A net-zero emission dust removal system for the thermal power industry

Abstract

This utility model relates to the field of environmental protection equipment technology in the thermal power industry, and discloses a net-zero emission dust removal system for the thermal power industry. It comprises a rotary pulse dust collector body, a PPS ultra-low emission filter bag assembly, and an intelligent control system. It adopts a 360° continuous rotating jet cleaning structure, combined with gradient-density arranged PPS ultra-fine fiber filter bags, forming a dynamic filtration-regeneration synergistic cleaning mechanism. A multi-stage flow guiding and distribution device is set at the front end of the dust collector inlet to achieve uniform distribution of flue gas. Combined with an adaptive cleaning control system based on differential pressure feedback, the dust removal efficiency stably reaches over 99.99%, and the outlet dust emission concentration is ≤2mg / m³. The modular housing design achieves ultra-low emission targets while reducing system operating resistance by 40%, extending filter bag lifespan to over 5 years, and reducing overall energy consumption by 20%-30%. This provides the thermal power industry with a net-zero emission solution integrating high-efficiency dust removal, energy saving, and intelligent operation and maintenance.

Description

Technical Field

[0001] This utility model relates to the field of environmental protection equipment technology in the thermal power industry, and in particular to an intelligent dust removal system for net-zero emissions in the thermal power industry. Background Technology

[0002] With increasingly stringent environmental standards, the requirements for dust removal equipment in the thermal power industry are constantly rising. Traditional dust removal equipment generally suffers from the following problems when dealing with flue gas with high dust concentrations:

[0003] 1. High energy consumption: For example, unreasonable distribution of filter bags and uneven airflow distribution can easily cause local blockage; incomplete cleaning of filter bags leads to high operating resistance and high energy consumption; the pulse cleaning mechanism adopts a high-pressure pulse system, which requires a high-pressure gas storage tank to prepare gas, which increases energy consumption and operating costs, and the pulse valves are prone to failure, making it unable to meet the dust cleaning needs under complex working conditions.

[0004] 2. Poor dust removal efficiency: The outlet dust concentration is difficult to consistently fall below 10 mg / m³, failing to meet ultra-low emission requirements. Especially under the goal of achieving ultra-low emissions, existing technologies struggle to simultaneously meet the demands for efficient dust removal, energy conservation, and intelligent operation and maintenance. For example, traditional dust collectors use a bottom-inlet hopper and offline cleaning valve, leading to increased overall resistance in the dust removal system and impacting fan energy consumption. Furthermore, the clean air chamber covers of dust collectors are mostly small compartments with multiple covers, affecting the overall sealing and insulation effect of the dust collector, resulting in reduced performance of the dust collector and filter bags.

[0005] 3. Insufficient intelligence: The dust cleaning cycle is fixed and cannot be dynamically adjusted according to the actual operating status, resulting in low efficiency or excessive energy consumption;

[0006] 4. Poor material durability: The filter bags lack sufficient resistance to oxidation and corrosion in high-temperature and acidic environments. The filter bags have a short lifespan (typically ≤18 months) and high replacement costs.

[0007] To address the aforementioned issues, this invention proposes a net-zero emission dust removal system for the thermal power industry. By innovatively employing a rotary low-pressure pulse cleaning mechanism, PPS ultrafine fiber gradient filter bag assembly, and an adaptive cleaning control strategy based on differential pressure feedback, combined with an integrated housing design, it achieves an organic integration of high-efficiency dust removal, energy saving, and intelligent operation and maintenance, providing a more advanced and reliable solution for the thermal power industry. Summary of the Invention

[0008] The purpose of this utility model is to solve the above-mentioned technical problems and provide a low-resistance, high-efficiency, net-zero emission intelligent dust removal system for the thermal power industry. It optimizes airflow distribution and space utilization through the concentric ring layout of filter bags, reduces operating pressure and energy consumption by adopting low-energy rotary jet cleaning technology, and realizes dynamic optimization of dust removal and fault early warning based on intelligent control, thereby improving the filtration performance, corrosion resistance and long-term operational stability of filter bags.

