Catalyst module quick change device

Abstract

The utility model belongs to engineering component technical field especially relates to catalyst module quick assembly and disassembly device. One kind catalyst module quick assembly and disassembly device, it is equipped with reactor bottom, as the frame base of vertical flue, including: a plurality of unit frame layers, it is equipped with unit frame layer top, and extends along unit frame layer length direction;Limit angle steel, it is welded on the transverse steel of unit frame layer;Guide rail channel steel, it is laid on unit frame layer, and is embedded between two limit angle steel, is used for guiding the movement of manual hydraulic car;Among them, catalyst module is hoisted to manual hydraulic car through electric hoist, and manual hydraulic car drives catalyst module to move horizontally along guide rail channel steel, and finally places catalyst module on the high layer. Through the cooperation of the high layer, limit angle steel and guide rail channel steel, catalyst module can be moved and positioned efficiently and quickly.

Description

Technical Field

[0001] This utility model belongs to the field of engineering component technology, and in particular relates to a rapid loading and unloading device for catalyst modules. Background Technology

[0002] The catalyst module is the core component of the SCR (Selective Catalytic Reduction) reactor, and its loading and unloading efficiency directly affects equipment maintenance costs and production continuity.

[0003] In the existing technology, the installation of catalyst modules mainly suffers from the following technical defects: The loading and unloading process is inefficient and labor-intensive. Traditional methods rely on temporary angle steel or channel steel as slide rail supports, along with hand-cranked hoists for positioning and adjustment. This process requires multiple operators to enter the reactor for construction, especially when installing the last few modules, where the operating space is extremely limited, greatly increasing the construction difficulty and time costs.

[0004] The safety risks are high, as vertical flues are generally quite tall, and there is a risk of collision, squeezing or falling during construction. This requires a large investment in safety protection resources and increases management costs.

[0005] The module is easily damaged. Improper operation can easily lead to deformation of the bottom of the catalyst module or wear and tear on the packaging, which not only reduces the catalyst recycling rate but also affects its reaction effect and indirectly increases the replacement cost.

[0006] Poor positioning accuracy and insufficient stability of the temporary support structure require repeated adjustments to the module's position, which prolongs the loading and unloading time and hinders the rapid resumption of production.

[0007] The aforementioned shortcomings limit the maintenance efficiency of SCR reactors. Therefore, there is an urgent need to develop a rapid loading and unloading device for catalyst modules.

[0008] It should be noted that the information disclosed in this background section is only for understanding the background technology of this application concept, and therefore, the above description is not considered to constitute information related to the technology. Utility Model Content

[0009] This disclosure provides at least one rapid loading and unloading device for a catalyst module.

[0010] This disclosure provides a rapid loading and unloading device for a catalyst module, comprising: Several unit frame layers are located at the bottom of the reactor, serving as the frame foundation for the vertical flue. The raised floor is located above the unit frame layer and extends along the length of the unit frame layer. The limiting angle steel is welded to the transverse steel of the unit frame layer; The guide rail channel steel is laid on the unit frame layer and embedded between two limiting angle steels to guide the movement of the manual hydraulic trolley; The catalyst module is hoisted onto a manual hydraulic trolley using an electric hoist. The manual hydraulic trolley then drives the catalyst module to move horizontally along the guide rail channel steel, and finally places the catalyst module on the pad level.

[0011] In one alternative embodiment, the padding layer is made of H-beams, and the flanges of the H-beams are provided with reinforcing ribs to prevent deformation under stress.

[0012] In one alternative embodiment, the spacing between the H-beams of two adjacent pad layers matches the size of the catalyst module, and the reinforcing ribs are evenly distributed along the flange.

[0013] In one optional embodiment, the pointed corner of the limiting angle steel is set upward, and the distance between two adjacent limiting angle steels can be adjusted to accommodate guide rail channel steels of different widths.

[0014] In one alternative implementation, the guide channel steel has an upward opening and its length covers the entire path from the reactor inlet to the pad level.

[0015] In one alternative embodiment, the manual hydraulic trolley includes forks and a rear wheel with auxiliary wheels, wherein the maximum lifting height of the forks is greater than the height of the padding layer.

[0016] In one alternative embodiment, the surface of the guide rail channel steel is coated with an anti-wear coating to reduce frictional wear with the manual hydraulic trolley.

[0017] In one optional embodiment, a gap is left between the limiting angle steel and the guide rail channel steel.

