Improving the Energy Efficiency of Cyclone Dust Collectors for Wood Product Factories

Dust collection systems represent a significant portion of a wood product manufacturer’s total electricity use. The system fan works against the static pressure of the entire system—the blast gates, the ductwork, and the upstream or downstream cyclone and/or baghouse. A poor system design (e.g., sharp elbows or undersized ductwork) increases the total amount of static pressure in the system, the fan’s performance curve shifts, increasing the total brake horsepower required by the fan (up to the maximum point on the curve). Additionally, system designers may oversize a dust collection system to ensure adequate dust capture and transport, either to accommodate system expansion or simply to be conservative. Since theoretical fan energy use increases with its velocity cubed, this can be an expensive safety net. This paper presents a comprehensive literature review about industrial cyclone dust collectors energy saving in relation to management, technologies, and policies. Energy-saving technologies like high-efficiency motors (HEMs), variable-speed drives (VSDs), leak detection, and pressure drop reduction have all been examined. Based on energy saving technologies results, it has been found that in the industrial sectors, a sizeable amount of electric energy, and utility bill can be saved using these technologies. Finally, various energy-saving policies were reviewed.

Flow Characteristics Diagnosis and Optimization for Dust Collectors Inflow Duct in Thermal Power Plants

火电厂烟风道用于输送烟气、冷风等介质，其设计优化水平不但影响火电厂烟风系统阻力的大小，而且影响与烟风道直接相连的各个设备的运行状态。某600MW机组除尘器前烟道设计不合理，存在磨损严重、进入除尘器烟气分配不均等问题，文中采用标准缸￡模型，利用Fluent求解器对该部分烟道的流场进行数值计算，诊断分析其存在的主要问题，提出的3个改造方案均可使烟道阻力大幅度下降、烟道磨损减轻、进入除尘器烟气分配均匀。同时，研究了缓转半径及烟气流速对该段烟道阻力和烟气分配的影响情况，计算结果表明该段烟道缓转半径宜选在0．875以上，烟气流速对该段烟道的性能基本没有影响。

Study on Selection of Dust Collectors for Large Capacity Thermal Power Units in High Altitude Areas

A dust collector is an important equipment in a thermal power plant,and reasonable selection of a dust collector is important for environmental protection in the power plant. Huaneng Xining Power Plant is located at an elevation of 2 360 m. Based on the characteristics of the high altitude area and their special requirements for dust collectors,the selection of dust collectors for the thermal power unit in the high altitude area was studied,and then two types of dust collectors( a rotary electrode electrostatic precipitator and electric-bag composite precipitator) for the thermal power unit were compared from the aspects of technological and economical feasibility. Finally,a proposal to select a suitable dust collector for the thermal power plant was put forward.

Application of Mechanical Similarity Laws to the Collection Efficiencies of Geometrically Types of Uni-Flow Cyclone Dust Collectors

From the mechanical similarity point of view, the centrifugal effect, Ar, and the Stokes number, St, as well as the Reynolds number, Re_c for the motion of solid particles in the cyclone are the relevant parameters. In order to apply these similarity laws for the prediction of the characteristics of the collection efficiency, ηc, geometrically similar types of uni-flow cyclones were used. The body diameters of the cyclones were D_1=30, 50, 69 and 99 mm, respectively. The feed particle concentration of the fly-ash particles was up to C_o = 60g/m^3. From the experimental results: (1) the pressure drop, △pc, in the cyclones was a function of not only the Reynods number, Re_c, but also the body diameter, D_1; (2) the collection efficiency, η_c, did not always increase with decreasing body diameter but there existed an optimal body size; (3) application of the mechanical similarity laws to the collection efficiency was not always sufficient for estimating the collection efficiency, since the feed particle concentration was an additional important factor; (4) a new parameter which was the ratio, E_(pf), of the apparent separation energy, W_p, of the solid particles to the energy loss, E_c, of the gas flow in the cyclone was introduced for discussing the collection efficiency; (5) Fuchs theory, used to estimate the collection efficiency, was examined. Fuchs theory may be applied for high feed particle concentration.

