CN221752811U - A device for purifying compressed air capable of recovering waste heat of compression and regulating regeneration gas - Google Patents
A device for purifying compressed air capable of recovering waste heat of compression and regulating regeneration gas Download PDFInfo
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Abstract
本实用新型涉及压缩空气净化技术,旨在提供一种能够回收压缩余热及再生气可调控的压缩空气纯化的装置。该装置包括通过管路依次连接的空气过滤器、无油空压机、余热回用换热器、冷却器、预冷机和纯化器;纯化器具有并联设置、能以进气吸附和再生脱附交替切换方式运行的双塔结构;待加热再生气的供气管路连接至余热回用换热器,后者通过管路依次连接比例调节阀、电加热器和纯化器,用于提供加热后的再生气;在纯化器的再生气放散管上设有CO2浓度监测仪。本实用新型从根本上解决了传统技术中纯化流程所存在的再生气调控性差、再生气耗量高、无油空压机压缩热未能充分利用的关键问题,从根本上大幅拓展纯化流程在不同行业的实用性和通用性。
The utility model relates to compressed air purification technology, and aims to provide a device for compressed air purification that can recover compressed waste heat and control regeneration gas. The device includes an air filter, an oil-free air compressor, a waste heat recovery heat exchanger, a cooler, a precooler and a purifier connected in sequence through pipelines; the purifier has a double-tower structure that is arranged in parallel and can operate in an alternating switching mode of intake adsorption and regeneration desorption; the gas supply pipeline of the regeneration gas to be heated is connected to the waste heat recovery heat exchanger, which is connected in sequence through pipelines to a proportional regulating valve, an electric heater and a purifier for providing heated regeneration gas; a CO2 concentration monitor is provided on the regeneration gas discharge pipe of the purifier. The utility model fundamentally solves the key problems of poor regeneration gas controllability, high regeneration gas consumption and insufficient utilization of compression heat of oil-free air compressors in the purification process in traditional technologies, and fundamentally and greatly expands the practicality and versatility of the purification process in different industries.
Description
技术领域Technical Field
本实用新型涉及压缩空气净化技术,特别涉及一种能够回收压缩余热及再生气可调控的压缩空气纯化的装置。The utility model relates to a compressed air purification technology, in particular to a compressed air purification device capable of recovering compression waste heat and regulating regeneration gas.
背景技术Background Art
在工业化生产中,经常需要利用空气净化技术以获得杂质含量较少的压缩空气。例如在空分行业,为了获取高纯度氮气或氧气,就需要针对原料压缩空气进行预先纯化处理。因此,针对压缩空气的纯化设备也就成为常规空分装置的基本配置。在压缩空气的纯化阶段,其整体工艺的基本流程是:空气→进口过滤器→原料气空压机→空气预冷机→纯化器→粉尘过滤器→用气点。In industrial production, air purification technology is often needed to obtain compressed air with less impurities. For example, in the air separation industry, in order to obtain high-purity nitrogen or oxygen, it is necessary to pre-purify the raw compressed air. Therefore, purification equipment for compressed air has become the basic configuration of conventional air separation units. In the purification stage of compressed air, the basic process of the overall process is: air → inlet filter → raw gas air compressor → air precooler → purifier → dust filter → gas point.
由于采用双塔体系作为纯化器,能够确保纯化处理过程的连续性,因此采用两个吸附塔切换运行是目前纯化设备通常采用的方案。为了满足后续工艺的严格要求,在吸附塔中通常以氧化铝和分子筛按照一定配比搭建双层吸附床体结构,实现对水蒸气、二氧化碳、乙炔等杂质的稳定性吸附。在运行过程中采取一塔吸附、一塔再生的切换运行方式,用于再生的气体可以使用成品气或空分装置现场产生的污氮。Since the use of a double-tower system as a purifier can ensure the continuity of the purification process, the use of two adsorption towers for switching operation is currently a common solution for purification equipment. In order to meet the strict requirements of subsequent processes, a double-layer adsorption bed structure is usually built in the adsorption tower with alumina and molecular sieves in a certain ratio to achieve stable adsorption of impurities such as water vapor, carbon dioxide, and acetylene. During the operation, a switching operation mode of one tower for adsorption and one tower for regeneration is adopted. The gas used for regeneration can be finished gas or contaminated nitrogen generated on-site by the air separation unit.
在纯化器的运行过程中,二氧化碳浓度对作为原料气的压缩空气所含水分非常敏感。传统空分体系中,为了确保二氧化碳浓度达标,对成品压缩空气的压力露点要求非常高。空气预冷机的作用在于确保进入吸附塔的压缩空气温度低于10℃(饱和含湿量达标);并且配套了气水分离器协同运行,以充分实现压缩空气中的气水分离,确保双层吸附床体稳定运行,成品气二氧化碳和乙炔等杂质浓度持续稳定达标。During the operation of the purifier, the concentration of carbon dioxide is very sensitive to the moisture content of the compressed air used as the raw gas. In the traditional air separation system, in order to ensure that the carbon dioxide concentration meets the standard, the pressure dew point requirements for the finished compressed air are very high. The role of the air precooler is to ensure that the temperature of the compressed air entering the adsorption tower is lower than 10°C (the saturated moisture content meets the standard); and it is equipped with a gas-water separator to operate in coordination to fully realize the gas-water separation in the compressed air, ensure the stable operation of the double-layer adsorption bed, and ensure that the concentration of impurities such as carbon dioxide and acetylene in the finished gas continues to meet the standard.
