Integrated pilot plant detection scr catalyst regeneration online quality system
By integrating a detection platform and a micro SCR reactor at the end of the SCR catalyst regeneration unit, online quality detection of the catalyst is achieved, solving the problems of detection lag and reliance on experience for parameter adjustment. This improves the stability of regeneration quality and production efficiency, and reduces costs.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SUZHOU XIRE ENERGY SAVING ENVIRONMENTAL PROTECTION TECH CO LTD
- Filing Date
- 2026-03-13
- Publication Date
- 2026-06-16
Smart Images
Figure CN122218154A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of catalyst regeneration technology, specifically relating to an online quality system for SCR catalyst regeneration that integrates pilot-scale testing. Background Technology
[0002] In the production of SCR catalyst regeneration, the current quality assessment method uses offline sampling testing, which has a significant lag. Sampling after catalyst regeneration takes about half a day, and sending samples to a professional pilot test bench for testing takes 2 to 3 days. Most regeneration plants do not have their own pilot test benches, and mailing samples for testing will further extend the testing cycle.
[0003] When test results reveal substandard quality, the entire batch of products has often already been produced, resulting in missed opportunities for process adjustments. This can easily lead to extensive rework and downgrading, causing high production costs. Furthermore, adjustments to regeneration process parameters rely solely on engineer experience, lacking real-time, objective test data feedback, making it difficult to achieve refined and adaptive process optimization. Moreover, current catalyst regeneration quality control only targets the adjustment of single operating parameters; there is no technical solution that uses final product performance data as a control signal to dynamically adjust regeneration process parameters, thus failing to guarantee the stability and consistency of regeneration quality. Summary of the Invention
[0004] This invention provides an online quality system for SCR catalyst regeneration that integrates pilot-scale testing, addressing the technical shortcomings of delayed SCR catalyst regeneration quality testing, reliance on experience for parameter adjustment, and lack of product performance feedback in single-parameter control.
[0005] To achieve the above objectives, the present invention employs the following technical solution: An integrated pilot-scale testing online quality system for SCR catalyst regeneration includes: The regeneration device is electrically connected to an integrated pilot-scale testing device and a control device; The regeneration device includes: The regeneration platform is provided with a cleaning component, a water washing component, an acid washing component and a drying component arranged sequentially along the regeneration process direction of the SCR catalyst module. The water washing assembly is equipped with an online turbidity meter and automatic water inlet and outlet control valves; The pickling assembly is equipped with a pH meter and an automatic control valve for reagent feeding. The integrated pilot-scale testing device includes a testing platform located at the end of the regeneration platform. A micro SCR reactor is fixed on the testing platform. The side of the micro SCR reactor closest to the regeneration platform is connected to the discharge end of the drying component via a quick-clamping interface to achieve automatic sampling and testing of the regenerated SCR catalyst sample.
[0006] In one alternative embodiment, the quick-clamp interface includes: A grasping device is connected to a transport body, which is configured corresponding to the micro SCR reactor; an online element detection device is fixed to the outside of the transport body. The grasping device is used to grasp small monomers in the SCR catalyst module and place the small monomers on the transport body; The transport body is used to transport the small monomers directly above the micro SCR reactor; The online elemental detection device is used to detect the elemental composition of the small monomers in real time during the process of the transmission body transporting the small monomers.
[0007] In one optional embodiment, the grasping device includes: A base on which the main body of the gripping device is mounted; A gripper is installed at the execution end of the main body of the gripping device; The gripping device body is used to drive the gripper to perform displacement and clamping actions, and the gripper is used to clamp or unload the small units of the SCR catalyst module.
[0008] In one optional embodiment, the micro SCR reactor has an internal lower flange, and a spring sealing ring is installed on the upper end face of the lower flange; The spring sealing ring is used to support and fix the small monomers transported into the micro SCR reactor.
[0009] In one alternative embodiment, a heating unit is fitted around the outside of the micro SCR reactor; The heating unit is used to maintain a constant temperature for the micro SCR reactor in order to regulate the reaction temperature inside the micro SCR reactor.
