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上海申榕环保标书翻译项目

迪朗上海翻译公司翻译校对

二、设计条件

  1. Design Conditions

2.1 企业废气污染物状况

2.1 Status of Enterprise Waste Gas Pollutants

喷漆量:15吨/年

Sprayed Paint Quantity: 15 tons/year

废水水量:1~2m3/h

Waste Water Volume:1~2m3/h

废气风量:150000 m3/h。

Exhaust Gas Volume: 150000 m3/h.

废气浓度:平均21mg/m3,最高50 mg/m3

Exhaust gas concentration:  21mg/m3 on average, maximum 50 mg/m3

排气方式:间歇+连续

Gas Exhaust Method: intermittent & continuous

2.2 公用工程

2.2 Public Engineering

公用工程

Public Engineering

参数

Parameter

电源

power supply

三相:380V,50Hz

Three-phase: 380V, 50Hz

压缩空气

Compressed air

压力:0.6MPa

Pressure: 0.6MPa

2.3 设计要求

2.3 Design Requirements

1、喷漆房用于产品和零部件的喷漆。

  1. Paint booth is used for products and parts painting.

设计时严格按照国家有关安全、卫生、消防及环保等方面的标准要求执行,结合产品及使用涂料现状,按喷漆工艺要求作相应调整。

The design is carried out in strict accordance with the relevant national standards for safety, health, fire protection and environmental protection. Combining with the current situation of the product and the using coatings, corresponding adjustments are made according to the requirements of the painting process.

2、具有防燃、防爆装置,符合GB14444-2006《喷漆室安全技术规定》与 GB5008-1992《爆炸和火灾危险场所电力装置设计规范》要求。

  1. Equipped with anti-combustion and explosion-proof devices, and meets the requirements of GB14444-2006 “Safety Technical Regulations for Paint Booth” and GB5008-1992 “Specification for Design of Electrical Devices in Explosive and Fire Hazardous Locations”.

所有电气设备都有可靠接地,其防护等级和绝缘等级满足国家相关标准要求

All electrical equipment has reliable grounding, and the protection level and insulation level meet the requirements of relevant national standards

3、喷漆房的噪音[80db(A)以下]、废气等排放达到国家和上海对机械工厂设计的有关环保要求。

  1. The noise [80db(A) or below] and exhaust gas emission of the paint booth meet the relevant environmental protection requirements of China and Shanghai for the design of machinery factories.

4、充分考虑设备运行的安全性,在压力控制方面均采用可靠的控制方式, 以保证设备的整体性能和质量。

  1. Fully considering the safety of equipment operation, we adopt reliable control methods in pressure control to ensure the overall performance and quality of the equipment.

各系统中有联锁互动的安全装置,确保设备、人身安全;

There are interlocking and interactive safety devices in each system to ensure equipment and personal safety.

5、设备美观大方,满足产品使用要求,运行可靠,操作简便,维护保养方便易行。

  1. The equipment is beautiful and elegent, which meets the requirements of reliable, simple operation, convenient and easy maintenance.

6、选用的配套件、材料及电器元件均质量可靠,技术领先,确保设备的整体性能和使用质量。

  1. The selected parts, materials and electrical components are of reliable quality and leading technology to ensure the overall performance and quality of the equipment.

7、本项目废气的处理效果与所需能耗跟生产过程有着较大的联系,需要保持废气的浓度跟风量处于相对稳定的范围内才使整个系统更好的运行,这样会在达到排放规范和标准的同时,又可最大程度的节约能源。

  1. The waste gas treatment effect of this project is closely related to the required energy consumption and the production process. It is necessary to keep the concentration and air volume of the waste gas within a relatively stable range to make the entire system work better, which needs to meet the emission standards and energy saving aim.

三、净化系统设计工艺及装置组成

  1. Design Process of Purification System  and Device Components

3.2 本方案制定的原则

3.2 Principles of This Plan

1、依据国家和当地有关环保法律、法规及产业政策要求对工业污染进行治理,充分发挥建设项目的社会效益、环境效益和经济效益。

  1. Industrial pollution must be treated In accordance with the requirements of national and local environmental protection laws, regulations and industrial policies. The social, environmental and economic benefits of the construction project shall be brought into full play.

2、积极稳妥地采用新技术、新设备,结合企业的现状和管理水平采用先进、可靠的改造技术和污染治理工艺,力求运行稳定、费用低、管理方便、维护容易,从而达到治理污染、保护环境的目的。

  1. Actively and steadily adopt new technologies and equipment with advanced and reliable  reconstruction technologies and pollution control process based on the current status and management level of the enterprise. Strive to achieve stable operation, low cost, convenient management and easy maintenance, so as to realize pollution control and environment protection.

3、妥善解决项目建设及运行过程中产生的污染物,避免二次污染。

  1. Properly solve the pollutants generated during the construction and operation of the project to avoid secondary pollution.

4、严格执行现行的防火、安全、卫生、环境保护等国家和地方颁布的规范、法规与标准。

  1. Strictly implement the current national and local regulations and standards for fire prevention, safety, health and environmental protection.

5、选择新型、高效、低噪设备、注意节能降耗。

  1. Choose new type, high-efficiency, low-noise equipment, and pay attention to energy saving.

3.3 本方案治理的基本目标

3.3 The Basic Goals of  This Program

清洗房废水:

Waste water from Cleaning booth:

根据国家相关规定应首先考虑按上海市废气排放的有关标准进行治理效果的综合监测验收,目标是喷漆室负压、密闭,收集效率 95%以上;达到VOCs排放浓度在70mg/m3以下,净化效率>95%的标准要求。

According to the relevant national regulations, the comprehensive monitoring and acceptance of the treatment effect should be considered in accordance with the relevant standards of Shanghai waste gas emission. The goal is to have a negative pressure and airtightness paint booth, with a collection efficiency of more than 95%, to achieve the VOCs emission concentration below 70mg/m3, and the purification efficiency above 95% of the standard requirements.

3.4 工艺选择路线

3.4 Process Selection

根据业主未来的生产规划及特点,其废气适宜于采用浓缩+燃烧系统进行处理,而对于业主的间歇式生产特点,燃烧系统适宜选用催化燃烧方式(CO),但浓缩段工艺有沸石及活性碳浓缩两种,对于选用何种方式现做出如下对比:

According to the owner’s future production plan and characteristics, the exhaust gas is suitable for treatment with a concentration and combustion system. For the owner’s intermittent production characteristics, the combustion system is suitable for Catalytic Oxidizer (CO), however the concentration selections includes zeolite and activated carbon. the following comparison are made for decision.

对比项

Items for Comparison

沸石浓缩工艺

Zeolite concentration process

活性碳浓缩工艺

Activated carbon concentration process

备注

Remarks

安全性

Safety

沸石本身为不可燃,正常运行情况下不会出现燃烧情况。

Zeolite is non-flammable and will not burn under normal operating conditions.

活性碳本身为可燃物,并且活性碳在吸附有机物质时还会产生吸附热,如果碳层或者气流不均匀,将会造成局部温度急剧升高点燃活性碳从而造成连锁燃烧;另外脱附过程中如果升温过快也会造成燃烧。

The activated carbon is combustible, and the activated carbon will also generate adsorption heat in adsorbing organic substances. If the carbon layer or the air flow is not uniform, it will cause the partial temperature rising sharply to ignite the activated carbon and result in chain combustion. In addition, during the desorption process, If the temperature rises too fast, it will also get burning.

浓缩倍率

Concentration rate

25~30

25~30

5

5

由于活性碳如果脱附风量过小,容易造成散热不佳,影响系统安全性,所以浓缩倍率无法提升

If the desorption air volume of activated carbon is too small, it is easy to cause poor heat dissipation and infulence the safety of the system, so the concentration rate cannot be increased.

系统处理效率

System processing efficiency

吸附净化效率95%以上

The adsorption purification efficiency above 95%

吸附净化效率85%以上

Adsorption purification efficiency above 85%

系统运行稳定性

System operation stability

沸石浓缩+燃烧系统无需切换管道,可以通过PLC控制,并且根据各点位的温度监控,实时调节风量配比,达到最稳定、节能的运行状态

The zeolite concentration and combustion system does not need to switch pipelines, and can be controlled by PLC, and according to the temperature monitoring of each point, the air volume ratio can be adjusted in real time to achieve the most stable and energy-saving operation state

活性碳浓缩+燃烧系统使用多个活性碳吸附器并联,定时切换吸脱附管,需使用大量切换阀门,而且脱附时间长,需要系统长时间保持运行状态,否则容易出现脱附不完全造成吸附效果不达标。

The activated carbon concentration and combustion system uses multiple activated carbon adsorbers in parallel. Switching the adsorption and desorption pipes regularly, requires a large number of switching valves, and long desorption time. The system needs to be kept in operation for a long time, otherwise it is easy to cause incomplete desorption and result in the adsorption effect not up to standard.