鉴于空气中二氧化碳的浓度通常在400ppm,而空分行业要求的纯化后压缩空气的二氧化碳浓度低于3ppm,实际运行时通常保持在1ppm以下。在优化的吸附温度下,双层吸附床中的氧化铝对水分高效分离,配合分子筛达成对二氧化碳等杂质的吸附分离。在吸附过程结束后,吸附床需要再生。为了确保床体的吸附特性,纯化流程采用变压和变温相结合的再生机制。再生气体可以是纯化器产出的成品压缩空气,也可以是后续空分装置产出的污氮(即非高纯氮)。再生过程包括放压、加热、吹冷、冲压、切换等环节,两塔配合实现连续运行和再生之间的切换。Considering that the concentration of carbon dioxide in the air is usually 400ppm, and the air separation industry requires that the concentration of carbon dioxide in the purified compressed air be less than 3ppm, it is usually kept below 1ppm during actual operation. At the optimized adsorption temperature, the alumina in the double-layer adsorption bed efficiently separates water, and cooperates with the molecular sieve to achieve the adsorption and separation of impurities such as carbon dioxide. After the adsorption process is completed, the adsorption bed needs to be regenerated. In order to ensure the adsorption characteristics of the bed, the purification process adopts a regeneration mechanism that combines pressure and temperature changes. The regenerated gas can be the finished compressed air produced by the purifier, or it can be the contaminated nitrogen (i.e., non-high-purity nitrogen) produced by the subsequent air separation unit. The regeneration process includes depressurization, heating, cooling, stamping, switching and other links. The two towers cooperate to achieve switching between continuous operation and regeneration.
由于分子筛和氧化铝的吸附特性,考虑大气中的二氧化碳浓度,现有工艺中纯化流程的主要运行能耗包括:预冷机组能耗、气水分离器能耗、吸附再生加热能耗、吸附再生吹冷气耗(对应压缩空气或者氮气的能耗)。其中,预冷机组能耗与生产荷载强度和环境工况相关;气水分离器能耗主要取决于分离原理和处理流量(流速);吸附再生加热能耗主要取决于处理气量、所需加热的再生气量、加热温度(分子筛特性)、加热时间;吹冷过程的主要能耗是放散的再生气量对应的能耗(冷吹时间)。目前对于采用成品压缩空气再生的纯化体系,行业通常认定再生放散的气量(包括加热阶段和冷吹阶段的放散)比例为20%,以确保对二氧化碳吸附的充分再生和系统稳定)。相应地,采用氮气(或污氮)再生的体系的放散比例目标,也是加热到吹冷的彻底性。Due to the adsorption characteristics of molecular sieves and alumina, and considering the concentration of carbon dioxide in the atmosphere, the main operating energy consumption of the purification process in the existing process includes: pre-cooling unit energy consumption, gas-water separator energy consumption, adsorption regeneration heating energy consumption, adsorption regeneration cold blowing gas consumption (corresponding to the energy consumption of compressed air or nitrogen). Among them, the energy consumption of the pre-cooling unit is related to the production load intensity and environmental conditions; the energy consumption of the gas-water separator mainly depends on the separation principle and the processing flow (flow rate); the adsorption regeneration heating energy consumption mainly depends on the processing gas volume, the required heating regeneration gas volume, the heating temperature (molecular sieve characteristics), and the heating time; the main energy consumption of the cold blowing process is the energy consumption corresponding to the released regeneration gas volume (cold blowing time). At present, for the purification system using finished compressed air regeneration, the industry generally recognizes that the proportion of regeneration released gas volume (including the release in the heating stage and the cold blowing stage) is 20% to ensure sufficient regeneration of carbon dioxide adsorption and system stability). Correspondingly, the release ratio target of the system using nitrogen (or dirty nitrogen) regeneration is also the thoroughness of heating to cold blowing.
对于普通的空分行业,其系统运行工况具有相对明显的稳定性,所以上述环节整体能耗也都相对较为稳定。但是,运用到压缩空气纯化流程的产业并不仅仅局限于空分行业,其中一个典型的应用示例是正极材料生产企业。由于生产工艺需求,此类产业也对成品压缩空气中的二氧化碳浓度有着相对严格的要求(低于20ppm或者更低)。此类生产企业的生产工艺对压缩空气的使用量存在较大的随机性,该工艺特点与空分行业的稳定运行之间存在着较为明显的差异,这就对压缩空气纯化流程的可调控性提出了要求。For the general air separation industry, the system operation conditions have relatively obvious stability, so the overall energy consumption of the above links is also relatively stable. However, the industry that uses the compressed air purification process is not limited to the air separation industry. One typical application example is the cathode material manufacturer. Due to production process requirements, such industries also have relatively strict requirements on the concentration of carbon dioxide in the finished compressed air (less than 20ppm or lower). The production process of such manufacturers has a large randomness in the use of compressed air. There is a relatively obvious difference between this process characteristic and the stable operation of the air separation industry, which puts forward requirements for the controllability of the compressed air purification process.
由此可见,压缩空气的纯化流程需要考虑不同用户的实际应用特点,具备良好的可调控性、低能耗、高效率的普适性特征。但是,当前的传统纯化流程在这几方面都具有较大的提升空间。对应的主要问题主要表现如下:It can be seen that the compressed air purification process needs to take into account the actual application characteristics of different users and have the universal characteristics of good controllability, low energy consumption and high efficiency. However, the current traditional purification process has a lot of room for improvement in these aspects. The corresponding main problems are mainly manifested as follows:
(1)再生过程调控性差的问题(1) Poor controllability of the regeneration process
对于给定的纯化流程,目前针对再生过程的调控手段非常有限,主要是通过调整加热时间和吹冷时间(运行周期)来应对工况的变化。一旦给定了设备选型,所能调整的能耗主要是预冷机和加热这两个环节。预冷机的变频、加热可以通过分组或者可控硅的方式调整。但存在的显著缺陷是,无法调整两塔连续交换处理过程中消耗的再生气量,无法通过对再生过程的调控来影响吸附剂的再生效果,进而对成品压缩空气的露点和二氧化碳浓度产生干预,因此整个纯化特征的调控性受限。For a given purification process, the current means of regulating the regeneration process are very limited, mainly by adjusting the heating time and the cooling time (operating cycle) to cope with changes in operating conditions. Once the equipment selection is given, the energy consumption that can be adjusted is mainly the pre-cooler and heating. The frequency conversion and heating of the pre-cooler can be adjusted by grouping or thyristor. However, the significant defect is that it is impossible to adjust the amount of regenerated gas consumed during the continuous exchange treatment of the two towers, and it is impossible to affect the regeneration effect of the adsorbent by regulating the regeneration process, and then interfere with the dew point and carbon dioxide concentration of the finished compressed air. Therefore, the controllability of the entire purification characteristics is limited.
