A cylindrical modular scr reactor

Abstract

This invention discloses a cylindrical modular SCR reactor, comprising a central flue gas inlet pipe with multiple layers of mixing guide plates inside and an ammonia injection mixing assembly at the top; multiple independent catalyst modules are connected to the top sidewall of the central flue gas inlet pipe via multiple branch pipes, a first shut-off valve, and flexible pipe connections; each catalyst module is arranged in a cylindrical manner around the central flue gas inlet pipe, and the outlet of each catalyst module is connected to a manifold cavity via a second shut-off valve; flue gas enters from the central flue gas inlet pipe, is rectified by the mixing guide plates and mixed by ammonia injection, and is then distributed to each catalyst module by the branch pipes, and discharged into the manifold cavity after denitrification; the top of the reactor is unobstructed by pipelines and can be hoisted as a whole; by closing the shut-off valves on the upper and lower sides of any catalyst module, independent isolation and online replacement without shutting down the system can be achieved for a single catalyst module, solving the problems of complex construction, difficult replacement, and the need for shutdown maintenance in traditional SCR systems.

Description

Technical Field

[0001] This invention relates to the field of flue gas denitrification technology, specifically to a cylindrical modular SCR reactor, which is particularly suitable for selective catalytic reduction denitrification equipment in flue gas purification systems such as coal-fired, gas-fired, and industrial furnaces. Background Technology

[0002] SCR (Selective Catalytic Reduction) denitrification is currently the mainstream technology for controlling nitrogen oxide emissions and is widely used in industries such as power, metallurgy, and chemicals. Traditional SCR reactors often employ a monolithic catalyst zone structure, which has the following technical drawbacks: 1. The catalyst frame is fabricated and assembled on-site, which involves complex construction procedures, long cycles, and difficulty in controlling installation accuracy. 2. The dense piping at the top of the reactor makes it impossible to hoist the catalyst as a whole; it can only be disassembled piece by piece, resulting in low replacement efficiency. 3. The catalyst unit lacks an independent isolation valve, requiring shutdown for maintenance, replacement, and repair, resulting in production interruption and economic losses; 4. Single module failures cannot be isolated and handled independently, which can easily affect the operation of the entire system.

[0003] Existing modular SCR technologies are mostly single-layer flat or multi-layer stacked structures, failing to achieve a coordinated combination of central air intake, cylindrical surround, independent double cut-off, unobstructed top overall hoisting, and online operation and maintenance. This makes it difficult to fundamentally solve the industry pain points of construction, replacement, and operation and maintenance. Summary of the Invention

[0004] The purpose of this invention is to provide a cylindrical modular SCR reactor that enables factory prefabrication of catalyst modules, rapid on-site assembly, independent isolation of individual modules, and online replacement and maintenance without shutting down the system, thereby reducing construction difficulty, improving operation and maintenance efficiency, and ensuring continuous production operation.

[0005] The objective of this invention is achieved through the following technical solution: A cylindrical modular SCR reactor, comprising: The vertically arranged central flue pipe has multiple layers of mixing guide plates inside along the height direction, and an ammonia injection mixing component is installed at the top. Multiple branch pipes, one end of which is sealed to the top side wall of the central flue pipe, and the other end is connected to the air inlet of the catalyst module via the first shut-off valve and the flexible pipe connection. Multiple independently sealed catalyst modules are arranged in a cylindrical manner around the central flue pipe. Each catalyst module has a lifting lug on its top, and its outlet is connected to the manifold via a second shut-off valve. The manifold is used to collect the flue gas discharged from each catalyst module and connect it to the main flue pipe; The top of the reactor is unobstructed by pipelines, forming a vertical hoisting channel for the entire catalyst module; by closing the first and second shut-off valves on the upper and lower sides of any catalyst module, the catalyst module can be independently isolated and replaced online.

[0006] As a further improvement of the present invention, the ammonia injection mixing assembly includes an ammonia injection pipe and an ammonia injection grille extending into the central flue pipe, the ammonia injection grille being located above the mixing guide plate.

[0007] As a further improvement of the present invention, the number of the branch pipes is matched with the number of catalyst modules, and each branch pipe is radially distributed with the central flue pipe as the center.

[0008] As a further improvement of the present invention, the catalyst module is an independent box made of high-temperature and corrosion-resistant steel plate welded together, and is filled with honeycomb, plate or corrugated catalyst units.

[0009] As a further improvement of the present invention, the cylindrical surrounding distribution is either a uniform annular distribution or a uniform fan-shaped distribution.

[0010] As a further improvement of the present invention, the confluence cavity is an annular gas collecting cavity or a circular gas collecting cavity.

[0011] As a further improvement of the present invention, the top of the central flue is provided with a first maintenance manhole, and each catalyst module is provided with a second maintenance manhole on its side, forming a double maintenance channel.

