Modularized carbon flue gas pretreatment system

Abstract

The invention provides a modularized carbon flue gas pretreatment system, interfaces among functional treatment modules are standardized interfaces, and a flue gas inlet pipeline in the inlet direction of each functional treatment module is connected with a bypass pipeline; the bypass pipeline is provided with a bypass valve for adjusting whether the carbon flue gas discharged by the pretreatment module or the previous functional treatment module passes through the current functional treatment module or not; a first sensor unit is arranged at an inlet of each function processing module, the data output end of each first sensor unit is in communication connection with the data input end of the control system, and the control system is used for obtaining smoke parameters at the inlet of the current function processing module. The starting logic of the current function processing module is triggered according to the flue gas parameters at the inlet of the current function processing module, different function processing modules can be flexibly selected and started according to the characteristic condition of the carbon flue gas, and the adaptability and flexibility of carbon flue gas treatment are effectively improved.

Description

Technical Field

[0001] The present invention relates to the field of flue gas treatment in the carbon industry, and in particular to a modular carbon flue gas pretreatment system. Background Art

[0002] As a typical traditional industry with high energy consumption and high emissions, the carbon industry faces urgent pressure to reduce emissions during its green transformation. Core production processes such as calcination, roasting, and graphitization rely on fossil fuels and related raw materials, generating flue gas that is a significant source of industrial carbon emissions. Deep decarbonization is urgently needed in the industry, and flue gas carbon capture technology is considered a key path to achieving this goal.

[0003] However, the complexity of the carbon production process and the diversity of raw materials result in significant complexity and volatility in the flue gas composition. The flue gases generated by different production processes have unique pollutant characteristics: in the calcination process, the flue gas generated by the high-temperature treatment of raw materials contains not only fluctuating concentrations of carbon dioxide, but also abrasive dust particles, sulfides, and nitrogen oxides; in the roasting process, due to the volatilization and combustion of organic raw materials, the flue gas contains a variety of complex organic pollutants, such as polycyclic aromatic hydrocarbons, asphalt smoke, and volatile organic compounds; the flue gas from the graphitization process exhibits high temperature, high dust content, and sudden changes in carbon dioxide concentration. These flue gases from different sources have significant differences in composition, pollutant concentration, and operating conditions, resulting in complex characteristics such as the coexistence of multiple pollutants, concentration gradient changes, and frequent fluctuations in operating conditions.

[0004] The complex operating conditions of carbon production processes place extremely high demands on flue gas pretreatment. Due to differences in the physical and chemical properties of dust particles in flue gas, traditional dust removal equipment can easily experience reduced efficiency or operational failures. The synergistic removal of sulfides and nitrogen oxides is significantly affected by fluctuations in operating conditions, making it difficult to maintain stable and efficient treatment in a changing environment. Furthermore, the presence of organic pollutants can adversely affect subsequent carbon capture systems, such as causing absorption liquid performance degradation and clogging of membrane separation modules.

[0005] Currently, traditional pretreatment technologies used in flue gas carbon capture systems in the carbon industry, such as cyclone dust removal, bag filters, wet desulfurization, dry desulfurization, and condensation dehumidification, can remove impurities such as dust, sulfur oxides, and water vapor from flue gas to a certain extent. However, their design concepts and process flows are relatively general and lack detailed consideration of the characteristics of carbon flue gas. When applied to carbon flue gas carbon capture systems, they often face numerous challenges. Carbon flue gas may contain high concentrations of multiple impurities, including dust (both coarse and fine particles), water vapor, sulfur oxides, nitrogen oxides, carbon monoxide, and other volatile organic compounds. The concentrations of these components fluctuate with production processes, raw material types, and operating conditions. Universal pretreatment processes struggle to efficiently remove all impurities, and some impurities can easily remain, impacting the performance and lifespan of downstream carbon capture systems. For example, a desulfurization system designed for high-sulfur flue gas may be insufficiently capable of handling dust or water vapor.

[0006] Traditional pretreatment systems typically utilize fixed process flows and equipment configurations. These systems are difficult to quickly adjust and optimize when flue gas composition changes significantly, making them unable to adapt to the flexibility and diversity of carbon industry production processes. Flue gas emissions and compositional characteristics vary significantly between carbon enterprises of different sizes. Universal pretreatment systems struggle to meet individual needs, resulting in wasted resources, poor treatment results, and limited adaptability and flexibility.

[0007] In response to this problem, the present invention provides a modular carbon flue gas pretreatment system to solve the above problem. Summary of the Invention

[0008] In order to solve the problems existing in the prior art, the present invention innovatively proposes a modular carbon flue gas pretreatment system, which effectively solves the problems of low adaptability and flexibility of carbon flue gas treatment caused by the prior art, and effectively improves the adaptability and flexibility of carbon flue gas treatment.

[0009] To achieve the above object, the present invention adopts the following technical solutions: A modular carbon flue gas pretreatment system comprises: a pretreatment module, a control system and at least one functional processing module selected from the following modules: a desulfurization module, a CO oxidation module, a dust removal module and a drying module; the interfaces between the various functional processing modules are standardized interfaces, and the flue gas inlet pipeline in the direction of the inlet of each functional processing module is connected to a bypass pipeline; the bypass pipeline is provided with a bypass valve for adjusting whether the carbon flue gas discharged from the pretreatment module or the previous functional processing module passes through the current functional processing module; a first sensor unit is provided at the inlet of each functional processing module, and the data output end of the first sensor unit is respectively communicated with the data input end of the control system, and the control system is used to respectively obtain the flue gas parameters at the inlet of the current functional processing module, and trigger the startup logic of the current functional processing module according to the flue gas parameters at the inlet of the current functional processing module.

[0010] The technical solution adopted by the present invention includes the following technical effects: 1. The interface between each functional processing module of the present invention is a standardized interface, and the flue gas inlet pipe in the direction of the inlet of each functional processing module is connected to a bypass pipe; a bypass valve is provided on the bypass pipe to adjust whether the carbon flue gas discharged by the pretreatment module or the previous functional processing module passes through the current functional processing module; a first sensor unit is provided at the inlet of each functional processing module, and the data output end of the first sensor unit is respectively communicated with the data input end of the control system, and the control system is used to respectively obtain the flue gas parameters at the inlet of the current functional processing module, and trigger the startup logic of the current functional processing module according to the flue gas parameters at the inlet of the current functional processing module. Different functional processing modules can be flexibly selected to start according to the characteristics of the carbon flue gas, effectively solving the problem of low adaptability and flexibility of carbon flue gas treatment caused by the existing technology, effectively improving the adaptability and flexibility of carbon flue gas treatment, and also reducing the energy consumption of carbon flue gas treatment.

[0011] 2. In the technical solution of the present invention, the first condenser is used to initially cool the flue gas temperature to a first temperature range and transport the initially cooled flue gas to the second condenser; the second condenser is used to cool the flue gas temperature again to a second temperature range and transport the again cooled flue gas to the electric heater; the maximum value of the second temperature range is less than the minimum value of the first temperature range, and the multi-stage condensation system deeply reduces the flue gas dew point by step-by-step cooling, so that the flue gas reaches the dryness required for subsequent treatment.

[0012] 3. The first control module in the technical solution of the present invention is used to judge the dust accumulation state by monitoring the internal pressure difference of the dust collector, and trigger automatic dust unloading when the pressure difference is greater than the preset pressure difference threshold; the circulating cooling water flow entering the first condenser is controlled according to the temperature difference before and after the flue gas is cooled by the first condenser; the circulating chilled water flow entering the second condenser is controlled according to the temperature difference before and after the flue gas is cooled by the second condenser, which not only ensures the effective treatment of the flue gas, but also enables the flue gas treatment process to adjust the parameters of different flue gas treatment equipment according to the flue gas conditions, thereby improving the reliability of flue gas treatment.

[0013] 4. In the technical solution of the present invention, the differential pressure sensors are respectively arranged at the pressure monitoring sections of different height layers of the filter bag inside the bag filter. The differential pressure sensors at the same height layer are evenly distributed to obtain the local pressure difference at different height layers of the filter bag. The second control module can calculate the ratio of the local pressure difference ΔPi at different height layers to the pressure difference ΔP at the inlet and outlet ends of the bag filter to locate the blockage position and achieve the accuracy of blockage positioning.

[0014] 5. The drying module in the technical solution of the present invention adopts a double-tower molecular sieve adsorption process. Through the alternating operation of adsorption and regeneration, the energy consumption is controlled within a reasonable range. Compared with the traditional deep freeze-drying process, the overall energy consumption of the system is effectively reduced, thereby improving the economic feasibility of carbon capture technology in the carbon industry.

[0015] It should be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0017] Figure 1 This is a schematic diagram of the overall process flow of the modular carbon flue gas pretreatment system integrated with the carbon capture system of the present invention; Figure 2 It is a structural diagram of the preprocessing module; Figure 3 This is a schematic diagram of the desulfurization module structure; Figure 4 Schematic diagram of the CO oxidation module structure; Figure 5 This is a schematic diagram of the dust removal module structure; Figure 6 It is a schematic diagram of the drying module structure; In the figure: 1. Pretreatment module; 2. Desulfurization module; 3. CO oxidation module; 4. Dust removal module; 5. Drying module; 101. Cyclone dust collector; 101a. First temperature sensor; 101b. First pressure transmitter; 101c. Second pressure transmitter; 101d. Ash discharge valve; 102. Demister; 103. First condenser; 103a. First electric regulating valve; 103b. Second temperature sensor; 103c. Third temperature sensor; 104. Second condenser; 104a. Second electric regulating valve; 104b. Fourth temperature sensor; 104c. Fifth temperature sensor; 105. Electric heater; 106. First flue gas inlet pipeline; 107. First cooling water inlet pipeline; 108. First Cooling water drainage pipeline; 109, second cooling water inlet pipeline; 110, second cooling water drainage pipeline; 111, first flue gas exhaust pipeline; 112, ash unloading pipeline; 201, alkali solution storage tank; 202, centrifugal pump; 203, alkali solution washing tower; 204, alkali solution circulation pump; 205, neutralization tank; 206, sedimentation tank; 207, filtrate collection tank; 208, sludge lifting pump; 209, sludge thickening tank; 210, sludge feed pump; 211, plate and frame filter press; 211a, first pressure sensor; 211b, second pressure sensor; 212, third electric regulating valve; 213, alkali solution conveying pipeline; 214, alkali solution circulation pipeline; 215, waste liquid conveying pipeline; 216, sludge conveying pipeline; 217, first Second flue gas inlet pipeline; 218, second flue gas exhaust pipeline; 219, filtrate recovery pipeline; 301, sixth temperature sensor; 302, catalyst preheater; 302a, first CO analyzer; 303, catalytic oxidation reactor; 304, seventh temperature sensor; 305, second CO analyzer; 306, flue gas cooler; 307, third pressure sensor; 308, first air compressor; 309, air storage tank; 310, filter; 311, flow meter; 312, regulating valve; 313, check valve; 314, third flue gas inlet pipeline; 315, mixed gas delivery pipeline; 316, first compressed air delivery pipeline; 317, third flue gas exhaust pipeline; 401, high-efficiency bag filter; 401a , eighth temperature sensor; 401b, inlet differential pressure sensor; 401c, outlet differential pressure sensor; 401d, filter inlet valve; 401e, filter exhaust valve; 402, star unloader; 403, second air compressor; 404, air distributor; 405, pulse valve; 406, fourth flue gas inlet pipeline; 407, fourth flue gas exhaust pipeline; 408, second compressed air transmission pipeline; 409, unloading pipeline; 501, first adsorption tower; 501a, first inlet valve; 501b, first exhaust valve; 501c, first desorption exhaust valve; 501d, first solenoid valve; 502, second adsorption tower; 502a, second inlet valve; 502b, second exhaust valve; 502c, second desorption exhaust valve;502d, second solenoid valve; 503, vacuum pump; 504, buffer tank; 505, condensate recovery device; 506, upper pressure equalizing valve; 507, lower pressure equalizing valve; 508, fifth flue gas inlet pipeline; 509, fifth flue gas exhaust pipeline; 510, sixth flue gas exhaust pipeline; 511, upper pressure equalizing pipeline; 512, lower pressure equalizing pipeline; 513, first desorption vacuum pipeline; 514, second desorption vacuum pipeline; 515, main desorption vacuum pipeline; 516, first desorption exhaust pipeline; 517, second desorption exhaust pipeline; 518, main desorption exhaust pipeline. DETAILED DESCRIPTION

