steps:

[0184] The VOC concentration, gas temperature and flow rate at each key position of the color coating production line are monitored in real time through the online monitoring module 1, and the collected data are transmitted to the central control module 8 in a timely manner. After receiving the data from the online monitoring module, the central control module 8 uses the built-in intelligent control algorithm to analyze and calculate according to the preset emission reduction target and production process requirements, and formulates the best emission reduction strategy;

[0185] For the production process, the production equipment control module 6 makes precise adjustments to the production equipment of the color coating production line according to the instructions issued by the central control module 8;

[0186] After the exhaust gas is generated, it first enters the pretreatment module 2, which effectively removes particulate matter and impurities in the exhaust gas and controls the exhaust gas humidity within the range of 30%-60%, creating suitable conditions for subsequent adsorption and catalytic combustion;

[0187] The exhaust gas treated by the pretreatment module 2 enters the adsorption concentration module 3, which works under the control of the central control module 8. The high-concentration VOC exhaust gas concentrated by the adsorption concentration module 3 enters the catalytic combustion module 4;

[0188] After receiving the high-concentration VOC waste gas, the catalytic combustion module 4 heats the waste gas to a catalytic combustion temperature of 200-500°C under the precise control of the central control module 8. At the same time, the heat generated by the combustion is recycled through the waste heat recovery module 5.

[0189] During the entire emission reduction process, the data storage and analysis module 9 continuously stores and deeply analyzes the data collected by the online monitoring module 1, the operating parameters of each module, and the emission reduction effect data through the central control module 8;

[0190] The remote monitoring module 10 remotely monitors the emission reduction system through the central control module 8. The management personnel can check the operating status, various parameters and alarm information of the system anytime and anywhere through the remote monitoring module 10, and remotely adjust some control parameters at the same time;

[0191] The safety protection module 7 always ensures the safe operation of the system. When the safety protection module 7 detects a dangerous accident, it issues an alarm and sends a signal to the central control module 8. The central control module 8 initiates corresponding emergency response measures to ensure the safety of personnel and equipment.

[0192] Example 2

[0193] Small color coating production line application:

[0194] Scenario Overview

[0195] A small color coating production line is mainly used to produce color coated plates for home appliance shells. The daily output is relatively low and the amount of VOC waste gas generated is also small. The production line previously used traditional activated carbon adsorption treatment, but the treatment effect was not good, and the activated carbon was frequently replaced, resulting in high operating costs.

[0196] System Configuration

[0197] Online monitoring module 1: VOC concentration sensors, temperature sensors and flow sensors are installed in key locations such as the coating area and drying area of ​​the color coating production line to monitor the VOC concentration, temperature and flow in the exhaust gas in real time.

[0198] Pretreatment module 2: Use small exhaust gas filtration and treatment equipment to effectively remove particulate matter and impurities in the exhaust gas and control the exhaust gas humidity between 30% and 40%.

[0199] Adsorption concentration module 3: It consists of two small adsorption towers and uses high-efficiency adsorbents to enrich VOCs in exhaust gas.

[0200] Catalytic combustion module 4: A small combustion device equipped with a transition metal oxide catalyst that can heat high-concentration VOC exhaust gas to 250-350°C for catalytic combustion.

[0201] Waste heat recovery module 5: A small high-efficiency heat exchanger is installed to recover the heat generated by catalytic combustion for preheating of the drying area, thereby improving energy efficiency.

[0202] Production equipment control module 6: A small PLC controller is used to accurately adjust the coating speed, drying temperature and other parameters of the production line.

[0203] Safety protection module 7: Fire dampers, explosion-proof doors and other fire-proof and explosion-proof devices are installed to ensure safe operation of the system.

[0204] Central control module 8: uses an industrial computer of ordinary performance, with built-in intelligent control algorithm, and adjusts the system operation strategy in real time according to the monitoring data.

[0205] Data storage and analysis module 9: uses a storage device with a smaller capacity and a built-in database management system to store and analyze system operation data.

