Gradient Hierarchy Desulfurizing Tower with S-Shaped Bubble Cap Trays
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Solution Overview
Problem
Conventional desulfurization technologies face challenges in achieving high efficiency for medium high sulfur coal and high sulfur coal, particularly in reducing SO2 content below 35 mg/Nm3, and struggle with dedusting fine dust particles, especially PM2.5, due to limitations in pH control, tower design, and mass transfer mechanisms.
Innovation Solution
A high-efficiency gradient hierarchy complex desulfurizing tower with an S-shaped rectangular bubble cap desulfurization and dedusting tray structure, incorporating an S-type gas liquid mass transfer mechanism, allows for pH control up to 6.4, segmental slurry collection, and enhanced mass transfer, increasing desulfurization efficiency to 99.5% and dedusting efficiency to 90% or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional single spray tower design is used, then device complexity is low, but desulfurization efficiency cannot reach 99.5% required for ultra-low emission
Solution Approach 1:
The desulfurization tower is divided into multiple functional stages: coarse desulfurization stage with spray layers, fine desulfurization stage with S-shaped bubble cap trays, and oxidization-cry stallization stage. Each stage performs a specific function, allowing the system to achieve 99.5% desulfurization efficiency through cumulative effect while keeping individual components relatively simple.
Solution Approach 2:
The patent introduces an S-shaped rectangular bubble cap tray structure that creates three-dimensional gas-liquid mass transfer pathways. The S-shaped design extends the contact path between flue gas and slurry from a simple vertical dimension to a complex three-dimensional trajectory, significantly enhancing mass transfer efficiency without requiring a larger tower footprint.
2Manufacturing precision
If pH value is controlled at 5.2-5.8 for conventional operation, then gypsum oxidation and crystallization proceed normally, but desulfurization activity is limited and cannot achieve ultra-high efficiency
Solution Approach 1:
The tower segments different pH control zones: the fine desulfurization stage maintains high pH (5.8-6.4) to maximize desulfurization activity, while the oxidization-cry stallization stage maintains lower pH (5.2-5.8) for stable gypsum formation. This spatial segmentation allows both conflicting requirements to be satisfied simultaneously in different locations.
Solution Approach 2:
Different regions of the tower are assigned different pH characteristics optimized for their specific functions. The S-shaped bubble cap tray region operates at higher pH for enhanced mass transfer and desulfurization activity, while the slurry pond operates at controlled lower pH for stable gypsum crystallization. Each local zone has quality parameters tailored to its purpose.
3Productivity
If total flow rate of absorption slurry is increased to improve desulfurization capacity, then more SO2 can be removed, but liquid overcapacity occurs and pressure drop increases making operation impossible
Solution Approach 1:
The absorption process is segmented into multiple stages with progressive SO2 removal. The coarse desulfurization stage handles bulk removal with higher slurry flow, while the fine desulfurization stage handles residual SO2 with optimized lower flow. This segmentation allows high overall capacity without excessive pressure drop in any single section.
Solution Approach 2:
The S-shaped bubble cap trays provide excessive mass transfer area and contact time beyond what conventional spray towers offer. This excessive action capability allows the system to achieve ultra-high desulfurization efficiency with moderate slurry flow rates, avoiding the liquid overcapacity and high pressure drop problems that would occur with higher flows in conventional designs.
4Manufacturing precision
If conventional spray layers are used, then structure is simple, but dedusting efficiency for fine dust particles like PM2.5 is insufficient
Solution Approach 1:
The S-shaped bubble cap trays introduce curved, three-dimensional flow paths that enhance turbulence and contact between flue gas and slurry. The S-shaped geometry creates multiple direction changes that increase the residence time and collision frequency between dust particles and liquid droplets, significantly improving dedusting efficiency for fine particles like PM2.5 compared to straight spray paths.
Solution Approach 2:
The patent transitions from two-dimensional spray patterns to three-dimensional S-shaped flow pathways. This dimensional enhancement creates additional contact surfaces and extends the interaction path between gas and liquid phases, enabling effective capture of fine dust particles that conventional spray systems cannot remove efficiently.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves ultra-high desulfurization and dedusting performance, suitable for medium high sulfur coal and high sulfur coal, with a single tower design that is adaptable and cost-effective, modifying existing systems, and effectively reduces SO2 and fine dust emissions.
Implementation Method 1
incorporating an S-type gas liquid mass transfer mechanism, allows for pH control up to 6.4, segmental slurry collection, and enhanced mass transfer
Implementation Method 2
S-shaped rectangular bubble cap desulfurization and dedusting tray structure
Implementation Method 3
interactions such as inertial impaction, interception, diffusion, agglomeration, gravity sedimentation and the like occur between dust particles in the gases and the droplets
Implementation Method 4
undergoes forced oxidation and crystallization in the slurry pond
Implementation Method 5
undergoes forced oxidation and crystallization in the slurry pond
Implementation Method 6
Slurry is ejected by a plurality of nozzles of each spray layer, moves downward, contacts counter-currently and interacts physically and chemically with the flue gases, and washes and removes sulfur dioxide in the flue gases
Implementation Method 7
interactions such as inertial impaction, interception, diffusion, agglomeration, gravity sedimentation and the like occur between dust particles in the gases and the droplets
Implementation Method 8
interactions such as inertial impaction, interception, diffusion, agglomeration, gravity sedimentation and the like occur between dust particles in the gases and the droplets
Implementation Method 9
After the slurry absorbed sulfur oxide SO2, flue dust and other pollutant from the flue gases
Data Source
AI summary
A high-efficiency gradient hierarchy complex desulfurizing tower includes a tower body. The tower body tower includes an oxidization and crystallization stage, a coarse desulfurization and dedusting stage, a fine desulfurization and dedusting stage, and a horizontal demisting stage from the bottom up. The oxidization and crystallization stage tower includes a pond and a separation mechanism provided in the pond and separating the pond into an upper area and a lower area. The coarse desulfurization and dedusting stage tower includes a gas distributing board and a multi-layer spray layer that are placed above a gas import, the spray layer being in connection with the pond. The fine desulfurization and dedusting stage tower includes a tube demister, a flushing layer, a film liquid holdup layer, a liquid holdup layer recycling can, the pH of slurry in the liquid holdup layer recycling can being higher than the pH of slurry in the pond.