Cooling and purifying system for industrial waste gas emission
By integrating cooling and purification into an industrial waste gas treatment system, multi-stage composite heat exchange and intelligent control are adopted, which solves the problems of low efficiency, high energy consumption and insufficient monitoring caused by equipment separation in the existing technology, and achieves efficient, stable and low-cost waste gas treatment.
Patent Information
- Application Number
- CN202511863729.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-11
- Publication Date
- 2026-01-23
AI Technical Summary
In existing industrial waste gas treatment systems, the separation of cooling and purification equipment leads to low efficiency, high energy consumption, unrecovered waste heat, large equipment footprint, easy leakage of connecting pipes, lack of real-time monitoring and control, and difficulty in ensuring that emissions meet standards.
Design an integrated cooling and purification system that adopts a multi-stage composite heat exchange structure and modular design, combined with an intelligent control system and adsorbent regeneration module, to achieve efficient cooling, waste heat recovery and real-time monitoring. The system reduces the risk of leakage through sealed pipeline connections and is adaptable to different waste gas characteristics.
It improves waste gas treatment efficiency, reduces energy consumption, reduces land occupation, reduces maintenance difficulty, ensures emission compliance, has strong adaptability, high operational stability, and reduces operating costs.
Smart Images
Figure CN121371901A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of industrial waste gas treatment, in particular to an industrial waste gas emission cooling and purification system. BACKGROUND
[0002] A large amount of waste gas with high temperature and high pollutant concentration is generated in industrial production process, which usually contains harmful gases such as VOCs, sulfides and nitrogen oxides, as well as a large amount of dust particles. If directly discharged, it will seriously pollute the atmospheric environment and endanger human health, so it must be cooled and purified before being discharged. At present, the cooling and purification treatment of industrial waste gas is mostly combined with separate equipment, that is, the high-temperature waste gas is first cooled by an independent cooling device, and then transported to a separate purification equipment for pollutant removal. This separate treatment mode has low treatment efficiency, and the cooling device and the purification equipment need to be connected by a long distance pipeline. During the transportation process, the temperature of the waste gas may rise, and the pollutants may diffuse, which may lead to the risk of reduced treatment effect of the subsequent purification unit, and the energy consumption is also serious. The existing cooling device mostly uses single heat exchange mode, and the water consumption of the water-cooled heat exchanger is large, and the operation cost is high. The cooling effect of the air-cooled tower is limited, and it is difficult to stably reduce the high-temperature waste gas to the appropriate temperature required by the purification unit. Moreover, a large amount of waste heat generated during the cooling process is not effectively recovered, which is directly discharged, causing energy waste. The entire equipment occupies a large area, and the installation and debugging are complex. The connecting pipeline between the devices is prone to waste gas leakage. Moreover, there is no unified monitoring and control system, which cannot real-time monitor the waste gas parameters in the treatment process, and it is difficult to ensure that the emission meets the standards, and the subsequent maintenance is difficult.
[0003] Therefore, the present application provides an industrial waste gas treatment system which integrates cooling and purification, is high-efficiency and low-energy-consumption, has wide adaptability and high integration, and becomes the key requirement to solve the current industrial waste gas emission treatment problem. SUMMARY
[0004] In view of the deficiencies of the prior art, the present application provides an industrial waste gas emission cooling and purification system for constructing a cooling and purification integrated linkage structure, eliminating the efficiency loss caused by equipment separation, improving the overall efficiency of industrial waste gas treatment, optimizing the heat exchange structure design, realizing rapid and stable cooling of high-temperature waste gas, recovering waste heat, reducing system energy consumption, designing an intelligent control system, adapting to the temperature, flow and pollutant composition changes of waste gas in different industries, improving system adaptability and operation stability, integrating adsorbent regeneration, online monitoring and other functions, reducing operation cost, ensuring emission standards, and simplifying maintenance process.