[0018] In order to clearly illustrate the technical features of this solution, the present invention is described in detail below through specific implementation methods and in conjunction with the accompanying drawings. The disclosure below provides many different embodiments or examples for realizing different structures of the present invention. In order to simplify the disclosure of the present invention, the components and settings of specific examples are described below. In addition, the present invention may repeat reference numbers and / or letters in different examples. This repetition is for the purpose of simplicity and clarity and does not itself indicate the relationship between the various embodiments and / or settings discussed. It should be noted that the components illustrated in the accompanying drawings are not necessarily drawn to scale. The present invention omits descriptions of well-known components and processing technologies and processes to avoid unnecessary limitations on the present invention.

[0019] Example 1 At the system integration level, traditional pretreatment systems suffer from significant shortcomings, including low modular design and insufficient integration. Each processing unit is typically assembled independently on-site, resulting in significant system issues such as large floor space, long installation cycles, and difficulty in controlling equipment linkage. This non-intensive layout not only complicates factory space planning and operation and maintenance management, but also severely restricts the overall effectiveness of the pretreatment system due to the difficulty in achieving coordinated and optimized operation of multiple processing units.

[0020] Therefore, given the complex characteristics of flue gas composition and fluctuating operating conditions in the carbon industry, there is an urgent need to develop a new flue gas pretreatment system that is more efficient, flexible, economical, and well-adaptable. This system can meet the urgent needs of carbon emission reduction in the carbon industry and promote the large-scale application and industrial development of carbon capture technology. The present invention aims to provide a pretreatment method and system that can cope with complex flue gas operating conditions. By optimizing the treatment process and using intelligent control methods, it can achieve efficient removal of multiple pollutants and adapt to operating conditions, providing stable and reliable feed gas conditions for subsequent carbon capture processes.

[0021] like Figure 1As shown, the present invention provides a modular carbon flue gas pretreatment system, comprising: a pretreatment module 1 (primary pretreatment), a control system and at least one functional processing module selected from the following modules: a desulfurization module 2 (alkaline solution washing desulfurization), a CO oxidation module 3 (CO catalytic oxidation), a dust removal module 4 (fine dust removal) and a drying module 5 (deep drying); the interfaces between the various functional processing modules are standardized interfaces, and the flue gas inlet pipeline in the inlet direction of each functional processing module is connected to a bypass pipeline; the bypass pipeline is provided with a bypass valve for adjusting whether the carbon flue gas discharged from the pretreatment module 1 or the previous functional processing module passes through the current functional processing module; a first sensor unit is provided at the inlet of each functional processing module, and the data output end of the first sensor unit is respectively communicated with the data input end of the control system, and the control system is used to respectively obtain the flue gas parameters at the inlet of the current functional processing module, and trigger the startup logic of the current functional processing module according to the flue gas parameters at the inlet of the current functional processing module.

[0022] Specifically, if Figure 2 As shown, the pre-processing module 1 includes a cyclone dust collector 101, a demister 102, a first condenser 103, a second condenser 104 and an electric heater 105 in sequence along the flue gas direction; The cyclone dust collector 101 is used to separate particulate dust in the carbon flue gas with a particle size greater than a preset particle size threshold, and transport the dust-removed flue gas to the first condenser 103; the first condenser 103 is used to preliminarily cool the flue gas temperature to a first temperature range, and transport the preliminarily cooled flue gas to the second condenser 104; the second condenser 104 is used to cool the flue gas temperature again to a second temperature range, and transport the re-cooled flue gas to the electric heater 105; the maximum value of the second temperature range is less than the minimum value of the first temperature range; the electric heater 105 is used to adjust the flue gas temperature to a preset target temperature and output it to a subsequent functional processing module.

[0023] The control system includes a first control module, and the pre-processing module 1 also includes a second sensor unit (arranged inside the pre-processing module), the second sensor unit includes a first pressure transmitter 101b arranged at the air inlet end of the cyclone dust collector 101, a second pressure transmitter 101c arranged at the air outlet end of the cyclone dust collector 101, a second temperature sensor 103b arranged at the air inlet end of the first condenser 103, a third temperature sensor 103c arranged at the air outlet end of the first condenser 103, a fourth temperature sensor 104b arranged at the air inlet end of the second condenser 104, and a fifth temperature sensor 104c arranged at the air outlet end of the second condenser 104; the first control module is used to obtain the first pressure transmitter 1 01b and the pressure data of the second pressure transmitter 101c are used to judge the dust accumulation state by monitoring the internal pressure difference of the cyclone dust collector 101, and trigger automatic dust unloading when the pressure difference is greater than the preset pressure difference threshold; the first control module is used to obtain the temperature data of the second temperature sensor 103b and the third temperature sensor 103c, and control the circulating cooling water flow entering the first condenser 103 according to the temperature difference before and after the flue gas is cooled by the first condenser 103; the first control module is used to obtain the temperature data of the fourth temperature sensor 104b and the fifth temperature sensor 104c, and control the circulating chilled water flow entering the second condenser 103 according to the temperature difference before and after the flue gas is cooled by the second condenser 103.

[0024] Specifically, the bottom ash discharge port of the cyclone dust collector 101 is connected to the ash discharge valve 101d, and the ash discharge valve 101d is connected to the external dust collection device through the ash discharge pipeline 112 to achieve automatic ash discharge.

[0025] When the cyclone dust collector 101 is operating normally, the flue gas is separated from dust by centrifugal force. The inlet and outlet pressure difference (ΔP1 = inlet pressure - outlet pressure) is mainly determined by the following factors: 1. The resistance along the flow of gas through the inner wall of the dust collector (about 30% of ΔP1); 2. The local resistance generated by dust particles hitting the wall under the action of centrifugal force (accounting for about 50% of ΔP1); 3. Dust accumulation in the hopper causes reduced flow cross-section resistance (approximately 20% of ΔP1).

[0026] When dust accumulates in the hopper or cone section, the flow cross section decreases, the air flow velocity increases, and the local resistance coefficient increases, resulting in a nonlinear increase in ΔP1.

[0027] The corresponding relationship between pressure difference and accumulation state is determined through industrial tests, and three levels of warning are divided: Mild accumulation: ΔP1=1.0-1.5kPa, the dust accumulation height in the hopper is ≤1 / 3 of the cone height, which does not affect the dust removal efficiency; Moderate accumulation: ΔP1=1.5-2.0kPa, the accumulation height reaches 1 / 3-2 / 3 of the cone height, and the dust removal efficiency decreases by 5-10%; Severe accumulation: ΔP1 ≥ 2.0 kPa, accumulation height > 2 / 3 cone height, which may cause airflow short-circuiting and a sudden drop of more than 20% in dust removal efficiency.

[0028] If a layered pressure monitoring system design is adopted: 1. Set up three layers of pressure monitoring sections inside the cyclone dust collector 101, with four pressure transmitters evenly distributed on each layer: The first layer (cylinder section): 200mm above the air inlet, monitoring the airflow stability of the cylinder section; The second layer (upper section of the cone): at 1 / 2 of the cone height, monitors the initial accumulation of dust in the cone section; The third layer (lower section of the cone): 100mm away from the ash hopper inlet, directly monitoring the ash hopper accumulation status; The second pressure transmitter 101c at the outlet collects the integrated pressure and calculates the total ΔP1 with the inlet 101b. The central control system calculates the local pressure difference ΔP at each layer. 1j , by comparing the ΔP of each layer 1j The ratio to the total ΔP1 determines the accumulation position: If ΔP 13 / ΔP1>0.4, it is determined that the ash hopper is heavily accumulated; If ΔP 12 / ΔP1>0.3 and ΔP 13 / ΔP1<0.4, judging that the middle part of the cone has moderate accumulation; If ΔP 11 / ΔP1>0.2 and ΔP 12 / ΔP1<0.3, it is determined that the cylinder section is slightly accumulated.

[0029] 2. Grading ash unloading strategy: Mild accumulation: When ΔP1 = 1.0-1.5 kPa, start the intermittent ash unloading mode, and the ash unloading valve 101d is opened for 5 seconds each time, with an interval of 30 minutes; Moderate accumulation: When ΔP1=1.5-2.0kPa, switch to continuous dust discharge mode, extend the opening time to 10 seconds / time, and the interval is 15 minutes; Severe accumulation: When ΔP1 ≥ 2.0 kPa, the emergency ash unloading procedure is triggered, and the ash unloading valve is continuously opened until ΔP1 < 1.5 kPa, and an alarm is sent to the DCS control system.

[0030] 3. Airflow compensation for layered dust unloading: When a layer ΔP 1j In case of abnormality, the system automatically adjusts the airflow parameters of the corresponding area: When the cone section accumulates, the tangential air velocity of the first layer (cylinder section) is increased (from 18m / s to 22m / s) to strengthen the centrifugal force to alleviate the accumulation; When the ash hopper is piled up, the vibrator at the bottom of the ash hopper is started and works synchronously with the ash discharge valve 101d to improve the ash discharge efficiency by 30%.

[0031] The cooling water inlet and outlet of the first condenser 103 are connected to the first cooling water inlet pipeline 107 and the first cooling water drain pipeline 108 respectively; a first electric regulating valve 103a is provided at the cooling water inlet end of the first condenser 103 for regulating the cooling water flow; a second temperature sensor 103b and a third temperature sensor 103c are provided at the air inlet end and the air outlet end of the first condenser 103 for monitoring the temperature before and after the flue gas is cooled. The first electric regulating valve 103a is electrically connected to the second and third temperature sensors 103b and 103c to realize automatic regulation of the cooling water flow.

[0032] The chilled water inlet and outlet of the second condenser 104 are connected to the second cooling water inlet pipeline 109 and the second cooling water drain pipeline 110 respectively; a second electric regulating valve 104a is provided at the chilled water inlet end of the second condenser 104, and a fourth temperature sensor 104b and a fifth temperature sensor 104c are provided at the air inlet end and the air outlet end respectively. The second electric regulating valve 104a is electrically connected to the fourth temperature sensor 104b and the fifth temperature sensor 104c. The chilled water flow rate is accurately controlled by monitoring the flue gas temperature to ensure that the flue gas dew point temperature drops below 10°C.