[0010] In one optional embodiment, the heating unit heats the micro SCR reactor at a temperature range of 300~380°C.
[0011] In one optional embodiment, the detection platform is further provided with a gas distribution device and an outlet flue gas analysis device; The gas distribution device is connected to the gas inlet of the micro SCR reactor; The outlet flue gas analysis device is connected to the outlet end of the micro SCR reactor.
[0012] In one optional embodiment, the gas distribution device includes: Gas cylinder assembly, flow meter, and preheating furnace; The gas cylinder assembly is connected to the flow meter via a pipeline. The outlet of the flow meter is connected to the inlet of the preheating furnace. The outlet of the preheating furnace is connected to the inlet of the micro SCR reactor. The gas distribution device is used to prepare and preheat the simulated flue gas and deliver it to the micro SCR reactor.
[0013] In one optional embodiment, the outlet flue gas analysis device includes: NO x Concentration detection instruments and NH3 concentration detection instruments, the NO x Both the NO concentration detection instrument and the NH3 concentration detection instrument are connected to the outlet end of the micro SCR reactor for real-time detection of NO in the flue gas at the outlet of the micro SCR reactor. x Concentration and NH3 concentration.
[0014] In an optional embodiment, the regeneration platform is further provided with a loading component, which is located on the side of the drying component away from the pickling component. The loading component is equipped with an automatic dosing pump for quantitatively adding the active component loading solution into the loading component. A non-contact identification module is provided above the acid washing assembly. The non-contact identification module includes a high-definition camera and a visual analysis unit. The high-definition camera is used to take pictures of the end face of the SCR catalyst module after acid washing. The visual analysis unit is electrically connected to the high-definition camera and is used to analyze the blockage ratio and wear degree of the captured images. The control device is an intelligent control device with embedded intelligent algorithms. The intelligent control device is electrically connected to the automated control component of the regeneration device and the detection component of the integrated pilot-scale testing device, respectively, and is used to receive detection data, calculate performance indicators, and issue process parameter adjustment instructions to the regeneration device.
[0015] Compared with the prior art, the present invention has the following beneficial effects: By installing a testing platform at the end of the regeneration process, coupled with a micro SCR reactor and a quick-clamping interface, online automatic sampling and testing of the regenerated catalyst is achieved, replacing traditional offline sampling and inspection. This completely solves the defects of delayed testing and batch generation of unqualified products. The water washing and acid washing components of the regeneration unit are equipped with online turbidity meters, pH meters, and various automatic control valves, providing real-time and objective process parameter data to the control device, solving the problem of parameter adjustment relying on engineers' experience. The regeneration unit, integrated pilot-scale testing device, and control device are electrically connected, allowing the test data to be fed back to the regeneration unit. This breaks the single-parameter control mode and enables the production parameters to be controlled by product performance data, ensuring the stability and consistency of SCR catalyst regeneration quality, significantly reducing rework costs, and improving the level of process refinement and adaptive optimization. Attached Figure Description
[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.
[0017] Figure 1 A schematic diagram of an integrated pilot-scale testing online quality system for SCR catalyst regeneration provided by the present invention; In the diagram: 1. Dust removal assembly; 2. Water washing assembly; 3. Acid washing assembly; 4. Drying assembly; 5. Water washing assembly; 6. Integrated pilot-scale testing device; 7. Regeneration device; 8. Control device. Detailed Implementation
[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.
[0019] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.
[0020] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0021] In the description of the embodiments of the present invention, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0022] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.
[0023] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.
