Description of the embodiments
In order that the present application may be readily understood, a more particular description of the invention will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Preferred embodiments of this application are given in the examples. This application may, however, be embodied in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
It will be understood that when an element is referred to as being "disposed on" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," "top," "bottom," "top," and the like are used herein for illustrative purposes only and are not meant to be the only embodiment.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein in the description of the application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The term "and/or" as used herein includes any and all combinations of one or more of the associated listed items.
Referring to fig. 2, an embodiment of the application discloses an ultrapure water cleaning energy saving and consumption reduction system in a polysilicon production process, which comprises a ceramic ring cleaning machine 100, a silicon material cleaning machine 200, a water quenching tank 300, a ground tank 400 and a ceramic membrane filter 500, wherein:
the porcelain ring washer 100 has an alkaline washing tank 110 and an ultrasonic tank 120, the porcelain ring washer 100 generally has 8 washing tanks, wherein 1-3 tanks are the alkaline washing tank 110, 85 ℃ ultrapure water and 70% caustic soda are used for alkaline washing the porcelain ring, 4-6 tanks are the ultrasonic tank 120, 85 ℃ ultrapure water is used, the porcelain ring after alkaline washing needs to be washed through the ultrasonic tank 120, the porcelain ring after alkaline washing is washed with surface floating ash in the ultrasonic tank 120 in an ultrasonic washing mode, impurities, alkali liquor and the like remained on the surface of the porcelain ring, 7 tanks are porcelain ring drying tanks, the washed porcelain ring is dried in the porcelain ring drying tanks by heating to 95 ℃,8 tanks are porcelain ring cooling tanks, and since the porcelain ring is heated and dried, there is a risk of burning staff when directly moving out of the porcelain ring washer 100, the porcelain ring is cooled to 30 ℃ by the porcelain ring cooling tanks, and then the porcelain ring washer 100 is moved out, so that the cleaning of the porcelain ring is completed.
The silicon material cleaning machine 200 is provided with a quick-discharge rinsing tank 210 and an ultrasonic pure water tank 220, the silicon material cleaning machine 200 is generally provided with 10 cleaning tanks, wherein 1 tank is the quick-discharge rinsing tank 210, 30 ℃ ultrapure water is used for cleaning floating ash and impurities on the surface of the silicon material, 2-4 tanks are the ultrasonic pure water tank 220, 70 ℃ ultrapure water is used for cleaning the silicon material with the floating ash on the surface, the ultrasonic pure water tank 220 is required for fine cleaning the silicon material with the floating ash on the surface, the ultrasonic pure water tank 220 is used for cleaning the silicon material with the floating ash on the surface, 5-9 tanks are silicon material drying tanks, the cleaned silicon material is dried in the silicon material drying tanks by heating to 85 ℃,10 tanks are silicon material cooling tanks, and because the silicon material is heated and dried, there is a risk of scalding staff when the silicon material is directly removed from the silicon material cleaning machine 200, the silicon material cooling tanks are required to be cooled to 30 ℃, and then the silicon material cleaning machine 200 is removed, and the cleaning of the silicon material is completed.
According to the above, the temperature of the ultrapure water in the alkaline washing tank 110 and the ultrasonic tank 120 is 85 ℃, the temperature of the ultrapure water in the quick-release rinsing tank 210 is 30 ℃, the temperature of the ultrapure water in the ultrasonic pure water tank 220 is 70 ℃, and at the same time, when the porcelain ring cleaning machine 100 is operated, the alkaline washing tank 110 consumes 10 tons of ultrapure water per hour and discharges 10 tons of wastewater at 85 ℃, the ultrasonic tank 120 consumes 1 ton of ultrapure water per hour and discharges 1 ton of wastewater at 85 ℃, and when the silicon material cleaning machine 200 is operated, the quick-release rinsing tank 210 consumes 3 tons of ultrapure water per hour and discharges 3 tons of wastewater at 30 ℃, and the ultrasonic pure water tank 220 consumes 9 tons of ultrapure water per hour and discharges 9 tons of wastewater at 70 ℃.
