Catalyst and Molecular Sieve (Aluminum Hydroxide, Alumina, Boehmite)
1.Material Overview
Molecular sieves are artificially synthesized hydrated aluminosilicates (zeolites) or natural zeolites that have the function of screening molecules.
Structurally, it contains numerous uniformly sized channels and neatly arranged pores. Molecular sieves with different pore sizes separate molecules of different sizes and shapes. Different pore sizes are obtained based on the varying molecular ratios of SiO2 and Al2O3. Types include: 3A (potassium A type), 4A (sodium A type), 5A (calcium A type), 10Z (calcium Z type), 13Z (sodium Z type), Y (sodium Y type), and sodium mordenite zeolite, among others. It exhibits high adsorption capacity, strong selectivity, and high temperature resistance. It is widely used in organic and petrochemical industries and is also an excellent adsorbent for coal gas dehydration. Its application in waste gas purification is also receiving increasing attention.
2.Process Introduction
The wet material is fed into the spin flash dryer through conveying equipment, where it is dispersed by the high-speed airflow from the bottom to up. Fine particles are directly dried by hot air and carried away as it is blown upwards. Large particles that cannot be directly blown away is quickly dispersed and dried by the flashing and dispersing blades during its descent, and then carried away by the air again. The dried and qualified material enters the rotary kiln, where it undergoes calcination. The calcinated catalyst is discharged through the discharge hood.
3. Technical Advantages
1) Process coordination with material characteristics
The spin flash dryer first rapidly processes wet materials (such as filter cake, viscous material), preventing agglomeration with its built-in crushing and dispersing mechanism.It rapidly dehydrates the materials to an optimal moisture level (10-15%) and seamlessly connects to the calcination kiln. The calcination kiln then precisely regulates the temperature (400-800°C) to facilitate material crystal transformation and activate their properties, creating a continuous process that ideally meets the dual demands of catalyst and molecular sieve materials for uniform drying and precise calcination.
2) High efficiency + optimized heat utilization
The waste heat from spin flash drying exhaust gas can be used to preheat combustion air of the rotary kiln. After heat exchange, the high-temperature exhaust gas from the rotary kiln can supplement the heat source for spin flash drying, increasing the thermal efficiency by more than 25% compared to single unit. Spin flash dryer pretreatment significantly reduces the dehydration of rotary kiln and reduces energy consumption in the high-temperature section. The overall system energy consumption is significantly lower than that of the segmented process of drying + transfer + calcination.
3) Precise quality control + environmental protection
Spin flash dryer ensures an even dispersion of materials, preventing local overheating or incomplete reactions during calcination. The rotary kiln features a segmented temperature control and atmosphere adjustment system, ensuring the consistent stability of crucial indicators like material crystal form, specific surface area, and activity. The whole process runs in a fully enclosed system complemented by a two-stage dust removal setup, achieving a dust recovery rate of no less than 95%. This ensures no material leakage or exhaust gas pollution, fully complying with the environmental protection standards of the fine chemical industry.
4. Technical Benefit
1) High product quality
Continuous and cooperative processing avoids secondary moisture absorption and contamination during material transfer. After calcination, the product has regular crystal structure, stable activity, and high purity. The qualification rate has been increased from 92% in the conventional process to over 98%, fully meeting the industrial application standards for catalysts and molecular sieves and enhancing market competitiveness.
2) Reduced overall costs
Waste heat utilization reduces steam and electricity consumption by 20-30%. Continuous automated operation reduces manual handling and operation costs by 80%.
Integrated equipment occupies only 60% of the space required for segmented processes, saving on infrastructure investment.
Combined equipment has fewer vulnerable parts, resulting in a corresponding decrease in maintenance costs.
3) Capacity and environmental protection
It is suitable for large-scale continuous production, which greatly shortens the production cycle; the closed and environmentally friendly design does not require additional exhaust gas treatment equipment, thus meeting environmental protection requirements.