High-efficiency operation process system and method for wet desulfurization

Abstract

The application discloses a wet desulfurization high-efficiency operation process system and method, and relates to the technical field of wet desulfurization processes.The system comprises a data acquisition module, a catalysis regulation module and the like.The data acquisition module is used for collecting nozzle state data sets, process operation data sets and catalysis process parameter sets of the wet desulfurization process, and pre-processing the collected data sets.The catalysis regulation module is used for comprehensively analyzing the pre-processed catalysis process parameter sets, obtaining slurry catalytic oxidation efficiency evaluation results, comparing the catalytic oxidation efficiency evaluation results with preset catalytic efficiency threshold values, and outputting catalysis state comparison results.The application solves the problem that traditional systems cannot distinguish between process abnormalities and equipment failure sources by calculating double-quantization indexes of gas-liquid matching evaluation values and nozzle blockage evaluation values, realizes directional positioning of abnormal causes, avoids production interruption and energy waste caused by blind adjustment of circulating pump frequency or shutdown for maintenance, and simultaneously realizes accurate monitoring and evaluation of gas-liquid mass transfer processes.

Description

Technical Field

[0001] This invention relates to the field of wet desulfurization technology, specifically to a high-efficiency operation process system and method for wet desulfurization. Background Technology

[0002] Wet desulfurization technology is currently the mainstream technology for removing sulfur dioxide from flue gas in coal-fired power plants and industrial boilers. Its core principle involves atomizing alkaline desulfurization slurry through a spray layer and ensuring full contact with the flue gas. Sulfur dioxide is removed through an acid-base neutralization reaction, and desulfurization byproducts are recovered through processes such as gypsum dehydration. Due to its high desulfurization efficiency, strong adaptability, and stable operation, this technology is widely used in various industrial flue gas treatment scenarios and is a key technical means to achieve pollutant emission standards. Its core performance depends on the gas-liquid mass transfer efficiency and the precision of reaction rate control.

[0003] During the operation of a wet desulfurization system, the supporting parameter acquisition and equipment control system is an important carrier to ensure the stable operation of the desulfurization system and maintain the desulfurization efficiency in compliance with standards. Through the collection of various parameters by sensors, it guides core operations such as adjusting the frequency of the circulating pump and judging the status of the nozzle, which directly affects the gas-liquid mixing flow pattern, mass transfer efficiency and desulfurization reaction effect.

[0004] However, existing wet desulfurization systems still have the following problems that need to be solved in actual operation. First, they lack the ability to quantitatively distinguish between process abnormalities and equipment failures. They can only judge system abnormalities by whether the desulfurization efficiency meets the standard, and cannot accurately identify whether the root cause of the abnormality is gas-liquid contact mismatch (insufficient mass transfer efficiency) or nozzle blockage (damaged mass transfer surface area). As a result, when problems occur, they can only blindly increase the frequency of the circulating pump or shut down the machine for troubleshooting. This not only wastes energy, but also easily leads to unplanned shutdowns, affecting the continuity of desulfurization process operation and reaction stability. Secondly, existing wet desulfurization catalytic oxidation processes rely solely on the addition of a single catalytic additive, failing to achieve coordinated matching between the catalytic oxidation process, gas-liquid mass transfer process, and dynamic control of slurry flow rate. This results in insufficient catalytic efficiency and incomplete calcium sulfite oxidation, which not only reduces the stability of the desulfurization reaction but also affects the quality of gypsum byproducts, further exacerbating the blind operation and energy waste of the desulfurization process. Therefore, this paper proposes a high-efficiency operation process system and method for wet desulfurization to address these issues. Summary of the Invention

[0005] Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a high-efficiency wet desulfurization process system and method, which solves the problems mentioned in the background section.

[0006] Technical solution To achieve the above objectives, the present invention provides the following technical solution: a high-efficiency wet desulfurization process system, comprising: The data acquisition module is used to collect the nozzle status dataset, process operation dataset, and catalytic process parameter set of the wet desulfurization process, and to preprocess the collected datasets. The catalytic regulation module is used to comprehensively analyze the pretreated catalytic process parameter set, obtain the slurry catalytic oxidation efficiency evaluation result, compare the catalytic oxidation efficiency evaluation result with the preset catalytic efficiency threshold, and output the catalytic state comparison result. The gas-liquid assessment module is used to comprehensively analyze the process operation dataset and the catalytic state comparison results, quantify the gas-liquid mass transfer efficiency of each spray layer, obtain the gas-liquid matching assessment results of each spray layer, and output the process state comparison results after comparing the gas-liquid matching assessment results of each spray layer with the preset threshold. The nozzle evaluation module is used to comprehensively analyze the nozzle status dataset for spray layers with abnormal process status comparison results, evaluate the impact of nozzle blockage on gas-liquid mass transfer surface area, obtain the nozzle blockage evaluation results for each spray layer, and output the nozzle status comparison results after comparing the nozzle blockage evaluation results of each spray layer with the preset threshold. The desulfurization early warning module is used to trigger early warning signals of corresponding levels based on the nozzle status comparison results and the catalyst status comparison results, and to control the corresponding spray layer to shut down when the nozzle blockage assessment results fall into the forced protection range. The frequency conversion adjustment module is used to determine the frequency adjustment scheme of each spray layer circulation pump branch based on the process state comparison results, nozzle state comparison results, and catalyst state comparison results, and to issue frequency conversion adjustment commands to the corresponding circulation pump branch to regulate the slurry flow rate of the corresponding spray layer.