[0009] In order to achieve the above technical objectives and meet the above technical requirements, the technical solution adopted by this utility model is: a net-zero emission intelligent dust removal system for the thermal power industry, including a rotary pulse dust collector body, a PPS ultra-fine fiber gradient filter bag assembly and an intelligent control system.

[0010] The PPS ultrafine fiber gradient filter bag assembly comprises several PPS ultrafine fiber gradient filter bags arranged in concentric rings around a central point. These bags are fixed to a perforated plate by a stainless steel frame. The perforations on the perforated plate are equidistant from the center, forming 8 to 25 concentric circles. The number of perforations in each circle increases progressively from the inside out: the innermost circle has the fewest perforations (e.g., 16), the second circle has more or less perforations than the innermost circle, the third circle has more perforations than the second circle, and so on. In other words, even-numbered circles have more or less perforations than the previous circle, and odd-numbered circles have fewer perforations than the previous circle. The number of holes must be greater than that of the previous ring, and so on up to the outermost ring (e.g., 18, 24, ...). The specific number is determined according to the diameter of the dust collector. Within the same ring, all holes are separated at equal angles in the circumferential direction, and the spacing between adjacent filter bags in the same ring is 30-50mm. Between two adjacent rings in the radial direction, the spacing between filter bags is 30-100mm, and the holes are offset by half a step from the holes of the previous ring in the circumferential direction. The offset length is 0-1 / 2 of the hole in the circumferential direction to improve airflow distribution and space utilization for installing filter bags.

[0011] Preferably, the number of holes in the perforated plate is 8-20 in the first ring from the inside out, 8-22 in the second ring, 10-24 in the third ring, 10-26 in the fourth ring, and so on until the outermost ring.

[0012] Preferably, the rotary pulse dust collector adopts an overall large-through-compartment design, with a 360° continuous rotating jet cleaning mechanism inside, and operates using ordinary compressed air, with a jet cleaning pressure range of 0.05-0.1MPa.

[0013] Preferably, the rotary jetting mechanism includes a vertical central air inlet jetting pipe. The upper end of the jetting pipe is connected to an air tank, and the lower end is provided with several radial distribution arms. The distribution arms open in a star shape at equal angles along the horizontal direction. Several nozzles are provided on the distribution arms. The nozzle orifice shape is rectangular (80-100mm long, 10-20mm wide) to adapt to flat filter bags. A tapered nozzle array is adopted, and the nozzle spacing gradually decreases from the center to the outside (150-300mm) to adapt to different filter bag densities. The jetting airflow is parallel to the filter bag axis, and the jetting cycle is adaptively adjusted through pressure difference feedback. The relative positions of the nozzles on different distribution arms are staggered to ensure that the jetting airflow is evenly distributed within one jetting cycle.

[0014] Operating parameters: The injection pressure only needs to be 0.05-0.1MPa (no high-pressure air tank required), and the injection cycle is adaptively adjusted by differential pressure feedback.

[0015] Preferably, the PPS ultrafine fiber gradient filter bag assembly includes several PPS ultrafine fiber gradient filter bags. The PPS ultrafine fiber gradient filter bags are elliptical flat cloth bags. The PPS ultrafine fiber gradient filter material adopts a four-layer composite structure, which consists of an anti-oxidation and corrosion-resistant ultrafine dust-attracting layer, a gradient density layer, a base fabric reinforcement layer, and a support reinforcement layer from the outside to the inside. The surface forms a microporous structure with an average pore size of <12 micrometers. The PPS ultrafine fiber gradient filter bags are completely perpendicular to the ground.

[0016] Antioxidant and corrosion resistant ultrafine dust-collecting layer: The ultrafine PPS fiber layer, treated with antioxidation and corrosion resistance, has a pore size of <12μm and a relatively dense structure, which can intercept and capture dust particles in dust-laden gas.

[0017] Gradient-density layer: An ultra-fine PPS fiber layer that rapidly forms a powder cake layer composed of dust particles at the beginning of the filtration process. As the filtration continues, the powder cake layer gradually becomes the main filter medium, enhancing dust retention.

