Scr catalyst module and replaceable sacrificial inlet wear shield assembly therefor

Abstract

The application discloses a replaceable sacrifice type entrance anti-wear edge protection assembly and an SCR catalyst module, and belongs to the technical field of coal-fired unit SCR denitration catalyst anti-wear. The edge protection assembly provided by the application is installed at the entrance end surface of the catalyst module, and comprises an edge protection body arranged in a frame shape along the edge of the entrance channel, a dust guide chamfer part arranged on the dust receiving side, a detachable positioning clamping part connected with the catalyst frame, a anti-falling limiting shoulder part located on the downstream side, and a wear mark groove arranged on the edge protection body. The dust guide chamfer part deflects the fly ash, and reduces the erosion on the edge of the channel; the detachable positioning clamping part realizes independent disassembly and assembly of the assembly; the anti-falling limiting shoulder part prevents accidental falling of the component; and the wear mark groove directly indicates the replacement time. By adopting the application, the wear is guided to the replaceable sacrifice part, the catalyst entrance structure is protected, the effective anti-wear is realized, and the convenience of maintenance and replacement and the safety of equipment operation are improved.

Description

Technical Field

[0001] This invention relates to the field of anti-wear technology for SCR denitrification catalysts in coal-fired power units, specifically to an SCR catalyst module and its replaceable sacrificial inlet anti-wear edge protector assembly. Background Technology

[0002] In the SCR denitrification unit of a coal-fired power plant, the first-layer catalyst is subjected to long-term erosion by dust-laden flue gas. Increased coal ash content, increased hard mineral content in fly ash, and skewed flue gas flow field or localized high-speed jets can all cause the edges of the pores at the catalyst inlet to become the primary wear areas. After the pore edges wear down, end face collapse, local pore enlargement, thinning of module edges, and increased localized bypass flow can easily occur, further affecting ammonia injection mixing and denitrification efficiency.

[0003] Existing anti-wear measures typically employ integral protective plates, fixed frames, wear-resistant coatings, or catalyst module replacement. Integral protective plates may affect the inlet opening area and flow field distribution; fixed frames are difficult to replace individually after localized wear; wear-resistant coatings lack visual indication of replacement after wear is complete; and directly replacing the entire catalyst module is costly. Especially when wear is concentrated at the inlet edge while the catalyst body remains active, replacing the entire module is not conducive to reducing maintenance costs.

[0004] Therefore, how to provide an SCR catalyst inlet anti-wear edge protection assembly that can make wear occur primarily on replaceable sacrificial parts, while also taking into account dust guiding, anti-detachment, positioning, wear indication, and segmented replacement, has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0005] The purpose of this invention is to provide an SCR catalyst module and its replaceable sacrificial inlet anti-wear edge protector assembly, so as to overcome the problems in the prior art where the edge of the catalyst inlet channel is easily washed away by large particles of fly ash, the existing overall anti-wear structure is difficult to replace locally, the degree of wear is not easy to identify, and the edge protector may fall off after it becomes loose.

[0006] The present invention solves the above-mentioned technical problems through the following technical solution: This invention provides a replaceable sacrificial inlet anti-wear edge protector assembly, installed on the inlet end face of an SCR catalyst module. It includes an edge protector body, a chamfered dust guide, a detachable positioning latch, an anti-detachment limiting shoulder, and a wear marking groove. The edge protector body is arranged in a grid or segmented grid pattern along the edge of the inlet channel of the catalyst module. The chamfered dust guide is located on the dust-facing side of the edge protector body. The detachable positioning latch is connected to the frame or inlet end face of the catalyst module. The anti-detachment limiting shoulder is located on the downstream side of the edge protector body. The wear marking groove is located on the dust-facing side or exposed side of the edge protector body to indicate the remaining wear thickness of the edge protector body.

[0007] A further improvement of the present invention is that the edge protection body includes a strip edge protection and a reinforcing node located at the intersection of the strip edge protection, the strip edge protection covers at least a portion of the dust-facing edge line of the catalyst inlet channel, and the reinforcing node covers the intersection area of ​​adjacent channel edges.

[0008] A further improvement of the present invention is that the chamfer angle of the ash guiding chamfer is 20° to 45°, and the chamfer surface of the ash guiding chamfer faces the central area or low-sensitivity area of ​​the catalyst channel, so that the fly ash impacting the edge protection body deviates from the sharp corner of the channel edge.

