Regenerative oxidation device and modular construction and installation method thereof

Abstract

The application discloses a heat accumulating type oxidation device and a modular construction and installation method thereof, adopts a thought of factory standardization prefabrication, on-site quick installation, layered sealing protection and intelligent joint debugging, sequentially completes seven core steps of functional module factory prefabrication, foundation construction and positioning reference setting, on-site modular quick assembly, multi-level sealing treatment, heat accumulator accurate installation, combustion system precise installation and system joint debugging, disassembles the RTO furnace into standardized functional modules which can be interchanged and independently maintained, effectively solves technical problems of low installation efficiency, poor sealing performance, difficult maintenance and insufficient operation adaptability of a traditional RTO furnace, and can be widely applied to VOCs waste gas treatment in various industrial fields such as chemical industry and coating.

Description

Technical Field

[0001] This invention belongs to the field of industrial waste gas treatment and environmental protection equipment installation technology. Specifically, it relates to a regenerative thermal oxidation device (RTO furnace) and its modular construction and installation method. Background Technology

[0002] Regenerative thermal oxidizers (RTO furnaces) have become the core equipment for treating industrial VOCs waste gas in industries such as chemical, coating, electronics, and pharmaceutical, thanks to their core advantages such as high heat recovery efficiency, thorough VOCs purification (removal rate of up to 95%), and stable and reliable operation. Their working principle is to heat the VOCs waste gas to above 760℃, so that the VOCs are completely oxidized and decomposed into carbon dioxide and water. At the same time, heat is recycled and recovered through ceramic heat storage, which greatly reduces the energy consumption of the equipment and meets the current industrial development needs of environmental protection and energy conservation.

[0003] However, existing RTO furnaces still have many technical defects in construction, installation, and subsequent operation and maintenance, which seriously restrict the performance of the equipment, the improvement of construction efficiency, and the convenience of operation and maintenance, as follows: 1. Low installation efficiency: Traditional RTO furnace bodies mostly adopt on-site welding or a large number of bolts for loose connection. The construction process is cumbersome and complex, and is greatly limited by the space, environmental conditions and skill level of the construction site, resulting in a long construction cycle (25-30 days for a typical project). At the same time, human operation errors can easily cause problems such as loose module connections and misaligned flanges, which require repeated debugging and rectification, further increasing construction costs and time. Some existing modular RTO furnaces only achieve simple disassembly and have not formed a standardized prefabrication and precise installation system. They still have problems such as low installation accuracy and slow docking efficiency, and have not achieved full standardization of module interface interchangeability and precise positioning control.

[0004] 2. Insufficient structural stability and sealing: RTO furnaces operate under high temperature (760-850℃) and vibration conditions for extended periods. Traditional connection methods are susceptible to loosening and aging / damage of seals due to thermal stress and vibration impacts. This leads to VOCs leakage and heat loss, reducing waste gas treatment and heat recovery efficiency, posing significant safety hazards, and failing to meet environmental protection and safety production standards. Existing technologies often employ single- or double-layer sealing structures, which cannot meet the sealing requirements of different temperature zones in RTO furnaces, resulting in insufficient sealing reliability. Furthermore, no interface protection or high-temperature sealing verification procedures are implemented.

[0005] 3. High maintenance difficulty and cost: Existing RTO furnaces have a compact internal structure, with core components such as heat storage medium and catalyst integrated into the overall cavity. Replacement requires extensive disassembly of the furnace body and surrounding modules, resulting in long-term equipment downtime (single maintenance downtime ≥ 8 hours), which seriously affects the normal production and operation of enterprises. Moreover, the labor and material costs during maintenance are high. Some modular RTO furnaces are not designed with independently detachable heat storage structures, and still require disassembly of the entire module. The convenience of operation and maintenance has not been substantially improved, and there is no independent catalyst replacement layer or real-time monitoring structure for the status of heat storage medium.

[0006] 4. Poor operational adaptability: The installation of the combustion system relies on the manual experience of construction personnel, lacking precise positioning tools and standardized procedures, resulting in insufficient burner installation accuracy, flame deviation, incomplete combustion, and increased fuel consumption. At the same time, the system has a weak response to fluctuations in VOC concentrations (20%-100%) and exhaust gas flow rates commonly encountered in industrial production, easily leading to problems such as unstable furnace temperature and substandard VOC treatment. The control logic of existing similar systems is relatively simple, unable to achieve multi-parameter linkage adjustment, and lacks integrated flame fault alarm and fuel emergency cut-off linkage functions, making it difficult to guarantee operational stability.

[0007] In view of the shortcomings of the existing technologies, especially the deficiencies of existing modular RTO furnaces in terms of prefabrication standardization, installation accuracy, sealing reliability, operation and maintenance convenience and intelligent adaptability, and in light of the technical limitations of existing patents, this invention develops a modular construction and installation method for RTO furnaces that can achieve efficient installation, high sealing performance, convenient maintenance and intelligent and stable operation. Summary of the Invention

[0008] The technical problem to be solved by the present invention is to provide a regenerative oxidation device and its modular construction and installation method, so as to achieve high construction efficiency, improved equipment airtightness and heat recovery efficiency, reduced operation and maintenance costs, and enhanced operational stability.

