0536-3371388
产品分类 PRODUCTS
联系我们
临朐泰丰环保科技有限公司
地 址:山东省潍坊市临朐县东城街道东五路北首
电 话:0536-3371388 3371328
传 真:0536-3371328
邮 箱:lqtfhg@163.com
您的位置:主页 > 技术交流 > 正文 技术交流

Technical solutions of ammonia synthetic tower catalyst loading

时间:2019-04-09 作者:泰丰环保科技 点击: 166 次

氨合成塔催化剂装填技术方案
 Technical solutions of ammonia synthetic tower catalyst loading
  • 工、器具的准备
 Tools and appliances preparation
  1. 装填氨合成催化剂工器具
  Tools and appliances of ammonia synthesis catalyst loading
1.1、装氨合成催化剂的漏斗四只,每只有一个接口,并将这四只漏斗组合焊接成一只大漏斗,在每个接口处扎上帆布软管,将氨合成催化剂倒入合成塔内。漏斗尺寸根据塔口直径制定,一般大漏斗直径为塔径的2/3~3/5。
    Four ammonia synthesis catalyst funnels, each one with a interface, and make the four together weld into a big one, wrap canvas hoses on each interface, pour  ammonia synthesis catalyst into the tower. Funnel size depends on the tower diameter, generally, big funnel size is 2/3~3/5 of tower diameter’s.
1.2、震荡器4只(两只备用),直径约50mm,震荡杆长度452mm,震荡速度≥12000r/min。
Oscillators, 4 (two spare), diameter about 50 mm, shock rod length 452 mm, shake speed 12000 r/min.
1.4、震动筛及筛网一张,筛网的网眼应为1×1mm(18目)。
A vibrating screen and one sieve, sieve mesh should be 1 x 1 mm (18mesh)
1.5、可将氨合成催化剂提升到合成塔顶部的吊斗2个,铁桶若干只。
  2 Skips, which can lift the ammonia synthesis catalysts to the tower top,                   and some iron drums.
1.6、长臂吊车一辆(50t或40t)或卷扬机1台。
one long arm crane (50 t / 40 t) or one hoist.
1.7、扒平氨合成催化剂的木耙子2把。
2 wooden rakes, grill flat ammonia synthesis catalyst.
1.8、用于密封所有环隙的工具。
Tools for sealing all ring gaps.
1.9、合成塔内照明用低压照明灯(24V)。
low voltage light, used in tower (24 v).
1.10、安全带、正压自给空气式(或长管式)防毒面具各4套。
Seat belt、positive pressure air self type (or long tubular)  gas mask,each four sets.
1.11、其它劳保用品由合成车间落实(其中劳保鞋必须采用不带硬件橡胶底鞋或布鞋)。
Other labor insurance supplies, implemented by synthesis workshop (labor insurance shoes must be used with no hardware rubber shoes or cloth shoes).
  • 氨合成催化剂的装填
The ammonia synthesis catalyst loading
  1. 准备措施及防护
Prepare measures and protection
1.1、确认合成塔内符合装填条件,氨合成催化剂框内杂物已清理干净,内件检查完整无损等。
All in tower should be under the loading conditions, be sure of ammonia synthesis catalyst box cleaned up,all inside should be intact, etc.
1.2、为了防止氨合成催化剂颗粒进入热电偶套管导管、环隙、气体出入口等处,在开始装填氨合成催化剂前应挡住所有环隙及开口,可用塑料布以及橡胶软管等。另外要保护好密封面免遭撞击。
In order to prevent the ammonia synthesis catalyst particles into the thermocouple catheter, gaps, gas entrance, all the gaps and openings should be blocked before starting to load ammonia synthesis catalyst,with plastic and rubber hose, etc. Besides, protect sealing surface from the impact.
1.3、合成塔顶部以及现场氨合成催化剂筛选处应垫以油布,以防氨合成催化剂遭污染和水浸。
 Top of tower and screening should be mat with cloth, in case of pollution and water.
1.4、安装好漏斗、送风管、抽风管、绳梯、照明、振荡器等。
Fix up the funnel, blast pipes, duct, rope ladder, lighting, oscillator, etc.
1.5、由于第一层是预还原氨合成催化剂,在过筛装填前方可将氨合成催化剂桶打开,以防氨合成催化剂在空气中停留时间过长而发生氧化。催化剂桶应避免放在太阳下长期直晒和与有水、水蒸汽的气体接触。
since the first layer is the pre-reduced ammonia synthesis catalyst, ahead of the sieving loading ammonia synthesis catalyst barrel can be opened, in case of ammonia synthesis catalyst in the air for a long time and oxidization. Catalyst long straight barrel should be avoided in the sun and the gas contact with water, water vapor.