[0009] A further improvement of the present invention is that the detachable positioning latch is a dovetail groove, an elastic buckle, a pressure plate bolt, a plug pin, an anti-loosening pin, or a combination thereof; the detachable positioning latch restricts the lateral and axial displacement of the edge protector body relative to the catalyst module.

[0010] A further improvement of the present invention is that the anti-detachment limiting shoulder abuts against the inner step, downstream end face or limiting groove of the catalyst module frame. When the detachable positioning snap part is loose, the anti-detachment limiting shoulder still restricts the edge protector body from falling into the catalyst channel.

[0011] A further improvement of the present invention is that the depth of the wear marking groove is 40% to 70% of the initial thickness of the edge protector body, and the wear marking groove is a continuous groove, an intermittent groove, a stepped groove, or a groove with a color identification layer.

[0012] A further improvement of the present invention is that a high-temperature resistant buffer pad is provided between the edge protection body and the inlet end face. The high-temperature resistant buffer pad is a ceramic fiber pad, an expanded graphite pad, a metal corrugated pad, or a composite high-temperature resistant pad, which is used to reduce the compression of the catalyst module inlet end face by thermal expansion and contraction and vibration.

[0013] A further improvement of the present invention is that the dust-facing side of the edge protector body is provided with a ceramic wear-resistant sheet, a welded wear-resistant layer, a sprayed wear-resistant layer or a high-chromium alloy wear-resistant layer, and the wear-resistant layer does not cover the identification boundary of the wear mark groove.

[0014] A further improvement of the present invention is that the edge protection assembly is divided into multiple segmented edge protections according to the inlet end face of the catalyst module. Each segmented edge protection is provided with an independent detachable positioning snap-fit ​​part and a wear marking groove, which can be independently disassembled and replaced with a spare edge protection through the inspection window along the disassembly and assembly direction.

[0015] The present invention also provides an SCR catalyst module, wherein the inlet end face of the SCR catalyst module is equipped with a replaceable sacrificial inlet anti-wear guard assembly as described above.

[0016] Compared with the prior art, the positive and progressive effects of the present invention are as follows: The replaceable sacrificial inlet anti-wear edge protector assembly provided by this invention arranges the edge protector body in a grid-like or segmented grid-like pattern along the edge of the catalyst inlet channel. This ensures that fly ash in the dust-laden flue gas first impacts the edge protector body rather than directly eroding the brittle matrix at the edge of the catalyst channel, thus achieving sacrificial protection: wear preferentially occurs on the replaceable edge protector, protecting the catalyst body. A chamfered ash-guiding portion is located on the ash-facing side of the edge protector body. When fly ash particles impact the edge protector, the chamfered surface guides the ash particles to the center area or low-sensitivity area of ​​the channel, preventing ash particles from directly cutting the sharp corners of the channel edge, effectively reducing local stress concentration and the risk of end-face collapse. A detachable positioning snap-fit ​​portion detachably connects the edge protector body to the catalyst module frame or inlet end face, allowing the edge protector to be independently removable after wear. Disassembly and replacement can be performed without removing the entire catalyst module; the anti-detachment limiting shoulder is located on the downstream side of the edge protector body. When the detachable positioning latch becomes loose due to vibration or thermal cycling, the anti-detachment limiting shoulder abuts against the inner step of the catalyst module frame, preventing the edge protector body from sliding and falling into the catalyst channel, thus avoiding blockage or secondary damage caused by the edge protector falling into the channel; the wear marking groove is set on the dust-facing side or exposed side of the edge protector body, allowing maintenance personnel to visually determine the remaining wear thickness of the edge protector and replace it in time before it is worn through or fails, thus avoiding damage to the catalyst body due to excessive wear; the above five components work together to fundamentally overcome the technical defects of existing technologies, such as the difficulty in independently replacing the overall anti-wear structure, the lack of intuitive judgment of the degree of wear, and the risk of edge protector falling off after loosening.

[0017] Furthermore, by setting reinforcing nodes at the intersections of the strip guards, the erosion resistance of the guard body in the area where adjacent channel edges meet is enhanced. In the grid-like guard, the intersections of the strip guards are subjected to fly ash impacts and stress concentrations from two directions. After setting reinforcing nodes, the wall thickness and structural strength in this area are locally reinforced, preventing the intersections from being worn through before other parts of the strip guard, thereby improving the overall service life and protective reliability of the guard.