[0009] To solve the above technical problems, according to one aspect of the present invention, a modular construction and installation method for a regenerative thermal oxidation device is provided, comprising: Step 1: The overall structure of the regenerative oxidizer is divided into an intake pretreatment module, a combustion chamber module, at least one regenerative chamber module, an exhaust module, and a control system module. The outer shell of each module is manufactured, the internal functional components are installed, the insulation layer is laid, and the standardized interfaces are processed in the factory. The standardized interface includes a sealing flange of uniform size, a sealing groove is set inside the sealing flange, and a positioning protrusion that fits with the sealing element is set inside the sealing groove. Step 2: Pour reinforced concrete foundation and pre-embed anchor bolts, accurately level the foundation plane, lay a wear-resistant and anti-slip layer on the foundation surface after leveling, install height-adjustable shock-absorbing supports on the foundation surface, mark module positioning reference points on the foundation, and lay guide rails that match the heat storage chamber module and combustion chamber module. Step 3: Install the modules in the following order: intake pretreatment module, heat storage chamber module, combustion chamber module, and exhaust module. First, use a rough positioning method, then use a hydraulic jacking device for precise positioning. At the same time, use a laser positioning instrument to monitor in real time to ensure docking accuracy. Then, use high-strength bolts to tighten and connect each module in stages. Install the control system module at a height of 1.2-1.5m above the ground, avoiding the equipment vibration area and high temperature radiation area. Step four: The flange faces of each module interface adopt a three-layer sealing structure: an inner high-temperature resistant seal, an outer leak-proof seal, and an interface protection seal. The inner layer is laid with a ceramic fiber gasket with a temperature resistance of ≥1200℃, and the surface of the ceramic fiber gasket is coated with high-temperature resistant sealant. The outer layer is installed with a silicone sealing ring with a temperature resistance of ≥350℃, which is embedded in the flange sealing groove and fits against the positioning protrusion. The interface protection seal is a sealing cover fixed with bolts at the edge of the flange to form a sealed cavity. After the sealing is completed, an airtightness test is performed. Step 5: Fill the unit-type heat storage chamber with the heat storage material using a layered combination method. The bottom layer is quartz honeycomb ceramic with a porosity of 15-20%, and the top layer is horseshoe ceramic rings. Push each unit-type heat storage chamber with the pre-installed heat storage material into the designated position in the heat storage chamber and lock it. Step 6: The burner module is fixed to the combustion chamber mounting port through the flange quick-installation structure and three-dimensional adjustment bracket, the burner position is calibrated, the fuel pipeline and air pipeline are connected, and the combustion control system is installed. Step 7: Perform cold-state debugging, hot-state debugging, and intelligent linkage debugging in sequence. The intelligent linkage debugging includes simulating VOCs concentration and exhaust gas flow fluctuations to verify the automatic adjustment function of the control system and testing the linkage response of leak warning and emergency handling.

[0010] In a preferred embodiment, during the installation of the internal functional components in step one, the combustion chamber module is covered with a refractory lining and a multi-layer insulation structure, and a preset temperature and pressure monitoring interface is provided with a sealed protection at the interface; the intake pretreatment module is equipped with a quick-release filter unit and a flow regulating valve.

[0011] As a preferred embodiment, in step one, the multi-layer insulation structure provided on the inner wall of the combustion chamber module consists of, from the inside out: a high-alumina refractory castable layer with a thickness of 100-150mm, a nanoporous insulation board layer with a thickness of 30-50mm, and a stainless steel protective shell layer with a thickness of 3-5mm.

[0012] In a preferred embodiment, in step two, the reinforced concrete foundation includes a gravel cushion layer and a waterproof and moisture-proof layer laid at the bottom.

[0013] In a preferred embodiment, in step three, the graded tightening involves applying 50% of the design torque the first time, 80% of the design torque the second time, and 110%-120% of the design torque the third time. After tightening, a torque wrench is used for re-inspection.

[0014] In a preferred embodiment, in step four, a high-temperature sealant with a temperature resistance of ≥1200℃ is evenly applied to the outer edge of the flange joint to form a secondary sealing layer.

[0015] In a preferred embodiment, in step five, stainless steel wire mesh or ceramic fiber slabs are laid between each heat storage layer as an isolation layer, and the isolation layer is fixed to the inner wall of the heat storage chamber with sealant.

[0016] In a preferred embodiment, in step six, the adjustment range of the three-dimensional adjustment bracket is: ±50mm up and down, ±30mm left and right, and ±20mm front and back. The three-dimensional adjustment bracket is made of 316L stainless steel, and a heat insulation pad is installed at the bottom of the three-dimensional adjustment bracket. A flow monitoring instrument and an emergency shut-off valve are installed on the fuel pipeline, and the combustion control system integrates flame fault alarm and automatic fuel shut-off functions.

[0017] In a preferred embodiment, in step seven, the hot-state debugging involves controlling the heating rate to ≤50℃ / h, maintaining a constant temperature of 150℃, 350℃, and 600℃ for 12 to 24 hours respectively to dry the moisture in the refractory material and insulation layer and release thermal stress, preventing furnace deformation. After the furnace is dried, the furnace temperature is raised to the set temperature, simulated VOCs waste gas is introduced, the automatic power adjustment function of the burner is tested, and the waste gas treatment efficiency and heat recovery efficiency are verified to ensure that all parameters meet the design standards.

[0018] According to another aspect of the present invention, a regenerative oxidation apparatus obtained by the above method is provided.

[0019] Compared with the prior art, the present invention has the following technical effects: 1. Significantly improved construction efficiency. Adopting the "standardized prefabrication in the factory and precise and rapid installation on site" model, combined with optimized design such as CNC prefabrication, laser positioning installation, and torque re-inspection, the amount of on-site high-altitude operations and welding work is greatly reduced, the construction cycle is shortened, the installation accuracy is significantly improved, human operation errors are effectively reduced, the later debugging costs are reduced, and the construction efficiency and quality are improved.