占地面积

The Footprint

100m2

100m2

143m2

143m2

上下双层布局

Layout with up and down double layer

耗材更换频率

Replacement frequency of consumables

沸石材料使用寿命一般在5~7年

The service life of zeolite materials is generally 5 to 7 years

活性碳颗粒由于本身强度,在使用过程中不可避免的会出现摩擦破碎,造成损失,并且由于脱附过程中会存在死区,所以整体寿命一般不会超过1年。

Due to the strength of activated carbon particles, friction and breakage will inevitably occur during use and causing losses. Because there will be dead zones in the desorption process, the overall life span generally does not exceed 1 year.

预处理过滤器均为每季度更换一次

The pretreatment filter is replaced every quarter

系统维护

system maintenance

沸石装置更换简便,只需1~2人即可完成,每1~2年可以对沸石进行采样检测,确认沸石劣化情况,若有需要,可以进行再生作业,保证使用寿命。

The zeolite device is easy to be  replaced and can be completed by just 1 or 2 person. The zeolite must be sampled and tested every 1 or 2 years to confirm the deterioration of the zeolite. If necessary, regeneration can be carried out to ensure the service life.

如果出现局部沸石材料损坏可以快速修复,不会影响生产。

If partial zeolite material damage occurs, it can be repaired quickly without stopping production.

活性碳更换工作量大,每次需要更换13吨左右活性碳,需要吊车及机械搬运工具辅助,并且容易造成周边环境二次污染;更换下来的饱和活性碳为环保重点管理的危险废弃物,需要委托专业单位进行处置,而现在危废处置单位的处置量有限,可能会出现需要排队无法及时处置的现象,这种情况下未能及时处置的饱和活性碳需要存放在专用的危废存放区。

Activated carbon replacement is a heavy workload, about 13 tons of activated carbon needs to be replaced each time, which requires the assistance of cranes and mechanical handling tools, and is likely to cause secondary pollution to the surrounding environment. the replaced saturated activated carbon is a hazardous waste regulated by environmental protection administration. Professional organizations are entrusted for disposal, and now the disposal capacity of the organization is limited, and there may be a phenomenon that needs to be queued and the waste cannot be disposed in time. In this situation, undisposed saturated activated carbon must be stored in a dedicated hazardous waste storage area.

燃烧装置运行维护部分基本相同

The operation and maintenance of the combustion device is basically the same

根据以上比较,从安全可靠、运行稳定、节能、易于维保、占地面积小及无二次污染等方面综合考虑,沸石浓缩装置更适合业主的实际需求,所以我方推荐的处理工艺流程为沸石浓缩+催化燃烧工艺。

Based on the above comparison, considering the safety and reliability, stable operation, energy saving, easy maintenance, small footprint and no secondary pollution, the zeolite concentration device is more suitable for the actual needs of the owner, so the treatment process we recommend is Zeolite concentration and catalytic combustion process.

3.5 浓缩装置样式选择

3.5 Concentration Device Selection

对于本项目风量大、浓度低,需要选用一种吸附稳定、浓缩倍率高、性价比良好的吸附材料。

For this project with large air volume and low concentration, it is necessary to select an adsorption material with stable characteristic, high concentration rate and cost-effective.

现在常见的沸石浓缩装置使用的吸附材料主要有日系和欧美系产品,其中日系产品浓缩倍率高、使用范围广,案例多更为符合本项目的需求。

The adsorption materials used in common zeolite concentration devices are mainly made in Japan, Europe and US. Japanese products have a high concentration rate and a wide range of applications. Many cases are in line with the needs of this project.

另外日系沸石浓缩装置又可以分为转轮结构及传统结构两类,其吸附装置运行结构、使用的沸石种类均有比较不同的特性,对于本项目使用何种样式的浓缩装置更适合业主的实际需求,先做出一下比较:

In addition, the Japanese zeolite concentration device can be divided into two types: the wheel structure and the traditional structure. The operation structure of the adsorption device and the type of zeolite used have different characteristics. Which type of concentration device will be used in this project to meet the actual situation of the owner will be discussed in the following comparison:

3.5.1结构原理

3.5.1 Structural Principle

转轮型

Wheel type

转筒型

Drum type

沸石材料结构:圆盘或扇型式

Zeolite material structure: disc shape or fan shape

安装方式:圆盘中心安装转轴,固定于两侧支架轴承上

Installation method: install the shaft in the center of the disc, and fix it on the bearings of the brackets on both sides

旋转方式:沿水平轴旋转

Rotation method: Turning around the horizontal axis

转轮分区:分为吸附、脱附及冷却区

Wheel zoning: divided into adsorption zone, desorption zone and cooling zone

分区密封方式:密封条安装与分区隔板上,运行时刮擦转盘表面密封

Sealing method of zones: the sealing strip is installed on the baffle plate , and the surface of the disc is scratched by sealing during operation

工艺流程:1.废气经过吸附区后净化排放

Process flow: 1. Waste gas is purified and discharged after passing through the adsorption zone

2.脱附热风吹过脱附区后,吹出的浓缩气体进入燃烧装置

  1. After the desorption hot air blows through the desorption zone, the blown out concentrated gas enters into the combustion device.

3.取新风吹过冷却区,对完成脱附的沸石降温,冷却区出风进行进一步升温后作为脱附热风进入脱附区

  1. Blow fresh air through the cooling zone to cool down the desorpted zeolite. The air from the cooling zone will be further heated and then enter into the desorption zone as desorption hot air.

沸石材料结构:模块式(红圈)

Zeolite material structure: modular (red circle)

安装方式:模块安装与钢结构转筒内部固定槽中

Installation method: module installation and fixed on groove in the steel drum

旋转方式:沿垂直轴旋转

Rotation method: Rotating around the vertical axis

转轮分区:分为吸附及脱附区

Wheel zoning: divided into adsorption zone and desorption zone

分区密封方式:密封条安装于模块钢结构转同上,运行过程中刮擦分区隔板表面密封。

Sealing method of zoning: The sealing strip is installed on the modular steel drum, and the scratched zoning baffle plate surface is sealed in operation.

工艺流程:1.废气经过吸附区后净化排放

Process flow: 1. Waste gas is purified and discharged after passing through the adsorption zone

  1. 取新风加热作为脱附热风吹过脱附区后,吹出的浓缩气体进入燃烧装置
  2. Heating fresh air as desorption hot air and blow through the desorption zone. Then the blown out concentrated gas enters into the combustion device

3.5.2性能比较

3.5.2 Performance Comparison

对比项

Items for Comparison

转轮型

Wheel type

转筒型

Drum type

备注

Remarks

吸附材料沸石含量

Zeolite content of adsorbent

50%

50%

75~80%

75~80%

生产工艺不同

Different production processes

脱附温度

Desorption temperature

180~220℃由于模块中含有较多基材,基材吸收的热量不会起到脱附的作用,所以需要更多的热量;而且基材存热过多,脱附完成后必需冷却后才能进入吸附阶段

180~220℃ Because the module contains more substrates, the heat absorbed by the substrate will not play a role in desorption, so more heat is needed. for this reason, the substrate must be cooled after desorption for adsorption stage.

150~180℃由于沸石含量高所以整体热能利用率高,吸附材料存热少,所以可以使用较低脱附温度,并且脱附完成无需冷却可直接进入吸附阶段

150~180℃ Because of the high zeolite content, the overall heat energy utilization rate is high, and the adsorption material has less heat storage, so a lower desorption temperature can be used, and directly get into the adsorption stage without cooling after desorption.

