Catalytic Apparatus

1. Field of the Invention

This invention relates to a catalytic apparatus. More particularly, the invention relates to the construction of the catalyst bed filling portion of a parallel flow type denitration apparatus.

2. Description of the Prior Art

In a dry type exhaust gas denitration apparatus, a catalyst bed is formed in the passage of high temperature boiler exhaust gas and ammonia gas is injected upstream of the gas passage to remove nitrogen oxides from the exhaust gas passing through the catalyst bed by decomposing them into water and nitrogen. Out of such apparatuses, there is a parallel flow type denitration apparatus in which a catalyst bed of plate type of honey-comb type catalyst is formed and which is featured in that the pressure loss in the course of the gas passing through the catalyst bed is such that it can be covered with the surplus in fan capacity provided in the boiler design stage. Referring to FIG. 1, the exhaust gas G produced in boiler 1 is denitrated in the catalyst bed 5 formed between economizer exit and air heater 2 and is then released to the open air from stack 4 through air heater 2 and dust collector 3. The catalyst bed 5 is formed by piling up in duct D, as shown in FIG. 2, a number of catalyst elements 6 each consisting of a plurality of catalyst plates 16 spaced as shown in FIG. 3. That is, in duct D there is provided a catalyst supporting beam 14 on which grating 12 or the like is placed. Catalyst elements 6 are carried in duct D through hatch 13 using a transporting means 17 such as chain block or the like and are then piled up by the human power of workers to form catalyst bed 5. Therefore, much labor and time are required for carrying in and out of and refilling with catalyst. Further, individual catalyst elements 6 have to be placed one by one and, hence, there is the possibility of their being located out of position, in which case smooth passing of exhaust gas G is disturbed. Therefore, constant control is necessary for the catalyst bed.

It is an object of this invention to provide a catalytic apparatus which facilitates carrying in and out of and refilling with catalyst.

It is another object of the invention to provide a catalytic apparatus which allows the exhaust gas to pass easily and can keep the quality of catalyst bed excellent at all times.

The foregoing objects have been accomplished by this invention. That is, a plurality of catalyst elements are arranged to form a catalyst block, and thus formed catalyst blocks are placed in the passage of exhaust gas. To facilitate the transportation and placing of catalyst blocks in the passage of exhaust gas, there can be provided in the passage of exhaust gas a car for transporting catalyst blocks which has a vertically moving table, a car guide, such as rail, which serves to guide the car, and a beam on which catalyst blocks are to be placed. Further, the gap between adjoining catalyst blocks, the gap between the reactor wall and the side of catalyst block and the space formed between the reactor wall and the member provided at the side of catalyst block adjacent thereto are sealed respectively by a seal plate provided at one side of the bottom of catalyst block, a wall seal plate extending from the reactor wall and a bridge seal plate so that short-circuiting of the gas being treated is prevented and dust accumulation is also prevented, thereby the reaction efficiency of catalyst can be raised.

FIG. 1 is a schematic view showing the passage of boiler exhaust gas in which a parallel flow type denitration apparatus is provided.

FIG. 2 is a sectional view of a duct, showing the conventional method of forming catalyst bed by use of catalyst elements.

FIG. 3 is a perspective view of a catalyst element.

FIG. 4 is a perspective view of a catalyst block.

FIG. 5 is a sectional view of a duct, showing the method of forming catalyst bed by use of catalyst blocks.

FIG. 6 is a side view of a car for transporting catalyst blocks.

FIG. 7 is a front view of the car with its table in the uppermost position.

FIG. 8 is a front view of the car with its table in the lowermost position.

FIG. 9 is a perspective view of an integrated catalyst unit.

FIG. 10 is a side view, partly in section, of a catalytic apparatus according to the invention.

FIG. 11 is a partly side view of the apparatus, illustrating installation of an integrated catalyst unit by use of the car.

FIG. 12 is a cross-section cut on line D--D of FIG. 10.

FIG. 13 is a cross-section cut on line E--E of FIG. 12.

FIG. 14 is a cross-sectional view showing the relation between seal plate 9 and the integrated catalyst unit.

FIG. 15 is a detailed view of part A of FIG. 10.

FIG. 16 is a detailed view of part B of FIG. 10.

FIG. 17 is a detailed view of part C of FIG. 10.

FIG. 4 shows a catalyst block 7 formed by assembling a plurality of catalyst elements 6 shown in FIG. 3. The catalyst block 7 is enclosed with plate 18 made of a metal or any other material having a similar effect so as to strengthen the block formation. In the catalyst block 7, catalyst elements 6 are arranged so that catalyst plates 16 thereof are in parallel with the gas stream G. Further, at the bottom of catalyst block 7, i.e., on the end face thereof at the discharge side of gas G, there is provided a lattice 18A to reinforce catalyst block 7. Still further, it is preferable to make the height h of catalyst block 7 equal to that of the catalyst bed to be formed in exhaust gas duct D. Thus formed catalyst blocks 7 are carried in duct D through hatch 13 by transporting means 17 as shown in FIG. 5 and are placed one by one in duct D by a car 8 moving on the rail 10 provided on supporting beam 14, so that a catalyst bed is formed. The exhaust gas G entering through flow control baffle 15 is denitrated while passing through catalyst plates 16 in catalyst block 7. It should be noted that the procedure for carrying out of and refilling with catalyst blocks 7 can be effected easily by reversing the above-described procedure for forming catalyst bed. The catalyst employed in the foregoing embodiment is of the plate type, but it may be of the corrugated type, honey-comb type or any other suitable type if it permits to circulate the gas.

