A method for assembling and constructing an rto device

Abstract

The application discloses a kind of RTO device assembly construction methods, and the risk of cross operation is reduced by specification process.Its core steps include: first, bottom air pipe, steel support and platform installation are carried out;Then hoist lifting valve, gas collecting chamber, heat storage chamber in turn;In heat storage chamber, fill heat storage ceramic according to the structure of "bottom ceramic square saddle ring, multilayer MLM honeycomb ceramic module, top square saddle ring";Hoist combustion chamber, burner again;Finally, install fan, air pipe and accessory structure.The air pipe welding adopts inside and outside mouthpiece fixed weld, effectively control gap and deformation.The method makes construction more standardized and efficient, reduces the risk of cross operation, improves the heat storage efficiency and is suitable for large RTO project.

Description

Technical Field

[0001] This invention relates to the field of environmental protection equipment construction technology, specifically to an assembly and construction method for an RTO device. Background Technology

[0002] With the increasing demand for VOCs treatment, RTO (Regenerative Thermal Oxidizer) units are developing towards larger scale and higher processing capacity. For example, the largest low-temperature methanol washing emission gas treatment RTO project in China requires a single unit to treat more than 110,000 Nm³ of pre-diluted waste gas. 3 With an annual operating time exceeding 8000 hours, the construction of such projects currently faces the following technical challenges: 1. Disorganized assembly and construction of the unit: The RTO unit consists of multiple components such as steel support, platform, gas collection chamber, heat storage chamber, and combustion chamber. It involves multiple trades working together and a large amount of equipment and materials being brought to the site. Traditional construction lacks clear procedures and processes, which can easily lead to omissions, high safety risks from cross-operations, and non-standard process acceptance records, which affect the stable operation of the equipment.

[0003] 2. Poor construction quality of thermal storage ceramics: The thermal storage chamber is the core component of the RTO device. Traditional thermal storage ceramics are filled with bulk fillers, which have problems such as small specific surface area, slow heat transfer, high pressure rise, and easy fouling. Even if combined fillers are used, there is no unified laying standard, large gaps between layers and disordered module orientation, resulting in low thermal storage efficiency and affecting the VOCs treatment effect.

[0004] 3. Numerous welding defects in large-diameter thin-walled ducts: RTO equipment ducts have large diameters (usually exceeding 1m) and thin wall thicknesses (generally ≤5mm). Traditional welding lacks dedicated fixing tools, making it prone to defects such as base material deformation, misalignment, and undercut. Furthermore, the weld gap is difficult to control, resulting in numerous welding leaks, poor work continuity, and the need for repeated rework, leading to low construction efficiency and high costs.

[0005] In the existing technology, there is no systematic construction plan for large-scale RTO devices, nor are there special welding and fixing tools for large-diameter thin-walled ducts. For example, GB / T50236-2011 "Construction Specification for Welding Engineering of On-site Equipment and Industrial Pipelines" only specifies general welding requirements and does not solve the personalized problems of RTO device construction; HJ1093-2020 "Technical Specification for Industrial Organic Waste Gas Treatment Engineering by Regenerative Combustion Method" only focuses on treatment technology and does not involve the optimization of construction process. Summary of the Invention

[0006] The purpose of this invention is to provide an assembly and construction method for an RTO device, which at least standardizes the assembly process of the RTO device and reduces the risk of cross-operations.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An assembly and construction method for an RTO device, comprising the following steps in sequence: Step 1: Install the bottom inlet and outlet air ducts; Step two, steel bracket installation; Step 3: Installation of the 2.4-meter steel platform, wherein the platform plate of the 2.4-meter steel platform is bolted to the steel support; Step 4: Install the lifting valve. Hoist the lifting valve to the predetermined position on the lower steel platform and connect the flange. Step 5: Hoisting of the gas collection chamber; after hoisting into place, it is welded and fixed to the steel support. Step 6: Hoist the heat storage chamber into place and connect it to the gas collection chamber flange; Step 7: Installation of 5.2-meter and 8-meter steel platforms. Install the 5.2-meter and 8-meter steel platforms respectively, and bolt them to the steel supports. Step 8: Filling the thermal storage ceramic. A layer of ceramic rectangular saddle rings is laid at the bottom of the heat storage chamber, followed by multiple layers of MLM plate-type honeycomb ceramic modules laid on the ceramic rectangular saddle rings, with the laying direction of adjacent layers rotated by 90°, and finally another layer of ceramic rectangular saddle rings is laid on top. Step nine: hoist the combustion chamber into place and weld it to the regenerator. Step 10: Install manholes and rupture discs; Step 11: Burner hoisting. The burner is hoisted to the top interface of the combustion chamber and connected to the combustion chamber flange. Step 12: Fan installation. A concrete foundation is used, and the fan is flexibly connected to the bottom inlet and outlet ducts. Step thirteen: Installation of pipes and other ductwork; Step fourteen: Install the top-floor canopy and bolt it to the steel platform support. Step 15: Hoisting of the equipment buffer tank. The buffer tank is installed vertically, and welded and fixed after the foundation is leveled.