(2)再生气耗高(2) High regeneration gas consumption
由于上述问题,再生用气的比例一旦给定,就无法根据实际流程对二氧化碳浓度要求的变化以及处理流量的变化而做出相应的调整。这就导致再生气耗持续居高不下,成为纯化流程中能耗居高的核心问题。Due to the above problems, once the proportion of regeneration gas is given, it cannot be adjusted accordingly according to the changes in the actual process requirements for carbon dioxide concentration and changes in the processing flow rate. This leads to the continued high consumption of regeneration gas, which becomes the core problem of high energy consumption in the purification process.
(3)压缩热未能充分利用(3) Compression heat is not fully utilized
考虑到原料空气中的二氧化碳浓度高达400ppm,所以再生过程中无论采用污氮还是成品压缩空气,都需要从较低温度(15℃左右)加热至170℃以上才能保证加热再生的充分性。再生温度若低于这个数值将会导致二氧化碳吸附效果变差。而在加热过程中所需热量和长时间加热所带来的能耗,也是纯化流程能耗的重要组成部分。Considering that the concentration of carbon dioxide in the raw air is as high as 400ppm, whether it is contaminated nitrogen or finished compressed air, it needs to be heated from a lower temperature (about 15℃) to above 170℃ to ensure the adequacy of heating regeneration. If the regeneration temperature is lower than this value, the carbon dioxide adsorption effect will deteriorate. The heat required in the heating process and the energy consumption caused by long-term heating are also important components of the energy consumption of the purification process.
鉴于采用预冷机的变频(阀门)调控、虑温度控制方式(可控硅调控)、周期调整等这些传统调控环节,也无法有效解决上述三个关键问题;本实用新型创新性地提出优化方案,以突破传统纯化流程存在的局限性。In view of the fact that traditional control links such as variable frequency (valve) control of the pre-cooler, temperature control method (thyristor control), cycle adjustment, etc., cannot effectively solve the above three key problems; the utility model innovatively proposes an optimization plan to break through the limitations of the traditional purification process.
实用新型内容Utility Model Content
本实用新型要解决的技术问题是,克服现有技术中的不足,提供一种能够回收压缩余热及再生气可调控的压缩空气纯化的装置。The technical problem to be solved by the utility model is to overcome the deficiencies in the prior art and provide a device for purifying compressed air which can recover compression waste heat and has adjustable regeneration gas.
为解决技术问题,本实用新型的解决方案是:To solve the technical problem, the solution of the utility model is:
提供一种能够回收压缩余热及再生气可调控的压缩空气纯化的装置,该装置包括通过管路依次连接的空气过滤器、无油空压机、余热回用换热器、冷却器、预冷机和纯化器;Provided is a compressed air purification device capable of recovering compression waste heat and regulating regeneration gas, the device comprising an air filter, an oil-free air compressor, a waste heat recovery heat exchanger, a cooler, a precooler and a purifier connected in sequence through pipelines;
所述纯化器具有并联设置的双塔结构,在各塔内均装填吸附剂;各塔的入口端均与待纯化压缩空气进气管和再生气进气管相连,各塔的出口端均与成品压缩空气出气管和再生气放散管相连;在各塔入口端和出口端的管路之间设有连接支管,在连接支管上设有阀门用于切换各塔与管路的连接关系;在成品压缩空气出气管和再生气放散管上,分别设有CO2浓度监测仪;The purifier has a double-tower structure arranged in parallel, and adsorbent is loaded in each tower; the inlet end of each tower is connected to the compressed air inlet pipe to be purified and the regeneration gas inlet pipe, and the outlet end of each tower is connected to the finished compressed air outlet pipe and the regeneration gas release pipe; a connecting branch pipe is provided between the pipelines at the inlet end and the outlet end of each tower, and a valve is provided on the connecting branch pipe for switching the connection relationship between each tower and the pipeline; CO2 concentration monitors are respectively provided on the finished compressed air outlet pipe and the regeneration gas release pipe;
所述余热回用换热器设有压缩空气入口、压缩空气出口,以及再生气进气口和再生气出气口;待加热再生气的供气管路连接至再生气进气口,再生气出气口通过管路依次连接比例调节阀、电加热器和纯化器,用于提供加热后的再生气。The waste heat recovery heat exchanger is provided with a compressed air inlet, a compressed air outlet, a regeneration gas inlet and a regeneration gas outlet; the gas supply pipeline of the regeneration gas to be heated is connected to the regeneration gas inlet, and the regeneration gas outlet is connected to a proportional control valve, an electric heater and a purifier in sequence through a pipeline to provide heated regeneration gas.
作为改进的技术方案,所述待加热再生气的供气管路是由纯化器出口端的成品压缩空气出气管连接至余热回用换热器的再生气进气口,以引出部分成品压缩空气作为再生气;或者,所述待加热再生气的供气管路是由外部的氮气供应装置连接至余热回用换热器的再生气进气口,以引入的氮气作为再生气,在氮气管路上设有增压泵(以满足充压保压的需求)。As an improved technical solution, the gas supply pipeline of the regenerated gas to be heated is connected from the finished compressed air outlet pipe at the outlet end of the purifier to the regeneration gas inlet of the waste heat recovery heat exchanger, so as to draw out part of the finished compressed air as the regeneration gas; or, the gas supply pipeline of the regenerated gas to be heated is connected from an external nitrogen supply device to the regeneration gas inlet of the waste heat recovery heat exchanger, and the introduced nitrogen is used as the regeneration gas, and a booster pump is provided on the nitrogen pipeline (to meet the needs of charging and maintaining pressure).
