BM—2.7型電解槽運(yùn)行總結(jié)江蘇梅蘭化工 伍華勝陳玉林姚俊155萬(wàn)噸/20046月底投產(chǎn)運(yùn)4510萬(wàn)噸/20056083月33個(gè)月。裝置的二次鹽水、電解、淡鹽水脫氯工序引進(jìn)意大利伍迪公司的工藝技術(shù)，承受自然循N2030，16N982。1、電解槽的技術(shù)參數(shù)電解槽數(shù)量12臺(tái)單元槽數(shù)104只/臺(tái)槽復(fù)極元件活性面積2.7m2設(shè)計(jì)電流密度6kA/m2合同的電流密度4.35kA/m2直流電耗<2100kwh/tNaOH一期(710JTC)4臺(tái)電解槽二期(720JTC)8臺(tái)電解槽項(xiàng)目單位A槽項(xiàng)目單位A槽B槽C槽D槽電流效率%97.38電流kA11.8011.8011.8011.80槽電壓v286.57286.97286.57286.67單元數(shù)只94949494單元槽電壓V3.0433.0533.0493.050NaOH濃度%wt31.0430.9931.0831.10鹽水流量m3/h17.3017.3017.4017.40陽(yáng)極液溫度℃85.986.586.685.9Cl2純度%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鹽水中NaOHg/l0.190.190.190.19Na2CO3g/l0.550.550.550.55HClOg/l1.381.381.301.34陽(yáng)極液流量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直流電耗kwh/tNaOH2082.3(90℃ 32%)2097.6( 無(wú)修定)備注：710JTC729410只。項(xiàng)目單位A槽B項(xiàng)目單位A槽B槽C槽D槽E槽F槽G槽H槽電流kA11.7911.8111.8111.8511.8011.8011.8012.10槽電壓v319.45319.34319.35319.14319.83318.94319.53314.08單元數(shù)只104104104104104104104104NaOH濃度%wt31.5031.5331.5731.4732.1732.0932.2532.11鹽水流量m3/h21.4621.8021.7421.7119.5019.3019.0019.21陽(yáng)極液溫度℃86.8087.5487.4487.0286.3286.1486.5186.50Cl2純度%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陽(yáng)極液中g(shù)/l0.230.250.260.280.160.210.320.28NaClO3Na2SO4g/l4.254.254.254.253.033.743.942.91陽(yáng)極液中g(shù)/l5.045.004.985.013.544.754.953.85Na2SO4鹽水中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陽(yáng)極液流量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電流效率%97.9597.9897.6297.8897.8097.6597.6797.51直流電耗kwh/t2079.82085.02091.02081.72067.22067.42068.42054.4NaOH32%條件下的數(shù)值從表一、表二可看出：BM2.7離子膜電解槽電流效率>97%；2〕氯氣純度>98，O2/C21；NaClO3、HClO含量低；pH9~10.5的掌握指標(biāo)。4、電解主裝置工藝設(shè)備簡(jiǎn)述電解主裝置電解槽及附件、二次鹽水過(guò)濾器、樹(shù)脂塔、陰極液泵、真空泵由伍迪公司供給，二次鹽PLCDCS操作中心，其它均為國(guó)產(chǎn)設(shè)備。整流變壓器由原江西變壓器廠和原南通變壓器廠生產(chǎn)〔現(xiàn)均改名稱〔現(xiàn)均改名稱DCSPTFE/CCCPVC/FRP，電解槽主管由伍迪公司供給。5、有關(guān)原鹽使用和鹽水的質(zhì)量離子膜裝置運(yùn)行的效果集中表達(dá)在膜的使用壽命延長(zhǎng)、電流效率的合理下降和槽電壓的合理上升，而優(yōu)良的效果要靠電解槽的優(yōu)質(zhì)設(shè)計(jì)制造技術(shù)水平、鹽水質(zhì)量的優(yōu)質(zhì)和操作治理技能水平三者的有效結(jié)合，在電解槽確定后，后二者顯得尤其重要。本文著重爭(zhēng)論原鹽使用和鹽水的質(zhì)量對(duì)膜的影響。我公司一次鹽水開(kāi)車至今使用過(guò)進(jìn)口鹽〔先期為澳鹽，后來(lái)為墨西哥鹽、海鹽〔山東鹽、精制鹽〔江蘇井神鹽業(yè)公司和金壇鹽業(yè)公司〕及隔膜堿蒸發(fā)回收的堿鹽水、離子膜自身裝置回收的淡鹽水。