A cleaning control method and system for removing rust and scale from a water cooling pipeline of a metallurgical furnace

Abstract

The present application relates to circulating water cooling control technical field, disclose a kind of metallurgical furnace water cooling pipeline rust and scale dissolving cleaning control method and system, method includes collecting pipeline flow section data, rust scale mass and distribution characteristics, comprehensive analysis determines the blockage grade, output trigger signal;When receiving the trigger signal of washable state, according to preset program in mechanical pretreatment program and chemical scale dissolving cleaning program Select one as start program;Again in turn start neutralization passivation program and pre-film protection program or chemical scale dissolving cleaning program, neutralization passivation program and pre-film protection program;Sensor and sampling point are arranged in the whole process of cleaning of four programs, real-time acquisition on-line monitoring data;Whether the current state deviates from safety interval according to preset threshold value is judged, dynamically generates control instruction;Receive on-line monitoring data, automatically execute control logic.The present application integrates data acquisition, program selection, real-time monitoring and closed-loop control.

Description

Technical Field

[0001] This invention relates to the field of circulating water cooling control technology, and in particular to a cleaning control method and system for rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces and kilns. Background Technology

[0002] Circulating cooling water systems are crucial in modern metallurgical smelting processes, and their reliable operation directly affects the safety and efficiency of core smelting equipment. Extensive carbon steel water-cooled pipes are installed around high-temperature equipment such as smelting furnaces, flues, and waste heat boilers, playing a vital role in removing high-temperature heat and protecting the furnace shell. However, due to the harshness of smelting conditions, water cooling systems frequently face corrosion and scaling problems. Firstly, smelting furnaces operate under high heat loads for extended periods, coupled with transient fluctuations. Heat flux densities vary and fluctuate over time in different parts of the furnace, with localized rapid temperature rises and falls in the furnace walls. Under complex stress, the cooling water also experiences multiple thermo-mechanical-chemical effects, with water temperatures in some areas ranging from 50–75°C and exhibiting significant fluctuations. Because smelting units operate continuously for long periods with little opportunity for shutdown for cooling and maintenance, corrosion and scaling products accumulate sufficiently. If water quality control is inadequate or material protection is insufficient, electrochemical corrosion and product deposition may occur on localized pipe walls, gradually developing into severe rust and scale blockage. On the other hand, smelting enterprises generally use softened water or reclaimed water as circulating cooling water. This type of water has low hardness but is mostly slightly acidic and has sufficient dissolved oxygen, often containing a certain concentration of Cl. - Corrosive ions, at low pH, Cl - Under conditions of high dissolved oxygen, accelerated electrochemical corrosion occurs on the inner wall of carbon steel, generating Fe... 2+ / Fe 3+ Further oxidation and hydrolysis lead to the deposition of a rust scale layer. Scale analysis shows that iron and oxygen constitute the majority of the blockage, with Fe3O4 and FeO(OH) as the main mineral phases. It exhibits a double-layered structure of dense black rust on the inside and loose brown rust on the outside, interspersed with small amounts of sulfur from sulfate or flue gas SO2, and chloride ions that damage the passivation film. Therefore, the scale in the circulating water system is essentially a rust deposition dominated by steel pipe corrosion products, rather than traditional CaCO3 hardness scale. Once this type of scale spreads in the water-cooled pipelines, it significantly reduces the effective pipe diameter, increases flow resistance, leading to a decrease in circulating water volume, an increase in the inlet and outlet temperature difference, a decrease in the heat transfer coefficient, an abnormal increase in the furnace shell and water jacket wall temperature, and a significant reduction in cooling margin. As the pipe wall continues to corrode and thin, and local overheating occurs, stress concentration can easily induce leakage or even pipe rupture accidents. If water suddenly leaks into the molten pool or flue in the high-temperature area, it may also cause violent vaporization and secondary explosion, posing a serious threat to the smelting furnace and personnel safety. At the same time, it forces the unit to operate at reduced load or be forced to shut down for maintenance, resulting in huge direct and indirect economic losses.

[0003] Currently used anti-scaling and cleaning measures are insufficient to effectively address corrosive scale buildup, primarily composed of rust. Traditional water treatment agents are mostly designed for hard scale such as CaCO3, and have limited dissolving ability for magnetite-type black rust and dense FeO(OH) deposits. Mechanical methods such as scraping, blasting, and high-pressure water flushing can only remove the outer, loose rust layer, having little effect on the firmly attached inner black rust, which easily re-accumulates and forms rust plugs in areas such as bends. While chemical cleaning can quickly dissolve rust with strong acids, without targeted formulations and process control, it can easily cause over-corrosion of the substrate and hydrogen embrittlement, leading to new safety and environmental risks. Existing solutions generally suffer from incomplete cleaning, damage to the substrate, and rapid re-clogging. The cleaning process lacks a phased, systematic approach and coordination with operational water quality management, resulting in a vicious cycle of corrosion and cleaning in the pipeline.

[0004] Therefore, the problem of rust and scaling in smelting water cooling systems is characterized by multi-factor coupling, strong concealment, and stubbornness in treatment. There is an urgent need for an efficient integrated cleaning and protection technology for rust-type deposits: a technology that can quickly and thoroughly dissolve and remove Fe3O4 / FeO(OH) rust and scale while ensuring on-site operation safety, simple and feasible process, and short construction period; a technology that can also inhibit secondary corrosion through passivation pre-filming and water quality stabilization control; and a technology that can extend the fault-free operation cycle of the water cooling system by combining online monitoring and early warning methods. Summary of the Invention

[0005] The main objective of this invention is to provide a cleaning control method and system for rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces and kilns, in order to solve the problems in the prior art of incomplete cleaning, damage to the substrate, and rapid re-clogging. The cleaning process lacks a phased and systematic approach and coordination with the operation of water quality management, which leads to a vicious cycle between corrosion and cleaning in the pipelines.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A cleaning control method for rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces and kilns, comprising: collecting pipeline flow cross-section and rust and scale characteristic data, determining the blockage level, and outputting a cleanable trigger signal; upon receiving the cleanable signal, adaptively selecting a start program from mechanical pretreatment and chemical cleaning according to the blockage level, and sequentially executing chemical cleaning, neutralization passivation, and pre-film protection processes; During the cleaning process, the concentration of iron ions, pH value, temperature, flow rate and corrosion rate of the substrate in the cleaning solution are monitored in real time. When the concentration of iron ions tends to stabilize and the pH rises to the set threshold, the system automatically switches from chemical cleaning to neutralization and passivation. When the corrosion rate approaches the safety limit, the current cleaning is automatically interrupted and the system is forced to switch to neutralization and passivation. Heating, circulation and chemical dosing are adjusted in real time to keep the temperature, flow rate and chemical concentration dynamically within the target range.

[0007] As a further improvement of the present invention, when a trigger signal indicating a washable state is received, one of the mechanical pretreatment program and the chemical scale removal cleaning program is selected as the start program according to a preset program; then the neutralization and passivation program and the pre-film protection program or the chemical scale removal cleaning program, the neutralization and passivation program and the pre-film protection program are started in sequence. Sensors and sampling points are deployed throughout the four cleaning processes to collect real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate, and weight loss of the corrosion test piece; based on preset thresholds, it is determined whether the current state deviates from the safe range, and control commands are dynamically generated.

[0008] As a further improvement of the present invention, the process of setting the preset program includes the following steps: When the clogging level is low, a trigger command is generated to directly start the chemical scale removal cleaning program, and the trigger command is output to the start end of the chemical scale removal cleaning program; when the clogging level is medium or high, a sequence control command is generated to first start the mechanical pretreatment program, and then start the chemical scale removal cleaning program after the mechanical pretreatment program is completed, and the sequence control command is output to the start end of the mechanical pretreatment program and the delayed start end of the chemical scale removal cleaning program. Based on the type of trigger instruction or sequence control instruction, the corresponding program chain template is retrieved from the preset program chain template library. There are two types of program chain templates: the first type consists of a chemical scale removal and cleaning program, a neutralization and passivation program, and a pre-film protection program connected in series; the second type consists of a mechanical pretreatment program, a chemical scale removal and cleaning program, a neutralization and passivation program, and a pre-film protection program connected in series. According to the program sequence in the program chain template, start signals are sent sequentially to the actuators corresponding to each program. When the program chain template is the first type, a start signal is first sent to the actuator of the chemical scale removal and cleaning program. After receiving the completion signal of the chemical scale removal and cleaning program, a start signal is then sent to the actuator of the neutralization and passivation program. After receiving the completion signal of the neutralization and passivation program, a start signal is finally sent to the actuator of the pre-film protection program. When the program chain template is the second type, a start signal is first sent to the actuator of the mechanical pretreatment program. After receiving the completion signal of the mechanical pretreatment program, a start signal is then sent to the actuator of the chemical scale removal and cleaning program. After receiving the completion signal of the chemical scale removal and cleaning program, a start signal is then sent to the actuator of the neutralization and passivation program. After receiving the completion signal of the neutralization and passivation program, a start signal is finally sent to the actuator of the pre-film protection program.

[0009] As a further improvement of the present invention, the process of retrieving the corresponding program chain template from the preset program chain template library includes the following steps: Extract the type identifier carried in the trigger instruction or sequence control instruction, and match the type identifier with the preset instruction type lookup table. When the matching result is a trigger instruction type, output the first type code; when the matching result is a sequence control instruction type, output the second type code. The received first type code and second type code are compared one by one with the pre-set associated codes of each template in the program chain template library; when the type code matches the associated code of the first template in the program chain template library, the storage address of the first template is located in the program chain template library; when the type code matches the associated code of the second template in the program chain template library, the storage address of the second template is located in the program chain template library. The corresponding template content is read from the program chain template library according to the storage address. The read template content is encapsulated into a template output data packet containing program sequence identifier and program connection order fields, and then sent to the program execution controller.

[0010] As a further improvement of the present invention, the process of extracting the type identifier carried in the trigger instruction or sequence control instruction includes the following steps: Receive the output trigger command or sequence control command, and separate the command header area and command payload area from the data packet of the trigger command or sequence control command; Read the congestion level code value from the fixed field bit in the instruction header area; at the same time, read the preset verification parameter corresponding to the congestion level code value from the instruction payload area, compare the congestion level code value with the preset verification parameter for consistency, and when the comparison result is consistent, mark the congestion level code value as a valid level code. The valid level code is matched with the preset level and type mapping table. When the valid level code corresponds to a low congestion level, the trigger instruction type identifier is output; when the valid level code corresponds to a medium or high congestion level, the sequence control instruction type identifier is output; the trigger instruction type identifier or the sequence control instruction type identifier is output to the preset instruction type lookup table.

[0011] As a further improvement of the present invention, the process of separating the instruction header region and the instruction payload region from the data packet of the trigger instruction or sequence control instruction includes the following steps: The system receives and outputs data packets containing trigger commands or sequence control commands. The data packets consist of a fixed-length command header containing a blockage level code and a cleaning program identifier, and a variable-length command body containing a mechanical pretreatment completion signal verification field and a chemical scale removal cleaning start delay parameter. After storing the data packets in a buffer, the system compares them byte by byte in the buffer with a preset command start identifier. When consecutive comparison results are completely consistent with the command start identifier, the starting position of the consecutive bytes is recorded as the data packet start boundary. Based on the recorded data packet start boundary, locate the byte position in the buffer at the preset header length field offset from the data packet start boundary, and read the header length value stored at the byte position; extract a continuous byte sequence from the buffer with the data packet start boundary as the starting point and the header length value as the truncation length, and output the extracted continuous byte sequence as the instruction header area; the instruction header area contains the congestion level code and the cleaning program identifier, which is used to read the congestion level code value; Based on the byte length occupied by the output instruction header area, the payload start boundary is obtained by adding the byte length to the data packet start boundary. From the payload start boundary to the end of the data packet in the buffer, the remaining continuous byte sequence is extracted and output as the instruction payload area. The instruction payload area contains the mechanical preprocessing completion signal verification field and the chemical scale removal cleaning start delay parameter, which are used to read the preset verification parameters. The instruction header area and the instruction payload area are output.