[0018] Furthermore, by limiting the chamfer angle of the ash-guiding chamfer to 20° to 45°, within this angle range, fly ash particles, after impacting the ash-guiding slope, can slide towards the center area or low-sensitivity area of ​​the channel at a reasonable deflection angle. If the chamfer angle is too small, the guiding effect is not obvious, and ash particles will still impact the edge of the channel; if the chamfer angle is too large, ash particles may bounce to the edge of adjacent channels, causing secondary scouring. The preferred angle range of 20° to 45° achieves the best guiding effect on the flow direction of ash particles.

[0019] Furthermore, by configuring the detachable positioning latches as dovetail grooves, elastic buckles, pressure plate bolts, plug pins, anti-loosening pins, or combinations thereof, a variety of flexible and reliable connection methods are provided. These latching structures can simultaneously limit the lateral and axial displacement of the edge protector body relative to the catalyst module, ensuring that the edge protector maintains an accurate installation position during operation. During maintenance, the worn edge protector can be removed and replaced with a spare edge simply by loosening the corresponding latching structure, making the operation simple and quick.

[0020] Furthermore, a dual protection mechanism is formed by the abutting engagement between the anti-detachment limiting shoulder and the inner step, downstream end face, or limiting groove of the catalyst module frame. Even if the detachable positioning latch loosens or fails under long-term high-temperature vibration, the anti-detachment limiting shoulder can still mechanically restrict the edge protector body within the frame, preventing it from falling into the catalyst channels. This effectively reduces the risk of catalyst channel blockage and secondary damage caused by edge protector detachment, and improves operational safety.

[0021] Furthermore, by setting the depth of the wear marking groove to 40% to 70% of the initial thickness of the edge protector body, sufficient remaining thickness is ensured to maintain short-term protective function even when the edge protector wears down to the marking groove position, thus reserving a reasonable buffer time for maintenance scheduling. Meanwhile, the wear marking groove can take various forms, such as continuous grooves, discontinuous grooves, stepped grooves, or grooves with color identification layers, to adapt to the identification needs of different maintenance methods (such as visual inspection, inspection window observation, or endoscopic inspection), improving the accuracy and convenience of wear judgment.

[0022] Furthermore, by setting a high-temperature resistant buffer pad between the edge protector body and the inlet end face, the relative displacement caused by thermal expansion and contraction and vibration is effectively absorbed, avoiding the direct rigid compression of the catalyst inlet end face by the edge protector body, which could cause localized fragmentation of the catalyst matrix. Materials such as ceramic fiber pads, expanded graphite pads, metal corrugated pads, or composite heat-resistant pads all possess excellent high-temperature resistance and appropriate elastic modulus, enabling long-term stable operation within an operating temperature range of 270~420℃, thus improving the reliability and service life of the edge protector assembly under thermal cycling and vibration environments.

[0023] Furthermore, by applying ceramic wear-resistant sheets, welded wear-resistant layers, sprayed wear-resistant layers, or high-chromium alloy wear-resistant layers to the dust-facing side of the edge protector, the wear resistance of the dust-facing surface of the edge protector is further improved. This wear-resistant layer, acting as the first line of defense, withstands the impact and cutting force of fly ash, slowing down the wear rate of the edge protector and extending its replacement cycle. Simultaneously, the wear-resistant layer does not cover the identification boundary of the wear marking grooves, ensuring that maintenance personnel can still accurately determine the actual remaining thickness of the edge protector through the wear marking grooves, thus balancing improved wear resistance and visual identification of wear conditions.

[0024] Furthermore, by dividing the edge protection assembly into multiple segmented edge protection sections according to the inlet end face of the catalyst module, each segmented edge protection section is equipped with an independent detachable positioning snap-fit ​​part and wear marking groove, modular and localized replacement of the edge protection is achieved. When the edge protection in a certain segment area wears to the point of replacement, it can simply be removed through the inspection window along the disassembly direction and replaced with a spare edge protection section. There is no need to remove other segmented edge protection sections or lift the entire catalyst module out, reducing maintenance workload and replacement time. This is especially suitable for site conditions where the internal space of the reactor is small and large hoisting equipment cannot enter.

[0025] The SCR catalyst module provided by this invention has a replaceable sacrificial inlet anti-wear guard assembly, as described above, installed on its inlet end face. By configuring this guard assembly, during operation, fly ash erosion primarily acts on the replaceable guard assembly, effectively protecting the edges of the catalyst body's channels. When the guard wears down, partial replacement of the worn guard can be achieved without replacing the entire catalyst module, thus improving the overall service life of the catalyst module and the economic efficiency of maintenance. Attached Figure Description

[0026] The accompanying drawings are provided to further understand the invention and constitute a part of this invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0027] Figure 1 This is a schematic diagram of the replaceable sacrificial SCR catalyst inlet anti-wear guard assembly of the present invention installed on the inlet end face of the catalyst module.

