WO2022127103A1 - 一种用于含油污泥裂解的系统及方法 - Google Patents
一种用于含油污泥裂解的系统及方法 Download PDFInfo
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- oil
- oily sludge
- sludge
- gas
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Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B53/00—Destructive distillation, specially adapted for particular solid raw materials or solid raw materials in special form
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F11/00—Treatment of sludge; Devices therefor
- C02F11/10—Treatment of sludge; Devices therefor by pyrolysis
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B47/00—Destructive distillation of solid carbonaceous materials with indirect heating, e.g. by external combustion
- C10B47/28—Other processes
- C10B47/32—Other processes in ovens with mechanical conveying means
- C10B47/44—Other processes in ovens with mechanical conveying means with conveyor-screws
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B57/00—Other carbonising or coking processes; Features of destructive distillation processes in general
- C10B57/02—Multi-step carbonising or coking processes
Definitions
- the invention belongs to the technical field of oily sludge treatment, and in particular relates to a system and method for cracking oily sludge.
- Oily sludge is oily solid waste produced in the process of petroleum exploration, exploitation, refining, tank cleaning, storage and transportation, and oily sewage treatment. It is difficult to handle and so on. Oily sludge contains a lot of toxic and harmful substances. If it is not treated in time, it will inevitably cause serious pollution to the surrounding soil, water, air and its biosphere.
- the conventional oily sludge thermal cracking resource treatment technology has defects such as serious secondary pollution, high cost, complex equipment, easy coking, and poor reliability, which restrict its popularization and application, especially the high oil content of the treated solid residue. Unable to meet the requirements of the "Agricultural Sludge Pollutant Control Standard” (GB 4284-2018) (oil content is less than 0.3%), it needs to be co-processed. A complete set of thermal cracking equipment that operates stably.
- the current domestic and foreign treatment methods for oily sludge that meet the standards are: 1. Enter the incinerator for high temperature incineration, and the remaining incineration products that meet the standards are landfilled or fired. This treatment method has high cost and low resource recovery rate; it is only possible to recover heat energy; if the oily sludge has a high moisture content, the temperature in the furnace will decrease after entering the incinerator, and a large amount of fuel needs to be added to improve the incineration performance; 2. Use drying Ordinary sludge is used to treat oily sludge.
- oily sludge Because of the particularity of oily sludge, ordinary machines are not suitable for the treatment of oily sludge, which leads to agglomeration and coking of oily sludge in the equipment, which makes the equipment scrapped; in addition, the oily sludge treated by the sludge drying process is often Not up to the mark. For example, equipment such as rotary kiln sludge dryers will coke inside the equipment in a very short period of time during the process of processing oily sludge, causing the equipment to fail to operate normally. 3. The oil sludge is treated by thermal cracking technology.
- the conventional oily sludge thermal cracking resource treatment technology has defects such as serious secondary pollution, high cost, complex equipment, easy coking, and poor reliability, which restrict its popularization and application, especially the high oil content of the treated solid residue. Co-processing needs to be carried out. At present, there is no complete set of thermal cracking equipment with oil content of treated sludge below 0.3% and stable operation in China.
- Chinese patent application CN108911456A provides a new oily sludge treatment method and system.
- this patent also uses three-stage cracking to crack oily sludge, first of all, the three-stage cracking method is different when the two are thermally cracked.
- This patent It is through the radiant heating tube that the oil sludge is more thoroughly cracked through a higher temperature, and the patented tertiary cracking is to process the oil sludge generated after the secondary cracking, so as to carbonize the oil sludge and form a dispersed powder.
- Granules the treatment of oily sludge in this patent is incomplete and cannot meet the requirements of environmental protection; at the same time, this patent does not better treat the gas-phase substances produced by oily sludge.
- the present invention proposes a method for cracking oily sludge, the method comprising the following steps:
- step a first-level cracking is performed on the oily sludge, and the moisture and light oil in the oily sludge are evaporated and cracked to obtain dried oily sludge;
- Step b performing secondary cracking on the dried oil sludge, evaporating and cracking the heavy oil in the oily sludge, and carbonizing the oily sludge;
- step c the light oil and the heavy oil are subjected to tertiary cracking during the evaporation process to obtain combustible gas with high calorific value.
- first-level cracking, the second-level cracking, and the third-level cracking all use radiation heating.
- step b the oil-containing sludge is carbonized to obtain dry powder particles, and the oil content of the dry powder particles is less than 0.3%.
- the oil-containing sludge undergoes three levels of cracking to obtain an oil-gas-water mixture, and the oil-gas-water mixture is discharged through a hydraulic ejector and enters the cracked gas purification separator; the cracked gas purification separator separates the water through circulation.
- the pump enters the hydraulic ejector for recycling; the pyrolysis gas purification separator separates oily sewage and enters the oil-water separator for oil-water separation; the combustible gas separated by the pyrolysis gas purification separator is desulfurized by the purifier to recover energy .
- the combustible gas separated by the pyrolysis gas purification separator is subjected to desulfurization treatment by a primary pyrolysis gas purification filter and a secondary pyrolysis gas purification filter in sequence to recover energy.