[0012] As a further improvement of the present invention, the process of extracting the remaining continuous byte sequence includes the following steps: Based on the output instruction header area, read the cleaning program identifier bit from the instruction header area. Based on the program type corresponding to the cleaning program identifier bit, obtain the first offset position and first field length of the mechanical pretreatment completion signal verification field, as well as the second offset position and second field length of the chemical scale dissolution cleaning start delay parameter from the preset load field configuration table. Output the obtained first offset position, first field length, second offset position, and second field length to the load extraction control terminal. Based on the first offset position and the first field length of the output, and taking the determined load start boundary as a reference, the load start boundary is offset backward by the first offset position to obtain the starting byte position of the mechanical preprocessing completion signal verification field; starting from the starting byte position, a byte sequence of the first field length is continuously extracted, and the byte sequence is used as the value of the mechanical preprocessing completion signal verification field; at the same time, the value of the mechanical preprocessing completion signal verification field is compared with the preset mechanical preprocessing completion standard check code. When the comparison is consistent, a load valid confirmation mark is generated; when the comparison is inconsistent, a load abnormality mark is generated and subsequent extraction is stopped. Based on the output second offset position and the second field length, and assuming the load valid confirmation flag is generated, the load start boundary is shifted backward by the second offset position to obtain the starting byte position of the chemical scale removal start delay parameter, using the load start boundary as a reference. A byte sequence of the second field length is continuously extracted from the starting byte position, and the byte sequence is used as the chemical scale removal start delay parameter value. The extracted mechanical preprocessing completion signal verification field value and the extracted chemical scale removal start delay parameter value are merged and encapsulated to form the instruction load area output.

[0013] As a further improvement of the present invention, the process of using the byte sequence as a mechanical preprocessing step to complete the signal verification field value includes the following steps: Based on the first offset position and the first field length of the output, and taking the determined load start boundary as a reference, the load start boundary is shifted backward by the first offset position to obtain the starting byte position of the mechanical preprocessing completion signal verification field. Starting from the starting byte position, the first field length bytes are read sequentially according to the preset byte-by-byte reading method. The read byte sequence is stored in the temporary verification buffer area and output as the original verification byte sequence. According to the preset verification field structure template, the mechanical preprocessing program type identifier and the mechanical preprocessing completion timestamp field are separated from the original verification byte sequence; the separated mechanical preprocessing program type identifier is matched with the preset mechanical preprocessing type lookup table; when the match is consistent, the mechanical preprocessing completion timestamp field is compared with the timestamp verification segment in the preset mechanical preprocessing completion standard verification code; when the absolute value of the difference is within the preset allowable range, a valid field structure identifier is generated. Under the premise of generating a valid identifier for the field structure, the original check byte sequence is summed and compared with the checksum field in the preset mechanical preprocessing completion standard check code. When the sum of the original check byte sequence matches the checksum field, the original check byte sequence is marked as a valid mechanical preprocessing completion signal check field value.

[0014] As a further improvement of the present invention, online monitoring data in the cleaning fluid is received, compared with preset process parameters, and control logic is automatically executed. The control logic includes: when the iron ion concentration tends to stabilize and the pH rises to the set threshold during the chemical scale dissolution stage, the stage switching is automatically triggered, and the process enters the neutralization and passivation process; when the corrosion rate monitoring value approaches the safety upper limit, the current cleaning is automatically interrupted and the process is forcibly switched to the neutralization stage; the heating device, circulation pump frequency and dosing pump output are adjusted in real time to make the key parameters of temperature, flow rate and reagent concentration dynamically converge to the target range, so as to achieve closed-loop optimization control of the entire process.

[0015] To achieve the above objectives, the present invention also provides the following technical solution: A cleaning and control system for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns includes: The blockage detection module is used to collect pipeline flow cross-sectional data, rust and scale quality and distribution characteristics, comprehensively analyze and determine the blockage level, and output a trigger signal for cleanable or non-cleanable status; providing a classification basis for mechanical pretreatment procedures. The rust and scale removal cleaning module is used to select one of the mechanical pretreatment program and the chemical scale removal cleaning program as the start program when a trigger signal indicating that the cleaning state is available is received. Then, it sequentially starts the neutralization and passivation program and the pre-film protection program, or the chemical scale removal cleaning program, the neutralization and passivation program and the pre-film protection program. Sensors and sampling points are deployed throughout the cleaning process of the four programs to collect real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate and weight loss of corrosion test pieces. Based on preset thresholds, it judges whether the current state deviates from the safe range and dynamically generates control commands. The online monitoring and control module is used to deploy sensors and sampling points throughout the entire cleaning process of the four procedures to collect real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate, and weight loss of the corrosion test piece; it determines whether the current state deviates from the safe range based on preset thresholds and dynamically generates control commands. The closed-loop feedback control module is used to receive online monitoring data, compare it with preset process parameters, and automatically execute control logic.

[0016] To achieve the above objectives, the present invention also provides the following technical solution: An electronic device includes a processor and a memory coupled to the processor, the memory storing program instructions executable by the processor; when the processor executes the program instructions stored in the memory, it implements the cleaning control method for rust removal and scale dissolution of water-cooled pipelines in metallurgical furnaces as described above.

[0017] To achieve the above objectives, the present invention also provides the following technical solution: A storage medium storing program instructions, which, when executed by a processor, implement a cleaning control method for rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces, as described above.

[0018] This invention determines the blockage level based on a comprehensive analysis of pipeline flow cross-sectional data and rust characteristics, providing a quantitative basis for cleaning feasibility and ensuring the targeted implementation of graded mechanical pretreatment procedures to avoid ineffective cleaning or equipment damage. Secondly, through a preset program, it adaptively selects between mechanical pretreatment and chemical descaling, and sequentially links neutralization, passivation, and pre-film protection procedures to form a multi-stage collaborative cleaning process. This effectively removes rust while ensuring the chemical stability and long-term corrosion resistance of the pipeline substrate. Furthermore, by utilizing sensors and sampling points deployed throughout the process, it monitors parameters such as iron ion concentration, pH value, temperature, flow rate, and weight loss of corrosion samples in real time. Combined with preset thresholds, it dynamically generates control commands to achieve immediate diagnosis and safety warnings of the cleaning process status. Through automatic comparison and logical control of online monitoring data and preset process parameters, it achieves intelligent switching and parameter optimization of key cleaning stages. Attached Figure Description

[0019] Figure 1 This is a schematic flowchart of one embodiment of the cleaning control method for rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces and kilns according to the present invention. Figure 2 This is a schematic flowchart illustrating the steps of an embodiment of the cleaning control method for rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces and kilns of the present invention, which outputs a trigger signal indicating a cleanable or non-cleanable state. Figure 3 This is a schematic diagram of the steps for setting a preset program in an embodiment of the cleaning control method for rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces and kilns according to the present invention. Figure 4 This is a schematic diagram of the steps for dynamically generating control commands in an embodiment of the cleaning control method for rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces and kilns according to the present invention. Figure 5 This is a schematic diagram of the functional modules of a cleaning and scale removal control system for water-cooled pipelines of metallurgical furnaces and kilns according to an embodiment of the present invention. Figure 6 This is a schematic diagram of the structure of an embodiment of the electronic device of the present invention; Figure 7 This is a schematic diagram of the structure of a storage medium according to an embodiment of the present invention; Figure 8 This is a schematic diagram illustrating the effect of elemental and phase composition analysis in rust and scale samples of the present invention. Figure 1 ; Figure 9 This is a schematic diagram illustrating the effect of elemental and phase composition analysis in rust and scale samples of the present invention. Figure 2 . Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] The terms "first," "second," and "third" in this invention are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first," "second," or "third" may explicitly or implicitly include at least one of those features. In the description of this invention, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified. All directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of this invention are only used to explain the relative positional relationships and movements between components in a specific orientation (as shown in the figures). If the specific orientation changes, the directional indication changes accordingly. Furthermore, the terms "including" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or devices.

[0022] References to embodiments herein mean that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0023] This invention relates to the field of maintenance and cleaning technology for water cooling systems in non-ferrous metal smelting equipment, particularly to methods for rust removal, scale removal, and operational protection of carbon steel water cooling pipelines in copper, lead, and nickel smelters, such as furnace shell cooling water jackets and flue gas waste heat boiler tube bundles. Specifically, it aims to efficiently remove rust and scale deposits from water cooling circulation pipelines, restore unobstructed cooling circuits, and protect the pipelines through measures such as chemical passivation pre-filming, thereby extending the cleaning cycle and ensuring the safe and stable operation of smelting equipment.

[0024] like Figure 1 As shown, this embodiment provides a method for cleaning and controlling rust removal and scale dissolution in water-cooled pipelines of metallurgical furnaces and kilns. Specifically, this method includes the following steps: Step S1: Collect pipeline flow cross-section data, rust and scale quality and distribution characteristics, comprehensively analyze and determine the blockage level, and output a trigger signal for cleanable or non-cleanable status; provide a classification basis for the mechanical pretreatment program; Step S2: When a trigger signal indicating that the cleaning state is received, select one of the mechanical pretreatment program and the chemical scale removal cleaning program as the start program according to the preset program; then start the neutralization and passivation program and the pre-film protection program or the chemical scale removal cleaning program, the neutralization and passivation program and the pre-film protection program in sequence. The process includes: Mechanical pretreatment: using methods such as blasting and high-pressure water flushing to transform the original blocked pipeline into a basically unobstructed pipeline with the flow cross-section restored to more than 50% and loose rust removed; Chemical descaling and cleaning: connecting the basically unobstructed pipeline to a circulating cleaning loop, using organic or inorganic acid systems to dissolve stubborn rust, forming a clean pipeline where the rust has been converted into soluble iron compounds and carried out, and the pipe wall substrate has not been corroded; Neutralization and passivation: neutralizing the clean pipeline with alkaline washing to remove residual acidic media, forming a pipeline with a neutral pH and no residual corrosive ions; Pre-film protection: injecting a passivating agent into the neutralized pipeline to form a dense protective film on the inner metal wall, creating a pipeline with corrosion resistance, ready for normal operation; Step S3: Deploy sensors and sampling points throughout the entire cleaning process of the four procedures to collect real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate, and weight loss of the corrosion test piece; determine whether the current state deviates from the safe range based on preset thresholds and dynamically generate control commands. Step S4: Receive online monitoring data, compare it with preset process parameters, and automatically execute control logic; The control logic includes: when the iron ion concentration tends to stabilize and the pH rises to the set threshold during the chemical scaling stage, the stage switching is automatically triggered, and the process enters the neutralization and passivation process; when the corrosion rate monitoring value approaches the safety upper limit, the current cleaning is automatically interrupted and the process is forcibly switched to the neutralization stage to prevent the substrate from being over-corroded; the heating device, circulation pump frequency and dosing pump output are adjusted in real time to make key parameters such as temperature, flow rate and reagent concentration dynamically converge to the target range, so as to achieve closed-loop optimization control of the entire process.

