Industrial VOC waste gas catalytic combustion treatment device
By designing an industrial VOC waste gas catalytic combustion treatment device that includes pretreatment, adsorption-desorption, catalytic combustion, waste heat recovery, and exhaust gas detection systems, the problem of inconvenient temperature adjustment in existing technologies has been solved, achieving automated temperature adjustment and efficient treatment.
Patent Information
- Application Number
- CN202510973793.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-15
- Publication Date
- 2025-10-28
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
Existing catalytic combustion treatment devices are inconvenient in selecting catalytic combustion temperature and cannot be adjusted in real time according to gas composition and concentration, resulting in unsatisfactory treatment efficiency.
An industrial VOC waste gas catalytic combustion treatment device was designed, which includes a pretreatment system, an adsorption-desorption system, a catalytic combustion system, a waste heat recovery system, a tail gas detection system, and a control system. The tail gas detection system detects the gas composition and concentration in real time, and the analysis processor and control system automatically adjust the catalytic combustion temperature.
It enables real-time adjustment of catalytic combustion temperature based on gas composition and concentration, improving processing efficiency, reducing manual operation, and saving energy.
Smart Images
Figure CN120845774A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of industrial organic waste gas treatment technology, specifically to an industrial VOC waste gas catalytic combustion treatment device. Background Technology
[0002] VOCs (volatile organic compounds) mainly include hydrocarbon compounds, benzene and benzene derivatives, alcohols, ketones, phenols, aldehydes, esters, amines, nitriles, cyanides, and other organic compounds. They primarily originate from automobile exhaust, and are found in industries such as electronics, chemicals, petrochemicals, coatings, printing, painting, furniture, and leather.
[0003] Characteristics of Organic Waste Gas Treatment: Organic waste gases are generally characterized by being flammable and explosive, toxic and harmful, insoluble in water, soluble in organic solvents, and difficult to treat. Commonly used treatment methods for organic waste gases include activated carbon adsorption, catalytic combustion, catalytic oxidation, acid-base neutralization, and plasma methods.
[0004] Current catalytic combustion treatment devices are not very convenient in selecting the catalytic combustion temperature. They usually use a pre-set temperature and cannot be adjusted in real time according to the gas composition and concentration, which affects the treatment efficiency of catalytic combustion and results in unsatisfactory catalytic combustion effect. Summary of the Invention
[0005] In order to overcome the above-mentioned defects of the prior art, the present invention provides an industrial VOC waste gas catalytic combustion treatment device to solve the problems existing in the background art.
[0006] This invention provides the following technical solution: an industrial VOC waste gas catalytic combustion treatment device, the industrial VOC waste gas catalytic combustion treatment device comprising:
[0007] The pretreatment system is capable of performing pretreatment operations, including dust removal, oil removal and water removal, on the VOC exhaust gas entering the device to ensure the normal operation of the subsequent treatment units.
[0008] An adsorption-desorption system is provided, which utilizes highly efficient adsorption materials to adsorb and concentrate low-concentration VOC waste gas, thereby increasing the concentration of VOCs in the waste gas and facilitating subsequent catalytic combustion treatment.
[0009] Catalytic combustion system: The catalytic combustion system can convert internal waste gas into harmless substances by increasing the internal temperature through oxidation;
[0010] Waste heat recovery system: The waste heat collection system can collect the heat generated by the catalytic combustion system and use it to heat the waste gas in the adsorption-desorption system;
[0011] Exhaust gas detection system: The exhaust gas detection system is equipped with two detection points. One detection point is set at the adsorption-desorption system to detect the composition and concentration of exhaust gas in the incoming gas, and the other detection point is set at the catalytic combustion system to detect the composition and concentration of gas after catalytic combustion.
[0012] Control system: The control system can automatically control the operation of the entire device, including switching of the adsorption and desorption processes, control of the temperature of the catalytic combustion system, and safety alarms.