[0020] 2. Excellent sealing and insulation performance. Utilizing a three-layer sealing structure combined with rigorous airtightness testing, it effectively prevents VOCs gas leakage and high-temperature heat loss, reducing heat loss. The multi-layer insulation structure of the combustion chamber and the layered combined heat storage body work synergistically to ensure stable system heat recovery efficiency, significantly reducing operating energy consumption and improving equipment energy-saving performance.

[0021] 3. Convenient maintenance and reduced operation and maintenance costs. The modular heat storage chamber structure supports online rapid replacement, with a single replacement time of ≤30 minutes, without disassembling the entire furnace body; at the same time, each module is designed with independent inspection doors and spare wiring terminals, which greatly reduces downtime losses, lowers operation and maintenance labor costs, and significantly improves enterprise production efficiency.

[0022] 4. Enhanced operational stability and adaptability. The precision installation of the combustion system, combined with PLC intelligent linkage control, ensures complete combustion and stable furnace temperature, and can automatically adapt to wide fluctuations in VOCs concentration (20%-100%) and exhaust gas flow rate (±10%). The laser leakage early warning module is linked with the emergency response system, improving the inherent safety of the system, effectively avoiding environmental and safety hazards, and ensuring long-term stable operation of the equipment. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the modular structure of the regenerative oxidation device of the present invention; In the diagram, 1-Intake pretreatment module, 2-Heat storage chamber module, 3-Combustion chamber module, 4-Exhaust module. Detailed Implementation

[0024] The modular construction and installation method for a quick-installation regenerative thermal oxidation device provided by a typical embodiment of the present invention takes "standardized prefabrication in the factory, precise and quick installation on site, layered sealing protection, and intelligent joint commissioning and adaptation" as its core concept. It disassembles the RTO furnace into standardized functional modules that can be interchanged and maintained independently. Through high-precision positioning, composite sealing, precision installation and intelligent joint commissioning throughout the entire process, it ensures construction quality and stable equipment performance.

[0025] Taking a regenerative thermal oxidizer (RTO) unit constructed by the applicant for a chemical company as an example, this chemical company uses ethylene tar as the main residue to produce lithium battery coating materials. Its entire process covers the treatment, light removal, purification, granulation, and packaging of carbon black base material / ethylene tar. The VOCs waste gas from the company's asphalt coating project mainly comes from various towers, reactors, and granulation processes during production. The requirements for the treatment system are: VOCs removal rate ≥99%, heat recovery efficiency ≥95%, construction period ≤15 days, and annual equipment operating time ≥8000 hours. Compared with existing similar modular RTO furnace projects, it is necessary to further reduce operation and maintenance costs and energy consumption.

[0026] Step 1: Factory prefabrication of functional modules 1. Module Division: The overall structure of the regenerative thermal oxidation unit (RTO furnace) is divided into five independent and standardized functional modules. Each module has a clearly defined function and unified interface, enabling full interchangeability. Each module also features an independent maintenance interface and location markers. Specifically, these include an intake pretreatment module 1, a combustion chamber module 3, at least one regenerator chamber module 2, an exhaust module 4, and a control system module. Unlike existing technologies that simply break down modules, this invention standardizes the interface dimensions, installation references, and maintenance paths for each module. Furthermore, it incorporates a module interchangeability verification step, allowing for flexible combinations under different operating conditions.

[0027] 2. Factory Prefabrication Process: Each module undergoes standardized prefabrication throughout the entire process in the factory, utilizing CNC and automated production equipment to reduce human error, as detailed below: 2.1 Shell Manufacturing: The shell is made of 8-12mm thick Q345R high-temperature resistant steel plate, formed by CNC cutting, bending, and welding. After welding, the weld is inspected for flaws (UT inspection, passing standard is Class II). Simultaneously, the weld undergoes high-temperature aging treatment to eliminate welding stress, ensuring the shell's strength meets standards, its sealing performance is good, and it satisfies the requirements for long-term operation under high-temperature conditions. This invention adds a high-temperature aging treatment step for the weld and optimizes welding process parameters to improve the shell's resistance to thermal deformation.

[0028] 2.2 Installation of internal functional components: The combustion chamber module 3 completes the laying of the inner wall refractory lining and insulation layer, and at the same time preset temperature and pressure monitoring interfaces to facilitate the subsequent installation of intelligent monitoring system; the intake pretreatment module 1 is equipped with filter unit (filtration accuracy ≤10μm) and flow regulating valve, and the filter unit adopts quick-release structure for easy on-site replacement; each module has completed the preset pipeline interface and electrical interface, and the interface is equipped with a sealed protective sleeve to avoid damage during transportation and hoisting, and to ensure quick docking during on-site installation. The integrated design of the new interface protective sleeve is also included.

[0029] 2.3 Insulation Layer Installation: Suitable insulation materials are selected based on the differences in module operating temperatures to form an insulation system. The combustion chamber module 3 adopts a multi-layer insulation structure, while the intake and exhaust modules 4 use ceramic fiber insulation layers with a thickness of 50-80mm. A thermally conductive insulating layer is installed between the insulation layer and the module shell to reduce heat conduction, ensuring excellent insulation performance and further reducing high-temperature heat loss and operating energy consumption.