浓缩倍率

Concentration rate

15~20倍

15-20 times

20~33倍

20~33 times

单台设备最大处理风量

Maximum processing air volume of a single device

100000m3/h

100000m3/h

200000m3/h

200000m3/h

由于传统转盘结构强度限制,无法做的过大

Due to the structural strength limit of the traditional disc type, it cannot be made too large

单台最大占地面积

Maximum footprint of a single unit

12m2

12m2

12m2

12m2

占地面积相同但处理风量相差1倍

The footprint is the same but the air volume is 1 times different

吸附材料更换方式

Absorption material replacement method

更换以整个或半个转轮为单位进行,需要起重机械配合,并且更换时间较长,若无备用系统需要长时间停产配合

The replacement is carried out in the whole or half of the wheel, which requires the cooperation of hoisting machinery, and the replacement time is long. If there is no backup system, it will take a long time to stop production.

以模块化吸附单元块为单元进行更换,无需特殊设备配合,1~2人使用简单工具即可更换,而且更换速度快,可在生产换班或短时间内完成

In the condition that the modular adsorption unit block is used for replacement, no special equipment is needed, and it can be replaced by 1 or 2 persons with simple tools, and the replacement speed is fast, which can be completed during a production shift or within a short rest.

运行稳定性

Operational stability

由于密封条运行过程中密封条与沸石表面产生接触摩擦,可能会造成永久损伤,同时在转轮表面产生VOC累积,可能会产生一定的安全问题

Due to the contact friction between the sealing strip and the surface of the zeolite during the operation, permanent damage may be caused. At the same time, the accumulation of VOC on the surface of the wheel may cause certain safety problems.

运行过程中密封条与沸石表面不发生接触,避免了可能会造成的沸石损伤

During operation, the sealing strip does not contact with the surface of the zeolite, which avoids possible damage to the zeolite

3.5.3性价比

3.5.3 Cost-effective

对比项

Items for Comparison

转轮型

Wheel type

转筒型

Drum type

备注

Remarks

吸附材料使用量

Adsorption material usage

100%

100%

70%

70%

同等工况下,转筒浓缩沸石投资成本大于传统转盘5%

Under the same working conditions, the investment of rotary drum concentrated zeolite is 5% higher than that of the traditional rotary wheel type

吸附材料价格

Adsorbent price

100%

100%

150%

150%

吸附材料使用寿命

Service life of adsorption material

N年

N years

1.5~2N年

1.5~2N years

使用寿命是传统吸附材料1~2倍,平均每年吸附耗材费用为传统的50%

The service life is 1~2 times of traditional adsorption materials, and the average annual cost of adsorption consumables is 50% of traditional adsorption materials.

单台设备最大处理风量

Maximum processing air volume of a single device

100000m3/h

100000m3/h

200000m3/h

200000m3/h

对于100000m2/h以上处理量的工程,转筒浓缩可以做到单台处置,无需设置两台,节约投资成本。

For the project with a processing capacity of more than 100,000 m2/h, it can be handled by a single rotary drum concentration unit without backup, which saves investment costs.

浓缩倍率

Concentration rate

15~20倍

15-20 times

20~33倍

20~33 times

转筒浓缩倍率高,可以保证后续燃烧装置投资为传统转盘浓缩的60%

The rotary drum has a high concentration ratio, which can ensure that the subsequent combustion device investment is 60% that of the traditional rotary wheel concentration uint.

3.5.4结论

3.5.4 Conclusion

根据以上多方面比较得出,转筒型在浓缩倍率、投资成本、运行节能以及后期维护等方面均有比较明显的优势,也更为符合本项目浓缩倍率高、节能稳定及维保简便等需求,所以此次项目的最终工艺选择为沸石转筒浓缩+催化燃烧工艺。

According to the comparison of the above aspects, the drum type has obvious advantages in concentration ratio, investment cost, operation energy saving, and later maintenance. It is more in line with the needs of this project for high concentration ratio, stable energy saving and easy maintenance. Therefore, the final process of this project is selected as the zeolite drum concentration and catalytic combustion process.

3.6 有机废气沸石转筒吸附—催化燃烧系统简介

3.6 Introduction to The Organic Waste Gas Zeolite Drum Adsorption Catalytic Combustion System

根据业主有机废气的相关参数及相关的处理要求,我们采用转轮浓缩+催化燃烧的方式进行处理。

According to the relevant parameters of the owner’s organic waste gas and treatment requirements, we adopt the method of rotary wheel enrichment and catalytic combustion for treatment.

简易流程如下:

The brief process is as follows:

有机废气经管道收集进入前置过滤器过滤和冷凝降温等设备进行预处理以后,进入沸石转筒装置吸附处理区进行净化处理,进入浓缩转筒的有机废气(上图,下同)在常温下被转筒吸附区吸附净化后直接排放至大气(最高净化效率可达95%)(),接着因转筒的转动而进入脱附区,吸附了有机物质的转筒在脱附区内被150-180℃小风量脱附(高倍浓缩)、高浓度小风量废气()进入催化燃烧处理系统。

The organic waste gas is collected through the pipeline and enters into the pre-filter and condensation cooling equipment for pretreatment, and then enters into the adsorption treatment zone of the zeolite drum device for purification treatment. The organic waste gas entering the concentration drum (as the above picture and the same as below) to be adsorpted and purified in the drum adsorption zone, then directly discharged to the atmosphere (the highest purification efficiency can reach 95%),  then enters the desorption zone due to the rotation of the drum. the adsorpting drum will be desorpted by180°C small air volume (high concentration), high concentration and small air volume exhaust gas () enter the catalytic combustion treatment system.

废气只要被加热到280-350℃,进入催化床就能被催化分解成水和二氧化碳后放热成为高温清洁气体(),温度交换后排入大气。

As long as the exhaust gas is heated to 280-350℃, it can be catalytically decomposed into water and carbon dioxide when it enters the catalyst bed, it releases heat to become a high-temperature clean gas and is discharged into the atmosphere after temperature exchange.

其中催化燃烧是典型的气-固相催化反应,其实质是活性氧参与的深度氧化作用。

The catalytic combustion is a typical gas-solid phase catalytic reaction, and the essence is the deep oxidation with active oxygen.

在催化燃烧过程中,催化剂的作用是降低活化能,同时催化剂表面具有吸附作用,使反应物分子富集于表面提高了反应速率,加快了反应的进行。

In the process of catalytic combustion, the role of the catalyst is to reduce the activation energy, at the same time, the surface of the catalyst has an adsorption effect, so that the reactant molecules are concentrated on the surface to increase the reaction rate and accelerate the reaction.

借助催化剂可使有机废气在较低的起燃温度条件下,发生无焰燃烧,并氧化分解为CO2和H2O,同时放出大量热能,其反应过程为:

With the help of a catalyst, the organic waste gas can undergo flameless combustion at a lower ignition temperature, and be oxidized and decomposed into CO2 and H2O, meanwhile a large amount of heat energy is released. The reaction process is as follow:

四、主要设备说明

  1. Description of Main Equipment

4.1设备房房体

4.1 Equipment Booth Booth Body

1.喷漆房外形尺寸:L14000×W9000×H8000mm;

  1. Overall dimensions of paint booth: L14000×W9000×H8000mm;

L14000×W6000×H8000mm;

L14000×W6000×H8000mm;

喷漆房数量:2间;

Number of paint booths: 2 booths;

喷房漆雾收集方式:顶部进风,侧面排风;

Collection method of paint mist in the paint booth:  inlet air from the top, and exhaust air from side wall.

喷漆房墙体:方钢管龙骨+75mm彩钢岩棉板,内衬1.5mm厚不锈钢;

Paint booth wall: square steel pipe keel and 75mm color steel rock wool board, lined with 1.5mm thick stainless steel;

喷漆房前后两端各设置一套卷帘门,工件进出大门呈通过式,大门规格为:W7000×H7500mm/ W4000×H7500mm,每扇门上各设三个观察窗,材质双层PVC布加保温层,电机防爆,柔性堆积门,并在每座喷漆房中部设置伸缩隔断,材质阻燃PVC布,电机防爆;

There are a set of rolling shutter doors at the front and back ends of the paint booth. The workpiece pass-through the doors. The size of the doors are: W7000×H7500mm/ W4000×H7500mm. Each door is equipped with three observation windows. The motor is explosion-proof, flexible stacking doors, and a telescopic partition is set in the middle of each paint booth, the material is flame-retardant PVC cloth, and the motor is explosion-proof;

喷漆室北侧前后两端设置紧急逃生门: W1000×H2000mm,外开;

Emergency escape doors are set at the front and rear ends of the north side of the paint booth: W1000×H2000mm with doors opened to the outside.