[0028] Figure 2 This is a structural diagram of the segmented edge protector, snap-fit ​​component, anti-loosening pin, and replacement method of the present invention.

[0029] Explanation of reference numerals in the attached drawings: 10, catalyst module; 20, inlet end face; 101, edge protector body or segmented edge protector; 102, ash guide chamfer; 103, detachable positioning snap-fit ​​or dovetail groove; 104, anti-detachment limiting shoulder or pressure plate bolt; 105, wear marking groove or anti-detachment locking pin; 106, high temperature resistant buffer pad; 107, reinforced node or inspection window; 108, disassembly and assembly direction; 109, spare edge protector. Detailed Implementation

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] Furthermore, it should 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 this invention according to the specific circumstances.

[0035] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. This is an explanation of the present invention and not a limitation thereof.

[0036] In SCR denitrification units of coal-fired power plants, the first-layer catalyst module is subjected to direct scouring by dust-laden flue gas for extended periods. When the ash content of the coal increases, the content of hard minerals in the fly ash increases, or when the flue gas flow field becomes skewed or localized high-speed jets occur, the edge of the channel at the inlet end face of the catalyst module becomes the primary and most severe wear area. Wear at the channel edge leads to end face collapse, local channel enlargement, and thinning of the module edge, which in turn increases localized bypass flow, affecting the uniformity of ammonia injection and overall denitrification efficiency. Existing anti-wear measures such as integral protective plates and fixed frames are difficult to replace individually after localized wear, and there is a lack of intuitive replacement indicators when the wear-resistant coating is worn away. Replacing the entire catalyst module is also costly. Especially when wear is concentrated only at the inlet edge while the catalyst body still retains activity, existing methods are insufficient to achieve both effective protection and economical maintenance.

[0037] Based on the above background, the present invention provides a replaceable sacrificial inlet anti-wear edge protector assembly. This assembly is installed on the inlet end face 20 of an SCR catalyst module 10 and includes an edge protector body 101, a dust-guiding chamfered portion 102, a detachable positioning latching portion 103, an anti-detachment limiting shoulder 104, and a wear marking groove 105. The edge protector body 101 is arranged in a grid-like or segmented grid-like pattern along the edge of the inlet channel of the catalyst module 10, so that fly ash particles in the dust-laden flue gas preferentially scour the edge protector body 101, rather than the channel edge of the catalyst itself. The dust-guiding chamfered portion 102 is located on the dust-facing side of the edge protector body 101, which can change the impact direction of the fly ash particles, causing them to deviate from the sharp corners of the channel edge. The detachable positioning latching portion 103 connects and positions the edge protector assembly to the frame or inlet end face 20 of the catalyst module 10, while the anti-detachment limiting shoulder 104 provides double safety protection to prevent accidental detachment of the component. The wear marking groove 105 visually indicates the remaining wear thickness of the guard body 101, providing a clear basis for determining when to replace it. This design prioritizes guiding wear to the replaceable sacrificial guard assembly, thereby protecting the catalyst module's inlet structure and improving maintenance convenience.

[0038] The technical solutions in the embodiments of the present invention will now be clearly and completely described with reference to the accompanying drawings. It should be noted that the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0039] Example 1 This embodiment provides a replaceable sacrificial inlet anti-wear edge protection assembly, which is installed on the inlet end face 20 of the SCR catalyst module 10 to protect the edge of the inlet channel of the catalyst module 10 from fly ash erosion and wear.

[0040] The edge protector body 101 is the main structural component of the edge protector assembly. It is arranged along the edge of the inlet channel of the catalyst module 10, and its specific shape is a grid or segmented grid. This arrangement allows the edge protector body 101 to cover and protect the dust-facing edge of the catalyst inlet channel. When dust-laden flue gas arrives, fly ash particles will first impact the edge protector body 101, rather than directly scouring the inlet end face 20 and the edge of the channel of the catalyst module 10, thereby transferring the wear to the edge protector body 101 as a sacrificial component.