作为改进的技术方案,在余热回用换热器的再生气进气口和再生气出气口之间设有旁路支管和用于切换的阀门,该旁路支管的一端位于再生气出气口和比例调节阀之间的管路上。As an improved technical solution, a bypass branch pipe and a valve for switching are provided between the regeneration gas inlet and the regeneration gas outlet of the waste heat recovery heat exchanger, and one end of the bypass branch pipe is located on the pipeline between the regeneration gas outlet and the proportional control valve.
作为改进的技术方案,所述无油空压机是离心式空气压缩机或螺杆式空气压缩机。As an improved technical solution, the oil-free air compressor is a centrifugal air compressor or a screw air compressor.
作为改进的技术方案,所述预冷机自带气水分离器。As an improved technical solution, the precooler is provided with a gas-water separator.
作为改进的技术方案,所述再生气放散管的末端为直排大气的放空口。As an improved technical solution, the end of the regeneration gas release pipe is a vent that is directly discharged into the atmosphere.
作为改进的技术方案,所述比例调节阀为电控阀门,并通过信号线连接至PLC控制器;所述PLC控制器和CO2浓度监测仪分别通过信号线连接至上位计算机。As an improved technical solution, the proportional control valve is an electrically controlled valve and is connected to a PLC controller via a signal line; the PLC controller and the CO2 concentration monitor are respectively connected to a host computer via signal lines.
作为改进的技术方案,所述纯化器的双塔及出入口管路的布局具体包括:两塔并联布置,在各塔内部以吸附剂搭建双层吸附床体结构;As an improved technical solution, the layout of the double towers and inlet and outlet pipelines of the purifier specifically includes: two towers are arranged in parallel, and a double-layer adsorption bed structure is built with adsorbent inside each tower;
两根并联管路的两端分别连接两个吸附塔底部的进气口,在其中一根管路上设有两个进气阀,另一根管路上设有两个排气阀;两个进气阀的中点通过管路连接至预冷机的出口,在该管路上设有阀门;两个排气阀的中点通过管路连接再生气放散管,该管路上设有CO2浓度监测仪;The two ends of the two parallel pipelines are respectively connected to the air inlets at the bottom of the two adsorption towers, one of the pipelines is provided with two air inlet valves, and the other pipeline is provided with two air exhaust valves; the midpoints of the two air inlet valves are connected to the outlet of the precooler through a pipeline, on which a valve is provided; the midpoints of the two air exhaust valves are connected to the regeneration gas release pipe through a pipeline, on which a CO2 concentration monitor is provided;
两根并联管路的两端分别连接两个吸附塔顶部的出气口,在其中一根管路上设有两个出气阀,另一根管路上设有两个再生阀;两个出气阀的中点连接成品压缩空气出气管,该管路上设有CO2浓度监测仪和出口总阀;两个再生阀的中点连接至电加热器的出口,在该管路上设有阀门。The two ends of the two parallel pipelines are respectively connected to the gas outlets at the top of the two adsorption towers. Two gas outlet valves are arranged on one of the pipelines, and two regeneration valves are arranged on the other pipeline. The midpoints of the two gas outlet valves are connected to the finished compressed air outlet pipe, on which a CO2 concentration monitor and an outlet main valve are arranged. The midpoints of the two regeneration valves are connected to the outlet of the electric heater, on which a valve is arranged.
作为改进的技术方案,所述纯化器出入口各管路上的阀门为电控阀门,分别通过信号线连接至PLC控制器,后者通过信号线连接至上位计算机。As an improved technical solution, the valves on the inlet and outlet pipelines of the purifier are electrically controlled valves, which are connected to the PLC controller through signal lines, and the PLC controller is connected to the host computer through signal lines.
与现有技术相比,本实用新型的有益效果是:Compared with the prior art, the beneficial effects of the utility model are:
1、本实用新型创新地引入比例调节阀,其控制目标是再生过程中使用的再生气(成品压缩空气或氮气)的流量。通过对塔内吸附剂再生效果的干涉,进一步去影响该塔在投运过程中产出成品压缩空气的二氧化碳浓度。1. The utility model innovatively introduces a proportional regulating valve, whose control target is the flow rate of the regeneration gas (finished compressed air or nitrogen) used in the regeneration process. By interfering with the regeneration effect of the adsorbent in the tower, the carbon dioxide concentration of the finished compressed air produced by the tower during operation is further affected.