[0030] 2.4 Standardized Interface Processing: Each module's mating end is processed with uniformly sized sealing flanges (DN300-DN1200, matched to module dimensions), locating pin holes (20mm diameter, positioning error ≤0.05mm), and guide grooves (50mm width, 10mm depth). The flange material is 316L stainless steel, and the flange face adopts a composite structure of concave and convex surfaces with a sealing groove. A pre-set sealing positioning protrusion within the sealing groove ensures interchangeability and high-precision mating between modules, while also providing an installation foundation for the subsequent three-layer sealing structure, laying a solid foundation for rapid on-site assembly. This invention introduces an integrated design of the sealing groove and positioning protrusion, optimizing flange processing accuracy and improving mating sealing and positioning accuracy.

[0031] 2.5 Prefabrication Inspection: After each module is prefabricated, strict pre-testing of air tightness (pressurized to 3kPa, held for 30min, pressure drop ≤0.05kPa), dimensional accuracy (module dimensional error ≤±2mm), and high-temperature resistance (simulating 760-850℃ high-temperature conditions, heat preservation for 24h, no deformation, no leakage) is carried out. Unqualified modules are immediately reworked to ensure that all prefabricated modules meet the on-site installation standards and avoid on-site rework. Existing similar construction methods only perform air tightness and dimensional tests. This invention adds high-temperature resistance test and module interchangeability verification to improve the quality of module prefabrication.

[0032] Step 2: Foundation construction and positioning benchmark setting 1. Foundation Casting: Based on the overall design parameters (module weight, dimensions, and dynamic load), a reinforced concrete foundation is cast on-site. The foundation strength grade is not lower than C35, and the foundation thickness is not less than 500mm. A 200mm thick crushed stone cushion layer and a 50mm thick waterproof and moisture-proof layer are laid on the bottom of the foundation to enhance its bearing capacity, stability, and moisture-proof performance. During the foundation casting process, anchor bolts (material Q235B, diameter 24-30mm, embedment depth not less than 600mm) are precisely pre-embedded. The anchor bolt spacing is 500-800mm, and the pre-embedding position error does not exceed 2mm. Anti-loosening lock nuts are installed on the top of the anchor bolts to ensure the firmness of subsequent module installation. This invention, through the integrated design of the added waterproof and moisture-proof layer and the anti-loosening structure of the anchor bolts, is suitable for humid conditions and optimizes the anchor bolt pre-embedding positioning process, thereby improving foundation stability.

[0033] 2. Foundation Leveling: A laser level (accuracy ±0.01mm / m) is used to precisely level the foundation plane, ensuring the flatness error does not exceed 0.05mm / m. After leveling, a wear-resistant and anti-slip layer is laid on the foundation surface to prevent slippage during module installation and operation, ensuring the horizontality of the module installation and avoiding misalignment and uneven stress caused by uneven foundation. This invention adds this structure and optimizes the leveling accuracy control process, improving the connection stability between the foundation and the module.

[0034] 3. Vibration Damper and Positioning Setup: Adjustable vibration damping supports (model ZTB-100, load capacity 10-20t, adjustment range ±50mm) are installed on the foundation surface. The spacing between the vibration damping supports is 1000mm. Multiple layers of vibration damping pads are installed inside the supports, with a temperature resistance of not less than 200℃. This effectively reduces vibration transmission during equipment operation, protects the foundation and module structure, and reduces the impact of vibration on sealing performance. Module positioning reference points are marked on the foundation (using stainless steel markers, positioning accuracy ±0.05mm) to clearly define the installation position of each module and ensure the verticality and accuracy of module installation.

[0035] Step 3: On-site modular assembly 1. Lifting Sequence: Following the predetermined sequence of "Intake Pretreatment Module 1 → Regenerator Module 2 → Combustion Chamber Module 3 → Exhaust Module 4", a truck crane (lifting capacity 20-50t) will be used for module lifting. Flexible slings will be used during lifting, with a load-bearing capacity of not less than 1.5 times the module weight. Soft pads will be placed at the contact points between the flexible slings and the modules. At the same time, special lifting lugs (made of 316L stainless steel, with a load-bearing capacity of not less than 2 times the module weight) will be installed on the top of the modules to prevent damage to the module surface and interfaces, ensure module integrity, and improve the safety and stability of the lifting.

[0036] 2. Precise Positioning: First, coarse positioning is performed using the positioning pin holes on the edge of the module. Then, a hydraulic jacking device (jacking force 5-10t, adjustment accuracy ±0.01mm) is used for precise positioning. At the same time, a laser positioning instrument is used to monitor the flange docking accuracy in real time, ensuring that the parallelism deviation of the flange surfaces of adjacent modules does not exceed 0.1mm and the flange docking gap does not exceed 0.5mm. The positioning pins are precisely inserted into the positioning pin holes without offset or loosening, ensuring the quality of subsequent sealing and connection.

[0037] 3. Fastening Connections: High-strength bolts (grade 10.9, specifications M24-M30) and locking mechanisms are used to connect and fix the flange faces of each module. The bolts are tightened in three stages diagonally: the first tightening torque is 50% of the design torque, the second is 80%, and the third is 110%-120% (design torque for M24 bolts is 350 N·m, and for M30 bolts it is 650 N·m). After tightening, a torque wrench is used for re-inspection to ensure that the torque meets the standard. Through staged tightening, the sealing gaskets are effectively pre-tightened and thermal stress during equipment operation is compensated, ensuring a firm and secure connection without loosening. This adapts to the thermal expansion and contraction requirements under high-temperature conditions and avoids problems caused by inadequate or excessive tightening, leading to seal failure.

