伍迪BM27电解槽运行总结

BM—2.7型电解槽运行总结江苏梅兰化工 伍华胜陈玉林姚俊155万吨/20046月底投产运4510万吨/20056083月33个月。装置的二次盐水、电解、淡盐水脱氯工序引进意大利伍迪公司的工艺技术，承受自然循N2030，16N982。1、电解槽的技术参数电解槽数量12台单元槽数104只/台槽复极元件活性面积2.7m2设计电流密度6kA/m2合同的电流密度4.35kA/m2直流电耗<2100kwh/tNaOH一期(710JTC)4台电解槽二期(720JTC)8台电解槽项目单位A槽项目单位A槽B槽C槽D槽电流效率%97.38电流kA11.8011.8011.8011.80槽电压v286.57286.97286.57286.67单元数只94949494单元槽电压V3.0433.0533.0493.050NaOH浓度%wt31.0430.9931.0831.10盐水流量m3/h17.3017.3017.4017.40阳极液温度℃85.986.586.685.9Cl2纯度%v/v98.798.798.698.6O2/Cl2%v/v0.80.91.00.9NaClO3g/l0.050.050.050.05NaClO3g/l0.220.220.220.22Na2SO4g/l2.562.562.562.56盐水中NaOHg/l0.190.190.190.19Na2CO3g/l0.550.550.550.55HClOg/l1.381.381.301.34阳极液流量m3/h13.3412.9413.0512.85ηNaClO3%0.270.260.260.25ηHClO%1.691.651.561.58ηNaOH%0.200.200.200.20ηNa2CO3%0.440.440.440.44ηO2%1.241.341.531.43直流电耗kwh/tNaOH2082.3(90℃ 32%)2097.6( 无修定)备注：710JTC729410只。项目单位A槽B项目单位A槽B槽C槽D槽E槽F槽G槽H槽电流kA11.7911.8111.8111.8511.8011.8011.8012.10槽电压v319.45319.34319.35319.14319.83318.94319.53314.08单元数只104104104104104104104104NaOH浓度%wt31.5031.5331.5731.4732.1732.0932.2532.11盐水流量m3/h21.4621.8021.7421.7119.5019.3019.0019.21阳极液温度℃86.8087.5487.4487.0286.3286.1486.5186.50Cl2纯度%v/v98.5698.5398.6398.6098.5098.6098.6098.60O2/Cl2%v/v0.530.460.530.460.600.600.600.60NaClO3g/l0.070.070.070.070.070.070.070.07阳极液中g/l0.230.250.260.280.160.210.320.28NaClO3Na2SO4g/l4.254.254.254.253.033.743.942.91阳极液中g/l5.045.004.985.013.544.754.953.85Na2SO4盐水中NaOHg/l0.200.200.200.200.130.130.340.23Na2CO3g/l0.910.910.910.910.440.610.570.73HClOg/l1.381.391.521.421.191.521.601.50阳极液流量m3/h18.1018.5318.5518.4216.6915.2015.1215.00ηNaClO3%0.330.380.410.450.210.230.290.27ηHClO%2.082.142.352.171.651.922.011.85ηNaOH%0.230.240.240.240.140.140.350.25ηNa2CO3%0.810.820.810.820.350.490.450.52ηO2%0.690.550.680.550.830.820.820.81电流效率%97.9597.9897.6297.8897.8097.6597.6797.51直流电耗kwh/t2079.82085.02091.02081.72067.22067.42068.42054.4NaOH32%条件下的数值从表一、表二可看出：BM2.7离子膜电解槽电流效率>97%；2〕氯气纯度>98，O2/C21；NaClO3、HClO含量低；pH9~10.5的掌握指标。4、电解主装置工艺设备简述电解主装置电解槽及附件、二次盐水过滤器、树脂塔、阴极液泵、真空泵由伍迪公司供给，二次盐PLCDCS操作中心，其它均为国产设备。整流变压器由原江西变压器厂和原南通变压器厂生产〔现均改名称〔现均改名称DCSPTFE/CCCPVC/FRP，电解槽主管由伍迪公司供给。5、有关原盐使用和盐水的质量离子膜装置运行的效果集中表达在膜的使用寿命延长、电流效率的合理下降和槽电压的合理上升，而优良的效果要靠电解槽的优质设计制造技术水平、盐水质量的优质和操作治理技能水平三者的有效结合，在电解槽确定后，后二者显得尤其重要。本文着重争论原盐使用和盐水的质量对膜的影响。我公司一次盐水开车至今使用过进口盐〔先期为澳盐，后来为墨西哥盐、海盐〔山东盐、精制盐〔江苏井神盐业公司和金坛盐业公司〕及隔膜碱蒸发回收的碱盐水、离子膜自身装置回收的淡盐水。