[0005] To achieve the above purpose, the present application is realized by the following technical scheme: An industrial waste gas emission cooling and purification system comprises an air inlet module, a heat exchange module, a purification unit, an air outlet module, a control system, a waste heat recovery module, an adsorbent regeneration module and an online monitoring module, each module is sequentially and sealingly connected through pipelines to form a closed loop treatment channel, each module is designed in a modular manner and is connected through sealing flanges and pipelines, so that installation and maintenance are facilitated, the heat exchange module is used for cooling high-temperature industrial waste gas to a preset purification temperature range, the purification unit is used for removing dust particles and harmful gases in the waste gas in layers, and the control system dynamically adjusts operation parameters of each module according to real-time monitoring data; The air inlet module comprises a waste gas buffer tank and a flow regulating valve, the waste gas buffer tank is internally provided with a buffer layer and a flow guide plate, the heat exchange module is a multistage composite heat exchange structure and comprises a primary water-cooled heat exchanger, a secondary air-cooled heat exchanger and a temperature equalization cavity which are sequentially and sealingly connected, the purification unit comprises a pretreatment cavity, an adsorption cavity and a catalytic oxidation cavity which are sequentially arranged along the flow direction of the waste gas, the adsorbent regeneration module comprises a hot air generator, a regeneration pipeline and a waste gas recovery pipeline, the control system comprises a PLC controller, temperature sensors, pollutant concentration sensors, flow sensors, pressure sensors and an actuator, each sensor is electrically connected to the PLC controller, the air outlet module is provided with an emergency discharge channel, the emergency discharge channel is connected in parallel to the air outlet pipeline and is provided with an emergency valve, and the online monitoring module comprises a gas analyzer, a data acquisition device and a remote transmission module. Through the above technical scheme, one end of the air inlet pipeline is connected to an industrial waste gas emission source, and the other end is sealingly connected to the inlet of the waste gas buffer tank; the outlet of the waste gas buffer tank is connected to the inlet of the heat exchange module through a pipeline, and a flow regulating valve is arranged on the pipeline; the waste gas buffer tank is internally provided with a flow guide plate and a buffer layer, the buffer layer is made of high-temperature-resistant ceramic material and is used for reducing the flow speed of the waste gas to avoid damage to subsequent modules caused by airflow impact, and the flow regulating valve is electrically connected to the control system and is used for dynamically adjusting the inlet flow of the waste gas according to the processing capacity of the subsequent modules.
[0006] Further, the primary water-cooled heat exchanger of the heat exchange module is provided with a waste heat recovery channel for recovering waste heat, the secondary air-cooled heat exchanger is provided with a variable frequency fan and heat dissipation fins, the temperature equalization cavity is internally provided with a temperature sensor, the temperature sensor is electrically connected to the control system, the primary water-cooled heat exchanger and the secondary air-cooled heat exchanger both adopt a tube-in-shell structure, the internal heat exchange tube group is designed in a spiral manner, the cooling liquid of the primary water-cooled heat exchanger is deionized water which is driven to circulate by a circulating pump, and the waste heat recovery channel is connected to an industrial heat device or a heating system; Through the technical scheme, the heat exchange module is a multi-stage composite heat exchange structure, comprising a primary water-cooled heat exchanger, a secondary air-cooled heat exchanger and a temperature equalization cavity which are sequentially and sealingly connected, adopts a shell-and-tube structure and the internal heat exchange tube group is designed in a spiral shape to increase the heat exchange area and heat exchange time, and through the synergistic effect of the primary water-cooled heat exchanger and the secondary air-cooled heat exchanger, the high-temperature industrial waste gas with an initial temperature of 500-1000℃ can be rapidly cooled to a suitable purification temperature range of 80-120℃, and the cooling efficiency is more than 80%.
[0007] Further, the pre-treatment cavity of the purification unit is provided with a two-stage filtering structure including a metal filter screen and a ceramic filter layer, the adsorption cavity is provided with at least two parallel adsorption units filled with activated carbon molecular sieve composite adsorbents, the catalytic oxidation cavity is provided with a catalytic reaction layer and an electric heating device, the inlet and outlet of the adsorption unit are provided with electromagnetic valves which are electrically connected with the control system, and the catalytic reaction layer is a platinum-rhodium noble metal catalyst and the electric heating device is used to maintain the temperature of the catalytic reaction layer at 200-250℃. Through the technical scheme, the purification unit adopts a layered treatment structure, sequentially including a pre-treatment cavity, an adsorption cavity and a catalytic oxidation cavity along the flow direction of the waste gas, and the cavities are connected through sealing flanges, facilitating disassembly and maintenance, the pre-treatment cavity is internally provided with a two-stage filtering structure, the first stage is a metal filter screen with a pore size of 80-100μm and the second stage is a ceramic filter layer with a pore size of 30-50μm, used to remove fine particles with a particle size of 10-100μm, the adsorption cavity is internally provided with at least two parallel adsorption units each filled with activated carbon molecular sieve composite adsorbents, the composite adsorbents take activated carbon as a carrier and load molecular sieve particles, wherein the mass ratio of activated carbon is 60%-70% and the mass ratio of molecular sieve is 30%-40%, have a high specific surface area and selective adsorption capacity, and can efficiently adsorb VOCs and harmful gases such as sulfides in the waste gas, the catalytic oxidation cavity includes a third shell, a catalytic reaction layer and an electric heating device, the third shell is made of high-temperature-resistant ceramic material, the catalytic reaction layer is a platinum-rhodium noble metal catalyst used to catalytically decompose the refractory VOCs and part of the harmful gases which are not completely removed by the adsorption unit, and the electric heating device is arranged on both sides of the catalytic reaction layer and electrically connected with the control system, used to maintain the temperature of the catalytic reaction layer at 200-250℃ to ensure the catalytic reaction efficiency.