[0013] Furthermore, the pretreatment system includes a dust collector, a dehumidifier, and an oil mist separator. The dehumidifier is equipped with activated carbon, and the dust collector is a wet electrostatic precipitator. The dust collector is located before the dehumidifier and performs dust and oil removal treatment before the exhaust gas enters the catalytic combustion furnace, so as to reduce the pollution and blockage on the catalyst surface and improve the catalytic effect.
[0014] Furthermore, the adsorption-desorption system includes an adsorption tower, a desorption fan, and a desorption heating device, wherein the desorption heating device is a hollow tubular structure and is internally connected to the waste heat recovery system.
[0015] Furthermore, the catalytic combustion system is internally equipped with a combustion device, a catalyst carrier, and an electric heater. The combustion device has two chambers: a catalytic chamber and a combustion chamber. The catalyst carrier material is honeycomb ceramic, which can increase the contact area with the gas during the catalytic reaction. At the same time, the honeycomb structure can reduce heat dissipation, which is more conducive to the catalytic reaction. The catalytic chamber is set inside a catalytic bed, and the catalyst carrier is set on the catalytic bed. The bottom of the electric heater is in contact with the waste heat recovery system.
[0016] Furthermore, the waste heat recovery system includes a heat exchanger, a connecting pipe, and an output pipe. The heat exchanger is located at the bottom of the electric heater in the catalytic combustion system, and the output pipe is located in the adsorption-desorption system and wrapped around the outer wall of the desorption heating device. The heat transfer medium in the heat exchanger is heat transfer oil, which has the advantages of high-efficiency heat transfer, good stability, strong adaptability, and environmental protection and energy saving.
[0017] Furthermore, the exhaust gas detection system includes detection sensors and an analysis processor. The detection sensors include a catalytic combustion gas sensor, a photoionization detector, a gas chromatography-flame ionization detector, an electrochemical sensor, and an infrared sensor.
[0018] Furthermore, the analysis processor includes a data collection module, a data preprocessing module, a data analysis module, and an output module. The data collection module is used to collect data from sensors at the detection points. The data preprocessing module is used for preliminary processing of the data, including data cleaning (removing noise, outliers, etc.), data standardization or normalization (making data of different dimensions comparable), and feature extraction (extracting features useful for model training from the raw data). The data analysis module is used for data analysis, processing, and storage. The output module interfaces with the control system.
[0019] Furthermore, the data analysis module includes a dataset, a training set, and an analysis module. The dataset is used to record the data processed by the preprocessing module and to classify and organize the data. The training set is used to train the analysis module. The training set collects a large amount of exhaust gas emission data, including parameters such as exhaust gas composition and concentration, concentration, and flow rate under normal conditions, as well as data on possible abnormal conditions. This data can come from sensors, monitoring stations, etc. of exhaust gas treatment equipment. This data is then imported into the analysis module, which performs data analysis on the dataset and combines it with the training set to obtain target data. The target data is then output to the control system through the output module.
[0020] The analysis module uses an autoencoder model, and selects appropriate parameters such as the number of layers, neurons, and activation function based on actual needs. The activation function chosen is Leaky ReLU, defined by the following formula:
[0021] f(x)=max(αx,x)f(x)=\max(\alpha x,x)f(x)=max(αx,x)
[0022] Here, α is a constant less than 1, called the leakage coefficient or negative slope. Generally, α is taken as a small value, such as 0.01.
[0023] The model is trained using training set data. During training, the model learns the normal exhaust emission pattern and attempts to minimize the reconstruction error (for autoencoders). Simultaneously, optimization algorithms such as backpropagation and gradient descent are used to update the model's weights and biases. Temperature verification is performed during training. When training the model on the training set data, the required combustion temperature within a specific gas concentration range is manually input beforehand, for example, setting the temperature for low-concentration exhaust gas treatment (<500ppm) and medium-concentration exhaust gas treatment (500ppm-200ppm). The system offers three settings: low concentration (>2000ppm) and high concentration (>2000ppm). For low concentration exhaust gas, the ignition temperature is around 180℃, with a stable combustion temperature between 250℃ and 300℃. For medium concentration exhaust gas, the ignition temperature is between 250℃ and 300℃, with a stable combustion temperature between 350℃ and 450℃. For very low concentration exhaust gas, the ignition temperature is above 350℃, with a stable combustion temperature between 500℃ and 700℃ or even higher. After detecting the composition and concentration of the exhaust gas, the system adjusts the combustion temperature according to the setting, which helps save energy.