[0033] The cyclone dust collector 101, the demister 102, the first condenser 103, the second condenser 104 and the electric heater 105 are connected via a first flue gas inlet pipe 106; the gas outlet of the electric heater 105 is connected to a subsequent module or a carbon capture system via a first flue gas exhaust pipe 111.

[0034] A sensor group 113 can also be installed at the outlet of the electric heater 105, including a third SO2 concentration analyzer, a third CO analyzer, a third dust particle size analyzer, and a third dew point meter. A first pneumatic valve 114 is installed at the inlet of the basic pretreatment module 1, and a second pneumatic valve 115 is installed at the outlet. Real-time monitoring of flue gas parameters ensures that the flue gas entering downstream modules meets design requirements (e.g., temperature ≤ 25°C, dust particle size > 10μm > 70%). Furthermore, outlet sensor data directly triggers the activation logic of functional modules. For example, if the outlet SO2 concentration is > 500mg / m³, desulfurization module 2 is automatically activated; if the dust particle size < 10μm > 30%, dust removal module 4 is activated. Furthermore, if outlet parameters are abnormal (e.g., temperature > 30°C), internal faults within the basic pretreatment module (e.g., insufficient refrigerant flow in the second condenser 104) can be quickly located, guiding maintenance personnel to conduct targeted repairs.

[0035] The cyclone dust collector 101 utilizes a high-efficiency cyclonic separation structure and wear-resistant materials to effectively remove coarse dust particles from the flue gas. The mist eliminator 102 utilizes corrosion-resistant materials to effectively remove liquid droplets and mist vapor from the flue gas. High-temperature flue gas (approximately 200°C) enters the cyclone dust collector 101 through the first flue gas inlet pipe 106. The first temperature sensor 101a monitors the flue gas temperature in real time, and the first pressure transmitter 101b monitors the inlet pressure. As the flue gas passes through the cyclone dust collector 101, coarse dust particles with a size greater than 10μm are separated. The second pressure transmitter 101c monitors the inlet and outlet pressure differential of the bag filter 101. When the pressure exceeds a set threshold (e.g., 2kPa), the control system triggers the ash discharge valve 101d to open, discharging the dust into a collection box through the ash discharge pipe 112. The valve automatically closes upon completion of the ash discharge. After cyclone dust removal, the flue gas (temperature approximately 180°C) enters the first condenser 103. The second temperature sensor 103b detects the inlet temperature, and the third temperature sensor 103c detects the outlet temperature. The intelligent control system adjusts the opening of the first electric control valve 103a based on the temperature difference (e.g., the target temperature is 45°C) and controls the flow of circulating cooling water (inlet temperature ≤ 32°C) to lower the flue gas temperature to 40-50°C while removing some moisture. The flue gas after primary condensation enters the second condenser 104. The fourth temperature sensor 104b detects the inlet temperature (approximately 45°C), and the fifth temperature sensor 104c detects the outlet temperature. The control system adjusts the flow of chilled water (inlet temperature ≤ 10°C) via the second electric control valve 104a to further cool the flue gas to 15-20°C. At this point, the flue gas dew point is less than 10°C, effectively removing moisture. After secondary condensation, the flue gas (at approximately 18°C) enters the electric heater 105. The intelligent control system uses PID control to adjust the power of the electric heater 105 to the set value (with an accuracy of ±1°C) based on the requirements of the downstream carbon capture system (e.g., a target temperature of 25°C). The flue gas is then output to subsequent modules via the first flue gas exhaust pipeline 111. All sensors and actuators in the basic pretreatment module 1 are electrically connected to the first control module, which communicates with the control system via industrial Ethernet. The control system monitors various parameters (such as temperature, pressure, and flow) in real time and automatically adjusts its operating strategy based on fluctuations in flue gas composition. For example, if the moisture content of the flue gas suddenly increases, the chilled water flow to the secondary condenser 104 is increased to ensure the dew point temperature meets the target.

[0036] The first control module (PLC) within pretreatment module 1 communicates in real time via industrial Ethernet with the following sensors: the first through fifth temperature sensors (monitoring flue gas temperatures at each stage), the first and third pressure transmitters (monitoring the dust removal pressure differential and system pressure), the electric control valve (controlling cooling water / chilled water flow), and a sensor group consisting of a third SO2 concentration analyzer, a third CO analyzer, a third dust particle size analyzer, and a third dew point meter. The PLC utilizes a modular programming architecture, dividing sensor data into "basic parameters" (temperature, pressure) and "additional characteristic parameters" (SO2 concentration, CO concentration, dust particle size, and dew point). Closed-loop control is achieved through the following strategies: 1. Pretreatment synergistic regulation driven by SO2 concentration: When the SO2 concentration is greater than 500ppm, the PLC determines that the flue gas is in a "high sulfur condition" and triggers the following linkage: (1) Condenser coordination: Increase the cooling water / chilled water flow rate through the first and second electric control valves (the adjustment range is positively correlated with the SO2 concentration), further reduce the flue gas temperature by 10-15°C, promote the dissolution of SO2 in water vapor, and reduce the load of subsequent desulfurization modules; (2) Early warning linkage: Send a signal to the PLC (second control module) in the desulfurization module 2 to automatically increase the flow rate of the alkali solution circulation pump (for example, from 50m³ / h to 80m³ / h) to ensure that the desulfurization efficiency is ≥95%.

[0037] 2. Pre-treatment temperature compensation triggered by CO concentration: When the CO concentration is greater than 1%, the PLC determines that the CO oxidation module 3 needs to be started, and the temperature pre-adjustment is performed in the pre-treatment stage: (1) Electric heater PID adjustment: Increase the flue gas temperature from the normal 25°C to 35-40°C (accuracy ±1°C) to ensure that the flue gas temperature entering the CO oxidation module 3 meets the catalyst preheating requirements (shortening the preheating time by 30%); (2) Safety interlock: If the CO concentration is greater than 5%, the PLC automatically activates the quick switching valve between the pretreatment module 1 and the CO oxidation module 3, eliminating unnecessary pretreatment steps and prioritizing CO oxidation efficiency.

[0038] 3. Optimization of dust removal strategy guided by dust particle size: The dust particle size analyzer analyzes the dust distribution in real time, and the first control module adjusts according to the following logic: (1) Coarse particles dominate (particle size > 10 μm, accounting for > 60%): Increase the triggering frequency of the cyclone dust collector dust discharge valve (for example, from once every 30 minutes to once every 15 minutes), and monitor the pressure difference through the second pressure transmitter. When the pressure difference is > 2.5 kPa, forced cleaning is performed; (2) Fine particles dominate (particle size <1μm, accounting for >30%): Send a signal to the fine dust removal module PLC (fourth control module) to start the pulse cleaning program in advance (the cycle is shortened from 60 seconds to 30 seconds) to prevent the filter bag from clogging.

[0039] 4. Precise adjustment of dew point temperature closed-loop control: The dew point meter provides real-time feedback on the flue gas dew point. The first control module ensures the dew point is ≤10°C by: (1) When the dew point is greater than 10°C, the first control module performs PID control according to the priority of "first adjusting the cooling water flow of the first condenser (maximum adjustment range 40%), and if it does not meet the standard, then adjusting the chilled water flow of the second condenser"; (2) Antifreeze protection: If the dew point is less than 5°C, the electric heater will automatically start to compensate for the temperature (temperature rise 5-8°C) to prevent the equipment from frosting.

[0040] In addition, the PLC uses fuzzy logic algorithms to comprehensively process the coupled effects of parameters such as temperature, pressure, SO2 concentration, and CO concentration. For example: When there is "high SO2 concentration (>800ppm) + high proportion of fine dust particles (<1μm proportion>40%)", the PLC will prioritize improving the condenser efficiency to promote SO2 dissolution, while increasing the cyclone dust collector unloading frequency to prevent dust and SO2 from combining to form acidic particles that clog the equipment.

[0041] If any data in the sensor group is abnormal (such as SO2 concentration jump > 20% or dew point meter failure), the PLC automatically switches to "redundant control mode" and estimates parameters based on historical data and correlation values ​​with other sensors to maintain stable system operation; When the CO concentration is greater than 10% or the dust particle size analyzer detects abnormally large particles (greater than 500 μm), the PLC triggers an emergency shutdown signal, closes the pretreatment module air inlet valve, and starts the bypass line.

[0042] Among them, such as Figure 3 As shown, the desulfurization module 2 includes an alkali liquid storage tank 201 and an alkali liquid washing tower 203; The alkali liquid storage tank 201 is connected to the alkali liquid washing tower 203 by a pipeline, which is used to transport the alkali liquid stored in the alkali liquid storage tank 201 to the alkali liquid washing tower 203. A pH sensor is installed in the middle of the inner wall of the alkali liquid washing tower 203 to monitor the pH value of the alkali liquid in the tower in real time. The tower body is equipped with multiple spray layers. The flue gas enters from the bottom of the tower and contacts the alkali liquid sprayed from the top of the tower in countercurrent. The first sensor unit includes a first SO2 concentration analyzer 220 provided at the air inlet end of the desulfurization module 2; The control system obtains the flue gas parameters collected by the first SO2 concentration analyzer 220, and triggers the startup logic of the desulfurization module 2 according to the flue gas parameters collected by the first SO2 concentration analyzer 220; wherein, if the SO2 concentration at the inlet of the desulfurization module 2 collected by the first SO2 concentration analyzer 220 is greater than the preset SO2 concentration threshold, the desulfurization module 2 is automatically started through the bypass valve at the air inlet end of the desulfurization module; if the SO2 concentration at the inlet of the desulfurization module 2 collected by the first SO2 concentration analyzer 220 is not greater than the preset SO2 concentration threshold (500 mg / m³), the desulfurization module 2 is automatically closed through the bypass valve at the air inlet end of the desulfurization module.

[0043] Specifically, the desulfurization module 2 further includes a centrifugal pump 202, an alkali solution circulation pump 204, a neutralization tank 205, a sedimentation tank 206, a filtrate collection tank 207, a sludge lifting pump 208, a sludge thickening tank 209, a sludge feed pump 210, and a plate and frame filter press 211; A pH sensor is installed in the middle of the inner wall of alkali liquid scrubber 203 to monitor the pH of the alkali liquid in real time. Liquid level gauges are installed at the top and bottom of the tower to monitor the liquid level. The liquid level control range is 1 / 3-2 / 3 of the tower height to prevent overflow or dry burning. Alkali liquid scrubber 203 utilizes a high-efficiency spray tower structure. The tower body is constructed of corrosion-resistant fiberglass or carbon steel, and features multiple internal spray layers. Flue gas enters the tower from the bottom through the second flue gas inlet line 217, where it comes into countercurrent contact with the alkali liquid sprayed from the top of the tower. The SO2 removal efficiency is ≥95%.

[0044] The desulfurization waste liquid is discharged from the bottom of the alkali liquid washing tower 203 into the neutralization tank 205 through the waste liquid conveying pipeline 215, and flows into the sedimentation tank 206 after acid-base neutralization; a mechanical agitator is installed in the center of the neutralization tank 205 to ensure that the waste liquid and the neutralizer are fully mixed; a pH sensor is installed on the inner wall of the neutralization tank 205 to monitor the pH value of the waste liquid after neutralization, with a control range of 6-9, and is adjusted in conjunction with the third electric control valve 212.