伍迪公司对梅兰进电解槽盐水〔04715日样品〕的分析〔表三〕分析工程CaSrBaMnFeMgAlCa+MgSiO2ppb398610832063128分析方法ICP旭化成公司对梅兰进电解槽盐水〔05年11月29日样品〕的分析〔表四〕分析工程CaBaMgAlSrFeNiSiO2Na2SO4ITOCpH0.004<0.001<0.01<0.05<0.005<0.01<0.012.513<0.11611.3指标ppmppmppmppmppmppmppmppmg/lmg/lmg/l旭化成<0.02<0.1<0.02<0.1<0.1<0.05<0.01<5<10<0.1<10标准ppmppmppmppmppmppmppmppmg/lmg/lmg/l分析方法ICP比色pH计I(1)Na2SO(1)4TOC(2,3)pH140ppb7.7g/l14ppm<1000I(1)Na2SO(1)4TOC(2,3)pH140ppb7.7g/l14ppm<1000ppb<10g/l<200ppb<8g/l12分析工程样品指标Nafion范围Nafion范围<4kA//m24~6kA//m2Al31.4ppb<100ppb<100ppbBa6.1ppb<1000ppb<500ppbCa13.4ppbCa+MgCa+MgMg3.7ppbCa+MgCa+MgCa+Mg17.1ppb<30ppb<20ppbSr1.0ppb<500ppb<400ppbFe117ppb<1000ppb<1000ppbNi<13ppb<10ppb<10ppbSiO23.60ppm<10ppm<6ppm分光光度计测量，其它用ICP测量；总有机碳测量；7ppm。Ca+Mg指标虽合格但渐渐上升；pH9~10.5的掌握值；Ni的指标偏高；TOC指标偏高；FeDuPont专家DuPontNafion膜的使用指南和离子膜电解技术介绍来看，上述偏离指标的杂质对标的偏离度，掌握在受控指标范围内。6、实际运行状况0.30.3DM碱IM碱中0.15DM碱IM碱中年份沟通电耗kwh/tNaOH电流密度kA/m2产量万吨备注20042251.7852.8004710JTC 046月底开车20052204.694.67.8345720JTC 056月底开车20062253.994.2314.718020072304.454.517.2301、071210日电解槽运行指标〔表七〕(710JTC42个月)项 目单位A槽B槽C槽D槽电流kA13.0013.0013.0413.03槽电压v340.1339.0340.1340.1单元数只104104104104NaOH浓度%wt32.1532.1032.2032.19盐水流量m3/h21.021.421.221.1阳极液温度℃86.886.787.586.5Cl2纯度%v/v98.198.298.198.2O2/Cl2%v/v0.90.90.90.9g/l0.040.040.040.04NaClO3g/l0.300.240.240.26Na2SO4g/l7.887.887.887.88Na2SO4g/l9.769.709.629.74盐水中NaOHg/l0.390.390.390.39Na2CO3g/l0.590.590.590.59HClOg/l2.302.312.262.28ηNaClO3%0.40ηHClO%2.93ηNaOH%0.41ηηNa2CO3电流效率直流电耗%%kwh/tNaOH0.4696.112259720JTC电解槽运行指标〔表八〕 (运行30个月)项目单位A槽B槽C槽D槽E槽F槽G槽H槽电流kA13.0513.0613.0613.0413.0613.0813.0313.04槽电压v334.8335.9341.1335.9335.9334.8335.9326.6单元数只104104104104104104104104NaOH浓度%wt32.3332.2532.3132.3532.1932.2532.3032.21盐水流量m3/h21.020.921.120.921.221.021.121.1阳极液温℃86.587.487.686.386.386.186.485.1度Cl2纯度%v/v98.498.398.498.498.398.498.498.4O2/Cl2%v/v0.600.700.600.600.700.600.600.60g/l0.050.05g/l0.050.050.050.050.050.050.050.05g/l0.280.320.280.260.300.230.260.28g/l7.997.997.997.997.997.997.997.99g/l9.989.959.989.909.849.929.809.89g/l0.350.350.350.350.350.350.350.35g/l0.670.670.670.670.670.670.670.67g/l2.422.302.362.342.402.382.322.34%0.370.370.370.370.370.370.370.37%2.972.972.972.972.972.972.972.97%0.360.360.360.360.360.360.360.36%0.520.520.520.520.520.520.520.52%%0.820.8296.620.820.820.820.8296.600.820.82kwh/tNaOH22472223NaClO3NaClO3盐水中Na2SO4阳极液中Na2SO4盐水中NaOH盐水中Na2CO3阳极液中HClOηNaClO3ηHClOηNaOHηNa2CO3ηO2电流效率直流电耗1、从表六可看出，06年、07年离子膜产量产能达设计产能，07年实际产量2、710JTC720JTC相比，710JTC720JTC；96%以上；4、720JTCH0.05v(H88只单元槽承受阴极侧造成膜污染，引起槽电压上升。7、装置存在的问题CPVC焊缝处常常泄漏，屡次造成单槽停车检修，给现场造成修理保养困难。、全部氯气安全阀全部内漏，被迫全部盲掉。、710JTC伍迪公司供给的二次盐水工序程控阀气缸属淘汰产品，不易购置。、720JTC装置过滤器曾设计有误，后我公司同伍迪公司屡次沟通，重设计在国内生产加工，运行效果较好。8、改进措施、对CPVC/FRP的碱管道用PPH材质管道更换。伍迪公司将氯气氢气过压保护系统改为压力掌握回路。、对710JTC装置二次盐水工序程控阀气缸设法选购同品质完全可互换的气缸。有碍9、结论BM2.7型离子膜电解槽运行稳定，装置安全牢靠，自动化程度高，易修理操作，槽电压上升速度相对较慢，膜效率