Before crushing the silicon bar, the silicon bar is subjected to water quenching treatment so as to generate a state of natural fracture or easy fracture, the silicon bar is firstly heated to a specific temperature and then placed into a water quenching water tank 300 to be cooled by ultrapure water, during the water quenching treatment of the silicon bar, ultrapure water with lower temperature is continuously added into the water quenching water tank 300, and ultrapure water with higher temperature in the water quenching water tank 300 is continuously discharged so as to keep the temperature of the ultrapure water in the water quenching water tank 300 at 80 ℃, that is, the temperature of the ultrapure water in the water quenching water tank 300 is 80 ℃, and meanwhile, during the water quenching treatment, the water quenching water tank 300 needs to consume 4 tons of ultrapure water per hour, and 4 tons of wastewater with 80 ℃ is discharged per hour.
The water inlets of the ultrasonic tank 120, the quick-discharge rinsing tank 210, the ultrasonic pure water tank 220 and the water quenching tank 300 are all connected with the ultrapure water pipeline 610 so as to enable ultrapure water to be introduced into the ultrasonic tank 120, the quick-discharge rinsing tank 210, the ultrasonic pure water tank 220 and the water quenching tank 300 for use, and the water outlets of the alkaline tank 110, the ultrasonic tank 120 and the quick-discharge rinsing tank 210 are all connected with the ground tank 400 so as to enable wastewater discharged from the alkaline tank 110, the ultrasonic tank 120 and the quick-discharge rinsing tank 210 to be introduced into the ground tank 400 for temporary storage, and the wastewater temporarily stored in the ground tank 400 is subsequently treated and discharged. Since the waste water discharged from the alkaline washing tank 110, the ultrasonic tank 120 and the quick-discharge rinsing tank 210 after washing is very dirty (the impurity components are complex and the content is high), the waste water discharged from the alkaline washing tank 110, the ultrasonic tank 120 and the quick-discharge rinsing tank 210 is introduced into the ground tank 400 for subsequent treatment and discharge, while the waste water discharged from the ultrasonic pure water tank 220 and the water quenching tank 300 is relatively clean (the impurity is silicon powder only and the content is relatively low), if the waste water is directly discharged into the ground tank 400, a certain waste is caused, and therefore, the water outlets of the ultrasonic pure water tank 220 and the water quenching tank 300 are connected with the inlet of the ceramic membrane filter 500 to introduce the waste water discharged from the ultrasonic pure water tank 220 and the water quenching tank 300 into the ceramic membrane filter 500 for filtering silicon powder, and since the waste water is mainly silicon powder and the content of other impurities is very low and can be basically ignored, after the waste water is filtered by the ceramic membrane filter 500, the waste water does not contain silicon powder, and clean filtered water (the silicon powder is filtered cleanly and the content of other impurities is very low and can be ignored basically).
Meanwhile, since the ultrasonic tank 120, the quick-discharge rinsing tank 210 and the ultrasonic pure water tank 220 have high requirements on water quality, and the alkaline washing tank 110 is a preliminary link for cleaning the ceramic ring, the requirements on water quality are low, and the filtered water filtered by the ceramic membrane filter 500 can be recycled, that is, the filtered water outlet of the ceramic membrane filter 500 is connected with the water inlet of the alkaline washing tank 110, that is, the filtered water filtered by the ceramic membrane filter 500 is introduced into the alkaline washing tank 110 for preliminarily cleaning the ceramic ring, so that the effect of saving ultrapure water is achieved by replacing the prior art in which the alkaline washing tank 110 uses ultrapure water for preliminarily cleaning the ceramic ring. After the ceramic membrane filter 500 filters, the part of wastewater does not contain silica powder, clean filtered water is obtained, the part of filtered water is introduced into the alkaline washing tank 110 for primarily cleaning the ceramic ring, and consumption of alkali liquor in the alkaline washing tank 110 due to the existence of silica powder in the filtered water can be avoided, that is, the silica powder is filtered through the ceramic membrane filter 500, and consumption of alkali liquor in the alkaline washing tank 110 during recycling of the filtered water can be avoided, so that direct recycling is prevented, and caustic soda consumption and waste are caused.