[0024] The exhaust gas detection system continuously monitors the incoming gas through sensors, updating its composition and concentration. Simultaneously, an analysis processor analyzes the gas concentration and matches it to the set combustion temperature, confirming the ignition and stable combustion temperatures required for catalytic combustion at the current concentration. This temperature value is then transmitted to the control system, which adjusts the catalytic combustion system temperature to the lowest setting. Meanwhile, a second sensor detects the composition and concentration of the exhaust gas. If the exhaust gas concentration is lower than a preset value, the control system gradually increases the catalytic combustion system temperature until the exhaust gas concentration is greater than or equal to the preset value.
[0025] Beneficial effects:
[0026] 1. This industrial VOC waste gas catalytic combustion treatment device is equipped with a tail gas detection system. The tail gas detection system is equipped with detection sensors, which are located in the pretreatment system and the catalytic combustion system. The sensors can detect the composition and concentration of the internal gas throughout the process, thereby clearly understanding the composition and concentration of the gas entering and exiting the device.
[0027] 2. This industrial VOC waste gas catalytic combustion treatment device has an internal analysis processor in its exhaust gas detection system. It can determine the current combustion temperature based on the composition and concentration of the gas entering and exiting the device, and adjust the temperature through the control system. This reduces manual operation and makes it more convenient to use. Attached Figure Description
[0028] Figure 1This is an overall module diagram of an industrial VOC waste gas catalytic combustion treatment device proposed in this invention;
[0029] Figure 2 This is a flow chart of the industrial VOC waste gas catalytic combustion treatment device proposed in this invention. Detailed Implementation
[0030] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.
[0031] Example 1
[0032] Please see Figure 1 An industrial VOC waste gas catalytic combustion treatment device, comprising:
[0033] The pretreatment system can perform pretreatment operations on the VOC exhaust gas entering the device, including dust removal, oil removal and water removal, to ensure the normal operation of subsequent treatment units.
[0034] Adsorption-desorption system: The adsorption-desorption system can use high-efficiency adsorption materials to adsorb and concentrate low-concentration VOC waste gas, increase the concentration of VOCs in the waste gas, and facilitate subsequent catalytic combustion treatment.
[0035] Catalytic combustion system: The catalytic combustion system can convert internal waste gas into harmless substances by increasing the internal temperature through oxidation;
[0036] Waste heat recovery system: The waste heat collection system can collect the heat generated by the catalytic combustion system and use it to heat the waste gas in the adsorption-desorption system;
[0037] Exhaust gas detection system: The exhaust gas detection system is equipped with two detection points. One detection point is set at the adsorption-desorption system to detect the composition and concentration of exhaust gas in the incoming gas, and the other detection point is set at the catalytic combustion system to detect the composition and concentration of gas after catalytic combustion.
[0038] Control system: The control system can automatically control the operation of the entire device, including switching of the adsorption and desorption processes, control of the temperature of the catalytic combustion system, and safety alarms.
[0039] The pretreatment system includes a dust collector, a dehumidifier, and an oil mist separator. The dehumidifier is equipped with activated carbon, and the dust collector is a wet electrostatic precipitator. The dust collector is located before the dehumidifier and performs dust and oil removal treatment before the exhaust gas enters the catalytic combustion furnace to reduce contamination and clogging on the catalyst surface and improve the catalytic effect.
[0040] The adsorption-desorption system includes an adsorption tower, a desorption fan, and a desorption heating device. The desorption heating device is a hollow tubular structure and is internally connected to the waste heat recovery system.
