I. Introduction of China NH3 SCR technology
NOx emissions form coal fired power plant account for 80% of total industrial nitrogen oxides emissions; it is the main source of NOx pollution in China, strength the management of NOx emission is imperative.
At present, SCR(Selective Catalytic Reduction) for denitrification of nitrogen oxides in smokes is the mainstream technology in the world. SCR use reduction function of NH3 to NOx, under the condition of temperate between 320~400℃, that catalyst reduction happens change NOx to N2 and water which have no impact to the environment . “Selective” means NH3 only select NOx for reducing reaction.
In 2010, Ministry of Environmental Protection of China issue 《Technology policy regarding to power plant nitrogen oxides treatment》， it explicitly point out the nitrogen oxides not only is the import stuff form to ozone, but also is the important reason from district fine particle pollution and dust haze. At the same time, nitrogen oxides have great risk to human health as the primary pollutant.
In Sept 21 2011, Ministry of Environmental Protection of China enacted 《Standard for atmospheric Pollutant Discharge of power plant》, the laws determine the emission concentration of nitrogen oxides is 100mg/m3, execution time since 2012 for new generating sets while since July 2014 for old generating sets. All Chinese power plants should follow the standards.
30 Nov 2011, National Development and Innovation Committee of China enacted 《The State adopts a comprehensive measure to control coal and electricity price, explicitly point out since 1 Dec 2011, implement policy of price markup 0.8 yuan to every KWH for those coal fired power plants which have installed and normal use the SCR denitrification system.
The “upgraded” National Emission Standard will be the powerful driving force to control emission of coal fired power plant and improve China air quality and control Acid Rain Pollution. Along with prevalent of Selective Catalytic Reduction (SCR) technology, domestic research and develop SCR catalyst emerged, catalyst is the key of SCR system, its design and select is depend on smoke condition and smoke composition. Three interacting factor to catalyst design is NOx removal rate, NH3 escape rates and catalyst volume. The mainly 3 type of catalyst board type, honeycomb type and corrugated board type.
At present, domestic famous universities and colleges (such as NANKAI University, Tsinghua University, Beijing University of Technology, Zhejiang university, Shandong University, Xi’an Jiaotong University, Nanjing University of Science and Technology, Taiyuan University of Science and Technology, Harbin Institute of Technology, Xiamen University, Fuzhou university, The Southwest Research & Design Institute of the Chemical Industry etc) are all cooperate manufacturers research and develop honeycomb catalyst.
At present, the main raw material of catalyst is Titanium Dioxide TiO and other additives, the specification usually is cross section 150mx150mm, long 1000mm~1500mm, honeycomb hole usually is square(hole size and quantity is various) , samples as below Chart 1,
Chart 1 SCR honeycomb denitrification catalyst
Chart 2 honeycomb denitrification catalyst working process↑
II.SCR honeycomb denitrification catalyst production technological process:
2.1. Production process brief description：
Honeycomb catalyst production mainly includes 10 steps:
1. Titanium Dioxide and minor ingredient selection (formula R&D)
2. High speed and uniformly mixing material
3. Use pre-extruder fully filters the wet materials.
4. Sent the filtered wet material to de-airing extruder for extrude forming
5. Automatic synchronized cutting machine is able to according to different length cutting the products
6. Use manipulator load the products to carton avoid its distortion.
7. Steam damping-drum drier
8. mesh-belt kiln
9. Fixed length cutting
10. Inspection and packing
2.2. Main production equipments：
Main equipments for producing above SCR honeycomb catalyst are R-19 intensive mixer, TCIW-2T box feeder, TCJ-250 pre-extruder, WDQ-150 automatic cutting machine, TCJ-310 powerful extruder, WDYD-150 manipulator etc, other corollary equipment are:2X-30 vacuum pump, SK-240PT water temperature control system etc.
At present, Xiangtan weida electrical and machinery manufacturer co., Ltd through introduce Japan, American and German technology, combined their design advantage and its many years experience in extruding industry, after years of effort successfully developed a series of honeycomb catalyst making machines such as horizontal high strength de-airing extruder, synchronized cutting machine, rewrite the history which only vertical hydraulic extruder can extrude honeycomb catalyst, improve productivity largely compare to vertical extruder is discontinuous production.
Xiangtan weida electrical and machinery manufacturer co., Ltd specialized in ceramic machinery design and manufacturer, have 30 years design and manufacture experience. At the same time, the company cooperates with domestic famous university and institute for technology discussion and exchange, joint research and development, its production technology is leading in the world.
