CN108547687A - 大功率分布式能源尾气净化DeNOx***及控制方法 - Google Patents
大功率分布式能源尾气净化DeNOx***及控制方法 Download PDFInfo
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Abstract
本发明公开了一种大功率分布式能源尾气净化DeNOx***,安装在分布式能源发动机的排气管上,包括DeNOx催化器、DeNOx控制器、计量混合器、尿素压力罐、尿素喷嘴、***传感器组件和监控组件;DeNOx催化器直接连接在分布式能源发动机的排气管上,尿素喷嘴安装在DeNOx催化器的进气管上,计量混合器同时与尿素喷嘴、尿素压力罐和DeNOx控制器连接;监控组件连接在DeNOx控制器连。上述大功率分布式能源尾气净化DeNOx******结构紧促,布局灵活,可以根据现有分布式能源机组的布局灵活调整***放置位置和空间;***采用模块化组合的方式,能够根据不同的机组配置不同的催化剂和喷射混合器。
Description
技术领域
本发明涉及汽车尾气处理技术领域,具体涉及大功率分布式能源尾气净化DeNOx***及控制方法。
背景技术
发动机的排气颗粒物主要包含三种成分:未燃的碳烟(Soot)、表面上吸附的有机可溶性物质(Soluble organic fractions,SOF)和硫酸盐,其中颗粒排放物质大部分是由碳和碳化物的微小颗粒组成的。
随着分布式能源技术的不断发展,越来越多的以垃圾填埋气、天然气等分布式能源被利用起来,为工业社会生产生活提供了大量的热电资源。然而随着这些大功率燃气机组的运用,其工作时产生的大量NOx(氮氧化物)污染物也越来越收到人们的关注。根据国家和地方环保部门制定的大气环境污染物排放指标,分布式能源尾气中所含有的NOx也需要进行净化处理。
1、分布式能源布局相对分散,集中形式处理尾气相对比较困难;
2、分布式能源由于所处环境和应用燃料的差异,不同的机组所产生的尾气NOx污染物浓度不一样,难以在发动机出厂时就配置统一的尾气净化***;
3、分布式能源发动机组多采用进口发动机产品,尾气净化***难以获取发动机工作状态信息;
4、大部分现有分布式能源机组已经投入运营,新增加尾气净化***不能影响到原有***的运行和布局;
5、个别分布式能源机组使用车用SCR***来做NOx净化,受制于车用SCR***自身水平的限制,往往需要多套车用SCR***才能满足要求;
6、传统的分布式能源机组尾气净化***是用PLC来控制***,需要特定的供配电和控制柜、电机和水泵等来完成***工作,***结构复杂且成本高昂。
发明内容
本发明要解决的技术问题是单位服现有技术的不足,提供了大功率分布式能源尾气净化DeNOx***,***结构紧促,布局灵活,可以根据现有分布式能源机组的布局灵活调整***放置位置和空间;***采用模块化组合的方式,能够根据不同的机组配置不同的催化剂和喷射混合器;
***采用嵌入式控制器作为***主控单元,使得控制***简单、布局方便、成本低,且通过高效的控制模型代码,可以实现尾气NOx污染物的自适应处理;取消尿素泵结构,直接应用加压尿素罐的形式取代尿素泵,使得***可以采用“1+N”(1个尿素罐和多个剂量喷射混合器)的形式进行配套,***构建灵活。
为达到上述目的,本发明采用的技术方案是:大功率分布式能源尾气净化DeNOx***,安装在分布式能源发动机的排气管上,包括DeNOx催化器、DeNOx控制器、计量混合器、尿素压力罐、尿素喷嘴、***传感器组件和监控组件;DeNOx催化器直接连接在分布式能源发动机的排气管上,尿素喷嘴安装在DeNOx催化器的进气管上,计量混合器同时与尿素喷嘴、尿素压力罐和DeNOx控制器连接;监控组件连接在DeNOx控制器连;