[0008] Further, the regeneration pipeline of the outlet gas module is connected with the adsorption unit of the adsorption cavity, and the waste gas recovery pipeline is connected with the waste gas buffer tank of the inlet gas module, used to recover the desorbed harmful gases in the regeneration process. By the technical scheme, one end of the gas outlet pipeline is sealingly connected with the outlet of the catalytic oxidation cavity, the other end is provided with a standard emission outlet, an emergency emission channel is connected in parallel on the gas outlet pipeline, and an emergency valve is arranged, the emergency valve is electrically connected with the control system, when the online monitoring module detects that the waste gas is not up to standard, the control system closes the standard emission outlet and opens the emergency valve, the waste gas not up to standard is returned to the air inlet module through the emergency emission channel for reprocessing, and the waste gas not up to standard is prevented from being emitted.
[0009] Further, the PLC controller of the control system adjusts the running states of the flow regulating valve, the variable frequency fan, the electromagnetic valve and the electric heating device according to the sensor data. By the technical scheme, the temperature sensors are arranged in the inlet of the primary water-cooled heat exchanger, the outlet of the secondary air-cooled heat exchanger, the temperature equalization cavity and the catalytic oxidation cavity, the pollutant concentration sensors are arranged in the inlet of the adsorption cavity, the outlet of the catalytic oxidation cavity and the standard emission outlet, the flow sensors are arranged on the air inlet pipeline and the gas outlet pipeline, and the pressure sensors are arranged in the heat exchangers and the purification units; the signal output ends of the sensors are electrically connected with the signal input ends of the PLC controller, and the PLC controller is provided with a control program, which can dynamically adjust the running parameters according to the real-time data collected by the sensors.
[0010] Further, the emergency valve of the gas outlet module is electrically connected with the control system, and when it is monitored that the waste gas is not up to standard, the emergency valve is opened to return the waste gas not up to standard to the air inlet module for reprocessing. By the technical scheme, the outlet of the hot air generator is connected with the adsorption unit of the adsorption cavity through a regeneration pipeline, the regeneration pipeline is provided with a regeneration valve, one end of the waste gas recovery pipeline is connected with the adsorption unit, and the other end is connected with the waste gas buffer tank of the air inlet module; when the adsorption efficiency of an adsorption unit decreases to a set threshold value, the control system closes the inlet and outlet electromagnetic valves of the adsorption unit and opens the regeneration valve, the hot air generator generates hot air at 150-200 DEG C, the hot air is introduced into the adsorption unit to regenerate the saturated adsorbent, the desorbed harmful gas is returned to the waste gas buffer tank through the waste gas recovery pipeline and reenters the treatment system, and after the regeneration is completed, the control system closes the regeneration valve and opens the inlet and outlet electromagnetic valves of the adsorption unit, so that the adsorption unit is reused.
[0011] Further, the gas analyzer of the online monitoring module is arranged at the standard emission outlet and is used for real-time detection of the concentration of waste gas pollutants, and the monitoring data is transmitted to the environmental protection supervision platform and the enterprise monitoring center through the remote transmission module. By the technical scheme, the gas analyzer is arranged at the standard emission outlet and is used for real-time detection of the concentration of harmful gases such as VOCs, sulfides, nitrogen oxides and dust content in the waste gas, and the data collector is electrically connected with the gas analyzer and is used for collecting monitoring data.
[0012] The application provides an industrial waste gas emission cooling and purification system. 1. The application provides an industrial waste gas emission cooling and purification system, compared with the prior art, the cooling module and the purification unit are integrated and designed, are directly connected through a sealed pipeline, the waste gas conveying distance and the leakage risk are reduced, meanwhile, the control system realizes the collaborative operation of the modules, dynamically adjusts parameters according to the waste gas characteristics, avoids the efficiency loss caused by independent operation of the equipment, greatly improves the treatment efficiency through the integrated linkage design, and adopts a water cooling+air cooling multistage composite heat exchange structure, spiral heat exchange pipe groups are matched with heat dissipation fins, so that high-temperature waste gas is quickly cooled to a suitable purification temperature, the waste heat of the primary water cooling heat exchanger is used for industrial production or heating through a recycling channel, energy reuse is realized, and the effects of multistage heat exchange and waste heat recovery make the energy consumption significantly reduced.
