SZS steam boiler productivity optimization and emission control system integration method

Abstract

The invention belongs to the technical field of SZS steam boilers, and discloses an SZS steam boiler productivity optimization and emission control system integration method, which specifically comprises the following steps: step 1, recording a boiler operation current situation, and recording operation parameters in detail: arranging professionals to carry out continuous operation monitoring on SZS series steam boilers for a month, key parameters of steam yield, pressure, temperature and fuel consumption of the boiler under different loads (low load, medium load and high load) are recorded. By optimizing and upgrading the pulse dust collector and the feeding port of the SZS steam boiler, it is ensured that the boiler operates in an efficient and stable state; the emission of pollutants can be reduced, the influence on the environment is reduced, and the environment-friendly image of an enterprise is improved; besides, combustion efficiency and energy consumption can be optimized, energy cost of enterprises is reduced, powerful support can be provided for continuous progress of the boiler technology through transformation and optimization, and sustainable development of the industrial field is promoted.

Description

Technical Field

[0001] This invention belongs to the field of SZS steam boiler technology, specifically an integrated method for SZS steam boiler capacity optimization and emission control system. Background Technology

[0002] The demand for SZS series steam boilers is showing a continuous growth trend. They are widely used in chemical, pharmaceutical, and food industries, mainly as key equipment to provide steam power to meet the needs of heating, drying, and sterilization in the production process. With the accelerated development of domestic industry, the demand for steam boilers in these industrial sectors continues to grow, providing a broad market development space for SZS series steam boilers.

[0003] With the continuous development of industrial technology, some problems have gradually emerged in the pulse dust collector and feed inlet of SZS series steam boilers. For example, the filtration performance of the pulse dust collector may decline due to dust accumulation on the surface of the filter bags, which in turn affects the combustion efficiency and production capacity of the boiler. As a key channel for materials to enter the boiler, the unobstructed flow and sealing of the feed inlet are directly related to the operational stability and safety of the boiler. Therefore, it is necessary to improve and optimize the pulse dust collector and feed inlet to enhance the boiler's production capacity and environmental performance, and reduce operating costs. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated method for optimizing the capacity and controlling the emission control system of an SZS steam boiler, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an integrated method for optimizing the capacity and emission control system of SZS steam boilers, the specific steps of which are as follows:

[0006] Step 1: Record the current operating status of the boiler

[0007] Detailed recording of operating parameters: Arrange professional personnel to conduct continuous operation monitoring of the SZS series steam boiler for one month, record key parameters such as steam output, pressure, temperature and fuel consumption of the boiler under different loads (low load, medium load and high load), record the pressure value of the boiler steam outlet at regular intervals every day, accurate to two decimal places, draw a curve of pressure change over time, and analyze the pressure fluctuation.

[0008] Analyze the failure history: Collect the boiler's failure records for the past year, including the time of failure, failure type, failure handling method and handling time. By analyzing the failure history, identify the weak links in the boiler operation and provide a basis for subsequent modifications.

[0009] Step Two: Pulse Jet Dust Collector Retrofit

[0010] Replacement and installation optimization of filter bags for pulse dust collectors, modification and upgrading of dust removal systems, and monitoring and optimization of technical indicators for pulse dust collector modification.

[0011] Step 3: Modification of the feed inlet

[0012] Optimize the feed inlet structure, improve the feed inlet sealing performance, accurately control the feed flow rate, and evaluate the feed inlet modification indicators;

[0013] Step 4: System Integration and Debugging

[0014] The optimized pulse dust collector and feed inlet are connected to the SZS steam boiler to complete system integration. After system integration, system debugging is performed to ensure stable operation.

[0015] Step 5: Verification and Continuous Optimization of Transformation Results

[0016] The modified boiler will be validated, and a feedback mechanism will be established for maintenance and optimization.

[0017] As a preferred embodiment of the present invention, the filter bag replacement and installation optimization in step two specifically includes:

[0018] Filter bag wear and clogging assessment: Turn on the pulse dust collector and conduct a comprehensive inspection of the existing filter bags. Use testing tools to measure the wear and clogging of the filter bags. Based on the filter bag material, usage time, and actual test results, formulate a replacement plan. Filter bags with severe wear or clogging exceeding 50% should be included in the replacement list.

[0019] Sealing treatment: During the replacement of filter bags, high-quality sealing materials and silicone sealing strips are selected to ensure the seal between the filter bags and the dust collector wall. During installation, the operating procedures are followed and sealing tools are used to press the sealing strips tightly to prevent leakage. After installation, a sealing test is performed by using a smoke generator to generate smoke inside the dust collector and observing whether there is any smoke leakage from the connection between the filter bags and the dust collector wall.

[0020] Mechanized installation: Introducing mechanized filter bag installation equipment, such as automatic filter bag installers, allows operators to set relevant parameters on the control panel, and the equipment can automatically complete the filter bag installation. During the installation process, built-in sensors monitor the filter bag installation position and force in real time to ensure that the filter bag is installed in place.

