Multi-gradient catalysis and self-cleaning SCR (Selective Catalytic Reduction) denitration honeycomb filtering equipment and processing device

Abstract

The invention discloses multi-gradient catalysis and self-cleaning SCR denitration honeycomb filtering equipment and a machining device.The multi-gradient catalysis and self-cleaning SCR denitration honeycomb filtering equipment comprises an SCR reactor body, a channel, a catalysis assembly and a self-cleaning assembly, a honeycomb base body is arranged on the SCR reactor body, and the channel is arranged in the honeycomb base body on the SCR reactor body in a penetrating mode; the catalysis assembly is installed on the channel to conduct catalytic denitration on flue gas passing through the channel, and the self-cleaning assembly is installed outside the SCR reactor body to conduct ash removal on the honeycomb base body. The device can fully adapt to changes of flue gas components and temperature, and the denitration effect is remarkably improved; the self-cleaning assembly achieves automatic dust removal, reduces manual maintenance cost, and prolongs the service life of equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of denitration, and particularly relates to a multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device and a processing device thereof. Background Art

[0002] Under the background of the accelerating global industrialization process, the emission of nitrogen oxides (NOx) in industrial flue gas has become one of the important sources of environmental pollution. NOx emissions not only cause acid rain, damage the ecological balance, but also lead to the formation of photochemical smog, seriously threatening human health and the living environment. Selective catalytic reduction (SCR) technology, with its high denitration efficiency, has become the mainstream technology for controlling NOx emissions in the current industrial field and is widely used in many industries such as thermal power generation, iron and steel smelting, and chemical production.

[0003] Currently, most of the SCR denitration devices used in industry adopt a honeycomb catalyst structure. Although this structure meets the requirements of flue gas treatment to a certain extent, there are still many problems to be solved. From the perspective of structural design, the catalysts of traditional SCR denitration devices are mostly single-stage structures, and the active components of the catalysts are evenly distributed on the entire honeycomb carrier, unable to perform targeted treatment according to the changes in the composition and temperature of the flue gas during the reaction process. Industrial flue gas has a complex composition, and there are differences in parameters such as temperature and flow rate at different positions in the SCR reactor. Single-stage catalysts are difficult to fully exert their catalytic performance, resulting in the denitration efficiency being difficult to further improve. Summary of the Invention

[0004] In order to solve the technical problems existing in the background art, the present invention proposes a multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device and a processing device thereof.

[0005] The multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device and a processing device thereof proposed by the present invention include: an SCR reactor body, channels, a catalytic component, and a self-cleaning component. A honeycomb matrix is provided on the SCR reactor body, and the channels are arranged through the honeycomb matrix on the SCR reactor body. The catalytic component is installed on the channels to catalytically denitrate the flue gas passing through the channels, and the self-cleaning component is installed outside the SCR reactor body to clean the ash on the honeycomb matrix.

[0006] Preferably, the catalytic component includes a first catalytic layer, a second catalytic layer, and a third catalytic layer. The first catalytic layer, the second catalytic layer, and the third catalytic layer are arranged at equal intervals in the channels, and the loading amounts of the catalytic active components of the first catalytic layer, the second catalytic layer, and the third catalytic layer are distributed in a gradient manner.

[0007] Preferably, the loading amount of the active component of the first catalytic layer is 100 - 200 g / m 3 , and that of the second catalytic layer is 200 - 300 g / m3 , the third catalytic layer is 150 - 250 g / m 3 .

[0008] Preferably, the catalytic active components of the first catalytic layer, the second catalytic layer and the third catalytic layer are selected from at least two combinations of TiO-based catalysts, molecular sieve catalysts, and noble metal catalysts, wherein the first catalytic layer uses a sulfur-resistant catalyst and the third catalytic layer uses a low-temperature active catalyst.

[0009] Preferably, the self-cleaning component includes multiple groups of ultrasonic generators, differential pressure sensors, and a controller;

[0010] Multiple groups of ultrasonic generators are all installed outside the SCR reactor body and correspond one by one to the first catalytic layer, the second catalytic layer, and the third catalytic layer;

[0011] The differential pressure sensor and the controller are installed on the SCR reactor body. The controller is communicatively connected to the differential pressure sensor and multiple groups of ultrasonic generators. When the controller determines through the real-time data of the differential pressure sensor that the differential pressure between the outside of the SCR reactor body and the channel exceeds the set threshold, it controls multiple groups of ultrasonic generators to perform an ultrasonic soot cleaning program.