[0025] In this embodiment, the pipeline flow cross-section data refers to the effective cross-sectional area of ​​the water-cooled pipeline that allows fluid to pass through, usually expressed as a percentage of the initial design diameter; for example, mechanical pretreatment requires restoring the flow cross-section to ≥50%. Rust and scale quality and distribution characteristics refer to the total mass of rust deposits removed from the pipeline, such as by weighing, as well as the location, thickness, looseness or density of the rust and scale on the inner wall of the pipeline, its double-layer structure, and spatial distribution characteristics such as the inner black rust Fe3O4 and the outer brown rust FeO(OH). Blockage level is a classification result based on a comprehensive evaluation of the flow cross-section data, rust and scale quality, and distribution characteristics, such as high, medium, and low levels, used to determine whether mechanical pretreatment is needed and the aggressiveness of subsequent cleaning schemes. Cleanable or non-cleanable state is a trigger signal output according to the blockage level; when the blockage degree is within the technically manageable range, such as a flow cross-section ≥50% or recoverable through mechanical pretreatment, it outputs "cleanable"; when the blockage is too severe or there is structural damage that cannot be safely cleaned, it outputs "non-cleanable". Sensors and sampling points are temporarily installed in the cleaning circulation loop of the detection device, including online sensors such as pH meters, thermometers, flow meters, iron ion concentration meters, and manual sampling ports, to acquire real-time process data. Iron ion concentration: the total iron ions (Fe) dissolved in the cleaning solution. 2+ / Fe 3+ Content, in mg / L; reflects the rate of rust dissolution and the amount of rust dissolved. pH value: the acidity or alkalinity of the cleaning solution. The pH should be controlled below 3 during the pickling stage and raised to 6.8-7.5 during the neutralization stage. Temperature: the actual temperature of the cleaning solution during circulation, in °C. Organic acid systems should be controlled at 50-70°C, and inorganic acid systems at room temperature to 50°C. Flow rate: the linear velocity of the cleaning solution flowing in the pipeline, in m / s. ≥1.5 m / s is required, preferably 2-3 m / s, to ensure turbulent flow. Corrosion test piece weight loss: a carbon steel test piece of known mass is placed in the cleaning loop, weighed after a certain time, and the mass loss is calculated and converted into the substrate corrosion rate (mm / a) to assess the degree of corrosion on the pipe wall during the cleaning process.

[0026] Preferably, the water-cooled pipeline rust removal and scale removal control method of this embodiment achieves the following comprehensive technical effects by integrating data acquisition, program selection, real-time monitoring, and closed-loop control: First, based on the comprehensive analysis of pipeline flow cross-section data and rust and scale characteristics, the blockage level is determined, providing a quantitative basis for cleaning feasibility and ensuring that the graded implementation of the mechanical pretreatment program is targeted, avoiding ineffective cleaning or equipment damage. Second, through a preset program, adaptive selection is made between mechanical pretreatment and chemical scale removal, and the neutralization, passivation, and pre-film protection programs are linked sequentially to form a multi-stage collaborative cleaning process, effectively removing rust and scale while ensuring the chemical stability and long-term corrosion resistance of the pipeline substrate. Third, with the help of sensors and sampling points deployed throughout the process, parameters such as iron ion concentration, pH value, temperature, flow rate, and weight loss of corrosion test pieces are monitored in real time, and control commands are dynamically generated in combination with preset thresholds to achieve immediate diagnosis and safety warning of the cleaning process status. Finally, through automatic comparison and logical control of online monitoring data and preset process parameters, intelligent switching and parameter optimization of key cleaning stages are achieved. Specifically, this includes: automatically triggering process switching based on changes in iron ion concentration and pH during the chemical scale removal stage; automatically interrupting cleaning and switching to the neutralization stage when the corrosion rate approaches the safety limit to prevent over-corrosion; and stabilizing parameters such as temperature, flow rate, and reagent concentration within the target range by real-time adjustment of heating, circulation, and dosing devices to achieve closed-loop optimization control of the entire process, thereby improving cleaning efficiency, ensuring operational safety, and extending pipeline service life.

[0027] Furthermore, such as Figure 2 As shown, the process of outputting the trigger signal for a cleanable or non-cleanable state in step S1 specifically includes the following steps: Step S11: Collect the remaining percentage data of the initial design diameter inside the pipeline, and weigh the deposits peeled off from the inner wall of the pipeline to obtain the total mass of rust and scale; at the same time, record the attachment location, thickness and looseness or density of the rust and scale on the inner wall of the pipeline to form a dataset of flow cross section data and rust and scale mass and distribution characteristics. Step S12: Input the data set of flow cross section data and rust quality and distribution characteristics into the judgment program. The judgment program will comprehensively evaluate the high, medium and low blockage levels based on the ratio of flow cross section data to total rust mass, combined with the attachment location, thickness and looseness or density of rust on the inner wall of the pipeline, and use this as the basis for the classification of the mechanical pretreatment program. Step S13: Based on the comprehensive evaluation of the blockage level, when the blockage level is high or medium, a trigger signal for a cleanable state is generated; when the blockage level is low or there is structural damage, a trigger signal for an uncleanable state is generated. The trigger signal is then output to the start selection terminal of the mechanical pretreatment program and the chemical scale removal cleaning program.

[0028] The initial design diameter and remaining percentage data of the pipeline refer to the percentage of the current diameter relative to the original design diameter, calculated by measuring the effective cross-sectional area of ​​the pipeline that can be traversed by fluid. This data is used to quantify the degree of blockage caused by rust and scale deposition and is one of the basic inputs for determining the blockage level. Deposits refer to the collective term for rust and scale that have adhered to and detached from the inner wall of the pipeline. These deposits are collected after being mechanically cleaned from the inner wall of the pipeline and used for weighing and characteristic analysis. The total mass of rust and scale refers to the total weight of all deposits cleaned from the inner wall of the pipeline after drying. Mass data and flow cross-sectional area data together constitute the core quantitative indicators for determining the blockage level, reflecting the total amount of rust and scale accumulated inside the pipeline. The location, thickness, and density of scale adhesion on the inner wall of the pipeline are considered. Location refers to the specific location of the scale on the inner wall, including different areas such as elbows, straight sections, and near welds. Thickness refers to the size of the scale layer accumulating from the inner wall surface outwards. Density refers to the physical structure of the scale layer; loose structures are easier to remove, while dense structures require chemical descaling. These three characteristics describe the spatial distribution and structural state of scale within the pipeline, serving as supplementary criteria for adjusting the blockage level and selecting pretreatment methods in the assessment process.

[0029] Preferably, this embodiment collects the remaining percentage data of the initial design diameter inside the pipeline and combines it with the total mass of rust scale obtained by weighing the deposits peeled off from the inner wall of the pipeline; simultaneously, it records the attachment location, thickness, and looseness or density of the rust scale on the inner wall of the pipeline, forming a complete dataset of flow cross-section data and rust scale mass and distribution characteristics. The dataset is input into a judgment program, and based on the ratio of the flow cross-section data to the total mass of rust scale, combined with the attachment location, thickness, and looseness or density of the rust scale on the inner wall of the pipeline, a comprehensive evaluation is performed to obtain a first-level result among the three levels of blockage: high, medium, and low. The first-level result provides a clear grading basis for the mechanical pretreatment program. Based on the blockage level obtained from the comprehensive evaluation, a trigger signal for a cleanable state is generated when the blockage level is high or medium, and a trigger signal for an uncleanable state is generated when the blockage level is low or structural damage exists. The trigger signal is output to the start selection terminal of the mechanical pretreatment program and the chemical scale removal cleaning program, providing direct decision input for the adaptive selection of the cleaning program.

[0030] In summary, this embodiment implements a coherent technical process from data acquisition and feature analysis to status determination. By quantitatively assessing pipeline blockage and rust characteristics, it provides an objective basis for cleaning feasibility, avoiding the uncertainty of experience-based judgments. Simultaneously, the generated trigger signals are directly linked to subsequent procedure selections, ensuring a precise correspondence between cleaning decisions and pretreatment grading, laying a reliable foundation for the initiation and execution of the entire cleaning control process.

[0031] Furthermore, step S12, which involves comprehensively evaluating and determining the highest level of congestion (high, medium, or low), specifically includes the following steps: Step S121: Calculate the ratio of the current diameter to the original diameter to the total mass of rust scale obtained by weighing the dried deposits cleaned from the inner wall of the pipe to obtain the cross-sectional area to mass ratio; at the same time, combine the recorded attachment location, thickness and looseness or density of rust scale on the inner wall of the pipe into a distribution feature description set. Step S122: Input the state and distribution feature description set of cross-sectional area to mass ratio into the judgment program. Based on the region where the attachment location is located, the range of thickness values, and the removal difficulty coefficient corresponding to the looseness or density in the distribution feature description set, perform an upward or downward level offset correction on the initial level interval of the cross-sectional area to mass ratio state to obtain the corrected blockage weight value. Based on the location of the adhesion, the thickness range, and the removal difficulty coefficient corresponding to the degree of looseness or density, the initial grade range of the cross-sectional area to mass ratio is adjusted upwards or downwards, and the following formula is constructed: Based on the grade offset correction formula for the region where the attachment location is located: in: The grade offset caused by the attachment location has the same dimension system as the initial grade interval; The distribution characteristics describe the region where the attachment locations are concentrated, and the value range is a preset discrete value such as the elbow region, weld region, and straight pipe section region; This is a position correction function that outputs the corresponding position influence coefficient based on the region where the attachment location is located. The value is 0.6 to 0.8 for the elbow region, 0.4 to 0.6 for the weld region, and 0.1 to 0.3 for the straight pipe section region. This is the initial design diameter of the pipeline, in millimeters. The current actual pipe diameter is the product of the percentage of the original pipe diameter and the initial design pipe diameter, expressed in millimeters. The position correction factor, ranging from 1 to 3, is used to amplify geometric differences to match the dimensions of the grade interval. This formula determines the positional influence coefficient based on the region where the deposits are located, reflecting the different weights of the impact of rust on flow capacity in different areas. Elbow areas, prone to localized blockages due to abrupt flow field changes, are assigned a higher influence coefficient; weld areas, with their uneven surfaces, are prone to rust adhesion and are assigned a medium influence coefficient; and straight pipe sections, with their uniform flow field, are assigned a lower influence coefficient. The geometric difference term in the formula... It represents the relative degree of diameter reduction, couples the spatial distribution of rust with the actual diameter reduction, and causes the influence coefficient of the same location to produce different offsets under different degrees of diameter reduction; it transforms the spatial distribution feature of rust attachment location into a quantifiable level offset, and realizes the dynamic correction of the blockage level by the location importance.

[0032] Grade offset correction formula based on thickness numerical range: in: This refers to the grade offset caused by thickness. The upper limit of the range of thickness values ​​in the distribution feature description set, in millimeters; This is a preset base thickness threshold, in millimeters. When the thickness is below this threshold, the offset is negative. This is the initial design diameter of the pipeline, in millimeters. This is the thickness correction factor, with a value ranging from 0.5 to 1.5. This formula is based on the relative difference in thickness. Determine the offset direction relative to the base offset. A positive offset is generated when the actual thickness exceeds the base threshold, and a negative offset is generated when it is below. Additional Items By introducing the ratio of thickness to pipe diameter, when the thickness approaches or exceeds the pipe diameter, this additional term amplifies the offset, reflecting the nonlinear growth of the blockage effect on flow when the thickness is too large. The accumulation degree characteristic of rust thickness is transformed into a quantifiable level offset, realizing the dynamic correction of the blockage level by thickness changes, and capturing the nonlinear influence of the thickness-to-pipe diameter ratio.