2.3 .Machinery list and quotation of Yearly output 3000m3 SCR honeycomb catalyst
|
Name |
Model |
Qty |
Unit price |
Amount |
Remark |
| Powder batching system | |||||
| deionizer water device |
CX-500 |
1 set |
|||
| deionizer water device tank |
10M3 |
2 pcs |
|||
| hold-up vessel |
1M3 |
2 pcs |
|||
| Dissolve vessel |
600L |
1 pcs |
|||
| hold-up vessel |
800L |
1 pcs |
|||
| Liquid metering pump |
0-264L/h |
5 Sets |
|||
| Liquid metering pump |
0-130L/h |
1 sets |
|||
| Liquid metering pump |
0-1000L/h |
2 sets |
|||
| Pneumatic actuator valve |
24 pcs |
||||
| Stainless steel 304 Pipe | |||||
| Stainless steel 304 bend | |||||
| Intensive mixer |
R-19 |
4 sets |
|||
| Cooling fan |
T35-11No.4A |
4 sets |
|||
| Smoke exhaust fan |
GD30K2-12No.5C |
1 sets |
|||
| bag dust collectorcartridge-type dust collector |
QF03R-1 |
1 sets |
|||
| Intensive mixer control system |
1 set |
||||
| Pipeline | |||||
| Intensive mixer steel platform | |||||
| Box feeder |
TCIW-2T |
1 set |
|||
| Pre-extruder |
TCJ-250 |
1 set |
|||
| Pre-extruder |
TCJ-250 |
1 set |
|||
| Automatic cutting machine |
WDQ-6 |
1 set |
In pre-extrude section | ||
| Powerful de-airing extruder |
TCJ-310 |
1 set |
|||
| Automatic cutting machine |
WDQ-150 |
1 set |
|||
| Vertical sawing machine |
T-360 |
1 set |
|||
| Manipulator |
WDPY-150 |
1 set |
|||
| Belt conveyor |
3 set |
||||
| Temperature controller |
240PT |
2 set |
|||
| Vacuum pump |
2X-30 |
1台 |
|||
| Temperature/pressure sensor |
1 set |
||||
| Mould |
150*150 |
1 set |
|||
| Simple mould clean machine |
1 set |
||||
| Cursing system |
1 set |
||||
| Air compression system |
1 set |
||||
| Control cable | |||||
| Installation charge | |||||
|
Total（RMB）： |
2.4 Main technical parameters of Yearly output 3000m3 SCR honeycomb catalyst
Raw material preparation chart：
Raw material batching flow description (Raw material take 5 kinds of powder for example : A、B、C、D、E; fluid based on 4 kinds: a、b、c、d )
1.Powder batching：
a)Storage 5 kinds powders A、B、C、D、E to powder silo A、B、C、D、E respectively;
b)According to batching ration sent the powders 将A、B、C、D、E to dosing tank per screw feeding system.
c)Open pneumatic discharge valve of dosing tank, input proportioned powder to intensive mixer once.
d)Open “mixer”, make the powders mixing 5~10 min in dry condition (mixing time is able to setup according to technique).
2. Fluid batching ：
a)Storage 4 kinds powders A、B、C、D to powder silo A、B、C、D respectively
b)According to batching ration sent the fluid a、b、c、d to fluid mixer per flow controller.
c) Open fluid mixer to mix the fluid uniformly.
d)Open“fluid pump”, according to pre-set flow uniformly spray the mixed fluid to intensive mixer per fluid pipes, make the powders mixing 5~6 hours with powders (mixing time is able to setup according to technique).
e) Open discharge hole, sent the mixed material to next process.