[0038] 4. Control system module installation: Install the control system module in a location that is easy to operate and maintain, preferably 1.2-1.5m above the ground. The control system module is connected to other functional modules using shielded cables. The cables must be laid in conduits (DN50 diameter, PVC material) for protection, and waterproof sealing joints must be used at the cable interfaces to avoid signal interference and moisture intrusion, and to ensure safe and reliable electrical connections.

[0039] Step 4: Multi-layer sealing treatment 1. Sealing Structure Installation: A three-layer sealing structure consisting of an inner high-temperature resistant seal, an outer leak-proof seal, and an interface protection seal is installed at the flange face of the module connection to ensure sealing performance, adapt to the sealing requirements of different temperature zones, and solve the problem of insufficient reliability of existing single-layer or double-layer seals, as detailed below.

[0040] (1) Inner layer: A ceramic fiber sealing gasket with a temperature resistance of ≥1200℃ and a thickness of 5mm is laid. The surface of the sealing gasket is coated with high temperature resistant sealant to adapt to high temperature working conditions and effectively prevent high temperature heat loss and VOCs exhaust gas leakage.

[0041] (2) Outer layer: Install a high-temperature silicone sealing ring with a temperature resistance of ≥350℃ and a thickness of 3mm. The sealing ring is embedded in the flange sealing groove and fits with the positioning protrusion to further enhance the sealing effect and adapt to the sealing requirements of normal temperature and medium temperature areas, forming double protection.

[0042] (3) Interface protection and sealing: A sealing cover is set on the edge of the flange. The sealing cover is fixed to the flange with bolts to form a sealed cavity, which prevents external dust and moisture from entering the sealing surface and extends the service life of the sealing components; the present invention adds an integrated protection design of the sealing cover.

[0043] (4) Secondary sealing: After the bolt connection is completed, a high-temperature sealant with a temperature resistance of ≥1200℃ is evenly applied to the outer edge of the flange joint to form a secondary sealing layer, which effectively seals the tiny gaps in the flange joint, eliminates the risk of leakage, and ensures that the sealing performance meets the standards. After the sealant is applied, a special tool is used to smooth it to ensure uniform sealing. This invention optimizes the sealant application process.

[0044] 2. Airtightness Test: After the sealing process is completed, a rigorous airtightness test is conducted on the entire system. Two testing methods are combined to ensure that all tests pass, as detailed below: (1) Fill with dry air or nitrogen to a pressure ≥5 kPa, maintain the pressure for 30 minutes, and the pressure drop should not be greater than 0.1 kPa.

[0045] (2) Supplementary test: A temperature rise and sealing test is performed on the flange interface in the high temperature area, that is, the temperature is raised to 760℃ and kept at the temperature for 2 hours without leakage, to ensure stable sealing performance under high temperature conditions.

[0046] (3) Leakage handling: If a leak is detected, immediately disassemble the flange, thoroughly clean the sealing surface (remove oil and debris), replace the seal and reapply sealant, and conduct the airtightness test again until it passes, ensuring that there is no risk of leakage.

[0047] Step 5: Heat storage element installation 1. Prefabricated heat storage chambers: Unitized heat storage chamber structures are pre-installed within heat storage module 2. Each heat storage chamber is an independent modular cavity made of 316L stainless steel, equipped with a high-temperature resistant guiding structure. The guide rails use a ball-bearing design to reduce frictional resistance, allowing for independent disassembly and replacement of each unit without disassembling the entire heat storage module 2, significantly improving maintenance convenience. Each heat storage chamber is equipped with an independent temperature monitoring interface for real-time monitoring of the heat storage medium's status.

[0048] 2. Layered Filling of the Heat Storage Body: The heat storage body adopts a layered composite filling method, with precise matching of materials and parameters for each layer. This achieves a synergistic effect of load-bearing, heat storage, and low-temperature catalysis, improving heat recovery efficiency and VOCs treatment effect. This differs from the single-material heat storage body design of existing similar projects. The specific layering is as follows: (1) Bottom layer: High-density quartz honeycomb ceramic with a porosity of 15%-20% and a thickness of 400mm (pore size 10×10mm, compressive strength ≥15MPa, temperature resistance ≥1200℃), mainly used for load-bearing and initial heat storage, to improve the overall stability of the heat storage body; This invention optimizes the porosity and pore size parameters; (2) Upper layer: filled with horseshoe ceramic rings for efficient heat storage and heat transfer, improving heat recovery efficiency.

[0049] 3. Layered isolation: A 3mm thick stainless steel wire mesh (100 mesh) or ceramic fiber diaphragm (2mm thick, temperature resistance ≥1200℃) is laid between each layer of heat storage. The isolation layer is fixed to the inner wall of the heat storage chamber with sealant to prevent the heat storage particles from moving downward or misaligning, avoid airflow short circuit, ensure uniform airflow distribution, and guarantee heat storage and catalytic effect.

[0050] 4. Heat storage chamber installation: Push the heat storage chamber with the pre-installed heat storage body into the designated position in the heat storage chamber, and fix it with a quick locking mechanism (pneumatic locking, locking force ≥5000N). After locking, perform a pressure test (pressure ≥0.3MPa, no loosening) to ensure that the heat storage chamber is tightly fitted to the inner wall of the heat storage chamber module 2 without loosening or displacement, and to ensure the stability of equipment operation.