[0008] As a preferred embodiment, in step eight, the laying sequence of each layer of MLM plate-type honeycomb ceramic modules is as follows: starting from the two furnace wall surfaces at one corner of the heat storage chamber, and continuously installing along the diagonal to the opposite furnace wall surface.

[0009] In a preferred embodiment, in step eight, the ceramic rectangular saddle ring has dimensions of 38mm × 22mm × 3.4mm and a laying height of 200mm.

[0010] In a preferred embodiment, in step eight, the size of the MLM plate-type honeycomb ceramic module is 305mm × 305mm × 101mm. In a preferred embodiment, in step eight, the gap between the MLM plate-type honeycomb ceramic module and the heat storage furnace wall insulation layer is filled using an MLM splitting module.

[0011] In a preferred embodiment, during the installation of the remaining ducts in step thirteen, the ducts are welded together, and fitting devices are arranged on the inner and outer sides of the duct ends to adjust the weld gap.

[0012] In a preferred embodiment, the alignment device includes a positioning plate, a nut, a stud, and a pressure plate; multiple positioning plates are spot-welded to the ends of the outer or inner walls of the duct, a nut is fixed to the front end of the positioning plate, the stud is installed inside the nut, and a pressure plate is provided at the front end of the stud; the nut extends to the end of the adjacent duct, and the pressure plate is pressed against the end of the adjacent duct by rotating the stud, adjusting the weld gap; after welding is completed, the weld point between the positioning plate and the duct is cut, and the alignment device is removed.

[0013] As a preferred embodiment, the number of duct connectors installed is determined based on the diameter of the duct, and the spacing between the duct connectors is 50mm.

[0014] Compared with existing RTO device construction schemes, the technical advantages of this invention include: 1. This invention makes assembly and construction more standardized and efficient, clarifies the core processes of the RTO device, solves the problem of chaotic cross-operations of multiple trades, reduces omissions, and reduces the safety risks of cross-operations by more than 60%; the process acceptance system ensures that the quality of each process is controllable, and the subsequent stable operation cycle of the equipment is extended to more than 5 years.

[0015] 2. This invention optimizes the thermal storage ceramic laying process, significantly improving thermal storage efficiency. It employs a filling structure of "bottom rectangular saddle ring + 1MLM ceramic (interlayer rotation 90°) + top rectangular saddle ring," increasing the specific surface area by 40% (compared to traditional bulk fillers), accelerating heat transfer by 30%, reducing pressure loss by 25%, and improving VOCs treatment efficiency to over 99% (compared to 95% in traditional processes).

[0016] 3. Improved duct welding quality and efficiency: The invention uses internal and external alignment devices to fix the gap between duct welds (2-3mm), avoiding deformation and misalignment of the base material. The welding defect rate is reduced from 20% in traditional processes to below 5%. The alignment devices are reusable (service life ≥50 times), improving welding efficiency by 50% and reducing construction costs by 30%.

[0017] The construction method provided by this invention is applicable to RTO devices with different treatment capacities (from 10,000 Nm3 / h to 250,000 Nm3 / h), and is especially suitable for large-scale low-temperature methanol washing exhaust gas treatment RTO projects. Attached Figure Description

[0018] Figure 1 This is a flowchart of the RTO device assembly and construction method provided by the present invention; Figure 2 This is a schematic diagram of the connector structure; Figure 3 This is a diagram showing the arrangement of the internal and external coupling devices.