III.SCR honeycomb denitrification catalyst machinery description:
1. CX-0.5T/H reverse osmosis +Mixed bed high-pure water equipment
|
SN |
Name |
Specification |
material |
Qty |
Remark |
|
|
1 |
Raw water booster pump |
CHL2-30 |
Stainless steel |
1set |
0.55KW | |
|
2 |
Multi-media Filter |
CXSF-300 |
glass reinforced plastic |
1 set |
Liner PE | |
|
3 |
Quartz sand |
4-60 mesh |
120Kg |
High quality | ||
|
4 |
Active carbon filter |
CXSF-300 |
glass reinforced plastic |
1set |
Liner PE | |
|
5 6 |
Active carbon | Shell |
80Kg |
High quality | ||
|
6 |
Cell filter |
CXUF-1 |
PE |
1set |
Include 5μprecision core filter | |
|
7 |
Reverse osmosis membrane |
ESPA4040 |
macromolecule |
2set |
||
|
8 |
high pressure pump |
CDL2-150 |
Stainless steel |
1set |
1.5KW | |
|
9 |
RO automatic washing system |
PVC |
antisepsis |
Full set |
Include washing antiseptic box | |
|
10 |
High and low voltage protection |
Full set |
Include touch operation panel（PLC operation system） | |||
|
11 |
Main frame system |
Full set |
||||
|
12 |
Electrical system | |||||
|
13 |
Middle water tank |
0.25T |
PE |
1pcs |
include liquid level control system | |
|
14 |
Pure water pump |
CHL2-30 |
Stainless steel |
1Set |
0.55KW | |
|
15 |
Coarse Mixed bed system |
CXMB-200 |
glass reinforced plastic |
1Set |
special and transparent | |
|
16 |
anion resins | macromolecule |
30L |
|||
|
17 |
cation resins | macromolecule |
15L |
|||
|
18 |
regenerative system |
Full set |
Include regeneration; antiseptic box | |||
|
19 |
Φ1130 Middle water tank |
1T |
PE |
1Pcs |
include liquid level control system | |
|
20 |
Pure water pump |
CHLF2-30 |
Stainless steel |
1Set |
0.55KW | |
|
21 |
Pipe valve system（flow meter、pressure gauge） |
ABS |
Full set |
|||
|
22 |
conductivity/ resistivity doctor CM-230/DZG-303 |
2Set |
Online display and test | |||
2. Liquid conveyor system
2.1 Hold-up vessel and Dissolve vessel (6 pcs): Include deionizer water, ammonia water hold-up vessel.
2.2 metering pump (8 set):include deionizer water, ammonia water metering pump etc.
2.3 pneumatic ball valve (24pcs): include reversing solenoid valve, MONITORING SWITCH
2.4 Others: Pipe arrangement (according actual site arrangement)
3. D type vertical intensive mixer
▲vertical intensive mixer main technical parameters:
● Effective volume: ф2080×610（2000L）
● Main shaft rotation speed: 750RPM(Maximum) adjustable
● Rotary speed: 8~9 RPM
● Total power: 139KW
● Mixing period: 960 (adjustable)
● Overall size: 3700×2500×2640mm
● Weight: around 7000kg
▲Main components introduction：
● Material introduction: Machine frame is high quality Carbon Construction Steel Q235A and 20# steel, Overall welding structure, All parts in touch with raw materials are made of acidproof alkali stainless steel 316L.
● Main purchased parts: Motor is domestic brand (Xiangtan)
Reducer: material harrower drive is SEW
Rotating plate drive is TX
● Electronic control introduction: Fully automatic control include material feeding, mixing, and discharge
●PLC adopt SIEMENS or Mitsubishi
T35-11No.4A Cooling Fan
Used for intensive mixer
Motor：YSF-7114-0.25KW（IP55）
air volume：3849m3/h
Wind pressure：88Pa
Rotating speed：1450r/min
The transmission medium of fan is microcorrosion acid saturated damp air, temperature is 95℃, Fan bearing adopt NSK, blade, shield and bearing block adopt stainless steel 304.
GD30K2-12No.5C
GD30K2-12No.5C ventilation fan
Used for intensive mixer
Motor：Y100L1-4-2.2KW
Air volume：8000m3/h
Wind pressure：200Pa
Rotating speed：1800r/min
The transmission medium of fan is microcorrosion acid saturated damp air, temperature is 95℃, Fan bearing adopt NSK, blade, shield and bearing block adopt stainless steel 304.
DF03-R
DF03-R cartridge-type dust collector
Air volume：Q=1500 m3/h
filter area:：30 m2（cartridge qty:3pcs）
cartridge size：Φ350×660 mm
Cartridge material: filter media is high quality PET + PTFE coating
Filter efficiency: 99.99%
Filter wind speed: V=0.833 m/min
Dust collector Emptying concentration: 20-50 mg/ m3
Cartridge temperature resistance: <100℃
Dust cleaning type: pulse cleaning
Computation of air compression (customer prepared): 0.3-0.5 m3/min
Air compression pressure: 0.45-0.5 Mpa
Discharge type: Φ150 mm electronic discharge valve (stainless steel 304)
Supporting centrifugal fan: 9-19 NO 4A
Air volume：1410-1704 m3/h
Wind pressure：3507-3253 Pa
Motor poser：3 KW
4. TCIW-2T Automatic box feeder
Main technical parameters:
▲Material：
● All parts in touch with raw materials are made of stainless steel 304
● Hopper adopts stainless steel 304 (4mm), effective volume is 1.5m3.