[0024] To address the technical deficiencies mentioned in the background art, embodiments of the present invention provide an integrated pilot-scale detection-based online quality system for SCR catalyst regeneration. The present invention will be further described in detail below with reference to the accompanying drawings: See Figure 1 An integrated pilot-scale testing online quality system for SCR catalyst regeneration includes: a regeneration device 7 electrically connected to an integrated pilot-scale testing device 6 and a control device 8; wherein, the regeneration device 7 includes: a regeneration platform, on which a cleaning component 1, a water washing component 2, an acid washing component 3, and a drying component 4 are sequentially arranged along the regeneration process direction of the SCR catalyst module; the water washing component 5 is equipped with an online turbidity meter and automatic water inlet and outlet control valves; the acid washing component 3 is equipped with a pH meter and an automatic reagent feeding control valve; the integrated pilot-scale testing device 6 includes a testing platform, which is located at the process end of the regeneration platform, and a micro SCR reactor is fixed on the testing platform. The side of the micro SCR reactor closest to the regeneration platform is connected to the discharge end of the drying component 4 through a quick-clamping interface to realize automatic sampling and testing of the regenerated SCR catalyst sample.
[0025] like Figure 1 As shown, the integrated pilot-scale testing SCR catalyst regeneration online quality system includes a regeneration device 7, which is electrically connected to an integrated pilot-scale testing device 6 and a control device 8. The regeneration device 7 provides a complete regeneration process for the SCR catalyst module, the integrated pilot-scale testing device 6 enables rapid online testing of the regenerated SCR catalyst sample, and the control device 8, as the core control unit of the system, receives the testing data from the integrated pilot-scale testing device 6 and sends process parameter adjustment commands to the regeneration device 7. The three form a closed-loop control system, breaking the problem of disconnect between testing and production in the existing regeneration process, and realizing direct guidance of the production process by the testing data.
[0026] In practice, the regeneration device 7 includes a regeneration platform, which provides a support for the regeneration of the SCR catalyst module. The platform is arranged linearly, and along the regeneration process direction of the SCR catalyst module, there are sequentially arranged a dust removal component 1, a water washing component 2, an acid washing component 3, and a drying component 4. Each component is seamlessly connected along the process direction. The SCR catalyst module can pass through each component sequentially through a conveying mechanism (such as a conveyor belt, roller conveyor, etc.) to complete the corresponding regeneration process, realizing the dust removal, cleaning, acid washing to remove impurities and drying of the deactivated SCR catalyst, laying the foundation for subsequent loading processes and quality inspection.
[0027] The washing assembly 2 is equipped with an online turbidity meter and automatic inlet and outlet water control valves. The online turbidity meter detects the turbidity value of the cleaning water in the washing assembly 2 in real time to determine the cleanliness of the cleaning water. When the turbidity value exceeds the preset threshold, it indicates that the impurity content in the cleaning water has reached the upper limit and cannot effectively clean the SCR catalyst module. At this time, the automatic inlet and outlet water control valves will automatically link together. The outlet water control valve opens to discharge sewage, and the inlet water control valve opens simultaneously to inject clean water until the turbidity value of the cleaning water in the washing assembly 2 returns to the preset range. This realizes the automatic replacement of the cleaning water in the washing assembly 2 without manual intervention, ensuring the cleaning effect of the washing process, and avoiding secondary pollution of the SCR catalyst module due to excessive impurities in the cleaning water.
[0028] In this embodiment, the online turbidity meter can be an industrial-grade online turbidity sensor, which has high detection accuracy and fast response speed. It can transmit turbidity detection data to the control device 8 in real time, providing data support for the operation of the automatic water inlet and outlet control valves. The automatic water inlet and outlet control valves are electric regulating valves, which can receive electrical signals from the control device 8 to achieve precise opening and closing control, and can adjust the water flow rate according to actual cleaning needs.
[0029] In this embodiment, the pickling assembly 3 is equipped with a pH meter and an automatic control valve for reagent feeding. The pH meter detects the pH value of the pickling solution in the pickling assembly 3 in real time to determine the pickling capacity of the pickling solution. During the pickling process, the pickling solution reacts with impurities such as alkali metals on the surface of the SCR catalyst module, resulting in a decrease in the concentration of the pickling solution and an increase in the pH value. When the pH value exceeds the preset process range, the pickling capacity decreases significantly and cannot effectively remove alkali metal impurities from the SCR catalyst module. At this time, the automatic control valve for reagent feeding will automatically open to add pickling agent to the pickling assembly 3 until the pH value of the pickling solution returns to the preset process range, thereby achieving automatic regulation of the pickling solution concentration, ensuring the impurity removal effect of the pickling process, and avoiding the reduction in activity of the SCR catalyst after regeneration due to alkali metal residue.