[0013] 2. The application provides an industrial waste gas emission cooling and purification system, compared with the prior device, has the advantages of intelligent control+adsorbent regeneration, a PLC control system is combined with multiple sensors for real-time monitoring, can adapt to the temperature, flow and pollutant component changes of waste gas in different industries such as chemical industry, metallurgy and building materials, and an adsorbent regeneration module greatly reduces the replacement cost of consumables, so that the whole system has high running stability, strong adaptability and economy.
[0014] 3. The application provides an industrial waste gas emission cooling and purification system, the whole system adopts a modular design, is connected through sealed flanges and pipelines, has a greatly reduced land occupation area compared with a traditional separate system, and is simple to install and debug; a dust collection groove of a pretreatment cavity, an adsorption unit of an adsorption cavity and the like can be separately detached, the maintenance process does not need to stop the whole system running, and the maintenance difficulty and downtime loss are greatly reduced. BRIEF DESCRIPTION OF DRAWINGS
[0015] Fig. 1 The figure is a system structure framework diagram of the industrial waste gas emission cooling and purification system of the application. Fig. 2 The figure is a system working flowchart of the industrial waste gas emission cooling and purification system of the application. DETAILED DESCRIPTION
[0016] The technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the application.
[0017] Embodiment 1: As Figs. 1-2As shown, the embodiment of the present application provides an industrial waste gas emission cooling and purification system, which comprises an air inlet module, a heat exchange module, a purification unit, an air outlet module, a control system, a waste heat recovery module, an adsorbent regeneration module and an online monitoring module, each module is sequentially and sealingly connected through a pipeline to form a closed loop treatment channel, each module is designed in a modular manner and connected through sealing flanges and pipelines for easy installation and maintenance, the heat exchange module is used to cool the high-temperature industrial waste gas to a preset purification temperature range, the purification unit is used to remove dust particles and harmful gases in the waste gas in layers, and the control system dynamically adjusts the operating parameters of each module according to real-time monitoring data; The air inlet module comprises an air inlet pipeline, a waste gas buffer tank and a flow regulating valve; one end of the air inlet pipeline is connected with an industrial waste gas emission source, the other end is sealingly connected with the inlet of the waste gas buffer tank, the outlet of the waste gas buffer tank is connected with the inlet of the heat exchange module through a pipeline, and the pipeline is provided with a flow regulating valve, and the inside of the waste gas buffer tank is provided with a flow guide plate and a buffer layer, the buffer layer is made of high-temperature resistant ceramic material and is used to reduce the flow speed of the waste gas to avoid damage to the subsequent modules caused by airflow impact, and the flow regulating valve is electrically connected with the control system and is used to dynamically adjust the inlet flow of the waste gas according to the processing capacity of the subsequent modules; The heat exchange module is a multi-stage composite heat exchange structure, which comprises a primary water-cooled heat exchanger, a secondary air-cooled heat exchanger and a temperature equalization cavity which are sequentially and sealingly connected, the primary water-cooled heat exchanger and the secondary air-cooled heat exchanger both adopt a shell-and-tube structure, and the internal heat exchange pipe group is designed in a spiral shape to increase the heat exchange area and time; The primary water-cooled heat exchanger comprises a first shell, a spiral heat exchange pipe group, a cooling liquid inlet, a cooling liquid outlet and a waste heat recovery channel, the first shell is made of high-temperature resistant stainless steel and is provided with a heat insulation layer on the inner wall, the spiral heat exchange pipe group penetrates through the inside of the first shell and is in communication with the air inlet pipeline and the secondary air-cooled heat exchanger at both ends, the cooling liquid inlet is arranged at the bottom of the first shell, the cooling liquid outlet is arranged at the top of the first shell, the cooling liquid is deionized water which is driven to flow outside the spiral heat exchange pipe group by a circulating pump to exchange heat with the waste gas in the pipe, and the waste heat recovery channel is connected with the cooling liquid outlet at one end and with an industrial production heat device or a heating system at the other end for recovering the waste heat of the waste gas absorbed by the cooling liquid; The secondary air-cooled heat exchanger comprises a second shell, a spiral heat exchange pipe group, a variable frequency fan and heat dissipation fins, the second shell is provided with an air inlet on one side and an air outlet on the other side, the variable frequency fan is installed at the air inlet, and the spiral heat exchange pipe group is externally fixed with heat dissipation fins made of aluminum alloy and distributed in a honeycomb shape to enhance the heat dissipation effect; the variable frequency fan is electrically connected with the control system and adjusts the air speed according to the waste gas cooling requirement; The temperature equalization chamber is located between the outlet of the secondary air-cooled heat exchanger and the inlet of the purification unit. It is equipped with a temperature sensor and a baffle plate. The temperature sensor is electrically connected to the control system to monitor the temperature of the exhaust gas after cooling in real time and feed the data back to the control system. The baffle plate is used to distribute the exhaust gas evenly and ensure that the temperature of the exhaust gas entering the purification unit is consistent. Through the synergistic effect of the primary water-cooled heat exchanger and the secondary air-cooled heat exchanger, high-temperature industrial waste gas with an initial temperature of 500-1000℃ can be rapidly cooled to a suitable purification temperature range of 80-120℃, with a cooling efficiency of over 80%.