[0041] The catalytic combustion system is equipped with a combustion device, a catalyst carrier, and an electric heater. The combustion device has two chambers: a catalytic chamber and a combustion chamber. The catalyst carrier material is honeycomb ceramic, which can increase the contact area with the gas during the catalytic reaction. At the same time, the honeycomb structure can reduce heat dissipation, which is more conducive to the catalytic reaction. The catalytic chamber is set inside the catalytic bed, and the catalyst carrier is set on the catalytic bed. The bottom of the electric heater is in contact with the waste heat recovery system.
[0042] The waste heat recovery system includes a heat exchanger, connecting pipes, and an output pipe. The heat exchanger is located at the bottom of the electric heater in the catalytic combustion system, and the output pipe is located in the adsorption-desorption system and wrapped around the outer wall of the desorption heating device. The heat transfer medium in the heat exchanger is heat transfer oil, which has the advantages of high-efficiency heat transfer, good stability, strong adaptability, and environmental protection and energy saving.
[0043] Example 2
[0044] Please see Figure 1-Figure 2 The exhaust gas detection system includes detection sensors and an analysis processor. The detection sensors include catalytic combustion gas sensors, photoionization detectors, gas chromatography-flame ionization detectors, electrochemical sensors, and infrared sensors.
[0045] The analysis processor includes a data collection module, a data preprocessing module, a data analysis module, and an output module. The data collection module is used to collect data from sensors at the detection points. The data preprocessing module is used for preliminary processing of the data, including data cleaning (removing noise, outliers, etc.), data standardization or normalization (making data of different dimensions comparable), and feature extraction (extracting features useful for model training from the raw data). The data analysis module is used for data analysis, processing, and storage. The output module interfaces with the control system.
[0046] The data analysis module includes a dataset, a training set, and an analysis module. The dataset records the data processed by the preprocessing module and performs data classification and organization. The training set is used to train the analysis module. The training set collects a large amount of exhaust gas emission data, including parameters such as exhaust gas composition and concentration, concentration, and flow rate under normal conditions, as well as data on possible abnormal conditions. This data can come from sensors and monitoring stations of exhaust gas treatment equipment. This data is then imported into the analysis module, which performs data analysis on the dataset and combines it with the training set to obtain target data. The output module then outputs the target data to the control system.
[0047] The analysis module uses an autoencoder model, and selects appropriate parameters such as the number of layers, neurons, and activation function based on actual needs. The activation function chosen is Leaky ReLU, defined by the following formula:
[0048] f(x)=max(αx,x)f(x)=\max(\alpha x,x)f(x)=max(αx,x)
[0049] Here, α is a constant less than 1, called the leakage coefficient or negative slope. Generally, α is taken as a small value, such as 0.01.
[0050] The model is trained using training set data. During training, the model learns the normal exhaust emission pattern and attempts to minimize the reconstruction error (for autoencoders). Simultaneously, optimization algorithms such as backpropagation and gradient descent are used to update the model's weights and biases. Temperature verification is performed during training. When training the model on the training set data, the required combustion temperature within a specific gas concentration range is manually input beforehand, for example, setting the temperature for low-concentration exhaust gas treatment (<500ppm) and medium-concentration exhaust gas treatment (500ppm-200ppm). The system offers three settings: low concentration (>2000ppm) and high concentration (>2000ppm). For low concentration exhaust gas, the ignition temperature is around 180℃, with a stable combustion temperature between 250℃ and 300℃. For medium concentration exhaust gas, the ignition temperature is between 250℃ and 300℃, with a stable combustion temperature between 350℃ and 450℃. For very low concentration exhaust gas, the ignition temperature is above 350℃, with a stable combustion temperature between 500℃ and 700℃ or even higher. After detecting the composition and concentration of the exhaust gas, the system adjusts the combustion temperature according to the setting, which helps save energy.
[0051] The exhaust gas detection system continuously monitors the incoming gas through sensors, updating its composition and concentration. Simultaneously, an analysis processor analyzes the gas concentration and matches it to the set combustion temperature, confirming the ignition and stable combustion temperatures required for catalytic combustion at the current concentration. This temperature value is then transmitted to the control system, which adjusts the catalytic combustion system temperature to the lowest setting. Meanwhile, a second sensor detects the composition and concentration of the exhaust gas. If the exhaust gas concentration is lower than a preset value, the control system gradually increases the catalytic combustion system temperature until the exhaust gas concentration is greater than or equal to the preset value.