- the present invention also provides a system for cracking oily sludge, the system comprising:
- the first-level cracking unit is used for first-level cracking of the oily sludge, and the moisture and light oil in the oily sludge are evaporated and cracked to obtain the dried oily sludge;
- a secondary cracking unit which is used for secondary cracking of the dried oil sludge, evaporating and cracking the heavy oil in the oily sludge, and carbonizing the oily sludge;
- the tertiary cracking unit is used for tertiary cracking of the light oil and the heavy oil in the evaporation process to obtain combustible gas with high calorific value.
- a radiant heating tube is arranged in the system, and the surface of the radiant heating tube is coated with a catalytic cracking coating.
- the main equipment of the cracking machine includes the first-level cracking unit, the second-level cracking unit and the third-level cracking unit; the system also includes a hydraulic ejector, one end of the hydraulic ejector is connected to the The main equipment of the cracking machine is connected to each other, and the other end is connected to the cracking gas purification separator through the oil-gas-water discharge pipe.
- the pressure balance box of the cracking machine is sequentially connected to the primary cracked gas purification filter and the secondary cracked gas purification filter, and the cracked gas storage cabinet is connected to the secondary cracked gas purification filter.
- the main equipment of the cracking machine is also provided with a burner, the burner is connected with a gas distribution main pipe, and the gas distribution main pipe is respectively connected to the cracked gas supply pipe and the supplementary natural gas pipe.
- the invention adopts the dry and wet oil sludge produced by gas fields and oil fields, and produces light oil, cement building materials, high-grade road roadbed materials, and road roadbed materials in oil areas through a thermal cracking process, and carries out harmless treatment, so as to avoid oil pollution.
- the rational utilization of sludge opens up a new way; the present invention is designed for the characteristics of oil sludge, and provides a complete set of oil sludge treatment steps and supporting equipment; the equipment used in the present invention has been improved in a targeted manner,
- the method of three-stage internal radiation heating the oil sludge renewal surface effectively solves the problem of coking and ensures the safe and normal operation of the equipment in the process; the theoretical basis of the heat of the invention is the thermal cracking of petroleum.
- the invention provides a reliable process composition, which ensures the normal operation of the treatment equipment while the oily sludge is qualified for treatment.
- Modular design of the whole process makes it easy to assemble, repair, and upgrade. It also has the characteristics of low maintenance cost and high degree of automation.
- the invention solves the problem that the oil sludge treatment equipment cannot be continuously produced, has no restrictions on the oil content and water content of the oil sludge, does not need to perform demulsification, dehydration and oil removal pretreatment on the oil sludge, and reduces the cost of water pollution treatment;
- the treatment of oily sludge is universal, applicable to oily sludge in all states, and the treatment effect reaches the standard; the invention can recover 50% of the oil in the oily sludge, and the cracked gas is used for sludge heating and cracking.
- this technology is non-oxidative cracking of oil sludge, generally does not produce secondary pollution (such as dioxins and furans), and the oil content and heavy metals of pyrolysis products meet the relevant discharge standards, realizing oil sludge
- the invention adopts the radiant tube heating technology that has undergone special technical treatment and special design, has high heating efficiency, high gas production rate, can efficiently recover high value-added oil and gas resources, and greatly reduces the The thermal cracking process is a matter of energy consumption.
- Fig. 1 shows the schematic flow chart of the oil sludge radiation cracking method in the embodiment of the present invention
- Fig. 2 shows the schematic diagram of the working principle of oil sludge radiation cracking in the embodiment of the present invention
- Fig. 3 shows the schematic diagram of the orientation of the main equipment of the cracking machine of the oil sludge radiation cracking system in the embodiment of the present invention
- FIG. 4 shows a schematic structural diagram of the direction of the pyrolysis gas purification separator of the oil sludge radiation cracking system in the embodiment of the present invention.
- 1- main equipment of cracking machine 2- hydraulic ejector, 3- cracked gas purification separator, 4- primary cracked gas purification filter, 5- secondary cracked gas purification filter, 6- cracked gas storage Cabinet, 7- pressure balance box of cracker, 8- oil sludge distributor, 9- discharger, 10- blower, 11- exhaust gas discharge pipe; 12- air distribution main pipe; 13- burner; 14- gas distribution main pipe ; 15- Discharge screw; 16- Discharge air closer; 17- Circulating water pipe; 18- Oil and gas water discharge pipe; 19- Supplementary natural gas pipe; 20- Pipe cleaner reducer; 21- Circulating water pump; 22- Cracking gas Air supply pipe.
- the present invention provides a system and method for cracking oily sludge.
- the oil and gas resources in the oily sludge are recovered by radiation cracking.
- the radiation cracking is divided into first-level cracking and second-level cracking. It can effectively solve the coking problem of the oil sludge cracking treatment process, and improve the efficiency of the process equipment.
- the working principle of radiative thermal cracking of oil sludge is to conduct indirect radiant heating of oil sludge under the condition of anaerobic and 550-650 °C temperature, so that the organic matter in the oil sludge is decomposed, and the oil sludge is converted into three phases. state matter.
- the gas phase is hydrogen, methane, ethane, ethylene, etc.;
- the liquid phase is mainly water and oil;
- the solid phase is inorganic minerals and carbon residue.
- Oily sludge is composed of water, oil and solid, and the petroleum hydrocarbons contained in it mainly include alkanes, olefins, naphthenes, asphaltenes and colloids. At around 100°C, it is mainly the evaporation of volatile components such as water; at around 200°C, the thermal cracking reaction of oil sludge begins, and the fastest conversion rate of the pyrolysis reaction is at 350-500°C. 370°C to start lysis.
