一、項(xiàng)目簡要介紹

　　1、 Project Overview

　　本項(xiàng)目是由綠聯(lián)凈化承建的某化肥廠7臺套歐洲某知名品牌燃?xì)鈨?nèi)燃發(fā)動機(jī)沼氣發(fā)電機(jī)組尾氣治理氮氧化物（NOx），經(jīng)過處理的尾氣需要滿足當(dāng)?shù)卮髿馕廴疚锱欧艠?biāo)準(zhǔn)中對氮氧化物（NOx）的排放要求。

　　This project is undertaken by Green Union Purification for the treatment of nitrogen oxides (NOx) in the exhaust gas of 7 sets of well-known European brand gas internal combustion engine biogas generator sets in a fertilizer plant. The treated exhaust gas needs to meet the local air pollutant emission standards for NOx emissions.

　　二、該清潔能源電廠治理需求簡述

　　2、 Brief description of the governance requirements for this clean energy power plant

　　1、項(xiàng)目名稱：某化肥廠沼氣清潔能源發(fā)電機(jī)組尾氣NOx治理項(xiàng)目

　　1. Project Name: NOx Treatment Project for Exhaust Gas of a Biogas Clean Energy Generator Unit in a Fertilizer Plant

　　2、項(xiàng)目類型：某化肥廠沼氣發(fā)電機(jī)組排放的尾氣中NOx治理工程

　　2. Project type: NOx treatment project for exhaust emissions from a biogas generator set in a certain fertilizer plant

　　3、發(fā)動機(jī)品牌：歐洲某知名燃?xì)鈨?nèi)燃發(fā)動機(jī)

　　3. Engine brand: A well-known European gas internal combustion engine

　　4、發(fā)電機(jī)組品牌：國內(nèi)某知名發(fā)電機(jī)組制造商

　　4. Generator set brand: a well-known domestic generator set manufacturer

　　5、數(shù)量：7臺套

　　5. Quantity: 7 sets

　　6、輸出功率：1169kW

　　6. Output power: 1169kW

　　三、項(xiàng)目背景和排放標(biāo)準(zhǔn)

　　3、 Project background and emission standards

　　某省區(qū)域性《大氣污染物綜合排放標(biāo)準(zhǔn)》 (DB37-2013)

　　Regional Comprehensive Emission Standards for Air Pollutants (DB37-2013) in a certain province

　　標(biāo)準(zhǔn)中要求“自2017年1月1日起，新建企業(yè)按所在控制區(qū)應(yīng)分別執(zhí)行表2中“重點(diǎn)控制區(qū)”和“一般控制區(qū)”的排放濃度限值，部分行業(yè)還應(yīng)按所在控制區(qū)從嚴(yán)執(zhí)行表3中相應(yīng)的排放濃度限值。”

　　The standard requires that from January 1, 2017, newly established enterprises should implement the emission concentration limits for "key control areas" and "general control areas" in Table 2 according to their respective control areas. Some industries should also strictly implement the corresponding emission concentration limits in Table 3 according to their respective control areas. ”

　　本項(xiàng)目最終按照“重點(diǎn)控制區(qū)NOx<100mg/m3”的標(biāo)準(zhǔn)執(zhí)行。

　　This project will ultimately be executed according to the standard of 'NOx<100mg/m3 in key control areas'.

　　四、此項(xiàng)目難點(diǎn)

　　4、 Difficulties in this project

　　4.1、硫化物影響：

　　4.1 Effects of Sulfides:

　　沼氣成分復(fù)雜，前端脫硫系統(tǒng)的穩(wěn)定性直接影響SCR系統(tǒng)效率和使用壽命，進(jìn)入SCR系統(tǒng)的尾氣中硫化物超標(biāo)會造成催化劑中毒失效；

　　The composition of biogas is complex, and the stability of the front-end desulfurization system directly affects the efficiency and service life of the SCR system. Excessive sulfide in the exhaust entering the SCR system can cause catalyst poisoning and failure;

　　4.2、硅氧烷影響：

　　4.2. Effects of Siloxanes:

　　沼氣中含有硅氧烷成分在發(fā)動機(jī)氣缸中燃燒時高溫而附著在發(fā)動機(jī)活塞氣門組建上對發(fā)動機(jī)造成重要損壞，同時，硅氧烷在溫度下降時會附著在SCR系統(tǒng)催化劑上，從而導(dǎo)致系統(tǒng)NOx處理效率下降；