[0021] As a preferred technical solution of the present invention, the dust removal system modification and upgrade in step two includes:

[0022] Pulse jet cleaning device modification: Remove the original pulse jet cleaning device and install a jet cleaning device using electromagnetic pulse valve technology. After installation, conduct a jet cleaning pressure test, use a pressure sensor to measure the jet cleaning pressure, and ensure that the jet cleaning pressure is within the specified range (0.3-0.5MPa).

[0023] Upgraded dust removal control system: An automated control system is introduced, which consists of a PLC, sensors, and actuators. The sensors monitor the pressure difference and temperature parameters of the dust collector in real time and transmit the data to the PLC. The PLC monitors and adjusts the dust removal process in real time according to the preset program. When the pressure difference of the dust collector reaches the set value, the PLC automatically issues a command to control the electromagnetic pulse valve to perform jet cleaning.

[0024] As a preferred technical solution of the present invention, the monitoring and optimization of the technical indicators for pulse dust collector modification in step two is divided into:

[0025] Filtration effect monitoring: Install dust concentration detectors at the inlet and outlet of the dust collector to monitor the dust concentration at the inlet and outlet in real time. Calculate the dust removal efficiency based on the monitoring data (dust removal efficiency = (inlet dust concentration - outlet dust concentration) / inlet dust concentration × 100%). Perform statistical analysis on the dust removal efficiency weekly to ensure that the dust removal efficiency meets the design requirements. When the dust removal efficiency decreases, check the filter bags for damage or blockage in a timely manner and adjust the cleaning parameters accordingly.

[0026] Dust removal effect evaluation: The dust collector is shut down for inspection every month to observe the dust accumulation on the surface of the filter bags. At the same time, the pressure changes during the operation of the dust collector are monitored and pressure-time curves are plotted.

[0027] Energy consumption monitoring and optimization: Install power monitoring instruments on the power supply line of the dust collector to monitor the energy consumption of the dust collector in real time. Based on the energy consumption under different operating conditions (low load, medium load, and high load operation of the boiler), formulate operation strategies according to the energy consumption change patterns.

[0028] As a preferred embodiment of the present invention, the specific content of the feed inlet structure optimization in step three is as follows:

[0029] Feed hopper and feed pipe design: Based on the material characteristics and boiler feeding requirements, the feed hopper and feed pipe were redesigned, adopting a streamlined design to reduce material resistance during the feeding process; the feed hopper was designed as a cone shape, wider at the top and narrower at the bottom, to allow the material to slide down smoothly; the feed pipe used a smooth inner wall material to reduce the friction between the material and the pipe wall; the dimensions of the feed hopper and feed pipe were determined to ensure that the material throughput capacity meets the boiler production requirements;

[0030] Application of material distribution control technology: Install guide plates or rotating distributors at the feed inlet. After installation, conduct material distribution tests and use image recognition technology or sampling analysis methods to evaluate the uniformity of material distribution in the furnace.

[0031] As a preferred embodiment of the present invention, the improved sealing performance of the feed inlet and the precise control of the feed flow rate in step three are respectively:

[0032] Improved inlet sealing performance

[0033] Improved sealing structure: The sealing structure of the feed inlet has been improved by adopting a double-layer sealing design. The inner layer uses a flexible rubber sealing ring to adapt to the friction and extrusion of materials; the outer layer uses a rigid metal sealing plate to enhance sealing reliability. A sealing pressure regulating device is set in the sealing structure to automatically adjust the sealing pressure according to the working pressure of the feed inlet to ensure sealing effect.

[0034] Sealing technology selection: Pneumatic sealing technology is selected, which uses a pneumatic device to apply pressure to the sealing component to make it fit tightly against the feed port. At the same time, the surface is treated before the sealing material is installed to ensure that the sealing surface is flat and smooth.

[0035] Precise control of feed flow rate

[0036] Feed control valve and technology application: An electric regulating feed control valve is adopted, which is controlled by a PLC control system. The feed flow rate is adjusted in real time according to the boiler's operating parameters. At the same time, flow feedback control technology is introduced, which feeds back the actual flow signal detected by the flow sensor to the PLC. The PLC compares the feedback signal with the set flow rate and automatically adjusts the opening of the electric regulating valve to achieve precise control of the feed flow rate.

[0037] Real-time monitoring and maintenance: Flow sensors and pressure sensors are installed on the feed pipeline to monitor the feed flow and pressure parameters in real time. The parameters are then transmitted to the central control room, and operators can monitor the operation of the feed inlet in real time through the monitoring screen.