[0045] Sludge at the bottom of sedimentation tank 206 is transported to sludge thickening tank 209 via sludge lift pump 208. After concentration, it is fed into plate and frame filter press 211 via sludge feed pump 210. A sludge scraper is installed at the bottom of sedimentation tank 206 to regularly scrape settled sludge into a sludge hopper. Inclined plate packing is installed in the middle of sedimentation tank 206 to effectively increase the settling area and improve solid-liquid separation efficiency. An agitator is installed inside sludge thickening tank 209 to prevent sludge sedimentation and maintain a uniform sludge concentration.

[0046] A first pressure sensor 211a and a second pressure sensor 211b are respectively provided at the feed end and the discharge end of the plate and frame filter press 211 to monitor the pressure changes during the filtration process. The filtrate flows into the filtrate collection tank 207 through the filtrate recovery pipeline 219 for reuse or discharge in compliance with standards, and the filter cake (gypsum) is recovered as a by-product.

[0047] The third electric regulating valve 212 is installed on the waste liquid conveying pipeline 215 between the neutralization tank 205 and the sedimentation tank 206, and is used to adjust the waste liquid flow rate according to the pH sensor data of the neutralization tank 205 and control the sedimentation time.

[0048] The second flue gas inlet pipeline 217 connects the alkali liquid washing tower 203 with the upstream module, and the second flue gas exhaust pipeline 218 connects the alkali liquid washing tower 203 with the downstream module; the alkali liquid storage tank 201, the centrifugal pump 202 and the alkali liquid washing tower 203 are connected through the alkali liquid conveying pipeline 213; the bottom of the alkali liquid washing tower 203 and the alkali liquid circulation pump 204 and the tower top spray layer are connected through the alkali liquid circulation pipeline 214; the alkali liquid washing tower 203 is connected to the neutralization tank 205, the sedimentation tank 206 and the filtrate collection tank 207 through the waste liquid conveying pipeline 215; the sedimentation tank 206, the sludge lifting pump 208, the sludge thickening tank 209, the sludge feed pump 210 and the plate and frame filter press 211 are connected through the sludge conveying pipeline 216, and the plate and frame filter press 211 is connected to the filtrate collection tank 207 through the filtrate recovery pipeline 219.

[0049] A second SO2 concentration analyzer 221 is installed at the outlet of desulfurization module 2. A first bypass line 222 is connected to the outlet of the first SO2 concentration analyzer 220 and the second flue gas inlet line 217. A first bypass valve 223 is installed on the first bypass line 222. A third pneumatic valve 224 is installed at the inlet of the alkali liquid scrubber 203, and a fourth pneumatic valve 225 is installed at the outlet. The control system also includes a second control module, which is used to obtain data from the pH sensor, the first pressure sensor 211a, and the second pressure sensor 211b (the sensor inside the third sensor unit) to control and adjust the third electric regulating valve 212.

[0050] Limestone slurry is stored in the alkali liquid storage tank 201 and delivered at a constant flow rate by centrifugal pump 202 via alkali liquid delivery pipeline 213 to the spray layer at the top of the alkali liquid scrubber 203. The alkali liquid circulation pump 204 extracts the reacted slurry from the bottom of the scrubber and returns it to the spray layer through the alkali liquid circulation pipeline 214, forming a circulating spray system. Flue gas enters the bottom of the alkali liquid scrubber 203 through the second flue gas inlet pipeline 217. As it flows upward from bottom to top, it forms a countercurrent contact with the limestone slurry sprayed at the top of the tower, achieving a highly efficient desulfurization reaction. A pH sensor within the tower monitors the pH of the alkali liquid in real time (initial value 7.5). When the pH drops to 6.5, the intelligent control system automatically triggers the centrifugal pump 202 to replenish fresh limestone slurry and simultaneously adjusts the flow rate of the alkali liquid circulation pump 204 to enhance the desulfurization reaction. The liquid level monitoring system uses a level gauge to provide real-time tower level data. When the liquid level exceeds two-thirds of the tower height, the alkali solution replenishment is automatically reduced. When it falls below one-third, an alarm is triggered and flue gas input is suspended, ensuring safe system operation. The desulfurization wastewater (containing CaSO₃, CaSO₄, and a small amount of impurities) generated by the reaction is discharged from the bottom of the alkali solution scrubber 203 through the wastewater conveying pipeline 215 into the neutralization tank 205. During this process, dilute sulfuric acid is added to adjust the pH to 6-9. A mechanical agitator operates continuously at a set speed to ensure thorough mixing of the wastewater and acid. A pH sensor in the neutralization tank 205 monitors the pH adjustment in real time. When the pH falls below 6, the third electric control valve 212 automatically reduces its opening to 50%, extending the wastewater retention time. When the pH reaches 7, the control valve fully opens, allowing the wastewater to flow into the sedimentation tank 206. The sedimentation tank 206 uses an inclined plate packing structure, which utilizes the principle of shallow sedimentation to significantly improve solid particle settling efficiency. The scraper operates according to a preset cycle, scraping sludge from the tank bottom into the sludge hopper. The sludge lift pump 208 then delivers it to the sludge thickening tank 209. The agitator in the thickening tank operates at a specific speed to prevent sludge compaction. After gravity concentration, the sludge moisture content is reduced from 95% to 80%. The concentrated sludge is fed into the plate and frame filter press 211 by the sludge feed pump 210. The first pressure sensor 211a monitors the feed pressure (1.0-1.2 MPa) in real time, and the second pressure sensor 211b monitors the filter cake forming pressure (1.5 MPa). The resulting gypsum filter cake has a moisture content of ≤60%. The filtrate produced during the filtration process flows into the filtrate collection tank 207. After treatment, it is reused in the preparation of alkali solution, achieving water recycling. The intelligent control system automatically increases the flow rate of the alkali solution circulation pump 204 and increases the opening of the third electric regulating valve 212 according to fluctuations in the SO2 concentration in the flue gas (such as a sudden increase in the SO2 concentration), ensuring that the desulfurization efficiency remains stable at above 95%. In addition, when the inlet and outlet pressure difference (ΔP=211a-211b) of the plate and frame filter press 212 exceeds 0.3MPa, the intelligent control system will determine that the filter cloth is blocked and automatically trigger the backwash program.

[0051] like Figure 4As shown, the CO oxidation module 3 includes a preheater 302, a catalytic oxidation reactor 303, and a flue gas cooler 306 connected in sequence by pipelines; The preheater 302 is used to preheat the flue gas before transporting it to the catalytic oxidation reactor 303; the catalytic oxidation reactor 303 is used to oxidize the CO in the flue gas under the action of a catalyst; the flue gas cooler 306 is used to cool the high-temperature flue gas after the oxidation reaction through circulating water heat exchange; the outlet of the flue gas cooler 306 is connected to the pipeline of the next functional processing module; the catalytic oxidation reactor 303 is also connected to the gas storage tank 309 pipeline to obtain the oxygen required for the oxidation reaction; The first sensor unit includes a first CO analyzer 302a provided at the air inlet end of the CO oxidation module 3; The control system obtains the flue gas parameters collected by the first CO analyzer 302a, and triggers the startup logic of the CO oxidation module 3 according to the flue gas parameters collected by the first CO analyzer 302a; wherein, if the CO concentration at the inlet of the CO oxidation module 3 collected by the first CO analyzer 302a is greater than the preset CO concentration threshold (0.5%), the CO oxidation module 3 is automatically started through the bypass valve at the air inlet end of the CO oxidation module 3; if the CO concentration at the inlet of the CO oxidation module 3 collected by the first CO analyzer 302a is not greater than the preset CO concentration threshold, the CO oxidation module 3 is automatically closed through the bypass valve at the air inlet end of the CO oxidation module 3.

[0052] Specifically, the CO oxidation module 3 further includes a first air compressor 308 , an air storage tank 309 , and a filter 310 .

[0053] The catalyst preheater 302 uses electric heating or flue gas waste heat recovery. A sixth temperature sensor 301 is set at its inlet to monitor the temperature of the flue gas to be preheated. At the same time, a first CO analyzer 302a is set to monitor the CO concentration in the flue gas in real time. When the concentration exceeds the set threshold, the catalytic oxidation reactor 303 is activated; and data support is provided for the amount of oxygen required for the catalytic reaction.

[0054] The catalytic oxidation reactor 303 is filled with a metal catalyst, and a seventh temperature sensor 304 and a second CO analyzer 305 are sequentially provided at the reactor outlet; the seventh temperature sensor 304 is used to monitor the flue gas temperature after the reaction and determine the catalyst activity state; the second CO analyzer 305 is used to detect the CO concentration after the reaction to ensure that the oxidation rate is ≥99%.

[0055] The first air compressor 308 compresses the air and stores it in the air storage tank 309, where impurities are removed by the filter 310. The compressed air is delivered through the first compressed air transmission pipeline 316, which is equipped with a flow meter 311, a regulating valve 312, and a check valve 313. The flow meter 311 monitors the air flow in real time, and the regulating valve 312 automatically adjusts the air supply according to the CO concentration. The check valve 313 is used to prevent smoke backflow and ensure system safety.

[0056] A third pressure sensor 307 is provided at the outlet of the flue gas cooler 306 to monitor the pressure of the flue gas after cooling to avoid pipeline blockage.

[0057] The third flue gas inlet pipeline 314 connects the upstream module with the catalyst preheater 302; the third flue gas exhaust pipeline 317 connects the flue gas cooler 306 with the downstream module; the catalyst preheater 302, the catalytic oxidation reactor 303 and the flue gas cooler 306 are connected via a mixed gas delivery pipeline 315.

[0058] A second bypass line 318 connects the outlet of the first CO analyzer 302a to the third flue gas inlet line 314; a second bypass valve 319 is installed on the second bypass line 318. A fifth pneumatic valve 320 is installed at the inlet of the catalyst preheater 302; a sixth pneumatic valve 321 is installed at the outlet of the third pressure sensor 307. The control system includes a third control module, which is used to obtain data from the sixth temperature sensor 301, the first CO analyzer 302a, the seventh temperature sensor 304, the second CO analyzer 305, and the third pressure sensor 307 (a sensor within the fourth sensor unit) and to control and regulate the first air compressor 308, the regulating valve 312, and the check valve 313.