▲ Technical requirements
●Y 90S-4 1.1KW 1400r/min
Driving motor of belt conveyor: Y 90S-4 1.1KW 1400r/min
● Reducer of belt conveyor: Cycloid reducer, NBWED 42
● Driving motor of feeding part: Y 132S-4 5.5KW 1440r/min
● Reducer of belt conveyor: Cycloid reducer, NBWY 27
● Belt conveyor: PVC material
● Electric control system: vertical type(include wiring between operation table to machine )
● Overall size(L×W×H)：约3500×1360×2890mm
● Power resource：380V three phase 50HZ
5.TCJ-250 Pre-extruder
▲Technical requirement：
● All parts in touch with raw materials are made of stainless steel 304
▲ Up part：
● Driving motor: Y200L2-6 22KW 970r/min
● Reducer: Cycloid reducer XWD9-35-22-6P
● Frequency converter: INVT
● Screw blade: Φ250mm 304 stainless steel
● Material cylinder: inner wall adopt stainless steel 304
● Rotating speed of extruding shaft: 25RPM (adjustable)
▲ Down part:
● Driving motor: Y200L2-6 22KW 970r/min
● Reducer: Cycloid reducer XWD9-35-22-6P
● Frequency converter: INVT
● Screw blade: Φ250mm, 304 stainless steel
● Extruding shaft: 40Cr
● Extruding cylinder: inner wall adopt stainless steel 304 with cooling water jacket.
● Rotating speed: 25RPM
● Extruding speed: 1.5~2.5T/H (adjustable)
● Overall size(L×W×H): 6000×1130×2088 mm
● Net weight: 6000kg
6. TCJ-310 high strength de-airing extruder
▲Technical requirements：
●All parts in touch with raw materials are made of stainless steel 304
▲Up part：
● Driving motor: SEW, DFV225S4/V 37KW 1470r/min
● Up shaft reducer: SEW, MC3PLSF05 1:55.7403
● UP shaft screw blade: Φ180mm, stainless steel, inner shaft water cooling
● Up material cylinder: inner wall adopt stainless steel with water cooling system
● Rotation speed of up extruding shaft: 29.6RPM (adjustable)
● Cutter: adopt stainless steel 304
▲ Down part:
● Driving motor of down shat: SEW, DFV280S4/V 75KW 1480r/min
● Reducer of down shaft: SEW, M3PSF60 1:86.5623
● Main screw blade: Φ310,stainless steel 304,inner shaft water cooling
● Supporting screw blade: Φ220 stainless steel, inner shaft water cooling
● Main shaft material: 40Cr
● Extruding cylinder: stainless steel with water cooling jacket
● Temperature and pressure sensor on extruding end, they convert signal and feedback to control plate.
▲ De-airing room
● Inner wall: stainless steel 304
● Vacuum pump: >550 liter/min
● Motor for de-airing room: 3Kw
● When vacuum pump working, noise should less than 75dB(within 1M), vacuum pump capacity should make negative pressure in vacuum room meet -0.096MPa.
● Reserve observation window on 4 sides of vacuum room
● Control cabinet: vertical type (include wiring between cabinet with machine)
● Cooling pipe: exposed part with thermal insulation jacket
● Power supply: 380V three phase 50HZ
● Over all size(L×W×H): 6650×1730×2200 mm
● Net weight: 12000 Kg
7. WDQ-150 Auto cutting machine
8. WDPY-150 Manipulator
▲ The function of manipulator：
The manipulator is placed after automatic cutting machine and Conveying positioning system, its main function is load the honeycomb adobe to tray, the process include clamping, lift, translational motion, put down, take off, lift, translational motion and put down.
● Frame: welding components
● Motor power: YEJ-80M24 0.75KW 1405r/min
● Reducer: RV63 1:25
● Up and down guide rail and air cylinder
● Clamp and open guide rail and air cylinder
● Sponge plywood
● Electrical control system
● Max. grabbing weight: 30kg
● Max. lifting distance: 100mm
● Max. displacement distance:1500mm
● Every meters of cycle time: 15s/time
●Overall size：2900×1800×2600mm
●Net weight：450 Kg
9. Automatic cutting machine（Finished product fixed length cutting）
▲Main technical parameters：
●Max cutting length：350mm ●Max cutting height：240mm
●Cutting bed size：440×490mm ●Blade length：2900mm
●Blade width：3-13mm
●Angle of Inclination of working platform：Back and forth 10º
●Angle of Inclination of working platform：Right and left 15º
●Main motor power：1HP
●Gear box motor power：1HP
●Gear box speed regulating：Total 4 gears: 30、50、80、130
●Welding capacity：3-13m/m
●Weight： 280Kg
●Overall size（LxWxH）：920×700×1720mm