[0012] Preferably, the inner wall of the honeycomb matrix is provided with a hydrophobic modification layer, the contact angle of the hydrophobic modification layer > 120°, and the porosity of the hydrophobic modification layer is maintained at 30 - 50%.

[0013] Preferably, the cross-section of the channel is a hexagonal structure, the side length of the channel is 2 - 5 mm, the opening ratio of the channel is 60 - 80%, and the wall thickness of the channel is 0.3 - 0.8 mm.

[0014] A processing device for a multi-gradient catalytic and self-cleaning SCR denitrification honeycomb filter device includes a honeycomb forming mold, a gradient impregnation system, a microwave drying kiln, and a self-cleaning component assembly table;

[0015] The honeycomb forming mold has an adjustable die core structure for forming through channels with different cross-sectional shapes;

[0016] The gradient impregnation system includes three independent liquid storage tanks and a programmable impregnation robotic arm;

[0017] The microwave drying kiln is equipped with a multi-stage temperature control module, and the drying temperature is adjustable in a gradient of 50 - 300 °C;

[0018] The self-cleaning component assembly table integrates an ultrasonic generator positioning fixture.

[0019] Preferably, the gradient impregnation system forms the catalytic component by sol-gel method in three times of impregnation. The composition of the impregnation liquid for each time is in a mass ratio of V2O5:WO3:TiO2 of 1:3:96, 3:5:92, and 2:4:94 respectively.

[0020] Preferably, the gradient impregnation system is provided with a visual positioning module, which uses a CCD camera to identify the impregnation position of the honeycomb body and controls the axial distribution accuracy of each catalyst layer to be ±1 mm;

[0021] The microwave drying kiln monitors the emission concentration of volatile organic compounds in real time through an on-line mass spectrometer, dynamically adjusts the drying temperature curve, and expands it in combination with the content of the technical disclosure to make it more perfect.

[0022] A multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device and processing device proposed by the present invention has the following advantages: Through a unique multi-gradient catalytic structure design, it can fully adapt to the changes in flue gas composition and temperature. Under the working conditions of 300-420 °C, the denitration efficiency is ≥95%, and the ammonia slip rate is ≤3 ppm, significantly improving the denitration effect; The self-cleaning component realizes automatic ash cleaning, and the ash cleaning efficiency is increased by more than 40% compared with the traditional method, reducing the manual maintenance cost and extending the service life of the equipment; The processing device realizes the precise gradient distribution of the catalyst active components through precise preparation processes, ensuring the stability and consistency of the equipment performance. The invention provides an efficient, stable and environmentally friendly solution for industrial flue gas denitration, and has broad application prospects and remarkable economic and social benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the internal structure of a multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device proposed by the present invention;

[0024] Figure 2 It is a structural diagram of the catalytic component of a multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device proposed by the present invention in the SCR reactor body. DETAILED DESCRIPTION OF THE INVENTION

[0025] Referring to Figure 1-2 , the present invention proposes a multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device and processing device, including an SCR reactor body 1, channels 2, a catalytic component 3 and a self-cleaning component 4. A honeycomb matrix is provided on the SCR reactor body 1, and the honeycomb matrix provides a place for catalytic reactions and flue gas circulation. The channels 2 are arranged through the honeycomb matrix, and their design directly affects the flue gas circulation efficiency and the contact area of catalytic reactions. The catalytic component 3 is installed on the channels 2 and can efficiently catalyze and denitrate the flue gas passing through the channels 2, converting nitrogen oxides in the flue gas into harmless nitrogen and water. The self-cleaning component 4 is installed outside the SCR reactor body 1 and can automatically clean the ash of the honeycomb matrix, keep the catalyst surface clean, and ensure the catalytic activity;