[0012] As a further improvement of the present invention, the catalyst module is a factory-prefabricated standardized module, which is assembled on site using flange docking, eliminating the need for on-site fabrication.

[0013] As a further improvement of the present invention, the flexible pipe connection is provided between the branch pipe and the catalyst module for quick disassembly and reassembly and alignment compensation during hoisting and disassembly.

[0014] As a further improvement of the present invention, a top flange is provided on the other end of the branch pipe, the top flange is connected to one end of the first shut-off valve, and the other end of the first shut-off valve is sealed to the air inlet of the catalyst module through a flexible pipe connection; a bottom flange is provided at the air outlet of the catalyst module, the bottom flange is connected to one end of the second shut-off valve, and the other end of the second shut-off valve is connected to the manifold.

[0015] The above technical solution has the following beneficial effects: 1. The factory adopts standardized prefabrication, and only flange connection and fixing are required on site. Complex processes such as on-site welding and pouring are eliminated, which greatly shortens the construction cycle, reduces the construction difficulty, and ensures the assembly accuracy and quality consistency. 2. Each catalyst module is equipped with a shut-off valve on both the top and bottom sides. Closing the valve can completely isolate the module, allowing for replacement or maintenance without stopping the machine. The remaining modules will continue to operate normally, ensuring continuous production and avoiding economic losses. 3. With no pipes obstructing the top of the reactor, the boom can be directly and vertically extended in, enabling the overall hoisting of the catalyst module and greatly improving installation and replacement efficiency; 4. The flue gas flow path is designed with central flue gas inlet, multi-layer mixing and guiding, top diversion to cylindrical surrounding modules, and bottom convergence. This ensures a simple and smooth flue gas flow path without unnecessary bends, guaranteeing uniform air intake in each module, sufficient denitrification reaction, and stable and reliable efficiency. 5. The integrated structural design avoids the complex internal support and pipeline obstruction of traditional reactors, effectively reducing flue gas flow resistance and reducing system energy consumption; 6. Manholes are provided at the top of the central flue gas inlet pipe and on the side of each catalyst module, allowing maintenance personnel to inspect and maintain the ammonia injection assembly, baffle plate, and catalyst module internally without shutting down the system, thus improving the convenience of operation and maintenance. Attached Figure Description

[0016] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0017] The structures, proportions, sizes, etc. shown in this specification are only used to complement the content disclosed in the specification for those skilled in the art to understand and read, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationships, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0018] Figure 1 This is a cross-sectional structural diagram provided by the present invention.

[0019] Figure 2 This is a top view structural diagram provided by the present invention.

[0020] In the picture: 1. Central smoke inlet pipe; 11. Mixing guide plate; 2. Ammonia injection mixing assembly; 21. Ammonia injection pipeline; 22. Ammonia injection grid; 3. Catalyst module; 4. Branch pipes; 5. Manifold cavity; 61. First shut-off valve; 62. Second shut-off valve; 7. Flexible pipe connections; 81. First maintenance manhole; 82. Second maintenance manhole. Detailed Implementation

[0021] In this invention, unless otherwise stated, directional terms such as "upper," "lower," "top," and "bottom" are generally used in relation to the direction shown in the accompanying drawings, or in relation to the vertical, perpendicular, or gravitational direction of the component itself; similarly, for ease of understanding and description, "inner" and "outer" refer to the inner and outer contours of each component itself, but the above directional terms are not intended to limit this invention.

[0022] First embodiment, such as Figures 1-2 As shown, a cylindrical modular SCR reactor includes: a central flue gas inlet pipe 1, an ammonia injection mixing component 2, multiple independent catalyst modules 3, branch pipes 4, a manifold 5, a shut-off valve 6, and a flexible pipe connection 7. The components work together to achieve flue gas denitrification treatment, and the structure is compact and easy to maintain.

[0023] The central flue gas inlet duct 1 is vertically arranged and can be made of high-temperature and corrosion-resistant steel. Inside the central flue gas inlet duct 1, multiple layers of mixing guide plates 11 are arranged along the height direction. The mixing guide plates 11 can be straight plates, curved plates, or louvered structures, all of which can achieve the function of flue gas rectification and uniform mixing of ammonia fumes. An ammonia injection mixing assembly 2 is installed at the top of the central flue gas inlet duct 1. The ammonia injection mixing assembly 2 includes an ammonia injection pipe 21 and an ammonia injection grille 22. The ammonia injection grille 22 extends into the interior of the central flue gas inlet duct 1 and is located above the mixing guide plates 11, ensuring that the ammonia gas can fully contact and uniformly mix with the flue gas after injection, thereby improving denitrification efficiency.