- Fig. 1 shows the schematic flow chart of the oil sludge radiation cracking method in the embodiment of the present invention. In Fig. 1, the following steps are included:
- step a first-level cracking is performed on the oily sludge, and the moisture and light oil in the oily sludge are evaporated and cracked to obtain dried oily sludge;
- Step b performing secondary cracking on the dried oil sludge, evaporating and cracking the heavy oil in the oily sludge, and carbonizing the oily sludge;
- step c the light oil and the heavy oil are subjected to tertiary cracking during the evaporation process to obtain combustible gas with high calorific value.
- FIG. 2 shows a schematic diagram of the working principle of oily sludge radiation cracking in the embodiment of the present invention.
- the oily sludge radiation cracking method includes the following steps:
- the oily sludge is torn, broken and iron removed, and then sent to the oily sludge distributor 8, and the oily sludge distributor 8 evenly sends the oily sludge to the propulsion screw in the main equipment 1 of the cracking machine;
- the oily sludge enters the first-stage cracker, and the oily sludge moves forward under the action of the propelling screw, and the surface of the oily sludge is constantly renewed.
- the radiant heat of the radiant heating tube radiates the surface of the oily sludge, and the reaction time is about 45 minutes.
- the pressure balance box 7 of the cracking machine maintains a slight positive pressure inside the main equipment 1 of the cracking machine to prevent air from entering, and the pressure is controlled to 50Pa.
- the temperature in the reaction chamber of the first-stage cracker is controlled at 450°C. The purpose is to heat the oily sludge and quickly evaporate the water and light oil in the oily sludge.
- a third-stage cracking reaction occurs, and the radiant heating tube controls
- the temperature is 900°C, and it is coated with a catalytic cracking coating to form a thermal field around the radiant heating tube that is conducive to the cracking reaction, so that the evaporated oil is further cracked into combustible gas with high calorific value;
- the radiant heating tube controls the temperature to 900 °C and is coated with a catalytic cracking coating.
- a thermal field is formed around the radiant heating tube that is conducive to the cracking reaction, so that the evaporated oil is further cracked into high calorific value. gas;
- the oily sludge is carbonized, and some harmful ions such as heavy metals are encapsulated.
- the oily sludge is in the form of dry powder particles, and the oil content of the oily sludge residue is reduced to below 0.3%, and the indicators meet the national standards.
- the harmless treatment of oil sludge is completed.
- the oil sludge is cooled by the discharge screw 15 and the discharge air closer 16 and then discharged from the cracker. This is the product that meets the standard and enters the ash storage tank for subsequent processing.
- the radiant heating tube heats the surface of the continuously updated oil sludge. Since the temperature of the oil sludge is slightly different from the temperature of the bottom tank of the propeller screw and the main equipment 1 of the cracking machine, the coking of the parts in contact with the oil sludge is reduced.
- the tank body at the bottom of the main equipment 1 is sprayed with anti-coking amorphous material to improve the anti-coking ability of the main equipment 1 of the cracking machine.
- the oil, gas and water in the main equipment 1 of the cracking machine are discharged from the main equipment 1 of the cracking machine through the hydraulic ejector 2 .
- the oil, gas and water in the main equipment 1 of the cracking machine are discharged through the hydraulic ejector 2 and enter the cracked gas purification separator 3 to separate the oil, gas and water three-phase, and the separated water enters the hydraulic ejector 2 through the circulating water pump 21 for recycling. It enters the oil-water separator to recover light pyrolysis oil, and the oil recovery rate reaches 50%, and the sewage enters the sewage treatment facility.
- the pyrolysis gas purification separator 3 separates the combustible gas into the pressure balance box 7 of the cracker.
- the pressure balance box 7 of the cracker is a buoy-type structure, and the internal pressure of the main device 1 of the cracker can be adjusted according to the counterweight, so as to keep the internal pressure of the main device 1 of the cracker.
- the positive pressure is constant to prevent air from entering the main equipment 1 of the cracking machine, resulting in potential safety hazards.
- the combustible gas coming out of the pressure balance box 7 of the cracking machine is desulfurized through the first-level cracking gas purification filter 4 and the second-level cracking gas purification filter 5 in turn. Then enter the self-preheating burner 13 to heat the radiant tube and recover energy. After purification, combustible gas is mixed with supplementary natural gas.
- the exhaust gas after combustion reaches the standard of natural gas boiler.
- the amount of supplementary natural gas varies with the oil content of oil sludge. Oil sludge with an oil content of more than 15% can achieve heat balance without supplementing natural gas.
- Fig. 3 shows a schematic structural diagram of the direction of the main device 1 of the cracking machine of the oil sludge radiation cracking system in the embodiment of the present invention
- the cracking unit and the three-stage cracking unit, the main equipment 1 of the cracking machine is also provided with radiant heating pipes, the main equipment 1 of the cracking machine is provided with a burner 13, and the burner 13 is connected to the gas distribution main pipe 14 for rational distribution of the gas.
- the main equipment 1 is provided with a blower 10 and an air distribution main pipe 12.