[0018] Base fabric reinforcement layer: The base fabric is made of PPS, aramid, or PTFE. It provides support for the filter bag: The base fabric has high strength and toughness, providing solid support for the surface layer, ensuring the dust collector bag maintains a stable shape during filtration and preventing deformation or damage due to external forces such as airflow impact and dust pressure.

[0019] Support reinforcement layer: The wear-resistant PPS fiber layer prevents the bag from wearing against the frame due to external forces such as airflow impact and dust pressure, improves the overall durability of the bag, and extends its service life.

[0020] Preferably, the surface of the PPS ultrafine fiber gradient filter media is treated with an antioxidant, which gives it antioxidant and acid / alkali corrosion resistance properties, and enables it to operate stably for a long time in an environment with a pH value of 2-11.

[0021] Preferably, the rotary pulse dust collector is equipped with a multi-stage flow distribution device and a spiral ash conveying mechanism inside its main body. The flow distribution device adopts a combination structure of tapered guide vanes and honeycomb air distribution plates, which can divide the airflow and make it evenly enter the interior of the dust collector for dust removal. The spiral ash conveying mechanism has an inclination angle of 15°-25°, and the ash conveying speed matches the dust accumulation rate, reducing secondary dust generation.

[0022] Preferably, the intelligent control system integrates a differential pressure sensor, an online dust concentration monitor, and an Internet of Things module to achieve dynamic optimization of dust removal frequency, real-time uploading of emission data, and fault early warning.

[0023] Preferably, the differential pressure sensor is installed at the inlet and outlet flue of the dust collector to monitor the differential pressure of the dust collector and realize adaptive control: when the differential pressure is >1200Pa, the enhanced dust removal mode is triggered; when the differential pressure is <800Pa, the energy-saving operation mode is switched to (reducing the blowing frequency); and when the differential pressure is 800Pa≤differential pressure≤1200Pa, the normal dust removal mode is used to achieve a dynamic balance between operating resistance and energy consumption.

[0024] Preferably, the intelligent control system is equipped with an automatic learning module, which can dynamically optimize and adjust the cleaning cycle frequency and energy consumption management strategy based on historical operating data to extend the filter bag life. The main body of the rotary pulse dust collector adopts an expandable modular design, which can flexibly adjust the size and capacity according to user needs. By increasing the number of concentric rings or adjusting the length of the distribution arm, it can flexibly adapt to different air volume requirements.

[0025] Compared with the traditional structure, the beneficial effects of this utility model are:

[0026] 1. It adopts a 360° continuous rotating dust removal structure, combined with gradient-density PPS microfiber filter bags, to form a dynamic filtration-regeneration synergistic dust removal mechanism; the incremental arrangement of the pores reduces the risk of blockage in the central area, optimizes airflow uniformity and space utilization; and provides the thermal power industry with a net-zero emission solution that integrates high-efficiency dust removal, energy saving and consumption reduction and intelligent operation and maintenance.

[0027] 2. By setting up a multi-stage flow distribution device at the front end of the bag filter inlet, the flue gas is evenly distributed. Combined with the adaptive dust removal control system based on differential pressure feedback, the dust removal efficiency can be stably maintained at over 99.99%, and the outlet dust emission concentration is ≤2mg / m³, meeting the ultra-low emission requirements and achieving net-zero emissions.

[0028] 3. The system innovatively adopts a modular housing design, which reduces the injection pressure by more than 50% and the operating resistance by 30-50% while achieving ultra-low emission targets, thus improving energy efficiency. The overall energy consumption is reduced by 20-30% compared with traditional dust removal systems, significantly improving economic efficiency.