[0024] The side wall of the central flue pipe 1 extends upward to form multiple branch pipes 4. The number of branch pipes 4 can be set according to the number of catalyst modules 3. One end of the branch pipe 4 is sealed to the top of the central flue pipe, and the other end is provided with a top flange. The top flange is connected to one end of the first shut-off valve 61. The other end of the first shut-off valve 61 is sealed to the air inlet of the catalyst module 3 through a flexible pipe connection 7. The flexible pipe connection 7 can be corrugated or rubber structure, which can absorb the axial and lateral displacement generated during the operation of the equipment, avoid pipeline stress damage, and facilitate the disassembly, maintenance and replacement of various components.

[0025] In this design, catalyst module 3 is an independent sealed enclosure, which can be made of high-temperature and corrosion-resistant steel plate. The enclosure is filled with catalyst units, which can be honeycomb, plate, or corrugated structures, all capable of achieving flue gas denitrification. Multiple catalyst modules 3 are arranged in a cylindrical ring around the central flue gas inlet pipe 1. This cylindrical ring distribution includes two modes: a uniform annular distribution and a uniform fan-shaped distribution. Both distribution modes can be flexibly selected based on the overall reactor size and flue gas processing capacity, and both ensure uniform flue gas distribution across all catalyst modules 3.

[0026] Each catalyst module 3 constitutes an independent sector structure, and the sector angle can be reasonably divided according to the number of catalyst modules 3. Each catalyst module 3 is isolated from the others. The catalyst modules 3 and the central flue gas inlet pipe 1 together constitute the main body of the cylindrical reactor. A bottom flange is provided at the gas outlet of the catalyst module 3. The bottom flange is connected to one end of the second shut-off valve 62, and the other end of the second shut-off valve 62 is connected to the manifold 5, ensuring that the flue gas passage of a single catalyst module 3 can be independently cut off during maintenance.

[0027] The manifold 5 is an annular or circular gas collection chamber, and its material is consistent with that of the central flue pipe 1. The annular gas collection chamber is adapted to the annularly distributed catalyst modules 3, and the circular gas collection chamber is adapted to the fan-shaped distributed catalyst modules 3. The two structures can be flexibly selected according to the actual layout. The gas outlets of all catalyst modules 3 are sealed and merged into this chamber. After being rectified and pressure-equalized by the manifold 5, the gas is discharged through the main flue pipe to ensure stable emission of flue gas.

[0028] In this design, each catalyst module 3 is equipped with a dedicated lifting lug on its top, enabling the overall lifting of the catalyst module 3 and facilitating its installation and disassembly. By closing the first shut-off valve 61 and the second shut-off valve 62 on the upper and lower sides of the corresponding catalyst module 3, the flue gas in the central flue gas inlet pipe 1 can be effectively blocked from entering the catalyst module 3. Simultaneously, by disassembling the flange at the connection point of the catalyst module 3, a single catalyst module 3 can be completely isolated and removed, achieving independent isolation of each module without affecting the normal operation of other modules. The reactor top is unobstructed, allowing the entire reactor to be lifted and replaced as a whole using a dedicated lifting tool, adapting to the operation and maintenance needs of different scenarios.

[0029] Each catalyst module 3 has a second maintenance manhole 82 on its side. The manhole can be circular or square and equipped with a sealed end cap. Together with the first maintenance manhole 81 at the top of the central flue gas pipe 1, they form a dual maintenance channel. Maintenance personnel can access the ammonia injection mixing assembly 2 and the mixing guide plate 11 through the first maintenance manhole 81, and access the internal components of the catalyst module 3 through the second maintenance manhole 82. This supports online operation and maintenance, allowing daily inspection and maintenance to be completed without downtime, thus improving operational efficiency.

[0030] During use, flue gas enters from the central flue pipe 1 from bottom to top. After being rectified and mixed by the multi-layer mixing guide plate 11 inside the pipe, it is evenly distributed to each catalyst module 3 by the top branch pipe 4. After the flue gas fully reacts with the catalyst inside the catalyst module 3 to achieve denitrification, it flows into the bottom confluence cavity 5 through the gas outlet of the catalyst module 3 and is finally stably discharged through the main flue pipe, ensuring that the denitrification process is continuous and efficient.

[0031] In this solution, all modules, fittings, and valves of the SCR reactor are prefabricated in the factory. Standardized production processes can be employed during factory prefabrication to ensure dimensional and assembly accuracy of each component. All prefabricated components can be made from high-temperature and corrosion-resistant steel. Fittings can be seamless or welded steel pipes, and valves can be gate valves, butterfly valves, or other components with shut-off and control functions. On-site installation only requires flange connection and fixing of each component, with sealing gaskets at the connection points to ensure sealing performance. Compared to conventional on-site fabrication of SCR reactor structures, this solution allows for complete prefabrication in the factory, eliminating the need for complex on-site welding and casting processes, significantly reducing on-site construction difficulty and avoiding quality deviations caused by environmental factors and personnel skill limitations during on-site fabrication.