[0206] Remote monitoring module 10: Equipped with an industrial tablet computer, managers can view the system operation status in real time through the remote monitoring platform.

[0207] Operation effect

[0208] After the system was put into operation, the VOC emission reduction effect was significant, the emission concentration was greatly reduced, and it met the national environmental protection emission standards.

[0209] The application of the waste heat recovery module 5 reduces the energy consumption of the drying area by about 20%, and the operating cost is significantly reduced.

[0210] Intelligent control algorithms automatically adjust equipment parameters according to production conditions, improving production efficiency and product quality.

[0211] Example 3

[0212] Medium-sized color coating production line application:

[0213] Scenario Overview

[0214] A medium-sized color coating production line is used to produce color coated steel plates for construction. The output is moderate, and the amount of VOC waste gas generated is relatively large. The original waste gas treatment system has limited processing capacity and cannot meet the increasingly stringent environmental protection requirements.

[0215] System Configuration

[0216] Online monitoring module 1: High-precision VOC concentration sensors, temperature sensors and flow sensors are arranged at multiple key locations of the production line to ensure accurate monitoring of exhaust gas data.

[0217] Pretreatment module 2: It uses large-scale exhaust gas filtration and treatment equipment with multi-stage filtration function, which can effectively remove various impurities in the exhaust gas and stably control the exhaust gas humidity between 40% and 50%.

[0218] Adsorption concentration module 3: It consists of four adsorption towers, which can automatically switch the working state of the adsorption tower according to the exhaust gas volume and concentration to achieve continuous and efficient adsorption concentration.

[0219] Catalytic combustion module 4: A large combustion device equipped with a precious metal catalyst is used to heat high-concentration VOC waste gas to 350-450°C for rapid catalytic combustion.

[0220] Waste heat recovery module 5: Install a large and efficient heat exchanger to use the recovered heat in multiple links of the production line, such as heating paint, preheating air, etc.

[0221] Production equipment control module 6: Use high-performance PLC controller to centrally control and accurately adjust multiple production equipment on the production line.

[0222] Safety protection module 7: A complete fire and explosion-proof monitoring and alarm system, as well as an emergency shut-off device, are set up to ensure that the system can operate safely under any circumstances.

[0223] Central control module 8: uses high-performance industrial computers with built-in advanced intelligent control algorithms, which can quickly process large amounts of data and formulate optimal operating strategies.

[0224] Data storage and analysis module 9: Use large-capacity storage devices and professional database management systems to perform long-term storage and in-depth analysis of system operation data.

[0225] Remote monitoring module 10: Equipped with multiple industrial tablet computers, managers from different departments can monitor the system operation in real time.

[0226] Operation effect

[0227] After the transformation, the VOC emission reduction efficiency has been greatly improved, and the emission concentration is far lower than the national environmental protection standards, effectively improving the surrounding environmental quality.

[0228] The extensive application of the waste heat recovery module 5 increases the comprehensive energy utilization rate of the production line by about 30%, significantly reducing the production cost.

[0229] The application of intelligent control systems makes the operation of the production line more stable and further improves product quality.

[0230] Example 4

[0231] Large color coating production line application:

[0232] Scenario Overview

[0233] A large-scale color coating production line is an important production link of a large steel enterprise, with high daily output and huge amount of VOC waste gas. The previous waste gas treatment system had problems such as insufficient treatment capacity, high energy consumption and low degree of automation.

[0234] System Configuration

[0235] Online monitoring module 1: High-precision and high-reliability VOC concentration sensors, temperature sensors and flow sensors are fully installed at various key locations of the production line to achieve all-round real-time monitoring of exhaust gas data.

[0236] Pretreatment module 2: It uses super-large exhaust gas filtration and treatment equipment with high-efficiency particle and impurity removal capabilities, as well as precise humidity adjustment functions to control the exhaust gas humidity between 50% and 60%.