再生气比例调节阀的设计目标是提高纯化流程的可调控性,采用的技术手段是优化再生气放散比例,而最终目标则是影响到成品气二氧化碳浓度。再生气比例调节阀的创新设计,从根本上打破传统纯化流程缺乏主动调控能力的局限性,全新构建了纯化流程的空气利用率提供自适应调控环节。首先,结合CO2浓度监测仪的使用,通过调节再生气流量可以保证放散再生气出口的CO2浓度在一定范围内受控地变化,从而对吸附剂的再生效果起到受控的效果。而该效果会进一步在该塔投入生产运行后,影响到成品气的二氧化碳浓度变化。其次,再生气比例调节阀的引入,可以为同一个流程在不同行业中的普适性提供了有效支撑。针对不同行业对出口二氧化碳浓度要求的差异性,可以有选择的确定控制目标取值。第三,针对不同生产荷载强度和环境工况,再生气比例调节阀可以进行适应性调节,以确保纯化流程高效稳定运行为前提,最大程度降低再生气的占比,降低放散能耗。最后,再生气比例调节阀的调控还可以与传统控制方式配合,整体优化运行能耗。在这个环节中,由于再生成品气比例的调整,还可以结合传统周期调整手段,进一步优化纯化流程的运行。应用再生气比例调节阀的调控,扩大了传统周期调整方式的调节范围。考虑避免纯化器塔体出现隧道效应,以空分20%再生气比例为基准,再生气比例调节阀可将再生气比例优化至15%-17%,比传统纯化流程相对少放散15%-25%的气耗。因此,从用气量角度考虑,该创新做法可以优化再生放散气量,大幅节约纯化器的再生能耗。The design goal of the regeneration gas ratio control valve is to improve the controllability of the purification process. The technical means used are to optimize the regeneration gas release ratio, and the ultimate goal is to affect the carbon dioxide concentration of the finished gas. The innovative design of the regeneration gas ratio control valve fundamentally breaks the limitation of the lack of active control ability of the traditional purification process, and newly builds the air utilization rate of the purification process to provide adaptive control links. First, combined with the use of the CO2 concentration monitor, by adjusting the regeneration gas flow rate, it can ensure that the CO2 concentration at the outlet of the released regeneration gas changes in a controlled range, thereby playing a controlled effect on the regeneration effect of the adsorbent. And this effect will further affect the change of carbon dioxide concentration in the finished gas after the tower is put into production. Secondly, the introduction of the regeneration gas ratio control valve can provide effective support for the universality of the same process in different industries. According to the differences in the requirements of different industries for the outlet carbon dioxide concentration, the control target value can be selectively determined. Third, according to different production load intensities and environmental conditions, the regeneration gas ratio control valve can be adaptively adjusted to ensure the efficient and stable operation of the purification process as a premise, minimize the proportion of regeneration gas, and reduce the energy consumption of release. Finally, the regulation of the regeneration gas ratio control valve can also be coordinated with the traditional control method to optimize the overall operating energy consumption. In this link, due to the adjustment of the regeneration product gas ratio, the operation of the purification process can be further optimized in combination with the traditional cycle adjustment method. The application of the regeneration gas ratio control valve expands the adjustment range of the traditional cycle adjustment method. Considering the avoidance of the tunnel effect in the purifier tower, the regeneration gas ratio control valve can optimize the regeneration gas ratio to 15%-17% based on the 20% regeneration gas ratio of the air separation, which is relatively 15%-25% less than the traditional purification process. Therefore, from the perspective of gas consumption, this innovative approach can optimize the regeneration release gas volume and greatly save the regeneration energy consumption of the purifier.
2、本实用新型在无油空压机的出口新增余热回用换热器,针对无油空压机实现压缩机排热的回收。成品压缩空气或氮气在进入电加热器加热之前,先在余热回用换热器中与来自无油空压机的热空气进行热交换,实现再生气的充分预热。通过充分回收压缩热能够有效降低再生气加热的能耗,现有技术中的余热回用换热器相对都比较成熟,增加的阻力损失都低于5kPa,比传统的水冷体系阻力还要小。在实际使用时可以直接利用无油空压机的余热,再生气的换热稳定性和热能品质得到明显提升,能够最大程度节约加热功耗。2. The utility model adds a waste heat recovery heat exchanger at the outlet of the oil-free air compressor to recover the exhaust heat of the compressor for the oil-free air compressor. Before the finished compressed air or nitrogen enters the electric heater for heating, it first exchanges heat with the hot air from the oil-free air compressor in the waste heat recovery heat exchanger to fully preheat the regenerated gas. The energy consumption of heating the regenerated gas can be effectively reduced by fully recovering the compression heat. The waste heat recovery heat exchangers in the prior art are relatively mature, and the increased resistance loss is less than 5kPa, which is smaller than the resistance of the traditional water cooling system. In actual use, the waste heat of the oil-free air compressor can be directly utilized, and the heat exchange stability and thermal energy quality of the regenerated gas are significantly improved, which can save the heating power consumption to the greatest extent.
从温差的角度,针对无油空压机的压缩热进行回热,可以降低加热再生环节能耗50%以上。回收利用压缩热后,电加热器只需要将再生气从95℃加热至170℃以上,能大幅度节约电能。即便是不考虑再生气比例调节阀带来的再生气耗下降和压缩空气利用率的提升,仅在电加热器的加热环节就可以至少节约50%的能耗。From the perspective of temperature difference, recovering the compression heat of the oil-free air compressor can reduce the energy consumption of the heating and regeneration process by more than 50%. After recycling the compression heat, the electric heater only needs to heat the regeneration gas from 95°C to above 170°C, which can greatly save electricity. Even if the reduction in regeneration gas consumption and the increase in compressed air utilization brought by the regeneration gas ratio control valve are not taken into account, at least 50% of energy consumption can be saved in the heating process of the electric heater alone.
3、本实用新型在使用比例调节阀调节作为再生气的氮气流量时,与传统氮气再生的纯化流程比较,加热节能在50%以上;氮气放散量只为传统氮气纯化流程的75%-85%,能够大幅减少氮气的排放,有助于氮气平衡高效利用。3. When the utility model uses a proportional regulating valve to adjust the flow rate of nitrogen used as regeneration gas, compared with the traditional nitrogen regeneration purification process, the heating energy saving is more than 50%; the nitrogen emission is only 75%-85% of the traditional nitrogen purification process, which can greatly reduce nitrogen emissions and contribute to the balanced and efficient utilization of nitrogen.