[0033] The formula for adjusting the level of difficulty of removal based on the degree of looseness or density is as follows: in: To eliminate the level offset caused by difficulty; The removal difficulty coefficient is used to describe the degree of looseness or density of the distribution characteristics. The value ranges from 0.3 to 2.0, with 0.3 to 0.7 for loose structures, 0.8 to 1.2 for moderately dense structures, and 1.3 to 2.0 for dense structures. The apparent density of the rust layer is expressed in grams per cubic centimeter and is estimated by the total mass of the rust and the volume of the rust removed. The preset reference density is expressed in grams per cubic centimeter, taking the typical density value of dense rust. This is a difficulty correction factor, ranging from 0.8 to 1.2. This formula is used to clear the difficulty factor. Using the base, an exponential term is introduced. The difficulty coefficient is amplified or reduced. When the apparent density of rust is higher than the reference density, the exponent is greater than 1, indicating that the dense structure is not only difficult to remove but also more resistant to chemical dissolution, requiring a higher level offset to trigger a more aggressive cleaning strategy. When the apparent density is lower than the reference density, the exponent is less than 1, and the offset caused by the loose structure is compressed. The physical structural characteristics of rust are transformed into quantifiable level offsets, enabling dynamic correction of the removal difficulty to the clogging level. Furthermore, the nonlinear amplification effect of structural density on treatment complexity is introduced through the density ratio.

[0034] Steps S1221 to S1223 correspond to the sequential execution of the three formulas; the first offset takes the initial level range as the object to be corrected, and is superimposed with the formula calculated in Formula 1. Output the first correction level range; the second offset uses the first correction level range as the object to be corrected, and is superimposed with the values ​​calculated by Formula 2. The second correction level range is output; the third offset uses the second correction level range as the object to be corrected, and is superimposed with the result calculated by Formula 3. The output is the corrected congestion weight value. The dimensions of all three formulas have been adjusted. The coefficients are unified to a dimensionless level offset consistent with the initial level range, ensuring the mathematical feasibility of successive superposition operations. The geometric difference term, thickness-to-diameter ratio term, and density ratio exponent term in the formula are coupled with the exponential amplification effect of the pipe diameter reduction degree, the nonlinear effect of the packing thickness, and the degree of structural compactness, respectively, so that the final blockage weight value simultaneously reflects the degree of physical blockage, the influence of spatial distribution, the nonlinearity of the packing thickness, and the difference in the difficulty of removal. Step S123: Compare the corrected blockage weight value with the preset weight value threshold ranges corresponding to the high, medium, and low blockage levels. When the corrected blockage weight value falls into the high blockage level threshold range, output the high blockage level; when it falls into the medium blockage level threshold range, output the medium blockage level; and when it falls into the low blockage level threshold range, output the low blockage level. When there are structural damage records in the distribution feature description set, the weight value comparison is not performed, and the low blockage level is directly output. The low blockage level is then used as the classification basis for the mechanical preprocessing program.

[0035] Preferably, this embodiment constructs a cross-sectional area to mass ratio state by calculating the ratio of the current pipe diameter to the original pipe diameter to the total mass of rust and scale. This index simultaneously reflects the degree of pipe diameter reduction and the density characteristics of the deposits. Simultaneously, it integrates the attachment location, thickness, and density to form a distribution feature description set, achieving a structured characterization of spatial distribution and physical properties. A dynamic correction mechanism based on distribution features is introduced. According to the functional importance of the attachment area, the blocking impact weight corresponding to the thickness range, and the removal difficulty coefficient corresponding to the density, the initial ratio state is corrected for grade range shift. Static geometric parameters are correlated with dynamic removal costs to generate a blocking weight value that combines the degree of physical blocking with the complexity of engineering treatment. Grade quantification output is achieved through preset threshold mapping. The comparison between the corrected weight value and the three-level threshold range (high, medium, and low) achieves a standardized conversion from continuous variables to discrete grades. A specially set structural damage priority judgment rule directly outputs a low blocking grade when structural damage to the pipeline is detected, ensuring that the mechanical pretreatment program prioritizes structural integrity risks.

[0036] In summary, this embodiment establishes a coupled analysis model of multi-source heterogeneous data, geometric measurement, mass measurement, spatial distribution, and physical properties; eliminates the evaluation bias of a single ratio index under special distribution scenarios through a dynamic correction mechanism; realizes the quantitative transformation of blockage status from physical description to engineering response strategy; ensures the completeness of pipeline system safety assessment through structural damage priority rules; and provides a hierarchical decision-making basis for mechanical pretreatment procedures that combines the degree of blockage and processing complexity.

[0037] Furthermore, such as Figure 3 As shown, the process of setting the preset program in step S2 specifically includes the following steps: Step S21: When the clogging level is low, a trigger command is generated to directly start the chemical scale removal cleaning program, and the trigger command is output to the start end of the chemical scale removal cleaning program; when the clogging level is medium or high, a sequence control command is generated to first start the mechanical pretreatment program, and then start the chemical scale removal cleaning program after the mechanical pretreatment program is completed, and the sequence control command is output to the start end of the mechanical pretreatment program and the delayed start end of the chemical scale removal cleaning program. Step S22: Based on the type of trigger instruction or sequence control instruction, retrieve the corresponding program chain template from the preset program chain template library; the program chain template is divided into two types. The first type of program chain template consists of a chemical scale removal and cleaning program, a neutralization and passivation program, and a pre-film protection program connected in series. The second type of program chain template consists of a mechanical pretreatment program, a chemical scale removal and cleaning program, a neutralization and passivation program, and a pre-film protection program connected in series. Step S23: According to the program sequence in the program chain template, send start signals to the corresponding actuators of each program in sequence; when the program chain template is the first type, first send a start signal to the actuator of the chemical scale removal and cleaning program, and after receiving the completion signal of the chemical scale removal and cleaning program, send a start signal to the actuator of the neutralization and passivation program, and after receiving the completion signal of the neutralization and passivation program, finally send a start signal to the actuator of the pre-film protection program; when the program chain template is the second type, first send a start signal to the actuator of the mechanical pretreatment program, and after receiving the completion signal of the mechanical pretreatment program, send a start signal to the actuator of the chemical scale removal and cleaning program, and after receiving the completion signal of the chemical scale removal and cleaning program, send a start signal to the actuator of the neutralization and passivation program, and after receiving the completion signal of the neutralization and passivation program, finally send a start signal to the actuator of the pre-film protection program.

[0038] Preferably, in this embodiment, when the clogging level is low, the system directly generates a trigger command to start the chemical scale removal cleaning program; when the clogging level is medium or high, the system generates a sequence control command to first start the mechanical pretreatment program, and then start the chemical scale removal cleaning program after the mechanical pretreatment program is completed. This ensures that differentiated pretreatment strategies are adopted for different clogging levels, avoiding overtreatment or undertreatment, thereby optimizing the initial response of the cleaning process. According to the command type, the system retrieves the corresponding template from the program chain template library: the first template includes a series combination of chemical scale removal cleaning, neutralization passivation, and pre-film protection programs; the second template adds a mechanical pretreatment program as the starting point based on the first template. This achieves standardized matching of the program chain, ensuring the integrity and consistency of the process structure under different cleaning scenarios through preset templates, reducing manual configuration errors. Following the sequence of the program chain templates, the system sequentially sends start signals to the execution mechanisms of each program, and triggers subsequent programs after receiving the completion signal of the preceding program. This achieves sequential control and coordinated execution between programs, ensuring that cleaning, neutralization, and protection stages are performed in strict sequence, avoiding program conflicts or resource waste, thereby improving the safety and system efficiency of the overall cleaning process.

[0039] In summary, this embodiment achieves automation, standardization, and adaptive adjustment of the cleaning process through blockage level determination, program chain template matching, and sequential control execution; it ensures that the optimal cleaning strategy can be selected under different blockage conditions, improving cleaning effect and equipment protection level, while reducing the need for manual intervention and operational risks, and optimizing resource utilization and system reliability.

[0040] Furthermore, the process of retrieving the corresponding program chain template from the preset program chain template library in step S22 specifically includes the following steps: Step S221: Extract the type identifier carried in the trigger instruction or sequence control instruction, and match the type identifier with the preset instruction type lookup table. When the matching result is a trigger instruction type, output the first type code; when the matching result is a sequence control instruction type, output the second type code. Step S222: Compare the received first type code and second type code with the preset associated codes of each template in the program chain template library one by one; when the type code matches the associated code of the first template in the program chain template library, locate the storage address of the first template in the program chain template library; when the type code matches the associated code of the second template in the program chain template library, locate the storage address of the second template in the program chain template library. Step S223: Read the corresponding template content from the program chain template library according to the storage address, encapsulate the read template content into a template output data packet containing the program sequence identifier and the program connection order field, and send the template output data packet to the program execution controller.

[0041] Preferably, in this embodiment, the type identifier is extracted from the instruction, and the corresponding type code is generated by matching it with an instruction type lookup table, thereby achieving accurate identification and classification of the instruction type. The generated first type code or second type code is compared one by one with the pre-set associated codes of each template in the program chain template library to complete the association mapping between the code and the template, thus locating the storage address of the corresponding template. Based on the storage address, the template content is read from the program chain template library, encapsulated into a template output data packet containing a program sequence identifier and a program connection order field, and sent to the program execution controller. This embodiment forms a complete process from instruction identification, template matching to content encapsulation and distribution, ensuring that the program chain template can be accurately and efficiently retrieved and transmitted according to the instruction type, providing structured template data support for program execution control.

[0042] Furthermore, the process of extracting the type identifier carried in the trigger instruction or sequence control instruction in step S221 specifically includes the following steps: Step S2211: Receive the output trigger command or sequence control command, and separate the command header area and command payload area from the data packet of the trigger command or sequence control command; Step S2212: Read the congestion level code value from the fixed field bit of the instruction header area; at the same time, read the preset verification parameter corresponding to the congestion level code value from the instruction payload area, compare the congestion level code value with the preset verification parameter for consistency, and when the comparison result is consistent, mark the congestion level code value as a valid level code. Step S2213: Match the valid level code with the preset level and type mapping table. When the valid level code corresponds to a low congestion level, output the trigger instruction type identifier; when the valid level code corresponds to a medium or high congestion level, output the sequence control instruction type identifier; output the trigger instruction type identifier or the sequence control instruction type identifier to the preset instruction type lookup table.

[0043] Preferably, in this embodiment, after receiving the instruction, the instruction header area and the instruction payload area are separated to realize the parsing of the instruction structure and the location of the data area. The congestion level code value is read from the instruction header area, and the corresponding preset verification parameters are read from the instruction payload area. The validity of the code value is verified through consistency comparison to ensure the accuracy and reliability of the level code. The valid level code is matched with a preset level and type mapping table, and the corresponding type identifier is output according to the level of congestion, completing the mapping and classification from level information to instruction type. This embodiment forms a complete process from instruction parsing, level verification to type matching, ensuring that the extraction process of type identifiers has structural standardization, data consistency, and mapping accuracy, providing reliable identifier input for instruction type encoding matching.