[0237] Adsorption and concentration module 3: It consists of six large adsorption towers, using advanced adsorption technology and automated control to achieve efficient enrichment and treatment of waste gas.

[0238] Catalytic combustion module 4: equipped with multiple large-scale and efficient combustion equipment, using high-performance precious metal catalysts, which can quickly heat high-concentration VOC exhaust gas to 400-500℃ for thorough catalytic combustion.

[0239] Waste heat recovery module 5: Install a large and complex heat exchange network to widely recycle the heat generated by catalytic combustion and reuse it in various links of the production line, such as heating production water, preheating raw materials, etc.

[0240] Production equipment control module 6: It uses advanced distributed PLC control system to comprehensively and accurately control and adjust the numerous production equipment on the production line.

[0241] Safety protection module 7: A multi-level, all-round fire and explosion protection system has been built, including automatic fire alarm system, explosion-proof pressure relief device, emergency sprinkler system, etc.

[0242] Central Control Module 8: It uses a top-level industrial computer cluster with built-in ultra-complex intelligent control algorithms, capable of processing massive amounts of data in real time and quickly formulating optimal operating strategies.

[0243] Data storage and analysis module 9: It adopts an enterprise-level data storage and analysis platform with powerful data processing and mining capabilities, providing strong support for the company's production decisions.

[0244] Remote monitoring module 10: A remote monitoring center has been established, equipped with multiple high-performance industrial tablet computers and a large-screen display system, so that managers can monitor the detailed operating status of the system in real time and perform remote operation and control.

[0245] Operation effect

[0246] After the system was put into use, it achieved efficient treatment of VOC waste gas, and the emission concentration reached the international advanced environmental protection standards, greatly improving the company's environmental image.

[0247] The efficient operation of the waste heat recovery module 5 reduces the energy consumption of the production line by about 40%, significantly improving the economic benefits of the enterprise.

[0248] The intelligent control system and perfect safety protection system ensure the stable operation of the production line, improve production efficiency and product quality, and protect the safety of personnel and equipment.

[0249] The examples given in the present invention are not intended to limit the implementation methods. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the implementation methods here, and the obvious changes or modifications derived therefrom are still within the protection scope of the present invention.

Claims

1. A VOC emission reduction system for a color coating production line, characterized in that: include: Online monitoring module (1), pretreatment module (2), adsorption concentration module (3), catalytic combustion module (4), waste heat recovery module (5), production equipment control module (6), safety protection module (7), central control module (8), data storage and analysis module (9), remote monitoring module (10); The online monitoring module (1) is used to collect VOC-related data in the color coating production line in real time and accurately; The pretreatment module (2) is used to create favorable conditions for the subsequent adsorption and catalytic combustion processes; The adsorption concentration module (3) is used to enrich VOC in the exhaust gas; The catalytic combustion module (4) is used to heat the high-concentration VOC waste gas sent from the adsorption concentration module (3) to a suitable catalytic combustion temperature; The waste heat recovery module (5) is used to recover the heat generated during the catalytic combustion process and transfer it to other links of the color coating production line; The production equipment control module (6) is used to accurately adjust the production equipment of the color coating production line; The safety protection module (7) is used to prevent fire or explosion accidents caused by catalytic combustion and other links; The central control module (8) is used to receive various data from various modules, and then analyze and calculate according to a preset program using a built-in intelligent control algorithm to formulate an optimal operation strategy and send corresponding control instructions to achieve coordinated operation of the entire system and efficient emission reduction; The data storage and analysis module (9) is used to manage and mine various types of data during the operation of the system; The remote monitoring module (10) is used to monitor the operating status, various parameters and alarm information of the emission reduction system in real time anytime and anywhere, and remotely adjust some control parameters to promptly respond to problems that arise during system operation; The online monitoring module (1), the pretreatment module (2), the adsorption concentration module (3), the catalytic combustion module (4), the waste heat recovery module (5), the production equipment control module (6), the safety protection module (7), the data storage and analysis module (9), and the remote monitoring module (10) are respectively connected to the central control module (8); The pretreatment module (2) is connected to the adsorption concentration module (3), the adsorption concentration module (3) is connected to the catalytic combustion module (4), and the catalytic combustion module (4) is connected to the waste heat recovery module (5).