[0032] This invention employs a factory prefabrication + on-site assembly construction mode, completely eliminating the on-site fabrication stage. This not only shortens the on-site construction cycle and reduces the workload of on-site personnel, but also significantly improves the overall assembly precision of the reactor and reduces the incidence of subsequent operation and maintenance failures. The reactor features an integrated structure with central mixing, top diversion, and bottom convergence. The flue gas flow channel design is simple and smooth, without unnecessary bends or obstructions, effectively reducing flue gas flow resistance and energy consumption. Simultaneously, it ensures uniform distribution of flue gas within each catalyst module, allowing the denitrification reaction to proceed fully and guaranteeing stable and reliable denitrification efficiency. Furthermore, the reactor top is free of any pipe obstructions, allowing the crane arm to extend vertically directly into the reactor, enabling the entire catalyst module to be lifted without disassembling other pipelines, significantly improving module replacement efficiency.

[0033] The core feature of this invention is that the catalyst module is divided into multiple independent units, each of which can be isolated individually via shut-off valves on its upper and lower sides. Because the catalyst module is a multi-unit design, shutting off one module allows the remaining modules to operate normally, minimizing the impact on the overall denitrification reaction effect and not affecting the reactor's normal operation. Furthermore, since there are no pipes obstructing the reactor, the boom can directly extend into the work area, enabling rapid replacement of the corresponding catalyst module without shutting down the reactor, significantly improving maintenance efficiency.

[0034] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0035] It should be noted that the terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in sequences other than those illustrated or described herein.

[0036] The above description is merely a preferred embodiment of the present invention and is not intended to limit the 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. A cartridge modular SCR reactor characterized by, include: A vertically arranged central flue (1) has multiple layers of mixing guide plates (11) inside along the height direction, and an ammonia injection mixing component (2) is provided at the top. Multiple branch pipes (4) are connected at one end to the top side wall of the central flue pipe (1) and at the other end to the air inlet of the catalyst module (3) via the first shut-off valve (61) and the flexible pipe connection (7). Multiple independently sealed catalyst modules (3) are arranged in a cylindrical manner around the central flue pipe (1). Each catalyst module (3) has a lifting lug on its top and its outlet is connected to the manifold (5) via a second shut-off valve (62). The manifold (5) is used to collect the flue gas discharged from each catalyst module (3) and connect it to the main flue pipe; The top of the reactor is unobstructed by pipelines, forming an overall vertical hoisting channel for the catalyst module (3); by closing the first shut-off valve (61) and the second shut-off valve (62) on the upper and lower sides of any catalyst module (3), the catalyst module (3) can be independently isolated and replaced online.

2. The cartridge modular SCR reactor of claim 1, wherein, The ammonia injection mixing assembly (2) includes an ammonia injection pipe (21) and an ammonia injection grille (22) extending into the central flue pipe (1), the ammonia injection grille (22) being located above the mixing guide plate (11).

3. The cartridge modular SCR reactor of claim 1, wherein, The number of the branch pipes (4) matches the number of catalyst modules (3), and each branch pipe (4) is radially distributed with the central flue pipe (1) as the center.

4. The cartridge modular SCR reactor of claim 1, wherein, The catalyst module (3) is an independent box made of high-temperature and corrosion-resistant steel plate, and is filled with honeycomb, plate or corrugated catalyst units.

5. The cartridge modular SCR reactor of claim 1, wherein, The cylindrical surrounding distribution can be either a uniform ring distribution or a uniform fan-shaped distribution.

6. The cartridge modular SCR reactor of claim 1, wherein, The confluence cavity (5) is an annular gas collecting cavity or a circular gas collecting cavity.

7. The cartridge modular SCR reactor of claim 1, wherein, The central flue (1) is provided with a first maintenance manhole (81) at the top, and each catalyst module (3) is provided with a second maintenance manhole (82) on the side, forming a double maintenance channel.

8. The cartridge modular SCR reactor of claim 1, wherein, The catalyst module (3) is a factory-prefabricated standardized module that is assembled on-site using flange docking, eliminating the need for on-site fabrication.

9. The cylindrical modular SCR reactor according to claim 1, characterized in that, The flexible pipe connection (7) is located between the branch pipe (4) and the catalyst module (3) for quick disassembly and reassembly and alignment compensation during hoisting and disassembly.

10. The cylindrical modular SCR reactor according to claim 1, characterized in that, A top flange is provided at the other end of the branch pipe (4), and the top flange is connected to one end of the first shut-off valve (61). The other end of the first shut-off valve (61) is sealed to the air inlet of the catalyst module (3) through a flexible pipe connection (7). A bottom flange is provided at the air outlet of the catalyst module (3), and the bottom flange is connected to one end of the second shut-off valve (62). The other end of the second shut-off valve (62) is connected to the manifold (5).

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