[0059] Low-temperature flue gas enters the catalyst preheater 302 via the third flue gas inlet line 314. The sixth temperature sensor 301 monitors the preheater inlet flue gas temperature in real time. The catalyst preheater 302 uses electrical heating to raise the flue gas temperature to 250°C. During this process, the first CO analyzer 302a continuously monitors the CO concentration in the inlet flue gas. The intelligent control system accurately calculates the required oxygen supply based on the CO oxidation reaction equation and the real-time CO concentration. It then drives the regulating valve 312 to dynamically adjust its opening, strictly matching the air supply to the CO concentration and ensuring the oxygen excess coefficient remains within the ideal range of 1.2-1.5. The flowmeter 311 and regulating valve 312 form a closed-loop control loop, ensuring a proportional relationship between the compressed air flow rate and the CO concentration. For example, when the CO concentration is 1%, the system automatically adjusts the air flow rate to 150 Nm³ / h (with an oxygen content of approximately 30 Nm³ / h), precisely meeting the stoichiometric requirements for complete CO oxidation. The preheated flue gas and air delivered by the oxygen supply system are thoroughly mixed in the mixed gas delivery pipeline 315, with the air flow rate monitored in real time by the flowmeter 311. After the mixed gas enters the catalytic oxidation reactor 303, a catalytic oxidation reaction occurs under the action of the Pt / Al2O3 catalyst. The reaction exotherm causes the flue gas temperature to rise to 350°C. The seventh temperature sensor 304 indicates that the reactor outlet temperature is stable at 350°C, within the catalyst's optimal activity temperature range of 200-400°C. Data from the second CO analyzer 305 shows that the CO concentration in the outlet flue gas has dropped to 0.015%, achieving an oxidation removal efficiency of 99.9%. The high-temperature flue gas after the reaction enters the flue gas cooler 306, where it is cooled to 60°C via circulating water heat exchange. The third pressure sensor 307 monitors the cooler outlet pressure in real time. When the measured value exceeds 15 kPa, the system determines that the cooler tube bundle is clogged and automatically triggers the backwash procedure. When the seventh temperature sensor 304 detects that the temperature inside the reactor exceeds the warning value of 400°C, the intelligent control system immediately performs dual adjustments: on the one hand, it reduces the electric heating power of the catalyst preheater 302, and on the other hand, it increases the circulating water flow of the flue gas cooler 306. Through two-way temperature control, it ensures that the catalyst is always in a safe operating temperature range to avoid overheating and deactivation.

[0060] like Figure 5 As shown, the dust removal module 4 includes a bag filter 401, a star-shaped discharger 402, a second air compressor 403 and an air distribution bag 404; The first air inlet of the bag filter 401 is connected to the pipeline of the previous functional processing module. The bag filter 401 is used to filter dust in the flue gas; the ash hopper at the bottom of the bag filter 401 is connected to the star-shaped discharger 402 via a pipeline. The second air inlet of the bag filter 401 is connected to the pipeline of the air distribution bag 404. The air inlet end of the air distribution bag 404 is connected to the air outlet end pipeline of the second air compressor 403, which is used to supply compressed air to the air distribution bag 404, so that the filter bag of the bag filter 401 expands and shakes, shaking off the dust attached to the outer surface for cleaning; The first sensor unit includes a first dust particle size analyzer 410 provided at the air inlet end of the dust removal module 4; The control system obtains the flue gas parameters collected by the first dust particle size analyzer 410, and triggers the start-up logic of the dust removal module 4 according to the flue gas parameters collected by the first dust particle size analyzer 410; wherein, if the dust particle size at the inlet of the dust removal module 4 collected by the first dust particle size analyzer 410 is greater than the preset dust particle size threshold, and the proportion of dust greater than the preset dust particle size threshold is greater than the preset percentage threshold, the dust removal module 4 is automatically started through the bypass valve at the air inlet end of the dust removal module 4; if the dust particle size at the inlet of the dust removal module 4 collected by the first dust particle size analyzer 410 is not greater than the preset dust particle size threshold, or the proportion of dust greater than the preset dust particle size threshold is not greater than the preset percentage threshold, the dust removal module 4 is automatically closed through the bypass valve at the air inlet end of the dust removal module 4.

[0061] An eighth temperature sensor 401a is installed at the inlet of the high-efficiency bag filter 401 to monitor the flue gas temperature in real time. An inlet differential pressure sensor 401b and an outlet differential pressure sensor 401c are installed at the inlet and outlet of the high-efficiency bag filter 401 to monitor the inlet and outlet pressures of the filter, respectively, and calculate the differential pressure value (ΔP2) to determine the degree of filter bag clogging.

[0062] Another air inlet of the high-efficiency bag filter 401 is connected to the air distribution bag 404 and the second air compressor 403 through a second compressed air transmission pipeline 408; a pulse valve 405 is provided on the second compressed air transmission pipeline 408.

[0063] The outlet of the high-efficiency bag filter 401 is connected to the next module via a fourth flue gas exhaust pipe 407, which is equipped with a filter exhaust valve 401e. The ash hopper at the bottom of the high-efficiency bag filter 401 is connected to the star-shaped discharger 402 via a discharge pipe 409.

[0064] A first dust particle sizer 410 is provided at the inlet of the fine dust removal module 4, and a second dust particle sizer 411 is provided at the outlet; a third bypass line 412 is connected between the outlet end of the first dust particle sizer 410 and the fourth flue gas inlet line 406; a third bypass valve 413 is provided on the third bypass line 412.

[0065] Low-temperature flue gas enters the high-efficiency bag filter 401 via the fourth flue gas inlet pipe 406, with the eighth temperature sensor 401a monitoring the inlet flue gas temperature in real time. As the flue gas flows from the outside of the filter bag to the inside, dust particles are trapped on the outer surface of the filter bag. The purified flue gas is discharged through the fourth flue gas exhaust pipe 407, meeting emission standards. The intelligent control system monitors the pressure differential in real time via the inlet and outlet differential pressure sensors 401b and 401c. The initial pressure differential ΔP2 is 800Pa, which is used to determine the operating status of the filter bag. When the pressure differential ΔP2 is ≥1500Pa, the system automatically triggers the pulse cleaning procedure: the second air compressor 403 starts, delivering compressed air at a pressure of 0.6MPa to the air distribution bag 404; the pulse valve 405 opens sequentially at a preset interval of 0.5 seconds, injecting high-pressure air into the filter bag, causing the bag to expand and vibrate instantly, shaking off dust adhering to the outer surface. The shaken dust falls into the ash hopper at the bottom of the high-efficiency bag filter 401 and is continuously discharged through the discharge pipe 409 by the star-shaped discharger 402 at a set speed. The system has a dual protection mechanism: when the eighth temperature sensor 401a detects that the flue gas temperature exceeds 180°C, it immediately and automatically closes the filter inlet valve 401d to prevent high-temperature damage to the filter bags. If the pressure differential ΔP2 still exceeds 1800Pa after cleaning, the intelligent control system determines that the filter bags are damaged, triggers an audible and visual alarm, and closes the filter inlet valve 401d. In addition, the control system records the cleaning frequency and pressure differential trends in real time, and uses big data analysis to predict the remaining service life of the filter bags, providing a scientific basis for equipment maintenance.

[0066] The dust removal module 4 also includes a fifth sensor unit, which includes an eighth temperature sensor 401a provided at the first air inlet of the bag filter 401, an inlet pressure sensor 401b provided at the first air inlet of the bag filter 401, an outlet pressure sensor 401c provided at the outlet of the bag filter 401, and pressure differential sensors provided at different levels inside the bag filter 401. The control system includes a fourth control module, which is used to obtain pressure data from the inlet pressure sensor 401b, the outlet pressure sensor 401c, and all the pressure differential sensors, and judge the degree of filter bag clogging based on the pressure data from the inlet pressure sensor 401b, the outlet pressure sensor 401c, and all the pressure differential sensors. Among them, the pressure differential sensors are respectively arranged at the pressure monitoring sections of different height layers of the filter bag inside the bag filter 401, and the pressure differential sensors at the same height layer are evenly distributed to obtain the local pressure difference of different height layers of the filter bag. The second control module is used to calculate the ratio of the local pressure difference ΔPi at different height layers to the pressure difference ΔP at the inlet and outlet ends of the bag filter 401 to locate the blockage position.

[0067] Specifically, when the bag filter is operating normally, the pressure difference (ΔP2 = inlet pressure - outlet pressure) is composed of three parts: Filter bag body resistance (clean filter bag is about 200-300Pa); Dust layer resistance (accounting for 70-80% of the total ΔP2 and positively correlated with the thickness of the dust accumulation); Structural resistance (ceiling panels, pipes, etc., about 100-150Pa).

[0068] When dust accumulates on the surface of the filter bag, the filtration channel becomes narrower, the air flow velocity increases, and the resistance of the dust layer increases exponentially, resulting in a nonlinear increase in ΔP2.

[0069] The corresponding relationship between pressure difference and blockage status is determined through industrial tests, and three levels of warning are divided: Mild blockage: ΔP2=800-1200Pa, dust layer thickness ≤0.5mm, filtration efficiency remains basically unchanged; Moderate blockage: ΔP2=1200-1500Pa, thickness 0.5-1.0mm, filtration efficiency decreases by 5-10%; Severe blockage: ΔP2 ≥ 1500Pa, thickness > 1.0mm, which may cause the filter bag to be damaged and the filtration efficiency to drop by more than 20%.

[0070] If the layered pressure monitoring system is designed: 1. Set up three layers of pressure monitoring sections inside the high-efficiency bag filter 401, with 4 differential pressure sensors evenly distributed on each layer: The first layer (top of the filter bag): 200mm from the top of the filter bag, monitor the dust accumulation on the top of the filter bag; The second layer (middle of the filter bag): at 1 / 2 of the filter bag height, monitor the distribution of the dust layer in the middle; The third layer (bottom of the filter bag): 100mm from the bottom of the filter bag, monitoring the dust return from the hopper; The inlet and outlet pressure difference sensors 401b / 401c collect the comprehensive pressure difference and form a coordinated judgment with the layered pressure difference. The central control system calculates the local pressure difference ΔP of each layer 2i , through each layer ΔP 2i The ratio with ΔP2 determines the blockage location: If ΔP 23 / ΔP2>0.4, it is judged that the lower part of the filter bag is severely blocked (caused by dust returning from the hopper); If ΔP 22 / ΔP2>0.3 and ΔP 23 / ΔP2<0.4, it is judged that the middle part of the filter bag is moderately blocked; If ΔP 21 / ΔP2>0.2 and ΔP 22 / ΔP2<0.3, it is judged that the upper part of the filter bag is slightly blocked (caused by high inlet dust concentration).

[0071] 2. Grading cleaning strategy: Mild blockage (ΔP2=800-1200Pa): Start the timed cleaning mode, and the pulse valve 405 sprays at "0.5 seconds / time, every 15 minutes"; Moderate blockage (ΔP2=1200-1500Pa): Switch to differential pressure trigger mode. For every 100Pa increase in ΔP2, the cleaning interval is shortened by 5 minutes. Severe blockage (ΔP2 ≥ 1500Pa): Triggering zone-based enhanced cleaning, adding 2 additional sprays to the filter bag area corresponding to the blockage layer (such as the middle), and an alarm prompting manual inspection.

[0072] 3. Airflow compensation for layered cleaning: When a layer ΔP 2i In case of abnormality, the system automatically adjusts the cleaning parameters of the corresponding area: When the lower part of the filter bag is clogged, increase the airflow pressure of the third layer of cleaning (from 0.6MPa to 0.8MPa) and extend the blowing time to 1 second; When the upper part of the filter bag is clogged, adjust the spraying order of the air distribution bag 404 to clean the upper filter bag first to ensure uniform airflow distribution.