In the prior art, each ceramic ring cleaner 100 consumes 11 tons of ultrapure water per hour, each silicon cleaner 200 consumes 12 tons of ultrapure water per hour, and each water quenching tank 300 consumes 4 tons of ultrapure water per hour, and if all three devices are operated singly and simultaneously, 11+12+4=27 tons of ultrapure water per hour are consumed. In this application, by supplementing the filtered water filtered by the ceramic membrane filter 500 to the caustic wash tank 110 instead of the ultrapure water supply originally used by the caustic wash tank 110, only 1 ton of ultrapure water is required per hour for each ceramic ring washer 100, 12 tons of ultrapure water is consumed per hour for each silicon washer 200, and 4 tons of ultrapure water is consumed per hour for each water quenching tank 300, and if these three devices are operated individually and simultaneously, 1+12+4=17 tons of ultrapure water is consumed per hour, it is found that compared with the prior art, 10 tons of ultrapure water can be saved per hour for each of these three devices in this application, and the water saving rate is as high as 37%.
Meanwhile, the temperature of the wastewater discharged from the ultrasonic pure water tank 220 is 70 ℃, the temperature of the wastewater discharged from the water quenching tank 300 is 80 ℃, the wastewater is mixed and then passes through the ceramic membrane filter 500, the temperature of the filtered water filtered by the ceramic membrane filter 500 is usually about 70 ℃, the part of the filtered water at 70 ℃ is directly connected into the alkaline washing tank 110 to clean the ceramic ring, the required temperature of the alkaline washing tank 110 is 85 ℃, the filtered water at 70 ℃ is heated to 85 ℃, compared with the prior art, the temperature of the ultra-pure water at normal temperature is heated to 85 ℃, the energy consumption can be obviously reduced, the energy is saved, and the cleaning speed can be effectively improved, because the temperature in the alkaline washing tank 110 can be quickly increased to 85 ℃, the time for heating the ultra-pure water at normal temperature is definitely longer than the time for heating the filtered water at 70 ℃ to 85 ℃, that is shorter than the time for heating the ultra-pure water at normal temperature to 85 ℃ in the prior art, the time for heating the ultra-pure water at 70 ℃ can be effectively heated to 85 ℃, and the cleaning speed can be effectively improved.
In the prior art, 1122 (1020+102) degrees of electricity are required to be consumed by each ceramic ring washer 100 per hour of heating ultrapure water (initial temperature is assumed to be 0 ℃) and 864 (108+756) degrees of electricity are required to be consumed by each silicon material washer 200 per hour of heating ultrapure water (initial temperature is assumed to be 0 ℃) and 384 degrees of electricity are required to be consumed by each water quenching tank 300 per hour of heating ultrapure water (initial temperature is assumed to be 0 ℃) and 1122+864+384=2370 degrees of electricity are consumed per hour if all three devices are operated singly and simultaneously. In this application, each ceramic ring washer 100 consumes 282 (180+102) degrees of electricity per hour of heating ultrapure water (initial temperature is assumed to be 0 ℃) and filtered water, each silicon washer 200 consumes 864 (108+756) degrees of electricity per hour of heating ultrapure water (initial temperature is assumed to be 0 ℃) and each water quenching tank 300 consumes 384 degrees of electricity per hour of heating ultrapure water (initial temperature is assumed to be 0 ℃) and 282+864+384=1530 degrees of electricity per hour if all three devices are operated singly and simultaneously. Compared with the prior art, the three devices in the method have the advantages that the power consumption can be saved by 840 degrees per hour when the three devices are operated simultaneously, and the power saving rate is as high as 35.4 percent, which is an unexpected effect.