所述***传感器组件包括压差传感器、氮氧传感器和排气温度传感器,所述排气温度传感器包括前排温传感器和后排温传感器;所述氮氧传感器包括前NOx传感器和后NOx传感器;所述压差传感器安装在DeNOx催化器上,前排温传感器安装在分布式能源发动机的排气管上,后排温传感器安装在DeNOx催化器的排气管上;所述前NOx传感器安装在前排温传感器和尿素喷嘴之间的排气管上,后NOx传感器安装在后排温传感器的排气管上。
所述尿素压力罐内安装有尿素温度传感器和尿素液位传感器,尿素温度传感器和尿素液位传感器同时与DeNOx控制器连接。
所述DeNOx催化器包括催化剂仓、检修旁道管、进口法兰和出口法兰,进口法兰和出口法兰分别连接在催化剂仓的进气口和出气口上;检修旁道管与催化剂仓平行设置,其两端分别与催化剂仓的进气口和出气口连接。
一种大功率分布式能源尾气净化控制方法,包括以下步骤:
(1).***上电之后,***控制柜内部24V电源开始工作,给***工作开关T15提供信号,告知***开启工作,***进入准备状态;
(2).***进入准备状态后,会持续检测T15信号状态,以判断T15信号是否导通,当***状态T15导通时,进入步骤(3);当***状态T15断开时,进入步骤(4);
(3).当***状态T15导通时,***控制***电源继电器闭合,给整个***的驱动电路进行供电,***进入工作状态;
(4).当***状态T15不导通时,***进行T15是否断电检测,检测T15信号是否断电;当确定T15信号断电时,进入步骤(5);当确定T15信号不断电时,在下一控制周期继续重复改步骤;
(5).当检测到T15信号断电时,控制***尿素喷嘴停止喷射工作;
(6).当***尿素喷嘴停止工作后,控制***尿素罐进行泄压操作,将***尿素罐压力控制在安全压力范围之内,并进行***喷嘴吹扫工作;吹扫过程持续一段时间,以确保喷嘴吹扫干尽;
(7).当***喷嘴吹扫完成后,进入***电源断电工作,切断***电源继电器,***进入关机状态;
(8).当***步骤(7)完成后,***即进入状态检测过程,在该过程中对***的工作状态和环境进行检测,判断***是否需要进行加热,当***需要进行加热时,进入步骤(9);当***不需要加热时,进入步骤(10);
(9).当***状态检测发现***需要进行加热时,先对***进行加热,包括对尿素管路、尿素罐等部位的加热,确保***尿素温度不低于-6℃,***尿素不进入解冻状态;***加热解冻完成后,进入步骤(10);
(10).当***状态检测完成后、***加热解冻解冻状态检测完成后,***进入喷射条件检测,检测***的的排气温度、发动机的排放是否达到本***的喷射条件,当条件满足时,***进入步骤(11);
(11).当***达到喷射条件时,***先进入尿素罐建压,当尿素罐压力达到预定值后按照初始喷射量进行喷射尿素;
(12).当***开始尿素喷射时,进行尾气排放的状态检测,判断***是否满足排放目标,当尾气排放满足目标值时,***按照当前的喷射量进行尿素喷射;当***排放不满足目标时,进入步骤(13)进行喷射量调整;
(13).当***喷射尿素后,检测到尾气排放达不到目标排放值时,进行尿素喷射量调整工作,并以调整后的尿素喷射量继续工作;在下一个工作控制循环中,通过步骤(12)来检测尿素喷射量的调整是否满足目标排放,然后重复本步骤,直至尾气排放满足排放目标为止。
由于上述技术方案的运用,本发明与现有技术相比具有下列优点:
