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1、Research and Development of Baosteel Swirl-JetSintering Flue Gas Desulphurization Technology SHEN Xiao-lin, LIU Dao-qing, ZHOU Jing(Environment and Resources Institute, R&D Center, Baoshan Iron and Steel Co., Ltd., Shanghai 201900, China)Abstract: The research background and technical features of BS
2、FGD (Swirl-Jet-Absorbing Wet Limestone-gypsum Sintering FGD Technology) process and equipments were introduced here in detail. The main contents, achievements ofpilot experiments, and engineering practices of BSFGD were analyzed and discussed systematically. Past engineeringpractice experiences indi
3、cate the fact is that the technology has the following merits, wide applicability to sintering flue gasfeatures such as temperature changing frequently, SOconcentration being unstable, flow rate fluctuating intensively; high pollutants removal efficiency; low investment and energy consumption; stabl
4、e and reliable running; utilizable byproduct (gypsum) etc. It has been proved that BSFGD has the value of a wide range of applications for large and medium-sized sintering machines flue gas desulphurization in the steel industry.Key words: sintering flue gas; desulphurization technology; research; e
5、ngineering practice1 IntroductionAt the beginning of the century, while was constituted, the experts of metallurgy point out that “Due to the complicacy of agglomerate and the otherness of sintering process, the technology of flue gas desulphurization used in power plants could not be applied in sin
6、tering flue gas desulfurization directly and blindly. The investment and running cost of FGD technology used in Iron and Steel Industry of other developed countries are usually too expensive to be accepted by Chinese companies.” Therefore, the technology of sintering flue gas desulfurization in chin
7、a was listed as important study topic in . Since there are few researches and technologies existing in this area, its significant to invent a technology with the properties of efficient, highly adaptive, cost-effective, safe and reliable in operation for Chinese Iron and Steel companies. In china, B
8、aosteel takes the lead in sintering FGD technology research and development at beginning of the year 2005.2 The Features of Baosteel Sintering Flue Gas Desulfurization Technology According to the production characters of large-scale sintering machine, considering the application of desulfurizer and
9、desulfurizing product and the actual condition of company, we contrast and analyze the technology of FGD used in market widely and deeply. Choosing wet limestone-gypsum sintering flue gas desulfurization as the base of technical route and then starting to research and develop through industrial test
10、s point at the sintering flue gas feature, and finally, and formed serial technology and equipment of Baosteel Swirl-Jet-Absorbing Wet Limestone-gypsum Sintering FGD with own intellectual property rights (Referred to as Baosteel Sintering flue gas desulfurization technology, and abbreviated as BSFGD
11、).2.1 Introduction of process flowFlue gas flow from main suction fans of sinter machines be pressurized by booster fan, then be cooled and pretreated in cooling equipment, and then perform the desulfurization reaction in Swirl-Jet Absorber, the purified flue gas discharge from chimney on standard a
12、fter demisting. The auxiliary systems such as limestone slurry preparation and gypsum dehydrationsystem are the same as normal wet FGD system, which are mature techniques. The process flow diagram of BSFGD is shown in Fig.1.2.2 Technical features2.2.1 Baosteel swirl-jet-absorbing wet limestone-gypsu