[0041] On the ash-facing side of the edge protector body 101, that is, the side directly receiving the flue gas flow, an ash-guiding chamfer 102 is provided. The presence of this chamfer 102 ensures that large particles of fly ash impacting the edge protector body 101 do not act perpendicularly to its surface, but are deflected along the chamfered surface. This deflected ash flow is guided to the central region or low-sensitivity region of the catalyst channels, effectively reducing the direct cutting action on the sharp edges of the channels, slowing down the wear rate of the edge protector body 101 itself, and optimizing the initial distribution of the flue gas.

[0042] The edge protection assembly is connected to the frame or inlet end face 20 of the catalyst module 10 via a detachable positioning latch 103. The main function of the detachable positioning latch 103 is to accurately and securely position the edge protection body 101 in a preset protective position during normal operation, restricting the lateral and axial displacement of the edge protection body 101 and preventing it from shifting due to flue gas impact or vibration.

[0043] On the downstream side of the edge protector body 101, i.e., the side facing the interior of the catalyst channel, an anti-detachment limiting shoulder 104 is provided. After assembly, the anti-detachment limiting shoulder 104 forms a blocking relationship with the corresponding structure on the catalyst module 10 frame. Even under extreme operating conditions, if the detachable positioning latch 103 loosens due to factors such as vibration or thermal cycling, the anti-detachment limiting shoulder 104 can act as a mechanical stop to firmly limit any tendency of the edge protector body 101 to fall into the catalyst channel, preventing it from being sucked into the catalyst channel and ensuring operational safety.

[0044] To facilitate maintenance personnel in determining the remaining lifespan of the edge protector body 101, a wear marking groove 105 is provided on the dust-facing side or an easily observable exposed side of the edge protector body 101. This wear marking groove 105 serves as a thickness gauge, with a preset initial depth from the dust-facing surface. During long-term operation, the surface of the edge protector body 101 gradually thins due to wear. When the worn surface reaches the bottom of the wear marking groove 105 or disappears, it visually indicates that the remaining wear thickness of the edge protector body 101 is nearing its limit, meeting the replacement criteria. By setting up the above structure, this embodiment guides the wear at the catalyst module inlet edge to the replaceable edge protector assembly. Through dust guiding, positioning, anti-detachment, and wear indication functions, it protects the catalyst while ensuring operational safety and intuitive maintenance.

[0045] Example 2 Based on Example 1, this example provides a further detailed description of several components of the edge protection assembly and offers a variety of preferred implementation methods.

[0046] The structure of the edge protector body 101 includes strip-shaped edge protectors and reinforcing nodes 107 located at the intersections of the strip-shaped edge protectors. The strip-shaped edge protectors cover at least a portion of the dust-facing edge of the catalyst inlet channel, while the reinforcing nodes 107 cover the intersection area of ​​adjacent channel edges. Since the channel intersection is a region where airflow convergence and fly ash impact are more concentrated, the reinforcing nodes 107, through local thickening or structural reinforcement, improve the intersection strength and erosion resistance of the grid-like edge protector body 101.

[0047] Regarding the chamfered portion 102 for guiding ash, its chamfer angle is preferably set to 20° to 45°. Within this angle range, the chamfered surface of the chamfered portion 102 faces the central region of the catalyst channel or a low-sensitivity region permitted by design. Such an angle and orientation setting can more effectively deflect most fly ash particles impacting the edge protector body 101 away from the sharp corners of the channel edge, achieving a ash guiding effect with lower flow resistance.

[0048] There are several ways to implement the detachable positioning latching part 103. Optionally, a dovetail groove structure can be used to achieve sliding positioning; or an elastic buckle can be used to achieve quick latching; or a pressure plate bolt can be used for tightening and fixing; or a plug pin can be used for through positioning; or an anti-loosening pin can be used for locking; or any combination of the above methods can be used. Regardless of the specific structure adopted, its core function is to effectively limit the lateral and axial displacement of the edge guard body 101 relative to the catalyst module 10 after assembly, ensuring its stable positioning.

[0049] The anti-detachment limiting shoulder 104 is specifically designed to abut against the inner step, downstream end face, or specially designed limiting groove of the catalyst module 10 frame. This abutment constitutes a second line of defense. When the detachable positioning latch 103 becomes accidentally loose due to long-term operation, the anti-detachment limiting shoulder 104 can still independently and reliably limit any displacement of the edge protector body 101 into the catalyst channel, preventing it from falling off and entering the downstream equipment.