[0018] The beneficial effects of this invention are as follows: It provides a rapid loading and unloading device for catalyst modules. Through the cooperation of the support structure and the guide rail channel steel, the catalyst module can be moved horizontally along a predetermined path after being hoisted onto the manual hydraulic trolley, and accurately placed in the target position in one go. This reduces the number of hoisting operations, lowers the risk of collision caused by repeated lifting of the catalyst module, and shortens the operation time. By welding limiting angle steel to the unit frame layer and embedding the guide rail channel steel between the two limiting angle steels to form a rigid constraint structure, it is ensured that the manual hydraulic trolley will not deviate during movement. The support structure adopts an H-beam steel reinforcement design, further improving the overall stability. This stable support can effectively prevent the catalyst module from slipping, ensuring the reliability of long-term operation, and is especially suitable for chemical plants under high wind pressure or high temperature conditions.

[0019] Other features and advantages of this invention will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the invention. The objectives and other advantages of this invention are realized and obtained through the structures particularly pointed out in the description and the accompanying drawings.

[0020] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the specific embodiments or related technologies of this utility model, the drawings used in the description of the specific embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0022] Figure 1 A top view of the unit frame layer provided in an embodiment of this disclosure; Figure 2 This is a front view of the unit frame layer provided in an embodiment of the present disclosure; Figure 3 This is a top view of the unit frame layer after the guide rail channel steel is laid, as provided in the embodiments of this disclosure. Figure 4 This is a front view of the unit frame layer after the guide rail channel steel is laid, as provided in the embodiments of this disclosure. Figure 5 A top view of the manual hydraulic trolley used for material transport provided in this embodiment of the disclosure; Figure 6 The manual hydraulic trolley for material transport provided in this embodiment of the disclosure enters the main view; Figure 7 A top view of the manually operated hydraulic trolley in the position after the catalyst module is in place, as provided in an embodiment of this disclosure. Figure 8 This is a front view of the manually operated hydraulic trolley exiting the position after the catalyst module is in place, as provided in an embodiment of this disclosure.

[0023] In the picture: 1. Unit frame layer; 2. Pad layer; 20. Reinforcing ribs; 3. Limiting angle steel; 4. Guide rail channel steel; 5. Manual hydraulic trolley; 51. Forks; 52. Rear wheels; 6. Catalyst module. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0025] In this document, when it is mentioned that a first component is located on a second component, this can mean that the first component can be directly formed on the second component, or that a third component can be inserted between the first and second components. Furthermore, in the accompanying drawings, the thickness of the components may be exaggerated or reduced for the purpose of effectively describing the technical content.

[0026] In this document, exemplary embodiments of the present disclosure will be described in more detail with reference to the accompanying drawings. As used herein, expressions such as “at least one of…” modify the entire list of elements when following a list of elements, rather than individual elements in the list. For example, the expression “at least one of a, b, and c” should be understood to include only a, only b, only c, both a and b, both a and c, both b and c, or all of a, b, and c.

[0027] The terminology used herein is for the purpose of describing specific exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may also be intended to include plural forms unless otherwise expressly stated herein. The terms “comprising,” “including,” and “having” are inclusive and thus specify the presence of features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or combinations thereof. The method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or shown, unless specifically identified as such. Additional or alternative steps may be employed.

[0028] As used herein, the phrases “in one embodiment,” “according to one embodiment,” “in some embodiments,” etc., generally refer to the fact that a particular feature, structure, or characteristic following the phrase can be included in at least one embodiment of this disclosure. Therefore, a particular feature, structure, or characteristic can be included in more than one embodiment of this disclosure, such that these phrases do not necessarily refer to the same embodiment. As used herein, the terms “example,” “exemplary,” etc., are used to “serve as an example, instance, or illustration.” Any implementation, aspect, or design described herein as “example” or “exemplary” is not necessarily to be construed as preferred or superior to other implementations, aspects, or designs. Rather, the use of the terms “example,” “exemplary,” etc., is intended to present concepts in a specific manner.

[0029] Research has shown that the catalyst module is the core component of the SCR (Selective Catalytic Reduction) reactor, and its loading and unloading efficiency directly affects equipment maintenance costs and production continuity.

[0030] In the existing technology, the installation of catalyst modules mainly suffers from the following technical defects: The loading and unloading process is inefficient and labor-intensive. Traditional methods rely on temporary angle steel or channel steel as slide rail supports, along with hand-cranked hoists for positioning and adjustment. This process requires multiple operators to enter the reactor for construction, especially when installing the last few modules, where the operating space is extremely limited, greatly increasing the construction difficulty and time costs.

[0031] The safety risks are high, as vertical flues are generally quite tall, and there is a risk of collision, squeezing or falling during construction. This requires a large investment in safety protection resources and increases management costs.