4、对于本实用新型而言,无油螺杆机尤其是变频无油螺杆机的余热利用也是一个重要的方向,同时对于用气波动程度较大的行业,离心机和变频无油螺杆机配合上述纯化流程结构,可以最大程度实现对应压缩空气系统的高效顺行。4. For the utility model, the utilization of waste heat of oil-free screw machines, especially variable frequency oil-free screw machines, is also an important direction. At the same time, for industries with large fluctuations in gas consumption, centrifuges and variable frequency oil-free screw machines combined with the above-mentioned purification process structure can maximize the efficient smooth operation of the corresponding compressed air system.
5、本实用新型的上述两个创新环节从根本上解决了纯化流程所存在的再生气调控性差、再生气耗量高、无油空压机压缩热未能充分利用这三个关键问题,为其高效低耗提供有力的支撑,并从根本上大幅拓展纯化流程在不同行业的实用性和通用性。5. The above two innovative links of the utility model fundamentally solve the three key problems existing in the purification process, namely, poor controllability of regenerated gas, high consumption of regenerated gas, and failure to fully utilize the compression heat of the oil-free air compressor, thereby providing strong support for its high efficiency and low consumption, and fundamentally and significantly expanding the practicability and versatility of the purification process in different industries.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为基于成品压缩空气进行再生的压缩空气纯化装置示意图。FIG. 1 is a schematic diagram of a compressed air purification device based on regeneration of finished compressed air.
图2为基于氮气进行再生的压缩空气纯化装置示意图。FIG. 2 is a schematic diagram of a compressed air purification device based on nitrogen regeneration.
图3为作为示例的纯化器的双塔及出入口管路的布局。FIG. 3 shows the layout of the double towers and inlet and outlet pipes of a purifier as an example.
图中的附图标记为:1空气过滤器;2无油空压机;3余热回用换热器;4冷却器;5预冷机;6纯化器;7CO2浓度监测仪;8电加热器;9CO2浓度监测仪;10比例调节阀;11氮气管路。The reference numerals in the figure are: 1 air filter; 2 oil-free air compressor; 3 waste heat recovery heat exchanger; 4 cooler; 5 precooler; 6 purifier; 7 CO 2 concentration monitor; 8 electric heater; 9 CO 2 concentration monitor; 10 proportional control valve; 11 nitrogen pipeline.
具体实施方式DETAILED DESCRIPTION
下面结合附图,对本实用新型的实现方式进行详细描述。The implementation of the present utility model is described in detail below in conjunction with the accompanying drawings.
本实用新型所述能够回收压缩余热及再生气可调控的压缩空气纯化的装置,其结构示意如图1、2所示。The structure of the device for purifying compressed air capable of recovering residual heat of compression and providing adjustable regeneration gas is shown in FIGS. 1 and 2 .
该装置包括通过管路依次连接的空气过滤器1、无油空压机2、余热回用换热器3、冷却器4、预冷机5和纯化器6;无油空压机2可选是离心式空气压缩机或螺杆式空气压缩机。预冷机5可选是自带气水分离器,或者在预冷机5和纯化器6之间单独配置气水分离器。The device comprises an air filter 1, an oil-free air compressor 2, a waste heat recovery heat exchanger 3, a cooler 4, a precooler 5 and a purifier 6 which are sequentially connected through pipelines; the oil-free air compressor 2 can be a centrifugal air compressor or a screw air compressor. The precooler 5 can be equipped with a gas-water separator, or a gas-water separator can be separately configured between the precooler 5 and the purifier 6.
纯化器6具有并联设置的A、B双塔结构,在各塔内均装填吸附剂;各塔的入口端均与待纯化压缩空气进气管和再生气进气管相连,各塔的出口端均与成品压缩空气出气管和再生气放散管相连;在各塔入口端和出口端的管路之间设有连接支管,在连接支管上设有阀门用于切换各塔与管路的连接关系;在成品压缩空气出气管和再生气放散管上,分别设有CO2浓度监测仪7和CO2浓度监测仪9。再生气放散管的末端为直排大气的放空口。The purifier 6 has a double tower structure of A and B arranged in parallel, and adsorbent is loaded in each tower; the inlet end of each tower is connected to the compressed air inlet pipe to be purified and the regeneration gas inlet pipe, and the outlet end of each tower is connected to the finished compressed air outlet pipe and the regeneration gas release pipe; a connecting branch pipe is provided between the pipelines at the inlet end and the outlet end of each tower, and a valve is provided on the connecting branch pipe for switching the connection relationship between each tower and the pipeline; a CO2 concentration monitor 7 and a CO2 concentration monitor 9 are provided on the finished compressed air outlet pipe and the regeneration gas release pipe, respectively. The end of the regeneration gas release pipe is a vent directly discharged into the atmosphere.
余热回用换热器3设有压缩空气入口、压缩空气出口,以及再生气进气口和再生气出气口;待加热再生气的供气管路连接至再生气进气口,再生气出气口通过管路依次连接比例调节阀10、电加热器8和纯化器6,用于提供加热后的再生气。为便于调控,所述比例调节阀优选为电控阀门,并通过信号线连接至PLC控制器;所述PLC控制器和CO2浓度监测仪分别通过信号线连接至上位计算机。The waste heat recovery heat exchanger 3 is provided with a compressed air inlet, a compressed air outlet, a regeneration gas inlet and a regeneration gas outlet; the gas supply pipeline of the regeneration gas to be heated is connected to the regeneration gas inlet, and the regeneration gas outlet is connected to the proportional control valve 10, the electric heater 8 and the purifier 6 in sequence through the pipeline to provide the heated regeneration gas. For the convenience of regulation, the proportional control valve is preferably an electric control valve, and is connected to the PLC controller through a signal line; the PLC controller and the CO2 concentration monitor are respectively connected to the host computer through signal lines.