[0007] Preferably, the nozzle status dataset includes the pressure difference before and after each spray layer nozzle; The process operation dataset includes the real-time flow rate at the outlet of each spray layer, the flue gas velocity in the corresponding area of ​​the desulfurization tower, and the SO2 concentration distribution value in the corresponding area of ​​the desulfurization tower outlet. The set of catalytic process parameters includes the concentration of catalytic aid in the desulfurization slurry, the concentration of calcium sulfite in the slurry, and the oxidation air volume data.

[0008] Preferably, the specific steps for obtaining the gas-liquid matching evaluation results of each spray layer are as follows: Traverse each spray layer in the desulfurization tower and extract the corresponding flow rate, flow velocity, and SO2 concentration data for each spray layer; The contact sufficiency between flue gas and slurry in each spray layer is analyzed, the gas-liquid mass transfer efficiency of each spray layer is quantified, and the gas-liquid matching of each spray layer is determined in combination with the SO2 target concentration at the outlet of the desulfurization tower to determine whether the gas-liquid matching of each spray layer meets the standard, and the gas-liquid matching evaluation results of each spray layer are generated. The normal range and early warning adjustment range for gas-liquid matching are preset, and the gas-liquid matching evaluation results of each spray layer are matched with the normal range and early warning adjustment range for gas-liquid matching. For spray layers that fall within the normal gas-liquid matching range, mark them as operating normally; for spray layers that fall within the gas-liquid matching early warning and adjustment range, mark them as process abnormal, and output the process status comparison results.

[0009] Preferably, the specific steps for obtaining the nozzle clogging assessment results for each spray layer are as follows: Traverse each spray layer marked as abnormal by the process status comparison results; Extract the pressure difference data before and after the nozzle of the spray layer marked as abnormal by the process state comparison results; Compare the historical differential pressure baseline values ​​of the spray layer marked as abnormal by the process condition comparison results; Based on the degree of pressure difference deviation between the pressure difference data before and after the nozzle and the historical pressure difference benchmark value, the clogging level of the nozzle is determined, and the clogging assessment results of the nozzles for each spray layer are generated.

[0010] Preferably, the specific steps for comparing the output nozzle state results are as follows: Preset the normal range, early warning adjustment range, and forced protection range for nozzle blockage; The nozzle clogging assessment results for each spray layer are matched with the normal range, early warning adjustment range, and mandatory protection range for nozzle clogging; The output nozzle status comparison results clearly indicate the degree of nozzle blockage in each spray layer and the corresponding damage to gas-liquid mass transfer efficiency.

[0011] Preferably, the specific steps for obtaining the output catalytic state comparison results are as follows: Preset catalytic efficiency target threshold and catalytic efficiency warning threshold; Based on the pretreated catalytic process parameter set, the slurry catalytic oxidation efficiency evaluation value is calculated by a quantitative formula. The catalytic oxidation efficiency assessment value is compared with a preset threshold. When the assessment value is greater than or equal to the catalytic efficiency threshold, the catalytic state comparison result of the catalytic efficiency meeting the standard is output. When the catalytic efficiency warning threshold is less than or equal to the evaluation value but less than the catalytic efficiency compliance threshold, the output will show the catalytic state comparison result with low catalytic efficiency. When the assessed value is less than the catalytic efficiency warning threshold, the output will show the comparison results of the catalytic state where the catalytic efficiency is not up to standard.

[0012] Preferably, the specific steps for triggering the corresponding level of warning signal are as follows: If the nozzle status comparison result falls within the normal range of nozzle blockage and the catalyst status comparison result shows that the catalytic efficiency meets the standard, no warning signal will be output. If the nozzle status comparison result falls within the nozzle blockage warning adjustment range or the catalyst status comparison result shows that the catalytic efficiency is not up to standard, a yellow warning signal will be triggered, and nozzle cleaning prompts and catalyst condition adjustment prompts will be pushed out. If the nozzle status comparison result falls into the nozzle blockage forced protection zone, a red warning signal is triggered, and the corresponding spray layer is immediately shut down.

[0013] Preferably, the specific steps for determining the frequency adjustment scheme of each spray layer circulation pump branch are as follows: For spray layers with abnormal processes but no nozzle blockage and catalytic efficiency meeting the standards, the frequency of the circulating pump is adjusted to change the slurry flow rate of the corresponding spray layer and optimize the gas-liquid contact matching. For spray layers with abnormal processes, slight nozzle blockage, and catalytic efficiency meeting the standards, the frequency of the circulating pump is increased to compensate for the slurry flow rate of the corresponding spray layer and make up for the loss of mass transfer surface area. For spray layers with abnormal processes and substandard catalytic efficiency, while adjusting the frequency of the circulating pump to optimize gas-liquid mass transfer, a corresponding adjustment command for the oxidation air volume is simultaneously pushed to enhance the catalytic oxidation reaction environment. For spray layers with severely clogged nozzles, no frequency adjustment is made, and the corresponding spray layer remains in a stopped state.

[0014] Preferably, the specific steps for issuing the frequency conversion adjustment command are as follows: The frequency converter adjustment command carries the identification of the circulating pump branch; Each spray layer circulating pump branch only receives frequency conversion adjustment commands that match its own identification; after the frequency conversion adjustment command is issued, the execution status of the frequency conversion adjustment command is fed back in real time.