[0073] like Figure 6 As shown, the drying module 5 includes a first adsorption tower 501, a second adsorption tower 502, a buffer tank 504, and a condensation recovery device 505; the first adsorption tower 501 and the second adsorption tower 502 are connected by a pipeline for drying the flue gas; every preset period, the first adsorption tower 501 and the second adsorption tower 502 switch between the adsorption stage and the desorption stage; the inlet end of the buffer tank 504 is connected to the drainage end pipeline of the first adsorption tower 501 and the second adsorption tower 502 respectively, and the inlet end of the condensation recovery device 505 is connected to the outlet end pipeline of the buffer tank 504 for condensing and recovering the moisture in the buffer tank 504; The first sensor unit includes a first dew point meter 519 provided at the air inlet end of the drying module 5; The control system obtains the flue gas parameters collected by the first dew point meter 519, and triggers the start-up logic of the drying module 5 according to the flue gas parameters collected by the first dew point meter 519; wherein, if the dew point temperature at the inlet of the drying module 5 collected by the first dew point meter 519 is greater than the preset dew point temperature threshold, the drying module 5 is automatically started through the bypass valve at the air inlet end of the drying module 5; if the dew point temperature at the inlet of the drying module 5 collected by the first dew point meter 519 is not greater than the preset dew point temperature threshold, the drying module 5 is automatically closed through the bypass valve at the air inlet end of the drying module 5.

[0074] The deep drying module 5 also includes a vacuum pump 503. The bottom inlet of the first adsorption tower 501 is connected to the fifth flue gas inlet pipeline 508, the bottom outlet is connected to the first desorption exhaust pipeline 516, and the other outlet is connected to the vacuum pump 503 via the first desorption vacuum pipeline 513; the top outlet of the first adsorption tower 501 is connected to the fifth flue gas exhaust pipeline 509; A first air inlet valve 501a is provided at the bottom inlet of the first adsorption tower 501; a first exhaust valve 501b is provided on the fifth flue gas exhaust pipeline 509; a first desorption exhaust valve 501c is provided on the first desorption exhaust pipeline 516; and a first solenoid valve 501d is provided on the first desorption vacuum pipeline 513.

[0075] The bottom inlet of the second adsorption tower 502 is connected to the fifth flue gas inlet pipeline 508, the bottom outlet is connected to the second desorption exhaust pipeline 517, and the other outlet is connected to the vacuum pump 503 through the second desorption vacuum pipeline 514; the top outlet of the second adsorption tower 502 is connected to the sixth flue gas exhaust pipeline 510.

[0076] A second air inlet valve 502a is provided at the bottom inlet of the second adsorption tower 502; a second exhaust valve 502b is provided on the sixth flue gas exhaust pipeline 510; a second desorption exhaust valve 502c is provided on the second desorption exhaust pipeline 517; and a second solenoid valve 502d is provided on the second desorption vacuum pipeline 514.

[0077] The upper pressure equalizing valve 506 connects the gas outlets at the top of the two towers through the upper pressure equalizing pipeline 511 to balance the high-pressure gas at the top of the towers; the lower pressure equalizing valve 507 connects the gas inlets at the bottom of the two towers through the lower pressure equalizing pipeline 512 to balance the raw gas pressure at the bottom of the towers.

[0078] The air outlet of the vacuum pump 503 is connected to the desorption vacuum main pipeline 515; the desorption vacuum main pipeline 515, the first desorption exhaust pipeline 516, the second desorption exhaust pipeline 517 and the buffer tank 504 are connected via the desorption exhaust main pipeline 518; the buffer tank 504 and the condensation recovery device 505, as well as the condensation recovery device 505 and the subsequent system equipment are connected via the desorption exhaust main pipeline 518.

[0079] The first adsorption tower 501 and the second adsorption tower 502 contain molecular sieve adsorbents. The valves of the adsorption towers are interlocked by PLC to achieve timing control. During the adsorption phase, the air inlet valve and the air outlet valve are opened. During the desorption phase, the desorption exhaust valve and the inlet valve of the vacuum pump 503 are opened. During the pressure equalization phase, the pressure equalization valve is opened and other valves are closed.

[0080] A first dew point meter 519 is installed at the inlet of the fifth flue gas inlet pipeline 508; a second dew point meter 520 is installed at the outlet of the first exhaust valve 501b; and a third dew point meter 521 is installed at the outlet of the second exhaust valve 502b. A fourth bypass pipeline 522 is connected between the outlet of the first dew point meter 519 and the fifth flue gas inlet pipeline 508; a fourth bypass valve 523 is installed on the fourth bypass pipeline 522. The control system includes a fifth control module, which is used to control and regulate the first intake valve 501a, the first exhaust valve 501b, the first desorption exhaust valve 501c, the first solenoid valve 501d, the second intake valve 502a, the second exhaust valve 502b, the second desorption exhaust valve 502c, the second solenoid valve 502d, the upper pressure equalizing valve 506, and the lower pressure equalizing valve 507.

[0081] During the adsorption stage, the flue gas after fine dust removal enters the fifth flue gas inlet pipe 508, is supplied to the bottom of the first adsorption tower 501 through the first air inlet valve 501a, and passes upward through the molecular sieve bed at a pressure of 0.6-1.0 MPa; water molecules are adsorbed by the molecular sieve micropores (the pore size of the 4A molecular sieve is 0.4 nm, and it preferentially adsorbs water molecules with a diameter of 0.32 nm), and the dried flue gas is discharged from the top fifth flue gas exhaust pipe 509 and the first exhaust valve 501b and enters the carbon capture system; at this time, the second adsorption tower 502 is in the desorption stage, the second desorption exhaust valve 502c is opened, and the second desorption exhaust pipe 517 is connected to the buffer tank 504.

[0082] The desorption phase consists of a sudden pressure drop phase and a deep desorption phase. First, during the sudden pressure drop phase, the first air inlet valve 501a and the first exhaust valve 501b are closed, and the first desorption exhaust valve 501c is opened. The residual gas in the first adsorption tower 501 (pressure drops from 0.8 MPa to 0.3 MPa) is discharged into the buffer tank 504 through the first desorption exhaust line 516. Water is condensed in the condensation recovery unit 505 (with a recovery rate of 95%). During the deep desorption phase, the first solenoid valve 501d is opened, the first desorption vacuum line 513 is connected to the main desorption vacuum line 515, and the vacuum pump 503 is started, reducing the pressure in the tower to 0.05 MPa. The water released by the molecular sieve is then processed along with the exhaust gas through the buffer tank 504 and the condensation recovery unit 505. The condensed water is then returned to the desulfurization module. At this point, the flue gas is transferred to the second adsorption tower 502, and the adsorption phase process repeats (the deep desorption step in the second adsorption tower 502 has been completed), ensuring an uninterrupted drying process. The dual towers are strictly synchronized through PLC. For example, when the first adsorption tower 501 is desorbing, the adsorption progress of the second adsorption tower 502 reaches 70%, avoiding flow fluctuations.

[0083] During the pressure equalization phase, vacuum pump 503 is shut down, and upper and lower pressure equalizing valves 506 and 507 are opened. The pressures in the first and second adsorption towers 501 and 502 are balanced from 0.8 MPa and 0.1 MPa to 0.45 MPa via upper and lower pressure equalizing pipes 511 and 512, respectively. This allows for the recovery of residual CO2 (70% concentration) from the high-pressure tower and reduces energy consumption by vacuum pump 503. The intelligent control system interlocks the pressure equalizing valves with the inlet and outlet valves of the adsorption towers: during the adsorption phase, the pressure equalizing valve is closed, while the inlet and outlet valves are open. During the pressure equalization phase, the inlet and outlet valves are closed, while the pressure equalizing valve is open.

[0084] The control system includes a master control module, which is connected to the first control module, the second control module, the third control module, the fourth control module, and the fifth control module respectively, and realizes the coordinated control of each functional processing module. Specifically, (1) SO2 concentration threshold triggers desulfurization module After the flue gas is treated by the pretreatment module 1, it is monitored in real time by the third SO2 concentration analyzer at the outlet. When the detection value is ≥500 mg / m³, the DCS system (master control module) sends an activation command to the second control module in the desulfurization module 2: open the third pneumatic valve 224 and start the alkali solution circulation pump 204 at the same time; monitor the pH value in the alkali solution washing tower 203 after 30 seconds. If the pH is less than 6.5, start the centrifugal pump 202 to replenish fresh alkali solution; if the SO2 concentration is less than 500 mg / m³, the DCS system controls the closure of the third pneumatic valve 224 and the fourth pneumatic valve 225, and opens the first bypass valve 223 at the same time, and the flue gas enters the downstream functional processing module through the first bypass line 222.

[0085] (2) CO concentration threshold triggers CO oxidation module Regardless of whether desulfurization module 2 is activated, the flue gas enters the CO concentration monitoring link (first CO analyzer 302a). When the CO concentration is ≥0.5%, the DCS system activates the CO oxidation module (third control module): the catalyst preheater 302 is started (electrically heated to 250°C), and the first air compressor 308 automatically adjusts the oxygen supply according to the CO concentration (oxygen excess coefficient 1.2-1.5). When the temperature of the catalytic oxidation reactor 303 rises above 200°C, the fifth pneumatic valve 320 is opened to ensure a CO oxidation rate of ≥99%. If the CO concentration is less than 0.5%, the DCS system closes the main valves of the CO oxidation module (fifth pneumatic valve 320 and sixth pneumatic valve 321) and opens the second bypass valve 319. The flue gas enters the next module through the second bypass line 318.

[0086] (3) Dust particle size classification triggers fine dust removal The flue gas after desulfurization / CO oxidation treatment enters the inlet of the fine dust removal module and is monitored by the first dust particle size analyzer 410. When the proportion of fine particles (<10μm) is ≥30%, the DCS system starts the high-efficiency bag filter 401: opens the filter air inlet valve 401d, and at the same time, the second air compressor 403 delivers compressed air to the air distribution bag 404 at a pressure of 0.6MPa to prepare for pulse cleaning; when the inlet and outlet pressure difference ΔP ≥1500Pa, the pulse valve 405 is automatically triggered to clean the dust at an interval of 0.5 seconds; if the proportion of fine particles is <30%, the main valve of the fine dust removal module is closed, and the third bypass valve 413 is opened. The flue gas enters the deep drying module through the third bypass pipe 412 for judgment.

[0087] (4) Moisture content threshold activates deep drying The moisture content of the flue gas is monitored at the inlet of the deep drying module through the first dew point meter 519. When the dew point temperature is greater than 10°C, the DCS system starts the dual-tower molecular sieve adsorption system: the first adsorption tower 501 opens the first air inlet valve 501a and the first exhaust valve 501b, and the second adsorption tower 502 enters the desorption stage; the adsorption tower is switched every 30 minutes, and the pressure of the two towers is balanced by the upper equalizing valve 506 and the lower equalizing valve 507 to ensure continuous drying; if the dew point temperature is ≤10°C, the main valve of the deep drying module is closed, the fourth bypass valve 523 is opened, and the flue gas enters the carbon capture system through the fourth bypass pipe 522.

[0088] Dynamic adjustment mechanism of module connection relationship: 1. Valve interlock control of modular pipelines: Pneumatic / electric valves are set at the inlet and outlet of each functional processing module, and interlocking control of pipeline on and off is achieved through PLC. Typical connection adjustment examples: Desulfurization module commissioning status: Open the third pneumatic valve 224 and the fourth pneumatic valve 225, close the desulfurization module bypass valve (first bypass valve 223), and the flue gas is processed by the alkali solution washing tower 203; Desulfurization module bypass status: The third pneumatic valve 224 and the fourth pneumatic valve 225 are closed, and the first bypass valve 223 is opened, so that the flue gas enters the downstream module through the first bypass pipeline 222 .