喷漆室两侧前后两端各设置一辆轨道式升降车,电机防爆,行走7米,高度7米,伸缩3米;

A rail-mounted lift truck is installed at the front and rear ends of the paint booth with 7 meters walking route, 7 meters lifting height, and 3 meters telescopic. and the motor is explosion-proof ;

排风管道为1.2mm厚镀锌钢板,保温回风管道为1.2mm厚镀锌钢板外衬50mm厚保温棉及0.5mm厚镀锌钢板衬板

The exhaust duct is 1.2mm thick galvanized steel sheet, and the heat preservation aire return duct is 1.2mm thick galvanized steel sheet, which is lined with 50mm thick insulation cotton and 0.5mm thick galvanized steel liner sheet.

给气风机:低噪音风扇,变频控制;

Air supply fan: low noise fan with frequency conversion control.

加热除湿系统,采用电加热新风除湿系统,保证喷漆室内温度可在 40-60℃范围内稳定控制,相对湿度需稳定控制在RH75 %以下;

Heating dehumidification system, with the electric heating fresh air dehumidification system to ensure that the temperature in the painting room can be stably controlled within the range of 40-60℃, and the relative humidity must be stably controlled below RH75%;

照明系统采用具有隔爆性能灯箱,  灯箱安装在墙体上,密封效果好,满足防尘及防爆要求。

The illumination system adopts a explosion-proof light box, which is installed on the wall with good sealing and meets the requirements of dust-proof and explosion-proof.

室内光照度达 600Lux 以上,房内光线柔和,光照均匀明亮,无照射死角;

The indoor illuminance is above 600Lux, the light in the booth is soft, uniform and bright without blind spot.

控制系统采用手动控制 、自动控制两种模式,显示:风机、马达运转状态、电机运转状态(Hz)、 风机压差值(ON/OFF)、设备运转状态与进出口压差值、各点温度、电磁阀状况(开/ 关)、报警信息等,另外控制系统还有一系列监控感应器并采取一系列措施保证生产安全:a. 室内安装可燃气体报警器(大门侧1米处),室内可燃气体浓度超过过爆炸下限(LEL)的25%时,喷室强制排风,并持续声光报警,室内可燃气体浓度达到爆炸下限50%时,系统互锁自动关闭喷漆作业;b.安装风速测速仪,测定风速,当风速低于设定值声光报警。

The control system adopts two modes as manual control and automatic control with displaying fan and motor running status, motor running status (Hz), fan pressure difference (ON/OFF), equipment running status, inlet and outlet pressure difference, temperatures at each point, solenoid valve status (open/close), alarm information and etc. In addition, the control system also has a series of monitoring sensors and measures to ensure production safety.a. Install a indoor combustible gas alarm (1 meter from the gate side). When the indoor combustible gas concentration exceeds 25% of the lower explosion limit (LEL), the paint booth will be forced to exhaust, and the sound-light alarm will occurs continuously. When the indoor combustible gas concentration reaches 50% of the explosion lower limit. the system interlocks is triggered and automatically shuts down the painting operation. b. Install an anemometer to measure the wind speed, when the wind speed is lower than the set value, sound and light alarm  occurs.

由于开口要求风速较低(不低于0.5m/s),容易受环境干扰,影响测定精度,因此可通过测量排风总风量推算截面风速方法;c.喷涂机与排风机设计连锁,当排风机未开启或排风管道内风速不达标时喷涂机无法开启。

Since the air outlet requires a low wind speed (no less than 0.5m/s), it is easily affected by environmental interference and disturb the measurement accuracy. Therefore, the cross-sectional wind speed can be calculated by measuring the total exhaust air volume; c. The painter and the exhaust fan are designed to be interlocked, therefore the painter cannot be initiated if the fan is not turned on or the wind speed in the exhaust duct is not up to the standard.

同时压缩空气管道安装流量计及密闭阀,实时检测压缩空气用量,当废气排风风量不满足要求是自动断开压缩空气供给;d.室内设计安装2套温控探头,用于检测室内温度,当室内温度超过设定值,持续声光报警并喷漆设备停止工作。

At the same time, the compressed air pipeline is equipped with a flow meter and a closed valve to detect the amount of compressed air in real time. When the exhaust air volume does not meet the requirements, the compressed air supply is automatically cut off; d.  2 sets of temperature control probes is installed indoor to detect the indoor temperature. When the indoor temperature exceeds the set value, the sound and light alarm will occured continusouly and the painting equipment will stop working.

需手动复位重新工作。

the system can be reset manually to work again.

系统实时记录两套温控探头温度;e. 在房体安全门上安装有压力保护装置,当房内空气压力大于 1300Pa 压力值时,安全门将自动打开泄压,以保证操作人员安全。

The system records the temperature of two sets of temperature control probes in real time; e. A pressure protection device is installed on the safety door of the booth. When the air pressure in the booth is more than 1300Pa, the safety door will automatically open and release the pressure to ensure the safety of the operator.

同时所有电气设备均采用带过载保护、短路保护及断相保护的线路设计,一旦发生设备故障报警,整个喷漆系统  停止工作。

At the same time, all electrical equipment adopts circuit design with overload protection, short circuit protection and phase failure protection. Once equipment failure alarm occurs, the entire painting system stops working.

2.清洗房外形尺寸:L8000×W9000×H8000mm

  1. Dimensions of cleaning booth: L8000×W9000×H8000mm

清洗房数量:1间

Number of cleaning booth: 1 booth

清洗房墙体:方钢管龙骨+75mm彩钢岩棉板,内衬1.5mm厚不锈钢;

Cleaning booth wall: square steel pipe keel + 75mm color steel rock wool board, lined with 1.5mm thick stainless steel;

喷漆室前后两端各设置一套卷帘门,工件进出大门呈通过式,大门规格为: W7000×H7500mm,材质双层PVC布加保温层,电机防爆,柔性堆积门,每扇门上各设至少三个观察窗;

There are 2 sets of rolling shutter doors each at the front and back ends of the paint booth. The workpiece pass-through the doors. The size of the door is: W7000×H7500mm, double-layer PVC cloth with insulation layer, explosion-proof motor, and flexible stacking doors. Each door has at least three Observation windows

清洗房北侧前后两端设置紧急逃生门: W1000×H2000mm,外开;

Emergency escape doors are set at the front and rear ends of the north side of the Cleaning booth: W1000×H2000mm, with opening to the outside;

清洗房两侧各设置一辆轨道式升降车,电机防爆,行走7米,高度7米,伸缩3米;

There is a rail-mounted lift truck on each side of the cleaning booth, the motor is explosion-proof, with 7 meters walking route, 7 meters lifting height, and 3 meters telescopic;

照明系统采用具有隔爆性能灯箱,  灯箱安装在墙体上,密封效果好,满足防尘及防爆要求。

The illumination system adopts a explosion-proof light box, which is installed on the wall with good sealing and meets the requirements of dust-proof and explosion-proof.

室内光照度达 600Lux 以上,房内光线柔和,光照均匀明亮,无照射死角;

The indoor illuminance is above 600Lux, the light in the booth is soft, uniform and bright without blind spot.

污水处理方案:净化后循环使用。

Sewage treatment plan: recycling after purification.

3.工程实例及常用材料合格证书

  1. Engineering examples and certificates of common materials

4.2 电解污水处理装置

4.2 Electrolysis Sewage Treatment Device

清洗房产生废水中主要含有灰尘、清洗剂及液压油等污染物,根据业主实际需求及前期沟通,本次通过实验确认之前提出的废水循环使用的可行性并确定设备规格。

The waste water produced in the Cleaning booth mainly contains pollutants such as dust, cleaning agent and hydraulic oil. According to the actual needs of the owner and the preliminary communication, this experiment confirm the feasibility of the previously proposed waste water recycling and determine the equipment specifications.

4.2.1实验

4.2.1 Experiment

1.废水状态:本次实验采用业主提供的废水样品,废水呈淡黄色、略浑浊(见图片1)

  1. Waste water status: in this experiment will uses the waste water sample provided by the owner, and the waste water is light yellow and slightly turbid (see picture 1)

2.实验一:使用小型电解实验装置对废水进行电解处理并观察废水变化及测试电导率(单位μs/cm),实验开始30分钟后,废水上部出现明显浮渣,水体开始变白变清,电导率略有上升为22.7(见图片2);1小时后浮渣继续增加,电导率为42(见图片3);2小时后电导率上升至96.9(见图片4)。

  1. Experiment 1: Use a small electrolysis experimental device to electrolyze the waste water and observe the changes in the waste water and test the conductivity (unit: μs/cm). 30 minutes after the start of the experiment, obvious scum appears in the upper layer of the wastewater, and the water body begins to become white and clear. the conductivity slight increase to 22.7 (see picture 2);  1 hour later, the scum continued to increase, and the conductivity was 42 (see picture 3); 2 hours later, the conductivity rose to 96.9 (see picture 4).