[0038] As a preferred embodiment of the present invention, the evaluation of the feed inlet modification indicators in step three includes:

[0039] Operational data recording and analysis: After the feed inlet modification is completed, record the operational data before and after the modification, including key parameters such as flow rate, pressure, and temperature. Use a data acquisition system to collect and store the data in real time, establish a database, and analyze the data in the database regularly every month to draw parameter change curves and compare the differences in data before and after the modification.

[0040] Performance improvement evaluation: The performance improvement of the feed inlet is evaluated by comparing the operating data before and after the modification.

[0041] As a preferred embodiment of the present invention, the system integration and debugging in step four specifically includes:

[0042] System Integration

[0043] Hardware connection: Connect the optimized pulse dust collector and feed inlet to the SZS steam boiler: connect the air inlet pipe of the pulse dust collector to the exhaust pipe of the boiler, and connect the discharge pipe of the feed inlet to the feed inlet of the boiler; connect the control cable of the pulse dust collector and the control cable of the feed inlet to the PLC system in the central control room.

[0044] Software integration: The control programs for the pulse dust collector and the feed inlet are integrated into the PLC system in the central control room. The software modules of the automatic control system of the pulse dust collector and the flow control system of the feed inlet are integrated with the main control system of the boiler to achieve coordinated control between the various devices.

[0045] System debugging

[0046] Individual unit commissioning: Perform individual unit commissioning on the pulse dust collector and the feed inlet separately. During the individual unit commissioning of the pulse dust collector, start the pulse jet cleaning device and check whether the electromagnetic pulse valve's jet action is normal and whether the jet pressure is stable; check whether all functions of the dust removal control system are implemented; during the individual unit commissioning of the feed inlet, start the feed control valve and check whether the feed flow rate can be adjusted according to the set value; check whether the sealing performance of the feed inlet is good and whether there is any leakage.

[0047] Linkage debugging: After the individual unit is debugged normally, linkage debugging of the pulse dust collector, feed inlet and boiler is carried out to simulate different operating conditions of the boiler, observe the coordinated operation between the equipment, and adjust and optimize in a timely manner for any problems that occur during linkage debugging to ensure the stability and reliability of the system after integration.

[0048] As a preferred technical solution of the present invention, the method for verifying and continuously optimizing the modification results in step five is as follows:

[0049] Verification of transformation results

[0050] Capacity improvement verification: Compare the steam output of the SZS steam boiler before and after the renovation. Under the same fuel consumption and operating time conditions, calculate the total steam output within one month before and after the renovation.

[0051] Verification of pollutant emission reduction: Using emission detection equipment, pollutants such as dust, sulfur dioxide, and nitrogen oxides in the flue gas of the modified boiler are sampled and tested, and the data are compared with the data before the modification.

[0052] Combustion efficiency and energy consumption optimization verification: The combustion efficiency of the boiler before and after the modification was tested using a thermal efficiency tester. At the same time, the fuel consumption was statistically analyzed over a month before and after the modification.

[0053] Continuous optimization

[0054] Establish a feedback mechanism: Establish user feedback channels to encourage operators and managers to promptly report problems and improvement suggestions that occur during boiler operation, set up a dedicated feedback email address and hotline, and collect feedback information regularly;

[0055] Regular maintenance and upgrades: Develop a regular maintenance plan to regularly inspect, maintain and service the pulse dust collector, feed inlet and boiler. Upgrade and modify the equipment in a timely manner according to technological development and actual operation needs to continuously improve the performance and reliability of the boiler.

[0056] The beneficial effects of this invention are as follows:

[0057] This invention optimizes and upgrades the pulse dust collector and feed inlet of the SZS steam boiler, ensuring that the boiler operates in a highly efficient and stable state. It also reduces pollutant emissions, minimizes environmental impact, and enhances the company's environmental image. Furthermore, it optimizes combustion efficiency and energy consumption, reducing the company's energy costs. Through this modification and optimization, it provides strong support for the continuous advancement of boiler technology, promotes sustainable development in the industrial sector, and is of great significance for improving the economic and social benefits of enterprises. Attached Figure Description

[0058] Figure 1 This is a flowchart of the present invention. Detailed Implementation

[0059] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0060] like Figure 1 As shown in the figure, this invention provides an integrated method for optimizing the capacity and controlling the emissions of an SZS steam boiler. The specific steps are as follows:

[0061] Step 1: Record the current operating status of the boiler

[0062] Detailed recording of operating parameters: Arrange professional personnel to conduct continuous operation monitoring of the SZS series steam boiler for one month, record key parameters such as steam output, pressure, temperature and fuel consumption of the boiler under different loads (low load, medium load and high load), record the pressure value of the boiler steam outlet at regular intervals every day, accurate to two decimal places, draw a curve of pressure change over time, and analyze the pressure fluctuation.

[0063] Analyze the failure history: Collect the boiler's failure records for the past year, including the time of failure, failure type, failure handling method and handling time. By analyzing the failure history, identify the weak links in the boiler operation and provide a basis for subsequent modifications.

