Application and development of metal filter materials in high-temperature gas filtration
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摘要: 介绍了Fe3Al金属间化合物过滤材料在洁净煤工业装置中的飞灰过滤器、310S合金滤芯在石油炼化S Zorb工艺中的反应器过滤器以及Hastelloy X合金滤芯在化工工艺活化炉过滤器中的应用情况，分析了金属过滤材料的耐温性、耐蚀性、抗热震性、可加工性和强度等性能。结果表明：在高温除尘介质过滤应用上，金属过滤材料比陶瓷材料具有更好的适应性和优越性。结合国家能源与环保产业发展战略与规划，预测了金属过滤材料将在金属与无机非金属复合过滤材料、高通量金属过滤膜材料等方向的突破与革新。Abstract: The application of metal filters in high-temperature gas filtration was introduced, including Fe3Al intermetallic compound filter material used in fly ash filter of clean coal industry, 310S alloy filter used in S Zorb process reactor filter of oil refining industry, and Hastelloy X alloy used in chemical engineering activation furnace filter. The properties of metal filter materials, such as temperature resistance, corrosion resistance, thermal shock resistance, workability, and strength, were analyzed. The results show that, the metal filter materials has the better adaptability and performance than the ceramic filter materials in high temperature dust removal processes. Combined with the development strategy of national energy and environmental protection industry, it is predicted the breakthrough and innovation of metal filter materials in the direction of metal and inorganic nonmetallic composite filter materials and high flux metal filter membrane materials.
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图 4 Fe3Al金属滤芯实际流量–压差运行曲线
Figure 4. Flow and pressure of Fe3Al intermetallic compound filter material
图 6 滤芯表面飞灰激光粒度
Figure 6. Laser particle size distribution of fly ash on filter surface
图 8 国产ME101滤芯过滤器处理量与压差的变化
Figure 8. Processing capacity and pressure of domestic ME101 work filter
图 9 国产ME101滤芯过滤器2~5个月处理量与压差的变化
Figure 9. Processing capacity and pressure of domestic ME101 work filter in 2~5 months
图 11 高温合金滤芯（a）和组件（b）宏观形貌
Figure 11. Macro-appearances of superalloy filters (a) and components (b)
表 1 壳牌煤气化装置合成气气体组分（体积分数）
Table 1. Syngas composition of Shell coal gasification device
% H2 N2 CO CO2 CH4 O2 + Ar H2S 20.90 16.19 60.68 1.97 0.01 0.18 0.04 
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表 2 不同状态滤芯样品的孔径与渗透性
Table 2. Pore size and permeability of different filters
样品状态与编号 孔径/ μm 渗透率/ [m3·(m2·Pa·min)-1] 最小 平均 最大 新滤芯 1# 6.41 6.50 36.63 1.51×10-3 2# 6.28 6.33 38.44 1.65×10-3 清洗一次的滤芯 1# 4.42 9.52 36.34 1.28×10-3 2# 4.47 9.07 35.46 1.21×10-3 清洗两次的滤芯 1# 4.36 8.76 38.13 1.55×10-3 2# 6.28 6.34 34.19 1.46×10-3
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表 3 不同种类滤芯的压溃强度
Table 3. Crushing strength of different filters
样品编号 新金属滤芯1# 新金属滤芯2# 清洗一次后的金属滤芯1# 清洗一次后的金属滤芯2# 清洗两次后的金属滤芯1# 清洗两次后的金属滤芯2# 陶瓷1# 陶瓷2# 压溃强度/ MPa 67 66 62 60 56 61 28 26
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表 4 不同种类滤芯的抗弯疲劳强度
Table 4. Bending fatigue strength of the different types of filters
滤芯种类 样品类型 最大断裂力/ N 断裂部位 新金属滤芯 焊缝端 306 紧邻焊缝的焊接热影响区 清洗一次后的金属滤芯 焊缝端 298 紧邻焊缝的焊接热影响区 清洗两次后的金属滤芯 焊缝端 279 紧邻焊缝的焊接热影响区 清洗后的陶瓷滤芯 异型端 206 靠异型端圆弧底部的直管2 mm处
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气体性质 进口压力/ kPa 进口温度/ ℃ 进口密度
/ (kg·m-3)进口流量
/ (m3·min-1)吸附剂含量
/ (grain·m-3)吸附剂密度
/ (kg·m-3)吸附剂粒径范围/ μm 颗粒平均粒径/ μm 烃蒸气 2944 441 38.25 64.09 9887 1906 0~100 25 氢气 2745 371 1.94 19.54 9887 1906 0~100 25 氮气 1310 371 7.33 27.70 9887 1906 0~100 25
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表 6 国产与进口ME101工作滤芯的孔隙特性与压溃强度
Table 6. Pore characteristics and crushing strength of domestic and imported ME101 work filter
滤芯种类 孔径/ μm 渗透率/ [m3·(m2·Pa·min)-1] 孔隙率/ % 压溃强度/ MPa 最大 平均 最小 国产工作滤芯 9.24 7.48 7.33 1.25×10-3 37.3 178.0 进口工作滤芯 9.93 7.40 7.26 1.16×10-3 37.2 123.5
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表 7 国产与进口工作滤芯管体及焊缝的拉伸性能
Table 7. Tensile properties of domestic and imported filter and weld
测试件 抗拉强度/ MPa 延伸率/ % 进口滤芯管体 123 9.7 进口滤芯焊缝 126 10.1 国产滤芯管体 132 11.2 国产滤芯焊缝 135 10.8
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表 8 典型高温活化炉过滤器设计条件和技术参数
Table 8. Design conditions and technical parameters of typical high temperature activation furnace filter
工艺气体 过滤能力 设计温度/ ℃ 操作温度/ ℃ 设计压力/ MPa 操作压力/ MPa 过滤介质 空气/氮气+ 催化剂颗粒 最大301 kg·h-1 982 15.5~982 0.034 0.00686 催化剂粉末
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表 9 高温合金滤芯的孔隙特性及压溃强度
Table 9. Pore characteristic and crushing strength of superalloy filters
孔隙率/ % 渗透率/
[m3·(m2·Pa·min)-1]孔径/ μm 压溃强度/ MPa 平均 最大 30~35 ≥2.5×10-3 19~23 28~33 ≥200
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