[0089] 2. Modular parallel / series operation switching: For high-load conditions, the same type of modules can be operated in parallel through pipeline switching, for example: When the flue gas volume is greater than 5000m³ / h, the DCS controls the opening of the air inlet valves of the two desulfurization modules. The flue gas enters the two alkali solution scrubbers 203 through the gas distribution pipelines and then merges into the same exhaust pipeline after treatment, doubling the treatment capacity.

[0090] Modular collaborative control and parameter linkage: 1. Cross-module parameter linkage adjustment: After the module is activated, the DCS system automatically adjusts the operating parameters of the relevant modules, for example: (1) When starting the desulfurization module, the chilled water flow of the second condenser 104 of the basic pretreatment module is adjusted in conjunction to reduce the flue gas temperature from 18°C ​​to 15°C, thereby reducing the dilution of the alkali solution by water vapor during the desulfurization process; (2) When the CO oxidation module is started, the electric heater 105 is linked to raise the flue gas temperature from 25°C to 30°C, ensuring that the catalyst preheater 302 quickly reaches the optimal reaction temperature (250°C).

[0091] 2. Real-time monitoring of modular operation status: The DCS system collects operating data from each module through industrial Ethernet to form a visual monitoring interface: The system displays the valve status (open / close) and treatment efficiency (such as SO2 removal rate) of each module in real time. When a module fails (such as abnormal liquid level in the alkali washing tower 203), the inlet and outlet valves (the third and fourth pneumatic valves) of the module are automatically closed, the system switches to bypass mode, and triggers an alarm.

[0092] The embodiments of the present invention adopt a modular design concept, breaking down the flue gas pretreatment process into single-function processing modules such as basic pretreatment, desulfurization, and CO oxidation. Users can flexibly select modules and combine them into a customized system based on the actual characteristics of the carbon flue gas, such as sulfur oxide concentration, dust particle size distribution, and carbon monoxide content. For example, for high-sulfur conditions with high sulfur content in raw materials, a basic pretreatment module and an alkaline solution washing and desulfurization module can be configured; for high-CO flue gas generated by a graphitization furnace, a CO oxidation module can be added; and for scenarios with extremely high flue gas cleanliness requirements, basic pretreatment, desulfurization, CO oxidation, fine dust removal, and deep drying modules can be connected in series. This flexible configuration solves the problem of traditional systems' lack of adaptability to complex flue gases.

[0093] Each functional processing module integrates efficient processing technology and equipment. The cyclone dust collector in the basic pre-treatment module adopts an efficient cyclone separation structure and wear-resistant materials, which can effectively remove coarse dust particles in the flue gas; the ridge-type mist eliminator uses corrosion-resistant materials, which can effectively remove droplets and mist-like water vapor in the flue gas; the multi-stage condensation system deeply reduces the flue gas dew point through step-by-step cooling, so that the flue gas reaches the dryness required for subsequent treatment. The desulfurization module adopts efficient alkaline liquid washing technology based on the characteristics of sulfur-containing flue gas, and is equipped with a spray tower and circulation system. By optimizing the gas-liquid contact process, the desulfurization efficiency is improved, and the accompanying waste liquid treatment unit realizes resource recovery and environmentally friendly emissions, ensuring efficient purification of high-sulfur flue gas. The CO oxidation module uses a metal catalyst to catalytically oxidize carbon monoxide in the flue gas into carbon dioxide under high temperature conditions. The synergistic effect of each module ensures that various impurities in the flue gas are effectively purified, providing the downstream carbon capture system with clean raw gas that meets the requirements.

[0094] The modules are connected using standardized flanges, quick connectors, or clamps. The equipment is prefabricated and integrated in the factory before being transported to the site, significantly shortening the on-site installation and commissioning cycle. The standardized interface design allows each module to be easily assembled like "building blocks." Compared to traditional on-site assembly methods, installation time can be significantly shortened while effectively reducing installation difficulty. The modular design optimizes system layout and reduces floor space. For example, the basic pretreatment module integrates cyclone dust removal, demisting, condensation, and other functions into a compact space, effectively reducing the equipment footprint compared to traditional decentralized layouts. This facilitates overall factory planning and enables rapid deployment and commissioning of the pretreatment system.

[0095] The modular structure system offers convenient maintenance and expansion capabilities. Individual modules can be isolated and repaired independently. For example, if a desulfurization module fails, it can be isolated from the system by switching valves, without affecting the normal operation of other modules. This avoids the drawbacks of overall system shutdowns in traditional systems and effectively shortens fault handling time. When a company's production capacity increases or flue gas characteristics change, the system can be upgraded by adding or replacing functional modules. For example, a new fine dust removal module can be added to meet higher cleanliness requirements, or a CO oxidation module with greater processing capacity can be replaced to cope with increased flue gas volume. This "plug-and-play" expansion method adapts to the dynamic adjustment of production processes in the carbon industry. Moreover, the pipelines, electrical and control interfaces of each functional processing module all adopt a unified protocol. New modules (such as deep drying modules) only need to be connected through the corresponding flue gas ducts (such as the fifth flue gas inlet duct), without the need to modify the original system. The processing capacity of the functional processing modules is designed according to standard specifications (such as the desulfurization module is divided into 1000m³ / h, 5000m³ / h and other specifications), and can be adapted to changes in flue gas volume by connecting modules of the same specifications in parallel or replacing large-capacity modules. For example, when the flue gas volume doubles, a CO oxidation module can be added and operated in parallel.

[0096] The system's modular, on-demand commissioning mechanism avoids the "over-design" of traditional systems to cope with extreme operating conditions. For example, for low-sulfur, low-CO flue gas, only a basic pretreatment module is required, significantly reducing equipment investment compared to traditional full-process systems. Furthermore, the modular design is combined with energy-saving technology optimization. The electric heater in the basic pretreatment module uses PID intelligent control, with a temperature adjustment accuracy of ±1°C, avoiding energy waste. The deep drying module uses a dual-tower molecular sieve adsorption process, which controls energy consumption within a reasonable range through alternating adsorption and regeneration. Compared with traditional deep freeze-drying processes, the overall system energy consumption is effectively reduced, thereby enhancing the economic feasibility of carbon capture technology in the carbon industry.

[0097] The control system is equipped with a distributed central control system (DCS, master control module) and independent PLC controllers in each module, forming an intelligent control architecture. The central control system (master control module) communicates with the PLCs in each module via industrial Ethernet, providing real-time monitoring of flue gas parameters such as temperature, pressure, and flow. Furthermore, the system supports remote diagnostics and maintenance, providing real-time access to the operating status of each module. When an anomaly occurs, it automatically issues an alarm and records fault information. For example, if the CO oxidation module experiences an abnormal temperature, safety interlock protection is immediately activated. Fault data is also transmitted to a remote server, enabling maintenance personnel to quickly locate the problem, reducing manual intervention and improving system operational stability and fault response efficiency.

[0098] The interface between each functional processing module of the present invention is a standardized interface, and the flue gas inlet pipe in the direction of the inlet of each functional processing module is connected to a bypass pipe; the bypass pipe is provided with a bypass valve for adjusting whether the carbon flue gas discharged by the pretreatment module or the previous functional processing module passes through the current functional processing module; a first sensor unit is provided at the inlet of each functional processing module, and the data output end of the first sensor unit is respectively communicated with the data input end of the control system, and the control system is used to respectively obtain the flue gas parameters at the inlet of the current functional processing module, and trigger the startup logic of the current functional processing module according to the flue gas parameters at the inlet of the current functional processing module. Different functional processing modules can be flexibly selected to start according to the characteristics of the carbon flue gas, effectively solving the problem of low adaptability and flexibility of carbon flue gas treatment caused by the existing technology, effectively improving the adaptability and flexibility of carbon flue gas treatment, and also reducing the energy consumption of carbon flue gas treatment.

[0099] In the technical solution of the present invention, the first condenser is used to initially cool the flue gas temperature to a first temperature range and transport the initially cooled flue gas to the second condenser; the second condenser is used to cool the flue gas temperature again to a second temperature range and transport the again cooled flue gas to the electric heater; the maximum value of the second temperature range is less than the minimum value of the first temperature range, and the multi-stage condensation system deeply reduces the flue gas dew point by step-by-step cooling, so that the flue gas reaches the dryness required for subsequent treatment.

[0100] The first control module in the technical solution of the present invention is used to judge the dust accumulation state by monitoring the internal pressure difference of the dust collector, and trigger automatic dust unloading when the pressure difference is greater than the preset pressure difference threshold; the circulating cooling water flow entering the first condenser is controlled according to the temperature difference before and after the flue gas is cooled by the first condenser; the circulating chilled water flow entering the second condenser is controlled according to the temperature difference before and after the flue gas is cooled by the second condenser, which not only ensures the effective treatment of the flue gas, but also enables the flue gas treatment process to adjust the parameters of different flue gas treatment equipment according to the flue gas conditions, thereby improving the reliability of flue gas treatment.

[0101] In the technical solution of the present invention, the differential pressure sensors are respectively arranged at the pressure monitoring sections of different height layers of the filter bag inside the bag filter. The differential pressure sensors at the same height layer are evenly distributed and are used to obtain the local pressure difference at different height layers of the filter bag. The second control module can calculate the ratio of the local pressure difference ΔPi at different height layers to the pressure difference ΔP at the inlet and outlet ends of the bag filter to locate the blockage position and achieve the accuracy of blockage positioning.

[0102] The drying module in the technical solution of the present invention adopts a double-tower molecular sieve adsorption process. Through the alternating operation of adsorption and regeneration, the energy consumption is controlled within a reasonable range. Compared with the traditional deep freeze-drying process, the overall energy consumption of the system is effectively reduced, thereby improving the economic feasibility of carbon capture technology in the carbon industry.

[0103] Although the above describes the specific embodiments of the present invention in conjunction with the accompanying drawings, it is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art on the basis of the technical solution of the present invention without any creative work are still within the scope of protection of the present invention.

Claims

1. A modular carbon flue gas pretreatment system, characterized by comprising: A pretreatment module (1), a control system, and at least one functional processing module selected from the following modules: a desulfurization module (2), a CO oxidation module (3), a dust removal module (4), and a drying module (5); the interfaces between the functional processing modules are standardized interfaces, and the flue gas inlet pipeline in the inlet direction of each functional processing module is connected to a bypass pipeline; the bypass pipeline is provided with a bypass valve for adjusting whether the carbon flue gas discharged from the pretreatment module (1) or the previous functional processing module passes through the current functional processing module; a first sensor unit is provided at the inlet of each functional processing module, and the data output end of the first sensor unit is respectively communicated with the data input end of the control system, and the control system is used to respectively obtain the flue gas parameters at the inlet of the current functional processing module, and trigger the startup logic of the current functional processing module according to the flue gas parameters at the inlet of the current functional processing module.

2. A modular carbon flue gas pretreatment system according to claim 1, characterized in that: The pre-processing module (1) includes a cyclone dust collector (101), a demister (102), a first condenser (103), a second condenser (104), and an electric heater (105) in sequence along the flue gas direction; The cyclone dust collector (101) is used to separate particulate dust with a particle size greater than a preset particle size threshold in carbon flue gas, and transport the dust-removed flue gas to a first condenser (103); the first condenser (103) is used to preliminarily cool the flue gas temperature to a first temperature range, and transport the preliminarily cooled flue gas to a second condenser (104); the second condenser (104) is used to cool the flue gas temperature again to a second temperature range, and transport the re-cooled flue gas to an electric heater (105); the maximum value of the second temperature range is less than the minimum value of the first temperature range; the electric heater (105) is used to adjust the flue gas temperature to a preset target temperature and output it to a subsequent functional processing module.