[0064] Step Two: Pulse Jet Dust Collector Retrofit

[0065] Replacement and installation optimization of filter bags for pulse dust collectors, modification and upgrading of dust removal systems, and monitoring and optimization of technical indicators for pulse dust collector modification.

[0066] Step 3: Modification of the feed inlet

[0067] Optimize the feed inlet structure, improve the feed inlet sealing performance, accurately control the feed flow rate, and evaluate the feed inlet modification indicators;

[0068] Step 4: System Integration and Debugging

[0069] The optimized pulse dust collector and feed inlet are connected to the SZS steam boiler to complete system integration. After system integration, system debugging is performed to ensure stable operation.

[0070] Step 5: Verification and Continuous Optimization of Transformation Results

[0071] The modified boiler will be validated, and a feedback mechanism will be established for maintenance and optimization.

[0072] By implementing the above specific methods and steps, the boiler's dust removal efficiency can be significantly improved, energy consumption reduced, production capacity and combustion efficiency increased, while enhancing the company's environmental image and market competitiveness.

[0073] Specifically, the filter bag replacement and installation optimization in step two includes:

[0074] Filter bag wear and clogging assessment: Turn on the pulse dust collector and conduct a comprehensive inspection of the existing filter bags. Use testing tools to measure the wear and clogging of the filter bags. Based on the filter bag material, usage time, and actual test results, formulate a replacement plan. Filter bags with severe wear or clogging exceeding 50% should be included in the replacement list.

[0075] Sealing treatment: During the replacement of filter bags, high-quality sealing materials and silicone sealing strips are selected to ensure the seal between the filter bags and the dust collector wall. During installation, the operating procedures are followed and sealing tools are used to press the sealing strips tightly to prevent leakage. After installation, a sealing test is performed by using a smoke generator to generate smoke inside the dust collector and observing whether there is any smoke leakage from the connection between the filter bags and the dust collector wall.

[0076] Mechanized installation: Introducing mechanized filter bag installation equipment, such as automatic filter bag installers, allows operators to set relevant parameters on the control panel, and the equipment can automatically complete the filter bag installation. During the installation process, built-in sensors monitor the filter bag installation position and force in real time to ensure that the filter bag is installed in place.

[0077] When assessing filter bag wear and clogging, obvious damage and holes on the filter bag surface indicate a significant decrease in air permeability. Automatic filter bag installation machines can automatically grab, position, and install filter bags, greatly improving installation efficiency and quality.

[0078] The dust removal system modification and upgrade in step two includes:

[0079] Pulse jet cleaning device modification: Remove the original pulse jet cleaning device and install a jet cleaning device using electromagnetic pulse valve technology. After installation, conduct a jet cleaning pressure test, use a pressure sensor to measure the jet cleaning pressure, and ensure that the jet cleaning pressure is within the specified range (0.3-0.5MPa).

[0080] Upgraded dust removal control system: An automated control system is introduced, which consists of a PLC, sensors, and actuators. The sensors monitor the pressure difference and temperature parameters of the dust collector in real time and transmit the data to the PLC. The PLC monitors and adjusts the dust removal process in real time according to the preset program. When the pressure difference of the dust collector reaches the set value, the PLC automatically issues a command to control the electromagnetic pulse valve to perform jet cleaning.

[0081] Electromagnetic pulse valves have advantages such as fast response speed and stable blowing pressure. During installation, follow the installation instructions for electromagnetic pulse valves to ensure that the valve body and the blowing pipe are tightly connected and there is no leakage. The automated control system allows operators to easily set and modify dust removal parameters, such as blowing cycle and blowing time, through the human-machine interface.

[0082] The monitoring and optimization of technical indicators for pulse dust collector retrofitting in step two are divided into:

[0083] Filtration effect monitoring: Install dust concentration detectors at the inlet and outlet of the dust collector to monitor the dust concentration at the inlet and outlet in real time. Calculate the dust removal efficiency based on the monitoring data (dust removal efficiency = (inlet dust concentration - outlet dust concentration) / inlet dust concentration × 100%). Perform statistical analysis on the dust removal efficiency weekly to ensure that the dust removal efficiency meets the design requirements. When the dust removal efficiency decreases, check the filter bags for damage or blockage in a timely manner and adjust the cleaning parameters accordingly.

[0084] Dust removal effect evaluation: The dust collector is shut down for inspection every month to observe the dust accumulation on the surface of the filter bags. At the same time, the pressure changes during the operation of the dust collector are monitored and pressure-time curves are plotted.

[0085] Energy consumption monitoring and optimization: Install power monitoring instruments on the power supply line of the dust collector to monitor the energy consumption of the dust collector in real time. Based on the energy consumption under different operating conditions (low load, medium load, and high load operation of the boiler), formulate operation strategies according to the energy consumption change patterns.