[0032] The module is easily damaged. Improper operation can easily lead to deformation of the bottom of the catalyst module or wear and tear on the packaging, which not only reduces the catalyst recycling rate but also affects its reaction effect and indirectly increases the replacement cost.

[0033] Poor positioning accuracy and insufficient stability of the temporary support structure require repeated adjustments to the module's position, which prolongs the loading and unloading time and hinders the rapid resumption of production.

[0034] The aforementioned shortcomings limit the maintenance efficiency of SCR reactors. Therefore, there is an urgent need to develop a rapid loading and unloading device for catalyst modules.

[0035] The defects in the above solutions and the reasons for their occurrence are the results of the inventors' practice and careful research. Therefore, the discovery process of the above problems and the solutions proposed in this disclosure should be considered as the inventors' contributions to this disclosure.

[0036] 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.

[0037] The following detailed description, with reference to the accompanying drawings, describes some embodiments of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0038] like Figure 1 and Figure 3As shown, at least one embodiment provides a rapid loading and unloading device for catalyst modules, comprising: several unit frame layers 1, which are located at the bottom of the reactor and serve as the frame foundation for the vertical flue; the unit frame layers 1 are typically welded from carbon steel to bear the flue load and the weight of the catalyst. A pad layer 2 is located above it and extends along the length of the unit frame layers 1 to form a support platform for the catalyst module 6, used to support the catalyst module 6 from the bottom. Limiting angle steel 3 is welded to the transverse steel of the unit frame layers 1, with its sharp corners facing upwards, used to engage the guide rail channel steel 4. The guide rail channel steel 4 is laid on the unit frame layers 1 and embedded between the two limiting angle steels 3, used to guide the movement of the manual hydraulic trolley 5; after the guide rail channel steel 4 is laid, the manual hydraulic trolley 5 moves along it to transport the catalyst module 6 to the pad layer 2. The catalyst module 6 is hoisted onto the manual hydraulic trolley 5 by an electric hoist, and the manual hydraulic trolley 5 drives the catalyst module 6 to move horizontally along the guide rail channel steel 4, finally placing the catalyst module 6 on the pad layer 2.

[0039] In the power industry, SCR reactors are mostly installed at the tail end of boilers, in confined spaces and high-temperature environments. The modular unit frame layer 1 of this invention can be prefabricated to adapt to different reactor sizes, reducing on-site welding work. For example, for a 1000MW unit, the reactor height may exceed 20 meters, requiring the unit frame layer 1 to be installed in sections; however, standardized interfaces enable rapid assembly. The selection of the manual hydraulic trolley 5 should consider load capacity. The catalyst module 6 typically weighs 1-3 tons, therefore the hydraulic trolley must be equipped with explosion-proof tires and a cushioning system to cope with the vibration environment of the power plant platform. Furthermore, electric hoist lifting must be coordinated with the reactor platform crane; industry standards require the lifting process to comply with GB / T 3811-2008 Crane Safety Regulations to avoid overloading or swaying.

[0040] Reference Appendix Figure 4 The H-beams of the upper level 2 are made of Q345B low-alloy steel, with a flange thickness of not less than 10mm to withstand long-term loads. Reinforcing ribs 20 are welded to both sides of the flanges, with spacing determined by load calculations, typically 500-800mm. During installation, the H-beams are fixed to the unit frame layer 1 by bolts or welding to ensure overall rigidity. In the chemical industry, SCR reactors may come into contact with corrosive flue gases; therefore, the surface of the H-beams needs to be coated with an epoxy anti-corrosion coating to extend their service life. The design of the reinforcing ribs 20 references the JB / T 5000-2007 heavy machinery standard, and their distribution is optimized through finite element analysis to prevent flange buckling. For new construction projects, the unit frame layer 1 can integrate the reinforcing ribs 20, reducing the load on the upper level 2, demonstrating the economic advantages of modular design.

[0041] Continue to refer to the appendix Figure 3The spacing between the H-beams of two adjacent support layers 2 matches the dimensions of the catalyst module 6, and the reinforcing ribs 20 are evenly distributed along the flange. The design of the spacing between the H-beams of two adjacent support layers 2 is based on the standard dimensions of the catalyst module 6. For example, if the common catalyst module 6 is 1.5m × 1.5m, then the spacing between the H-beams of the support layers 2 is set to 1.4m, leaving a clearance for easy installation. The even distribution of the reinforcing ribs 20 ensures uniform load distribution and avoids local stress concentration.