***结构紧促,布局灵活,可以根据现有分布式能源机组的布局灵活调整***放置位置和空间;***采用模块化组合的方式,能够根据不同的机组配置不同的催化剂和喷射混合器;
***采用嵌入式控制器作为***主控单元,使得控制***简单、布局方便、成本低,且通过高效的控制模型代码,可以实现尾气NOx污染物的自适应处理;取消尿素泵结构,直接应用加压尿素罐的形式取代尿素泵,使得***可以采用“1+N”(1个尿素罐和多个剂量喷射混合器)的形式进行配套,***构建灵活。
附图说明
下面结合附图对本发明技术方案作进一步说明:
图1为本发明***组成原理示意图;
图2为本发明控制方法原理示意图。
具体实施方式
下面结合附图和具体实施例对本发明作进一步的详细说明。
功率分布式能源尾气净化DeNOx***,安装在分布式能源发动机的排气管上,包括DeNOx催化器、DeNOx控制器、计量混合器、尿素压力罐、尿素喷嘴、***传感器组件和监控组件;DeNOx催化器直接连接在分布式能源发动机的排气管上,尿素喷嘴安装在DeNOx催化器的进气管上,计量混合器同时与尿素喷嘴、尿素压力罐和DeNOx控制器连接;监控组件连接在DeNOx控制器连。
计量混合器采用博世BOSCH尿素泵喷射计量泵总成SM-A38作为核心部件,配合外置混合腔。
***传感器组件包括压差传感器、氮氧传感器和排气温度传感器,排气温度传感器包括前排温传感器和后排温传感器;氮氧传感器包括前NOx传感器和后NOx传感器;压差传感器安装在DeNOx催化器上,前排温传感器安装在分布式能源发动机的排气管上,后排温传感器安装在DeNOx催化器的排气管上;前NOx传感器安装在前排温传感器和尿素喷嘴之间的排气管上,后NOx传感器安装在后排温传感器的排气管上。
压差传感器的工作原理是被测压力直接作用于传感器的膜片上,使膜片产生与水压成正比的微位移,使传感器的电容值发生变化,和用电子线路检测这一变化,并转换输出一个相对应压力的标准测量信号。技术参数为:量程:±(50Pa~200Pa~1KPa~10KPa~100KPa);输出信号:4~20mA(二线制)、0~5V、1~5V、0~10V(三线制);供电电压:24VDC(9~36VDC);环境温度:常温(-20~85℃);零点温漂移:≤±0.05%FS℃;量程温度漂移:≤±0.05%FS℃;补偿温度:0~70℃;安全过载:150%FS;极限过载:200%FS;响应时间:1mS(上升到90%FS);负载电阻:电流输出型:最大800Ω;电压输出型:大于5KΩ;绝缘电阻:大于2000MΩ(100VDC);密封等级:IP65;长期稳定性能:0.1%FS/年;振动影响:在机械振动频率20Hz~1000Hz内,输出变化小于0.1%FS;电气接口(信号接口):引出导线。
排气温度传感器采用WZ系列热电阻型,性能可靠,量程大。
尿素压力罐内安装有尿素温度传感器和尿素液位传感器,尿素温度传感器和尿素液位传感器同时与DeNOx控制器连接。尿素液位传感器采用日佳鑫光的KR644型传感器。
DeNOx催化器包括催化剂仓、检修旁道管、进口法兰和出口法兰,进口法兰和出口法兰分别连接在催化剂仓的进气口和出气口上;检修旁道管与催化剂仓平行设置,其两端分别与催化剂仓的进气口和出气口连接。
其中,催化剂仓内的催化箱采用模块化组装的形式进行布置,可以根据不同分布式能源机组的需求灵活配置不同当量的催化剂体积。
DeNOx***的尿素喷射计量是通过计量混合器来完成。计量混合器连接尿素压力罐的出液管上,通过计量混合器来控制尿素的喷射量。计量混合器采用模块化的结构形式,可以根据分布式能源机组的不同配置不同数量的计量混合器。计量的功能由安装在其中的电磁计量阀完成,混合的功能由接入的压缩空气来进行混合。