本实用新型可使用成品压缩空气或氮气作为再生气。因此,如图1中所示,以管路接至纯化器的成品压缩空气出气管和余热回用换热器的再生气进气口,从纯化器的出口引出部分成品压缩空气作为再生气。或者,如图2中所示,以管路连接外部氮气供应设备和余热回用换热器的再生气进气口,从装置外部引入氮气作为再生气。当本实用新型的纯化装置是用于空分系统时,可以直接引入空分装置的污氮(即非高纯氮)作为再生气。The utility model can use finished compressed air or nitrogen as regeneration gas. Therefore, as shown in FIG1, a pipeline is connected to the finished compressed air outlet pipe of the purifier and the regeneration gas inlet of the waste heat recovery heat exchanger, and part of the finished compressed air is drawn out from the outlet of the purifier as regeneration gas. Alternatively, as shown in FIG2, a pipeline is connected to the external nitrogen supply equipment and the regeneration gas inlet of the waste heat recovery heat exchanger, and nitrogen is introduced from the outside of the device as regeneration gas. When the purification device of the utility model is used in an air separation system, the contaminated nitrogen (i.e., non-high purity nitrogen) of the air separation device can be directly introduced as regeneration gas.
为使再生气能够用于脱附后的冷却,在余热回用换热器的再生气进气口和再生气出气口之间设有旁路支管和用于切换的阀门,该旁路支管的一端位于再生气出气口和比例调节阀之间的管路上。为便于识读,图1、2中省略了再生气进气口和再生气出气口两处的阀门。In order to enable the regenerated gas to be used for cooling after desorption, a bypass branch pipe and a valve for switching are provided between the regenerated gas inlet and the regenerated gas outlet of the waste heat recovery heat exchanger, and one end of the bypass branch pipe is located on the pipeline between the regenerated gas outlet and the proportional control valve. For ease of reading, the valves at the regenerated gas inlet and the regenerated gas outlet are omitted in Figures 1 and 2.
作为示例,本实用新型提供如图3所示的纯化器的双塔及出入口管路的布局。As an example, the present invention provides a layout of double towers and inlet and outlet pipelines of a purifier as shown in FIG3 .
具体包括:A、B两塔并联布置,在各塔内部以吸附剂搭建双层吸附床体结构;两根并联管路的两端分别连接两个吸附塔底部的进气口,在其中一根管路上设有两个进气阀,另一根管路上设有两个排气阀;两个进气阀的中点通过管路连接至预冷机的出口,在该管路上设有阀门;两个排气阀的中点通过管路连接再生气放散管,该管路上设有CO2浓度监测仪;两根并联管路的两端分别连接两个吸附塔顶部的出气口,在其中一根管路上设有两个出气阀,另一根管路上设有两个再生阀;两个出气阀的中点连接成品压缩空气出气管,该管路上设有CO2浓度监测仪和出口总阀;两个再生阀的中点连接至电加热器的出口,在该管路上设有阀门。作为优选,纯化器出入口各管路上的阀门为电控阀门,分别通过信号线连接至PLC控制器,后者通过信号线连接至上位计算机。Specifically, the two towers A and B are arranged in parallel, and a double-layer adsorption bed structure is built inside each tower with an adsorbent; the two ends of the two parallel pipelines are respectively connected to the air inlets at the bottom of the two adsorption towers, two air inlet valves are arranged on one of the pipelines, and two exhaust valves are arranged on the other pipeline; the midpoints of the two air inlet valves are connected to the outlet of the precooler through a pipeline, and a valve is arranged on the pipeline; the midpoints of the two exhaust valves are connected to the regeneration gas release pipe through a pipeline, and a CO2 concentration monitor is arranged on the pipeline; the two ends of the two parallel pipelines are respectively connected to the air outlets at the top of the two adsorption towers, two air outlet valves are arranged on one of the pipelines, and two regeneration valves are arranged on the other pipeline; the midpoints of the two air outlet valves are connected to the finished compressed air outlet pipe, and a CO2 concentration monitor and an outlet main valve are arranged on the pipeline; the midpoints of the two regeneration valves are connected to the outlet of the electric heater, and a valve is arranged on the pipeline. Preferably, the valves on each pipeline of the purifier inlet and outlet are electrically controlled valves, which are respectively connected to the PLC controller through signal lines, and the latter is connected to the host computer through signal lines.
吸附塔中的碳分子筛可选地采用暴风雪法填装方式,并从顶部进行压紧,避免高压气流冲击导致分子筛粉化,保证分子筛长时间运行使用。通过采用不等势均压,能够提高吸附塔床层压缩空气纯度由低至高连续分布的连续性,易于快速制取纯度合格的压缩空气,从而提高净化效果、确保分子筛性能指标。这些都是吸附塔的常规操作内容,本实用新型不做要求。The carbon molecular sieve in the adsorption tower can be optionally filled by the snowstorm method and compacted from the top to avoid the molecular sieve pulverization caused by the impact of high-pressure airflow, so as to ensure the long-term operation of the molecular sieve. By adopting unequal potential equalization, the continuity of the continuous distribution of the compressed air purity of the adsorption tower bed from low to high can be improved, and it is easy to quickly produce compressed air with qualified purity, thereby improving the purification effect and ensuring the performance indicators of the molecular sieve. These are the routine operation contents of the adsorption tower, and the utility model does not make any requirements.
作为示例,下面对本实用新型所述压缩空气纯化装置的使用方法说明如下:As an example, the method of using the compressed air purification device of the utility model is described as follows:
(1)通过切换阀门,使纯化器6运行在A塔进气吸附且B塔保压待用的状态;(1) By switching the valves, the purifier 6 is operated in a state where the A tower is inlet and adsorbs gas and the B tower is maintained at pressure and is in standby mode;
(2)利用引风机(图中未示出)向空气过滤器1输入常压的空气,经无油空压机2压缩后使其压力和温度均得到提升;热空气在余热回用换热器3中与再生气进行换热,然后送入冷却器4中降温,再经过预冷机5(自带气水分离器)的降温脱水处理,得到温度低于10℃的待纯化压缩空气,将其作为纯化器6的原料气;(2) An induced draft fan (not shown) is used to input air at normal pressure into the air filter 1, and the air is compressed by the oil-free air compressor 2 to increase its pressure and temperature. The hot air exchanges heat with the regenerated air in the waste heat recovery heat exchanger 3, and then is sent to the cooler 4 for cooling. After cooling and dehydration treatment by the precooler 5 (with its own air-water separator), the compressed air to be purified with a temperature below 10°C is obtained, which is used as the raw gas for the purifier 6.