Contributions of the Secondary Jet to the Tangential Velocity Distribution and to the Collection Efficiency of the Fixed Guide Vane Type Axial Flow Cyclone Dust Collector

In order to control the maximum tangential velocity V?m(m/s)of the turbulent rotational air flow and the collection efficiencyηc(%)using the fly ash of the mean diameter X R50=5.57?m,two secondary jet nozzles were installed to the body of the axial flow cyclone dust collector with the body diameter D1=99mm.Then in order to estimate V?m(m/s),the conservation theory of the angular momentum flux with Ogawa combined vortex model was applied.The comparisons of the estimated results of V?m(m/s)with the measured results by the cylindrical Pitot-tube were shown in good agreement.And also the estimated collection efficienciesηcth(%)basing upon the cut-size Xc(?m)which was calculated by using the estimated V?m(m/s)and also the particle size distribution R(Xp)were shown a little higher values than the experimental results due to the re-entrainment of the collected dust.The best method for adjustment ofηc(%)related to the contribution of the secondary jet flow is principally to apply the centrifugal effect?c(1).Above stated results are described in detail.

Estimations of the Maximum Tangential Velocity V_(θm) in the Vortex Core Region and also the Mean Rotational Velocity V_(oi) near the Concave Wall Surface in the Returned Flow Type Cyclone Dust Collector

There are many types of cyclone dust collectors for separating the fine solid and dust particles from gases in the various industries and also in the home used purposes. For estimating the power loss and the collection efficiency, one of the most important factors is the maximum tangential velocity V0m in the vortex core region in the cyclone body. In order to determine V0~ by the simple method, it is useful to apply the mechanical balance of the angular momentum fluxes under the assumption of Ogawa combined vortex model which is composed of the quasi-forced vortex in the vortex core region and also the quasi-free vortex surrounded the vortex core region and also under the assumption of the introduction of equivalent length Heq corresponding to the cone spaces of the cyclone body and the dust bunker. On the other hand, the mean rotational velocity Voi near the concave wall surface is also estimated by the mechanical balance of angular momentum fluxes with the moment of viscous friction force. For confirming the general applications of the obtained equations, the returned flow types cyclones changed the throat diameter D3 are designed. The material of the cyclone is the transparent acrylic resin. Therefore the inner surface of the cyclone body can be regarded as smooth surface. The comparisons of the measured velocities V~ and Voi by a cylindrical Pitot tube are shown in good agreement with those of the proposed equations. The above stated results are described in detail.

Numerical Simulation of Dust Removal in the Cyclone Collector of a Straw Crusher Based on a Discrete Phase Model

The cyclone dust collector is an important subsystem of straw crushers used in agriculture.In the present study,a new type of dust collector with involute morphology is proposed to obtain better dust removal efficiency with respect to that of classical tangential and spiral dust collectors.A discrete phase model(DPM)method is used in synergy with a turbulence model,and the SIMPLE algorithm to simulate the flow field inside the dust collector and the related particle dynamics.It is shown that the internal flow field features a primary swirl,a secondary swirl and blockage effects.Moreover,for the involute dust collector,the tangential velocity in the initial stage and the pressure in the high-pressure area are larger than those obtained for the classical types.The dust removal efficiency is 37.11%,25.3%,and 16.37%for the involute type dust collector,the tangential type and the spiral type,respectively.

Experimental investigation on atomization and collecting efficiency of wind-spray dust controller and its parameters optimization

In order to enhance the atomization efficiency of atomizer, a new type of wind-spray dust controller combining the rotary-atomization and colliding broken of droplets was designed by the method of opening the water circulation within the blades. The experiment test for dust controller was conducted by adjusting the following parameters: rotating speed, diversion hole-exit diameter, and colliding tooth angle. Results show that the atomization efficiency increases firstly then decreases with them. And the optimal parameters are obtained with rotating speed 1500-2200 r/min, diversion hole-exit diameter 2-2.5 mm and colliding tooth angle 30°-40°, and under these conditions the corresponding atomization efficiency tops to 95%. Then, the atomization situation under the optimal parameters is held from the aspect of simulation internal flow field and the results of droplet size(30-80 μm) are got, which indicates that the conclusion on the optimized parameters of dust controller is reasonable. The collecting efficiencies of different dust concentrations are determined, ranging from 85% to 98.4%, which shows that the designed dust controller can obtain a good atomizing effect and achieve well dustfall efficiency for the wetting dust control of coal mine.