[0029] 4. Intelligent management is achieved through an intelligent control system, dynamically adjusting to reduce ineffective dust removal by 20%, and the fault early warning accuracy rate reaches over 95%. Reliability is enhanced, the corrosion resistance life of the filter bags is increased to over 5 years, and the maintenance cycle is extended. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of this utility model;

[0031] Figure 2 This is a schematic diagram of the PPS ultrafine fiber gradient filter media structure of this utility model;

[0032] In the diagram: 100. Rotary pulse dust collector body; 101. Flow distribution device; 102. Spiral ash conveying mechanism; 200. PPS ultra-fine fiber gradient filter bag assembly; 201. PPS ultra-fine fiber gradient filter bag; 201-1. Antioxidant and corrosion-resistant ultra-fine dust-gathering layer; 201-2. Gradient densification layer; 201-3. Base fabric reinforcement layer; 201-4. Support reinforcement layer; 202. Stainless steel frame; 300. Rotary jet cleaning mechanism; 301. Air tank; 302. Jet pipe; 303. Distribution arm; 304. Nozzle; 500. Intelligent control system; 501. Differential pressure sensor. Detailed Implementation

[0033] The present invention will be further described below.

[0034] Example 1: Application in a 50MW coal-fired power plant

[0035] Installation and configuration:

[0036] The main body of the rotary pulse dust collector is Φ8m×12m, and it is equipped with 2400 PPS ultra-fine fiber gradient filter bags (spacing 30-80mm) and the nozzle spacing of the blow pipe is 150-180mm.

[0037] Operation process:

[0038] After being diverted by the multi-stage flow distribution device 101, the flue gas enters the filter bag area evenly, and the dust is intercepted to form a filter cake.

[0039] When the differential pressure sensor detects a differential pressure value >1200Pa, the intelligent system activates the enhanced dust removal mode: the rotating blow arm sprays air at a speed of 2r / min at a pressure of 0.1MPa for 5 minutes.

[0040] The collected dust is conveyed to the ash storage silo via a spiral ash conveying mechanism 102 at an inclination angle of 20° and a rotation speed of 8 r / min.

[0041] Effect verification:

[0042] According to third-party testing, the dust concentration at the outlet is stable at 1.2-2 mg / m³, with a dust removal efficiency of 99.976%; the average system resistance is ≤800 Pa.

[0043] After 32 months of use, the filter bags retain more than 95% of their strength, and the system’s annual power consumption is reduced by 31.6% year-on-year.

[0044] Annual operating costs will be reduced by approximately RMB 282,200.

[0045] Calculation formula: ;

[0046] Parameter description:

[0047] Total operating cost savings;

[0048] Annual power consumption (kWh) of traditional / new systems (Q is the air volume in m³ / h, ΔP is the resistance in Pa, t is the annual operating hours, and η is the fan efficiency).

[0049] Industrial electricity price (yuan / kWh), taken as 0.6 yuan / kWh;

[0050] Total number of filter bags: Approximately 2400 bags are needed for a 50MW unit;

[0051] Cost per filter bag (RMB): The unit price of a PPS gradient filter bag is approximately RMB 120.

[0052] The lifespan of traditional / new filter bags (in months) is 18 / 60 months respectively.

[0053] Annual maintenance cost (RMB) for traditional / new systems, including pulse valve replacement, seal repair, etc.

[0054] Substitute the data from the example:

[0055] Energy saving: Q is the air volume t represents 8000 hours of operation per year, and η represents 80% of the fan efficiency. ; . = 416,700 kWh, saving 250,000 yuan;

[0056] Filter bag replacement costs are reduced: Ten thousand yuan;

[0057] Maintenance cost savings: Pulse valve failure rate reduced by 80% → approximately 21,000 yuan;

[0058] Total savings: 25 + 1.12 + 2.1 = 282,200 yuan.

[0059] Example 2: Application in a 20MW biomass cogeneration project

[0060] Installation and configuration:

[0061] The main body of the rotary pulse dust collector is Φ4m×10m, with 1200 PPS ultra-fine fiber gradient filter bags (spaced 90mm apart) and a nozzle spacing of 160mm on the blow pipe.

[0062] Operation process:

[0063] Biomass flue gas with high humidity (flue gas humidity > 12%) enters the filter bag area after being pre-dehydrated by the flow distribution device 101;

[0064] When the online dust concentration monitor detects an instantaneous value > 8 mg / m³, the intelligent system triggers high-frequency dust removal (blowing pressure 0.1 MPa, lasting 5 minutes).