[0044] Furthermore, the process of separating the instruction header region and the instruction payload region from the data packet of the trigger instruction or sequence control instruction in step S2211 specifically includes the following steps: Step S22111: Receive the output data packet containing trigger instructions or sequence control instructions. The data packet consists of a fixed-length instruction header containing a blockage level code and a cleaning program identifier, and a variable-length instruction body containing a mechanical pretreatment completion signal verification field and a chemical scale removal cleaning start delay parameter. After storing the data packet in the buffer, compare it bit by bit with the preset instruction start identifier in the buffer in byte by byte. When the consecutive comparison results are completely consistent with the instruction start identifier, record the starting position of the consecutive bytes as the data packet start boundary. Step S22112: Based on the recorded data packet start boundary, locate the byte position in the buffer at the preset header length field offset from the data packet start boundary, and read the header length value stored at the byte position; extract a continuous byte sequence from the buffer with the data packet start boundary as the starting point and the header length value as the truncation length, and output the extracted continuous byte sequence as the instruction header area; the instruction header area contains the congestion level code and the cleaning program identifier, which are used to read the congestion level code value; Step S22113: Based on the byte length occupied by the output instruction header area, the payload start boundary is obtained by adding the byte length to the data packet start boundary. From the payload start boundary to the end of the data packet in the buffer, the remaining continuous byte sequence is extracted and the extracted continuous byte sequence is output as the instruction payload area. The instruction payload area contains the mechanical preprocessing completion signal verification field and the chemical scale removal cleaning start delay parameter, which are used to read the preset verification parameters. The instruction header area and the instruction payload area are output.

[0045] Preferably, this embodiment accurately identifies the starting boundary of the data packet by comparing the byte-level sequence with the preset instruction start identifier, providing a reference position for region separation. The packet header length value is read based on the offset of the packet header length field. A continuous byte sequence is extracted based on the data packet starting boundary and the packet header length to achieve accurate extraction of the instruction header region, ensuring reliable acquisition of the congestion level code and cleaning procedure identifier. The payload starting boundary is calculated based on the byte length of the instruction header region, and the remaining byte sequence up to the end of the data packet is extracted to complete the complete separation of the instruction payload region, ensuring effective reading of the mechanical preprocessing completion signal verification field and the chemical scale removal cleaning start delay parameter. This embodiment constructs a complete parsing process from data packet start identification and header region positioning to payload region segmentation, realizing the structured separation of the instruction header and payload region, providing an accurate data partitioning basis for subsequent reading of the congestion level code and comparison of verification parameters.

[0046] Furthermore, the process of extracting the remaining consecutive byte sequence in step S22113 specifically includes the following steps: Step S221131: According to the output instruction header area, read the cleaning program identifier bit from the instruction header area. According to the program type corresponding to the cleaning program identifier bit, obtain the first offset position and the first field length of the mechanical pretreatment completion signal verification field, and the second offset position and the second field length of the chemical scale dissolution cleaning start delay parameter from the preset load field configuration table. Output the obtained first offset position, first field length, second offset position, and second field length to the load extraction control terminal. Step S221132: Based on the output first offset position and the first field length, and using the determined load start boundary as a reference, offset the load start boundary backward by the first offset position to obtain the starting byte position of the mechanical preprocessing completion signal verification field; continuously extract a byte sequence of the first field length starting from the starting byte position, and use the byte sequence as the mechanical preprocessing completion signal verification field value; at the same time, compare the mechanical preprocessing completion signal verification field value with the preset mechanical preprocessing completion standard check code. When the comparison is consistent, generate a load valid confirmation flag; when the comparison is inconsistent, generate a load abnormality flag and stop subsequent extraction. Step S221133: Based on the output second offset position and the second field length, and on the premise of generating a valid load confirmation identifier, with the load start boundary as the reference, offset the load start boundary backward by the second offset position to obtain the start byte position of the chemical scale removal cleaning start delay parameter. Starting from the start byte position, continuously extract the byte sequence of the second field length, and use the byte sequence as the chemical scale removal cleaning start delay parameter value. Combine and encapsulate the extracted mechanical preprocessing completion signal verification field value and the extracted chemical scale removal cleaning start delay parameter value to form the instruction load area output.

[0047] Preferably, this embodiment queries the load field configuration table based on the cleaning program identifier bit to obtain the offset position and field length of the verification field and delay parameter, realizing dynamic adaptation and parameter positioning of the internal structure of the load. Based on the first offset position and the first field length, the mechanical preprocessing completion signal verification field value is located and extracted. The load validity is verified by comparing it with a preset standard verification code, generating a load validity confirmation flag or an anomaly flag to ensure the data's reliable state before subsequent processing. Under the premise of valid load confirmation, the chemical scale removal cleaning start delay parameter value is located and extracted based on the second offset position and the second field length. The verification field value and the delay parameter value are merged and encapsulated to form a complete instruction load area output. This embodiment achieves accurate parsing and condition extraction of fields within the load area, ensures data validity through a verification mechanism, and supports dynamic adaptation of the field structure according to the program type, ensuring the integrity of the instruction load and the accurate acquisition of business parameters.

[0048] Furthermore, step S221132, which involves using the byte sequence as a mechanical preprocessing step to complete the signal verification field value, specifically includes the following steps: Step S2211321: Based on the first offset position and the first field length of the output, and taking the determined load start boundary as the reference, offset the load start boundary backward by the first offset position to obtain the starting byte position of the mechanical preprocessing completion signal verification field. Starting from the starting byte position, read the first field length bytes sequentially according to the preset byte-by-byte reading method, and store the read byte sequence into the temporary verification buffer area as the original verification byte sequence output. Step S2211322: According to the preset verification field structure template, separate the mechanical preprocessing program type identifier bit and the mechanical preprocessing completion timestamp field from the original verification byte sequence; match the separated mechanical preprocessing program type identifier bit with the preset mechanical preprocessing type lookup table; when the match is consistent, compare the mechanical preprocessing completion timestamp field with the timestamp verification segment in the preset mechanical preprocessing completion standard verification code; when the absolute value of the difference is within the preset allowable range, generate a valid field structure identifier. Step S2211323: Under the premise of generating a valid field structure identifier, the original check byte sequence is summed and compared with the checksum field in the preset mechanical preprocessing completion standard check code. When the sum of the original check byte sequence matches the checksum field, the original check byte sequence is marked as a valid mechanical preprocessing completion signal check field value.

[0049] Preferably, this embodiment can locate and extract the mechanical preprocessing completion signal verification field from a specific load, parse and verify the field structure, and ultimately confirm the integrity and validity of the field value; it ensures the accurate extraction of the verification field through offset positioning and byte reading; it verifies the compliance of the field's logical structure through program type identifier bit matching and timestamp difference comparison; and it ensures the integrity of the field data through accumulation and comparison. Together, these methods ensure the reliable verification of the mechanical preprocessing completion signal, providing accurate data basis for subsequent processing.

[0050] Furthermore, such as Figure 4 As shown, the process of dynamically generating control commands in step S3 specifically includes the following steps: Step S31: Compare the iron ion concentration, pH value, temperature value, flow rate value, and corrosion rate value obtained in real time from the sensor and sampling point with the preset safety range of the current cleaning program. When all monitored values ​​are within their respective preset safety ranges, a normal status indicator is generated. When any monitored value exceeds its preset safety range, the type of monitored value and the direction of the exceedance are recorded as a deviation feature vector. Step S32: Input the output deviation feature vector into the deviation type discriminator. The deviation type discriminator matches the monitoring value type and deviation direction contained in the deviation feature vector with the preset deviation type mapping table. When the deviation feature vector corresponds to a combination where the iron ion concentration exceeds the upper limit and the pH value is lower than the lower limit, an overactive chemical scaling reaction indicator is output. When the corrosion rate value corresponding to the deviation feature vector exceeds the upper limit, a substrate over-corrosion risk indicator is output. When the temperature value or flow rate value corresponding to the deviation feature vector exceeds the range, a process parameter deviation indicator is output. Step S33: Input the output deviation type identifier into the control instruction generator. The control instruction generator calls the corresponding control instruction template from the preset instruction template library according to the deviation type identifier. When a chemical scaling reaction overreaction identifier is received, the dosing pump frequency reduction instruction template and the diluent injection instruction template are combined to generate the first control instruction. When a substrate over-corrosion risk identifier is received, the emergency interruption instruction template and the forced neutralization start instruction template are combined to generate the second control instruction. When a process parameter deviation identifier is received, the heating device power adjustment instruction template or the circulating pump frequency adjustment instruction template is called according to the specific deviation direction of the temperature or flow rate value in the deviation feature vector to generate the third control instruction. Output the first control instruction, the second control instruction, or the third control instruction.

[0051] Preferably, in this embodiment like Figure 5 As shown, this embodiment also provides an embodiment of a cleaning control system for rust removal and scale dissolution of water-cooled pipelines in metallurgical furnaces and kilns. In this embodiment, the cleaning control system for rust removal and scale dissolution of water-cooled pipelines in metallurgical furnaces and kilns is applied to the cleaning control method for rust removal and scale dissolution of water-cooled pipelines in metallurgical furnaces and kilns as described in the above embodiment. The cleaning control system for rust removal and scale dissolution of water-cooled pipelines in metallurgical furnaces and kilns includes a blockage degree detection module 1, a rust removal and scale dissolution cleaning module 2, an online monitoring and control module 3, and a closed-loop feedback control module 4, which are connected in sequence. The blockage detection module 1 is used to collect pipeline flow cross-sectional data, rust and scale quality and distribution characteristics, comprehensively analyze and determine the blockage level, and output a trigger signal indicating whether the pipe is cleanable or not; providing a grading basis for the mechanical pretreatment program. The rust and scale removal cleaning module 2 is used to select one of the mechanical pretreatment program and the chemical scale removal cleaning program as the start program when it receives the trigger signal indicating that the pipe is cleanable; then it sequentially starts the neutralization and passivation program and the pre-film protection program or the chemical scale removal cleaning program, the neutralization and passivation program and the pre-film protection program; sensors and samples are deployed throughout the cleaning process of the four programs. The system collects real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate, and weight loss of the corrosion test piece; it determines whether the current state deviates from the safe range based on preset thresholds and dynamically generates control commands; the online monitoring and control module 3 is used to deploy sensors and sampling points throughout the cleaning process of the four procedures to collect real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate, and weight loss of the corrosion test piece; it determines whether the current state deviates from the safe range based on preset thresholds and dynamically generates control commands; the closed-loop feedback control module 4 is used to receive online monitoring data, compare it with preset process parameters, and automatically execute control logic.

[0052] Preferably, the various modules of the water-cooled pipeline rust removal and scale dissolution cleaning control system in this embodiment operate collaboratively to achieve fully automated management of the entire process from detection and cleaning to monitoring and adjustment. Its technical effects are mainly reflected in the following: The blockage detection module comprehensively judges the blockage level by collecting pipeline flow cross-sectional data, rust and scale quality and distribution characteristics, providing a grading basis for subsequent cleaning procedures and ensuring the targeted and safe nature of the cleaning operation; the output trigger signal directly determines whether the system enters the cleaning process, thereby avoiding improper cleaning of severely blocked or structurally damaged pipelines. The rust removal and scale dissolution cleaning module selects between mechanical pretreatment and chemical scale dissolution cleaning procedures based on the trigger signal, and sequentially initiates the neutralization passivation and pre-film protection processes. This module deploys sensors and sampling points throughout the cleaning process to collect data such as iron ion concentration, pH value, temperature, flow rate, and weight loss of corrosion test pieces in real time, forming continuous monitoring of the cleaning status. The online monitoring and control module, based on the real-time collected data and according to preset safety thresholds, judges whether the cleaning process deviates from the normal range, dynamically generates adjustment commands, and realizes immediate correction of cleaning parameters, ensuring that the cleaning process is under control. The closed-loop feedback control module receives online monitoring data, compares it with preset process parameters, and automatically executes control logic to complete a fully closed-loop adjustment from data acquisition and status judgment to command execution. This mechanism effectively improves the stability and consistency of the cleaning process, reduces the need for human intervention, and enhances the system's adaptability to fluctuations in operating conditions.