[0030] Furthermore, the pH meter uses an industrial-grade online pH sensor, whose detection data can be transmitted to the control device 8 in real time; the automatic control valve for chemical feeding uses a quantitative dosing valve, which can accurately control the amount of pickling agent added based on the detection data of the pH meter, avoiding waste or insufficient addition of pickling agent.
[0031] In an optional embodiment, the regeneration platform is further provided with a loading component. The loading component is located on the side of the drying component 4 away from the pickling component 3. That is, the drying component 4 is a transition process between the pickling component 3 and the loading component. After the SCR catalyst module is dried by the drying component 4, it directly enters the loading component for loading of active components, ensuring the working effect of the loading process and avoiding uneven loading of active components due to incomplete drying.
[0032] The loading component is equipped with an automatic dosing pump, which is used to quantitatively add the active component loading solution into the loading component. The active component loading solution is selected from active component solutions such as ammonium metavanadate solution that are compatible with SCR catalyst. The automatic dosing pump can receive instructions from the control device 8 to precisely adjust the dosing amount and dosing speed of the loading solution, thereby realizing dynamic control of the concentration of the active component loading solution. This ensures that the active component loading amount of the SCR catalyst module meets the process requirements and solves the problem that the concentration of the loading solution is fixed in the existing loading process and cannot be adjusted according to the test data.
[0033] In this embodiment, a non-contact identification module is provided above the pickling assembly 3. The non-contact identification module includes a high-definition camera and a visual analysis unit. The high-definition camera is electrically connected to the visual analysis unit. The high-definition camera is an industrial-grade high-definition camera, whose shooting angle covers the working area of the pickling assembly 3, allowing for clear imaging of the end face of the pickled SCR catalyst module. After imaging, the image data is transmitted to the visual analysis unit in real time. The visual analysis unit has built-in image recognition and analysis algorithms used to analyze the blockage ratio and wear degree of the images captured by the high-definition camera.
[0034] The specific analysis process is as follows: First, the image is preprocessed to remove noise and correct distortion. Then, image recognition technology is used to identify the number of through holes and plugs on the end face of the SCR catalyst module and calculate the plug ratio. At the same time, the wear area on the windward side of the SCR catalyst module is identified, the wear depth is measured, and the degree of wear is determined.
[0035] When the visual analysis unit determines that the blockage rate exceeds the performance guarantee value (usually 3%), it indicates that the cleaning and rinsing process of the SCR catalyst module is incomplete, resulting in severe internal blockage of the catalyst. Even with continued processing, its performance cannot be restored. In this case, the system will determine that the SCR catalyst module needs to be reworked or scrapped. When the analysis shows that the maximum wear (fracture) depth of the unit is greater than 10% of its height, it indicates that the SCR catalyst module is severely damaged and meets the scrapping guidelines. The system will determine that the SCR catalyst module should be scrapped directly and will control the conveying mechanism to stop transporting it to the subsequent drying component 4 and loading component. This prevents damaged catalyst from entering subsequent processes and causing energy waste, while also reducing the cost of ineffective regeneration. The non-contact identification module enables rapid online detection and screening of SCR catalyst modules after acid washing, preemptively removing unqualified modules and improving the overall efficiency and quality of regeneration production.
[0036] The integrated pilot-scale testing device 6 includes a testing platform, which is located at the end of the regeneration platform process. That is, after the SCR catalyst module completes all regeneration processes through the regeneration device 7, it directly enters the testing platform for quality testing without the need for offline transfer, thus fundamentally solving the problem of testing lag caused by the existing offline testing methods.
[0037] A micro SCR reactor is fixed on the testing platform. The micro SCR reactor is the core testing component of the integrated pilot-scale testing device 6. It is designed based on the principle of fluid mechanics similarity and is a laboratory miniaturized structure of the large SCR reactor. It can accurately simulate the actual working environment of the SCR catalyst and realize the testing of the denitrification performance of the regenerated SCR catalyst sample.