[0065] The spiral conveyor mechanism 102 operates at an inclination angle of 18° and a rotation speed of 10 r / min.

[0066] Effect verification:

[0067] According to third-party testing, the outlet dust concentration is ≤2mg / m³, the dust removal efficiency is 99.96%, and the average system resistance is ≤800Pa.

[0068] After 30 months of use, the filter bag retains more than 95% of its strength, and after 28 months of use, the pressure difference increases by only 9%.

[0069] The system's annual power consumption decreased by 24.3% year-on-year.

[0070] Comparative Example 1: Traditional Bag Filter System (Comparative Example 1)

[0071] The actual operating conditions are similar to those in Example 1.

[0072] Structure and operating parameters:

[0073] Filter bag material: 1200 ordinary PPS filter bags are arranged with a non-gradient encryption design;

[0074] Dust removal method: No intelligent control module, fixed frequency dust removal, with a fixed cycle of once per hour.

[0075] Performance data:

[0076] Outlet dust concentration: 8-15mg / m³, system resistance: ≥1500Pa, additional booster fan required;

[0077] After 18 months of operation, the filter bag clogging and breakage rate is >5%;

[0078] Filter bag lifespan: Due to frequent temperature and humidity fluctuations, the lifespan is shortened to 24 months.

[0079] Comparative Example 2: Traditional Pulse Jet Dust Collection System (Comparative Example 2)

[0080] The actual operating conditions and the main body size of the dust collector are similar to those in Example 2.

[0081] Structure and operating parameters:

[0082] Filter bag material: 1200 ordinary PPS filter bags are arranged with a non-gradient encryption design;

[0083] Dust removal method: Fixed frequency dust removal, with a fixed frequency of once every 40 minutes;

[0084] Flue gas temperature fluctuation range: 80-180℃, no intelligent temperature control system.

[0085] Performance data:

[0086] Outlet dust concentration: 12-15 mg / m³, system resistance: average 1600 Pa;

[0087] After 18 months of operation, the filter bag breakage rate is >5%;

[0088] Filter bag lifespan: Due to frequent fluctuations in temperature and humidity, the lifespan is shortened to 22 months.

[0089] For a comparison of specific parameters between the examples and the comparative examples, please refer to Table 1.

[0090] Table 1 Comparison of specific parameters between the examples and comparative examples

[0091] index Example 1 Example 2 Comparative Example 1 Comparative Example 2 Exit dust concentration (mg / m³) ≤5 ≤5 8-15 12-15 Filter bag lifespan (months) ≥36 ≥36 24 22 System resistance (Pa) ≤800 ≤800 ≥1500 ≥1600 Overall energy consumption reduced 31.6% 24.3% Baseline value (no optimization) Baseline value (no optimization)

[0092] The above embodiments of this utility model are merely examples to clearly illustrate this utility model, and are not intended to limit the scope of protection of this utility model. All equivalent technical solutions also fall within the scope of this utility model, and the patent protection scope of this utility model should be defined by each claim.

Claims

1. A net-zero emission dust removal system for the thermal power industry, characterized in that: It includes a rotary pulse dust collector body (100), a PPS ultra-fine fiber gradient filter bag assembly (200), and an intelligent control system (500). The PPS ultrafine fiber gradient filter bag assembly (200) includes several PPS ultrafine fiber gradient filter bags (201). These bags are arranged in concentric rings around a central point and fixed to a perforated plate by a stainless steel frame (202). The perforations on the perforated plate are equidistantly arranged along the center, forming 8 to 25 concentric circles. The number of perforations in each circle increases progressively from the inside out: the innermost circle has the fewest perforations, the second circle has more or less than or equal to the innermost circle, and the third circle has more than the second circle. The even-numbered outer rings have a number of holes greater than or equal to the previous ring, and the odd-numbered rings must have a number of holes greater than the previous ring, and so on until the outermost ring. Within the same ring, all holes are separated at equal angles in the circumferential direction, and the spacing between adjacent filter bags in the same ring is 30-50mm. Between two adjacent radial rings, the spacing between filter bags is 30-100mm, and their holes are offset by half a step from the holes of the previous ring in the circumferential direction. The offset length is 0-1 / 2 of the hole opening in the circumferential direction, in order to improve airflow distribution and space utilization for installing filter bags.