[0015] The efficient operation process of wet desulfurization includes the following steps: Step 1: Collect the nozzle status dataset, process operation dataset, and catalytic process parameter set of the wet desulfurization process, and preprocess the collected datasets. Step 2: Perform a comprehensive analysis on the pretreated catalytic process parameter set to obtain the slurry catalytic oxidation efficiency evaluation results. After comparing the catalytic oxidation efficiency evaluation results with the preset catalytic efficiency threshold, output the catalytic state comparison results. Step 3: Perform a comprehensive analysis of the process operation dataset and the catalytic state comparison results, quantify the gas-liquid mass transfer efficiency of each spray layer, obtain the gas-liquid matching evaluation results of each spray layer, compare the gas-liquid matching evaluation results of each spray layer with the preset threshold, and output the process state comparison results. Step 4: For spray layers with abnormal process status comparison results, perform comprehensive analysis on the nozzle status dataset to obtain the nozzle clogging assessment results for each spray layer. After comparing the nozzle clogging assessment results for each spray layer with the preset threshold, output the nozzle status comparison results. Step 5: Based on the nozzle status comparison results and catalyst status comparison results, trigger the corresponding level of early warning signal, and when the nozzle blockage assessment result falls into the forced protection range, control the corresponding spray layer to shut down. Step 6: Based on the process status comparison results, nozzle status comparison results, and catalyst status comparison results, determine the frequency adjustment scheme for each spray layer circulation pump branch, issue frequency conversion adjustment commands to the corresponding circulation pump branches, and regulate the slurry flow rate of the corresponding spray layer.

[0016] Beneficial effects The present invention has the following beneficial effects: (1) The wet desulfurization high-efficiency operation process system and method accurately characterize the degree of gas-liquid contact adaptation, gas-liquid mass transfer efficiency and nozzle flow capacity damage by calculating the gas-liquid matching evaluation value and the nozzle blockage evaluation value. This solves the problem that traditional systems cannot distinguish between process abnormalities and equipment failures, realizes the directional location of abnormal causes, avoids production interruption and energy waste caused by blindly adjusting the frequency of the circulating pump or shutting down for maintenance, and realizes accurate monitoring and evaluation of the gas-liquid mass transfer process.

[0017] (2) The wet desulfurization high-efficiency operation process system and method, by adding an independent catalytic control module, realizes the precise quantitative evaluation of the wet desulfurization catalytic oxidation process. At the same time, it establishes a synergistic optimization mechanism for the catalytic oxidation process, gas-liquid mass transfer process, and slurry flow frequency conversion control, which solves the problems of the existing technology's inability to fully utilize catalytic efficiency and poor desulfurization reaction stability, and improves the completeness of the desulfurization reaction and operational stability.

[0018] (3) The wet desulfurization high-efficiency operation process system and method, through the differentiated compensation factor matching strategy based on the basic difference and the catalytic efficiency deviation, combined with the formula to calculate the target operating frequency of the circulating pump, realizes the precise adjustment of slurry flow on demand, and adopts differentiated frequency compensation for different working conditions such as simple gas-liquid contact mismatch, nozzle blockage superposition, and insufficient catalytic efficiency, optimizes the gas-liquid mixing flow state, and avoids the increase in energy consumption caused by excessive flow while ensuring that the desulfurization efficiency meets the standard.

[0019] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0020] Figure 1 This is a structural diagram of the high-efficiency wet desulfurization process system of the present invention; Figure 2 This is a flowchart of the efficient operation process of wet desulfurization according to the present invention. Detailed Implementation

[0021] 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.

[0022] This invention provides a technical solution: a high-efficiency wet desulfurization process system, such as... Figure 1 As shown, it includes: The data acquisition module is used to collect nozzle status datasets, process operation datasets, and catalytic process parameter sets for wet desulfurization processes, and to preprocess them to provide accurate and synchronous basic data for quantifying gas-liquid mass transfer efficiency, evaluating catalytic oxidation efficiency, assessing the impact of nozzle blockage, and controlling subsequent reaction rates.

[0023] The nozzle status dataset includes the pressure difference before and after each spray layer nozzle, which is collected by differential pressure transmitters installed in the nozzle inlet and outlet pipelines. It is mainly used to evaluate the impact of nozzle blockage on the gas-liquid mass transfer surface area. The process operation dataset includes real-time slurry flow rate at the outlet of each spray layer, flue gas velocity in the corresponding area of ​​the desulfurization tower, and SO2 concentration distribution value in the corresponding area of ​​the desulfurization tower outlet. These data are collected by electromagnetic flowmeters, pipeline flow sensors, and in-situ gas analyzers, respectively. All sensors have a sampling frequency of 1Hz, which is used to quantify the sufficiency of gas-liquid contact and the desulfurization reaction effect. The catalytic process parameter set includes the concentration of catalyst aid in the desulfurization slurry, the concentration of calcium sulfite in the slurry, and the oxidation air volume data. These are collected by an online multi-parameter water quality analyzer installed in the slurry pool of the desulfurization tower and a Pitot tube air volume sensor in the outlet pipe of the oxidation fan, respectively. The sampling frequency is consistent with other process parameters.

[0024] All sensor data are collected synchronously using the same timestamp, with a time error of no more than 10ms, which can effectively avoid distortion of mass transfer efficiency and reaction state assessment caused by data misalignment. The normalization processing of the collected data adopts the conventional min-max method to map the parameters to the [0,1] interval. Abnormal data removal is performed synchronously in the preprocessing stage: instantaneous peak data exceeding 3 times the normal range are removed, and missing data is filled in using linear interpolation, providing a unified benchmark for subsequent gas-liquid mass transfer efficiency calculation, catalytic efficiency assessment, and reaction state assessment.