Next, in order to facilitate the transportation and placing of catalyst block 7 which is large in volume and weight, the means for transporting catalyst blocks, shown in FIGS. 6-8, can be used. The reference numeral 8 designates a car for transporting catalyst blocks 7. On the top of this car is provided a table 9 for placing catalyst blocks. The table 9 is driven hydraulically or by other means to move up and down. When the table has moved up to the uppermost position 9', the placing plane of table 9 is at a position higher than the top end face 14', shown in FIG. 7, of catalyst supporting beam 14. With the table at the lowermost position, the placing plane is at a position lower than the top end face 14' of supporting beam 14. The reference numeral 11 is a car moving rope provided before and behind car 8 in the moving direction thereof. The method of placing catalyst block 7 will be described hereinbelow. Referring to FIG. 5, catalyst block 7 is first carried in duct D through hatch 13 by block transporting means 17. In this case, just under catalyst block 7 is located car 8 with table 9 at the uppermost position. Next, after catalyst block 7 is placed completely, the operator moves car 8 by pulling in the rope. In this case, the car can be made to move freely because the bottom of catalyst block 7 is higher than the top end face 14' of supporting beam 14 as shown in FIG. 7. When catalyst block 7 reaches a predetermined position, table 9 is lowered slowly. Thus catalyst block 7 is placed on supporting beam 14, and a space is formed between the placing plane of table 9 and the bottom of catalyst block 7 as shown in FIG. 8. Car 8 thus set free is returned by the rope 11, provided on the opposite side to the above-mentioned rope, to the position at which catalyst block is suspended. The reference numeral 10 designates a rail for moving car 8. By repeating the above procedure, a catalyst bed is formed in exhaust gas duct D.

Next, in order to prevent short-circuiting of the reaction gas stream when catalyst blocks are placed in the passage of exhaust gas, the gap between adjoining catalyst blocks, the gap between the side of catalyst block and the wall of reactor, and the space formed between the reactor wall and the member provided at the side of catalyst block are sealed so as to prevent short-circuiting of the reaction gas stream, and further a dust prevention member is provided to prevent dust accumulation in the reactor, thereby the reaction efficiency of catalyst can be maintained constant at all times.

Employed as the catalyst block is an integrated catalyst unit 19 (FIG. 9) that is formed by housing catalyst elements 6 as shown in FIG. 3 in a box-shaped framework 19A. In FIG. 10, in the catalytic apparatus D, integrated catalyst units 19 are arranged in a plurality of stages, in two stages in the figure. Further, in the uppermost stage thereabove there may be placed an integrated catalyst unit 19 which is smaller in size. Such integrated catalyst units when installed will not leave inutile spaces. However, since a single integrated catalyst unit weighs about 600 kg, special care must be exercised in handling and installing them.

FIG. 11 exemplifies the state in which an integrated catalyst unit is installed using an installation car. Integrated catalyst unit 19 is placed on installation car 8 and is carried to the fixed position by the force of a wire 11 connected to winch 20. Unloading at the fixed position may be done either by a hydraulic device 21 or by a hand hoist 23 mounted on ceiling rail 22. In this case, when as described in the above, in order to seal the gap between adjoining integrated catalyst units, seal plate 24 is attached to one side of the bottom of integrated catalyst unit 19 as shown in FIGS. 10 and 14, the above gap can be sealed by merely joining integrated catalyst units, so that short-circuiting of the reaction gas stream is prevented. On the top end face of the framework 19A of integrated catalyst unit 19, there are provided a plurality of flow control bars 25 which also serve to reinforce the framework.

FIG. 12 is a cross-section cut on line D--D of FIG. 10. It can be seen from this figure that due to the presence of pillar 26 in the catalytic apparatus there is formed a fairly large gap f between wall 27 and integrated catalyst unit 19 when installed. Therefore, when installing integrated catalyst unit 19, it is necessary to attach to wall 27 a wall seal plate 28 which automatically prevents the reaction gas from passing the above gap f. FIG. 15 is a partly sectional view showing the state in which integrated catalyst unit 19 is installed on the wall side. Stopper 29 is attached to wall 27 and serves to fix the stopping position of the car. In this case, to prevent dust accumulation and gas stream in the above-mentioned gap f, there is provided, as shown in FIG. 16, a bridge seal plate 30 which bridges the distance between wall 27 and the top end side of integrated catalyst unit 19. Usually employed as the crossbeam 31 of catalytic apparatus D which is located close to the bottom of integrated catalyst unit 19 is an I-section member whose top is flat. In this case, dust contained in the reaction gas may adhere by bridging to the bottom of integrated catalyst unit and, according to circumstances, accumulate taking root thereat. Therefore, when a bent member forming slopes with a base angle larger than the angle of repose of the dust, i.e., a longitudinal member having a cross-section in the form of angle, is attached to the top of the I-section member as shown in FIG. 17 and is used as dust prevention member 32, it will contribute to continuous operation of the apparatus with no dust accumulation.

According to this embodiment, there are many advantages. For example, there is no leakage of the gas due to its short-circuiting, and the efficiency of removal of deleterious components contained in the gas is raised. Further, the apparatus can operate continuously with no bridging trouble due to dust accumulation. Furthermore, integrated catalyst units can be changed easily.

According to this invention, the catalyst bed can be formed easily, and carrying out of and refilling with catalyst can be done in a short time by a small number of persons.

Further, since catalyst blocks and also catalyst elements can be arranged in good order, the quality of the formed catalyst bed is excellent and denitration can be done effectively.