(3)将待纯化压缩空气送入A塔,在通过吸附床体时由吸附剂吸收气态CO2和残余水分;根据成品压缩空气出气管上CO2浓度监测仪9的实测数值和成品控制指标的要求,适时地切换连接支管上的阀门,改为将B塔投入运行;(3) The compressed air to be purified is sent to Tower A, where the gaseous CO 2 and residual moisture are absorbed by the adsorbent when passing through the adsorption bed; according to the measured value of the CO 2 concentration monitor 9 on the finished compressed air outlet pipe and the requirements of the finished product control index, the valve on the connecting branch pipe is switched in time to put Tower B into operation instead;
(4)在B塔进气吸附的同时,按以下操作方式对A塔进行再生脱附:(4) While the air is being adsorbed in tower B, tower A is regenerated and desorbed in the following manner:
将待加热再生气引入余热回用换热器3的再生气进气口,与来自无油空压机2的热空气进行换热;预热后的再生气通过比例调节阀10进入电加热器8,被进一步加热至170℃以上;高温再生气被送入A塔对吸附剂进行再生脱附,放散的再生气直接排入大气;此过程中,利用比例调节阀10调整再生气的流量,使再生气放散管上CO2浓度监测仪的实测数值符合预定的控制目标;The regenerated gas to be heated is introduced into the regenerated gas inlet of the waste heat recovery heat exchanger 3 to exchange heat with the hot air from the oil-free air compressor 2; the preheated regenerated gas enters the electric heater 8 through the proportional control valve 10 and is further heated to above 170°C; the high-temperature regenerated gas is sent to the A tower to regenerate and desorb the adsorbent, and the released regenerated gas is directly discharged into the atmosphere; in this process, the flow rate of the regenerated gas is adjusted by the proportional control valve 10 so that the actual measured value of the CO2 concentration monitor on the regenerated gas release pipe meets the predetermined control target;
当CO2浓度监测仪9的实测数值达到再生脱附要求时,停止电加热器8运行;切换余热回用换热器3的旁路支管上阀门,使未经加热的再生气进入A塔进行吹冷降温,放散的再生气直接排入大气;待A塔温度稳定后关闭再生气放散管上的阀门进行充压,达到运行压力时关闭比例调节阀10停止供气;关闭A塔出入口管路上阀门,保压待用;When the measured value of the CO2 concentration monitor 9 reaches the regeneration and desorption requirement, stop the operation of the electric heater 8; switch the valve on the bypass branch of the waste heat recovery heat exchanger 3 to allow the unheated regenerated gas to enter Tower A for cooling, and the released regenerated gas is directly discharged into the atmosphere; after the temperature of Tower A stabilizes, close the valve on the regenerated gas release pipe for pressurization, and when the operating pressure is reached, close the proportional regulating valve 10 to stop the gas supply; close the valves on the inlet and outlet pipelines of Tower A to maintain the pressure for standby use;
当使用成品压缩空气作为再生气时,控制引出量不超过成品压缩空气总量的20%;当使用外部氮气供应装置引入的氮气作为再生气时,根据压力情况启动设于氮气管路上的增压泵(图中未示出),以满足充压保压的需求。When finished compressed air is used as regeneration gas, the lead-out amount is controlled not to exceed 20% of the total amount of finished compressed air; when nitrogen introduced from an external nitrogen supply device is used as regeneration gas, the booster pump (not shown in the figure) installed on the nitrogen pipeline is started according to the pressure conditions to meet the needs of charging and maintaining pressure.
(5)循环执行步骤(1)至(4),使纯化器6保持双塔轮流切换的运行状态,持续稳定输出成品压缩空气。(5) Steps (1) to (4) are executed cyclically, so that the purifier 6 maintains the operation state of double-tower switching in turn and continuously and stably outputs finished compressed air.
图1中是从纯化器6出口(CO2浓度监测仪之后)直接引出成品压缩空气,以此作为待加热的再生气,控制其引出量不超过成品压缩空气总量的20%。由于是纯化器6直接产出的压缩空气,因此能够满足再生脱附后的充压保压要求,无需额外配置增压泵。In Figure 1, finished compressed air is directly drawn from the outlet of the purifier 6 (after the CO 2 concentration monitor) as the regeneration gas to be heated, and the amount of the drawn air is controlled not to exceed 20% of the total amount of finished compressed air. Since the compressed air is directly produced by the purifier 6, it can meet the pressure charging and pressure maintenance requirements after regeneration and desorption, and no additional booster pump is required.
图2中是从纯化装置外部的氮气供应装置(如空分系统)引入氮气作为再生气。根据氮气供应压力的情况,可选择地在氮气管路上设置增压泵,以满足再生脱附后的充压保压要求。In Figure 2, nitrogen is introduced from a nitrogen supply device (such as an air separation system) outside the purification device as regeneration gas. According to the nitrogen supply pressure, a booster pump can be optionally installed on the nitrogen pipeline to meet the pressure filling and pressure maintenance requirements after regeneration and desorption.
以上对本实用新型的具体实施例进行了描述。需要理解的是,本实用新型并不局限于上述特定实施方式,本领域技术人员可以在权利要求的范围内做出各种变形或修改,这并不影响本实用新型的实质内容。The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art can make various modifications or variations within the scope of the claims, which does not affect the essence of the present invention.
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