[0053] In summary, this embodiment achieves precise control, real-time status monitoring, and dynamic adjustment of the cleaning process through functional integration and data linkage, thereby improving the efficiency of rust and scale removal while ensuring the safety of the pipeline structure and the controllability of the cleaning process.

[0054] like Figure 6 As shown, this embodiment provides an embodiment of an electronic device 4, which includes a processor 51 and a memory 52 coupled to the processor 51.

[0055] The memory 52 stores program instructions for implementing the cleaning control method for rust removal and scale dissolution of water-cooled pipelines in metallurgical furnaces and kilns according to any of the above embodiments.

[0056] The processor 51 is used to execute program instructions stored in the memory 52 for the layout of the chemical pump body processing equipment.

[0057] The processor 51 can also be referred to as a CPU (Central Processing Unit). The processor 51 may be an integrated circuit chip with signal processing capabilities. The processor 51 can also be a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. A general-purpose processor can be a microprocessor or any conventional processor.

[0058] Furthermore, Figure 7 This is a schematic diagram of the structure of a storage medium according to an embodiment of this application. The storage medium 6 in this embodiment stores program instructions 61 capable of implementing all the methods described above. These program instructions 61 can be stored in the storage medium in the form of a software product, including several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) or processor to execute all or part of the steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks, or terminal devices such as computers, servers, mobile phones, and tablets.

[0059] In the several embodiments provided by this invention, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be an indirect coupling or communication connection between apparatuses or units through some interfaces, and may be electrical, mechanical, or other forms.

[0060] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated units described above can be implemented in hardware or as software functional units. The above are merely embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the description and drawings of the present invention, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

[0061] This invention provides a phased, high-efficiency cleaning process for rust and scale removal in water-cooled pipelines, comprising four sequential stages: mechanical pretreatment, chemical scale removal and cleaning, neutralization and passivation, and pre-film protection. First, severely clogged areas undergo mechanical unblocking pretreatment, including disassembling easily accessible pipe sections for manual descaling, internal cleaning of large-diameter pipes using jet cleaning, and localized high-pressure water jet flushing, to remove loose rust and sediment deposits and initially restore the basic flow cross-section. After mechanical cleaning, a specially formulated cleaning solution is introduced into the pipeline for scale removal using a circulating chemical cleaning method: chemical agents are first used to dissolve, reduce, and complex rust deposits, converting the attached rust into soluble iron compounds that are carried away by the flowing cleaning solution. After chemical cleaning, the system is immediately neutralized with an alkaline solution to remove residual acid and neutralize any precipitated acidic corrosion products, restoring the system's pH to a slightly alkaline level to protect the substrate from subsequent corrosion. Subsequently, a passivating pre-filming agent is added to the pipeline, and the inner wall of the metal is passivated under circulating flow conditions, promoting the formation of a dense and complete protective film on its surface and improving corrosion resistance. The entire process, through multi-stage and orderly operation, achieves thorough removal of rust and scale and effective protection of the pipeline inner wall, restoring the cooling system to normal operation and significantly extending the operating cycle before the next scaling.

[0062] Online monitoring and control are employed during the cleaning process to ensure safe and controllable operation. Temporary sensors or sampling ports are installed in the circulation loop to monitor real-time indicators such as iron ion concentration, pH, and temperature of the cleaning solution, assessing the rust dissolution rate and substrate corrosion rate. When the rate of increase in iron ion concentration slows down, it indicates that the main rust has dissolved, and the pickling stage can be terminated. If the corrosion rate indicator or the weight loss of the corrosion test piece approaches the threshold, timely measures are taken, such as cooling, adding corrosion inhibitors, or ending the cleaning process, to ensure the safety of the substrate. Furthermore, by adjusting the circulation pump flow rate and pipeline valve openings, the flow rate of the cleaning solution in each branch is ensured to be no less than the design requirements to avoid stagnant dead zones. The cleaning process of this invention also includes a closed-loop feedback control: cleaning parameters such as time, temperature, and concentration are dynamically adjusted based on online monitoring data, and the cleaning stage can be extended when necessary to achieve the desired effect, truly realizing scientific, efficient, and safe pipeline rust removal and cleaning operations.

[0063] Before chemical cleaning, the cooling water pipelines are pre-treated mechanically to clear any major blockages and ensure the chemical cleaning solution circulates throughout the system. The operating steps are as follows: 1. System Isolation and Drainage: At a suitable time for maintenance, shut down the cooling water system and isolate the pipeline to be cleaned from the main circulation. Close relevant valves; if no shut-off valve is available, use temporary sealing methods to treat each section. Open the drain outlet or remove the low-point flange to release accumulated water and loose sediment from the pipeline. If necessary, introduce compressed air or nitrogen from the highest point of the system to purge residual liquid from the pipes, preventing stagnant water from diluting the acid solution during subsequent chemical additions.

[0064] 2. Disassembly, Inspection, and Manual Descaling: For easily disassembled pipe sections, such as flange connections, disassemble and inspect them, manually removing any large, visible rust deposits. Especially for straight pipe sections with larger inner diameters, use a long-handled steel brush or scraper to remove loose rust. For the interior of irregularly shaped components such as elbows, use a flexible cleaning rod to repeatedly pull and break up blockages. Collect and weigh the removed rust and impurities to assess the severity of the blockage. Operators must wear dust masks and goggles to avoid inhaling rust dust and getting skin scratches from rust.

[0065] 3. Cleaning with a cleaning nozzle and foam ball: For long straight pipes or U-shaped pipes, use a mechanical cleaning nozzle to unclog them. Select a flexible shaft cleaning nozzle or foam ball that matches the pipe diameter, and repeatedly pass it through the pipe under the propulsion of water flow or compressed air to push out loose rust and scale. The foam ball cleaning can be performed while the pipe is still wet to utilize the water film lubrication and reduce damage to the pipe wall. For coiled water jackets, this step can be omitted due to the numerous bends making cleaning difficult.

[0066] 4. High-Pressure Water Flushing: A high-pressure cleaner is used to flush the inside of the pipeline, further removing loosely attached rust and residue. High-pressure water at approximately 8–12 MPa (about 80–120 kgf) is used, sprayed through a specialized nozzle inserted into the pipe section. The nozzle should have a specific jet angle and rotational motion to ensure the water flow impacts the pipe wall in all directions, peeling off loosely adhered iron oxide scale. For severely clogged areas where the nozzle cannot pass through, flushing can be performed from both ends until the blockage is cleared. Rust-inducing water generated during high-pressure flushing should be promptly drained from the lowest point, and solid debris should be collected using a filter to prevent it from flowing into subsequent circulation stages and clogging pumps or pipelines.

[0067] After the above mechanical pretreatment, most of the loose scale and silt should be removed, and the main pipeline should be basically unobstructed, ensuring at least >50% flow cross-section. After pretreatment, all cleaning ports should be resealed to prepare for the next step of chemical cleaning. Note: During the mechanical pretreatment stage, avoid causing mechanical damage to the substrate. For example, use moderate force with the steel brush to prevent scratching through the thinned pipe wall; use appropriate high-pressure water pressure to avoid penetrating weakened areas.

[0068] After mechanical unclogging, chemical descaling is immediately performed to dissolve and remove stubborn rust and scale remaining on the walls of the smelting water-cooled pipes. Chemical cleaning operates on the core mechanisms of rust dissolution, reduction, and complexation. For the main rust and scale components, Fe3O4 and FeO(OH), the cleaning agent converts them into soluble iron salts or stable complexes that enter the solution through acid dissolution and complexation. For example, the following reaction occurs in a strong acid cleaning system: Fe2O3 (one of the main components of rust) + 6HCl → 2FeCl3 + 3H2O Fe3O4 (magnetite black rust) + 8HCl → FeCl2 + 2FeCl3 + 4H2O The generated Fe 2+ and Fe 3+ Furthermore, it reacts with anions in the cleaning solution to form soluble salts, such as FeCl2 and FeCl3, which are soluble in water. The decomposition products of corrosion inhibitors such as hexamethylenetetramine during acid washing can react with Fe... 3+ They form complexes, slowing down corrosion of the substrate. In organic acid cleaning systems, organic acids such as citric acid provide H₂. + FeOOH dissolves, and its carboxyl groups can complex with Fe. 2+ / Fe 3+ A stable iron citrate complex is formed, thereby increasing the solubility of rust. To accelerate the dissolution of magnetite Fe3O4, a reducing agent is introduced into the formulation of this invention to dissolve the sparingly soluble Fe... 3+ Reduced to readily soluble Fe 2+ For example, adding ascorbic acid (vitamin C) or sulfites can reduce the Fe content in Fe3O4. 3+ Reduction to produce Fe 2+ The rust is then complexed and carried out by organic acids. At suitable temperatures, the dissolution of rust follows a kinetic rate equation: the dissolution rate is fastest in the initial stage of cleaning, with a rapid increase in Fe ion concentration; as the rust layer thickness decreases and the diffusion resistance of the products increases, the dissolution rate gradually decreases, exhibiting a typical logarithmic decay curve. Therefore, this invention promotes the reaction rate and ensures complete dissolution of the rust by increasing the cleaning solution temperature and appropriately extending the circulation time.

[0069] Specifically, this invention provides two chemical cleaning formulas based on the properties of rust and scale in smelting water-cooled pipelines, which can be selected according to the site conditions: Option 1: Mild complexing-reduction cleaning formula, organic acid system: Main components: Citric acid 5–8% (mass percentage, same below), EDTA-2Na disodium ethylenediaminetetraacetate 0.5–2%, reducing agent such as ascorbic acid (VC) or sodium sulfite 0.5–1%, corrosion inhibitor 0.2–0.5%, penetrant / surfactant as appropriate, nonylphenol polyoxyethylene ether NP-10, about 0.1%, balance is demineralized water.

[0070] Mechanism of action: Citric acid is a weak organic acid that can slowly dissolve iron oxide, and its citrate ion has a strong effect on Fe. 3+ / Fe 2+ It has a complexing effect; EDTA is a strong chelating agent that can chelate Fe ions to prevent hydrolysis and precipitation, and improve the dissolution ability of rust; reducing agents (VC, etc.) can chelate the sparingly soluble Fe ions. 3+ Reduced to Fe 2+ The corrosion inhibitor is further stabilized by the complexing agent. Benzotriazole, thiourea derivatives, or sulfonates can be used in combination to adsorb onto the metal surface and form a protective film, slowing down the direct corrosion of the substrate by the acid. Surfactants reduce the surface tension of the solution, promoting the penetration of the solution into the micropores of the rust layer and carrying away the dissolved products.

[0071] Operating parameters: This formulation is a mild system and is best used in prolonged circulation at relatively high temperatures to maximize its effectiveness. Heat the cleaning solution to approximately 60°C before starting circulation, maintaining the temperature range between 50–70°C. Maximize the flow rate to ≥1.5 m / s to ensure turbulence. Cleaning time depends on the scale thickness, generally 6–10 hours. During this period, take samples every 20–30 minutes to test for Fe. 2+ Adjust the concentration and pH, and replenish citric acid and reducing agents as needed to maintain acidity and complexing capacity. If the solution pH rises above 3 or Fe... 2+ Once the concentration stops increasing, it indicates that the main rust has been completely dissolved, and the cycle can be terminated. For thick scale, the saturated rust solution can be drained midway, and a fresh solution can be prepared to continue cleaning, thus improving efficiency. Throughout the process, ensure that the solution does not foam excessively and that color changes are monitored. Initially pale yellow, it gradually turns orange-red or green, indicating that a large amount of iron ions have dissolved.