1.6、装填期间,应不断地从塔顶向塔内送空气,同时用真空泵间断将里面的粉尘向外抽,以降低里面的粉尘浓度。真空泵引风管口可放入到离催化剂层表面约1M处高度。
 During loading, should send air constantly from top tower to inside tower, at the same time,in order to reduce the dust concentration inside,draw dust from inside to outside by vacuum pump. Vacuum pump guide duct can be placed into 1m height place from the catalyst layer surface.
1.7、现场安装有可移动的安全灯(24V),以供塔内照明使用,安全灯不得直接放置在催化剂层表面,以免引发催化剂发热。
On-site installation need a removable lamp (24 v), used for the tower lighting, lamp shall not be placed directly on the surface of the catalyst layer, so as not to cause catalyst hot.
1.8、第一层预还原氨合成催化剂装填时,应安装临时测温电偶,监测催化剂层的温度;发现塔内温度上升时,应立刻停止装填,所有人员撤离合成塔,并通入氮气降温,等塔内催化剂床层温度恢复正常后,先用空气置换,使塔内气体氧含量大于20%后,操作人员方可重新入塔作业。
As loading the first layer pre-reduced ammonia synthesis catalyst , should install temporary temperature measuring thermocouple, monitor the temperature of the catalyst layer; Since the tower temperature rises, should immediately stop loading, all staff should evacuate from synthetic tower, cool and ventilate with nitrogen, after the tower of catalyst bed temperature return to normal, first displace by air, once the tower gas oxygen content up  to more than 20%, operators can be back into the tower.
1.9  装填顺序:先对第三层进行装填,完成后装填第二层,最后装第一层。
loading order: loading the third layer first, then the second layer, at last loading the first layer.
1.10 装填应选择天气干燥、通风的日子,催化剂桶应放置于通风、避免阳光长期直晒、周边无水汽、无污染物的地方,在装填前方可打开,以防催化剂被污染,造成质量下降。特别是预还原催化剂,以免引起因阳光晒后温度上升,造成氧化,发热,甚至引起烧坏。
When loading, should choose the day,dry and ventilated, barrels of the massive catalyst should place in ventilated, avoid long-term direct sunlight, no water vapour &no pollution around, open it before the loading, in case of catalyst polluted, cause the loss of quality. Especially pre-reduced catalyst, prevent temperature rise from the sun, causing oxidation, heating, and even burning out.
1.11 对一层的预还原氨合成催化剂,要求要尽量在短时间内一次装完,同时装填时,应安装临时测温电偶,专人负责监控,一旦发现温升,应按1.8方案进行。
For one layer of the pre-reduced ammonia synthesis catalyst, should finish loading in a short period time as soon as possible, loading at the same time, should install temporary temperature measuring thermocouple, the specialist is responsible for monitoring, once found the temperature rising, should proceed with the scheme 1.8.
  1. 装填程序Loading procedure:
2.1、打开氨合成催化剂桶,用筛网将氨合成催化剂过筛后装入吊斗;筛网上氨合成催化剂厚度不宜超过20cm。
Open the ammonia synthesis catalyst barrels, sieve the ammonia synthesis catalyst into the skip; ammonia synthesis catalyst thickness on screen should not be more than 20 cm.
2.2、为了控制装填密度,应当始终记录筛选和装填氨合成催化剂的数量。将过筛后的氨合成催化剂用吊车或卷扬机吊入装填漏斗中,再沿帆布袋分撒开到合成塔催化剂筐内。
In order to control the loading density, should always record the quantity
 of screening and loading. Put the sieved ammonia synthesis catalyst in loading hopper by a crane or hoist crane, and then along the canvas bag Scatter synthetic tower catalyst into the basket.
2.3、氨合成催化剂振荡。
Ammonia synthesis catalyst oscillations.
2.3.1、当第三床层、第二床层氨合成催化剂装填高度每增加250mm时,用木耙子将氨合成催化剂扒平,禁止操作人员直接站在催化剂上,可在催化剂上铺上木板,人员站在上面进行操作。扒平后,再进行下一步装填。
Every time when the third bed & second bed loading height increase 250 mm, flat the ammonia synthesis catalyst with a wooden rake , forbidden operators stand directly on the catalyst, put the board on catalyst is available, staff standing inboard. Grilled flat, and then on to the next step loading
2.3.2、各层的装填要求尽可能紧密。同一层要求各段均匀,装填密度误差应小于3%。可在装填高度和装填量上进行记录。
Each layer loading require as closely as possible. Same layer uniform requirements paragraphs, loading density error should be less than 3%. Record the loading height and loading quantity.