　　The presence of siloxane components in biogas during combustion in engine cylinders can cause significant damage to the engine piston and valve assembly due to high temperatures. At the same time, siloxane can adhere to the SCR system catalyst when the temperature drops, leading to a decrease in the NOx treatment efficiency of the system;

　　4.3、尾氣排溫高：

　　4.3. High exhaust temperature:

　　中溫SCR催化劑兼顧了可靠性、處理效率和經(jīng)濟(jì)性，中溫催化劑理想工作溫度在260-400℃，實(shí)際工況往往沼氣內(nèi)燃發(fā)動機(jī)尾氣排溫都超過這個溫度。理想的方式是經(jīng)過合理的降溫再進(jìn)入SCR反應(yīng)器，但這樣會造成熱損失致使后端余熱鍋爐或者溴化鋰空調(diào)裝置能源轉(zhuǎn)化效率降低，在實(shí)際工作場景中往往得不到投資方支持。而采用高溫催化劑價格昂貴，同時因?yàn)閷α蚧锏葰怏w成分敏感而性能不穩(wěn)定，使用壽命不能保障。到目前為止國內(nèi)還沒有高溫分子篩催化劑使用壽命超過24000小時的應(yīng)用案例，極少數(shù)國外廠商也不能保證高溫催化劑的使用壽命，如此種種不確定性無疑給商業(yè)電站造成不僅投資高昂，而且后期綜合運(yùn)營成本也高昂并且不可控等；

　　The medium temperature SCR catalyst balances reliability, treatment efficiency, and economy. The ideal working temperature for the medium temperature catalyst is between 260-400 ℃, but in actual operating conditions, the exhaust temperature of biogas internal combustion engines often exceeds this temperature. The ideal way is to enter the SCR reactor after reasonable cooling, but this will cause heat loss and reduce the energy conversion efficiency of the back-end waste heat boiler or lithium bromide air conditioning unit, which often does not receive support from investors in practical work scenarios. However, the use of high-temperature catalysts is expensive, and their performance is unstable due to sensitivity to gas components such as sulfides, which cannot guarantee their service life. So far, there have been no application cases in China where the service life of high-temperature molecular sieve catalysts exceeds 24000 hours, and a very small number of foreign manufacturers cannot guarantee the service life of high-temperature catalysts. Such uncertainties undoubtedly cause not only high investment for commercial power plants, but also high and uncontrollable comprehensive operating costs in the later stage;

　　4.4、綜合經(jīng)濟(jì)性：

　　4.4 Comprehensive Economy:

　　目前以沼氣等為主要燃料的內(nèi)燃發(fā)電站基本由企業(yè)出資承建，運(yùn)行時需要一定的經(jīng)濟(jì)收益確保項(xiàng)目投入產(chǎn)出符合預(yù)期。而在實(shí)際的SCR系統(tǒng)選型招標(biāo)采購時，由于這個產(chǎn)業(yè)剛剛興起，全球范圍內(nèi)優(yōu)質(zhì)的供應(yīng)商極少，注重品質(zhì)的采購單位往往以進(jìn)口燃?xì)獍l(fā)動機(jī)性能優(yōu)良為評價標(biāo)準(zhǔn)而順延選擇進(jìn)口的SCR系統(tǒng)供應(yīng)商。具體甄選時，需注意以下三個方面：

　　At present, internal combustion power plants that mainly use biogas and other fuels are mostly funded and constructed by enterprises, and a certain economic benefit is required to ensure that the project's input and output meet expectations during operation. In the actual bidding and procurement of SCR system selection, as this industry is just emerging, there are very few high-quality suppliers worldwide. Purchasing units that focus on quality often choose imported SCR system suppliers based on the excellent performance of imported gas engines as the evaluation criteria. When selecting, attention should be paid to the following three aspects:

　　第一方面，國內(nèi)領(lǐng)先的SCR系統(tǒng)供應(yīng)商與國外相當(dāng)。根據(jù)近兩年的浸泡式深入研究后，需要特別提醒的是，在燃?xì)鈨?nèi)燃機(jī)脫硝領(lǐng)域國內(nèi)與國外除開高溫催化劑領(lǐng)域有差距之外，系統(tǒng)開發(fā)上幾乎處于同等水平，主要技術(shù)來自于汽車SCR技術(shù)與火電廠脫硝技術(shù)的融合并基于燃?xì)鈨?nèi)燃發(fā)動機(jī)特性進(jìn)行創(chuàng)新，已經(jīng)取得了突破性成績并做了很好的商業(yè)應(yīng)用。目前國內(nèi)領(lǐng)先的大功率內(nèi)燃機(jī)SCR系統(tǒng)供應(yīng)商如同互聯(lián)網(wǎng)產(chǎn)業(yè)一樣國內(nèi)外難分伯仲；