[0018] Example 2: like Figs. 1-2 As shown, this embodiment of the invention provides an industrial waste gas emission cooling and purification system. The purification unit adopts a layered treatment structure, which includes a pretreatment chamber, an adsorption chamber and a catalytic oxidation chamber in sequence along the waste gas flow direction. The chambers are connected by sealing flanges, which facilitates disassembly and maintenance. The pretreatment chamber is equipped with a two-stage filtration structure. The first stage is a metal filter screen with a pore size of 80-100μm, which is used to remove large dust particles with a particle size greater than 100μm from the exhaust gas. The second stage is a ceramic filter layer with a pore size of 30-50μm, which is used to remove fine dust particles with a particle size of 10-100μm. A dust collection tank is provided at the bottom of the pretreatment chamber. The dust collection tank is removable for easy cleaning of the collected dust. The adsorption chamber contains at least two parallel adsorption units. Each adsorption unit is filled with an activated carbon-molecular sieve composite adsorbent. The composite adsorbent uses activated carbon as a carrier and loads molecular sieve particles. The activated carbon accounts for 60%-70% of the mass, and the molecular sieve accounts for 30%-40% of the mass. It has a high specific surface area and selective adsorption capacity, and can efficiently adsorb harmful gases such as VOCs and sulfides in waste gas. The top of the adsorption chamber is equipped with an adsorbent filling port, and the bottom is equipped with an adsorbent discharge port to facilitate the replenishment and replacement of the adsorbent. Each adsorption unit is equipped with a solenoid valve at the inlet and outlet. The solenoid valve is electrically connected to the control system to realize the switching operation of the adsorption unit. The catalytic oxidation chamber includes a third shell, a catalytic reaction layer, and an electric heating device. The third shell is made of high-temperature resistant ceramic material and contains a catalytic reaction layer. The catalytic reaction layer is a platinum-rhodium precious metal catalyst with a platinum content of 0.1%–0.3% and a rhodium content of 0.05%–0.1%. It is used to catalytically decompose the recalcitrant VOCs and some harmful gases that were not completely removed by the adsorption unit. The electric heating device is located on both sides of the catalytic reaction layer and is electrically connected to the control system. It is used to maintain the temperature of the catalytic reaction layer at 200–250°C to ensure the catalytic reaction efficiency. The outlet of the catalytic oxidation chamber is equipped with a pollutant concentration sensor, which is electrically connected to the control system and is used to monitor the pollutant content of the purified exhaust gas in real time. The air outlet module comprises an air outlet pipeline, a standard emission port and an emergency emission channel, the emergency emission channel is connected in parallel to the air outlet pipeline, and an emergency valve is arranged on the emergency emission channel, the emergency valve is electrically connected with the control system, when the online monitoring module detects that the waste gas is not up to standard, the control system closes the standard emission port and opens the emergency valve, so that the waste gas not up to standard is returned to the air inlet module through the emergency emission channel for reprocessing, thereby avoiding emission of waste gas not up to standard.