2. A VOC emission reduction system for a color coating production line according to claim 1, characterized in that: The online monitoring module (1) comprises a VOC concentration sensor, a temperature sensor and a flow sensor which are arranged at key positions of the color coating production line; the VOC concentration sensor adopts the principle of photoionization detection.

3. The VOC emission reduction system for a color coating production line according to claim 1 is characterized in that: The pre-treatment module (2) is an exhaust gas filtering and processing device, which can control the exhaust gas humidity within the range of 30%-60%.

4. The VOC emission reduction system for a color coating production line according to claim 1 is characterized in that: The adsorption concentration module (3) is composed of a plurality of adsorption towers.

5. The VOC emission reduction system for a color coating production line according to claim 1 is characterized in that: The catalytic combustion module (4) is a combustion device equipped with a high-efficiency precious metal catalyst or a transition metal oxide catalyst, which can heat the exhaust gas to a catalytic combustion temperature of 200-500°C.

6. The VOC emission reduction system for a color coating production line according to claim 1 is characterized in that: The waste heat recovery module (5) is a high-efficiency heat exchanger device.

7. The VOC emission reduction system for a color coating production line according to claim 1 is characterized in that: The production equipment control module (6) is a PLC controller, the central control module (8) uses a high-performance industrial computer with a built-in intelligent control algorithm, the data storage and analysis module (9) is a storage device with a built-in database management system, and the remote monitoring module (10) is an industrial tablet computer with a built-in remote monitoring platform software.

8. The VOC emission reduction system for a color coating production line according to claim 1 is characterized in that: The safety protection module (7) is a fire-proof and explosion-proof device.

9. A VOC emission reduction method for a color coating production line based on the system according to any one of claims 1 to 8, characterized in that: The following steps are involved: The VOC concentration, gas temperature and flow rate at each key position of the color coating production line are monitored in real time through the online monitoring module (1), and the collected data are transmitted to the central control module (8) in a timely manner. After receiving the data from the online monitoring module, the central control module (8) uses the built-in intelligent control algorithm to analyze and calculate according to the preset emission reduction target and production process requirements, and formulates the best emission reduction strategy; For the production process, the production equipment control module (6) accurately adjusts the production equipment of the color coating production line according to the instructions issued by the central control module (8); After the exhaust gas is generated, it first enters the pretreatment module (2), which effectively removes particulate matter and impurities in the exhaust gas and controls the exhaust gas humidity within the range of 30%-60%, thereby creating suitable conditions for subsequent adsorption and catalytic combustion; The waste gas treated by the pretreatment module (2) enters the adsorption concentration module (3), the adsorption concentration module (3) operates under the control of the central control module (8), and the high-concentration VOC waste gas concentrated by the adsorption concentration module (3) enters the catalytic combustion module (4); After the catalytic combustion module (4) receives the high-concentration VOC waste gas, it heats the waste gas to a catalytic combustion temperature of 200-500° C. under the precise control of the central control module (8). At the same time, the heat generated by the combustion is recovered and utilized through the waste heat recovery module (5); During the entire emission reduction process, the data storage and analysis module (9) continuously stores and deeply analyzes the data collected by the online monitoring module (1), the operating parameters of each module, and the emission reduction effect data through the central control module (8); The remote monitoring module (10) remotely monitors the emission reduction system through the central control module (8). The management personnel can check the operating status, various parameters and alarm information of the system at any time and anywhere through the remote monitoring module (10), and at the same time, remotely adjust some control parameters; The safety protection module (7) always ensures the safe operation of the system. When the safety protection module (7) detects a dangerous accident, it issues an alarm and sends a signal to the central control module (8). The central control module (8) initiates corresponding emergency response measures to ensure the safety of personnel and equipment.

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