[0025] The catalytic control module is used to comprehensively analyze the set of catalytic process parameters after pretreatment, obtain the slurry catalytic oxidation efficiency evaluation result, compare the catalytic oxidation efficiency evaluation result with the preset catalytic efficiency threshold, and output the catalytic state comparison result, providing quantitative basis for gas-liquid mass transfer evaluation, process early warning, and frequency conversion control.

[0026] The specific method for obtaining the evaluation results of slurry catalytic oxidation efficiency is as follows: In the formula, This represents the catalytic oxidation efficiency evaluation value, without units, and ranges from 0 to 1. A higher value indicates higher catalytic oxidation efficiency of calcium sulfite and a more complete desulfurization reaction. This represents the normalized value of the real-time concentration of the catalyst aid in the slurry, obtained from data collected by an online water quality analyzer after preprocessing. This represents the normalized value of real-time oxidation airflow, obtained from preprocessed data collected by the airflow sensor. This indicates the baseline design concentration of the catalyst promoter, in mg / L, with a value of 5 mg / L. This represents the baseline value for design oxidation air volume, in meters (m³). 3 / h, determined based on the design air volume of the desulfurization tower under rated operating conditions.

[0027] The catalyst used in this scheme is a manganese-iron composite catalytic system, with soluble manganese salt as the core catalytic component and soluble iron salt as the synergistic component. It can effectively reduce the activation energy of the calcium sulfite oxidation reaction, improve the oxidation reaction rate and completeness, and is compatible with the synergistic regulation logic of this scheme.

[0028] The preset threshold for catalytic efficiency is 0.9, and the preset warning threshold is 0.7. The catalytic oxidation efficiency assessment value C is compared with the preset threshold: When C≥0.9, the output shows the comparison results of catalytic states that meet the catalytic efficiency standard; When 0.7≤C<0.9, the output shows the comparison results of catalytic states with low catalytic efficiency; When C < 0.7, the output comparison results of catalytic states with substandard catalytic efficiency are provided.

[0029] The gas-liquid assessment module is used to comprehensively analyze the process operation dataset and catalytic state comparison results, optimize the gas-liquid mass transfer efficiency of desulfurization slurry and flue gas in the spray layer, obtain the gas-liquid matching assessment results of each spray layer, and compare them with the preset threshold to output the process state comparison results, providing a quantitative basis for desulfurization reaction rate control.

[0030] The specific steps to obtain the gas-liquid matching evaluation results of each spray layer are as follows: traverse each spray layer; extract the flow rate, velocity, and SO2 concentration data corresponding to each spray layer; perform comprehensive analysis on the extracted data, quantify the gas-liquid contact sufficiency, and obtain the gas-liquid evaluation value of each spray layer, which directly reflects the gas-liquid mass transfer efficiency.

[0031] The gas-liquid assessment values ​​are obtained as follows: In the formula, This represents the gas-liquid assessment value, specifically a quantitative evaluation result of the suitability of flue gas and slurry contact and the gas-liquid mass transfer efficiency within each spray layer. The higher the value, the higher the gas-liquid mass transfer efficiency and the more complete the desulfurization reaction; This represents the normalized value of the real-time flow rate of the spray layer slurry, which is obtained by normalizing the slurry flow rate data collected by the electromagnetic flow meter. Its value directly affects the gas-liquid contact area and mass transfer efficiency. This represents the real-time normalized value of the flue gas velocity in the spray layer. It is obtained by normalizing the flue gas velocity data collected by the pipeline flow velocity sensor. The flue gas velocity affects the gas-liquid contact time, which in turn affects the mass transfer efficiency and reaction effect. The value of 0.85 represents the design slurry flow rate coefficient of the spray layer. It serves as the design reference correction coefficient for the slurry flow rate of the spray layer and can be matched with the design specifications for the gas-liquid mass transfer process. The value is the average of three sets of 1:1 spray layer physical tests. This represents the design flue gas velocity coefficient of the spray layer, with a value of 0.90. It serves as the design benchmark correction coefficient for the flue gas velocity of the spray layer, adapting to the design requirements for optimizing gas-liquid mass transfer efficiency.

[0032] The normalized value of the SO2 target concentration at the desulfurization tower outlet is set to 0.8. The gas-liquid evaluation value Q is compared with this target value: when Q≥0.8, the gas-liquid matching is judged to be up to standard, and the corresponding spray layer is marked as operating normally. At this time, the gas-liquid mass transfer efficiency is up to standard, and the desulfurization reaction is sufficient. When Q<0.8, the gas-liquid matching is judged to be abnormal, and the corresponding spray layer is marked as process abnormal. At this time, the gas-liquid mass transfer efficiency is insufficient, the desulfurization reaction does not achieve the expected effect, and the process status comparison result is output.

[0033] The core application and implementation of gas-liquid assessment values: For spray layers with process anomalies, a basic difference is calculated, where the basic difference = 0.8 - Q. For example, if a spray layer is calculated to have Q = 0.6, then the basic difference = 0.8 - 0.6 = 0.2. This difference directly reflects the degree of insufficient gas-liquid contact and low mass transfer efficiency caused by flow / velocity mismatch in the current spray layer. It serves as the core quantitative basis for subsequent frequency conversion adjustments, improving mass transfer efficiency and reaction rate, aligning with the technical requirements of gas-liquid mass transfer process control.