In the ultrapure water cleaning energy-saving consumption-reducing system in the polycrystalline silicon production process disclosed by the embodiment of the application, (1) after the waste water discharged by the ultrasonic pure water tank 220 and the water quenching tank 300 is filtered by the ceramic membrane filter 500, the waste water is recycled to the alkaline washing tank 110 for primarily cleaning the ceramic ring by the alkaline washing tank 110, and the ultrapure water is used for primarily cleaning the ceramic ring instead of the alkaline washing tank 110 in the prior art, so that the effect of saving the ultrapure water is achieved. (2) The silica powder is filtered by the ceramic membrane filter 500, so that the silica powder in the filtered water can be prevented from being consumed by alkali liquor in the alkali washing tank 110 during recycling, and the consumption and waste of caustic soda caused by direct recycling are prevented. (3) The temperature of the wastewater discharged from the ultrasonic pure water tank 220 is 70 ℃, the temperature of the wastewater discharged from the water quenching tank 300 is 80 ℃, the wastewater and the wastewater are mixed and then pass through the ceramic membrane filter 500, the process has a certain natural temperature reduction, the temperature of the filtered water filtered by the ceramic membrane filter 500 is about 70 ℃, the filtered water at the temperature of 70 ℃ is directly connected into the alkaline washing tank 110 to clean the ceramic ring, and the temperature required by the alkaline washing tank 110 is 85 ℃, and only the filtered water at the temperature of 70 ℃ is heated to 85 ℃, compared with the prior art, the temperature of the ultra-pure water at the normal temperature is heated to 85 ℃, the energy consumption can be obviously reduced by only heating the filtered water at the temperature of 70 ℃, and the energy can be saved. (4) Because the temperature in the caustic wash tank 110 can be quickly raised to 85 ℃, and the prior art needs to heat the normal-temperature ultrapure water to 85 ℃, certainly the time taken to heat the normal-temperature ultrapure water to 85 ℃ is longer than the time taken to heat the normal-temperature filtered water to 85 ℃ in the application, that is, the time taken to heat the normal-temperature ultrapure water to 85 ℃ in the application is shorter than the time taken to heat the normal-temperature ultrapure water to 85 ℃ in the prior art, the heating can be completed in a short time and the required temperature can be reached, and therefore the cleaning speed can be effectively improved. The above (3) and (4) are unexpected effects.
In order to further improve the energy saving and consumption reduction degree, optionally, the shell structure of the ceramic ring cooling tank of the ceramic ring cleaning machine 100 and the shell structure of the silicon material cooling tank of the silicon material cleaning machine 200 are of a jacket structure, the ultrapure water pipeline 610 is connected with the inlet of the jacket structure, the outlet of the jacket structure is connected with the water inlets of the ultrasonic tank 120, the quick-discharge rinsing tank 210, the ultrasonic pure water tank 220 and the water quenching tank 300, when the ceramic ring and the silicon material are cooled in the ceramic ring cooling tank and the silicon material cooling tank, the ceramic ring and the silicon material release heat, the released heat is absorbed by the ultrapure water in the jacket structure to improve the temperature of the ultrapure water, and then the ultrapure water is used for cleaning after being heated in the ultrasonic tank 120, the quick-discharge rinsing tank 210, the ultrasonic pure water tank 220 and the water quenching tank 300, and the energy (electric quantity) consumption of the subsequent heating to the required temperature can be improved through absorbing the heat in the ceramic ring and the silicon material cooling, firstly the effect of heat utilization can be achieved, secondly, the energy saving and consumption reduction degree can be further improved, and further reduced.