[0019] In the diagram, 1-positioning plate, 2-nut, 3-stud, 4-pressure plate, 5-air duct. Detailed Implementation

[0020] To enable those skilled in the art to better understand the present invention, the present invention will be further described clearly and completely below with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other.

[0021] The basic concept of this implementation method is to standardize the assembly process of the RTO device, mainly following the principles of bottom-up and large-scale assembly. By rationally arranging the arrival time of materials and equipment, the working hours of workers of various trades, the location of equipment stacking, and the scheduling of construction machinery, the omissions during construction can be reduced, the risks of cross-operations can be lowered, and the process acceptance can be controlled.

[0022] like Figure 1 As shown, the assembly and construction method of the RTO device provided by a typical embodiment of the present invention shall be implemented in the following steps in sequence: construction preparation, placement of bottom inlet and outlet air ducts, installation of steel brackets, installation of 2.4-meter steel platform, installation of lift valve, hoisting of gas collection chamber, hoisting of heat storage chamber, installation of 5.2-meter and 8-meter steel platforms, filling of heat storage ceramics, hoisting of combustion chamber, installation of manhole and rupture disc, hoisting of burner, installation of fan, installation of pipelines and other air ducts, installation of top-floor canopy, and hoisting of equipment buffer tank.

[0023] Construction preparation Verify the equipment and material specifications (such as the material of the steel support and the size of the thermal storage ceramic), clean the construction site, set up temporary safety protection facilities, and provide technical instructions to the construction personnel (including procedures and safety requirements).

[0024] Bottom inlet and outlet air ducts in place The duct positions are located according to the design drawings, and a crane is used to lift and place it in place. After temporary fixation, the levelness is checked and the deviation is controlled within ≤3mm / m.

[0025] Steel bracket installation The steel bracket is made of Q235B steel and is welded and fixed according to the drawings. After installation, the verticality is checked and the deviation is ≤1mm / m. Anti-corrosion treatment is carried out by applying two coats of epoxy zinc-rich primer.

[0026] 2.4-meter steel platform installation The platform plate is made of patterned steel plate, preferably 6mm thick. The platform plate is bolted to the steel support. The bolt torque is as required by the design, usually 30-50 N·m. After installation, the flatness deviation is checked to be ≤2mm / m.

[0027] lift valve installation The lifting valve is hoisted to the designated position on the platform, the flange is connected, and the sealing gasket is made of heat-resistant asbestos. The valve's opening and closing flexibility is checked to ensure there is no jamming.

[0028] Gas collection chamber hoisting The equipment is lifted using two cranes, with the lifting points calculated based on the equipment's center of gravity. During the lifting process, the lifting speed is controlled to be ≤0.5m / min. After positioning, it is welded and fixed to the steel support, with a weld height ≥8mm.

[0029] Heat storage chamber hoisting The same method as the gas collection chamber hoisting is used. After being in place, it is connected to the gas collection chamber flange. The flange gap is controlled to be ≤2mm and sealed with sealant.

[0030] 5.2-meter and 8-meter steel platform installation Install the 5.2-meter and 8-meter steel platforms respectively. The specific steps are the same as for the 2.4-meter steel platform installation. The platform railings are installed simultaneously, with a height of ≥1.2m and a spacing of ≤150mm.

[0031] Thermal storage ceramic loading The interior of the heat storage chamber is mainly divided into two parts: the interior is filled with heat storage ceramics to achieve the function of heat storage and heating, and the exterior is covered with insulation material for heat insulation. The heat storage ceramics are filled after the equipment arrives on site.

[0032] A layer of ceramic rectangular saddle rings is laid at the bottom of the heat storage chamber, followed by the laying of multi-layer MLM (Multi-Layer Media) plate-type honeycomb ceramic modules on the ceramic rectangular saddle rings, with the laying direction of adjacent layers rotated by 90°, and finally another layer of ceramic rectangular saddle rings is laid on top.