[0072] Option 2: Rapid strong acid-inhibiting cleaning formula, inorganic acid system: Main components: hydrochloric acid (HCl), industrial 31% concentrated acid diluted to 5-7%, sodium chloride (NaCl) 1-3% (to enhance ionic strength and aid in rust dissolution), hexamethylenetetramine 0.1% (corrosion inhibitor), hexamethylenetetramine 0.05% (corrosion inhibitor, which can work in conjunction with hexamethylenetetramine), surfactant 0.1%, and the balance being water; hexamethylenetetramine hydrolyzes in acid to formaldehyde, which can inhibit the uniform corrosion of steel by acid; hexamethylenetetramine is also a commonly used pickling corrosion inhibitor. Mechanism of action: Hydrochloric acid is a strong acid and dissolves rust rapidly. Fe₂O₃ and Fe₃O₄ react with HCl to form soluble FeCl₂ / FeCl₃, which quickly dissolves the loose rust layer. High concentrations of Cl₂... - Ion-enhanced Fe 3+The combined action of these two agents prevents Fe(OH)3 precipitation. The aldehydes released from the decomposition of the corrosion inhibitor hexamethylenetetramine in acid can form an organic film on the metal surface, significantly reducing the corrosion rate of the substrate. The combination of these two agents allows hydrochloric acid to remove rust without damaging the iron. The surfactant helps the acid penetrate deep into the rust layer, accelerating the complete reaction.

[0073] Operating parameters: This formula is a rapid strong acid system. The cleaning temperature can range from room temperature to 50℃. Higher temperatures are beneficial to the reaction but also exacerbate corrosion, so heating is generally not required or only slightly heated to 40℃. The cleaning time is relatively short, typically 1–3 hours to complete the main scale dissolution. During this period, corrosion indicators must be closely monitored. The iron ion concentration or the weight loss rate of the coated substrate should be measured every 10 minutes to ensure that the corrosion rate is within a safe range, <0.5 mm / a instantaneous rate. If the indicator of accelerated corrosion suddenly increases the Fe concentration or a large amount of hydrogen gas appears, the acid washing should be stopped immediately and a neutralization and passivation step should be performed. Strong acid cleaning should not be prolonged to avoid over-corrosion of the substrate. For stubborn local rust nodules, consider pausing the circulation and allowing the acid solution to statically soak for 10–20 minutes before continuing to enhance the erosion of the rust. The criteria for completion of cleaning are: the sample solution is clear and pale yellow and the iron ion concentration no longer increases significantly, indicating that most of the rust has been dissolved.

[0074] Solution Selection and Process: Generally, Solution 1 is preferred for primary cleaning because the organic acid system is gentler on the substrate, has a higher safety factor, and is suitable for thoroughly dissolving rust and scale inside the pipeline. Solution 2 can be used as an auxiliary method or in specific scenarios: when the pipeline is severely blocked and there is an urgent need to quickly open the main flow channel, a hydrochloric acid system can be used to flush and open the flow for a short time, dissolving most of the blockage and quickly restoring the circulation channel. Then, switch to a citric acid system for fine cleaning to remove residual rust and scale. This combination of strong acid opening and organic acid fine cleaning can balance speed and thoroughness and has been applied in the method of this invention. In addition, if there are stainless steel components in the system (some valves and fittings are made of stainless steel), the use of Cl-containing solutions should be avoided. - The hydrochloric acid system, to prevent Cl - This can induce stress corrosion cracking in stainless steel. For deposits on stainless steel, a mixed acid cleaning solution of nitric acid and hydrofluoric acid can be used. A short-term immersion in a solution of 5% HNO3 + 1% HF (by volume) is performed on the stainless steel surface. HF dissolves silicate scale and chromium oxides, while HNO3 passivates the stainless steel surface. However, HF operation is highly hazardous and requires strict control of time and personnel protection. HF can cause severe chemical burns, necessitating appropriate protective clothing and the availability of Ca solution. In practice, a separate bypass cleaning circuit can be built for the stainless steel section to prevent HF from entering the carbon steel pipeline and corroding the carbon steel. After cleaning, thorough rinsing and neutralization with water are essential to prevent adverse effects of residual acid on the system materials.

[0075] Regardless of the chemical cleaning formula used, proper control of process parameters is crucial for both cleaning effectiveness and safety. Based on experimental data and practical cleaning operations, this invention proposes the following key control parameter ranges and operational points: Temperature: Increased temperature helps accelerate the dissolution of rust and scale, but it also increases the corrosion rate of the substrate. Generally, the cleaning solution temperature is controlled between 40–60℃. For mild organic acid systems, the upper limit of around 60℃ can be used to enhance the complexation reaction rate; for strong acid systems, overheating is not advisable, typically between room temperature and 50℃, to prevent uncontrolled corrosion. In practice, a circulating heater can be used to raise the temperature and monitor temperature stability to avoid localized overheating.

[0076] Flow rate: Maintaining sufficient circulation velocity to ensure turbulence is crucial for improving mass transfer and removing rust and scale. During cleaning, the linear velocity within the pipe should be ≥1.5 m / s, preferably around 2–3 m / s. If the original system pump cannot provide sufficient velocity, a temporary circulation pump can be added, or segmented cleaning can be performed to shorten the loop. It is important to ensure balanced flow across all branches to prevent some branches from having excessively high velocities due to low resistance, while others have insufficient velocities. The main resistance can be artificially increased by adjusting valves to distribute more flow to higher-resistance branches, ensuring a uniform flow field throughout the system. Dead zones with insufficient flow velocity are prone to becoming cleaning blind spots and rust and scale collectors and should be carefully avoided.

[0077] Time: The duration of chemical cleaning depends on the thickness of the scale and the formulation. Mild formulations typically require several hours of circulation contact time to completely dissolve the scale, usually 6–12 hours on-site, and can be carried out overnight. Strong acid formulations are fast and effective, typically completing the main scale dissolution within 1–3 hours. Determining the cleaning endpoint requires comprehensive consideration of the amount of rust dissolved, corrosion indicators, and the state of the cleaning solution: the cleaning can be stopped when the iron concentration in the sample solution tends to stabilize and the rust scale is basically gone. It is better to skip some cleaning time to ensure thoroughness than to extend it excessively, especially with strong acids, to avoid unnecessary damage to the substrate.

[0078] Monitoring Frequency: During the cleaning process, it is recommended to collect samples of the cleaning solution every 15–30 minutes at regular intervals to analyze the iron ion concentration, solution pH, and appearance color. An increase in iron concentration indicates that rust is dissolving, and this should continue until the concentration no longer increases significantly. A decrease in pH indicates acid consumption; the pH should be below the target upper limit (<3) and should not rise sharply, otherwise acid replenishment is necessary. For strong acid systems, monitoring can be conducted at a higher frequency, every 10 minutes, to closely monitor corrosion dynamics. For the strip corrosion test, the strips can be removed every hour to observe the surface condition and weigh multiple strips in rotation; through these monitoring methods, precise control and timely adjustments to the cleaning process can be achieved.

[0079] Pressure control: Maintain the cleaning circuit at near-atmospheric pressure or slightly above atmospheric pressure. Since the chemical reaction may produce gases, especially hydrochloric acid which releases H2, avoid completely closing the system to prevent pressure buildup. Install expansion tanks or open collection tanks to release air bubbles, and install vent valves at high points in the pipeline. Also, ensure the circulating pump outlet pressure is not too high (<0.3–0.5 MPa) to prevent leaks at weak points. If any leaks or drips are detected in the pipeline, immediately stop the pump and reduce the pressure.

[0080] Safety and Environmental Protection: The operating area should be well-ventilated. Unauthorized personnel are strictly prohibited from entering the site during strong acid cleaning. Provide necessary personal protective equipment, including acid-resistant clothing, goggles, and rubber gloves. Prepare alkaline solutions, lime milk or NaOH solution, and tap water for emergency neutralization and rinsing. When the cleaning solution needs to be replaced or discharged, it must first be neutralized to pH 7–8 with alkali, then filtered to remove heavy metal precipitates before being treated or recycled according to environmental regulations. Keep baking soda or lime on site in case of acid leaks. Avoid contact between perchloric acid cleaning waste liquid and oxidants containing hypochlorite to prevent side reactions. All sampled waste liquid should be centrally treated and not indiscriminately poured into sewage.

[0081] By controlling the above parameters, the cleaning process of this invention can achieve efficient dissolution of rust and scale and controllable micro-corrosion of the substrate while ensuring safety.

[0082] Selecting the appropriate cleaning formula and process based on different site conditions is key to achieving the best results from the method of this invention. The following is a comparative analysis of the applicable scope, advantages, disadvantages, and supporting measures of the two main cleaning systems, and provides the basis for selection: Mild complexing-reduction system, citric acid + EDTA, etc.: Suitable for applications with large scale buildup and long downtimes. This system is highly safe for the substrate, exhibiting low corrosion even after several hours of immersion, making it particularly suitable for thorough cleaning of large equipment such as refining furnaces. Its advantages include good dissolving ability for magnetite black scale; under the action of the reducing agent, stubborn black rust can be gradually complexed and dissolved; high tolerance for mixed scale, including mud, sand, and oil; and the citric acid's ability to dissolve calcium... 2+ Mg 2+ It also has a certain complexing effect and can dissolve a small amount of scale; the cleaning process is easy to control, and the possibility of violent reactions and dangers is low. The disadvantage is its slow speed: treating thick rust scale requires long-term circulation; heating can partially speed it up, but it still takes several hours or even more than ten hours to complete. Furthermore, the citric acid system has limited cleaning power for grease and grime, and pre-treatment with alkali to remove grease may be necessary. Selection criteria: When the scale layer is thick, hard, and there is sufficient time, organic acid complexing systems should be preferred to achieve gentle yet thorough cleaning.

[0083] A rapid strong acid-inhibition system, hydrochloric acid + corrosion inhibitor: suitable for severe blockages requiring rapid flow or where the scale is mainly composed of easily soluble rust. Its significant advantage is its fast reaction rate; it has a strong dissolving effect on Fe2O3, Fe3O4, etc., and can clear blockages in a short time. It is particularly effective for rapid cleaning of simple pipelines and small equipment, such as heat exchanger tube bundles, where acid washing can be completed within hours. The main risks of this system are substrate corrosion and safety: if corrosion inhibition is inadequate, hydrochloric acid can cause rapid uniform corrosion or even pitting corrosion of steel; the release of H2 during the reaction can easily cause gas lock or explosive gas accumulation, therefore good ventilation and exhaust are essential. Additionally, high Cl... - Environmental factors may pose potential risks to subsequent operations, and residual chlorine, if not removed, will continue to corrode. Selection criteria: When a short-term resumption of operation is required, such as when production can only be shut down for a few hours or when the system scale is primarily loose red rust, a hydrochloric acid system can be considered. However, good monitoring and emergency response capabilities are essential, as well as thorough neutralization and passivation after cleaning to prevent residual acid damage. For large areas of dense black rust, strong acids alone are often insufficient for complete removal. Hydrochloric acid has limited solubility for Fe3O4 and may form an iron salt passivation film on the rust surface, hindering further reactions. Therefore, it is not advisable to use it as the sole method but is better suited for use in conjunction with a complexing system.