Because caustic soda needs to be added into the alkaline washing tank 110 for washing, in the process of washing the ceramic ring, silica powder on the ceramic ring reacts with caustic soda to generate sodium silicate, and then the sodium silicate is discharged into the ground tank 400 together, that is, in the ground tank 400, the residual caustic soda of the reaction and the sodium silicate obtained after the reaction exist, the waste water in the ground tank 400 contains alkali and salt, so that the subsequent treatment discharge is not favored, and on the basis of the condition that the waste water in the ground tank 400 contains no caustic soda, the concentrated water outlet of the ceramic membrane filter 500 is connected with the ground tank 400 and is used for removing alkaline substances (residual caustic soda of the reaction), after the ceramic membrane filter 500 filters the waste water, clean filtered water is produced, concentrated water enriched with silica powder is also produced, and the concentrated water is introduced into the ground tank 400, so that the silica powder in the concentrated water continuously reacts with the residual caustic soda in the ground tank 400 to generate sodium silicate, and the waste water in the ground tank 400 contains only sodium silicate, and does not contain caustic soda.
In this application, silica flour is separated from filtered water through ceramic membrane filter 500 and is recycled to the inside of the system (filtered water is recycled to alkaline washing tank 110, concentrated water is used for consuming alkali liquor in ground tank 400), and according to the concentrated water component and the filtered water component, the concentrated water containing silica flour is used for treating residual alkali liquor in ground tank 400, and filtered water from which silica flour is removed is recycled to alkaline washing tank 110, so that not only can the pure water consumption be saved, but also the problem of additional consumption of caustic soda due to introduction of silica flour into alkaline washing tank 110 can be avoided. The ceramic membrane filter 500 not only performs a filtering function, but also provides a dual-purpose effect of treating the concentrated water of the residual alkali solution in the ground tank 400.
Because silica flour and caustic soda reaction can produce hydrogen, therefore, the system disclosed herein can also include hydrogen storage tank 620, and the top of ground jar 400 is provided with the gas outlet, and the gas outlet links to each other with hydrogen storage tank 620, and hydrogen that the reaction obtained is retrieved through hydrogen storage tank 620 avoids the hydrogen extravagant, and this part hydrogen can be used for cold hydrogenation stage to use.
In order to promote the reaction of the silicon powder and the caustic soda in the ground tank 400, so that the reaction of the caustic soda in the ground tank 400 is complete and is consumed, optionally, a stirring device is arranged in the ground tank 400, and the waste water in the ground tank 400 is stirred by the stirring device, so that the caustic soda in the waste water is fully contacted with the silicon powder and reacts, the consumption of the caustic soda in the waste water is complete, the waste water in the ground tank 400 is ensured to only contain sodium silicate, and the waste water is ensured to contain no caustic soda, thereby being beneficial to ensuring no waste discharge in subsequent treatment. At the same time, the waste water in the ground tank 400 is agitated by the agitating means, so that the hydrogen in the waste water is advantageously released and then recovered.
In this application, filter the silica flour in the waste water through ceramic membrane filter 500, specifically, the filtration aperture of ceramic membrane filter 500 is less than or equal to 20nm, filtration aperture is less than or equal to 20nm, can filter the silica flour of 99.7% more, can improve the clean degree of filtration water, so that the silica flour content of filtration water is lower, thereby can avoid consuming caustic soda in alkaline wash tank 110, and then make ceramic membrane filter 500 filter more silica flour and can avoid filtering water and exist silica flour and lead to its alkali lye in alkaline wash tank 110 when the retrieval and utilization, thereby prevent direct retrieval and utilization and cause the consumption and the waste of caustic soda. Meanwhile, when the silicon rod coming out of the reduction furnace is cleaned by the silicon powder cleaning machine 200, silicon powder particles attached to the silicon rod are very fine due to complex chemical reaction in the reduction furnace, so that the silicon powder cleaned from the silicon rod cannot be filtered cleanly by conventional filtering equipment, the ceramic membrane filter 500 is adopted, the filtering aperture is less than or equal to 20nm, the fine silicon powder can be effectively filtered, and the silicon powder is prevented from entering the alkaline washing tank 110 to consume alkaline liquor.