- the oily sludge is placed in the oil sludge distributor 8 and enters the main equipment 1 of the cracking machine through the oil sludge propeller.
- the feeder 9 is discharged.
- the discharger 9 is provided with a discharge screw 15 and a discharge air lock 16.
- the main equipment 1 of the cracking machine is also provided with a tail gas discharge pipe 11.
- the tail gas discharge pipe 11 is communicated with the radiation heating pipe to burn the gas The generated exhaust gas is discharged.
- the oil sludge distributor 8 is a cuboid with an upper opening, and a propelling screw is arranged on the oil sludge propeller, and the propelling screw is inserted through the oil sludge distributor 8 into the main body 1 of the cracking machine.
- the oil sludge distribution The device 8 is an opening structure above a cuboid, and the shape of the cuboid is only used as an example, and is not limited to the shape of a cuboid.
- Fig. 4 shows a schematic structural diagram of the direction of the pyrolysis gas purifying separator 3 of the oil sludge radiation cracking system in the embodiment of the present invention.
- the hydraulic ejector 2 enters the pyrolysis gas purification separator 3 through the oil-gas-water discharge pipe 18, and the pyrolysis gas purification separator 3 is respectively connected with the circulating water pump 21, the pressure balance box 7 of the cracker, the oil-water separator, and the pressure balance box of the cracker.
- the circulating water pump 21 is connected with the hydraulic ejector 2 through the circulating water pipe 17, and the main equipment 1 of the cracking machine is connected with the cracking gas.
- a pipeline cleaner is arranged between the gas purification separators 3, the oil, gas and water enter the cracked gas purification separator 3 through the hydraulic ejector 2 and the pipeline cleaner, and a pipeline cleaner reducer 20 is arranged on the pipeline cleaner.
- the primary cracked gas purification filter 4 and the secondary cracked gas purification filter 5 are both cylindrical, and the shape is not limited to this specific shape, and applications that only change the shape on this basis are all within the scope of protection of the present invention
- the pyrolysis gas storage cabinet 6 is a cylindrical structure with a depression on the upper end
- the pressure balance box 7 of the cracking machine is a cylindrical structure with a convex upper end.