[0034] The nozzle evaluation module is used to comprehensively analyze the nozzle status dataset for spray layers with abnormal process status comparison results, evaluate the impact of nozzle blockage on gas-liquid mass transfer surface area and mass transfer efficiency, obtain the nozzle blockage evaluation results for each spray layer, and compare them with preset thresholds to output the nozzle status comparison results, providing support for mass transfer efficiency optimization and reaction control.

[0035] The specific steps to obtain the nozzle blockage assessment results for each spray layer are as follows: traverse each spray layer marked as abnormal by the process state comparison results; extract the pressure difference data before and after the nozzle; compare with the historical pressure difference benchmark value of the spray layer; and obtain the nozzle blockage assessment value for each spray layer based on the degree of pressure difference deviation to clarify the damage of the blockage degree to the gas-liquid mass transfer surface area.

[0036] The nozzle clogging assessment value is obtained as follows: In the formula, This represents the nozzle clogging assessment value, specifically a quantitative assessment of the degree of impairment to the flow capacity of each spray layer's nozzles and the impact on the mass transfer surface area. The higher the value, the more severe the nozzle clogging, the smaller the gas-liquid mass transfer surface area, and the lower the mass transfer efficiency. This represents the normalized value of the real-time differential pressure of the nozzle, which is obtained by normalizing the differential pressure data before and after the nozzle is collected by the differential pressure transmitter. Changes in differential pressure can directly reflect the degree of nozzle blockage. This represents the normalized historical differential pressure benchmark value of the nozzle, which is obtained by normalizing the average differential pressure over 30 consecutive days of normal nozzle operation, providing a reliable benchmark for clogging assessment. This represents the nozzle differential pressure reference correction factor, with a value of 1.0. It serves as the calibration factor for the nozzle differential pressure reference value and is adapted to the evaluation specifications for fluid handling.

[0037] The historical differential pressure benchmark is updated every 3 months, taking the average of stable operating differential pressure over 30 consecutive days within the update period. The criteria for stable operation are: daily nozzle differential pressure fluctuation ≤ ±3%, and no interference conditions such as equipment start-up / shutdown, sudden changes in slurry concentration (fluctuation > 5%), or sudden changes in flue gas volume (fluctuation > 10%). Abnormal data such as equipment start-up / shutdown and slurry concentration fluctuation are also removed to avoid clogging assessment bias caused by long-term benchmark distortion and ensure the accuracy of mass transfer efficiency assessment.

[0038] Preset threshold ranges: U < 5% is the normal range, where there is no obvious blockage in the nozzle, the gas-liquid mass transfer surface area is not damaged, and the mass transfer efficiency is normal; 5% ≤ U < 15% is the warning adjustment range, where the nozzle is slightly blocked, the mass transfer surface area is slightly reduced, and the mass transfer efficiency is slightly decreased; U ≥ 15% is the forced protection range, where the nozzle is severely blocked, the mass transfer surface area is significantly reduced, the mass transfer efficiency is seriously insufficient, and the desulfurization reaction is on the verge of failure; the nozzle blockage assessment value U is matched with the range, the degree of blockage of each nozzle is clearly marked, and the corresponding damage to the gas-liquid mass transfer efficiency is displayed, and the nozzle status comparison results are output.

[0039] If the calculated value of U=18%, it falls into the mandatory protection zone, directly triggering the red warning and shutdown action of the desulfurization early warning module to prevent mass transfer failure from causing a complete abnormality in the desulfurization reaction, thus meeting the safety control requirements of the fluid processing process. If the calculated value of U=8%, it falls into the warning adjustment zone, and the additional difference is calculated. The additional difference = U×0.005=8%×0.005=0.04. This additional difference represents the extra flow loss difference caused by nozzle blockage and the corresponding decrease in mass transfer efficiency. It is used to superimpose the basic difference to calculate the comprehensive compensation requirement. The problem of insufficient mass transfer surface area is made up for by flow compensation. The coefficient 0.005 is obtained from the linear fitting test of nozzle blockage degree and flow loss. The goodness of fit R2=0.98, and the data correlation is significant. If the calculated value of U=3%, it falls into the normal zone. It is determined that the process abnormality is only caused by the mismatch between flow rate and velocity. The mass transfer surface area is not damaged. There is no need to calculate the additional difference. Only the flow rate needs to be adjusted to optimize the mass transfer efficiency.

[0040] The desulfurization early warning module is used to trigger corresponding level early warning signals based on the nozzle status comparison results and catalytic status comparison results. When the nozzle blockage assessment result falls into the mandatory protection range, it controls the corresponding spray layer to shut down, so as to avoid gas-liquid mass transfer failure or catalytic reaction runaway, which would lead to a significant decrease in desulfurization reaction efficiency and excessive pollutant emissions, thus meeting the safety control requirements of the reaction process.

[0041] If the nozzle blockage assessment value U < 5% and the catalytic oxidation efficiency assessment value C ≥ 0.9, no warning signal is output. Instead, the process anomaly information and the basic difference are directly pushed to the frequency converter adjustment module. The gas-liquid mass transfer efficiency is optimized through flow adjustment to ensure normal reaction. If 5% ≤ U < 15% or 0.7 ≤ C < 0.9, a yellow warning signal is triggered and a corresponding prompt is pushed to prevent the blockage from worsening or the catalytic efficiency from continuing to decline, ensuring the stable progress of the desulfurization reaction. If U ≥ 15%, a red warning signal is triggered and the power supply to the corresponding spray layer inlet valve and circulating pump is immediately cut off to terminate the operation of the spray layer. This prevents mass transfer failure from causing a complete abnormality in the desulfurization reaction, avoiding environmental exceedances and equipment damage.