[0086] After the pressure-time curve is plotted, if the pressure rises too quickly or the pressure fluctuates greatly, it indicates that the ash removal effect is not good, and the ash removal cycle or injection pressure needs to be adjusted. When monitoring and optimizing energy consumption, the operating strategies include: when the boiler is running at low load, appropriately extending the ash removal cycle, reducing the number of ash removals, and reducing energy consumption.

[0087] The specific details of the feed inlet structure optimization in step three are as follows:

[0088] Feed hopper and feed pipe design: Based on the material characteristics and boiler feeding requirements, the feed hopper and feed pipe were redesigned, adopting a streamlined design to reduce material resistance during the feeding process; the feed hopper was designed as a cone shape, wider at the top and narrower at the bottom, to allow the material to slide down smoothly; the feed pipe used a smooth inner wall material to reduce the friction between the material and the pipe wall; the dimensions of the feed hopper and feed pipe were determined to ensure that the material throughput capacity meets the boiler production requirements;

[0089] Application of material distribution control technology: Install guide plates or rotating distributors at the feed inlet. After installation, conduct material distribution tests and use image recognition technology or sampling analysis methods to evaluate the uniformity of material distribution in the furnace.

[0090] The guide plate can be adjusted according to the flow direction of the material to ensure that the material is evenly distributed in the furnace; the rotary distributor disperses the material to different positions through rotation, reducing the collision and accumulation between materials. In addition, anti-clogging devices such as vibrators, crushers or agitators are added to the feed inlet to prevent the material from clogging during the feeding process and ensure the stable operation of the boiler.

[0091] Among them, the improved sealing performance of the feed inlet and the precise control of the feed flow rate in step three are respectively:

[0092] Improved inlet sealing performance

[0093] Improved sealing structure: The sealing structure of the feed inlet has been improved by adopting a double-layer sealing design. The inner layer uses a flexible rubber sealing ring to adapt to the friction and extrusion of materials; the outer layer uses a rigid metal sealing plate to enhance sealing reliability. A sealing pressure regulating device is set in the sealing structure to automatically adjust the sealing pressure according to the working pressure of the feed inlet to ensure sealing effect.

[0094] Sealing technology selection: Pneumatic sealing technology is selected, which uses a pneumatic device to apply pressure to the sealing component to make it fit tightly against the feed port. At the same time, the surface is treated before the sealing material is installed to ensure that the sealing surface is flat and smooth.

[0095] Precise control of feed flow rate

[0096] Feed control valve and technology application: An electric regulating feed control valve is adopted, which is controlled by a PLC control system. The feed flow rate is adjusted in real time according to the boiler's operating parameters. At the same time, flow feedback control technology is introduced, which feeds back the actual flow signal detected by the flow sensor to the PLC. The PLC compares the feedback signal with the set flow rate and automatically adjusts the opening of the electric regulating valve to achieve precise control of the feed flow rate.

[0097] Real-time monitoring and maintenance: Flow sensors and pressure sensors are installed on the feed pipeline to monitor the feed flow and pressure parameters in real time. The parameters are then transmitted to the central control room, and operators can monitor the operation of the feed inlet in real time through the monitoring screen.

[0098] The inner seal can use high-performance sealing materials, such as PTFE gaskets, which have advantages such as corrosion resistance, wear resistance, and good sealing performance; the electric regulating feed control valve has advantages such as fast response speed and high control accuracy, enabling more precise control of the feed; at the same time, the feed control valve is regularly maintained and serviced every quarter, checking the valve's sealing performance and the flexibility of the actuator, to ensure that the valve can operate stably for a long time.

[0099] The evaluation of the feed inlet modification indicators in step three includes:

[0100] Operational data recording and analysis: After the feed inlet modification is completed, record the operational data before and after the modification, including key parameters such as flow rate, pressure, and temperature. Use a data acquisition system to collect and store the data in real time, establish a database, and analyze the data in the database regularly every month to draw parameter change curves and compare the differences in data before and after the modification.

[0101] Performance improvement evaluation: The performance improvement of the feed inlet is evaluated by comparing the operating data before and after the modification.

[0102] When evaluating the performance improvement effect, if the feed flow rate is more stable after the modification and the flow fluctuation range is reduced (e.g., from ±10% to ±5%), it indicates that the feed flow control effect has been improved; if the leakage at the feed port is significantly reduced and the material leakage rate is reduced (e.g., from 5% to below 1%), it indicates that the sealing performance has been improved.

[0103] Specifically, the system integration and debugging in step four includes:

[0104] System Integration

[0105] Hardware connection: Connect the optimized pulse dust collector and feed inlet to the SZS steam boiler: connect the air inlet pipe of the pulse dust collector to the exhaust pipe of the boiler, and connect the discharge pipe of the feed inlet to the feed inlet of the boiler; connect the control cable of the pulse dust collector and the control cable of the feed inlet to the PLC system in the central control room.