- the cracked gas storage cabinet 6 is communicated with the main gas distribution main pipe 14 through the cracked gas supply pipe 22, and the cracked gas supply pipe 22 is connected with a supplementary natural gas pipe 19.
- the combustible gas and supplementary natural gas are mixed for use, and the exhaust gas after combustion
- the amount of supplemented natural gas varies with the oil content of the oil sludge, and the oil sludge with an oil content of more than 15% can achieve heat balance without supplementing natural gas.
- the invention adopts the dry and wet oil sludge produced by gas fields and oil fields, and produces light oil, cement building materials, high-grade road roadbed materials, and road roadbed materials in oil areas through a thermal cracking process, and carries out harmless treatment, so as to avoid oil pollution.
- the rational utilization of sludge opens up a new way; the present invention is designed for the characteristics of oil sludge, and provides a complete set of oil sludge treatment steps and supporting equipment; the equipment used in the present invention has been improved in a targeted manner,
- the method of secondary internal radiation heating the oil sludge renewal surface effectively solves the problem of coking and ensures the safe and normal operation of the equipment in the process; the theoretical basis of the heat of the present invention is the thermal cracking of petroleum.
- the invention provides a reliable process composition, which ensures the normal operation of the treatment equipment while the oily sludge is qualified for treatment.
- Modular design of the whole process makes it easy to assemble, repair, and upgrade. It also has the characteristics of low maintenance cost and high degree of automation.
Abstract
本发明提出一种用于含油污泥裂解的系统及方法，采用利用气田、油田产生的干湿油污泥，通过热裂解工艺，生产轻质油、水泥建材原料、高等级公路路基材料、油区公路路基材料，进行无害化处理，为油污泥的合理利用开辟出新的途径；本发明是针对油污泥特性设计，提供了一整套完整的油污泥处理步骤，以及配套的设备；本发明所使用设备进行过有针对性的改进，采用三级内部辐射加热油污泥更新面的方式，有效的解决了结焦问题，保证工艺内设备的安全、正常运行；本发明提供一个可靠的工艺组成，使含油污泥被处理合格的同时，保证处理设备的运行正常。整套工艺模块化设计，易于组装、检修、升级改造，还兼有维护成本低，自动化程度高的特点。
Description
本发明属于含油污泥处理技术领域，特别涉及一种用于含油污泥裂解的系统及方法。
含油污泥是石油勘探、开采、炼制、清罐、储运及含油污水处理过程中所产生的含油固体废弃物，具有产量大、含油量高、重质组分高、综合利用方式少、处理难度大等特点。含油污泥中含有大量的有毒有害物质，若不及时加以处理整治，将势必对周围土壤、水体、空气及其生物圈造成严重污染。
由于我国的油气田开采技术比较落后，过去对于在开采过程中所产生的油泥，其处理方法多采用填埋的方法，有些油气田干脆弃于定点的坑中，这样的油泥坑在油气田的采油采气区有很多。由于这些油泥坑的存在对环境产生了严重的影响，破坏了当地生态环境，占用了大片农民土地，更严重的是油泥逐步向地层深度渗透，污染地下及地表水资源，对人类和地表生物的健康和生存造成威胁，同时浪费了大量的石油资源。目前全球能源紧张，原油油价上涨，含油污泥中一般含有10％-40％干重的石油组分，这些石油资源随油泥等流失，是对资源的极大浪费。我国每年产生的大量油泥砂，约300多万吨，可回收至少560万桶原油，直接减少损失近16亿元人民币。
在环保形势愈加严峻的压力下，油田、炼化企业所积累的含油污泥带来的污染问题受到国家的高度重视，企业需要妥善处置生产活动中产生的 含油污泥。