[0033] More specifically, a 200mm high ceramic rectangular saddle ring (38×22×3.4mm) is laid at the bottom of the regenerator, ensuring uniformity and no gaps. Eleven layers of MLM plate-type honeycomb ceramic modules (305×305×101mm) are then laid on the ceramic rectangular saddle ring. Each layer of MLM plate-type honeycomb ceramic modules is laid flat with the opening facing upwards, continuously installed from one corner of the regenerator furnace wall along the diagonal to the opposite furnace wall. Adjacent layers are rotated 90° to ensure that the ceramic plates between layers are vertical and that adjacent modules are flush and without gaps.

[0034] After a whole layer of MLM plate-type honeycomb ceramic rectangular modules is installed, if there is a gap (>5mm) between the MLM plate-type honeycomb ceramic module and the furnace wall insulation layer, the MLM disassembled modules are used to fill the gap to ensure that the filling is dense.

[0035] Top layer: After the MLM panel-type honeycomb ceramic module is installed, a 200mm high ceramic rectangular saddle ring (same as the bottom layer) is laid on top.

[0036] Combustion chamber hoisting A single crane is used for hoisting, with the lifting point set at the lifting lug on the top of the combustion chamber. After the combustion chamber is in place, it is welded to the regenerator, and the weld is subjected to non-destructive testing (penetration testing) to ensure that there are no defects.

[0037] Manhole and rupture disc installation The manhole cover is bolted (equipped with a heat-resistant sealing gasket). The rupture disc is selected according to the design pressure, usually 0.1MPa. After installation, the sealing performance is checked (using an airtightness test, pressure 0.05MPa, pressure held for 30 minutes with no leakage).

[0038] Burner hoisting The burner is hoisted to the top interface of the combustion chamber and connected to the combustion chamber flange. The sealing gasket is a high-temperature resistant graphite gasket. After connection, the ignition system wiring is checked.

[0039] Fan installation The fan foundation is made of concrete (strength C30). After the fan is in place, it is leveled with a horizontal deviation of ≤0.1mm / m. The fan and the duct are connected flexibly (rubber expansion joint, temperature resistance ≥200℃).

[0040] Pipe and other air duct installation The air ducts are connected by welding, while the pipelines (such as fuel gas pipelines) are connected by threads. After installation, a pressure test is conducted (air pressure test, pressure 0.6MPa, pressure held for 1 hour with no pressure drop).

[0041] The alignment device includes a positioning plate 1, a nut 2, a stud 3, and a pressure plate 4. Multiple positioning plates 1 are spot-welded to the ends of the outer or inner walls of the duct 5. Nuts 2 are fixed to the front ends of the positioning plates 1, and studs 3 are installed inside the nuts 2. Pressure plates 4 are set at the front ends of the studs 3. Nuts 2 extend to the ends of adjacent ducts 5. By rotating the studs 3, the pressure plates 4 are pressed against the ends of adjacent ducts 5 to adjust the weld gap. After welding is completed, the weld points between the positioning plates and the ducts are cut, and the alignment device is removed.

[0042] For example, the positioning plate 1 is made of the same steel plate as the air duct 5 (thickness 8-10mm, size 100×50mm), the nut (M12) is welded to one side of the positioning plate, the stud (M12×100mm) is threaded to the nut, and the front end of the stud is welded with a circular pressure block (diameter 30mm, material same as the positioning plate).

[0043] Instructions for using the duct alignment device: After the duct is hoisted into place, roughly align it. Place the alignment devices on the inner and outer sides of the duct ends. The number of alignment devices depends on the duct diameter: 4 on each side for diameters of 1-1.5m; 6 on each side for diameters of 1.5-2m; and 8 on each side for diameters > 2m, evenly distributed. Spot weld the positioning plate 1 to the outer or inner wall of the duct 5, with a weld length of 10-15mm and a spacing of 50mm. Rotate the stud 3 to press the pressure block 4 against the adjacent duct ends, adjusting the weld gap to 2-3mm to ensure the welds on the ducts 5 are relatively fixed. After welding, cut the weld between the positioning plate 1 and the duct 5, remove the alignment devices (which can be reused), and grind away any remaining metal from the spot weld to make the inner wall of the duct smooth (roughness Ra≤6.3μm).

[0044] Rooftop canopy installation The canopy is made of color steel plate (0.8mm thick) and bolted to the steel platform support. After installation, check the drainage slope (≥5°).