13、m sintering FGD technology Use limestone powders (250 meshes) as desulfurizing agent, Ca/S is equal to 1.01 to 1.03, and the cost of desulfurizer is low. The FGD system run steadily and safely, over 95% synchronous operation rate with sintering machine. The desulphurization efficiency is greater tha
14、n 90%, the exhaust concentration of SO and dust is less than 100 and 50mg/m separately, and the removal efficiency of SO, HCl and HF will be greater than or equal to 50%, 80% and 90% separately. The gypsum is good enough to meet the requirements of using as resources, in which the content of CaSO2HO
15、 is over 90%, the content of moisture is below 10%, the pH value is 6-8. It shows excellent economics that the investment and operation cost is 70%- 80% to the cost of other sintering flue gas desulfurization technology.2.2.2 Cooling device for pretreatmentA cooling device as pretreatment was set be
16、fore the absorbing tower to overcome the difficulty to cool down the flue gas whose temperature fluctuated seriously and frequently, maintain the safety of absorbing tower and provide the best temperature for desulphurization reaction. This component was helpful to protect the gas-gas heater (GGH) f
17、rom blocking in traditional FGD technology and to promote the cooling efficiency of flue gas.The heavy metals, alkali metals and a part of dust in flue gas were removed by the device, which was useful to restrain the blocking problem and scale formation in the absorbing tower and improve the quality
18、 of gypsum. Furthermore, most HF and HCl in flue gas were removed by the device, which can prevent eroding for the material of absorbing tower and other subsequent devices. 2.2.3 Swirl-jet-absorbing tower The reaction container was designed to be the swirl-jet absorber on the basis of aerodynamics k
19、nowledge. The limestone slurry in the absorber performed as continuous phase, the flue gas was erupted from Swirl-Jet device and separated into fine bubbles in the absorber, as dispersion phase. Then the gas and the limestone slurry reacted thoroughly with high mass transfer efficiency. This process
20、 can keep the system stable when violent fluctuation of flue gas flow rate and SOconcentration, with high desulphurization and dedusting efficiency. In this process, the absorbing reaction can be completed in one cycle, so that the limestone slurry dont need to be repeatedly cycled, which can lower
21、the energy consumption, Furthermore, the products of gypsum were well-crystallized, larger particle size, and utilizable.2.2.4 Integrated demisterThe expansive space in the top of the absorber, which is empty, combined with the external demister to compose integrated demister, which is good for elim
22、inating the moisture in the flue gas.3 Technical Developments in Pilot Experiment and Engineering Practice3.1 Device for pilot experimentsThe pilot experiments system with capacity of 90000 m/h flue gas is composed of six subsystems as following: SO absorbing system, limestone slurry preparation sys
23、tem, flue gas system, gypsum dehydration system, process water system and DCS control system. Fig.2.3.2 Research content in pilot experiment and engineering practice(1) Through experimental study on every influencing factors of desulphurization efficiency, found out the main factors and essentials t
24、o ensure FGD system running continually and steadily in the long term, made the debugging-programs of large-scale FGD project, and developed complete set of rules, specification requirements, and standards for BSFGD, etc. (2) By experimental investigation on a variety of swirl-jet devices and coolin