[0050] The depth of the wear marking groove 105 is 40% to 70% of the initial thickness of the edge protector body 101. Setting the depth within this range ensures that the edge protector body 101 still has sufficient safety thickness to prevent immediate wear-through failure when a replacement reminder is issued, while also providing timely reminders for replacement to avoid wear on the catalyst module 10. The wear marking groove 105 can be a continuous groove, an intermittent groove, a stepped groove, or a groove filled with a color recognition layer to adapt to the observation needs of different field environments, such as observation through an endoscope or remote visual inspection.

[0051] To alleviate stress issues that may arise between the edge protector body 101 and the inlet end face 20 of the catalyst module 10 due to differences in the coefficients of thermal expansion of the materials, system vibration, and assembly tolerances, a high-temperature resistant buffer pad 106 can be provided between the edge protector body 101 and the inlet end face 20. This high-temperature resistant buffer pad 106 can be a ceramic fiber pad, an expanded graphite pad, a metal corrugated pad, or a composite high-temperature resistant pad. Its function is to absorb deformation and buffer vibration, thereby reducing the local compression of the catalyst module 10 inlet end face by the edge protector assembly and protecting the physical integrity of the catalyst.

[0052] To further enhance the wear resistance of the edge protector body 101, an additional layer of wear-resistant material can be added to its dust-facing side. Optionally, this wear-resistant material can be a ceramic wear-resistant sheet that is bonded and fixed, a wear-resistant layer formed by welding, a wear-resistant coating formed by thermal spraying, or a high-chromium alloy wear-resistant layer. It should be particularly noted that, regardless of the type of wear-resistant layer used, its arrangement must not cover the identification boundary of the wear marking groove 105 to ensure that the indicating function of the wear marking groove 105 is not affected.

[0053] In a preferred embodiment, the entire edge protector assembly can be divided into multiple independent segmented edge protectors according to the layout of the inlet end face 20 of the catalyst module 10. Each segmented edge protector is equipped with an independent detachable positioning latch 103 and a wear marking groove 105. This modular, segmented structure allows maintenance personnel to individually remove the worn segmented edge protector through the maintenance window 107 along the disassembly / removal direction 108 when a local area is severely worn, and then install a spare edge protector 109 to complete the replacement. The entire replacement process does not require the complete disassembly or replacement of the catalyst module 10, achieving precise and efficient local maintenance.

[0054] Example 3 This embodiment fully illustrates the working process and replacement method of the edge protection component in any of the foregoing embodiments.

[0055] When dust-laden flue gas enters the SCR reactor and directly impacts the inlet end face 20 of the first catalyst module 10, it first comes into contact with the edge protection assembly installed there. Large fly ash particles directly impact the edge protection body 101 and the ash-guiding chamfer 102 on its ash-facing side. The ash-guiding chamfer 102, with its 20° to 45° inclined surface, changes the trajectory of the fly ash particles, guiding them to the center area of ​​the channel, avoiding concentrated cutting of the particles at the sharp edges of the catalyst channel. The edge protection body 101 becomes a sacrificial wear part.

[0056] During prolonged operation, due to thermal expansion and contraction and continuous flue gas vibration, the detachable positioning latches 103 (such as dovetail grooves, pressure plate bolts, etc.) firmly hold the edge protection assembly in its installed position. The anti-detachment limiting shoulder 104, which works in conjunction with it, is always in contact or near contact with the inner step or limiting groove of the catalyst module 10 frame, serving as a safety backup and fundamentally eliminating the risk of components falling into the channel. Simultaneously, the high-temperature resistant buffer pad 106 located between the edge protection body 101 and the inlet end face 20 continuously absorbs and offsets thermal stress and mechanical vibration, protecting the catalyst end face.

[0057] As wear continues, the thickness of the edge protector body 101 gradually decreases. When the worn surface reaches the wear marking groove 105, which is 40% to 70% of the initial thickness, the continuous groove or the groove with a color identification layer will be worn flat or disappear, giving a clear visual replacement signal. Operation or maintenance personnel can observe this wear indicator through periodic shutdown inspections or through the inspection window 107 located on the flue, thereby accurately determining when the replacement cycle has been reached.

[0058] Once replacement is confirmed, maintenance personnel do not need to remove the entire catalyst module 10. For segmented edge protector assemblies, only the segmented edge protectors with excessive wear need to be operated on. Maintenance personnel enter through the maintenance window 107, release the detachable positioning latch 103 of the segmented edge protector (e.g., loosen the pressure plate bolts or pull out the anti-loosening pin), and then remove the worn segmented edge protector from the catalyst module 100 in the disassembly / reassembly direction 108. Subsequently, a new spare edge protector 109 is installed in the opposite disassembly / reassembly direction 108, and the detachable positioning latch 103 is retightened or locked, thus completing the replacement of a single segmented edge protector. The entire process achieves effective protection of the catalyst inlet edge, clear lifespan management, and convenient partial replacement.