[0042] The frequency conversion adjustment module is used to determine the frequency adjustment scheme of each spray layer circulation pump branch based on the process state comparison results, nozzle state comparison results, catalytic state comparison results, basic difference, and additional difference, and then issues frequency conversion adjustment commands to the corresponding circulation pump branches. This module optimizes the gas-liquid mixing flow state by regulating the slurry flow rate, adapts to the catalytic oxidation reaction conditions, and thus improves the gas-liquid mass transfer efficiency and the desulfurization chemical absorption reaction rate, achieving dual optimization of mass transfer and catalytic reaction efficiency.

[0043] The specific steps for determining the frequency adjustment scheme of each spray layer's circulating pump branch are as follows: For spray layers with abnormal processes and nozzle blockage assessment value U < 5% and catalytic efficiency meeting the standard, retrieve the basic difference calculated by the gas-liquid assessment module. If the basic difference ≤ 0.1, the compensation factor is set to 0.1; if 0.1 < basic difference ≤ 0.2, the compensation factor is set to 0.2; if the basic difference > 0.2, the compensation factor is set to 0.3. Optimize the gas-liquid mixing flow state by adjusting the flow rate to improve mass transfer efficiency and ensure sufficient reaction. The range of compensation factor values ​​is determined based on three sets of 1:1 spray layer physical test data. The test conditions are: the spray layer uses dual-fluid atomizing nozzles, with 36 nozzles, a desulfurization slurry concentration of 20%, a flue gas velocity of 3.5–4.5 m / s, and an SO2 inlet concentration of 2000 mg / m³. 3 The experiment verified the linear correlation between the difference and the frequency compensation amplitude, ensuring that the adjusted gas-liquid evaluation value can stably reach the target value, and that the gas-liquid mass transfer efficiency and desulfurization reaction rate can meet the design requirements.

[0044] For spray layers with abnormal processes but 5% ≤ U < 15% and catalytic efficiency meeting the standard, the basic difference and additional difference are first retrieved to calculate the comprehensive difference. The comprehensive difference equals the basic difference plus the additional difference. If the comprehensive difference is ≤ 0.15, the compensation factor is 0.2; if 0.15 < comprehensive difference ≤ 0.25, the compensation factor is 0.3; if the comprehensive difference is > 0.25, the compensation factor is 0.4. By compensating for the insufficient mass transfer surface area caused by nozzle blockage, the mass transfer efficiency and reaction rate meet the standards through a larger flow compensation. For spray layers with abnormal processes and substandard catalytic efficiency, in addition to the above frequency adjustments, an adjustment command to increase the oxidation air volume by 10%-15% is simultaneously pushed to enhance the oxygen-rich environment of the catalytic oxidation reaction and improve the catalytic reaction efficiency. For spray layers with nozzle clogging assessment value U≥15%, no frequency adjustment is made, and the machine is kept in a shutdown state to avoid ineffective energy consumption and prevent the reaction efficiency from getting out of control. The target operating frequency of the circulating pump is obtained as follows: In the formula, This indicates the target operating frequency of the circulating pump, specifically the operating frequency value that the circulating pump needs to be adjusted to. It directly determines the slurry flow rate, and thus affects the gas-liquid mixing flow pattern, mass transfer efficiency, and reaction rate. This indicates the current operating frequency of the circulating pump, specifically the real-time operating frequency value of the circulating pump. This refers to the compensation factor, specifically a frequency correction coefficient determined based on the basic difference or comprehensive difference, used to precisely control the flow rate to optimize mass transfer efficiency and catalytic reaction conditions.

[0045] Taking a case with process abnormality and U < 5% but catalytic efficiency meeting the standard as an example: If the basic difference = 0.2, then the compensation factor K = 0.2. Assuming the current operating frequency of the circulating pump S = 50Hz, then the target operating frequency A = 50 × (1 + 0.2) = 60Hz. That is, the circulating pump needs to be adjusted to operate at 60Hz to increase the slurry flow rate, optimize the gas-liquid mixing flow pattern, increase the gas-liquid contact area, improve the mass transfer efficiency, and ensure sufficient desulfurization reaction. Taking a case with process abnormality and 5% ≤ U < 15% but catalytic efficiency meeting the standard as an example... Example: If the basic difference = 0.2 and the additional difference = 0.04, then the comprehensive difference = 0.2 + 0.04 = 0.24, the compensation factor K = 0.3, and assuming the current operating frequency of the circulating pump S = 50Hz, then the target operating frequency A = 50 × (1 + 0.3) = 65Hz. That is, the circulating pump needs to be adjusted to operate at 65Hz to significantly increase the flow rate, make up for the insufficient mass transfer surface area caused by nozzle blockage, and optimize the gas-liquid mixing flow state to ensure that the mass transfer efficiency and desulfurization reaction rate meet the standards.

[0046] The frequency conversion adjustment command carries the identification of the circulating pump branch. Each spray layer circulating pump branch only receives frequency conversion adjustment commands that match its own identification. After the command is issued, the execution status is fed back in real time to ensure that the gas-liquid mass transfer efficiency and desulfurization reaction status can be precisely controlled. After the frequency adjustment is completed, the system re-collects data and calculates the gas-liquid evaluation value Q every 10 minutes. If Q is still < 0.8, the compensation factor is re-selected and adjusted again at 1.2 times the comprehensive difference until the mass transfer efficiency meets the standard and the reaction is sufficient. If Q still does not meet the standard after two consecutive adjustments, a device fault troubleshooting prompt is pushed to the operation and maintenance terminal to avoid long-term insufficient mass transfer efficiency leading to abnormal reaction.