　　Firstly, the leading SCR system suppliers in China are comparable to those abroad. After in-depth research on immersion type in the past two years, it should be noted that in the field of denitrification of gas internal combustion engines, there is a gap between China and foreign countries except for the field of high-temperature catalysts. The system development is almost at the same level, and the main technology comes from the integration of automotive SCR technology and thermal power plant denitrification technology, and innovation based on the characteristics of gas internal combustion engines has achieved breakthrough results and made good commercial applications. At present, the leading domestic supplier of high-power internal combustion engine SCR system is like the Internet industry;

　　第二方面是，國內(nèi)外廠商在全程服務(wù)上有差異。SCR系統(tǒng)不同于燃?xì)鈨?nèi)燃發(fā)電機(jī)組，并非標(biāo)準(zhǔn)產(chǎn)品。每一個項(xiàng)目需要根據(jù)目標(biāo)發(fā)動機(jī)排溫、燃?xì)獬煞帧⒐ぷ鳝h(huán)境、治理目標(biāo)、以及實(shí)際工作場景等等進(jìn)行個性化定制方案，在這個總市場需求并不大的領(lǐng)域要求國外供應(yīng)商提供及時快捷的售前服務(wù)目前還沒有出現(xiàn)。極少數(shù)國外代理商只停留在賣產(chǎn)品的層面，不是不想提供服務(wù)，而是沒有合適的人力資源和足夠收益支撐。

　　The second aspect is that there are differences between domestic and foreign manufacturers in terms of full-service. The SCR system is different from gas internal combustion generator sets and is not a standard product. Each project requires personalized customized solutions based on target engine exhaust temperature, gas composition, working environment, governance goals, and actual work scenarios. In this field where the overall market demand is not high, foreign suppliers are required to provide timely and efficient pre-sales services, which has not yet emerged. A very small number of foreign agents only stay at the level of selling products, not because they do not want to provide services, but because they do not have suitable human resources and sufficient revenue support.

　　第三方面，定制開發(fā)和運(yùn)行成本上的差異。SCR系統(tǒng)的經(jīng)濟(jì)性由目標(biāo)燃?xì)鈿怏w成分和尾氣溫度、催化劑性能和價格、反應(yīng)器封裝結(jié)構(gòu)和材料工藝、混合管設(shè)計制造合理性、控制噴射系統(tǒng)精確度、反應(yīng)流場是否合理科學(xué)、前期項(xiàng)目方案定制開發(fā)和后期長遠(yuǎn)應(yīng)急服務(wù)等等核心要素組成，國內(nèi)外同時具備這些要素于一身的供應(yīng)商少之又少。行業(yè)發(fā)展之初，劣幣驅(qū)除良幣。內(nèi)燃機(jī)SCR系統(tǒng)屬于新生事物，設(shè)計方、招標(biāo)方、投資方、監(jiān)理方、使用方等相關(guān)板塊都缺乏專業(yè)選型考核標(biāo)準(zhǔn)，一部分投資方存在應(yīng)付驗(yàn)收的驗(yàn)收后期擱置不用的僥幸心理，從而在實(shí)際采購過程中并不容易甄選到綜合能力均衡的供應(yīng)商。一個重要表現(xiàn)是，供應(yīng)商抓住采購方既要達(dá)標(biāo)又要低價的心理，低價中標(biāo)并盲目承諾系統(tǒng)處理指標(biāo)排放達(dá)標(biāo)，而在項(xiàng)目實(shí)施過程中排放不達(dá)標(biāo)無法驗(yàn)收，造成整個項(xiàng)目不能獲得合法運(yùn)行批文而損失巨大的心理脅迫采購單位加價的情形屢次出現(xiàn)。還有一種情況是，即使暫時排放達(dá)標(biāo)，但是由于催化劑的使用壽命短和整套系統(tǒng)設(shè)計欠合理，控制系統(tǒng)不夠精準(zhǔn)，催化劑更換費(fèi)用和尿素消耗量巨大，造成經(jīng)濟(jì)性大大下降，同時氨排放也超標(biāo)，造成了新的污染。