[0052] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims
1. An industrial VOC waste gas catalytic combustion treatment device, characterized in that: The industrial VOC waste gas catalytic combustion treatment device includes: The pretreatment system is capable of performing pretreatment operations, including dust removal, oil removal and water removal, on the VOC exhaust gas entering the device to ensure the normal operation of the subsequent treatment units. An adsorption-desorption system is provided, which utilizes highly efficient adsorption materials to adsorb and concentrate low-concentration VOC waste gas, thereby increasing the concentration of VOCs in the waste gas and facilitating subsequent catalytic combustion treatment. Catalytic combustion system: The catalytic combustion system can convert internal waste gas into harmless substances by increasing the internal temperature through oxidation; Waste heat recovery system: The waste heat collection system can collect the heat generated by the catalytic combustion system and use it to heat the waste gas in the adsorption-desorption system; Exhaust gas detection system: The exhaust gas detection system is equipped with two detection points. One detection point is set at the adsorption-desorption system to detect the composition and concentration of exhaust gas in the incoming gas, and the other detection point is set at the catalytic combustion system to detect the composition and concentration of gas after catalytic combustion. Control system: The control system can automatically control the operation of the entire device, including switching of the adsorption and desorption processes, control of the temperature of the catalytic combustion system, and safety alarms.
2. The industrial VOC waste gas catalytic combustion treatment device according to claim 1, characterized in that: The pretreatment system includes a dust collector, a dehumidifier, and an oil mist separator. The dehumidifier contains activated carbon, and the dust collector is a wet electrostatic precipitator, which is located in front of the dehumidifier.
3. The industrial VOC waste gas catalytic combustion treatment device according to claim 1, characterized in that: The adsorption-desorption system includes an adsorption tower, a desorption fan, and a desorption heating device. The desorption heating device is a hollow tubular structure and is internally connected to the waste heat recovery system.
4. The industrial VOC waste gas catalytic combustion treatment device according to claim 1, characterized in that: The catalytic combustion system is equipped with a combustion device, a catalyst carrier, and an electric heater. The combustion device has two chambers: a catalytic chamber and a combustion chamber. The catalyst carrier is made of honeycomb ceramic. The catalytic chamber is equipped with a catalytic bed, and the catalyst carrier is placed on the catalytic bed. The bottom of the electric heater is in contact with the waste heat recovery system.
5. The industrial VOC waste gas catalytic combustion treatment device according to claim 3, characterized in that: The waste heat recovery system includes a heat exchanger, a connecting pipe, and an output pipe. The heat exchanger is located at the bottom of the electric heater in the catalytic combustion system. The output pipe is located in the adsorption-desorption system and is wrapped around the outer wall of the desorption heating device. The heat transfer medium in the heat exchanger is heat transfer oil.
6. The industrial VOC waste gas catalytic combustion treatment device according to claim 1, characterized in that: The exhaust gas detection system includes detection sensors and an analysis processor. The detection sensors include a catalytic combustion gas sensor, a photoionization detector, a gas chromatography-flame ionization detector, an electrochemical sensor, and an infrared sensor.
7. The industrial VOC waste gas catalytic combustion treatment device according to claim 6, characterized in that: The analysis processor includes a data collection module, a data preprocessing module, a data analysis module, and an output module. The data collection module is used to collect data from sensors at detection points. The data preprocessing module is used for preliminary processing of the data. The data analysis module is used for data analysis, processing, and storage. The output module interfaces with the control system.
8. The industrial VOC waste gas catalytic combustion treatment device according to claim 7, characterized in that: The data analysis module includes a dataset, a training set, and an analysis module. The dataset is used to record the data processed by the preprocessing module and to classify and organize the data. The training set is used to train the analysis module. The analysis module is used to perform data analysis on the dataset and combine it with the training set to obtain the target data. The target data is then output to the control system through the output module.