[0038] The side of the micro SCR reactor closest to the regeneration platform is connected to the discharge end of the drying component 4 via a quick-clamping interface. The quick-clamping interface is the connecting component between the regeneration device 7 and the integrated pilot-scale testing device 6, enabling automatic sampling and transportation of SCR catalyst samples after regeneration. This ensures the timeliness and accuracy of sampling, eliminates the need for manual sampling, significantly shortens sampling time, and improves testing efficiency.
[0039] In one optional embodiment, the quick-clamping interface includes a gripping device, a transport body, and an online element detection device. The gripping device is connected to the transport body, which is configured to correspond to the micro SCR reactor, i.e., the transport end of the transport body extends directly above the micro SCR reactor to ensure that the sample can be accurately transported into the micro SCR reactor. The online element detection device is fixed on the outside of the transport body, with its detection probe facing the transport surface of the transport body, and can perform real-time element detection on the SCR catalyst sample on the transport body.
[0040] The gripping device is used to grasp small monomers in SCR catalyst modules. SCR catalyst modules consist of multiple uniformly sized small monomers; typically, the small monomers in honeycomb catalysts are 150mm long and wide. This size is compatible with the internal dimensions of micro SCR reactors, ensuring accurate detection. The gripping device includes a base, a main body, and a gripper. The base provides a stable mounting foundation for the device. The main body is mounted on the base, and the gripper is installed at the actuator end of the main body. The main body can be an industrial robot or an electric sliding module, possessing multi-dimensional displacement adjustment capabilities, which can drive the gripper to perform displacement and clamping actions, achieving precise grasping of the small monomers in the SCR catalyst module.
[0041] In this embodiment, the gripper is a pneumatic or electric gripper with adjustable gripping force. It can hold small monomers stably, avoiding damage to the catalyst sample due to excessive gripping force. At the same time, it can unload the small monomers and place them stably on the transport body.
[0042] In this embodiment, a high-precision servo conveyor belt is selected as the main transmission body. It has high transmission accuracy and stable operation, and can accurately transport the small single unit placed by the gripping device to the top of the micro SCR reactor, ensuring that the sample can fall accurately into the micro SCR reactor and avoid sample deviation leading to detection errors. The running speed of the high-precision servo conveyor belt can be adjusted according to the detection requirements, and its working state is controlled by the control device 8, which can achieve linkage operation with the gripping device and the micro SCR reactor.
[0043] In this embodiment, a LIBS online elemental analysis device is selected, which has the capability of rapid, real-time, and non-contact elemental detection. It can perform real-time detection of the elemental composition of small monomers during the transport process. The detected elements include key elements related to SCR catalyst activity, such as V₂O₅, K₂O, and SiO₂. After detection, the elemental analysis data is transmitted to the control device 8 in real time. The control device 8 compares the detection data with preset elemental target values to analyze whether the elemental composition of the catalyst sample meets the process requirements, and provides elemental-level data support for subsequent process parameter adjustments. The LIBS online elemental analysis device has high detection accuracy and fast response speed, and can operate synchronously with the transport process, completing the detection without interrupting the transport, thus ensuring detection efficiency.
[0044] In one optional embodiment, the micro SCR reactor has a lower flange inside, which is fixedly installed at the bottom of the micro SCR reactor. A spring sealing ring is installed on the upper end face of the lower flange. The spring sealing ring is made of elastic material and has a certain degree of extensibility and support. When the small monomer falls into the micro SCR reactor from the transport body, the bottom end of the small monomer will abut against the spring sealing ring. The spring sealing ring can support and fix the small monomer transported into the micro SCR reactor, ensuring the installation stability of the small monomer in the micro SCR reactor and avoiding the small monomer from shifting or shaking due to flue gas impact during the detection process. At the same time, the spring sealing ring can seal the gap between the small monomer and the lower flange, ensuring that the simulated flue gas can flow through the pores of the small monomer and avoid flue gas leakage that may cause detection errors.