包钢高炉喷吹煤粉利用率的测定

利用透射光偏光显微镜,对包钢高炉重力除尘灰、旋风除尘灰和布袋除尘灰中的碳素种类进行定性和定量分析,以测定高炉喷吹煤粉利用率。测定结果表明,3号高炉喷吹煤粉利用率上下限分别为89.03%和79.46%,4号高炉的喷吹煤粉利用率上下限分别为91.51%和84.14%。认为,3号高炉和4号高炉所使用喷吹煤粉来自同一系列,因此可以通过采取稳定煤粉粒度波动、优化富氧鼓风和提高入炉焦炭强度等措施,来提高喷吹煤粉利用率。

旋风滤布除尘器的除尘性能研究

为了解决传统旋风除尘器对颗粒捕集效率差、袋式除尘器使用寿命短等问题,将传统旋风除尘与滤布除尘有效结合,形成一种优势互补的一体式旋风滤布除尘装置。采用数值模拟和试验相结合的方法,探究在不同出口压力的条件下,旋风滤布除尘器的除尘效率及压力损失情况。利用Fluent软件对旋风滤布除尘器的除尘性能进行模拟,模拟采用雷诺应力模型(Reynolds Stress Model, RSM)和多相流模型(Discrete Phase Model, DPM)。通过搭建试验平台,测试除尘装置的除尘性能,验证数值模拟的可靠性与正确性。结果表明:旋风滤布除尘器的除尘效率相对于旋风除尘有明显的提高,旋风滤布除尘器的除尘效率与出口负压呈正相关,旋风滤布除尘总效率随出口负压的增加而逐渐增加,且旋风滤布除尘器除尘效率的最小值都高于旋风除尘部分除尘效率的最大值;旋风滤布除尘器的压力损失随出口负压的增加而线性增大,压力损失增大使得除尘器损耗的功率也增多,且压力损失的上升速度快于除尘效率的提升速度;在旋风滤布除尘器中,负压增大后,旋风除尘捕获大粒径颗粒,逃逸到滤布部分的颗粒粒径都较小,降低了滤布被大颗粒划破的风险,提高了滤袋的使用寿命。

超长滤袋排气管结构对滤袋特性影响数值研究

滤袋表面过滤风速轴向分布不均会导致滤袋上部过早损坏,这一问题对于超长滤袋而言更为突出,为改善超长滤袋表面过滤风速的均匀性,针对典型10 m超长滤袋(设计过滤风速为1.0 m/min)采用袋口增设一段内伸排气管方式以改善滤袋内部流场结构。研究结果表明:当增设内伸排气管结构时可以大幅改善滤袋表面过滤风速的均匀性,存在最优的排气管内伸长度和直径的组合可改善超长滤袋过滤特性;当排气管内伸长度为滤袋长度的一半时滤袋表面过滤风速的均匀性最好;增加排气管直径会降低除尘器运行压降;综合考虑运行压降和滤袋表面轴向速度,当排气管内伸长度为滤袋长度的0.2倍,直径为滤袋直径的0.8倍时可以提升约30%的过滤风速表面分布均匀性,此时除尘器的运行压降下降0.65%,滤袋表面轴向速度峰值增加7.75%。

基于YOLOv3的袋式除尘器滤袋破损自动检测方法

干式除尘装置中袋式除尘器的滤袋在长时间使用后会出现破损,造成能源消耗增加、除尘效率降低、污染环境等严重问题。为此,本文采用在除尘舱室处搭建粉尘烟雾检测摄像头,并基于YOLOv3算法检测袋口烟雾的泄漏情况。试验检测步骤:①根据真实除尘舱室尺寸设计袋式除尘器袋口烟雾泄漏实验室平台,采集不同洞口烟雾泄漏的图像数据;②使用软件标注这些图像数据;③搭建Darknet深度学习框架,采用YOLOv3算法对图像数据进行训练,并依据模型计算结果识别破袋情况。结果表明:模型对于批量图像的识别准确率能达到91%以上,对于连续视频的识别准确率可达95.65%。本文系统可以减少除尘器运行中的人工检测,降低工厂人力资源成本和工人劳动强度,可以避免生产中的安全隐患和损失,可以为工厂的生产安全及定期维护提供技术指导,也为全厂智能化生产提供了有效的方案。