Preferably, the water yield of the ceramic membrane filter 500 is equal to or higher than 85%, the total amount of wastewater discharged from the ultrasonic pure water tank 220 and the water quenching tank 300 is 13 tons per hour, while the alkaline washing tank 110 needs 10 tons per hour of filtered water, and at the same time, a part of wastewater is consumed when the ceramic membrane filter 500 filters and cannot realize dry-wet separation, and a part of wastewater is discharged into the ground tank 400, so that the water yield of the ceramic membrane filter 500 is equal to or higher than 85% according to the supply-demand relationship, and 13×85% =11.05, that is, the filtered water of the ceramic membrane filter 500 produces water per hour is 11 tons, so that the requirement of the alkaline washing tank 110 can be satisfied to reach the supply-demand balance, the condition of supply and demand is avoided, and the whole system can stably operate.
As described above, the wastewater discharged from the alkaline washing tank 110, the ultrasonic tank 120 and the quick-discharge rinsing tank 210 is introduced into the ground tank 400, since the temperature of 10 tons of wastewater discharged from the alkaline washing tank 110 per hour is 85 ℃, the temperature of 1 ton of wastewater discharged from the ultrasonic tank 120 per hour is 85 ℃, and the temperature of 3 tons of wastewater discharged from the quick-discharge rinsing tank 210 per hour is 30 ℃, if these wastewater having temperature are directly discharged into the ground tank 400, it is inevitable that heat in these wastewater is wasted, and therefore, in an alternative embodiment, the system disclosed herein further comprises a first heat exchanger, wherein the water outlets of the alkaline washing tank 110, the ultrasonic tank 120 and the quick-discharge rinsing tank 210 are all connected to the tube side inlet of the first heat exchanger, the tube side outlet of the first heat exchanger is connected to the ground tank 400, the ultrapure water tube 610 is connected to the shell side inlet of the first heat exchanger, and the shell side outlets of the ultrasonic tank 120, the quick-discharge rinsing tank 220 and the water quenching tank 300 are all connected to the water inlets of the ultrasonic tank 300.
The discharged hot waste water is introduced into the tube pass of the first heat exchanger to exchange heat with the ultrapure water in the shell pass of the first heat exchanger, so that the ultrapure water in the shell pass of the first heat exchanger is heated, the temperature of the ultrapure water is increased, the ultrapure water is preheated, the temperature of the ultrapure water can be increased by recycling heat in the waste water, the energy (electricity) consumption for subsequent heating to the required temperature can be reduced, the effect of heat utilization can be achieved, the energy saving and consumption reduction degree can be further improved, and the electricity consumption can be further reduced.
Further, the temperature of 3 tons of wastewater discharged per hour from the quick-discharge rinsing tank 210 is 30 ℃, the preheating effect on ultrapure water is poor, and if the wastewater is mixed with other wastewater, the temperature of the mixed whole wastewater is reduced, so that the preheating effect on ultrapure water is poor.
The hot waste water discharged from the alkaline washing tank 110 and the ultrasonic tank 120 is only introduced into the second heat exchanger to preheat the ultrapure water, so that the temperature reduction of the whole waste water after mixing caused by the mixed preheating of the waste water discharged from the quick-discharge rinsing tank 210 at the temperature of only 30 ℃ is avoided, the deterioration of the preheating effect on the ultrapure water is avoided, the heat recovery in the waste water is ensured, the preheating effect on the ultrapure water is ensured, the energy (electric quantity) consumption for subsequent heating to the required temperature is further ensured, and the power consumption is further reduced.
The technical features of the above-described embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above-described embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
The above examples only represent a few embodiments of the present application, which are described in more detail and are not to be construed as limiting the scope of the claims. It should be noted that it would be apparent to those skilled in the art that various modifications and improvements could be made without departing from the spirit of the present application, which would be within the scope of the present application. Accordingly, the scope of protection of the present application is to be determined by the claims appended hereto.