2. The net-zero emission dust removal system for the thermal power industry according to claim 1, characterized in that: The perforated plate has 8-20 holes in the first ring from the inside out, 8-22 holes in the second ring, 10-24 holes in the third ring, 10-26 holes in the fourth ring, and so on until the outermost ring.

3. The net-zero emission dust removal system for the thermal power industry according to claim 1, characterized in that: The main body (100) of the rotary pulse dust collector adopts an overall large open compartment design and is equipped with a 360° continuous rotating jet blowing mechanism (300) inside. It operates with ordinary compressed air and the blowing pressure range is 0.05-0.1MPa.

4. The net-zero emission dust removal system for the thermal power industry according to claim 3, characterized in that: The rotary blowing mechanism (300) includes a vertical central air inlet blowing pipe (302). The upper end of the blowing pipe (302) is connected to the air bag (301), and the lower end is provided with several radial distribution arms (303). The distribution arms (303) open in a star shape at equal angles in the horizontal direction. Several nozzles (304) are provided on the distribution arms (303). The nozzles (304) have a rectangular nozzle orifice shape and adopt a tapered nozzle array. The spacing between the nozzles (304) gradually decreases from the center to the outside. The spacing between the nozzles (304) is 150-300mm. The blowing airflow is parallel to the filter bag axis. The blowing cycle is adaptively adjusted by pressure difference feedback. The relative positions of the nozzles (304) on different distribution arms (303) are staggered.

5. The net-zero emission dust removal system for the thermal power industry according to claim 1, characterized in that: The PPS ultrafine fiber gradient filter bag (201) is an elliptical flat cloth bag. The PPS ultrafine fiber gradient filter material adopts a four-layer composite structure, which consists of an anti-oxidation and corrosion resistant ultrafine dust-attracting layer (201-1), a gradient densification layer (201-2), a base fabric reinforcement layer (201-3), and a support reinforcement layer (201-4) from the outside to the inside. The surface forms a microporous structure with an average pore size of <12 micrometers. The PPS ultrafine fiber gradient filter bag (201) is completely perpendicular to the ground.

6. The net-zero emission dust removal system for the thermal power industry according to claim 5, characterized in that: The PPS ultrafine fiber gradient filter media undergoes an anti-oxidation treatment on its surface, giving it anti-oxidation and anti-acid and alkali corrosion properties, enabling it to operate stably for a long time in an environment with a pH value of 2-11.

7. The net-zero emission dust removal system for the thermal power industry according to claim 1, characterized in that: The rotary pulse dust collector body (100) is equipped with a multi-stage flow distribution device (101) and a spiral ash conveying mechanism (102). The flow distribution device (101) adopts a combination structure of tapered guide vanes and honeycomb air distribution plate, which can divide the airflow and make it evenly enter the interior of the dust collector body for dust removal. The spiral ash conveying mechanism (102) has an inclination angle of 15°-25° and the ash conveying speed matches the dust accumulation rate.

8. The net-zero emission dust removal system for the thermal power industry according to claim 1, characterized in that: The intelligent control system (500) integrates a differential pressure sensor (501), an online dust concentration monitor, and an Internet of Things module to achieve dynamic optimization of dust removal frequency, real-time uploading of emission data, and fault early warning.

9. The net-zero emission dust removal system for the thermal power industry according to claim 8, characterized in that: The differential pressure sensor (501) is installed at the inlet and outlet flue of the dust collector. When the differential pressure is greater than 1200Pa, it triggers the enhanced dust removal mode, and when the differential pressure is less than 800Pa, it switches to the energy-saving operation mode.

10. The net-zero emission dust removal system for the thermal power industry according to claim 1, characterized in that: The intelligent control system (500) is equipped with an automatic learning module, which can dynamically optimize the dust removal frequency and energy consumption management strategy based on historical operating data. The main body (100) of the rotary pulse dust collector adopts a modular design, which can flexibly adjust the size and capacity according to user needs.

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