3.实验二:将电解后的废水与原始废水混合,模拟循环混合状态,混合后水体电导率为37.8(见图片5);净化1小时候电导率上升为121.6(见图片6),净化后的水体基本无色透明(见图片7),将中部水体取出静置后,会有部分絮体沉降产生(见图片8),水体电导率下降为72.5(见图片9)。

  1. Experiment 2: Mix the electrolyzed wastewater with the original wastewater to simulate the cyclic mixing state. After mixing, the conductivity of the water is 37.8 (see picture 5); the conductivity rises to 121.6 (see picture 6) after purification for 1 hour. The water body is basically colorless and transparent (see picture 7). sampling the central layer water and stay still, some flocs will settle (see picture 8), and the conductivity of the water body drops to 72.5 (see picture 9).

图片1 实验水样照片     图片2 实验一     图片3 实验一

Picture 1 Experimental water sample picture Picture 2 Experiment 1 Picture 3 Experiment 1

图片4 实验一    图片5 实验二    图片6 实验二    图片7 净化后水样

Picture 4 Experiment 1 Picture 5 Experiment 2 Picture 6 Experiment 2 Picture 7 Purified water sample

图片8 水体底部沉降絮体            图片9 静置后水体电导率

Picture 8 Settling flocs at the bottom of the water body Picture 9 Conductivity of the water body after staying still

4.结论:本次实验中废水经过电解净化后,水体变为洁净,大部分废渣可以上浮,较易去除,而根据业主要求处理后水体电导率不能大于500,而此次实验中最高电导率为121.6,并且静置一段时间后电导率下降至72.5。

  1. Conclusion: After the wastewater is purified by electrolysis in this experiment, the water body becomes clean, and most of the waste residue can float up and is easier to be removed. According to the owner’s request, the conductivity of the water body after treatment  cannot be greater than 500, and the highest conductivity in this experiment It is 121.6, and the conductivity drops to 72.5 after staying still for a period of time.

此现象表明实验中的较高电导率的出现,主要是由于水体中杂质转化为絮体后,仍有部分较轻的絮体悬浮在水体中;另外由于小型电解装置并不是实时循环,杂质去除后仍不停有铝离子电解进入水体,离子浓度变高造成电解率偏高。

This phenomenon shows that the higher conductivity in the experiment is mainly due to the fact that after the impurities in the water body are converted into flocs, there are still some lighter flocs suspended in the water body. In addition, because the small electrolytic device does not circulate in real time, aluminum ions are still electrolyzed into the water body after the impurities are removed , and higher ion concentration resulting in a higher electrolysis rate.

所以通过静置后电导率便会下降,实际设备中的循环水箱即可达到此效果,并且实际设备会不断有循环水进入,只需要按照废水的实际情况设置运行时间便可以保证没有过多离子进入水体,所以完全可以满足业主对于循环水电导率的要求。

Therefore, the conductivity will drop after staying still, and the circulating water tank in the actual equipment can achieve this effect with continuously entering circulating water. We only need to set the operating time according to the actual situation of the wastewater to ensure that there are no excessive ions enter into the water body, so it can fully meet the requirements of the circulating water conductivity.

4.2.2设计方案

4.2.2 Design Plan

采用废水循环利用方式时,前期清洗使用循环水,最后使用清水进行最后冲洗,冲洗后的废水作为补充水进入循环系统,设计循环系统处理量:5m3/d,由于现场并无现成循环水池,因此我司设计在该集水池边再行制作一个3米×4米×1.5米的循环池,池中分为废水收集区及沉降排放池;随后在该循环池边上安装1台电解废水净化装置进行处理,处理后的循环水流入沉降排放池用于下次清洗,并且设置1套压滤装置用于去除沉降滤渣,系统处理流程如下:

When the wastewater recycling method is adopted, circulating water is used for pre-cleaning, and clean water is used for final flushing. The rinsed wastewater enters the circulation system as supplementary water. The designed treatment capacity of the circulation system is 5m3/d. Because there is no existing circulating pond on site, so our company designed another 3m×4m×1.5m circulating pond beside the collecting pond. The pond is divided into a waste water collection area and a sedimentation discharge area; then an electrolytic waste water purification device is installed beside the circulating pond for treatment, the treated circulating water flows into the sedimentation discharge pond for the next cleaning, and a filter press device is set to remove the sedimentation filter residue. The system processing flow is as follows:

4.2.3预期效果

4.2.3 Expected Effect

1.通过上述改造后,将保持循环水不发臭。

  1. After the above transformation, the circulating water will not be odorous.

2.通过上述改造后,循环水可持续循环使用,无需排放。

  1. After the above transformation, the circulating water can be used recyclly without discharge.

3.废水处理机能够完全替代投加絮凝剂,并且产生的废渣量较小、自动化程度高,废渣容易清理。

  1. The highly-automated waste water treatment machine can completely replace the role of flocculant, the amount of waste residue produced is small and easily to be cleaned.

4.3 废气预处理系统

4.3 Exhaust Gas Pretreatment System

4.3.1三级过滤器

4.3.1 Three-stage Filter

油漆废气含有较多的颗粒物,废气中的颗粒物会在沸石材料表面不断的堆积、聚集,不断增加的颗粒物会影响转筒浓缩装置的净化效果,为了保护沸石转筒的吸附净化性能,有机废气进入浓缩装置之前必须经过过滤器,考虑到系统的压力损失以及浓缩转筒对颗粒物浓度的要求,在沸石转轮前端设有三级袋式过滤器,过滤等级分别为G4、F7、F9,不同等级过滤器为模块化设计,组装方便。

Paint waste gas contains a lot particulates, which will continue to accumulate on the surface of the zeolite material. The increasing particulates will affect the purification effect of the drum concentration device. In order to sustain the adsorption and purification performance of the zeolite drum. Organic waste gas must pass through a filter before entering into the concentration device . Considering the pressure loss of the system and the requirement of the concentration drum for the concentration of particulates, a three-stage bag filter is installed at the front of the zeolite wheel. The filtration grades are G4, F7, F9. The filter adopts a modular design with different grades and easily to be assembled.

在过滤器前后设置压差计根据压差的变化来确定更换周期,保证废气处理系统正常、安全、稳定运行。

Differential pressure gauges are installed at the front and rear of the filter to determine the replacement cycle according to the change of the pressure difference to ensure the normal, safe and stable operation of the exhaust gas treatment system.

4.4 浓缩系统

4.4 Concentration System

废气风量

Exhaust air volume

150000m3/h

150000m3/h

废气进气浓度

Inlet Exhaust Gas Concentration

50mg/m3(最高)

50mg/m3 (maximum)

浓缩倍率

Concentration rate

30

30

净化效率

Purification efficiency

95%

95%

废气进气温度

Inlet Exhaust gas temperature

常温(<30℃)

Normal temperature (<30℃)

脱附所需风量

Air volume required for desorption

5000m3/h

5000m3/h

脱附所需温度

Temperature required for desorption

180±5℃

180±5℃

浓缩废气浓度

Concentration of concentrated waste gas

1.27±0.25g/m3(最高)

1.27±0.25g/m3 (maximum)

型号

model

HRH-1524,一共72块800H模块

HRH-1524, 72 pieces of 800H modules in total

本方案转筒参数一览表

Drum Parameters List for This Scheme

众所周知沸石材料是整个浓缩装置的核心, 本设备采用世界最先进沸石转筒技术和最高效的沸石模块,作为装置核心的沸石模块是由多层沸石纸叠放成蜂窝状的成型模块。

As we known that zeolite material is the core of the entire concentration device. This equipment adopts the world’s most advanced zeolite drum technology and the most efficient zeolite module. As the core of the device, the zeolite module is a honeycomb shaped module made of multiple layers of zeolite paper.

这种沸石纸是使用业界最先进的湿式抄纸法工艺,把粉末状的沸石和骨骼纤维及粘合剂(有机,无机)制成瓦楞状纸张(见下图)。

This zeolite paper uses the industry’s most advanced wet papermaking process to mix powdered zeolite, bone fibers and binders (organic, inorganic) into corrugated paper (see the picture below).