[0026] The catalytic assembly 3 includes a first catalytic layer 31, a second catalytic layer 32, and a third catalytic layer 33. These three catalytic layers are arranged at equal intervals in the channel 2 to form a gradient catalytic structure. The loading amounts of the catalytic active components in each catalytic layer are distributed in a gradient manner. Among them, the loading amount of the active component in the first catalytic layer 31 is 100 - 200 g / m 3 , the second catalytic layer 32 is 200 - 300 g / m 3 , and the third catalytic layer 33 is 150 - 250 g / m 3 . This gradient loading design can reasonably distribute the catalytic activity according to the reaction process of the flue gas in the channel, improve the denitration efficiency. The catalytic active components are selected from at least two combinations of TiO2-based catalysts, molecular sieve catalysts, and noble metal catalysts. Among them, the first catalytic layer 31 uses an anti-sulfur catalyst, which can effectively resist the poisoning effect of sulfur-containing compounds in the flue gas on the catalyst and extend the service life of the catalyst; the third catalytic layer 33 uses a low-temperature active catalyst, which can achieve efficient denitration at a lower temperature and broaden the applicable temperature range of the equipment,

[0027] The self-cleaning assembly 4 includes multiple groups of ultrasonic generators, differential pressure sensors, and a controller. The multiple groups of ultrasonic generators are all installed outside the SCR reactor body 1 and correspond one-to-one to the first catalytic layer 31, the second catalytic layer 32, and the third catalytic layer 33, and can perform ash cleaning on each catalytic layer specifically. The differential pressure sensor and the controller are installed on the SCR reactor body 1. The controller is communicatively connected to the differential pressure sensor and multiple groups of ultrasonic generators. When the controller determines through the real-time data of the differential pressure sensor that the differential pressure between the outside of the SCR reactor body 1 and the channel 2 exceeds the set threshold, it indicates that the ash accumulation in the channel is serious and affects the flue gas flow. At this time, the controller controls the multiple groups of ultrasonic generators to perform an ultrasonic ash cleaning program. The high-frequency vibration generated by the ultrasonic waves can effectively remove the ash on the surface of the catalyst without manual intervention, realizing automatic cleaning and improving the continuity and stability of the equipment operation;

[0028] The inner wall of the honeycomb matrix is provided with a hydrophobic modification layer. The contact angle of this hydrophobic modification layer > 120°, and it has good hydrophobicity, which can effectively prevent the attachment of dust, moisture, etc. on the surface of the honeycomb matrix. At the same time, the porosity of the hydrophobic modification layer is maintained at 30 - 50%. On the premise of ensuring hydrophobicity, it does not affect the flue gas flow and the catalytic reaction, further improving the anti-pollution ability of the equipment. In addition, the cross-section of the channel 2 is a hexagonal structure, which has good mechanical properties and space utilization rate. The side length of the channel 2 is 2 - 5 mm, the opening ratio is 60 - 80%, and the wall thickness is 0.3 - 0.8 mm. The reasonable design of the size parameters can optimize the flue gas flow path and improve the catalytic reaction efficiency;

[0029] The processing device of the multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter equipment includes:

[0030] Honeycomb forming die: The honeycomb forming die has an adjustable die core structure. By adjusting the die core structure, through-channels with different cross-sectional shapes can be formed. This design can meet the requirements of different working conditions for the honeycomb matrix structure, improve the adaptability of the equipment. In actual production, the size and shape of the channels can be flexibly adjusted according to factors such as flue gas flow and composition to optimize the flue gas flow and catalytic reaction effect;

[0031] Gradient impregnation system: The gradient impregnation system includes three independent liquid storage tanks and a programmable control impregnation robotic arm. The three independent liquid storage tanks store impregnation liquids with different compositions respectively. The catalytic component 3 is impregnated and formed three times by the sol-gel method. The mass ratio of the composition of the impregnation liquid each time is V2O5:WO3:TiO2 = 1:3:96, 3:5:92, 2:4:94 respectively. This precise composition control can achieve the gradient loading of catalytic active components. At the same time, the gradient impregnation system is equipped with a visual positioning module, which uses a CCD camera to identify the impregnation position of the honeycomb body and controls the axial distribution accuracy of each catalytic layer to be ±1 mm, ensuring the precise distribution of the catalytic layer in the channel and giving full play to the advantages of gradient catalysis;