  1. 装填期间及装填之后的措施
   Measures during loading and after loading
3.1、装填期间要防止氨合成催化剂遇水,并保持合成塔内件中有足够的新鲜空气。
During loading, prevent ammonia synthesis catalyst from water, and keep enough fresh air in synthetic tower internals.
3.2、在停装氨合成催化剂时,要停送空气,用氮气进行吹扫置换。
While stop loading ammonia synthesis catalyst, stop sending air, purg & substitute
with nitrogen.
3.3、在重新进行氨合成催化剂装填以及安装内件时,要确认断开所有氮气接口,输入空气,确认氧含量大于20%,方可工作。
when restart to load ammonia synthesis catalyst and install internal parts, make sure of disconnecting all nitrogen interface, input air, oxygen content more than 20%,after that then work.
3.4、第三床层氨合成催化剂装填结束后,用氮气吹扫置换,然后关闭手孔盖,按要求吊入安装好的第二床层框,以后类推。
After finish the third bed ammonia synthesis catalyst loading, purge and replace with nitrogen, then close the hand hole cover, lift into the second bed box installed already as requirement, later on.
3.5、装填结束后,应立刻会签《合格证》,并将大盖复位。装填后的氨合成催化剂要保持在氮气氛围中,直到开车为止。
After loading, should immediately sign the certificate of approval, and will be reset. Keep the ammonia synthesis catalyst in a nitrogen atmosphere, until it start to operate.
4、装填注意事项Loading attentions:
4.1、两床层氨合成催化剂的装填量,第二层要装填到盖板处,第一层要装填到内件的上边缘。
Loading amount of 2 ammonia synthesis catalyst bed layer, the second floor to fill to the cover plate, the first layer to fill to the internal parts of the upper edge.
4.2、安装内件盖之前,要彻底清理所有密封表面。在清理密封表面以及螺栓时,严禁使用氯化物。
Before install a cover, clean up all the sealing surface. When clean sealing surface and bolt, chloride is strictly prohibited.
4.3、在氨合成催化剂床盖板封闭之前,应检查氨合成催化剂床、环隙以及气体进、出口,清除所有杂物。
Before close the ammonia synthesis catalyst bed cover, should check the ammonia synthesis catalyst bed, clearance, and the inlet and outlet of the gas, remove all debris.
安全注意事项: Security considerations:
  1. 此项工作应把安全放在第一位,安环科自始至终要派专人负责现场监护,合成车间、技术科应指定专人负责,以确保工作的顺利完成。
We should put safety first, security depart should send specialist to protect from beginning to end, synthesis workshop, engineering department should appoint someone in charged to operate, ensure the work goes smoothly.
  1. 参加此项工作的人员,特别是外来“三类人员”均须经安环科进行安全教育。情况允许时应进行体检合格。
For the staff participating in the work, especially foreign“Three kinds of people”, safety education should be taught by security depart .Arrange medical examination while available.
  1. 工作人员进入容器内,一定要办理《进入设备作业许可证》,听从负责安全人员的指挥,做好安全监护工作。
The staff who need go into the container, must get the equipment operation license, guided by security personnel, make sure of safety monitoring well.
  1. 严格禁止操作人员带水和与装填无关的物品进塔。
It is strictly forbidden that operators take water and other goods irrespective of loading into the tower.
  1. 装填工作一结束,即会签《合格证》将大盖复位。
Once loading work over, the certificate of approval will be signed and reset the lid .
  1. 电器部门要负责电器和照明工作。分析部门负责分析工作等。
Electrical department will be responsible for electrical and lighting work, analysis
department is for the analysis work, etc.
  1. 事先做好计划工作,有方案、有责任人。
    Planning work should be arranged first, plan, responsible person , both need.
8、要求做好准备工作,成立开领导小组,负责指挥和协调工作。
本方案为初步方案,请领导小组责成有关部门按设备、阀门等编号,编写具体实施方案
Requirement:do preparation work well, set up a leading group, be responsible for directing and coordinating work.
This is the preliminary scheme, please instruct relevant departments according to numbers of equipment, valves etc, write the specific implementation plan.