这样就连骨骼纤维的间隙中都含有沸石,所以纸中含有的沸石总量将会增加,而且还具有很难让沸石脱落的特性。

In this way, zeolite is contained even in the gaps between the bone fibers, so the total amount of zeolite contained in the paper will increase, and zeolite is hard to fall off.

沸石含量的比率越高,不仅沸石模块具有更强的吸附脱附有机溶剂,水分等的能力,而且相对于骨骼纤维来说热容量低的沸石的比率越高,模块在吸附浓缩系统中的加热脱附能耗效率会大步提升。

The higher ratio of zeolite content, the zeolite module has stronger ability to adsorb and desorb organic solvents, moisture, etc.Compared with bone fiber, the higher ratio of zeolite with low heat capacity, the heating energy efficiency and desorption of the module get higher in the adsorption concentration system.

沸石模块的沸石含有率在75~80wt%是世界最高的,所以比第二位(50wt%)的能耗效率提升30%以上。

The zeolite content rate of the zeolite module is the highest in the world with 75~80wt%, so it is more than 30% higher than the No. 2 energy efficiency (50wt%) .

实现高倍浓缩(见下图),单台可处理风量的最大化,充分实现节能运行。

Achieve high concentration (see figure below), maximize the air volume that can be handled by a single unit, and fully realize energy-saving operation.

4.5 催化燃烧器

4.5 Catalytic Combuster

催化装置参数表

Catalytic device parameter table

HR数量

HR quantity

1套

1 set

转筒转速

Rotating speed of drum

3rph

3rph

CO处理实际废气风量

Actual exhaust gas volume for CO treatment

5000Nm3/h(转筒脱附气)

5000Nm3/h (rotating drum desorption gas)

CO处理设计废气风量

Designed exhaust gas volume for CO treatment

5000Nm3/h

5000Nm3/h

CO废气VOC去除率

CO exhaust gas VOC removal rate

≥98%

≥98%

换热器换热效率

Heat exchanger efficiency

60%

60%

CO氧化室温度

CO oxidation chamber temperature

350 ℃

350 ℃

4.6 控制系统

4.6 Control System

本控制系统专为三级过滤+浓缩转筒+催化燃烧装置系统设计,根据工艺要求,采用现场手动控制 、自动控制两种模式。

This control system is specially designed for the three-stage filtration, concentration drum and catalytic combustion device system. According to the process requirements, it adopts two modes as on-site manual control and automatic control.

现场手动模式:触摸屏操作界面上的“手动/自动”开关选择“手动”方式时,可通过触摸屏操作界面上的按钮实现对单个设备的“运行”或“停止”操作,也可通过现场操作进行必要的手动控制,同时可满足系统主要设备检修及维护的需要。

On-site manual mode: Selects the “manual” mode by touching “manual/automatic” switch on the touch screen operation interface, the button on the touch screen operation interface can be used to realize the “run” or “stop” operation of a single device, or it can be operated on site by manual control to meet the needs of repairing and maintenance.

自动模式:触摸屏操作界面上的“手动/自动”开关选择“自动”方式时,系统设备的安全由触摸屏根据废气系统的实际工况及生产要求来完成对整套设备或单个设备的“运行”或“停止”控制,而不需要人工干预,从而最大限度的实现了系统的自动运行,减少人员配置,为废气处理系统的经济运行提供保证。

Automatic mode: When press the “Manual/Automatic” switch on the touch screen operation interface and select the “Automatic” mode, the safety of the system equipment is controlled by the touch screen according to the actual working conditions and production requirements of the exhaust system, and determines the “Run” or “Stop” of the system or single equipment without manual intervention, thereby maximizing the automatic operation of the system, reducing personnel allocation, and providing a guarantee for the economic operation of the exhaust gas treatment system.

4.7自动控制过程及说明

4.7 Automatic Control Process and Description

按自动运行按钮启动设备后,阀门位置检查确认。

After pressing the automatic operation button to start the equipment, the valve position is checked and confirmed.

废气进气阀开或关(根据预热温度控制)。

The exhaust gas inlet valve is opened or closed (controlled according to the preheating temperature).

新风补充阀开或关(根据催化温度控制)。

The fresh air supplement valve is opened or closed (controlled according to the catalytic temperature).

热交换旁路阀开或关(根据脱附温度及预热温度控制)。

The heat exchange bypass valve is opened or closed (controlled according to the desorption temperature and preheating temperature).

脱附温度调节阀开或关(根据脱附温度控制)。

The desorption temperature regulating valve is opened or closed (controlled according to the desorption temperature).

阀门延时1分钟检测,若检测异常则报警。

The valve is detected with a delay of 1 minute, and if the detection is abnormal, alarm occurs.

阀门检测正常,吸附风机启动,转筒马达启动,CO排风机及脱附风机启动,阀门切换。

The valve detection is normal, the adsorption fan start, the drum motor start, the CO exhaust fan and the desorption fan start, and the valve is switched.

CO排风机及脱附风机启动,压力检测延时60秒,若检测异常则报警;

The CO exhaust fan and the desorption fan are started, and the pressure detection is delayed for 60 seconds. If the detection is abnormal, the alarm occurs;

CO风机和脱附风机启动后,进行压力检测正常后,吹扫3分钟后燃烧器依次实施炉膛清扫、点火、升温、正常工作,根据催化燃烧预热温度设定值控制加热;

After the CO fan and the desorption fan are started with a normal pressure test result.  the combustor will perform furnace cleaning, ignition, heating, and normal operation after 3 minutes of air purging. The heating is controlled according to the set value of the catalytic combustion preheating temperature.

温度调节:*:>350℃燃烧器停止运行,

Temperature adjustment: *: >350℃ the combustor stops running,

*:<350℃时,燃烧机按温度大小调节运行。

*: <350℃, the combustor will operate adjustly according to the temperature.

燃烧机若启动异常则自锁停止并报警。

If the combustor starts abnormally, it will get self-locking, stopping and alarming.

阀门运行(当压力检测正常后运行,阀门最大100%和最小0%,开度可由PLC程序限位。)

Valve operation (when the pressure detection is normal, the valve will start to operate, the valve opening is between 100% maximum and 0% minimum, the opening can be limited by the PLC program.)

进气阀:

Inlet valve:

当预热温度≧设定值废气进气阀逐渐开大。

When the preheating temperature is greater than or equal to the set value, the exhaust gas inlet valve is gradually opened.

当预热温度<设定值废气进气阀逐渐关小。

When the preheating temperature is less than the set value, the exhaust gas inlet valve gradually closes.

新风补充阀:

Fresh air supplement valve:

当催化温度≧设定值时,新风补充阀逐渐开大;

When the catalytic temperature is greater than or equal to the set value, the fresh air supplement valve gradually opens;

新风补充阀逐渐关小;

The fresh air supply valve gradually closes;

脱附温度调节阀:

Desorption temperature regulating valve:

实际温度<脱附温度设定值:

Actual temperature < Desorption temperature setting value:

脱附温度调节阀开大,以提高热风温度;

Open the desorption temperature control valve to increase the hot air temperature;

实际温度>脱附温度设定值:

Actual temperature>Desorption temperature setting value:

脱附温度调节阀关小,以降低热风温度;

The desorption temperature control valve is closed to reduce the temperature of the hot air;

换热旁路阀:

Heat exchange bypass valve:

当脱附温度≤设定值且预热温度小于310℃,换热旁路阀根据脱附温度设定值控制,脱附温度<设定值换热旁路阀关小;

When the desorption temperature is less than the set value and the preheating temperature is less than 310℃, the heat exchange bypass valve is controlled according to the set value of the desorption temperature, and the bypass valve is closed when the desorption temperature is less than the set value;

当脱附温度≧设定值且预热温度>310℃,换热旁路阀根据预热温度设定值控制。

When the desorption temperature is greater than or equal to the set value and the preheating temperature is greater than 310℃, the heat exchange bypass valve is controlled according to the set value of the preheating temperature.

当脱附温度大于设定值且预热温度≤设定值时,换热旁路阀开大;

When the desorption temperature is greater than the set value and the preheating temperature less than or equal to the set value, the heat exchange bypass valve opens;

当脱附温度大于设定值且预热温度≧设定值时,换热旁路阀关小;

When the desorption temperature is greater than the set value and the preheating temperature is greater than or equal to the set value, the heat exchange bypass valve is closed;

转筒运行

Drum operation

转筒是连续运转的,每小时约3圈,在设备调试初期即确定转速,正常运行时不需更改转速。

The drum runs continuously, about 3 turns per hour. The speed is determined at the early stage of equipment configration, and there is no need to change the speed during normal operation.