伍迪公司對(duì)梅蘭進(jìn)電解槽鹽水〔04715日樣品〕的分析〔表三〕分析工程CaSrBaMnFeMgAlCa+MgSiO2ppb398610832063128分析方法ICP旭化成公司對(duì)梅蘭進(jìn)電解槽鹽水〔05年11月29日樣品〕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指標(biāo)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標(biāo)準(zhǔn)ppmppmppmppmppmppmppmppmg/lmg/lmg/l分析方法ICP比色pH計(jì)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分析工程樣品指標(biāo)Nafion范圍Nafion范圍<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分光光度計(jì)測(cè)量，其它用ICP測(cè)量；總有機(jī)碳測(cè)量；7ppm。Ca+Mg指標(biāo)雖合格但漸漸上升；pH9~10.5的掌握值；Ni的指標(biāo)偏高；TOC指標(biāo)偏高；FeDuPont專家DuPontNafion膜的使用指南和離子膜電解技術(shù)介紹來(lái)看，上述偏離指標(biāo)的雜質(zhì)對(duì)標(biāo)的偏離度，掌握在受控指標(biāo)范圍內(nèi)。6、實(shí)際運(yùn)行狀況0.30.3DM堿IM堿中0.15DM堿IM堿中年份溝通電耗kwh/tNaOH電流密度kA/m2產(chǎn)量萬(wàn)噸備注20042251.7852.8004710JTC 046月底開(kāi)車20052204.694.67.8345720JTC 056月底開(kāi)車20062253.994.2314.718020072304.454.517.2301、071210日電解槽運(yùn)行指標(biāo)〔表七〕(710JTC42個(gè)月)項(xiàng) 目單位A槽B槽C槽D槽電流kA13.0013.0013.0413.03槽電壓v340.1339.0340.1340.1單元數(shù)只104104104104NaOH濃度%wt32.1532.1032.2032.19鹽水流量m3/h21.021.421.221.1陽(yáng)極液溫度℃86.886.787.586.5Cl2純度%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鹽水中NaOHg/l0.390.390.390.39Na2CO3g/l0.590.590.590.59HClOg/l2.302.312.262.28ηNaClO3%0.40ηHClO%2.93ηNaOH%0.41ηηNa2CO3電流效率直流電耗%%kwh/tNaOH0.4696.112259720JTC電解槽運(yùn)行指標(biāo)〔表八〕 (運(yùn)行30個(gè)月)項(xiàng)目單位A槽B槽C槽D槽E槽F槽G槽H槽電流kA13.0513.0613.0613.0413.0613.0813.0313.04槽電壓v334.8335.9341.1335.9335.9334.8335.9326.6單元數(shù)只104104104104104104104104NaOH濃度%wt32.3332.2532.3132.3532.1932.2532.3032.21鹽水流量m3/h21.020.921.120.921.221.021.121.1陽(yáng)極液溫℃86.587.487.686.386.386.186.485.1度Cl2純度%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鹽水中Na2SO4陽(yáng)極液中Na2SO4鹽水中NaOH鹽水中Na2CO3陽(yáng)極液中HClOηNaClO3ηHClOηNaOHηNa2CO3ηO2電流效率直流電耗1、從表六可看出，06年、07年離子膜產(chǎn)量產(chǎn)能達(dá)設(shè)計(jì)產(chǎn)能，07年實(shí)際產(chǎn)量2、710JTC720JTC相比，710JTC720JTC；96%以上；4、720JTCH0.05v(H88只單元槽承受陰極側(cè)造成膜污染，引起槽電壓上升。7、裝置存在的問(wèn)題CPVC焊縫處常常泄漏，屢次造成單槽停車檢修，給現(xiàn)場(chǎng)造成修理保養(yǎng)困難。、全部氯氣安全閥全部?jī)?nèi)漏，被迫全部盲掉。、710JTC伍迪公司供給的二次鹽水工序程控閥氣缸屬淘汰產(chǎn)品，不易購(gòu)置。、720JTC裝置過(guò)濾器曾設(shè)計(jì)有誤，后我公司同伍迪公司屢次溝通，重設(shè)計(jì)在國(guó)內(nèi)生產(chǎn)加工，運(yùn)行效果較好。8、改進(jìn)措施、對(duì)CPVC/FRP的堿管道用PPH材質(zhì)管道更換。伍迪公司將氯氣氫氣過(guò)壓保護(hù)系統(tǒng)改為壓力掌握回路。、對(duì)710JTC裝置二次鹽水工序程控閥氣缸設(shè)法選購(gòu)?fù)焚|(zhì)完全可互換的氣缸。有礙9、結(jié)論BM2.7型離子膜電解槽運(yùn)行穩(wěn)定，裝置安全牢靠，自動(dòng)化程度高，易修理操作，槽電壓上升速度相對(duì)較慢，膜效率