[0106] Software integration: The control programs for the pulse dust collector and the feed inlet are integrated into the PLC system in the central control room. The software modules of the automatic control system of the pulse dust collector and the flow control system of the feed inlet are integrated with the main control system of the boiler to achieve coordinated control between the various devices.

[0107] System debugging

[0108] Individual unit commissioning: Perform individual unit commissioning on the pulse dust collector and the feed inlet separately. During the individual unit commissioning of the pulse dust collector, start the pulse jet cleaning device and check whether the electromagnetic pulse valve's jet action is normal and whether the jet pressure is stable; check whether all functions of the dust removal control system are implemented; during the individual unit commissioning of the feed inlet, start the feed control valve and check whether the feed flow rate can be adjusted according to the set value; check whether the sealing performance of the feed inlet is good and whether there is any leakage.

[0109] Linkage debugging: After the individual unit is debugged normally, linkage debugging of the pulse dust collector, feed inlet and boiler is carried out to simulate different operating conditions of the boiler, observe the coordinated operation between the equipment, and adjust and optimize in a timely manner for any problems that occur during linkage debugging to ensure the stability and reliability of the system after integration.

[0110] During hardware connection, it is necessary to ensure that the pipes and cables between the devices are correctly and securely connected, without leaks or short circuits. After software integration, when the boiler load changes, the PLC system can automatically adjust the cleaning parameters of the pulse dust collector and the feed flow rate at the inlet to ensure stable boiler operation. During linkage commissioning, during boiler startup, check whether the feed inlet can feed according to the predetermined startup procedure and whether the pulse dust collector can start dust removal in time after the boiler exhausts. During boiler shutdown, check whether each device can safely shut down according to the shutdown procedure.

[0111] The verification and continuous optimization of the transformation results in step five are carried out in the following way:

[0112] Verification of transformation results

[0113] Capacity improvement verification: Compare the steam output of the SZS steam boiler before and after the renovation. Under the same fuel consumption and operating time conditions, calculate the total steam output within one month before and after the renovation.

[0114] Verification of pollutant emission reduction: Using emission detection equipment, pollutants such as dust, sulfur dioxide, and nitrogen oxides in the flue gas of the modified boiler are sampled and tested, and the data are compared with the data before the modification.

[0115] Combustion efficiency and energy consumption optimization verification: The combustion efficiency of the boiler before and after the modification was tested using a thermal efficiency tester. At the same time, the fuel consumption was statistically analyzed over a month before and after the modification.

[0116] Continuous optimization

[0117] Establish a feedback mechanism: Establish user feedback channels to encourage operators and managers to promptly report problems and improvement suggestions that occur during boiler operation, set up a dedicated feedback email address and hotline, and collect feedback information regularly;

[0118] Regular maintenance and upgrades: Develop a regular maintenance plan to regularly inspect, maintain and service the pulse dust collector, feed inlet and boiler. Upgrade and modify the equipment in a timely manner according to technological development and actual operation needs to continuously improve the performance and reliability of the boiler.

[0119] During capacity enhancement verification, if the steam output increases significantly after the modification (e.g., by more than 10%), it indicates that the boiler capacity has been improved. During pollutant emission reduction verification, if the pollutant emission concentration decreases significantly (e.g., dust emission concentration decreases from the original 50 mg / m³), it indicates that the boiler capacity has been improved. 3 Reduced to 20 mg / m 3The following indicates that pollutant emissions are under control; when verifying the optimization of combustion efficiency and energy consumption, if the combustion efficiency is improved after the modification (e.g., from the original 85% to over 90%) and the fuel consumption is reduced (e.g., fuel consumption is reduced by more than 5% under the same steam output), it indicates that the combustion efficiency and energy consumption have been optimized.

[0120] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0121] 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 alterations 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 integrated method for optimizing the capacity and controlling the emission control system of an SZS steam boiler, characterized in that, The specific steps are as follows: Step 1: Record the current operating status of the boiler Detailed recording of operating parameters: Arrange professional personnel to conduct continuous operation monitoring of the SZS series steam boiler for one month, record key parameters such as steam output, pressure, temperature and fuel consumption of the boiler under different loads (low load, medium load and high load), record the pressure value of the boiler steam outlet at regular intervals every day, accurate to two decimal places, draw a curve of pressure change over time, and analyze the pressure fluctuation. Analyze the failure history: Collect the boiler's failure records for the past year, including the time of failure, failure type, failure handling method and handling time. By analyzing the failure history, identify the weak links in the boiler operation and provide a basis for subsequent modifications. Step Two: Pulse Jet Dust Collector Retrofit Replacement and installation optimization of filter bags for pulse dust collectors, modification and upgrading of dust removal systems, and monitoring and optimization of technical indicators for pulse dust collector modification. Step 3: Modification of the feed inlet Optimize the feed inlet structure, improve the feed inlet sealing performance, accurately control the feed flow rate, and evaluate the feed inlet modification indicators; Step 4: System Integration and Debugging The optimized pulse dust collector and feed inlet are connected to the SZS steam boiler to complete system integration. After system integration, system debugging is performed to ensure stable operation. Step 5: Verification and Continuous Optimization of Transformation Results The modified boiler will be validated, and a feedback mechanism will be established for maintenance and optimization.