[0047] High-efficiency operation methods of wet desulfurization, such as Figure 2 As shown, it includes the following steps: Step 1: Collect the nozzle status dataset, process operation dataset, and catalytic process parameter set of the wet desulfurization process, and perform preprocessing. Step 2: Perform a comprehensive analysis on the pretreated catalytic process parameter set to obtain the slurry catalytic oxidation efficiency evaluation results. After comparing the catalytic oxidation efficiency evaluation results with the preset catalytic efficiency threshold, output the catalytic state comparison results. Step 3: Perform a comprehensive analysis of the process operation dataset and the catalytic state comparison results to obtain the gas-liquid matching evaluation results of each spray layer. After comparing the results with the preset threshold, output the process state comparison results. Step 4: For spray layers with abnormal process status comparison results, perform comprehensive analysis on the nozzle status dataset to obtain the nozzle blockage assessment results for each spray layer. After comparing the results with the preset threshold, output the nozzle status comparison results. Step 5: Based on the nozzle status comparison results and catalyst status comparison results, trigger the corresponding level of early warning signal, and when the nozzle blockage assessment result falls into the forced protection range, control the corresponding spray layer to shut down. Step 6: Based on the process status comparison results, nozzle status comparison results, and catalyst status comparison results, determine the frequency adjustment scheme for each spray layer circulation pump branch, issue frequency conversion adjustment commands to the corresponding circulation pump branches, and optimize the gas-liquid mixing flow state and catalytic oxidation reaction efficiency.

[0048] 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.

[0049] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. A high-efficiency wet desulfurization process system, characterized in that, include: The data acquisition module is used to collect the nozzle status dataset, process operation dataset, and catalytic process parameter set of the wet desulfurization process, and to preprocess the collected datasets. The catalytic regulation module is used to comprehensively analyze the pretreated catalytic process parameter set, obtain the slurry catalytic oxidation efficiency evaluation result, compare the catalytic oxidation efficiency evaluation result with the preset catalytic efficiency threshold, and output the catalytic state comparison result. The gas-liquid assessment module is used to comprehensively analyze the process operation dataset and the catalytic state comparison results, quantify the gas-liquid mass transfer efficiency of each spray layer, obtain the gas-liquid matching assessment results of each spray layer, and output the process state comparison results after comparing the gas-liquid matching assessment results of each spray layer with the preset threshold. The nozzle evaluation module is used to comprehensively analyze the nozzle status dataset for spray layers with abnormal process status comparison results, evaluate the impact of nozzle blockage on gas-liquid mass transfer surface area, obtain the nozzle blockage evaluation results for each spray layer, and output the nozzle status comparison results after comparing the nozzle blockage evaluation results of each spray layer with the preset threshold. The desulfurization early warning module is used to trigger early warning signals of corresponding levels based on the nozzle status comparison results and the catalyst status comparison results, and to control the corresponding spray layer to shut down when the nozzle blockage assessment results fall into the forced protection range. The frequency conversion adjustment module is used to determine the frequency adjustment scheme of each spray layer circulation pump branch based on the process state comparison results, nozzle state comparison results, and catalyst state comparison results, and to issue frequency conversion adjustment commands to the corresponding circulation pump branch to regulate the slurry flow rate of the corresponding spray layer.

2. The high-efficiency wet desulfurization process system according to claim 1, characterized in that, The nozzle status dataset includes the pressure difference before and after the nozzle of each spray layer; The process operation dataset includes the real-time flow rate at the outlet of each spray layer, the flue gas velocity in the corresponding area of ​​the desulfurization tower, and the SO2 concentration distribution value in the corresponding area of ​​the desulfurization tower outlet. The set of catalytic process parameters includes the concentration of catalytic aid in the desulfurization slurry, the concentration of calcium sulfite in the slurry, and the oxidation air volume data.

3. The high-efficiency wet desulfurization process system according to claim 1, characterized in that, The specific steps for obtaining the gas-liquid matching evaluation results for each spray layer are as follows: Traverse each spray layer in the desulfurization tower and extract the corresponding flow rate, flow velocity, and SO2 concentration data for each spray layer; The contact sufficiency between flue gas and slurry in each spray layer is analyzed, the gas-liquid mass transfer efficiency of each spray layer is quantified, and the gas-liquid matching of each spray layer is determined in combination with the SO2 target concentration at the outlet of the desulfurization tower to determine whether the gas-liquid matching of each spray layer meets the standard, and the gas-liquid matching evaluation results of each spray layer are generated. The normal range and early warning adjustment range for gas-liquid matching are preset, and the gas-liquid matching evaluation results of each spray layer are matched with the normal range and early warning adjustment range for gas-liquid matching. For spray layers that fall within the normal gas-liquid matching range, mark them as operating normally; for spray layers that fall within the gas-liquid matching early warning and adjustment range, mark them as process abnormal, and output the process status comparison results.

4. The high-efficiency wet desulfurization process system according to claim 1, characterized in that, The specific steps for obtaining the nozzle clogging assessment results for each spray layer are as follows: Traverse each spray layer marked as abnormal by the process status comparison results; Extract the pressure difference data before and after the nozzle of the spray layer marked as abnormal by the process state comparison results; Compare the historical differential pressure baseline values ​​of the spray layer marked as abnormal by the process condition comparison results; Based on the degree of pressure difference deviation between the pressure difference data before and after the nozzle and the historical pressure difference benchmark value, the clogging level of the nozzle is determined, and the clogging assessment results of the nozzles for each spray layer are generated.