[0045] Equipment buffer tank hoisting The buffer tank is installed vertically, and is welded and fixed after the foundation is leveled. After the buffer tank is connected to the pipeline, a water pressure test is performed (pressure 1.0MPa, pressure held for 30 minutes without leakage).

[0046] The scope of protection claimed by this invention is not limited to the specific embodiments described above. For those skilled in the art, this invention can have various modifications and alterations. Any modifications, improvements, and equivalent substitutions made within the concept and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A method for assembling and constructing an RTO device, characterized in that, Perform the following steps in sequence: Step 1: Install the bottom inlet and outlet air ducts; Step two, steel bracket installation; Step 3: Installation of the 2.4-meter steel platform, wherein the platform plate of the 2.4-meter steel platform is bolted to the steel support; Step 4: Install the lifting valve. Hoist the lifting valve to the predetermined position on the lower steel platform and connect the flange. Step 5: Hoisting of the gas collection chamber; after hoisting into place, it is welded and fixed to the steel support. Step 6: Hoist the heat storage chamber into place and connect it to the gas collection chamber flange; Step 7: Installation of 5.2-meter and 8-meter steel platforms. Install the 5.2-meter and 8-meter steel platforms respectively, and bolt them to the steel support frame. Step 8: Filling the thermal storage ceramic. A layer of ceramic rectangular saddle rings is laid at the bottom of the heat storage chamber, followed by multiple layers of MLM plate-type honeycomb ceramic modules laid on the ceramic rectangular saddle rings, with the laying direction of adjacent layers rotated by 90°, and finally another layer of ceramic rectangular saddle rings is laid on top. Step nine: hoist the combustion chamber into place and weld it to the regenerator. Step 10: Install manholes and rupture discs; Step 11: Burner hoisting. The burner is hoisted to the top interface of the combustion chamber and connected to the combustion chamber flange. Step 12: Fan installation. A concrete foundation is used, and the fan is flexibly connected to the bottom inlet and outlet ducts. Step thirteen: Installation of pipes and other ductwork; Step fourteen: Install the top-floor canopy and bolt it to the steel platform support. Step 15: Hoisting of the equipment buffer tank. The buffer tank is installed vertically, and welded and fixed after the foundation is leveled.

2. The RTO device assembly and construction method according to claim 1, characterized in that: In step eight, the laying sequence of each layer of MLM panel-type honeycomb ceramic modules is as follows: starting from the two furnace wall surfaces in one corner of the regenerator, and continuously installing along the diagonal to the opposite furnace wall surface.

3. The RTO device assembly and construction method according to claim 2, characterized in that: In step eight, the ceramic rectangular saddle ring has dimensions of 38mm × 22mm × 3.4mm and a laying height of 200mm.

4. The RTO device assembly and construction method according to claim 3, characterized in that: In step eight, the dimensions of the MLM plate-type honeycomb ceramic module are 305mm×305mm×101mm.

5. The RTO device assembly and construction method according to claim 2, 3 or 4, characterized in that: In step eight, the gap between the MLM panel-type honeycomb ceramic module and the regenerative furnace wall insulation layer is filled using the MLM disassembly module.

6. The RTO device assembly and construction method according to claim 5, characterized in that: In step thirteen, when installing the remaining air ducts, the air ducts are welded together, and the weld gap is adjusted by placing a jointing device on the inner and outer sides of the air duct ends.

7. The RTO device assembly and construction method according to claim 6, characterized in that: The alignment device includes a positioning plate, a nut, a stud, and a pressure plate. Multiple positioning plates are spot-welded to the ends of the outer or inner walls of the duct. Nuts are fixed to the front ends of the positioning plates, studs are installed inside the nuts, and pressure plates are set at the front ends of the studs. Nuts extend to the ends of adjacent ducts. By rotating the studs, the pressure plates are pressed against the ends of adjacent ducts to adjust the weld gap. After welding is completed, the weld points between the positioning plates and the ducts are cut, and the alignment device is removed.

8. The RTO device assembly and construction method according to claim 7, characterized in that: The number of duct connectors to be installed is determined based on the diameter of the duct, and the spacing between the duct connectors is 50mm.

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