[0032] Microwave drying kiln: The microwave drying kiln is equipped with a multi-stage temperature control module, and the drying temperature can be adjusted in a gradient of 50 - 300 °C. It can perform precise drying treatment according to the characteristics of different catalytic materials. In addition, the microwave drying kiln uses an on-line mass spectrometer to monitor the emission concentration of volatile organic compounds in real time, dynamically adjusts the drying temperature curve, ensures the environmental protection and high efficiency of the drying process, and at the same time ensures that the performance of the catalytic material is not affected;

[0033] Self-cleaning component assembly table: The self-cleaning component assembly table integrates an ultrasonic generator positioning fixture, which can accurately position the installation position of the ultrasonic generator, ensure the correspondence between the ultrasonic generator and the catalytic layer, and improve the assembly accuracy and reliability of the self-cleaning component;

[0034] The parameters are as follows:

[0035] Side length of honeycomb unit: 10 mm, wall thickness 0.8 mm, fractal level 3;

[0036] Catalyst loading: 1.2 g / cm for the outer layer 3 , 0.8 g / cm for the inner layer 3 ;

[0037]

[0038] Assembly of the multi-gradient catalysis and self-cleaning SCR denitration honeycomb filter equipment:

[0039] Install the prepared honeycomb substrate on the SCR reactor body 1, ensure firm installation and good sealing to prevent flue gas leakage. Then, install the first catalyst layer 31, the second catalyst layer 32, and the third catalyst layer 33 in the channels 2 in sequence according to the design requirements, ensure that the catalyst layers are evenly spaced, and the loading amount of the catalytic active components meets the gradient requirements. During the installation process, special installation tools can be used to ensure the accurate installation position of the catalyst layer and avoid deviation affecting the denitration effect. Next, install multiple groups of ultrasonic generators outside the SCR reactor body 1 to make them correspond to each catalyst layer one by one. At the same time, install the differential pressure sensor and the controller at appropriate positions on the SCR reactor body 1 and complete the communication connection to ensure that the self-cleaning component can work normally;

[0040] Use of the processing device for the multi-gradient catalytic and self-cleaning SCR denitration honeycomb filtration equipment:

[0041] Honeycomb substrate forming: According to the design requirements, adjust the adjustable die core structure of the honeycomb forming die, determine the cross-sectional shape and size of the channels 2, put the raw materials for preparing the honeycomb substrate into the die, and form a honeycomb substrate blank with through channels through forming processes such as extrusion and injection molding. Then, perform appropriate processing on the blank, such as grinding and polishing, to improve the surface quality and dimensional accuracy of the honeycomb substrate,

[0042] Catalytic component preparation: Put the honeycomb substrate blank into the gradient impregnation system. The impregnation robotic arm immerses the honeycomb substrate into the impregnation liquids in three independent liquid storage tanks in sequence according to the preset program. After each impregnation, perform a drying treatment to ensure that the impregnation liquid is fully cured to form a catalyst layer. Through the cooperation of the visual positioning module and the CCD camera, accurately control the axial distribution position of each catalyst layer to achieve the preparation of the gradient catalytic structure,

[0043] Drying treatment: Send the impregnated honeycomb substrate into the microwave drying kiln, set the drying temperature curve of the multi-stage temperature control module according to the characteristics of the catalytic material and the process requirements. The online mass spectrometer monitors the emission concentration of volatile organic compounds in real time. When the concentration is abnormal, automatically adjust the drying temperature to ensure the smooth progress of the drying process and at the same time ensure that the performance of the catalytic material is not affected. After drying, cool the honeycomb substrate to room temperature;

[0044] Self-cleaning component assembly: On the self-cleaning component assembly table, use the ultrasonic generator positioning fixture to accurately install the ultrasonic generator at the predetermined position outside the SCR reactor body 1 and complete the connection with the controller. Debug the assembled self-cleaning component to ensure that it can work normally and achieve the automatic ash cleaning function.

[0045] Among them, the performance test data is as follows:

[0046]

[0047] As described above, it is only the preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution of the present invention and its inventive concept, making equivalent substitutions or changes, shall be covered by the protection scope of the present invention.

Claims

1. A multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device, characterized in that, Including: An SCR reactor body (1), channels (2), a catalytic component (3) and a self-cleaning component (4). A honeycomb substrate is provided on the SCR reactor body (1). The channels (2) are disposed through the honeycomb substrate on the SCR reactor body (1). The catalytic component (3) is installed on the channels (2) to catalytically denitrate the flue gas passing through the channels (2). The self-cleaning component (4) is installed outside the SCR reactor body (1) to clean the ash of the honeycomb substrate.