目前常规的含油污泥热裂解资源化处理技术存在二次污染严重、成本较高、设备复杂、易结焦、可靠性差等缺陷，制约了其推广应用，尤其是处理后的固体残渣含油率高，无法满足《农用污泥污染物控制标准》(GB 4284-2018)的要求(含油率低于0.3％)，需要再进行协同处置，目前国内尚未发现处理后污泥含油率在0.3％以下，且稳定运行的成套热裂解设备。
国内外目前对于含油污泥达标的处理方式是：1.进焚烧炉进行高温焚烧，焚烧所剩余的达标产物进行填埋或者烧制砖等。这种处理方式成本高，资源回收率低；仅有可能回收热能；若含油污泥含水率高，进入焚烧炉后会致使炉内温度降低，需要补充大量燃料提高焚烧性能；2.用烘干普通污泥的方式来处理含油污泥。因为含油污泥的特殊性，普通的机器并不能适应于含油污泥的处理，从而导致含油污泥在设备内结块焦化，使设备报废；另外，污泥烘干工艺处理的含油污泥往往不能达标。例如：回转窑污泥烘干机等设备在处理油污泥的过程中，会在极短时间内在设备内部结焦，致使设备不能正常运转。3.通过热裂解技术对油污泥进行处理。但由于热裂解温度较烘干更高，炉体结焦更加严重，进而影响热解效果和设施的稳定运行。目前常规的含油污泥热裂解资源化处理技术存在二次污染严重、成本较高、设备复杂、易结焦、可靠性差等缺陷，制约了其推广应用，尤其是处理后的固体残渣含油率高，需要再进行协同处置，目前国内尚未发现处理后污泥含油率在0.3％以下，且稳定运行的成套热裂解设备。
中国专利申请CN108911456A提供一种新的含油污泥处理方法及系统，该专利虽然也是通过三级裂解对含油污泥进行裂解处理，首先，两者进行 热裂解时三级裂解的方式不同，本专利是通过辐射加热管通过更高的温度使得油污泥的裂解更加彻底，而该专利的三级裂解是对二级裂解后产生的油泥渣进行处理，以将油泥渣碳化，形成分散的粉状颗粒，该专利对含油污泥的处理不彻底，无法满足环保的要求；同时该专利并没有对油污泥产生的气相物质进行更好的处理，本专利将油污泥裂解后产生的裂解气进行净化过滤，将净化去硫后的裂解气进行储存，作为能源供给燃烧器燃烧使用，有利于能源的回收利用，同时满足环保的要求；最后本申请是通过水力引射器将油污泥裂解后产生的油气水混合物引射到裂解气净化分离器，使得油气水混合物能够顺畅的进入到裂解气净化分离器中进行分离，使得油气水混合物的分离更加的彻底，该专利也没有涉及到该技术方案，同时也没有给出该技术方案的启示说明。
因此，如何实现残渣含油率和重金属达标以满足后续处置和综合利用要求，同时最大限度地简化系统、提高设备抗结焦性、可靠性、稳定性，对于推动本技术产业化应用，促进生态文明建设均有重要的现实意义。
发明内容
针对上述问题，本发明提出一种用于含油污泥裂解的方法，所述方法包括以下步骤：
步骤a、对含油污泥进行一级裂解，蒸发裂解出所述含油污泥中的水分和轻质油，得到干化油泥；
步骤b、对所述干化油泥进行二级裂解，蒸发裂解出所述含油污泥中的重质油，并将所述含油污泥碳化；
步骤c、蒸发过程中对所述轻质油和所述重质油进行三级裂解，得到高热值的可燃气。
进一步的，所述一级裂解、所述二级裂解、所述三级裂解均采用辐射加热方式。
进一步的，步骤b中所述含油污泥碳化得到干粉状颗粒，所述干粉状颗粒的含油率小于0.3％。
进一步的，所述含油污泥经过三个层级的裂解得到油气水混合物，所述油气水混合物通过水力引射器排出，进入到裂解气净化分离器；所述裂解气净化分离器分离出水通过循环泵进入所述水力引射器循环使用；所述裂解气净化分离器分离出含油污水进入油水分离器进行油水分离；所述裂解气净化分离器分离出的可燃气通过净化器脱硫处理，回收能源。
进一步的，所述裂解气净化分离器分离出的所述可燃气依次经过一级裂解气净化过滤器和二级裂解气净化过滤器脱硫处理，回收能源。
本发明还提供一种用于含油污泥裂解的系统，所述系统包括：
一级裂解单元，用于对含油污泥进行一级裂解，蒸发裂解出所述含油污泥中的水分和轻质油，得到干化油泥；
二级裂解单元，用于对所述干化油泥进行二级裂解，蒸发裂解出所述含油污泥中的重质油，并将所述含油污泥碳化；
三级裂解单元，用于对蒸发过程中对所述轻质油和所述重质油进行三级裂解，得到高热值的可燃气。
进一步的，所述系统内设置辐射加热管，所述辐射加热管表面涂覆有催化裂解涂层。
进一步的，所述裂解机主体设备包括所述一级裂解单元、所述二级裂解单元和所述三级裂解单元；所述系统还包括水力引射器，所述水力引射器一端与所述裂解机主体设备相连通，另一端通过油气水排出管连接裂解气净化分离器，所述裂解气净化分离器远离所述水力引射器一端分别连接循环水泵、油水分离器和裂解机压力平衡箱，所述裂解机压力平衡箱依次 连接一级裂解气净化过滤器和二级裂解气净化过滤器，裂解气储存柜连接所述二级裂解气净化过滤器。
进一步的，所述裂解机主体设备上还设置有燃烧器，所述燃烧器上连接有燃气分配主管，所述燃气分配主管分别连接裂解气供气管和补充天然气管。
本发明采用利用气田、油田产生的干湿油污泥，通过热裂解工艺，生产轻质油、水泥建材原料、高等级公路路基材料、油区公路路基材料，进行无害化处理，为油污泥的合理利用开辟出新的途径；本发明是针对油污泥特性设计，提供了一整套完整的油污泥处理步骤，以及配套的设备；本发明所使用设备进行过有针对性的改进，采用三级内部辐射加热油污泥更新面的方式，有效的解决了结焦问题，保证工艺内设备的安全、正常运行；本发明热的理论基础是石油的热裂解，通过热裂解机，同时达到去水和去油两个目的。本发明提供一个可靠的工艺组成，使含油污泥被处理合格的同时，保证处理设备的运行正常。整套工艺模块化设计，易于组装、检修、升级改造，还兼有维护成本低，自动化程度高的特点。
同时本发明解决油污泥处理设备不能连续化生产问题，对油污泥含油率、含水率没有限制，无需对油污泥进行破乳脱水除油预处理，减少水污染处理费用；本发明对含油污泥的处理是普适性的，对各状态油污泥都适用，处理效果达标；本发明可对含油污泥里面的50％油进行回收，裂解气用于污泥加热裂解，在处理油污泥的同时，回收了资源；本技术是油污泥无氧化裂解，总体上不产生二次污染(如二噁英和呋喃)，热解产物含油率和重金属满足相关排放标准，实现了油泥的资源化和无害化利用，环境效益好；本发明采用经过特殊技术处理和专门设计的辐射管加热技术，加热效率高，产气率高，可高效回收高附加值油气资源，大幅度减少热裂解工艺的事能源消耗。