[0042] Reference Appendix Figure 6 The guide rail channel steel 4 is made of cold-formed channel steel, with an upward opening to facilitate the insertion of the wheels of the manual hydraulic trolley 5. The surface of the guide rail channel steel 4 is coated with an anti-wear coating to reduce frictional wear with the manual hydraulic trolley 5. The length of the guide rail channel steel 4 is customized according to the reactor depth, such as 10-15 meters. The path design avoids bends and maintains a straight line to reduce friction. In large power plants, the reactor inlet may be far from the pad height 2; the guide rail channel steel 4 can be segmented and spliced, with beveled transitions at the joints to ensure smooth movement. The upward opening design conforms to ANSI MH standards to prevent derailment. In practical applications, a safety passage must be reserved along the path for easy emergency evacuation of personnel.

[0043] Reference Appendix Figure 8 The manual hydraulic trolley 5 includes forks 51 and rear wheels 52 with auxiliary wheels. The maximum lifting height of the forks 51 is greater than the height of the platform 2. The lifting height of the forks 51 of the manual hydraulic trolley 5 is set to 300-500mm, higher than the height of the platform 2 (usually 200-300mm), ensuring smooth placement of the catalyst module 6. The auxiliary wheels enhance stability and prevent tipping. The hydraulic trolley must be CE certified, and the forks 51 have an anti-slip coating to adapt to oily environments. In the chemical industry, an explosion-proof model is available to avoid the risk of sparks. The lifting height can be finely adjusted via the hydraulic system to meet the needs of different reactors and reduce manual intervention. Figure 7 F1 indicates the direction of entry for catalyst module 6; Figure 8 F2 indicates the direction of movement when the manual hydraulic trolley 5 is withdrawn.

[0044] A gap is left between the limiting angle steel 3 and the guide rail channel steel 4 to prevent jamming. The gap is set at 2-5mm to allow for thermal expansion and manufacturing tolerances, while ensuring guiding accuracy.

[0045] In the description of the embodiments of this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" 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 utility model based on the specific circumstances.

[0046] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this utility model 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 this utility model. Furthermore, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence unless expressly indicated herein. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, region, layer, or segment discussed above may be referred to as the second element, component, region, layer, or segment.

[0047] Based on the above-described preferred embodiments of this utility model, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the technical concept of this utility model. The technical scope of this utility model is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A rapid loading and unloading device for catalyst modules, characterized in that, include: Several unit frame layers (1) are located at the bottom of the reactor and serve as the frame foundation for the vertical flue. The padding layer (2) is located above the unit frame layer (1) and extends along the length of the unit frame layer (1); The limiting angle steel (3) is welded to the transverse steel of the unit frame layer (1); The guide rail channel steel (4) is laid on the unit frame layer (1) and embedded between two limiting angle steels (3) to guide the movement of the manual hydraulic trolley (5); The catalyst module (6) is hoisted onto the manual hydraulic trolley (5) by an electric hoist. The manual hydraulic trolley (5) drives the catalyst module (6) to move horizontally along the guide rail channel steel (4) and finally places the catalyst module (6) on the pad height (2).

2. The catalyst module rapid loading and unloading device as described in claim 1, characterized in that, The padding layer (2) is made of H-beams, and the flanges of the H-beams are provided with reinforcing ribs (20) to prevent deformation under stress.

3. The catalyst module rapid loading and unloading device as described in claim 2, characterized in that, The spacing between the H-beams of two adjacent pad heights (2) matches the size of the catalyst module (6), and the reinforcing ribs (20) are evenly distributed along the wing plate.

4. The catalyst module rapid loading and unloading device as described in claim 1, characterized in that, The pointed corners of the limiting angle steel (3) are set upwards, and the spacing between two adjacent limiting angle steels (3) can be adjusted to accommodate guide rail channel steels (4) of different widths.

5. The catalyst module rapid loading and unloading device as described in claim 1, characterized in that, The opening of the guide channel steel (4) faces upward, and its length covers the entire path from the reactor inlet to the pad height (2).

6. The catalyst module rapid loading and unloading device as described in claim 1, characterized in that, The manual hydraulic trolley (5) includes forks (51) and rear wheels (52) with auxiliary wheels, the maximum lifting height of the forks (51) being greater than the height of the padding layer (2).

7. The catalyst module rapid loading and unloading device as described in claim 1, characterized in that, The guide rail channel steel (4) is coated with an anti-wear coating to reduce frictional wear with the manual hydraulic trolley (5).

8. The catalyst module rapid loading and unloading device as described in claim 1, characterized in that, A gap is left between the limiting angle steel (3) and the guide rail channel steel (4).

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