(1) Field and project background
This project belongs to the field of energy conservation and environmental protection.
During start-up/shutdown, normal production and accident conditions, related production equipment of petrochemical enterprises will produce a large amount of combustible gases that cannot be recycled. In order to ensure safe production and meet environmental protection requirements, these combustible gases must be processed by burning through torch facilities. Early torch facilities were mainly elevated torches. In 2003, based on years of torch technology accumulation and operating experience, our department developed an open ground torch in view of the shortcomings of elevated torches such as large area, incomplete combustion, black smoke, serious light pollution and high noise. Significant results have been achieved in energy conservation and environmental protection.
(2) Main technical content and innovation
This project distributes a large amount of combustible exhaust gas to numerous burners arranged on the ground for treatment. A metal fence is arranged around the burner to shield the outside world from heat radiation, noise and flames. Through research on key technologies such as multi-stage combustion open ground torch combustion technology, hierarchical control technology, anti-flashback technology, ignition technology and heat radiation evaluation, the above-mentioned problems existing in the elevated torch have been solved, the safe combustion of combustible exhaust gas has been achieved, and environmental protection requirements have been achieved and a number of technical innovations have been achieved:
(1) A plumx burner of special structure has been developed for use with open ground torches. This burner uses a combination of pressure injection technology and steam smoke suppression technology to ensure smoke-free combustion within the full operating pressure range.
(2) A pressure staged combustion control technology has been developed to ensure smoke-free and stable combustion of exhaust gas within the full flow range and significantly save the amount of smoke-reducing steam.
(3) Developed uninterrupted water seal technology to ensure effective isolation between the torch system and production equipment, avoid flashback, and achieve intrinsic safety.
(4) A premixed long-burning lamp ignition system has been developed, which adopts two forms: direct ignition and indirect ignition, achieving successful ignition of the torch under all-weather conditions.
(5) For the first time in China, a numerical simulation study on the thermal radiation of open ground torches based on key parameters such as emissions, exhaust gas characteristics, burner type and number was carried out. Through demonstration projects, the calculation results were verified and established for the safety of petrochemical production units. Multi-stage combustion open ground torches laid the theoretical foundation.
The comprehensive technology of this project has reached the international advanced level, and has been authorized for 1 invention patent and 1 utility model patent, filling the domestic gap in this field. This project won the first prize for scientific and technological progress by China Shipbuilding Industry Corporation.
(3) Technical and economic indicators and characteristics
(1) Can adapt to 0t/h~With a large emission requirement of 1000t/h, the burner can achieve smokeless combustion within the flow range of 0 to 100%;
(2) Each set of devices saves 300 acres of land resources (about 90 million yuan);
(3) Each set saves 2.5 million yuan in steam and other public works consumption every year;
(4) Ensure that tempering is avoided under any working conditions to ensure the safety of the torch system and upstream devices;
(5) Ensure the safety and reliability of the ignition system;
(6) Avoid light pollution, noise pollution, heat radiation and fire rain.
(4) Promotion and application and social and economic benefits
In 2012, China's first open ground torch for methanol to olefins with independent intellectual property rights was built in Heyuan, Ningbo. From then on to 2014, our firm has successively undertaken the research and development and design tasks of open ground torches in Zhangjiagang Yangzijiang Petrochemical Co., Ltd. and Zhejiang Xingxing New Energy Technology Co., Ltd. From 2012 to 2014, the cumulative contract value was 174 million yuan, saving more than 200 million yuan in initial investment and nearly 1000 acres of land; during operation, 5000 tons of steam, 400 tons of fuel gas, and 1000 tons of nitrogen were saved, and wastewater emissions were reduced by 5000 tons and waste gas emissions were reduced by 28,000 tons. In 2015, it undertook the open ground torch project of China Tianchen Engineering Co., Ltd., with a contract value of 21.26 million yuan. The project has good economic benefits, and the social benefits brought by its characteristics such as low noise, low light pollution, and low heat radiation are incalculable, which is of great significance to the development of energy conservation and environmental protection.