[0019] Embodiment 3 As shown in Figs. 1-2 The control system comprises a PLC controller, temperature sensors, pollutant concentration sensors, flow sensors, pressure sensors and actuators, the temperature sensors are arranged in the inlet of the primary water-cooled heat exchanger, the outlet of the secondary air-cooled heat exchanger, the temperature equalization cavity and the catalytic oxidation cavity respectively, the pollutant concentration sensors are arranged in the inlet of the adsorption cavity, the outlet of the catalytic oxidation cavity and the standard emission port respectively, the flow sensors are arranged on the air inlet pipeline and the air outlet pipeline, and the pressure sensors are arranged in the heat exchangers and the purification units respectively, the signal output ends of the sensors are electrically connected with the signal input ends of the PLC controller, and the signal output ends of the PLC controller are electrically connected with the flow regulating valves, the frequency conversion fans, the electromagnetic valves, the electric heating devices, the emergency valves and other actuators. The PLC controller has a built-in control program, which can dynamically adjust the following operating parameters according to the real-time data collected by the sensors. 1. The opening degree of the flow regulating valve is adjusted to control the waste gas inlet flow, so as to ensure the stability of the system processing load. 2. The rotating speed of the cooling liquid circulating pump of the primary water-cooled heat exchanger and the wind speed of the frequency conversion fan of the secondary air-cooled heat exchanger are adjusted to control the waste gas cooling speed and the final temperature, which is maintained at 80-120℃. 3. The working state of the adsorption unit is switched according to the pollutant concentration data at the outlet of the catalytic oxidation cavity, so as to ensure the adsorption efficiency. 4. The power of the electric heating device is adjusted to maintain the temperature of the catalytic reaction layer at 200-250℃. 5. When the pressure sensor detects that the pressure in a certain module exceeds the set threshold value, an alarm signal is sent, and the related actuators are automatically adjusted to avoid damage to the equipment. Embodiment 4 As shown in Figs. 1-2As shown, the embodiment of the present application provides an industrial waste gas emission cooling and purification system, the adsorbent regeneration module includes a hot air generator, a regeneration pipeline and a waste gas recovery pipeline, the outlet of the hot air generator is connected with the adsorption unit of the adsorption cavity through the regeneration pipeline, a regeneration valve is arranged on the regeneration pipeline, one end of the waste gas recovery pipeline is connected with the adsorption unit, and the other end is connected with the waste gas buffer tank of the gas inlet module, when the adsorption efficiency of a certain adsorption unit decreases to a set threshold, the control system closes the inlet and outlet electromagnetic valves of the adsorption unit, opens the regeneration valve, the hot air generator generates hot air at 150-200°C, and the hot air is introduced into the adsorption unit to purge and regenerate the saturated adsorbent, the desorbed harmful gas in the regeneration process is returned to the waste gas buffer tank through the waste gas recovery pipeline and reenters the treatment system, after the regeneration is completed, the control system closes the regeneration valve and opens the inlet and outlet electromagnetic valves of the adsorption unit, so that the adsorption unit is put into use again, the online monitoring module includes a gas analyzer, a data collector and a remote transmission module, the gas analyzer is arranged at the standard emission outlet and is used for detecting the concentration of harmful gases such as VOCs, sulfides and nitrogen oxides and the dust content in the waste gas in real time, the data collector is electrically connected with the gas analyzer and is used for collecting monitoring data, the remote transmission module is electrically connected with the data collector and can transmit the monitoring data to the environmental protection supervision platform and the enterprise monitoring center in real time, so as to realize real-time monitoring and tracing of emission data.
[0020] Working principle: The whole process of the industrial waste gas emission cooling and purification system is operated by the control system in cooperation with each module, so as to ensure the treatment efficiency, pollutant removal effect and operation stability, and the specific steps are as follows: Step 1: Waste gas introduction and pretreatment The high-temperature waste gas generated by industrial production is connected to the system through the gas inlet pipeline, and first enters the waste gas buffer tank. The buffer layer and the flow guide plate made of high-temperature resistant ceramic material in the tank reduce the flow rate of the waste gas, avoid the high-speed airflow from impacting the subsequent heat exchange pipe group and the filter material, and at the same time make the waste gas uniformly distributed, reduce the treatment dead angle caused by local airflow concentration, and the flow sensor at the outlet of the gas inlet pipeline and the waste gas buffer tank collects the waste gas flow data in real time and transmits it to the PLC controller. The controller adjusts the opening degree of the flow regulating valve according to the real-time treatment load of the subsequent heat exchange module and the purification unit, so that the waste gas entering flow is stabilized at 5000-20000 m 3 / h, so as to ensure the balanced operation load of the system and avoid overload or efficiency waste; Step 2: Multistage heat exchange and waste heat recovery The high-temperature exhaust gas after flow regulation enters the spiral heat exchange pipe group of the primary water-cooled heat exchanger. The controller starts the cooling liquid circulating pump to drive the deionized water to circulate outside the heat exchange pipe. The exhaust gas and the cooling liquid exchange heat through the pipe wall. The temperature of the exhaust gas is rapidly reduced from 500-1000℃ to 250-300℃. The temperature of the cooling liquid increases after absorbing heat and is transported to industrial heat equipment or heating system through the waste heat recovery channel to realize energy recycling. The exhaust gas after primary cooling enters the secondary air-cooled heat exchanger. The controller adjusts