5. The high-efficiency wet desulfurization process system according to claim 1, characterized in that, The specific steps for comparing the output nozzle status results are as follows: Preset the normal range, early warning adjustment range, and forced protection range for nozzle blockage; The nozzle clogging assessment results for each spray layer are matched with the normal range, early warning adjustment range, and mandatory protection range for nozzle clogging; The output nozzle status comparison results clearly indicate the degree of nozzle blockage in each spray layer and the corresponding damage to gas-liquid mass transfer efficiency.

6. The high-efficiency wet desulfurization process system according to claim 1, characterized in that, The specific steps for obtaining the output catalytic state comparison results are as follows: Preset catalytic efficiency target threshold and catalytic efficiency warning threshold; Based on the pretreated catalytic process parameter set, the slurry catalytic oxidation efficiency evaluation value is calculated by a quantitative formula. The catalytic oxidation efficiency assessment value is compared with a preset threshold. When the assessment value is greater than or equal to the catalytic efficiency threshold, the catalytic state comparison result of the catalytic efficiency meeting the standard is output. When the catalytic efficiency warning threshold is less than or equal to the evaluation value but less than the catalytic efficiency compliance threshold, the output will show the catalytic state comparison result with low catalytic efficiency. When the assessed value is less than the catalytic efficiency warning threshold, the output will show the comparison results of the catalytic state where the catalytic efficiency is not up to standard.

7. The high-efficiency wet desulfurization process system according to claim 1, characterized in that, The specific steps for triggering the corresponding level of warning signal are as follows: If the nozzle status comparison result falls within the normal range of nozzle blockage and the catalyst status comparison result shows that the catalytic efficiency meets the standard, no warning signal will be output. If the nozzle status comparison result falls within the nozzle blockage warning adjustment range or the catalyst status comparison result shows that the catalytic efficiency is not up to standard, a yellow warning signal will be triggered, and nozzle cleaning prompts and catalyst condition adjustment prompts will be pushed out. If the nozzle status comparison result falls into the nozzle blockage forced protection zone, a red warning signal is triggered, and the corresponding spray layer is immediately shut down.

8. The high-efficiency wet desulfurization process system according to claim 1, characterized in that, The specific steps for determining the frequency adjustment scheme for each spray layer circulation pump branch are as follows: For spray layers with abnormal processes but no nozzle blockage and catalytic efficiency meeting the standards, the frequency of the circulating pump is adjusted to change the slurry flow rate of the corresponding spray layer and optimize the gas-liquid contact matching. For spray layers with abnormal processes, slight nozzle blockage, and catalytic efficiency meeting the standards, the frequency of the circulating pump is increased to compensate for the slurry flow rate of the corresponding spray layer and make up for the loss of mass transfer surface area. For spray layers with abnormal processes and substandard catalytic efficiency, while adjusting the frequency of the circulating pump to optimize gas-liquid mass transfer, a corresponding adjustment command for the oxidation air volume is simultaneously pushed to enhance the catalytic oxidation reaction environment. For spray layers with severely clogged nozzles, no frequency adjustment is made, and the corresponding spray layer remains in a stopped state.

9. The high-efficiency wet desulfurization process system according to claim 1, characterized in that, The specific steps for issuing the frequency converter adjustment command are as follows: The frequency converter adjustment command carries the identification of the circulating pump branch; Each spray layer circulation pump branch only receives frequency conversion adjustment commands that match its own identification. After the frequency converter adjustment command is issued, the execution status of the frequency converter adjustment command is fed back in real time.

10. A high-efficiency wet desulfurization process method, applied to the high-efficiency wet desulfurization process system according to any one of claims 1 to 9, characterized in that, Includes the following steps: Step 1: Collect the nozzle status dataset, process operation dataset, and catalytic process parameter set of the wet desulfurization process, and preprocess the collected datasets. Step 2: Perform a comprehensive analysis on the pretreated catalytic process parameter set to obtain the slurry catalytic oxidation efficiency evaluation results. After comparing the catalytic oxidation efficiency evaluation results with the preset catalytic efficiency threshold, output the catalytic state comparison results. Step 3: Perform a comprehensive analysis of the process operation dataset and the catalytic state comparison results, quantify the gas-liquid mass transfer efficiency of each spray layer, obtain the gas-liquid matching evaluation results of each spray layer, compare the gas-liquid matching evaluation results of each spray layer with the preset threshold, and output the process state comparison results. Step 4: For spray layers with abnormal process status comparison results, perform comprehensive analysis on the nozzle status dataset to obtain the nozzle clogging assessment results for each spray layer. After comparing the nozzle clogging assessment results for each spray layer with the preset threshold, output the nozzle status comparison results. Step 5: Based on the nozzle status comparison results and catalyst status comparison results, trigger the corresponding level of early warning signal, and when the nozzle blockage assessment result falls into the forced protection range, control the corresponding spray layer to shut down. Step 6: Based on the process status comparison results, nozzle status comparison results, and catalyst status comparison results, determine the frequency adjustment scheme for each spray layer circulation pump branch, issue frequency conversion adjustment commands to the corresponding circulation pump branches, and regulate the slurry flow rate of the corresponding spray layer.

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