[0045] Because the specifications of the small monomers are uniform, the dimensions of the lower flange and spring sealing ring are designed according to the specifications of the small monomers to ensure the compatibility between the small monomers and the micro SCR reactor. After the small monomers are installed, a uniform annular gap is formed between its outer wall and the inner wall of the micro SCR reactor. This structural design ensures that the simulated flue gas can flow evenly through the entire channel of the small monomer after entering from the top of the micro SCR reactor, and then flow out from the bottom of the micro SCR reactor, accurately simulating the actual working flow field of the SCR catalyst and ensuring the authenticity and reference value of the test results.
[0046] Furthermore, a heating unit is fitted on the outside of the micro SCR reactor. The heating unit is an electric heating jacket or a tubular heating furnace, which is tightly fitted to the outer wall of the micro SCR reactor to achieve uniform heating of the micro SCR reactor.
[0047] The heating unit is used to maintain a constant temperature for the micro SCR reactor, thereby adjusting the reaction temperature inside the micro SCR reactor and ensuring that the detection process is carried out at the preset reaction temperature, accurately simulating the actual working temperature environment of the SCR catalyst.
[0048] In one optional embodiment, the heating unit heats the micro SCR reactor at a temperature range of 300~380℃, which is the conventional operating temperature of the SCR catalyst. The specific heating temperature can be precisely adjusted by the control device 8 according to the design parameters of the SCR catalyst and the actual working requirements. The heating unit can transmit the internal temperature data of the micro SCR reactor to the control device 8 in real time. The control device 8 achieves constant temperature control of the heating unit based on the temperature data to avoid detection errors caused by temperature fluctuations.
[0049] In one optional embodiment, the detection platform is further equipped with a gas distribution device and an outlet flue gas analysis device. The gas distribution device is connected to the inlet end of the micro SCR reactor and is used to provide the micro SCR reactor with simulated flue gas that meets the process requirements. The outlet flue gas analysis device is connected to the outlet end of the micro SCR reactor and is used to perform real-time detection of the outlet flue gas of the micro SCR reactor. The two work together to realize the detection of the denitrification performance of the SCR catalyst sample.
[0050] The gas distribution system includes a gas cylinder assembly, a flow meter, and a preheating furnace. The gas cylinder assembly consists of multiple gas cylinders, each filled with NO. x The system provides simulated flue gas including gases such as NH3, O2, and water vapor. Each gas cylinder is connected to a flow meter via pipelines, each equipped with a valve for individual on / off control of the gas. High-precision mass flow meters are used to accurately control the flow rate of each gas, enabling precise formulation of the simulated flue gas composition and concentration to meet the needs of different testing conditions.
[0051] In this embodiment, the outlet of the flow meter is connected to the inlet of the preheating furnace. The preheating furnace is an electric heating furnace, which preheats the mixed gas prepared by the flow meter to the same reaction temperature (300~380℃) as the inside of the micro SCR reactor. This prevents internal temperature fluctuations caused by the low-temperature mixed gas entering the micro SCR reactor, ensuring temperature stability during the detection process. The outlet of the preheating furnace is connected to the inlet of the micro SCR reactor. The preheated simulated flue gas enters the micro SCR reactor through this pipeline and undergoes a denitrification reaction with the catalyst sample.
[0052] All components of the gas distribution device, including valves, flow meters, and preheating furnaces of the gas cylinder group, are electrically connected to the control device 8. The control device 8 can issue commands according to the detection requirements to precisely adjust the flow rate of each gas, the concentration of the simulated flue gas, and the preheating temperature, thereby realizing the automated control of the gas distribution device and ensuring the accuracy of the simulated flue gas preparation and the preheating effect.
[0053] In this embodiment, the outlet flue gas analyzer includes NO. x Concentration detection instruments and NH3 concentration detection instruments, NO x Both the concentration detection instrument and the NH3 concentration detection instrument are connected to the outlet of the micro SCR reactor via pipelines, which can collect the outlet flue gas of the micro SCR reactor in real time for concentration detection.