[0051] Step 6: Installation of the combustion system 1. Burner Installation: The burner module (heat load 50-200kW, matched according to the air volume) is fixed to the predetermined installation port of the combustion chamber module 3 via a flange-type quick-installation structure and a three-dimensional adjustment bracket. The adjustment range of the three-dimensional adjustment bracket is ±50mm vertically, ±30mm horizontally, and ±20mm front-to-back. The three-dimensional adjustment bracket is made of 316L stainless steel and has a heat insulation pad at the bottom (temperature resistance ≥800℃) to prevent high-temperature conduction damage to the bracket, ensuring installation stability and high-temperature resistance, and adapting to the high-temperature operating conditions of the combustion chamber.

[0052] 2. Precise Calibration: Before installation, use a positioning fixture (accuracy ±0.1mm) to calibrate the installation angle and position of the burner. At the same time, use an infrared positioning instrument to monitor the overlap between the burner axis and the combustion chamber axis to ensure that the overlap deviation between the combustion flame center and the combustion chamber axis is ≤5mm. This will prevent flame deviation from causing local overheating of the combustion chamber and damage to the lining, thus ensuring the service life of the equipment.

[0053] 3. Pipeline Connection: Connect fuel pipelines (material 316L stainless steel, pipe diameter DN25-DN50, wall thickness 3-5mm) to air pipelines (material Q235B, pipe diameter DN100-DN200, wall thickness 4-6mm) using quick-connect sealing joints. The joints have 3 layers of high-temperature resistant sealing gaskets (temperature resistance ≥400℃) inside, and anti-loosening clamps are set on the outside to ensure the connection is sealed, prevent fuel leakage, and ensure operational safety. At the same time, the fuel pipeline is equipped with flow monitoring and emergency shut-off valves, which can realize real-time monitoring of fuel flow and abnormal shut-off. The pipeline diameter and wall thickness parameters are optimized, and a 3-layer sealing gasket design is added.

[0054] 4. Control System Installation: Install the combustion control system, including an integrated control cabinet, a flame detector with a detection range of 0-1500℃ and a response time of ≤0.5s, a temperature sensor with a measurement accuracy of ±1℃, and a pressure sensor with a measurement range of 0-1MPa and an accuracy of ±0.5%FS. All sensors and actuators are securely wired and the signal transmission is smooth. The control system integrates flame fault alarm and automatic shut-off functions to ensure precise control and safety protection of the combustion system, ensure rapid shutdown under abnormal operating conditions, and guarantee operational safety.

[0055] Step 7: Installation and commissioning of the pipeline valve system.

[0056] 1. Pipeline installation: Install prefabricated segmented main air ducts. Each segment of the duct is connected to the guide groove (40mm wide) through a positioning boss (5mm high). The welded joints are subjected to 100% non-destructive testing. After welding, the inner wall of the duct is derusted and treated with anti-corrosion to ensure the quality and service life of the duct welding, prevent gas leakage, and ensure the stability of system operation.

[0057] 2. Valve Installation: Install an integral lift valve or rotary valve. Adjust the sealing gap between the valve plate and valve seat using precision shims. The valve seat is made of high-temperature ceramic with a temperature resistance of ≥1200℃. The valve plate is made of 316L stainless steel with a 0.5mm thick wear-resistant coating. The valve seat uses a non-grinding installation process. Adjust the sealing gap to ≤0.05mm using 0.1-0.2mm thick precision shims to ensure excellent valve sealing performance. The valve is driven by a pneumatic actuator (action response time ≤0.5s), linked with the PLC control system to achieve precise and rapid valve switching. A position feedback sensor is installed on the valve to monitor its opening and closing status in real time, facilitating remote monitoring.

[0058] 3. Electrical Wiring: Connect the complete control system modules, complete the wiring of all sensors and actuators, strictly comply with the standard requirements for wiring specifications, make clear wiring labels, and use insulation and waterproof protection at the wiring points to facilitate future maintenance and repair; at the same time, spare wiring terminals are provided to facilitate future equipment upgrades and maintenance.

[0059] 4. System Integration and Debugging: This phase consists of three stages: cold-state debugging, hot-state debugging, and intelligent linkage debugging. It comprehensively verifies equipment operating parameters to ensure compliance with design requirements. Unlike existing projects that only perform cold-state and hot-state debugging, this phase adds an intelligent linkage debugging step, as detailed below: (1) Cold commissioning: Simulate valve switching sequence, verify the linkage control logic of rotary valve or lift valve, and ensure smooth valve operation and accurate switching; carry out pipeline system purging operation to remove debris and dust in the pipeline to avoid pipeline blockage or equipment damage; conduct air pressure test, with no leakage and no deformation as the qualified standard.

[0060] (2) Hot commissioning: The furnace is heated in stages, and the heating rate is strictly controlled to not exceed 50℃ / h. The furnace is kept at 150℃, 350℃ and 600℃ for 12 to 24 hours respectively to dry the moisture in the refractory material and insulation layer and release thermal stress to prevent the furnace body from deforming. After the furnace is heated, the furnace temperature is raised to the set temperature (not lower than 760℃), simulated VOCs waste gas is introduced, the automatic adjustment function of the burner power is adjusted, the waste gas treatment efficiency and heat recovery efficiency are verified, and all parameters are ensured to meet the design standards.