DeNOx***的尿素的存储和建压的功能由尿素压力罐来进行。尿素压力罐由不锈钢材质构成,其中包括有尿素液位、温度传感器、尿素出液管、尿素罐压力表、尿素罐压力传感器、手动泄压阀、建压管嘴、泄压管嘴等元器件构成。通过自动控制建压管嘴和泄压管嘴的通断,给尿素罐内提供一定压力的压缩空气,从而将尿素水建压。带有压力的尿素水通过尿素出液管链接计量混合器,由计量混合器负责喷射控制。从而完成整体***的尿素喷射控制。
DeNOx***的尿素水的雾化和喷射由雾化喷嘴来进行。雾化喷嘴由多个进液管口和一个主雾化空气结构、文丘里管、雾化器端盖构成。采用这种形式的连接器,一个喷嘴可以雾化不同计量的尿素水。节省了传统的多个喷嘴的安装形式。
一种大功率分布式能源尾气净化控制方法,包括以下步骤:
(1).***上电之后,***控制柜内部24V电源开始工作,给***工作开关T15提供信号,告知***开启工作,***进入准备状态;
(2).***进入准备状态后,会持续检测T15信号状态,以判断T15信号是否导通,当***状态T15导通时,进入步骤(3);当***状态T15断开时,进入步骤(4);
(3).当***状态T15导通时,***控制***电源继电器闭合,给整个***的驱动电路进行供电,***进入工作状态;
(4).当***状态T15不导通时,***进行T15是否断电检测,检测T15信号是否断电;当确定T15信号断电时,进入步骤(5);当确定T15信号不断电时,在下一控制周期继续重复改步骤;
(5).当检测到T15信号断电时,控制***尿素喷嘴停止喷射工作;
(6).当***尿素喷嘴停止工作后,控制***尿素罐进行泄压操作,将***尿素罐压力控制在安全压力范围之内,并进行***喷嘴吹扫工作;吹扫过程持续一段时间,以确保喷嘴吹扫干尽;
(7).当***喷嘴吹扫完成后,进入***电源断电工作,切断***电源继电器,***进入关机状态;
(8).当***步骤(7)完成后,***即进入状态检测过程,在该过程中对***的工作状态和环境进行检测,判断***是否需要进行加热,当***需要进行加热时,进入步骤(9);当***不需要加热时,进入步骤(10);
(9).当***状态检测发现***需要进行加热时,先对***进行加热,包括对尿素管路、尿素罐等部位的加热,确保***尿素温度不低于-6℃,***尿素不进入解冻状态;***加热解冻完成后,进入步骤(10);
(10).当***状态检测完成后、***加热解冻解冻状态检测完成后,***进入喷射条件检测,检测***的的排气温度、发动机的排放是否达到本***的喷射条件,当条件满足时,***进入步骤(11);
(11).当***达到喷射条件时,***先进入尿素罐建压,当尿素罐压力达到预定值后按照初始喷射量进行喷射尿素;
(12).当***开始尿素喷射时,进行尾气排放的状态检测,判断***是否满足排放目标,当尾气排放满足目标值时,***按照当前的喷射量进行尿素喷射;当***排放不满足目标时,进入步骤(13)进行喷射量调整;
(13).当***喷射尿素后,检测到尾气排放达不到目标排放值时,进行尿素喷射量调整工作,并以调整后的尿素喷射量继续工作;在下一个工作控制循环中,通过步骤(12)来检测尿素喷射量的调整是否满足目标排放,然后重复本步骤,直至尾气排放满足排放目标为止。
以上仅是本发明的具体应用范例,对本发明的保护范围不构成任何限制。凡采用等同变换或者等效替换而形成的技术方案,均落在本发明权利保护范围之内。
Claims (4)
1.一种大功率分布式能源尾气净化DeNOx***,安装在分布式能源发动机的排气管上,其特征在于:包括DeNOx催化器、DeNOx控制器、计量混合器、尿素压力罐、尿素喷嘴、***传感器组件和监控组件;DeNOx催化器直接连接在分布式能源发动机的排气管上,尿素喷嘴安装在DeNOx催化器的进气管上,计量混合器同时与尿素喷嘴、尿素压力罐和DeNOx控制器连接;监控组件连接在DeNOx控制器连;