2. The multi-gradient catalytic and self-cleaning SCR denitration honeycomb filtration device according to claim 1, characterized in that, The catalytic component (3) includes a first catalytic layer (31), a second catalytic layer (32) and a third catalytic layer (33). The first catalytic layer (31), the second catalytic layer (32) and the third catalytic layer (33) are arranged at equal intervals in the channels (2). The loading amounts of the catalytic active components of the first catalytic layer (31), the second catalytic layer (32) and the third catalytic layer (33) are distributed in a gradient.

3. A multi-gradient catalytic and self-cleaning SCR denitration honeycomb filtration device according to claim 2, characterized in that, The active component loading of the first catalyst layer (31) is 100 - 200 g / m 3 , that of the second catalyst layer (32) is 200 - 300 g / m 3 , and that of the third catalyst layer (33) is 150 - 250 g / m 3 .

4. A multi-gradient catalytic and self-cleaning SCR denitration honeycomb filtration device according to claim 3, characterized in that, The catalytic active components of the first catalytic layer (31), the second catalytic layer (32) and the third catalytic layer (33) are selected from at least two combinations of TiO₂-based catalysts, molecular sieve catalysts, and noble metal catalysts. Among them, the first catalytic layer (31) uses a sulfur-resistant catalyst, and the third catalytic layer (33) uses a low-temperature active catalyst.

5. The multi-gradient catalytic and self-cleaning SCR denitration honeycomb filtration device according to claim 4, wherein, The self-cleaning component (4) includes multiple groups of ultrasonic generators, a differential pressure sensor and a controller; Multiple groups of ultrasonic generators are all installed outside the SCR reactor body (1) and correspond one by one to the first catalytic layer (31), the second catalytic layer (32) and the third catalytic layer (33); The differential pressure sensor and the controller are installed on the SCR reactor body (1). The controller is communicatively connected to the differential pressure sensor and multiple groups of ultrasonic generators. When the controller determines through the real-time data of the differential pressure sensor that the differential pressure between the outside of the SCR reactor body (1) and the channels (2) exceeds the set threshold, it controls multiple groups of ultrasonic generators to perform an ultrasonic ash cleaning procedure.

6. The multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device according to claim 5, wherein, The inner wall of the honeycomb substrate is provided with a hydrophobic modification layer. The contact angle of the hydrophobic modification layer > 120°, and the porosity of the hydrophobic modification layer is maintained at 30 - 50%.

7. The multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device according to claim 6, wherein, The cross-section of the channels (2) is a hexagonal structure. The side length of the channels (2) is 2 - 5 mm. The porosity of the channels (2) is 60 - 80%, and the wall thickness of the channels (2) is 0.3 - 0.8 mm.

8. A processing device for a multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device according to any one of claims 1-7, characterized in that, Including a honeycomb forming mold, a gradient impregnation system, a microwave drying kiln and a self-cleaning component assembly table; The honeycomb forming mold has an adjustable core structure for forming through channels with different cross-sectional shapes; The gradient impregnation system includes three independent liquid storage tanks and a programmable control impregnation robotic arm; The microwave drying kiln is equipped with a multi-stage temperature control module, and the drying temperature is adjustable in a gradient of 50 - 300 °C; The self-cleaning component assembly table integrates an ultrasonic generator positioning fixture.

9. The processing device of a multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device according to claim 8, characterized in that, The gradient impregnation system forms the catalytic component 3 by three-time impregnation through the sol-gel method. The composition of the impregnation liquid each time is in a mass ratio of V₂O₅:WO₃:TiO₂ of 1:3:96, 3:5:92, and 2:4:94 respectively.

10. The processing device of a multi-gradient catalytic and self-cleaning SCR denitration honeycomb filter device according to claim 9, characterized in that, The gradient impregnation system is provided with a visual positioning module. The visual positioning module uses a CCD camera to identify the impregnation position of the honeycomb body and controls the axial distribution accuracy of each catalytic layer to be ±1 mm; The microwave drying kiln monitors the emission concentration of volatile organic compounds in real time through an on-line mass spectrometer and dynamically adjusts the drying temperature curve.

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