25、g pre-treating methods, we have obtained the best configuration and design parameters of processing parameters and key equipments, and established the thermodynamic and dynamic calculation models of FGD system. (3) Through long-term experiment at pilot plant, search and discover laws and solutions t
26、o various problems that may occur in sintering flue gas desulfurization process, such as clogging, deposition, etc. Develop control programs of large-scale FGD project, such as the key parameters, instrument configuration. (4) In response to the technical requirements that the surface of slurry tank
27、 must be steady, carry out experiments on side-entry slurry agitation and oxidation air distribution, set up relevant models, find out various kinds of control parameter laws, develop complete set technology of slurry agitation and forced oxidation. (5) Carry out antiseptics experiments of over 100
28、test pieces at every representative site, provide the basis for antiseptics selection, develop several special-purpose antiseptic scaly clays suitable to sintering FGD, and a complete set of antiseptic program of sintering FGD project.(6) Develop such series sets of manufacturing, processing and ins
29、talling technology of sintering flue gas desulfurization system, and provide technical guidance.(7) Experimental study on Emergency Preparedness for emergency situations, develop relevant emergency preplans technical regulation.(8) Research on the utilization of Sintering FGD gypsum, such as adding
30、to steel slag powder or slag powder to substitute for cement directly, and achieved significant results.(9) Research and analyze the characteristics of sintering FGD waste water, develop wastewater treatment and reuse technology, propose wastewater treatment technology and program.(10) Feasibility s
31、tudy program, preliminary design, and design schemes have been made for three typical large-type sintering FGD projects in the whole metallurgical industry, which have with different flue gas flow rates and different characteristics.4 Engineering Applications By experts evaluation, Baosteel decided
32、to put the results of BSFGD research into practical application. Based on unified plan, the BSFG R&D Team of Baosteel Research Institute was responsible for the completion of technical assembly, and supported comprehensive technical guidance and support for layout of plant, configuration and manufac
33、ture of equipments, heart system construction, debugging, and operating, etc.4.1 Scale of projectsOverview of three set of sintering FGD units is shown in Table 1.4.2 Engineering operationAfter putting into operation, this three sintering desulphurization units running steadily, every technical econ
34、omical indicators can meet the design requirements, Synchronous operation rate can reach more than 95%.4.3 Pollutant removal efficiencyUnder the situation of flow rate fluctuating intensively, temperature changing frequently, SO concentration being unstable, the economical desulphurization efficienc
35、y should be 90%, and the FGD can run steadily with over 95% desulfurization efficiency. The dust collection efficiency is over 85%, and the removal efficiency of SO, HCl and HF will be greater than or equal to 50%, 80% and 90% separately. The condensed fluid pH value of white fog exit from chimney i
36、s about 6.0 to 6.5. Waste water about 3 to 5 t/h can be sent to in-plant wastewater treatment system, and then return to sintering process utilization. The byproduct is gypsum, in which the content of CaSO2HO is over 90%, with high degree of crystallization and low impurity content, its quality is s