[0059] The material, number of blocks, snap-fit ​​method, and wear mark groove shape of the edge protection assembly can be adjusted according to the size of the catalyst module, the shape of the inlet end face, and the on-site maintenance space.

[0060] See Figure 1 The catalyst module 10 has an inlet end face 20, and a guard body 101 is provided along the edge of the inlet channel. A dust-guiding chamfer 102 is provided on the dust-facing side of the guard body 101, and the chamfer angle of the dust-guiding chamfer 102 can be from 20° to 45°. When dust-laden flue gas enters the catalyst module 10, large particles of fly ash preferentially impact the guard body 101 and the dust-guiding chamfer 102, guiding the ash particles to the center area or low-sensitivity area of ​​the channel, thereby reducing direct scouring of the inlet channel edge. A detachable positioning latch 103 is provided between the guard body 101 and the catalyst module 10 frame. The detachable positioning latch 103 can be a dovetail groove, an elastic buckle, a pressure plate bolt, a plug pin, or a combination thereof. An anti-detachment limiting shoulder 104 is located downstream of the guard body 101 and abuts against the inner step of the catalyst module 10 frame. When the fastener loosens due to vibration or thermal cycling, the anti-detachment limiting shoulder 104 can still prevent the edge protector body 101 from moving into the catalyst channel. A wear marking groove 105 is provided on the dust-facing side or exposed side of the edge protector body 101. Preferably, the depth of the wear marking groove 105 is 40% to 70% of the initial thickness of the edge protector body 101. When the edge protector body 101 wears down to the wear marking groove 105, it can be determined that the edge protector at that point is close to the replacement thickness. To avoid thermal expansion and contraction and assembly errors directly affecting the catalyst inlet end face 20, a high-temperature resistant buffer pad 106 can be provided between the edge protector body 101 and the inlet end face 20; a reinforcing node 107 can be provided at the intersection of the strip edge protectors.

[0061] See Figure 2 The edge protection assembly can be divided into multiple segmented edge protection sections 101 according to the inlet end face 20. Each segmented edge protection section 101 can be independently positioned by a dovetail groove 103, a pressure plate bolt 104, and an anti-loosening pin 105. During maintenance, the operator observes the wear marking groove 106 through the maintenance window 107. When the segmented edge protection section meets the replacement conditions, the corresponding segmented edge protection section is removed along the disassembly / reassembly direction 108, and a spare edge protection section 109 is installed. This replacement process does not require the complete removal of the catalyst module 10, which reduces the workload of maintenance.

[0062] In summary, this invention enables wear to occur preferentially on the replaceable edge protector assembly, reducing the risk of catalyst channel edge wear and end face collapse; the ash guiding chamfer 102 can change the local impact direction of ash particles, reducing direct scouring of the sharp corners of the channel edges; the segmented edge protector can be independently disassembled and installed, avoiding the need to replace the entire catalyst module 10 due to local wear; the anti-detachment limiting shoulder improves operational safety, and the wear marking groove improves the intuitiveness of maintenance judgment; the high-temperature resistant buffer pad 106 and the reinforced nodes improve the stability of the assembly under thermal cycling and vibration environments.

[0063] Finally, it should be noted that the embodiments listed above are merely one or more specific manifestations of the technical solution of this invention. Their purpose is to clearly illustrate the concept, principle, and application of this invention through specific examples, and is by no means intended to limit the scope of protection of this invention to these specific embodiments. In fact, the true value of this invention lies in its proposed technical ideas and innovations, rather than its manifestations or implementation methods.

[0064] For those skilled in the art, after thoroughly reading and understanding the technical solution of this invention, they are fully capable of making various changes, modifications, or equivalent substitutions to the specific implementation of the invention based on their own professional knowledge and skills. These changes may include, but are not limited to: adjusting the range of technical parameters, optimizing the algorithm flow to improve efficiency, and replacing some technical components to achieve better compatibility or reduce costs. As long as these modified technical solutions substantially retain the technical features claimed by the original invention, that is, they can still achieve the core functions and effects of this invention, then these changes should be considered to fall within the scope of protection of the pending claims of this invention.