发生异常

Abnormal occurs

若设备发生异常:则声光报警输出,操作人员应立即查看报警原因,做好应急准备。

If the equipment is abnormal: sound and light alarm occur, the operator should check the cause of the alarm immediately and prepare for the emergency.

停机

Shut-down

按自动停止按钮后,燃烧器根据停机延时设定值自动停止。

After pressing the automatic stop button, the combustor will automatically stop according to the stop delay setting value.

当炉膛温度>100℃时, CO排风机、脱附风机、吸附风机、转筒马达保持运行;

When the furnace temperature is more than 100℃, the CO exhaust fan, desorption fan, adsorption fan and drum motor keep running;

当炉膛温度≤100℃时,CO排风机及脱附风机停止工作,而吸附风机、转筒马达再根据吸附风机停机延时自动停止。

When the furnace temperature is less than or equal to 100℃, the CO exhaust fan and desorption fan stop working, and the adsorption fan and drum motor will automatically stop according to the stop delay of the adsorption fan.

4.8 电气及自控安全措施

4.8 Electrical and Automatic Control Safety Measures

本项目电控系统设计是以PLC自动控制为核心,包括人机界面操作中心、安全联锁、声光报警等,并配置适当的指示灯和控制按钮为辅助。

The design of the electronic control system of this project is based on PLC automatic control, including man-machine interface operation center, safety interlock, sound-light alarm and etc., and equiped with appropriate indicator lights and control buttons as auxiliary.

(1)根据工艺要求改变控制参数。

(1) Change the control parameters according to the process requirements.

(2)自动运行时具有连锁功能。

(2)  interlocking function is available during automatic operation.

(3)自动运行时可根据工艺条件退出运行

(3) The operation can be exited according to the process conditions during automatic operation

(4)系统具有自我诊断功能,运行时出现的异常情况可报警及自动停机。

(4) The system has a self-diagnosis function, which can alarm and stop automatically when abnormal conditions occur during operation.

(5)系统运行时采用PLC程序全自动控制,且具有记忆功能,当系统停运后再启动时可根据上次的运行状态自动选择运行模式。

(5) The system adopts PLC program for full-automatic control in running and has a memory function. When the system is stopped and restarted, the running mode can be automatically selected according to the last running state.

1、电源:主电源380V±5%、3相、50HZ,采用三相五线制供电。

  1. Power supply: the main power supply is 380V±5%, three-phase, 50HZ, adopts three-phase five-wire system.

2、控制柜的技术要求:

  1. Technical requirements of the control cabinet:

(1)为了保持柜内温度低于各元件允许的最高温度,要提供强制的通风;风扇电源为220V,50HZ,风扇要有防护手指免受伤害措施,噪声要满足标准要求,风扇要用可拆清洗式的滤网。

(1) In order to keep the temperature in the cabinet below the maximum allowable temperature of each component, ventilation must be provided; the fan power supply is 220V, 50HZ, the fan with removalable cleaning filter must have measures to protect fingers from injury, and the noise must meet the standard requirements,

(2)控制柜要留有20%安装空间,以备将来增加元件之用,控制柜内的结构和所有内部连线要符合有关标准的具体要求。

(2) 20% installation space of  the control cabinet should be reserved to prepare for adding components in the future. The structure and all internal wiring in the control cabinet should meet the specific requirements of relevant standards.

(3)电控柜面板和各操作站面板都必须设置急停按钮,操作工位按需要配置急停按钮。

(3) The panel of the electric control cabinet and the panel of each operation station must be equipped with an emergency stop button, and the operating stand shall be equipped with an emergency stop button as required.

3、PLC主要控制点位:

  1. PLC Main Control Points:

(1)进出风单元控制

(1) Control of air inlet and outlet units

系统吸附/脱附作业时,控制设备进/出风口阀门,及时反馈数字信号,同时控制吸附/脱附风机的启停。

During the adsorption/desorption operation of the system, the inlet/outlet valve of the equipment is controlled to feed back digital signals in time, and control the start and stop of the adsorption/desorption fan at the same time.

(2)燃烧单元控制

(2) Combustion unit control

燃烧炉自动升温控制以及内部温度、压力、高温阀连锁控制。

Automatic heating control of combustion furnace and interlocking control of internal temperature, pressure and high temperature valve.

(3)报警控制

(3) Alarm control

当系统内部温度、压力超出设定范围时,系统会进行相应的连锁反应包括声光报警、强制关闭系统、启动应急处理单元等。

When the internal temperature and pressure of the system exceed the set range, the system will carry out corresponding chain reactions including sound and light alarm, forced system shutdown, and activation of emergency processing units.

当喷漆室内有机溶剂浓度超过设定值时,立即报警,送排风系统继续工作,报警方式为声光报警。

When the concentration of the organic solvent in the painting room exceeds the set value, sound and light alarm occurs immediately, and the air supply and exhaust system will continue to work.

4、在失电情况下的保护措施:

  1. Protective Measures in Power Loss:

(1)电源切断或设备急停时,为避免设备损坏或人身伤害,不允许设备运动执行元件有任何运动。

(1) When the power supply is cut off or the equipment is stopped in an emergency, in order to avoid equipment damage or personal injury, no actuator movement of the equipment is allowed.

(2)电控系统及元件必须能够适应工厂电网上的电压偏差、波动±5%、闪变和各种谐波及脉冲干扰。

(2) The electronic control system and components must be able to adapt to the voltage deviation,  ±5% fluctuation, flicker, and various harmonics and pulse interference cause by the factory power supply.

(3)供电系统有缺相、欠压时,该系统电源开关必须随之自动断电;在线路中其它电压干扰,或失电后,被中断的程序必须能够重新启动运行。

(3) When there is phase loss or undervoltage of the power supply system, power switch of the system must be automatically cut off; after the voltage interference or power loss occurs, the interrupted program must be able to be reinitiated.

5、用电设备的保护:

  1. Protection of electrical equipment:

(1)每条回路单独采用漏电、短路、过流保护装置,每条回路单独采用过载保护装置,不允许自动再次接通电源。

(1) Each circuit adopts leakage, short circuit, and overcurrent protection devices separately, and each circuit adopts separate overload protection devices, and it is not allowed to be automatically reinitiated.

(2)限位开关和各种保护开关装置,在回路中使用继电器去执行动作。

(2) Limit switches and various protective switch devices adopt  relays to perform actions in the loop.

6、我公司PLC自动控制系统的优点:

  1. The advantages of our company’s PLC automatic control system:

(1)可靠性高,抗干扰能力强:PLC系统采用现代大规模集成电路技术,经严格的生产工艺制造,内部电路也采取了先进的抗干扰技术,具有很高的可靠性,此外,PLC带有硬件故障自我检测功能,出现故障时可及时发出警报信息。

(1) High reliability and strong anti-interference ability: The PLC system adopts modern large-scale integrated circuit technology and is manufactured by strict production technology. The internal circuit also adopts advanced anti-interference technology, which has high reliability. In addition, PLC is desiged With hardware failure self-detection function, an alarm message can be sent in time when a failure occurs.

(2)易学易懂,操作简便: PLC系统只使用少量开关量逻辑控制指令就可以方便地实现继电器电路的功能,触摸屏界面,操做简单。

(2) Easy to learn and easy to operate: The PLC system can easily realize the function of the relay circuit with only a few switching logic control instructions. The touch screen interface is simple to operate.

(3)协调控制,配合生产:PLC系统与生产线联动,控制各环节调节阀门,实现“信号反馈及时,反应操作迅速”的控制模式。

(3) Coordinated control and production: The PLC system is linked with the production line to operate each control valve, and realize the control mode of “timely signal feedback and rapid response”.

(4)预防报警,应急控制:当系统内部压力、温度超出设定范围,信号及时反馈中央CPU,同时声光报警、紧急停机制动,确保整个系统的安全。

(4) Preventive alarm and emergency control: When the internal pressure and temperature of the system exceed the set range, the signal will be fed back to the central CPU in time, meanwhile sound and light alarms occur, and emergency stop is triggered to ensure the safety of the entire system.