本发明的其它特征和优点将在随后的说明书中阐述，并且，部分地从 说明书中变得显而易见，或者通过实施本发明而了解。本发明的目的和其他优点可通过在说明书、权利要求书以及附图中所指出的结构来实现和获得。
为了更清楚地说明本发明实施例或现有技术中的技术方案，下面将对实施例或现有技术描述中所需要使用的附图作一简单地介绍，显而易见地，下面描述中的附图是本发明的一些实施例，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1示出了本发明实施例中油污泥辐射裂解方法流程示意图；
图2示出了本发明实施例中油污泥辐射裂解工作原理示意图；
图3示出了本发明实施例中油污泥辐射裂解系统裂解机主体设备方向结构示意图；
图4示出了本发明实施例中油污泥辐射裂解系统裂解气净化分离器方向结构示意图。
图中，1-裂解机主体设备，2-水力引射器，3-裂解气净化分离器，4-一级裂解气净化过滤器，5-二级裂解气净化过滤器，6-裂解气储存柜，7-裂解机压力平衡箱，8-油污泥布料器，9-出料器，10-送风机，11-尾气排出管；12-空气分配主管；13-燃烧器；14-燃气分配主管；15-出料螺旋；16-出料闭风器；17-循环水管；18-油气水排出管；19-补充天然气管；20-管道清洁器减速机；21-循环水泵；22-裂解气供气管。
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例中的附图，对本发明实施例中的技术方案进行清楚、完整地说明，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
本发明提供了一种用于含油污泥裂解的系统及方法，通过辐射裂解回收油污泥中的油气资源，辐射裂解分成一级裂解、二级裂解还让三级裂解三个层级对含油污泥进行处理，提高了油气回收率，有效解决油污泥裂解处理工艺结焦问题，提高了工艺设备效率。
油污泥辐射热裂解工作原理是在无氧和550～650℃的温度条件下，对油污泥进行间接辐射加热，使油污泥中的有机物发生分解，将油污泥转变成三种相态物质。气相为氢气、甲烷、乙烷、乙烯等；液相以水油为主；固相为无机矿物质与残炭。
含油污泥由水、油、固三部分构成，其中含有的石油烃主要包括烷烃类、烯烃类、环烷烃、沥青质及胶质等。在100℃左右，主要是水分等易挥发组分的蒸发；在200℃左右，油污泥的热裂解反应开始，而热解反应转化速率最快是在350～500℃，重质油是在370℃开始裂解。
图1示出了本发明实施例中油污泥辐射裂解方法流程示意图，图1中，包括以下步骤：
步骤a、对含油污泥进行一级裂解，蒸发裂解出所述含油污泥中的水分和轻质油，得到干化油泥；
步骤b、对所述干化油泥进行二级裂解，蒸发裂解出所述含油污泥中的重质油，并将所述含油污泥碳化；
步骤c、蒸发过程中对所述轻质油和所述重质油进行三级裂解，得到高热值的可燃气。
具体的，图2示出了本发明实施例中含油污泥辐射裂解工作原理示意图，图2中，含油污泥辐射裂解方法包括以下步骤：
含油污泥撕裂破碎、除铁后送入油污泥布料器8，油污泥布料器8将含油污泥均匀送入裂解机主体设备1中的推进螺旋；
含油污泥进入一级裂解器，含油污泥在推进螺旋作用向前运动，同时油污泥表面不断更新，辐射加热管的辐射热对含油污泥表面进行辐射加热， 反应时间约为45分钟。裂解机压力平衡箱7保持裂解机主体设备1内部微正压运行，防止空气进入，压力控制50Pa。一级裂解器反应室内温度控制在450℃，其目的是为了把含油污泥进行加热并迅速蒸发掉油污泥中水分和轻质油，油水蒸发过程中发生三级裂解反应，辐射加热管控制温度900℃，并涂有催化裂解涂层，在辐射加热管周围形成有利于裂解反应热场，使蒸发油进一步裂解为高热值的可燃气；
含油污泥从一级裂解器出来后，进入二级裂解器，油污泥在推进螺旋作用向前运动，同时油污泥表面不断更新，辐射热管的辐射热对油污泥表面进行辐射加热，反应时间约为45分钟。裂解器微正压运行，防止空气进入，压力控制50Pa。二级裂解器反应室温度约在650℃左右，油泥表面照射温度700℃，其目的是蒸发裂解出油污泥中绝大部分油、裂解油污泥中长链分子的有机物，碳化油污泥，油污泥达到出料端含油率降至0.3％以下。裂解油蒸发过程中发生三级裂解反应，辐射加热管控制温度900℃，并涂有催化裂解涂层，在辐射加热管周围形成有利于裂解反应热场，使蒸发油进一步裂解为高热值的可燃气；
具体的，油污泥碳化，把一些重金属等有害离子包裹在内，经过二级裂解，含油污泥呈干粉状颗粒，油污泥残渣含油率降至0.3％以下，各项指标达到国家标准，油污泥无害化处理完成。处理后油污泥通过出料螺旋15和出料闭风器16冷却后排出裂解器，此为达标产物，进入灰渣贮存池，等待后续的处理。
具体的，辐射加热管对不断更新油污泥表面加热，由于油污泥温度与推进螺旋和裂解机主体设备1底部槽体温度差别小，减轻与油污泥接触部件结焦，推进螺旋和裂解机主体设备1底部槽体喷涂抗结焦非晶材料，提高裂解机主体设备1抗结焦能力。裂解机主体设备1内油气水通过水力引射器2排出裂解机主体设备1。
裂解机主体设备1内油气水通过水力引射器2排出，进入裂解气净化 分离器3，将油气水三相分离，分离出水通过循环水泵21进入水力引射器2循环使用，多余的含油污水进入油水分离器回收轻质裂解油，油回收率达50％，污水进入污水处理设施。
裂解气净化分离器3分离出可燃气进入裂解机压力平衡箱7，裂解机压力平衡箱7为浮筒式结构，根据配重可以调节裂解机主体设备1内部压力，保持裂解机主体设备1内部微正压恒定，防止空气进入裂解机主体设备1，出现安全隐患。
裂解机压力平衡箱7出来的可燃气依次通过一级裂解气净化过滤器4和二级裂解气净化过滤器5脱硫处理，净化后可燃气经压缩机增压后送入裂解气储存柜6，然后进入自预热燃烧器13加热辐射管，回收能源。净化后可燃气与补充天然气混合使用，燃烧后的尾气达到天然气锅炉标准，补充天然气量随油污泥的油含量变化，含油率15％以上油污泥可以达到热量平衡，无需补充天燃气。
