旋转填充床中化学反应与转子质量不平衡的耦合作用机制

Rotor mass unbalance is a common fault of rotating packed beds. The source of the fault is the unbalanced mass generated by chemical reactions, which is the biggest obstacle to replace traditional towers in the production of nanometer materials and sulfur removal. To perform temperate mechanical balance on rotors only according to rotor dynamics has not completely resolve the effect on the rotor mass unbalance by the chemical reactions. Few people has researched on the mechanism of the rotor mass unbalance by the chemical reactions. It has not been reported that the research result of chemical reaction engineering is integrated into a rotor dynamic model to resolve the rotor mass unbalance. The project intends to take the process of magnesium carbonate preparation by a rotating packed bed as the research object, research on the effect of the multi-parameter variation of the rotor packed bed on the mass increase rate and distribution of adhesives, establish a mass increase rate and distribution model of the adhesives, explore the effect rule on rotor parameters, i.e. unbalanced mass, phase and vibration amplitude, by the multi-parameter variation through theoretical analysis, coupling modeling, fluid simulation, numerical analysis and experimental tests, and reveal the mechanism of the rotor mass unbalance by the chemical reactions. From the view of multidisciplinary fusion, the formation and development variation rule of the unbalance mass has been researched, the mechanism of predicting, suppressing and eliminating the rotor mass unbalance by the combination of mechanical balance and chemical reaction conditions has been established, and the scientific foundation for long-period stable operation of the rotating packed bed has been provided.

转子质量不平衡是旋转填充床常见故障，根源是化学反应产生不平衡质量，是制备纳米材料和脱硫中替代传统塔器的最大障碍。仅从转子动力学角度将转子暂时机械平衡，并未彻底根治化学反应对转子质量不平衡的作用效应。很少有人研究化学反应对转子质量不平衡的作用机制，融合化学反应工程学和转子动力学解决转子质量不平衡的研究尚未见报道。本项目拟以旋转填充床制备纳米碳酸镁为研究对象，研究多参数变化对黏附物的质量增加速率和分布的作用效应，建立黏附物质量增加速率和分布规律模型，通过理论分析、耦合建模、流体模拟、数值分析及实验测试，探索多参数变化对转子不平衡质量、相位及振动幅值等参数的作用规律，揭示出旋转填充床中化学反应与转子质量不平衡的耦合作用机制。从多学科融合的角度，研究出不平衡质量形成和发展变化规律，构建机械平衡和化学反应条件调节相结合进行预测、抑制和消除转子质量不平衡的机制，为旋转填充床长周期稳定运行提供科学依据。

转子质量不平衡是旋转填充床的常见故障，原因是化学反应中物料黏附转子填料且不均匀分布形成可变不平衡质量，由此引发的转子不平衡振动会破坏轴承、轴封，造成物料泄漏，严重制约填充床在制备纳米材料和脱硫脱硝领域替代传统塔器的工业化和规模化进程。本项目针对旋转填充床化学反应黏附导致的转子不平衡问题开展研究，研究了旋转填充床化学反应中参数变化对转子填料黏附质量产生的作用效应，揭示了多参数变化对黏附质量产生的作用规律，提出了旋转填充床运行全过程影响因素挖掘与风险预测方法，构建了化学反应多参数变化对转子黏附质量的耦合作用模型；提出了旋转填充床设计方法和超重力反应器球形转子设计方法并开发了相关设计软件，加工并搭建了旋转填充床试验台，验证了化学反应中转子上物质黏附机理、黏附物质量增加模型、转子运行状态预警及转子流体性能；建立了基于流体力学分析的转子反应空间流体分布模型，提出一种基于流体力学分析的旋转填料床转子结构优化设计方法，构建了基于参数变化的转子黏附物质量增加和分布规律模型及其对填充床转子振动幅值、振动频率的影响效应，通过正交试验得到了影响填充床转子振动响应特性因素的主次关系，建立了迷宫密封动盘振幅预测模型、轴承载荷预测模型和轴承寿命预测模型，通过参考轴承预测寿命判断更换轴承、轴封等配件的合适时机，给出调控决策避免可能产生的安全隐患；提出了一种基于超声波清洗的双电磁离合式旋转填充床监控系统设计方法、监控策略和调控机制，通过PLC编写了使主备用两个填充床在停机、工作、清洗三种状态间自动切换的的控制程序，提出了旋转填充床不平衡调控方法策略，并设计旋转填充床新结构及控制系统调控机制，研究了转子不平衡对化学反应的影响效应规律，通过机械平衡和化学反应条件调节结合的方法预测、抑制和消除化学反应参数条件变化对转子不平衡的影响，解决填充床长周期运转中物料泄漏问题，促进其工业化和规模化进程。