(5)调节模式,节能控制:PLC会根据整套系统的开启、运行、关闭状态自动调整自身的工作模式,最大限度降低设备的运行能耗。

(5) Regulation mode, energy-saving control: PLC will automatically adjust its own working mode according to the on-off and running status of the entire system to minimize the energy consumption of the equipment.

4.9 系统特点

4.9 System Features

有机废气转筒吸附催化燃烧脱附是将吸附与催化燃烧工艺进行有机的结合,兼顾了两者的优点,达到优势互补的效果,使其应用范围更广,治理废气更加灵活,运行成本更加低廉。

Organic waste gas rotating drum adsorption and catalytic combustion desorption is an combination of adsorption and catalytic combustion processes, combining the advantages of both method, achieving mutual support effect and popular using, more flexible in waste gas treatment, and lower operating costs .

装置特点如下:

The features of the device are as follows:

特有的沸石材料保证转筒装置的高吸、脱附效率,使原本大风量、低浓度的VOCs废气,转换成小风量、高浓度的废气,便于后段处理。

The unique zeolite material ensures the high absorption and desorption efficiency of the rotating drum device, so that the original large air volume and low concentration of VOCs waste gas can be converted into small air volume, high concentration waste gas, which is convenient for subsequent treatment.

2、沸石转筒吸附VOCs所产生的压降极低,可大大减少风机电力能耗。

  1. The pressure drop caused by the adsorption of VOCs by the zeolite drum is extremely low, which can greatly reduce the power consumption of the fan.

3、整体系统采用预组合模块化设计,具备了最小的空间需求,且提供了持续性及无人化的操控模式。

  1. The overall system adopts a pre-combined modular design, which has the smallest space requirement and provides a continuous and unmanned control mode.

4、高去除率的转筒装置设计保证经过转筒浓缩后的废气,可达到国家最严格的排放标准。

  1. The design of the drum device with high removal rate ensures that the exhaust gas through the drum can meet the strictest national emission standards.

5、模块化设计,使转筒设备的维护和材料的再生简单易行。

  1. Modular design makes the maintenance of the drum equipment and the regeneration of materials simple and easy.

6、催化燃烧与直接燃烧相比具有起燃温度低,能耗也小的显著特点。

  1. Compared with direct combustion, catalytic combustion has the remarkable characteristics of low light-off temperature and low energy consumption.

在废气浓度高的情况下,达到起燃温度后便无需外界供热。

In the case of high exhaust gas concentration, external heating is not required after reaching the light-off temperature.

7、处理效率高(>85%),最终产物为无害的CO2和H2O(杂原子有机化合物还有其他燃烧产物),因此无二次污染问题。

  1. High treatment efficiency (>85%), and the final products are harmless CO2 and H2O (heteroatomic organic compounds and other combustion products), so there is no problem of secondary pollution.

由于温度低,能大量减少NOX的生成。

Due to the low temperature, the production of NOX can be greatly reduced.

4.10 排气烟囱

4.10 Exhaust Chimney

排风烟囱底部(0-10m)采用12mm钢板制作,(10-20m)采用10mm钢板制作,(20-32m)采用8mm钢板制作,设置锥形风帽,钢材表面处理后外涂防锈底漆及面漆,底部3 米高度用耐高温岩棉做外保温,外包镀锌铁皮。

The bottom of the exhaust chimney (0-10m) is made of 12mm steel plate, (10-20m) made of 10mm steel plate, (20-32m) made of  8mm steel plate, and equipped with a conical hood, the surface of the steel is covered with anti-rust primer and top coat, the 3 meters bottom is coated with high temperature resistant rock wool for external insulation, which is covered with galvanized iron sheet.

烟囱固定方式:底部与烟囱基础螺栓连接与焊接相结合,外包镀锌铁皮,烟囱底部3米使用耐高温岩棉保温,烟囱周围设置旋转楼梯及框架并采用纤绳固定,15米高度处设置采样平台。

Chimney fixing method: the bottom of the chimney is fixed by a combination of foundation bolts and welding, and coated with galvanized iron. The 3 meters bottom of the chimney is insulated with high temperature resistant rock wool. A spiral staircase and frame are set around the chimney and fixed with fiber ropes. A sampling platform is set at a height of 15 meters. .

4.12 VOCs治理设施运行监控仪

4.12 VOCs treatment Facility Operation Monitor

上海市生态环境局颁发《关于开展本市重点行业挥发性有机物综合治理工作》通知中,企业有项任务是对标对表,完成VOCs综合治理“一厂一方案(2.0)”工作,各企业都应积极采取管控措施减少VOCs排放,从源头替换、过程控制到末端治理,甚至运行监控都将VOCs治理理念渗透到各环节,把VOCs减排工作做细做好。

In the notice issued by the Shanghai Municipal Bureau of Ecology and Environment on “the Comprehensive Treatment of Volatile Organic Compounds in Key Industries in Shanghai”, the company’s tasks meet the standards and complete the VOCs comprehensive treatment plan. All companies should actively take effective control measures to reduce VOCs emission .

在运行管理环节以下几点是要重点保证的:

The following points must be ensured in the operation management:

设定控制指标,并划定正常运行的范围限值;

Set the control index and fix the range limit in normal operation;

连续测量并记录治理设施控制指标温度、压力(压差)、时间和频率值;

Continuously measure and record the temperature, pressure (pressure difference), time and frequency values of the control indicators of the treatment facility;

总用电量瞬时值和累计值连续测量记录;

Continuously measure and record the instantaneous value and accumulated value of total power consumption;

发生故障时将故障报警信息及时报送并设置明显故障标识。

When a failure occurs, the failure alarm information must be reported in time and an obvious failure identification must be set.

根据环保相关要求,以及我方以往项目经验的经验,我方开发了VOCs治理设施运行监控仪,其将整个系统的各项运行参数集中收集整合,方便运行管理人员能够及时、有效、便捷的监控、掌握整个系统的运行情况,其主要监控参数见表1。

According to environmental protection requirements and previous experience, we have developed a VOCs treatment facility operation monitor, which collects and integrates various operating parameters of the entire system, so that operation managers can monitor in a timely, effective and convenient manner. Master the operation status of the entire system, the main monitoring parameters are shown in Table 1.

表1 VOCs治理设施运行监控仪监控内容

Table 1 Content of VOCs treatment facility operation monitor

设备及设施

Equipments and facilities

监控指标

Monitoring indicators

喷漆房

Paint Booth

室内温湿度

Indoor temperature and humidity

VOCs治理设备

VOCs Treatment Equipment

1.处理风量2.设施用电量

  1. Air volume handled 2. Electricity consumption of facilities

换热器

Heat Exchanger

进出口温度

Inlet and outlet temperature

浓缩装置

Concentrator

1.吸附周期2.脱附时间及温度

  1. Adsorption cycle 2. Desorption time and temperature

催化氧化器

Catalytic Oxidizer

催化床温度

Catalytic Bed Temperature

排风风机

Exhaust fan

电机频率

Motor frequency

排气筒

Exhaust pipe

出口浓度(对比用)

Outlet concentration (for comparison)

注:除上表中的各项参数外,也可根据业主要求及实际情况增加监控项目

Note: In addition to the parameters in the above table, monitoring items can also be added according to the owner’s requirements and actual conditions

所有监控内容的实时数据将直观的显示在监控仪主界面上(图1),各并且项数据除实时显示之外,还会以数据曲线方式显示(图2),其中将显示实时数据、运行曲线、正常运行上下限,并且每张运行曲线图还可进行放大,放大后的曲线图可以上下左右拖动查看,并且曲线可以以年、月、日不同时间单位进行显示。

The real-time data of all monitoring content will be displayed intuitively on the main interface of the monitor (Figure 1). In addition to real-time display, the data of each item will also be displayed in a data curve (Figure 2), which will display real-time data, running curve and upper and lower limits. and each operation curve can be enlarged. The enlarged curve can be dragged up and down for viewing, and the curve can also be displayed in different time units by year, month, and day.

所有数据每一天都会生成一个EXCEL文件,若需导出文件可直接拔出SD卡,插入电脑中即可。

All data will be collected and generate an EXCEL file every day, if need to export the file, you can directly pull out the SD card and insert it into the computer.

本设备有专用通信软件,能为有需求的用户配套物联网系统,提供多组设备联网、云端存储及手机APP显示等功能。

This device has specialized communication software, which can support the Internet of Things system for the necessary users, and provide functions such as of multiple sets group networking, cloud storage, and mobile APP display.


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