2. The integrated method for SZS steam boiler capacity optimization and emission control system according to claim 1, characterized in that: Step two, specifically the filter bag replacement and installation optimization, includes: Filter bag wear and clogging assessment: Turn on the pulse dust collector and conduct a comprehensive inspection of the existing filter bags. Use testing tools to measure the wear and clogging of the filter bags. Based on the filter bag material, usage time, and actual test results, formulate a replacement plan. Filter bags with severe wear or clogging exceeding 50% should be included in the replacement list. Sealing treatment: During the replacement of filter bags, high-quality sealing materials and silicone sealing strips are selected to ensure the seal between the filter bags and the dust collector wall. During installation, the operating procedures are followed and sealing tools are used to press the sealing strips tightly to prevent leakage. After installation, a sealing test is performed by using a smoke generator to generate smoke inside the dust collector and observing whether there is any smoke leakage from the connection between the filter bags and the dust collector wall. Mechanized installation: Introducing mechanized filter bag installation equipment, such as automatic filter bag installers, allows operators to set relevant parameters on the control panel, and the equipment can automatically complete the filter bag installation. During the installation process, built-in sensors monitor the filter bag installation position and force in real time to ensure that the filter bag is installed in place.

3. The integrated method for SZS steam boiler capacity optimization and emission control system according to claim 1, characterized in that: The dust removal system modification and upgrade described in step two includes: Pulse jet cleaning device modification: Remove the original pulse jet cleaning device and install a jet cleaning device using electromagnetic pulse valve technology. After installation, conduct a jet cleaning pressure test, use a pressure sensor to measure the jet cleaning pressure, and ensure that the jet cleaning pressure is within the specified range (0.3-0.5MPa). Upgraded dust removal control system: An automated control system is introduced, which consists of a PLC, sensors, and actuators. The sensors monitor the pressure difference and temperature parameters of the dust collector in real time and transmit the data to the PLC. The PLC monitors and adjusts the dust removal process in real time according to the preset program. When the pressure difference of the dust collector reaches the set value, the PLC automatically issues a command to control the electromagnetic pulse valve to perform jet cleaning.

4. The integrated method for SZS steam boiler capacity optimization and emission control system according to claim 1, characterized in that: Step two, which involves monitoring and optimizing the technical indicators for pulse dust collector retrofitting, includes: Filtration effect monitoring: Install dust concentration detectors at the inlet and outlet of the dust collector to monitor the dust concentration at the inlet and outlet in real time. Calculate the dust removal efficiency based on the monitoring data (dust removal efficiency = (inlet dust concentration - outlet dust concentration) / inlet dust concentration × 100%). Perform statistical analysis on the dust removal efficiency weekly to ensure that the dust removal efficiency meets the design requirements. When the dust removal efficiency decreases, check the filter bags for damage or blockage in a timely manner and adjust the cleaning parameters accordingly. Dust removal effect evaluation: The dust collector is shut down for inspection every month to observe the dust accumulation on the surface of the filter bags. At the same time, the pressure changes during the operation of the dust collector are monitored and pressure-time curves are plotted. Energy consumption monitoring and optimization: Install power monitoring instruments on the power supply line of the dust collector to monitor the energy consumption of the dust collector in real time. Based on the energy consumption under different operating conditions (low load, medium load, and high load operation of the boiler), formulate operation strategies according to the energy consumption change patterns.

5. The integrated method for SZS steam boiler capacity optimization and emission control system according to claim 1, characterized in that: The specific details of the feed inlet structure optimization mentioned in step three are as follows: Feed hopper and feed pipe design: Based on the material characteristics and boiler feeding requirements, the feed hopper and feed pipe were redesigned, adopting a streamlined design to reduce material resistance during the feeding process; the feed hopper was designed as a cone shape, wider at the top and narrower at the bottom, to allow the material to slide down smoothly; the feed pipe used a smooth inner wall material to reduce the friction between the material and the pipe wall; the dimensions of the feed hopper and feed pipe were determined to ensure that the material throughput capacity meets the boiler production requirements; Application of material distribution control technology: Install guide plates or rotating distributors at the feed inlet. After installation, conduct material distribution tests and use image recognition technology or sampling analysis methods to evaluate the uniformity of material distribution in the furnace.