37、uperior to conventional power plants FGD gypsum and natural wet FGD gypsum, and it can fully satisfy the requirements of Chinas building materials.4.4 Benefit analysis(1) In case of dealing with equal exhaust gas flow, compare and analyze with other wet FGD and CFB semi-dry FGD technology, the One-t
38、ime investment and running costs of Baosteel Sintering FGD is about 70% to 80% of the other FGD technology.(2) Mei Steel Branch No.3 Sintering FGD Project has been the demonstration projects of environmental protection in Nanjing district and Jiangsu Province. The Stainless Steel Branch No.1 Sinteri
39、ng FGD Project and Baosteel Branch No.3 Sintering FGD Project can complete the SO2 emission reduction task, and create environmental condition for sustainable development of enterprises.(3) According to the actual sulfur content, this three sintering desulphurization units can reduce about 15000 to
40、20000 ton of SO emission, and save industrial discharge taxes about 20000 thousand RMB annually. Little wastewater and byproduct gypsum can be utilized comprehensively, so BSFGD is an energy-saving and emission-reduction technology, it can reach an agreement to Cyclic Economy.(4) Develop and innovat
41、e independently, the technology developed by Baosteel will be the effective solutions to sintering flue gas desulfurization, which is the difficult problem of the whole metallurgical industry.5 Brief SummaryThe Baosteel sintering FGD technology was developed for the complex characteristics of sinter
42、ing flue gas, which has the following merits, including high efficiency, stable running, simple process, cheap absorbent, utilizable byproduct, and advanced techno-economic indicators, etc, so, the BSFGD technology has extensive use value to the flue gas desulfurization of large and medium-sized sin
43、tering machine.第五届国际大会论文集在科学和技术的炼铁 研究和开发宝钢涡流喷射烧结烟气脱硫技术 沈小林，刘道清，周静 （环境与资源学院、研发中心、宝山钢铁有限公司,上海201900,中国）文摘: 研究背景及技术特点,BSFGD(涡流喷射吸收石灰石-石膏湿法脱硫技术的烧结过程和设备详细介绍。主要内容、成果的试点实验,和工程实践进行了详细的分析和讨论BSFGD系统。过去的工程实践经验表明事实是,这项技术有以下优点,广泛适用于烧结烟气特性如温度变化频繁,SOconcentration being unstable,流量脉动强烈;污染物去除效率高,低投资和能耗,运行稳定可靠;可利用的副产
44、品(石膏)等。已经证明,BSFGD的值为范围广泛的应用于大型和中型烧结烟气脱硫的机器在钢铁行业。关键词: 烧结烟气脱硫技术;研究;工程实践1 简介 在本世纪初,而是构成,专家的冶金指出:“由于复杂性的结块和烧结过程的差异性,烟气脱硫技术用于核电厂无法应用于烧结烟气脱硫直接和盲目。投资和运行成本的脱硫技术用于钢铁行业的其他发达国家通常太贵由中国公司接受。”因此,烧结烟气脱硫技术在中国被列为重要研究课题。因为很少有研究和技术现有的在这方面,它的重大发明的技术性能的高效、高适应性、性价比高、操作安全可靠,中国钢铁公司。在中国,宝钢带头烧结烟气脱硫技术的研究与开发在2005年初。2 宝钢烧结烟气脱硫技
45、术的的特性根据生产大型烧结机的特点,考虑到应用的脱硫剂,脱硫产品和实际情况的公司,我们对比和分析了烟气脱硫技术用在市场广泛和深入。选择烧结烟气脱硫石灰石-石膏湿法为基础的技术路线,然后开始研究和开发通过工业测试点在烧结烟气特性,最后,形成了系列技术和设备的宝钢涡流喷射吸收湿石灰石-石膏烟气脱硫烧结用自己的知识产权(称为宝钢烧结烟气脱硫技术,缩写为BSFGD)。2.1工艺流程的介绍烟气流量从主吸球迷烧结矿机是通过增压风机加压,然后被冷却并进行预处理,然后在冷却设备进行脱硫反应在涡流喷射吸收,净化烟气从烟囱排放标准后除雾。辅助系统,如石灰石浆液制备及石膏dehydrationsystem同正常的湿
46、法烟气脱硫系统,这是成熟的技术。流程流图是图1所示BSFGD。2.2技术特点2.2.1宝钢涡流喷射吸收石灰石-石膏湿法脱硫技术的烧结 使用石灰石粉(250目)作为脱硫剂,Ca / S等于1.01到1.03,而成本低的脱硫剂。烟气脱硫系统运行的稳定和安全,超过95%同步运行率和烧结机。脱硫效率大于90%,废气和粉尘的浓度小于100和50毫克/米分别去除效率的所以,盐酸和高频将大于或等于50%,分别为80%和90%。石膏是好的足以满 足要求的使用资源,卡索2的内容是超过90%,是何内容的水分低于10%,pH值是6 - 8。它显示了出色的经济学,投资和运行费用是70% - 80%的成本其他烧结烟气脱
47、硫技术。2.2.2冷却装置的预处理一个冷却装置作为预处理是设置在吸收塔克服困难去冷却烟气的温度波动严重和频繁,保持安全的吸收塔和提供最佳温度脱硫反应。这个组件是有助于保护气-气加热器(热交换器)从阻塞在传统的脱硫技术,促进烟气的冷却效率。沉重的金属,碱金属和一部分粉尘烟气中被移除的装置,它是有用的约束问题和垢阻塞在吸收塔和提高质量的石膏。此外,大多数高频和HCl烟气中被删除的设备,它可以防止侵蚀的材料吸收塔和其他后续设备。2.2.3涡流喷射吸收塔反应容器被设计用于涡流喷射吸收空气动力学知识的基础上。石灰石泥浆在吸收器进行连续阶段,烟气从涡流喷射装置和爆发分为细泡沫吸收体,分散阶段。然后气体与石灰石浆液反应传质效率高的彻底。这个过程可以保持系统稳定剧烈波动时的烟气流量和SO2浓度，脱硫、除尘效率高。在这个过程中,吸收反应可以完成在一个周期,所以,石灰石泥浆不需要反复循环的,它可以降低能耗,此外,产品的石膏是结晶良好的、更大的粒子大小和可利用的。2.2 .4综合除雾器广阔的空间在顶部的吸收器,它是空的,再加上外部的除雾器除雾器组合集成,这有利于消除烟气中的水分。3技术发展在预试验和工程实践3