低阻文丘里振弦栅除尘系统内流场模拟研究

为探究除尘系统流场分布情况以及粉尘与液滴颗粒对除尘系统性能的影响,运用Fluent模拟研究气态单相流、气固两相流和气固液三相流的流场分布情况,分析除尘器在不同工况条件下压力与流场分布规律以及颗粒的运动情况。结果表明:除尘系统流场主要受除尘器结构的影响,受粉尘颗粒的影响较小;液滴颗粒的存在会提高系统的除尘效率;加入液滴颗粒后,粉尘运动凌乱度增强,与液滴碰撞作用加强,促进了细微粉尘的凝聚,但同时会影响除尘器流场稳定性,增加除尘系统阻力损失。

烧结除尘系统90°弯管壁面冲蚀磨损规律

基于实验和CFD-DPM模型分析对烧结除尘系统中90°弯管管壁的冲蚀磨损进行研究,分析粉尘质量浓度、管道流速、颗粒直径、管道弯径比及管道直径对弯管冲蚀率的影响,将模拟结果与实验值进行验证,模拟结果与实验数据吻合良好,表明模拟结果基本可信。结果表明:弯管最大冲蚀速率随粉尘质量浓度的增加而线性增长,且粉尘质量浓度不同时,冲蚀率最大位置基本相同,主要集中在50°~70°;弯管最大冲蚀率随管道流速增加且表现为指数函数增长,当管道流速大于15 m/s时,冲蚀率增大趋势明显;随着粉尘粒径的增加,弯管的最大冲蚀率增大,但当颗粒直径大于150μm时,最大冲蚀率的增加速率随粒径增加而降低;冲蚀率随弯径比增大呈减小趋势,壁面冲蚀率随管径增大而减小。该研究结果可为弯管冲蚀耐磨研究和工程设计提供理论参考。

结构参数对闭口体系新型激波吹灰器工作特性的影响研究

锅炉吹灰器可以有效实现清除锅炉内部的积灰,提高锅炉运行效率,对锅炉安全运行具有重要意义。SPG型激波吹灰器是在传统激波吹灰器基础上发展而来的闭口体系新型高性能吹灰器,使用数值方法对该装置的可行性进行验证,并分析工作特性,可以为实际应用与改进提供参考。基于CFD技术,将SPG型激波吹灰器作为研究对象,使用动网格技术对设备内活塞的真实运动过程进行仿真模拟,利用Fluent软件模拟计算SPG型激波吹灰器内部流场的连续变化这一动态过程,并通过调整喷管、燃烧室以及压力蓄能器的结构参数,在出口处监测得到各部件结构参数变化对排气特性的影响规律,获取其工作特性。结果表明:喷管的长径比从2增加到4时,出口参数峰值出现滞后现象,但压力峰值与速度峰值获得显著提升,且喷管的扩张段改为直管可以降低膨胀损失,适当增加喷管长径比并直接连接直管是一种较好的方案;燃烧室径向和轴向壁面之间的间距缩短均可使出口压力峰值提高,但轴向距离缩短压力峰值增加幅度更大;在压力蓄能器中,去除阻尼装置压力提升较少,且无法减缓活塞复位,使排出气体减少,去除限位器后喷管出口压力大幅提高,但其峰值持续时间变短。

岩巷掘进工作面控风净化除尘系统设计与应用

针对岩巷掘进工作面压风风流携带迎头粉尘弥漫扩散造成粉尘治理难度大的问题,提出了掘进面“控风—净化”综合粉尘治理方案,构建了由湿式旋流除尘器、易装拆控尘装置、便移式负压风筒等组成的岩巷掘进面高效除尘系统,对比分析了除尘系统的不同安装方案对除尘效果的影响;综合考虑现场除尘效果与劳动强度,明确了湿式旋流除尘器最佳安装方案以及负压风筒与控尘装置的最优安装位置。在某矿辅运大巷岩巷掘进面进行了现场应用,结果表明:当负压风筒安装至通风风筒对侧,吸尘口距巷道迎头3 m,控尘装置位于通风风筒压风口后方5 m时,迎头高浓度粉尘在通风风筒压风、控尘装置控风及除尘器抽尘共同作用下被控制在迎头附近,并不断向负压风筒吸尘口运移最终被除尘器抽入净化,除尘器前方全尘和呼尘除尘效率分别达到95.9%和94.9%以上,除尘器后方全尘和呼尘除尘效率分别达到96.5%和95.4%以上,显著提升了巷道可见度,有效解决了岩巷掘进面通风造成的粉尘治理难题。