the air speed of the variable frequency fan according to the exhaust gas temperature data collected by the temperature sensor. The exhaust gas flows in the spiral heat exchange pipe group. The honeycomb-shaped aluminum alloy heat dissipation fins outside the pipe enhance the heat dissipation effect. The temperature of the exhaust gas is further reduced to 100-150℃. The cooled exhaust gas enters the temperature equalization cavity. The guide plate in the cavity makes the temperature of the exhaust gas uniform. The temperature sensor monitors the temperature of the exhaust gas in real time and feeds back to the controller. If the temperature is higher than 120℃, the controller increases the air speed of the variable frequency fan or the rotating speed of the cooling liquid circulating pump. If the temperature is lower than 80℃, the controller reduces the air speed of the fan or the rotating speed of the pump. Finally, the exhaust gas is stably controlled in the suitable purification temperature range of 80-120℃. Step 3: layered purification treatment The temperature qualified exhaust gas enters the pretreatment cavity of the purification unit. The first-stage metal filter removes the large particles with a particle size greater than 100μm. The second-stage ceramic filter layer intercepts the fine particles with a particle size of 10-100μm. The filtered dust falls into the bottom detachable dust collection tank, which can be cleaned regularly to avoid dust blocking the subsequent adsorption and catalysis units. The dust-removed exhaust gas enters the adsorption cavity. At least two parallel adsorption units operate simultaneously or alternately in the cavity. The composite adsorbent efficiently captures VOCs, sulfides, nitrogen oxides and other harmful gases in the exhaust gas through high specific surface area and selective adsorption capacity. The controller monitors the adsorption efficiency in real time according to the pollutant concentration sensor data at the inlet of the adsorption cavity and the outlet of the catalytic oxidation cavity. When the adsorption efficiency of a certain adsorption unit decreases to a set threshold, the controller closes the inlet and outlet electromagnetic valves of the unit, switches to the standby adsorption unit, and ensures continuous adsorption process without interruption. The exhaust gas after adsorption treatment enters the catalytic oxidation cavity. The controller starts the electric heating device to maintain the temperature of the platinum-rhodium noble metal catalytic reaction layer at 200-250℃. The difficult-to-degrade VOCs and part of the harmful gases that are not completely removed by the adsorption unit are oxidized and decomposed under the action of the catalyst to form harmless CO2 and H2O. The pollutant concentration sensor at the outlet of the catalytic oxidation cavity detects the pollutant content of the treated exhaust gas in real time. The data is fed back to the controller as the basis for adsorption unit switching and system parameter adjustment. Step 4: emission monitoring and emergency backflow The purified exhaust gas is transported to the standard emission outlet through the outlet pipeline. The gas analyzer of the online monitoring module detects the concentrations of VOCs, sulfides, nitrogen oxides and dust content in the exhaust gas in real time. After the detection data is processed by the data collector, it is synchronized to the environmental protection supervision platform and the enterprise monitoring center through the remote transmission module. If the monitoring data meets the national environmental protection emission standard, the controller maintains the opening of the standard emission outlet. The exhaust gas is discharged at high altitude after passing through the rainproof cap and the silencer. If the monitoring data does not meet the standard, the controller immediately closes the standard emission outlet and opens the emergency valve of the emergency emission channel. The exhaust gas that does not meet the standard is transported to the exhaust gas buffer tank of the intake module through the reflux pipeline, reenters the entire processing flow, and avoids direct emission of exhaust gas that does not meet the standard. Step 5: adsorbent regeneration; When the controller determines that a certain adsorption unit is saturated, after switching to the standby unit, the adsorbent regeneration module is started: the electromagnetic valve of the adsorption unit and the exhaust gas channel is closed, and the regeneration valve of the regeneration pipeline is opened. The hot air generator is started to generate hot air at 150-200℃, which is introduced into the saturated adsorption unit through the regeneration pipeline to purge and desorb the activated carbon molecular sieve composite adsorbent. The harmful gas adsorbed by the adsorbent is desorbed by the hot air to form high-concentration pollution gas. The high-concentration pollution gas generated by desorption is returned to the exhaust gas buffer tank of the intake module through the exhaust gas recovery pipeline, mixed with newly introduced industrial exhaust gas, and reprocessed to avoid secondary pollution. After regeneration is completed, the controller closes the regeneration valve and opens the inlet and outlet electromagnetic valves of the adsorption unit to make it re-enter the adsorption work and prolong the service life of the adsorbent. Step 6: real-time regulation and data tracing of the system; During system operation, temperature sensors, pressure sensors, flow sensors, and pollutant concentration sensors continuously collect data and transmit it to the PLC controller in real time. The controller dynamically optimizes the operating parameters based on the collected real-time data: adjusts the speed of the cooling liquid circulating pump and the speed of the variable frequency fan to stabilize the cooling effect, adjusts the power of the electric heating device to maintain the catalytic reaction temperature, adjusts the opening of the flow regulating valve to adapt to the fluctuation of exhaust gas flow, and sends an alarm signal and automatically adjusts the relevant actuators when the pressure sensor detects that the internal pressure exceeds the set threshold to avoid equipment damage. The monitoring data of the online monitoring module, the adjustment records of the controller, and the adsorbent regeneration records are stored in the data collector, supporting environmental protection supervision departments and enterprise operation and maintenance analysis to ensure that the system operation is traceable and controllable.