　　The third aspect is the difference in customized development and operating costs. The economy of SCR system is composed of core elements such as target gas composition and exhaust temperature, catalyst performance and price, reactor packaging structure and material process, rationality of mixing tube design and manufacturing, precision of control injection system, rationality and scientificity of reaction flow field, customized development of early-stage project plan, and long-term emergency service in the later stage. There are very few suppliers at home and abroad who possess all these elements simultaneously. At the beginning of industry development, bad money drives out good money. The SCR system for internal combustion engines is a new phenomenon, and there is a lack of professional selection and assessment standards for the design, bidding, investment, supervision, and user sectors. Some investors have a lucky mentality of waiting for acceptance in the later stage, making it difficult to select suppliers with balanced comprehensive capabilities in the actual procurement process. An important manifestation is that suppliers seize the mentality of the purchaser to both meet standards and offer low prices, winning bids at low prices and blindly promising to meet the emission standards of the system. However, during the implementation of the project, if the emissions do not meet the standards, they cannot be accepted, resulting in the inability to obtain legal operating permits for the entire project and causing huge losses. The situation of psychological coercion to the procurement unit to increase prices has repeatedly occurred. There is also a situation where even if the emissions temporarily meet the standards, due to the short service life of the catalyst and the unreasonable design of the entire system, the control system is not precise enough, the cost of catalyst replacement and urea consumption are huge, resulting in a significant decrease in economy. At the same time, ammonia emissions also exceed the standard, causing new pollution.

　　本項(xiàng)目經(jīng)測算，尿素消耗不超過0.006元/kWh。

　　According to calculations, the urea consumption of this project does not exceed 0.006 yuan/kWh.

　　五、綠聯(lián)凈化解決方案

　　5、 Green Union Purification Solution

　　1、技術(shù)方案：SCR+ASC，整體設(shè)計原理布局如下：

　　1. Technical solution: SCR+ASC, the overall design principle layout is as follows:

　　本結(jié)構(gòu)示意圖為綠聯(lián)凈化原創(chuàng)，版權(quán)所有

　　This structural diagram is an original creation of Green Union Purification, all rights reserved

　　2、原理說明：

　　2. Principle explanation:

　　系統(tǒng)化學(xué)反應(yīng)方程式示意圖如下：

　　The schematic diagram of the system chemical reaction equation is as follows:

　　本結(jié)構(gòu)示意圖為綠聯(lián)凈化原創(chuàng)，版權(quán)所有

　　This structural diagram is an original creation of Green Union Purification, all rights reserved

　　3、尿素供給系統(tǒng)：

　　3. Urea supply system:

　　六、系統(tǒng)控制原理示意圖

　　6、 Schematic diagram of system control principle

　　本結(jié)構(gòu)示意圖為綠聯(lián)凈化原創(chuàng)，版權(quán)所有

　　This structural diagram is an original creation of Green Union Purification, all rights reserved

　　本系統(tǒng)根據(jù)目標(biāo)發(fā)動機(jī)治理需求，在混合管前端通過前NOx傳感器、溫度傳感器采集尾氣參數(shù)及功率大小等一并傳輸給PLC系統(tǒng)控制尿素噴射量。在SCR反應(yīng)器出口端通過NOx傳感器、溫度傳感器、氨逃逸傳感器（可選）等采集處理后的NOx含量，出口溫度和NH3濃度 （通過可選傳感器實(shí)現(xiàn)）。在電控系統(tǒng)液晶控制顯示屏上會實(shí)時顯示出對應(yīng)數(shù)據(jù)，也可以遠(yuǎn)機(jī)位的方式在中央控制室實(shí)時監(jiān)測，不需要單獨(dú)采購煙氣分析儀分析處理后煙氣成分。本系統(tǒng)經(jīng)過擴(kuò)展，處理系統(tǒng)各種數(shù)據(jù)還可自動同步到云端，通過PC和移動客戶端可實(shí)時監(jiān)測實(shí)際排放指標(biāo)。

　　This system collects exhaust parameters and power levels through front NOx sensors and temperature sensors at the front end of the mixing pipe according to the target engine governance requirements, and transmits them to the PLC system to control the urea injection amount. Collect and process the NOx content, outlet temperature, and NH3 concentration at the outlet of the SCR reactor through NOx sensors, temperature sensors, ammonia escape sensors (optional), and other sensors. The corresponding data will be displayed in real-time on the LCD control screen of the electronic control system, and can also be monitored in real-time in the central control room through remote monitoring. There is no need to purchase a separate flue gas analyzer to analyze and process the composition of the flue gas. This system has been expanded and can automatically synchronize various data to the cloud. Real time monitoring of actual emission indicators can be achieved through PC and mobile clients.

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