[0061] (3) Intelligent linkage debugging: simulate VOCs concentration and exhaust gas flow fluctuations to verify the automatic adjustment capability of the PLC control system, ensure that the furnace temperature fluctuation does not exceed ±10℃ and the VOCs treatment efficiency is not less than 99%; test the linkage response of the laser leakage early warning module and the emergency treatment system to ensure that the alarm can be sounded quickly and the gas intake can be cut off when a leak occurs; test the remote monitoring function to ensure that the equipment operating parameters can be transmitted in real time and remotely controlled, and complete the installation of the entire device.

[0062] Another typical embodiment of the present invention provides a regenerative oxidation device constructed based on the above-described installation method, which specifically includes the following components: 1. Modular furnace body: It is composed of prefabricated air intake pretreatment module 1, combustion chamber module 3, at least one regenerator module 2, exhaust module 4 and control system module, which are combined through standardized interfaces and a three-layer sealing structure. Each module can be disassembled and replaced independently to adapt to different working conditions. It has high installation accuracy and good sealing performance. Each module is designed with an independent maintenance door, which can realize online maintenance and greatly reduce installation and maintenance costs.

[0063] 2. Combustion chamber module 3: Its inner wall is equipped with a multi-layer insulation structure, from the inside out as follows: (1) Bottom layer: a high-alumina refractory castable layer with a thickness of 100 to 150 mm (Al2O3 content not less than 75%, temperature resistance not less than 1400℃, compressive strength not less than 25MPa). The castable adopts a high-temperature curing process to enhance adhesion, withstand high temperature, protect the furnace shell, and extend the service life of the equipment. (2) Middle layer: a nanoporous insulation board layer with a thickness of 30 to 50 mm (thermal conductivity not exceeding 0.03 W / (m·K) and temperature resistance not less than 1000℃). The insulation boards are spliced ​​with sealant to reduce heat leakage from gaps, which is used for efficient heat preservation, reducing heat loss and improving heat recovery efficiency. (3) Outer layer: a stainless steel protective shell with a thickness of 3 to 5 mm (material is 304 stainless steel). The protective shell adopts a corrugated structure to enhance the resistance to heat deformation, protect the insulation layer, improve the overall strength of the combustion chamber, and prevent damage from external forces.

[0064] 3. Heat Storage Module 2: It contains multiple independently detachable unit-type heat storage chambers. Each heat storage chamber is filled with ceramic heat storage bodies of different porosities and materials in layers (the bottom layer is a quartz honeycomb structure and the top layer is a horseshoe ceramic ring). The bottom of the heat storage chamber is equipped with a high-temperature resistant guide structure that cooperates with the external guide rail of the equipment. It is equipped with a quick locking mechanism, which can realize the unit-type online quick replacement without stopping the machine for disassembly, greatly improving the operation and maintenance efficiency and reducing downtime losses. At the same time, the heat storage module 2 is equipped with a differential pressure monitoring interface to monitor the blockage of the heat storage body in real time, which facilitates timely maintenance.

[0065] 4. Intelligent Monitoring and Automatic Adjustment System: Integrating a programmable logic controller (PLC), an IoT communication module (supporting 4G / 5G remote transmission), and multiple sensors, this system enables intelligent monitoring and automatic adjustment throughout the entire equipment operation process. Unlike existing systems with simple monitoring designs, it adds multi-parameter linkage adjustment and remote control functions. Specific configurations are as follows: (1) Sensor configuration: VOCs concentration detector and flow meter installed on the intake pipe to monitor intake parameters in real time; temperature sensor and differential pressure sensor installed in the combustion chamber and heat storage chamber to monitor equipment operation status in real time; laser gas leak sensor installed at each flange connection to monitor sealing performance in real time and eliminate leakage risks; flow sensor and pressure sensor newly installed on the fuel pipeline to monitor fuel supply status in real time.

[0066] (2) Control logic: The PLC controller automatically adjusts the burner power, valve switching cycle and fan speed based on real-time parameters such as VOCs concentration, exhaust gas flow rate, furnace temperature, pressure difference and fuel flow rate to ensure stable furnace temperature, complete combustion and optimal heat recovery efficiency; when the laser gas leak sensor detects VOCs leakage, it immediately triggers an audible and visual alarm and cuts off the intake valve and fuel supply to prevent exhaust gas leakage and ensure operational safety; at the same time, it supports remote parameter setting, fault alarm and maintenance reminder to improve equipment management efficiency; the control logic algorithm is optimized and a fuel supply linkage control function is added.

[0067] (3) Supporting auxiliary systems: including waste gas collection system, fan system and emergency treatment system. The emergency treatment system is linked with the PLC control system. When the RTO furnace malfunctions, the emergency bypass valve can be quickly opened to introduce VOCs waste gas into the activated carbon adsorption device for temporary treatment, ensuring that the waste gas always meets the emission standards and avoiding the risk of exceeding environmental protection standards; at the same time, an emergency filtration unit for waste gas pretreatment is added to prevent impurities from entering the emergency adsorption device and extend the service life of the adsorbent; the design of the new emergency filtration unit is also included.