3. A modular carbon flue gas pretreatment system according to claim 2, characterized in that: The control system includes a first control module, and the pre-processing module (1) further includes a second sensor unit, wherein the second sensor unit includes a first pressure transmitter (101b) provided at the air inlet end of the cyclone dust collector (101), a second pressure transmitter (101c) provided at the air outlet end of the cyclone dust collector (101), a second temperature sensor (103b) provided at the air inlet end of the first condenser (103), a third temperature sensor (103c) provided at the air outlet end of the first condenser (103), a fourth temperature sensor (104b) provided at the air inlet end of the second condenser (104), and a fifth temperature sensor (104c) provided at the air outlet end of the second condenser (104); the first control module is used to obtain the first pressure transmitter (101b); 1b) and the pressure data of the second pressure transmitter (101c) so as to judge the dust accumulation state by monitoring the internal pressure difference of the cyclone dust collector (101), and trigger automatic dust unloading when the pressure difference is greater than a preset pressure difference threshold; the first control module is used to obtain the temperature data of the second temperature sensor (103b) and the third temperature sensor (103c), and control the flow rate of circulating cooling water entering the first condenser (103) according to the temperature difference before and after the flue gas is cooled by the first condenser (103); the first control module is used to obtain the temperature data of the fourth temperature sensor (104b) and the fifth temperature sensor (104c), and control the flow rate of circulating chilled water entering the second condenser (103) according to the temperature difference before and after the flue gas is cooled by the second condenser (103).

4. A modular carbon flue gas pretreatment system according to claim 1, characterized in that: The desulfurization module (2) includes an alkali solution storage tank (201) and an alkali solution washing tower (203); The alkali liquid storage tank (201) is connected to the alkali liquid washing tower (203) through a pipeline for transporting the alkali liquid stored in the alkali liquid storage tank (201) to the alkali liquid washing tower (203); a pH sensor is provided in the middle of the inner wall of the alkali liquid washing tower (203) to monitor the pH value of the alkali liquid in the tower in real time; multiple spray layers are provided inside the tower body, and the flue gas enters from the bottom of the tower and contacts the alkali liquid sprayed from the top of the tower in countercurrent; The first sensor unit comprises a first SO2 concentration analyzer (220) arranged at the air inlet end of the desulfurization module (2); The control system obtains flue gas parameters collected by the first SO2 concentration analyzer (220), and triggers the start-up logic of the desulfurization module (2) according to the flue gas parameters collected by the first SO2 concentration analyzer (220); wherein, if the SO2 concentration at the inlet of the desulfurization module (2) collected by the first SO2 concentration analyzer (220) is greater than a preset SO2 concentration threshold, the desulfurization module (2) is automatically started through a bypass valve at the air inlet end of the desulfurization module; if the SO2 concentration at the inlet of the desulfurization module (2) collected by the first SO2 concentration analyzer (220) is not greater than the preset SO2 concentration threshold, the desulfurization module (2) is automatically closed through the bypass valve at the air inlet end of the desulfurization module.

5. The modular carbon flue gas pretreatment system according to claim 1 is characterized in that: The CO oxidation module (3) includes a preheater (302), a catalytic oxidation reactor (303), and a flue gas cooler (306) connected in sequence by pipelines; The preheater (302) is used to preheat the flue gas and then transport it to the catalytic oxidation reactor (303); the catalytic oxidation reactor (303) is used to generate an oxidation reaction with CO in the flue gas under the action of a catalyst; the flue gas cooler (306) is used to cool the high-temperature flue gas after the oxidation reaction through circulating water heat exchange; the outlet of the flue gas cooler (306) is connected to the pipeline of the next functional processing module; the catalytic oxidation reactor (303) is also connected to the pipeline of the gas storage tank (309) to obtain oxygen required for the oxidation reaction; The first sensor unit comprises a first CO analyzer (302a) arranged at the air inlet end of the CO oxidation module (3); The control system acquires flue gas parameters collected by the first CO analyzer (302a), and triggers the start-up logic of the CO oxidation module (3) according to the flue gas parameters collected by the first CO analyzer (302a); wherein, if the CO concentration at the inlet of the CO oxidation module (3) collected by the first CO analyzer (302a) is greater than a preset CO concentration threshold, the CO oxidation module (3) is automatically started via a bypass valve at the air inlet end of the CO oxidation module (3); if the CO concentration at the inlet of the CO oxidation module (3) collected by the first CO analyzer (302a) is not greater than the preset CO concentration threshold, the CO oxidation module (3) is automatically closed via the bypass valve at the air inlet end of the CO oxidation module (3).

6. A modular carbon flue gas pretreatment system according to claim 1, characterized in that: The dust removal module (4) includes a bag filter (401), a star-shaped discharger (402), a second air compressor (403), and an air distribution bag (404); The first air inlet of the bag filter (401) is connected to the pipeline of the previous functional processing module, and the bag filter (401) is used to filter dust in the smoke; the ash hopper at the bottom of the bag filter (401) is connected to the star-shaped discharger (402) through a pipeline, the second air inlet of the bag filter (401) is connected to the pipeline of the air distribution bag (404), and the air inlet end of the air distribution bag (404) is connected to the air outlet end pipeline of the second air compressor (403) for conveying compressed air to the air distribution bag (404), so that the filter bag of the bag filter (401) expands and shakes, and the dust attached to the outer surface is shaken off, thereby performing dust cleaning; The first sensor unit comprises a first dust particle size analyzer (410) arranged at the air inlet end of the dust removal module (4); The control system obtains the flue gas parameters collected by the first dust particle size analyzer (410), and triggers the startup logic of the dust removal module (4) according to the flue gas parameters collected by the first dust particle size analyzer (410); wherein, if the dust particle size at the inlet of the dust removal module (4) collected by the first dust particle size analyzer (410) is greater than a preset dust particle size threshold, and the proportion of dust larger than the preset dust particle size threshold is greater than a preset percentage threshold, the dust removal module (4) is automatically started through the bypass valve at the air inlet end of the dust removal module (4); if the dust particle size at the inlet of the dust removal module (4) collected by the first dust particle size analyzer (410) is not greater than the preset dust particle size threshold, or the proportion of dust larger than the preset dust particle size threshold is not greater than the preset percentage threshold, the dust removal module (4) is automatically closed through the bypass valve at the air inlet end of the dust removal module (4).

7. A modular carbon flue gas pretreatment system according to claim 6, characterized in that: The dust removal module (4) further includes a fifth sensor unit, the fifth sensor unit including an inlet pressure sensor (401b) provided at the first air inlet of the bag filter (401), an outlet pressure sensor (401c) provided at the outlet of the bag filter (401), and differential pressure sensors provided at different levels inside the bag filter (401); the control system includes a second control module, the second control module being used to obtain pressure data from the inlet pressure sensor (401b), the outlet pressure sensor (401c), and all differential pressure sensors, and to determine the degree of filter bag clogging based on the pressure data from the inlet pressure sensor (401b), the outlet pressure sensor (401c), and all differential pressure sensors; The differential pressure sensors are respectively arranged at the pressure monitoring sections at different height layers of the filter bag inside the bag filter (401), and the differential pressure sensors at the same height layer are evenly distributed, and are used to obtain the local pressure difference values ​​at different height layers of the filter bag. The fourth control module is used to calculate the ratio of the local pressure difference at different height layers to the pressure difference value at the inlet and outlet ends of the bag filter (401) to locate the blockage position.

8. The modular carbon flue gas pretreatment system according to claim 1, characterized in that: The drying module (5) comprises a first adsorption tower (501), a second adsorption tower (502), a buffer tank (504), and a condensation recovery device (505); the first adsorption tower (501) and the second adsorption tower (502) are connected by a pipeline for drying the flue gas; the first adsorption tower (501) and the second adsorption tower (502) switch between the adsorption stage and the desorption stage at every preset period; the inlet end of the buffer tank (504) is connected to the drainage end pipelines of the first adsorption tower (501) and the second adsorption tower (502), respectively; the inlet end of the condensation recovery device (505) is connected to the outlet end pipeline of the buffer tank (504), for condensing and recovering the moisture in the buffer tank (504); The first sensor unit comprises a first dew point meter (519) arranged at the air inlet end of the drying module (5); The control system obtains the flue gas parameters collected by the first dew point meter (519), and triggers the start logic of the drying module (5) according to the flue gas parameters collected by the first dew point meter (519); wherein, if the dew point temperature at the inlet of the drying module (5) collected by the first dew point meter (519) is greater than a preset dew point temperature threshold, the drying module (5) is automatically started through a bypass valve at the air inlet end of the drying module (5); if the dew point temperature at the inlet of the drying module (5) collected by the first dew point meter (519) is not greater than the preset dew point temperature threshold, the drying module (5) is automatically closed through the bypass valve at the air inlet end of the drying module (5).

9. A modular carbon flue gas pretreatment system according to claim 8, characterized in that: During the adsorption stage, the flue gas enters the bottom of the first adsorption tower (501) and passes upward through the molecular sieve bed; water molecules are adsorbed by the molecular sieve micropores, and the flue gas is discharged into the carbon capture system after drying; at this time, the second adsorption tower (502) is in the desorption stage, and the second adsorption tower (502) is connected to the buffer tank (504); the desorption stage is divided into a pressure drop stage and a deep desorption stage, first entering the pressure drop stage, the residual gas in the first adsorption tower (501) is discharged into the buffer tank (504), and the water is condensed in the condensation recovery device (505); in the deep desorption stage, the water analyzed by the molecular sieves of the first adsorption tower (501) and the second adsorption tower (502) is processed with the exhaust gas through the buffer tank (504) and the condensation recovery device (505), and the condensed water is reused in the desulfurization module (2).

10. A modular carbon flue gas pretreatment system according to claim 9, characterized in that: The pipeline between the first adsorption tower (501) and the second adsorption tower (502) further includes an upper pressure equalizing valve (506) and a lower pressure equalizing valve (507), wherein the upper pressure equalizing valve (506) is arranged in the pipeline between the top gas outlet of the first adsorption tower (501) and the top gas outlet of the second adsorption tower (502), and is used to balance the high-pressure gas pressure between the top of the first adsorption tower (501) and the top of the second adsorption tower (502); the lower pressure equalizing valve (507) is arranged in the pipeline between the bottom gas outlet of the first adsorption tower (501) and the bottom gas outlet of the second adsorption tower (502), and is used to balance the high-pressure gas pressure between the top of the first adsorption tower (501) and the top of the second adsorption tower (502). The raw gas pressure at the bottom of the tower between the bottom and the bottom of the second adsorption tower (502); the working stage of the first adsorption tower (501) and the second adsorption tower (502) also includes a pressure equalization stage, so that the pressure between the first adsorption tower (501) and the second adsorption tower (502) is balanced. In the adsorption stage, the upper pressure equalization valve (506) and the lower pressure equalization valve (507) are both closed, and the inlet and outlet valves of the first adsorption tower (501) and the second adsorption tower (502) are opened; in the pressure equalization stage: the inlet and outlet valves of the first adsorption tower (501) and the second adsorption tower (502) are closed, and the upper pressure equalization valve (506) and the lower pressure equalization valve (507) are both closed.

Images