所述***传感器组件包括压差传感器、氮氧传感器和排气温度传感器,所述排气温度传感器包括前排温传感器和后排温传感器;所述氮氧传感器包括前NOx传感器和后NOx传感器;所述压差传感器安装在DeNOx催化器上,前排温传感器安装在分布式能源发动机的排气管上,后排温传感器安装在DeNOx催化器的排气管上;所述前NOx传感器安装在前排温传感器和尿素喷嘴之间的排气管上,后NOx传感器安装在后排温传感器的排气管上。
2.根据权利要求1所述的大功率分布式能源尾气净化DeNOx***,其特征在于:所述尿素压力罐内安装有尿素温度传感器和尿素液位传感器,尿素温度传感器和尿素液位传感器同时与DeNOx控制器连接。
3.根据权利要求1所述的大功率分布式能源尾气净化DeNOx***,其特征在于:所述DeNOx催化器包括催化剂仓、检修旁道管、进口法兰和出口法兰,进口法兰和出口法兰分别连接在催化剂仓的进气口和出气口上;检修旁道管与催化剂仓平行设置,其两端分别与催化剂仓的进气口和出气口连接。
4.一种大功率分布式能源尾气净化控制方法,其特征在于,包括以下步骤:
(1).***上电之后,***控制柜内部24V电源开始工作,给***工作开关T15提供信号,告知***开启工作,***进入准备状态;
(2).***进入准备状态后,会持续检测T15信号状态,以判断T15信号是否导通,当***状态T15导通时,进入步骤(3);当***状态T15断开时,进入步骤(4);
(3).当***状态T15导通时,***控制***电源继电器闭合,给整个***的驱动电路进行供电,***进入工作状态;
(4).当***状态T15不导通时,***进行T15是否断电检测,检测T15信号是否断电;当确定T15信号断电时,进入步骤(5);当确定T15信号不断电时,在下一控制周期继续重复改步骤;
(5).当检测到T15信号断电时,控制***尿素喷嘴停止喷射工作;
(6).当***尿素喷嘴停止工作后,控制***尿素罐进行泄压操作,将***尿素罐压力控制在安全压力范围之内,并进行***喷嘴吹扫工作;吹扫过程持续一段时间,以确保喷嘴吹扫干尽;
(7).当***喷嘴吹扫完成后,进入***电源断电工作,切断***电源继电器,***进入关机状态;
(8).当***步骤(7)完成后,***即进入状态检测过程,在该过程中对***的工作状态和环境进行检测,判断***是否需要进行加热,当***需要进行加热时,进入步骤(9);当***不需要加热时,进入步骤(10);
(9).当***状态检测发现***需要进行加热时,先对***进行加热,包括对尿素管路、尿素罐等部位的加热,确保***尿素温度不低于-6℃,***尿素不进入解冻状态;***加热解冻完成后,进入步骤(10);
(10).当***状态检测完成后、***加热解冻解冻状态检测完成后,***进入喷射条件检测,检测***的的排气温度、发动机的排放是否达到本***的喷射条件,当条件满足时,***进入步骤(11);
(11).当***达到喷射条件时,***先进入尿素罐建压,当尿素罐压力达到预定值后按照初始喷射量进行喷射尿素;
(12).当***开始尿素喷射时,进行尾气排放的状态检测,判断***是否满足排放目标,当尾气排放满足目标值时,***按照当前的喷射量进行尿素喷射;当***排放不满足目标时,进入步骤(13)进行喷射量调整;
(13).当***喷射尿素后,检测到尾气排放达不到目标排放值时,进行尿素喷射量调整工作,并以调整后的尿素喷射量继续工作;在下一个工作控制循环中,通过步骤(12)来检测尿素喷射量的调整是否满足目标排放,然后重复本步骤,直至尾气排放满足排放目标为止。
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