[0068] The scope of protection claimed by this invention is not limited to the specific embodiments described above. For those skilled in the art, this invention can have various modifications and alterations. Any modifications, improvements, and equivalent substitutions made within the concept and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A modular construction and installation method for a regenerative thermal oxidation device, characterized in that, include: Step 1: The overall structure of the regenerative oxidizer is divided into an intake pretreatment module, a combustion chamber module, at least one regenerative chamber module, an exhaust module, and a control system module. The outer shell of each module is manufactured, the internal functional components are installed, the insulation layer is laid, and the standardized interfaces are processed in the factory. The standardized interface includes a sealing flange of uniform size, a sealing groove is set inside the sealing flange, and a positioning protrusion that fits with the sealing element is set inside the sealing groove. Step 2: Pour reinforced concrete foundation and pre-embed anchor bolts, accurately level the foundation plane, lay a wear-resistant and anti-slip layer on the foundation surface after leveling, install height-adjustable shock-absorbing supports on the foundation surface, mark module positioning reference points on the foundation, and lay guide rails that match the heat storage chamber module and combustion chamber module. Step 3: Install the modules in the following order: intake pretreatment module, heat storage chamber module, combustion chamber module, and exhaust module. First, use a rough positioning method, then use a hydraulic jacking device for precise positioning. At the same time, use a laser positioning instrument to monitor in real time to ensure docking accuracy. Then, use high-strength bolts to tighten and connect each module in stages. Install the control system module at a height of 1.2-1.5m above the ground, avoiding the equipment vibration area and high temperature radiation area. Step four: The flange faces of each module interface adopt a three-layer sealing structure: an inner high-temperature resistant seal, an outer leak-proof seal, and an interface protection seal. The inner layer is laid with a ceramic fiber gasket with a temperature resistance of ≥1200℃, and the surface of the ceramic fiber gasket is coated with high-temperature resistant sealant. The outer layer is installed with a silicone sealing ring with a temperature resistance of ≥350℃, which is embedded in the flange sealing groove and fits against the positioning protrusion. The interface protection seal is a sealing cover fixed with bolts at the edge of the flange to form a sealed cavity. After the sealing is completed, an airtightness test is performed. Step 5: Fill the unit-type heat storage chamber with the heat storage material using a layered combination method. The bottom layer is quartz honeycomb ceramic with a porosity of 15-20%, and the top layer is horseshoe ceramic rings. Push each unit-type heat storage chamber with the pre-installed heat storage material into the designated position in the heat storage chamber and lock it. Step 6: The burner module is fixed to the combustion chamber mounting port through a flange structure and a three-dimensional adjustment bracket. The burner position is calibrated, the fuel pipeline and air pipeline are connected, and the combustion control system is installed. Step 7: Perform cold-state debugging, hot-state debugging, and intelligent linkage debugging in sequence. The intelligent linkage debugging includes simulating VOCs concentration and exhaust gas flow fluctuations to verify the automatic adjustment function of the control system and testing the linkage response of leak warning and emergency handling.

2. The modular construction and installation method for the regenerative oxidation device according to claim 1, characterized in that: In step one, during the installation of the internal functional components, the combustion chamber module is laid with a refractory lining and a multi-layer insulation structure, and a preset temperature and pressure monitoring interface is provided with a sealed protection at the interface; the intake pretreatment module is equipped with a quick-release filter unit and a flow regulating valve.

3. The modular construction and installation method for the regenerative oxidation device according to claim 2, characterized in that: In step one, the multi-layer insulation structure installed on the inner wall of the combustion chamber module consists of, from the inside out: a high-alumina refractory castable layer with a thickness of 100-150mm, a nanoporous insulation board layer with a thickness of 30-50mm, and a stainless steel protective shell layer with a thickness of 3-5mm.

4. The modular construction and installation method for the regenerative thermal oxidation device according to claim 1, 2, or 3, characterized in that: In step two, the reinforced concrete foundation includes a gravel cushion layer and a waterproof and moisture-proof layer laid at the bottom.

5. The modular construction and installation method for the regenerative thermal oxidation device according to claim 4, characterized in that: In step three, the graded tightening involves applying 50% of the design torque the first time, 80% of the design torque the second time, and 110%-120% of the design torque the third time. After tightening, a torque wrench is used for re-inspection.

6. The modular construction and installation method for the regenerative thermal oxidation device according to claim 1 or 5, characterized in that: In step four, a high-temperature sealant with a temperature resistance of ≥1200℃ is evenly applied to the outer edge of the flange joint to form a secondary sealing layer.

7. The modular construction and installation method for the regenerative thermal oxidation device according to claim 6, characterized in that: In step five, stainless steel wire mesh or ceramic fiber slabs are laid between each layer of heat storage as an isolation layer, and the isolation layer is fixed to the inner wall of the heat storage chamber with sealant.

8. The modular construction and installation method for the regenerative thermal oxidation device according to claim 7, characterized in that: In step six, the adjustment range of the three-dimensional adjustment bracket is: ±50mm up and down, ±30mm left and right, and ±20mm front and back. The three-dimensional adjustment bracket is made of 316L stainless steel and a heat insulation pad is installed at the bottom of the three-dimensional adjustment bracket. A flow monitoring instrument and an emergency shut-off valve are installed on the fuel pipeline. The combustion control system integrates flame fault alarm and automatic fuel shut-off functions.

9. The modular construction and installation method for the regenerative thermal oxidation device according to claim 1 or 8, characterized in that: In step seven, the hot-state commissioning involves controlling the heating rate to ≤50℃ / h, maintaining a constant temperature of 150℃, 350℃, and 600℃ for 12 to 24 hours respectively to dry the moisture in the refractory material and insulation layer and release thermal stress to prevent furnace deformation. After the furnace is dried, the furnace temperature is raised to the set temperature, simulated VOCs waste gas is introduced, the automatic power adjustment function of the burner is tested, and the waste gas treatment efficiency and heat recovery efficiency are verified to ensure that all parameters meet the design standards.

10. A regenerative oxidation apparatus obtained by any one of claims 1-9.

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