卷烟工艺风力负压波动分析与对策

目前国内大多数卷烟厂采用模块化扁布袋除尘器实现集中工艺风力与除尘,除尘器配置的脉冲喷吹清灰系统周期性的喷射压缩空气进入除尘布袋,造成卷烟工艺风力负压规律性波动,影响烟支卷制质量。为了解决以上不足,通过优化改造,实现独立控制每列喷吹电磁阀的脉冲信号通断,使得两列同序号的电磁阀不同时工作,分时喷吹,每次喷吹时减少一半的压缩空气流量,从而降低脉冲喷吹对负压的波动幅度,保障烟支卷制质量的一致性。

基于全因子数值模拟的侧进风式滤筒除尘器流场优化研究

工业除尘器作为工业安全生产、绿色制造的重要装置,如何提高其除尘效率和降低耗能是未来产品的发展方向。针对除尘器滤筒仓核心部分,选取滤筒安装位置A、底部漏斗结构B和扰流板长度C三因素二水平进行全因子流场仿真优化实验,以过滤总流量与流量综合不均系数作为评价指标,对实验数据进行极差分析获得最优组合。仿真结果表明,改进机型相较原型机,过滤总流量提升了4.21%,流量综合不均系数降低了75.75%,并解决了位于进气口处的滤筒易受气流冲蚀作用与滤筒仓内存在二次扬尘的问题。根据仿真结果试制了改进机型,改进机型的实际过滤总流量测试与仿真计算得到的过滤总流量误差为0.54%,数值仿真优化方法能有效指导滤筒除尘器优化设计,有利于延长滤筒的使用寿命和提高产品品质。

多孔介质布膜元件对水膜除尘器除尘性能的影响

通过实验,研究了多孔介质布膜元件对水膜除尘器除尘效率的影响,讨论了进气量、用水量、气水比对除尘效率的作用效果。在此基础上,采用计算流体力学DPM模型,研究了进气量和颗粒粒径对除尘效率的影响。研究表明,在除尘实验中,采用多孔介质布膜元件可有效提高除尘效率,用水量越低,提高效果越明显;进气量和进水量对除尘效率具有显著的正向影响,但进气量的影响要大于进水量;不论是否存在多孔介质,除尘效率在气水比为21 m 3/kg达到最大值。模拟结果显示,在实验最大风量的条件下,对粒径94.55μm及以上的颗粒,具有100%的除尘效果;对于粒径68.58μm及以上的颗粒,能具有良好的除尘效率,数值可以在90%以上。

滤筒除尘器喷吹孔孔径的优化

【目的】为控制各个喷吹管气流量的均匀性,对喷吹管上的喷吹孔径进行优化,提高滤筒除尘器清灰效果。【方法】自制高压脉冲喷吹气流量测量装置对现有喷吹管气流量进行测定,采用光纤传感分析仪测试除尘器滤筒各部分的侧壁压力峰值,分析各滤筒清灰效果不均匀的原因;以滤筒各部位侧壁压力峰值作为清灰均匀性效果评估指标,优化喷吹孔径。【结果】优化前4个喷吹孔径均为19 mm,喷吹孔的气流量依次为13.69、 14.78、 16.03、 16.93 L,对应4个滤筒上、中、下部侧壁压力峰值的最小值分别为最大值的37%、 26%、 20%,气流量均匀度标准差为1.41;优化后4个喷吹孔径分别为23、 20、 18、 17 mm,喷吹气流量依次为14.05、 15.08、 15.87、 16.13 L,对应4个滤筒上、中、下部测壁压力峰值的最小值为最大值的56%、 56%、 53%,气流量均匀度标准差降为0.93。【结论】优化后的喷吹管气流量均匀化程度提高,可实现滤筒除尘器的均匀清灰。