[0054] NO x Concentration detection instruments can be selected from brands such as Testo, Rosemount, and Siemens, using online NO... x The concentration detector has high detection accuracy and fast response speed, and can detect NO in the outlet flue gas in real time. xConcentration; NH3 concentration detection instruments can be online NH3 concentration meters from brands such as SICK, which can detect the NH3 concentration in the outlet flue gas in real time, thus realizing the detection of ammonia slip.
[0055] NO x Both the concentration detection instrument and the NH3 concentration detection instrument are electrically connected to the control device 8, which can transmit the real-time detected concentration data to the control device 8. The control device 8 can then adjust the NO concentration based on the concentration of the imported simulated flue gas. x Concentration and NO in the outlet flue gas x The concentration was used to calculate the denitrification efficiency of the catalyst sample. At the same time, the detected ammonia slip was combined to comprehensively judge whether the denitrification performance of the catalyst sample met the process requirements. The setting of the outlet flue gas analysis device enabled real-time and accurate detection of the denitrification performance of the catalyst sample, providing core performance data support for subsequent process parameter adjustments.
[0056] In one optional embodiment, the control device 8 is an intelligent control device, which is an industrial-grade controller, such as a PLC or industrial computer. It has embedded intelligent algorithms, including PID control algorithms, data processing algorithms, and process parameter optimization algorithms. It is the core control and data processing unit of the entire system. The intelligent control device is electrically connected to the automation control components of the regeneration device 7 and the detection components of the integrated pilot-scale testing device 6, respectively, to realize bidirectional data transmission and precise command issuance.
[0057] During operation, the SCR catalyst module is conveyed by the conveying mechanism and passes through the cleaning component 1, water washing component 2, acid washing component 3, drying component 4 and loading component in sequence along the process direction of the regeneration platform. All regeneration processes are completed according to the set process parameters. The acid-washed SCR catalyst module is detected and screened by a non-contact identification module to remove unqualified modules with blocked holes and severe damage. Qualified modules continue to the subsequent processes.
[0058] The regenerated SCR catalyst module is not removed from the production line but directly enters the testing platform of the integrated pilot-scale testing device 6. A gripping device with a quick-clamping interface precisely grabs the small monomers from the catalyst module and places them on a transport body. The transport body then conveys the small monomers directly above the micro SCR reactor. During transport, an online elemental detection device performs elemental analysis on the small monomers. After the small monomers fall into the micro SCR reactor, they are supported and fixed by spring-sealed rings. A gas distribution device prepares and preheats simulated flue gas, which is then introduced into the micro SCR reactor to react with the small monomers in a denitrification reaction. A heating unit maintains the interior of the micro SCR reactor at a preset reaction temperature. An outlet flue gas analyzer monitors the outlet flue gas of the micro SCR reactor in real time to obtain NO... x And NH3 concentration data.
[0059] The intelligent control device receives all the detection data from the integrated pilot-scale testing device 6, calculates key performance indicators such as denitrification efficiency, catalyst activity, and ammonia slip, compares them with preset target values to determine whether the regeneration quality is qualified, and identifies the reasons for non-compliance by combining elemental analysis data. For the reasons for non-compliance, the intelligent control device generates process parameter adjustment instructions and sends them to the corresponding automated control components of the regeneration device 7, and the optimized new parameters are used for production starting from the next batch of catalyst modules. If the test is qualified, the current process parameters are recorded, the catalyst module is taken off the production line and packaged, and the system continuously tests and controls subsequent batches to form a closed-loop optimization.
[0060] The component structures, working principles, and control methods not described in detail in this embodiment are all mature industrial automation technologies in the prior art. Appropriate equipment and technical means can be selected according to actual production needs, and none of them exceed the protection scope of this invention.
[0061] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.