6. The integrated method for SZS steam boiler capacity optimization and emission control system according to claim 1, characterized in that: The improved inlet sealing performance and precise control of feed flow rate mentioned in step three are as follows: Improved inlet sealing performance Improved sealing structure: The sealing structure of the feed inlet has been improved by adopting a double-layer sealing design. The inner layer uses a flexible rubber sealing ring to adapt to the friction and extrusion of materials; the outer layer uses a rigid metal sealing plate to enhance sealing reliability. A sealing pressure regulating device is set in the sealing structure to automatically adjust the sealing pressure according to the working pressure of the feed inlet to ensure sealing effect. Sealing technology selection: Pneumatic sealing technology is selected, which uses a pneumatic device to apply pressure to the sealing component to make it fit tightly against the feed port. At the same time, the surface is treated before the sealing material is installed to ensure that the sealing surface is flat and smooth. Precise control of feed flow rate Feed control valve and technology application: An electric regulating feed control valve is adopted, which is controlled by a PLC control system. The feed flow rate is adjusted in real time according to the boiler's operating parameters. At the same time, flow feedback control technology is introduced, which feeds back the actual flow signal detected by the flow sensor to the PLC. The PLC compares the feedback signal with the set flow rate and automatically adjusts the opening of the electric regulating valve to achieve precise control of the feed flow rate. Real-time monitoring and maintenance: Flow sensors and pressure sensors are installed on the feed pipeline to monitor the feed flow and pressure parameters in real time. The parameters are then transmitted to the central control room, and operators can monitor the operation of the feed inlet in real time through the monitoring screen.

7. The integrated method for SZS steam boiler capacity optimization and emission control system according to claim 1, characterized in that: The evaluation of the feed inlet modification indicators mentioned in step three includes: Operational data recording and analysis: After the feed inlet modification is completed, record the operational data before and after the modification, including key parameters such as flow rate, pressure, and temperature. Use a data acquisition system to collect and store the data in real time, establish a database, and analyze the data in the database regularly every month to draw parameter change curves and compare the differences in data before and after the modification. Performance improvement evaluation: The performance improvement of the feed inlet is evaluated by comparing the operating data before and after the modification.

8. The integrated method for SZS steam boiler capacity optimization and emission control system according to claim 1, characterized in that: The system integration and debugging described in step four specifically include: System Integration Hardware connection: Connect the optimized pulse dust collector and feed inlet to the SZS steam boiler: connect the air inlet pipe of the pulse dust collector to the exhaust pipe of the boiler, and connect the discharge pipe of the feed inlet to the feed inlet of the boiler; connect the control cable of the pulse dust collector and the control cable of the feed inlet to the PLC system in the central control room. Software integration: The control programs for the pulse dust collector and the feed inlet are integrated into the PLC system in the central control room. The software modules of the automatic control system of the pulse dust collector and the flow control system of the feed inlet are integrated with the main control system of the boiler to achieve coordinated control between the various devices. System debugging Individual unit commissioning: Perform individual unit commissioning on the pulse dust collector and the feed inlet separately. During the individual unit commissioning of the pulse dust collector, start the pulse jet cleaning device and check whether the electromagnetic pulse valve's jet action is normal and whether the jet pressure is stable; check whether all functions of the dust removal control system are implemented; during the individual unit commissioning of the feed inlet, start the feed control valve and check whether the feed flow rate can be adjusted according to the set value; check whether the sealing performance of the feed inlet is good and whether there is any leakage. Linkage debugging: After the individual unit is debugged normally, linkage debugging of the pulse dust collector, feed inlet and boiler is carried out to simulate different operating conditions of the boiler, observe the coordinated operation between the equipment, and adjust and optimize in a timely manner for any problems that occur during linkage debugging to ensure the stability and reliability of the system after integration.

9. The integrated method for SZS steam boiler capacity optimization and emission control system according to claim 1, characterized in that: The method for verifying and continuously optimizing the transformation results described in step five is as follows: Verification of transformation results Capacity improvement verification: Compare the steam output of the SZS steam boiler before and after the renovation. Under the same fuel consumption and operating time conditions, calculate the total steam output within one month before and after the renovation. Verification of pollutant emission reduction: Using emission detection equipment, pollutants such as dust, sulfur dioxide, and nitrogen oxides in the flue gas of the modified boiler are sampled and tested, and the data are compared with the data before the modification. Combustion efficiency and energy consumption optimization verification: The combustion efficiency of the boiler before and after the modification was tested using a thermal efficiency tester. At the same time, the fuel consumption was statistically analyzed over a month before and after the modification. Continuous optimization Establish a feedback mechanism: Establish user feedback channels to encourage operators and managers to promptly report problems and improvement suggestions that occur during boiler operation, set up a dedicated feedback email address and hotline, and collect feedback information regularly; Regular maintenance and upgrades: Develop a regular maintenance plan to regularly inspect, maintain and service the pulse dust collector, feed inlet and boiler. Upgrade and modify the equipment in a timely manner according to technological development and actual operation needs to continuously improve the performance and reliability of the boiler.

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