BM—2.7型電解槽運行總結江蘇梅蘭化工 伍華勝陳玉林姚俊155萬噸/20046月底投產運4510萬噸/20056083月33個月。裝置的二次鹽水、電解、淡鹽水脫氯工序引進意大利伍迪公司的工藝技術，承受自然循N2030，16N982。1、電解槽的技術參數電解槽數量12臺單元槽數104只/臺槽復極元件活性面積2.7m2設計電流密度6kA/m2合同的電流密度4.35kA/m2直流電耗<2100kwh/tNaOH一期(710JTC)4臺電解槽二期(720JTC)8臺電解槽項目單位A槽項目單位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( 無修定)備注：710JTC729410只。項目單位A槽B項目單位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陽極液中g/l0.230.250.260.280.160.210.320.28NaClO3Na2SO4g/l4.254.254.254.253.033.743.942.91陽極液中g/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。4、電解主裝置工藝設備簡述電解主裝置電解槽及附件、二次鹽水過濾器、樹脂塔、陰極液泵、真空泵由伍迪公司供給，二次鹽PLCDCS操作中心，其它均為國產設備。整流變壓器由原江西變壓器廠和原南通變壓器廠生產〔現均改名稱〔現均改名稱DCSPTFE/CCCPVC/FRP，電解槽主管由伍迪公司供給。5、有關原鹽使用和鹽水的質量離子膜裝置運行的效果集中表達在膜的使用壽命延長、電流效率的合理下降和槽電壓的合理上升，而優良的效果要靠電解槽的優質設計制造技術水平、鹽水質量的優質和操作治理技能水平三者的有效結合，在電解槽確定后，后二者顯得尤其重要。本文著重爭論原鹽使用和鹽水的質量對膜的影響。我公司一次鹽水開車至今使用過進口鹽〔先期為澳鹽，后來為墨西哥鹽、海鹽〔山東鹽、精制鹽〔江蘇井神鹽業公司和金壇鹽業公司〕及隔膜堿蒸發回收的堿鹽水、離子膜自身裝置回收的淡鹽水。伍迪公司對梅蘭進電解槽鹽水〔04715日樣品〕的分析〔表三〕分析工程CaSrBaMnFeMgAlCa+MgSiO2ppb398610832063128分析方法ICP旭化成公司對梅蘭進電解槽鹽水〔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標準ppmppmppmppmppmppmppmppmg/lmg/lmg/l分析方法ICP比色pH計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分光光度計測量，其它用ICP測量；總有機碳測量；7ppm。Ca+Mg指標雖合格但漸漸上升；pH9~10.5的掌握值；Ni的指標偏高；TOC指標偏高；FeDuPont專家DuPontNafion膜的使用指南和離子膜電解技術介紹來看，上述偏離指標的雜質對標的偏離度，掌握在受控指標范圍內。6、實際運行狀況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產量萬噸備注20042251.7852.8004710JTC 046月底開車20052204.694.67.8345720JTC 056月底開車20062253.994.2314.718020072304.454.517.2301、071210日電解槽運行指標〔表七〕(710JTC42個月)項 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單元數只104104104104NaOH濃度%wt32.1532.1032.2032.19鹽水流量m3/h21.021.421.221.1陽極液溫度℃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電解槽運行指標〔表八〕 (運行30個月)項目單位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陽極液中Na2SO4鹽水中NaOH鹽水中Na2CO3陽極液中HClOηNaClO3ηHClOηNaOHηNa2CO3ηO2電流效率直流電耗1、從表六可看出，06年、07年離子膜產量產能達設計產能，07年實際產量2、710JTC720JTC相比，710JTC720JTC；96%以上；4、720JTCH0.05v(H88只單元槽承受陰極側造成膜污染，引起槽電壓上升。7、裝置存在的問題CPVC焊縫處常常泄漏，屢次造成單槽停車檢修，給現場造成修理保養困難。、全部氯氣安全閥全部內漏，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品，不易購置。、720JTC裝置過濾器曾設計有誤，后我公司同伍迪公司屢次溝通，重設計在國內生產加工，運行效果較好。8、改進措施、對CPVC/FRP的堿管道用PPH材質管道更換。伍迪公司將氯氣氫氣過壓保護系統改為壓力掌握回路。、對710JTC裝置二次鹽水工序程控閥氣缸設法選購同品質完全可互換的氣缸。有礙9、結論BM2.7型離子膜電解槽運行穩定，裝置安全牢靠，自動化程度高，易修理操作，槽電壓上升速度相對較慢，膜效率