Claims
1. An online quality system for SCR catalyst regeneration integrating pilot-scale testing, characterized in that, include: The regeneration device is electrically connected to an integrated pilot-scale testing device and a control device; The regeneration device includes: The regeneration platform is provided with a cleaning component, a water washing component, an acid washing component and a drying component arranged sequentially along the regeneration process direction of the SCR catalyst module. The water washing assembly is equipped with an online turbidity meter and automatic water inlet and outlet control valves; The pickling assembly is equipped with a pH meter and an automatic control valve for reagent feeding. The integrated pilot-scale testing device includes a testing platform located at the end of the regeneration platform. A micro SCR reactor is fixed on the testing platform. The side of the micro SCR reactor closest to the regeneration platform is connected to the discharge end of the drying component via a quick-clamping interface to achieve automatic sampling and testing of the regenerated SCR catalyst sample.
2. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 1, characterized in that, The quick-clamping interface includes: A grasping device is connected to a transport body, which is configured corresponding to the micro SCR reactor; an online element detection device is fixed to the outside of the transport body. The grasping device is used to grasp small monomers in the SCR catalyst module and place the small monomers on the transport body; The transport body is used to transport the small monomers directly above the micro SCR reactor; The online elemental detection device is used to detect the elemental composition of the small monomers in real time during the process of the transmission body transporting the small monomers.
3. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 2, characterized in that, The grasping device includes: A base on which the main body of the gripping device is mounted; A gripper is installed at the execution end of the main body of the gripping device; The gripping device body is used to drive the gripper to perform displacement and clamping actions, and the gripper is used to clamp or unload the small units of the SCR catalyst module.
4. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 2, characterized in that, The micro SCR reactor is equipped with a lower flange inside, and a spring sealing ring is installed on the upper end face of the lower flange; The spring sealing ring is used to support and fix the small monomers transported into the micro SCR reactor.
5. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 1, characterized in that, A heating unit is fitted on the outside of the micro SCR reactor; The heating unit is used to maintain a constant temperature for the micro SCR reactor in order to regulate the reaction temperature inside the micro SCR reactor.
6. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 5, characterized in that, The heating unit provides a heating temperature range of 300~380℃ for the micro SCR reactor.
7. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 1, characterized in that, The detection platform is also equipped with a gas distribution device and an outlet flue gas analysis device. The gas distribution device is connected to the gas inlet of the micro SCR reactor; The outlet flue gas analysis device is connected to the outlet end of the micro SCR reactor.
8. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 7, characterized in that, The gas distribution device includes: Gas cylinder assembly, flow meter, and preheating furnace; The gas cylinder assembly is connected to the flow meter via a pipeline. The outlet of the flow meter is connected to the inlet of the preheating furnace. The outlet of the preheating furnace is connected to the inlet of the micro SCR reactor. The gas distribution device is used to prepare and preheat the simulated flue gas and deliver it to the micro SCR reactor.
9. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 7, characterized in that, The outlet flue gas analysis device includes: NO x Concentration detection instruments and NH3 concentration detection instruments, the NO x Both the NO concentration detection instrument and the NH3 concentration detection instrument are connected to the outlet end of the micro SCR reactor for real-time detection of NO in the flue gas at the outlet of the micro SCR reactor. x Concentration and NH3 concentration.
10. The integrated pilot-scale testing online quality system for SCR catalyst regeneration according to claim 1, characterized in that, The regeneration platform is also equipped with a loading component, which is located on the side of the drying component away from the pickling component. The loading component is equipped with an automatic dosing pump, which is used to quantitatively add the active component loading solution into the loading component. A non-contact identification module is provided above the acid washing assembly. The non-contact identification module includes a high-definition camera and a visual analysis unit. The high-definition camera is used to take pictures of the end face of the SCR catalyst module after acid washing. The visual analysis unit is electrically connected to the high-definition camera and is used to analyze the blockage ratio and wear degree of the captured images. The control device is an intelligent control device with embedded intelligent algorithms. The intelligent control device is electrically connected to the automated control component of the regeneration device and the detection component of the integrated pilot-scale testing device, respectively, and is used to receive detection data, calculate performance indicators, and issue process parameter adjustment instructions to the regeneration device.