[0021] In this paper, the following points need attention: 1. The drawings of the embodiments of the present disclosure only involve the structures involved in the embodiments of the present disclosure, and other structures can be referred to the general design.
[0022] 2. Embodiments of the present disclosure and features in embodiments can be combined with each other in case of no conflict to obtain new embodiments.
[0023] Although embodiments of the present application have been shown and described, it would be appreciated by those skilled in the art that changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present application, the scope of which is defined by the appended claims and their equivalents. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present application without creative labor fall within the scope of protection of the present application.
Claims
1. An industrial waste gas emission cooling and purification system, comprising an air inlet module, a heat exchange module, a purification unit, an air outlet module, a control system, a waste heat recovery module, an adsorbent regeneration module, and an online monitoring module, characterized in that: Each module is sequentially and sealed through pipes to form a closed-loop processing channel. Each module adopts a modular design and is connected by sealed flanges and pipes for easy installation and maintenance. The heat exchange module is used to cool the high-temperature industrial waste gas to a preset purification temperature range. The purification unit is used to remove dust particles and harmful gases from the waste gas in layers. The control system dynamically adjusts the operating parameters of each module according to real-time monitoring data. The intake module includes an exhaust gas buffer tank and a flow regulating valve. The exhaust gas buffer tank has a buffer layer and a guide plate inside. The heat exchange module is a multi-stage composite heat exchange structure, including a primary water-cooled heat exchanger, a secondary air-cooled heat exchanger, and a temperature equalization chamber connected in sequence and sealed. The purification unit includes a pretreatment chamber, an adsorption chamber, and a catalytic oxidation chamber in sequence along the exhaust gas flow direction. The adsorbent regeneration module includes a hot air generator, a regeneration pipeline, and an exhaust gas recovery pipeline. The control system includes a PLC controller, a temperature sensor, a pollutant concentration sensor, a flow sensor, a pressure sensor, and an actuator. Each sensor is electrically connected to the PLC controller. The exhaust module has an emergency emission channel connected in parallel to the exhaust pipeline and equipped with an emergency valve. The online monitoring module includes a gas analyzer, a data acquisition unit, and a remote transmission module.
2. The industrial waste gas emission cooling and purification system according to claim 1, characterized in that: The primary water-cooled heat exchanger of the heat exchange module is equipped with a waste heat recovery channel for recovering waste heat from exhaust gas. The secondary air-cooled heat exchanger is equipped with a variable frequency fan and heat dissipation fins. The temperature equalization chamber has a built-in temperature sensor, which is electrically connected to the control system. Both the primary water-cooled heat exchanger and the secondary air-cooled heat exchanger adopt a shell-and-tube structure, and the internal heat exchange tube group is designed in a spiral manner. The coolant of the primary water-cooled heat exchanger is deionized water, which is circulated by a circulating pump. The waste heat recovery channel is connected to industrial heat equipment or a heating system.
3. The industrial waste gas emission cooling and purification system according to claim 1, characterized in that: The pretreatment chamber of the purification unit has a two-stage filtration structure, including a metal filter and a ceramic filter layer. The adsorption chamber has at least two parallel adsorption units, which are filled with activated carbon molecular sieve composite adsorbent. The catalytic oxidation chamber has a catalytic reaction layer and an electric heating device. The inlet and outlet of the adsorption unit are equipped with solenoid valves, which are electrically connected to the control system. The catalytic reaction layer is a platinum-rhodium precious metal catalyst, and the electric heating device is used to maintain the temperature of the catalytic reaction layer at 200-250℃.
4. The industrial waste gas emission cooling and purification system according to claim 1, characterized in that: The regeneration pipe of the exhaust module is connected to the adsorption unit of the adsorption chamber, and the waste gas recovery pipe is connected to the waste gas buffer tank of the intake module, which is used to recover the harmful gases desorbed during the regeneration process.
5. The industrial waste gas emission cooling and purification system according to claim 1, characterized in that: The PLC controller of the control system adjusts the operating status of the flow regulating valve, variable frequency fan, solenoid valve, and electric heating device based on sensor data.
6. The industrial waste gas emission cooling and purification system according to claim 1, characterized in that: The emergency valve of the exhaust module is electrically connected to the control system. When the exhaust gas fails to meet the standard, the emergency valve opens and the substandard exhaust gas flows back to the intake module for reprocessing.
7. The industrial waste gas emission cooling and purification system according to claim 1, characterized in that: The gas analyzer of the online monitoring module is installed at the emission outlet to monitor the concentration of pollutants in the exhaust gas in real time. The monitoring data is transmitted to the environmental protection supervision platform and the enterprise monitoring center through the remote transmission module.