图3示出了本发明实施例中油污泥辐射裂解系统裂解机主体设备1方向结构示意图；图3中，系统包括裂解机主体设备1，裂解机主体设备1内部设置一级裂解单元、二级裂解单元和三级裂解单元，裂解机主体设备1内部还设置辐射加热管，裂解机主体设备1上设置燃烧器13，燃烧器13上连接燃气分配主管14用于对燃气进行合理分配，裂解机主体设备1上设置送风机10和空气分配主管12，含油污泥置于油污泥布料器8内，通过油污泥推进器进入裂解机主体设备1，经过三层裂解处理完成的碳化油污经过出料器9排出，出料器9上设置出料螺旋15和出料闭风器16，裂解机主体设备1上还设置尾气排出管11，尾气排出管11与辐射加热管相连通，将燃气燃烧产生的尾气排出。
具体的，油污泥布料器8为上方开口的长方体，油污泥推进器上设置推进螺旋，推进螺旋穿插油污泥布料器8进入到裂解机主体1内，本发明实施例中油污泥布料器8为长方体上方开口结构，该长方体这一形状仅作 为一种示例说明，并不仅限于长方体这一形状。
图4示出了本发明实施例中油污泥辐射裂解系统裂解气净化分离器3方向结构示意图，图4中，含油污泥经过三层裂解在裂解机主体设备1内形成油气水，油气水经过水力引射器2并通过油气水排出管18进入到裂解气净化分离器3，裂解气净化分离器3上分别连接循环水泵21、裂解机压力平衡箱7和油水分离器，裂解机压力平衡箱7依次连接一级裂解气净化过滤器4、二级裂解气净化过滤器5和裂解气储存柜6，循环水泵21通过循环水管17与水力引射器2相连通，裂解机主体设备1与裂解气净化分离器3之间设置管道清洁器，油气水经过水力引射器2和管道清洁器进入到裂解气净化分离器3中，管道清洁器上设置管道清洁器减速机20。
具体的，本实施例中，一级裂解气净化过滤器4和二级裂解气净化过滤器5均为圆柱形，该形状不局限于这一具体形状，在此基础上只改变形状的申请均在本发明的保护范围之内，裂解气储存柜6为上端有凹陷的圆柱体结构，裂解机压力平衡箱7为上部有凸起的圆柱体结构。
图3中，裂解气储存柜6通过裂解气供气管22与燃气分配主管14相连通，裂解气供气管22上连接有补充天然气管19，净化后可燃气与补充天然气混合使用，燃烧后的尾气达到天然气锅炉标准，补充天然气量随油污泥的油含量变化，含油率15％以上油污泥可以达到热量平衡，无需补充天燃气。
本发明采用利用气田、油田产生的干湿油污泥，通过热裂解工艺，生产轻质油、水泥建材原料、高等级公路路基材料、油区公路路基材料，进行无害化处理，为油污泥的合理利用开辟出新的途径；本发明是针对油污泥特性设计，提供了一整套完整的油污泥处理步骤，以及配套的设备；本发明所使用设备进行过有针对性的改进，采用二级内部辐射加热油污泥更新面的方式，有效的解决了结焦问题，保证工艺内设备的安全、正常运行；本发明热的理论基础是石油的热裂解，通过热裂解机，同时达到去水和去 油两个目的。本发明提供一个可靠的工艺组成，使含油污泥被处理合格的同时，保证处理设备的运行正常。整套工艺模块化设计，易于组装、检修、升级改造，还兼有维护成本低，自动化程度高的特点。
尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (9)
- 一种用于含油污泥裂解的方法，其特征在于，所述方法包括以下步骤：步骤a、对含油污泥进行一级裂解，蒸发裂解出所述含油污泥中的水分和轻质油，得到干化油泥；步骤b、对所述干化油泥进行二级裂解，蒸发裂解出所述含油污泥中的重质油，并将所述含油污泥碳化；步骤c、蒸发过程中对所述轻质油和所述重质油进行三级裂解，得到高热值的可燃气。
- 根据权利要求1所述的用于含油污泥裂解的方法，其特征在于，所述一级裂解、所述二级裂解、所述三级裂解均采用辐射加热方式。
- 根据权利要求1所述的用于含油污泥裂解的方法，其特征在于，步骤b中所述含油污泥碳化得到干粉状颗粒，所述干粉状颗粒的含油率小于0.3％。
- 根据权利要求1所述的用于含油污泥裂解的方法，其特征在于，所述含油污泥经过三个层级的裂解得到油气水混合物，所述油气水混合物通过水力引射器排出，进入到裂解气净化分离器；所述裂解气净化分离器分离出水通过循环泵进入所述水力引射器循环使用；所述裂解气净化分离器分离出含油污水进入油水分离器进行油水分离；所述裂解气净化分离器分离出的可燃气通过净化器脱硫处理，回收能源。
- 根据权利要求4所述的用于含油污泥裂解的方法，其特征在于，所述裂解气净化分离器分离出的所述可燃气依次经过一级裂解气净化过滤器和二级裂解气净化过滤器脱硫处理，回收能源。
- 一种用于含油污泥裂解的系统，其特征在于，所述系统包括：一级裂解单元，用于对含油污泥进行一级裂解，蒸发裂解出所述含油污泥中的水分和轻质油，得到干化油泥；二级裂解单元，用于对所述干化油泥进行二级裂解，蒸发裂解出所述 含油污泥中的重质油，并将所述含油污泥碳化；三级裂解单元，用于对蒸发过程中对所述轻质油和所述重质油进行三级裂解，得到高热值的可燃气。
- 根据权利要求6所述的系统，其特征在于，所述系统内设置辐射加热管，所述辐射加热管表面涂覆有催化裂解涂层。
- 根据权利要求6所述的系统，其特征在于，所述系统包括裂解机主体设备，所述裂解机主体设备包括所述一级裂解单元、所述二级裂解单元和所述三级裂解单元；所述系统还包括水力引射器，所述水力引射器一端与所述裂解机主体设备相连通，另一端通过油气水排出管连接裂解气净化分离器，所述裂解气净化分离器远离所述水力引射器一端分别连接循环水泵、油水分离器和裂解机压力平衡箱，所述裂解机压力平衡箱依次连接一级裂解气净化过滤器和二级裂解气净化过滤器，裂解气储存柜连接所述二级裂解气净化过滤器。
- 根据权利要求8所述的系统，其特征在于，所述裂解机主体设备上还设置有燃烧器，所述燃烧器上连接有燃气分配主管，所述燃气分配主管分别连接裂解气供气管和补充天然气管。
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