[0065] Furthermore, with the continuous progress and development of technology, new technical means and methods are constantly emerging, which provides ample space for further improvement and perfection of this invention. Therefore, the scope of protection of this invention should also include reasonable and foresightful improvements and extensions based on existing technology. As long as these improvements and extensions do not depart from the basic principles and core concepts of this invention, they should be considered equivalents of this invention and are equally protected by patent rights.

Claims

1. A replaceable sacrificial inlet anti-wear edge protector assembly, characterized in that, Installed on the inlet end face (20) of the SCR catalyst module (10), the edge protector body (101), the ash guide chamfer (102), the detachable positioning snap-fit ​​part (103), the anti-detachment limiting shoulder (104), and the wear marking groove (105) are included. The edge protector body (101) is arranged in a grid or segmented grid shape along the edge of the inlet channel of the catalyst module (10). The ash guide chamfer (102) is located on the ash-facing side of the edge protector body (101). The detachable positioning snap-fit ​​part (103) is connected to the frame or inlet end face (20) of the catalyst module (10). The anti-detachment limiting shoulder (104) is located on the downstream side of the edge protector body (101). The wear marking groove (105) is located on the ash-facing side or the exposed side of the edge protector body (101) to indicate the remaining wear thickness of the edge protector body (101).

2. The replaceable sacrificial inlet anti-wear edge protector assembly according to claim 1, characterized in that, The edge protector body (101) includes a strip edge protector and a reinforcing node (107) located at the intersection of the strip edge protectors. The strip edge protector covers at least a portion of the dust-facing edge of the catalyst inlet channel, and the reinforcing node (107) covers the intersection area of ​​adjacent channel edges.

3. The replaceable sacrificial inlet anti-wear edge protector assembly according to claim 1, characterized in that, The chamfer angle of the ash guiding chamfer (102) is 20° to 45°, and the chamfer surface of the ash guiding chamfer (102) faces the central area or low-sensitivity area of ​​the catalyst channel, so that the fly ash impacting the edge protector body (101) is deflected from the sharp corner of the channel edge.

4. The replaceable sacrificial inlet anti-wear edge protector assembly according to claim 1, characterized in that, The detachable positioning latch (103) is a dovetail groove, elastic buckle, pressure plate bolt, plug pin, anti-loosening pin or a combination thereof; the detachable positioning latch (103) restricts the lateral displacement and axial displacement of the edge protector body (101) relative to the catalyst module (10).

5. The replaceable sacrificial inlet anti-wear edge protector assembly according to claim 1, characterized in that, The anti-detachment limiting shoulder (104) abuts against the inner step, downstream end face or limiting groove of the catalyst module (10) frame. When the detachable positioning snap-fit ​​part (103) is loose, the anti-detachment limiting shoulder (104) still restricts the edge protector body (101) from falling into the catalyst channel.

6. The replaceable sacrificial inlet anti-wear edge protector assembly according to claim 1, characterized in that, The depth of the wear marking groove (105) is 40% to 70% of the initial thickness of the edge protector body (101), and the wear marking groove (105) is a continuous groove, a discontinuous groove, a stepped groove or a groove with a color identification layer.

7. The replaceable sacrificial inlet anti-wear edge protector assembly according to claim 1, characterized in that, A high-temperature resistant buffer pad (106) is provided between the edge protector body (101) and the inlet end face (20). The high-temperature resistant buffer pad (106) is a ceramic fiber pad, an expanded graphite pad, a metal corrugated pad or a composite heat-resistant pad, used to reduce the pressure of thermal expansion and contraction and vibration on the inlet end face of the catalyst module (10).

8. The replaceable sacrificial inlet anti-wear edge protector assembly according to claim 1, characterized in that, The dust-facing side of the edge protector body (101) is provided with a ceramic wear-resistant sheet, a welded wear-resistant layer, a sprayed wear-resistant layer or a high-chromium alloy wear-resistant layer, and the wear-resistant layer does not cover the identification boundary of the wear marking groove (105).

9. The replaceable sacrificial inlet anti-wear edge protector assembly according to claim 1, characterized in that, The edge protection assembly is divided into multiple segmented edge protections according to the inlet end face (20) of the catalyst module (10). Each segmented edge protection is provided with an independent detachable positioning snap-fit ​​part (103) and a wear mark groove (105). It can be independently disassembled and replaced with a spare edge protection (109) through the inspection window (107) along the disassembly and assembly direction (108).

10. An SCR catalyst module, characterized in that, The inlet end face (20) of the SCR catalyst module (10) is fitted with a replaceable sacrificial inlet anti-wear edge assembly according to any one of claims 1 to 9.

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