Spray Dryer Washing Unit for No-Drainage Operation
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Solution Overview
Problem
Air pollution control systems face challenges in effectively spray drying desulfurized effluent due to the presence of solid components, leading to unsatisfactory drying and potential clogging, while also requiring a solution for no drainage and safe, efficient washing of the spray dryer.
Innovation Solution
A spray drying apparatus with a spray nozzle for dehydrated filtrate, a flue gas introduction port, a drying region, a discharge port, and a washing unit, along with detection and control systems to manage spray and dry failures, allowing for remote washing and efficient operation without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If desulfurized effluent is spray-dried with flue gas from a boiler, then no drainage operation is achieved, but deposit or scale generation inside the spray dryer occurs due to high ash concentration and precipitated salt
Solution Approach 1:
The system segments the flue gas flow path into multiple regions: a primary drying region where desulfurized effluent is evaporated, and a separate washing region where generated deposits are removed. This segmentation allows the drying function and washing function to operate independently, preventing deposit accumulation in the drying region while maintaining no-drainage operation stability.
Solution Approach 2:
A washing unit is introduced as an intermediary system that uses clean air or water to remove deposits from the spray dryer interior. This intermediary washing mechanism mediates between the drying process that generates deposits and the need to maintain operational reliability, allowing continuous no-drainage operation without scale accumulation.
2Ease of repair
If the spray dryer interior is washed during boiler operation by partitioning inlet and outlet with dampers, then washing can be performed, but operator safety is compromised due to difficulty in direct entry
Solution Approach 1:
The spray dryer is equipped with an automated washing unit that performs self-cleaning without requiring operator entry into the apparatus. The washing unit can be activated remotely or automatically, allowing the system to service itself by removing deposits from internal surfaces, thereby maintaining washing capability while eliminating safety risks associated with operator exposure to hot flue gas environments.
Solution Approach 2:
The manual washing process requiring operator entry and mechanical partitioning with dampers is replaced by an automated washing unit that can be controlled remotely. This substitution eliminates the need for operators to physically enter the hazardous environment, replacing manual mechanical operations with automated control systems that prioritize operator safety while maintaining washing functionality.
3Ease of operation
If a washing unit is added to enable remote washing, then operator safety is improved and washing efficiency increases, but device complexity increases
Solution Approach 1:
The washing unit is designed with multi-functionality, serving both as a deposit removal system and as part of the overall effluent treatment process. By integrating the washing function into the existing spray dryer structure and using materials or processes that serve multiple purposes (e.g., the washing system also preparing surfaces for potential inspection or maintenance), the added complexity is minimized while achieving improved operator safety and washing efficiency.
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 apparatus ensures stable no-drainage operation by reducing clogging and enabling quick, safe washing of the spray dryer, maintaining system efficiency and safety.
Implementation Method 1
a spray nozzle (54) for spraying dehydrated filtrate (33) into a spray drying apparatus body
Implementation Method 2
a drying region (L) formed in the spray drying apparatus body for drying the sprayed dehydrated filtrate (33) with flue gas
Implementation Method 3
an introducing port (52) provided in the spray drying apparatus body for introducing flue gas (18) to dry the dehydrated filtrate (33) sprayed from the spray nozzle (54)
Implementation Method 4
a washing unit (60) for washing the spray nozzle (54) and the inside of the apparatus body with washing liquid
Data Source
AI summary
A method of spray drying and washing using a spray drying apparatus, includes: spraying dehydrated filtrate from a spray nozzle hung down from a top side of the spray drying apparatus; introducing a part of flue gas into the spray drying apparatus to dry the dehydrated filtrate; wherein a compressed air is introduced into the spray nozzle to facilitate the spraying and into the wash nozzle to perform air purging during the spray drying, and jetting washing liquid from a wash nozzle provided on a side wall of the spray drying apparatus to wash the spray nozzle and an inside of the spray drying apparatus body, wherein the feeding of the dehydrated filtrate to the spray nozzle is stopped during the washing.