[0084] Nitric acid / hydrofluoric acid systems are used for stainless steel components only in special circumstances, such as when stainless steel heat exchangers or pipes in a system have deposited insoluble scale, such as silica, sulfate scale, or Cr2O3 film. This system is highly corrosive to carbon steel and is generally not used directly on carbon steel piping. Therefore, if its use is necessary, stainless steel components are typically cleaned in a separate loop, isolating them from the carbon steel system. Hydrofluoric acid dissolves silicate scale and passivates oxide films, while nitric acid promotes passivation of the stainless steel surface and oxidizes Fe. 2+ Avoid hydrogen embrittlement. This method is highly risky; HF is extremely toxic and corrosive to glass and skin, and must be carried out under the guidance of a professional. Therefore, the use of HF is not recommended in most copper smelting water cooling systems unless silica deposition is confirmed and there is no other alternative.

[0085] In summary, in the preferred embodiment of this invention, cleaning with complexing-reducing organic acids is the primary method, supplemented by short-term strong acid cleaning. Specifically, a citric acid solution is mainly used for long-term circulation, with hydrochloric acid used initially to open the pathways or, if necessary, a short-term application of strong acid to clean localized, insoluble residues later. This combination offers complementary advantages: citric acid ensures thorough cleaning, while hydrochloric acid ensures rapid and unobstructed flow, overcoming stubborn rust. Simultaneously, corrosion monitoring is maintained throughout the entire process, and the solution is adjusted immediately upon detection of any abnormalities.

[0086] To implement the above cleaning process, a temporary cleaning circuit needs to be set up on-site, and the corresponding equipment and chemicals need to be prepared. The following describes the equipment and layout for the cleaning operation, as well as the key operational points: (1) Cleaning Loop and Equipment Layout: This invention adopts an on-site circulating cleaning method to complete the internal cleaning of the pipeline without dismantling the main equipment. The cleaning loop set up on-site typically includes: a temporary cleaning tank, a circulating pump, connecting hoses or pipes, a filter device, and necessary valves, flow meters, and monitoring points. The cleaning tank is selected from acid and alkali resistant plastic tanks or rubber-lined metal tanks, and its capacity is determined according to the system volume, generally more than 50% of the water volume of the system being cleaned, to ensure sufficient circulation volume; the circulating pump should be a self-suction corrosion-resistant centrifugal pump, with a head and flow rate that meet the requirements of spreading the cleaning solution throughout the system. If it is necessary to overcome the lifting height of the high-level water jacket and pipeline resistance, sufficient flow velocity should be ensured at the far end; acid-resistant hoses, such as reinforced PVC hoses or rubber hoses, are used for connecting pipelines. Temporary interface flanges are installed at the system inlet and outlet or discharge port, and connected to the hoses to form a closed loop. To monitor the flow rate and pressure, pressure gauges and flow meters are installed at the pump outlet, or the flow rate is estimated using the pump characteristic curve to grasp the real-time operating conditions. A temporary filter or screen should be connected in series in the circuit to trap large pieces of rust that fall off during the cleaning process, preventing blockage of the circulation pump or pipeline. The filter should be inspected and cleaned regularly.

[0087] The original cooling water inlet and outlet pipes were disconnected and connected to a temporary circuit. The cleaning solution was pumped from the cleaning tank, entered one end of the pipe to be cleaned through a hose, and then flowed back to the cleaning tank from the other end of the pipe. An exhaust port and a stirring device were installed above the cleaning tank, which could be used to stir with compressed air or circulate with a small pump to keep the solution composition uniform and release gas. The entire system forms a closed loop, and operators can add chemicals, take samples, and observe the process at the cleaning tank.

[0088] (2) Chemical Dosing and Replacement: Before initially starting the cleaning cycle, add the prepared chemical solution to the cleaning tank according to the calculated dosage. To ensure accurate proportioning, each component can be dissolved one by one in the tank or a stock solution can be prepared in advance and added all at once. After starting the circulation pump, check that all interfaces are sealed and leak-free, and gradually increase the flow rate to the target value. During the cleaning process, if the monitoring shows a decrease in acidity or depletion of complexing agent, a pH rise to >4, or a change in solution color from yellow to light, the corresponding chemical should be added in time. When adding, it should be poured slowly into the cleaning tank to avoid sudden changes in local concentration. Safety tip: Do not directly add solid EDTA or concentrated acid into the pipeline; it should be dissolved and diluted in the tank before adding. In cases where the cleaning solution needs to be replaced, if the pickling solution is saturated with iron ions or the corrosion inhibitor has failed, the circulation should be stopped first, the old solution should be drained and collected as much as possible, and then a new solution should be prepared according to the original formula for recirculation. The old solution can be temporarily stored in a spare tank for subsequent neutralization treatment. To prevent a large amount of air from entering the pipeline during fluid changes and thus avoid the reformation of air locks, a priming bucket or air vent valve can be installed at the pump inlet to help release air.

[0089] (3) Zone and Circulation Path Switching: For cooling systems with complex structures and multiple parallel branches, a zone-by-zone, segmented cleaning strategy can be adopted. First, clean the main circulation pipe and one branch, and close the other branches; after completion, replace the hose to connect and clean another branch, thus covering all loops one by one. After each section is cleaned, rinse it with clean water before moving on to the next section to avoid rust particles from one section flowing into the uncleaned section and causing blockage. In this embodiment, for the two major loops of the furnace shell water jacket and the waste heat boiler tube bundle, we clean them in two batches: first clean the furnace shell serpentine water jacket pipe, and then clean the waste heat boiler U-shaped tube bundle loop. For this purpose, a temporary isolation plate is installed at the junction of the two loops to divide the system into two independent circulation cleaning, which has a good effect. Another key point is the adjustment of the flow direction: if necessary, the flow direction of the cleaning fluid in the pipeline can be changed to remove scale by reverse flushing. For structures that are prone to unidirectional sludge accumulation, such as parallel tube bundles with a single inlet and multiple outlets, the inlet and outlet hoses can be switched midway to achieve backflushing and remove the previously unshed deposits.

[0090] (4) Material Compatibility and Protection: All components used in the cleaning system should have good corrosion resistance. Temporary hoses and seals must be acid and alkali resistant; the impeller and flow parts of the circulating pump should preferably be made of stainless steel, engineering plastics, or corrosion-resistant alloys to prevent corrosion by the cleaning solution. Protective measures should be taken in advance for components in the original system that may be affected by acid: for example, sensitive temperature probes, pressure gauges, and other instruments can be removed or isolated; some rubber gaskets are not acid resistant, and if necessary, they should be replaced with fluororubber or the component should be temporarily removed. Considering that hydrochloric acid is also highly corrosive to copper and its alloys, if there are copper components in the system, such as brass valves, contact with hydrochloric acid should be avoided, or sufficient corrosion inhibitors should be ensured. Construction personnel must wear acid-resistant gloves and goggles when adding chemicals and taking samples, and a clean water tank should be available at the operating location for immediate rinsing in case of accidental acid splashing.

[0091] (5) Practical Operation Details: After cleaning begins, a dedicated person should be assigned to monitor the circulating pump and tank, and observe the liquid level and pressure at all times. If the liquid level in the cleaning tank drops, it may be due to a leak in the system or air entering the pump. Appropriate liquid replenishment should be made, and the leak point should be checked. Monitoring personnel should regularly record data such as temperature, pH, and iron ion concentration as a basis for judging the cleaning progress. If acid leakage occurs at any point during the cleaning process, the process should be stopped immediately. After depressurization, the leaking area should be flushed with water and neutralized. Repairs should then be made as appropriate. Small leaks can be temporarily plugged with wooden wedges or rubber gaskets; serious leaks require stopping cleaning and welding repairs.

[0092] This invention employs the weight loss method and the iron ion concentration method as corrosion monitoring methods: Pre-weighed carbon steel test pieces are placed in the cleaning circuit, and the weight loss is calculated by reweighing them at different time points to obtain the average corrosion rate (mm / a); simultaneously, the Fe concentration in the cleaning solution is measured online. 2+The rate of increase in iron concentration, combined with the volume of the cleaning solution, can be used to estimate the instantaneous rate of steel dissolution. An increase of 1 mg / L in iron ions can roughly correspond to a corrosion weight loss of 7.6 g / m² for carbon steel (based on a 1 mg / L increase in iron ion concentration). 3 (Volume calculation). Based on this, a safety threshold is set during the cleaning process to control the total iron concentration from not exceeding a certain upper limit or the corrosion rate from not exceeding a specified value. If the value is approached, pickling is immediately stopped and the process proceeds to the next step, thereby controlling the corrosion loss of the substrate within an acceptable range.

[0093] In addition, the waste liquid after cleaning must be treated in accordance with requirements before being discharged to ensure that it meets the discharge standards or is recycled, so as to prevent heavy metals and acids and alkalis in the rust water from polluting the environment.

[0094] After completing the main cleaning and confirming that the rust and scale have been largely removed, immediately proceed with post-treatment operations, including neutralization, passivation pre-filming, and ongoing water quality management after resuming operation. This step is crucial for consolidating the cleaning effect and preventing secondary corrosion.

[0095] (1) Alkaline washing and neutralization: After the chemical cleaning cycle is stopped, acid and dissolved Fe remain in the pipeline. 2+ Fe 3+ For corrosive media, neutralization and removal must be carried out as soon as possible. First, drain the pickling solution and initially flush the system with clean water to dilute and remove as much residual liquid as possible. Then, prepare a 1–2% NaOH or Na₂CO₃ alkaline solution, or adjust the pH to around 10 using ammonia, and add it to the system and circulate for 0.5–1 hour to raise the pH in the pipes to a slightly alkaline level, approximately 6.8–7.5. During the alkaline washing process, pay attention to venting and preventing pressure buildup. The alkaline solution can neutralize residual acid and reduce Fe₂O₃ content. 3+ Hydrolysis produces Fe(OH)3 precipitate, which settles at the lowest point in the system. After alkaline washing, the system is thoroughly drained again and the pipeline is flushed with plenty of clean water until the pH of the effluent is around 7 and there is no rust color. After neutralization treatment, the internal environment of the system returns to neutral, creating conditions for the next passivation step.

[0096] (2) Passivation Pre-filming: Forming a dense protective film on the surface of carbon steel is an effective measure to prevent the pipe wall from immediately rusting again after cleaning. This invention uses inorganic passivating agents or organic pre-filming agents to pre-film the inside of the pipe. Preferred passivating agents include: sodium nitrite (NaNO2) 0.5–1.0%, sodium metamolybdate (Na2MoO4) about 0.5%, or sodium dihydrogen phosphate (NaH2PO4) 0.5–1.0%, etc. Among them, sodium nitrite can form a dense oxide film such as γ-Fe2O3 with iron, molybdate can adsorb on the steel surface to form a protective film, and phosphate promotes the formation of a poorly soluble iron phosphate film. These passivating agents can be used alone or in combination. During operation, the passivating agent is added to water according to the calculated amount to prepare a solution. Generally, the pH is adjusted to 8–9, the system is filled and circulated for 2–4 hours, and the temperature is maintained at 30–50℃. During the process, the solution concentration is monitored and the agent is added as needed. The passivation process is complete when a uniform blue-black or yellow-green film appears on the surface of the pads or pipe wall. The specific color varies depending on the passivating agent; sodium nitrite typically forms a blue-black oxide film, while phosphate may produce a light green film. After passivation, circulation is stopped, the passivation solution is slowly drained, and the pipe is kept moist to prevent rapid drying and damage to the film. It is crucial that the passivation stage be carried out under fully neutralized conditions after acid washing; otherwise, nitrite ions may convert to nitric acid under acidic conditions, exacerbating corrosion. Passivation treatment forms a preliminary protective film on the pipe wall, providing corrosion protection for the system to be put back into operation.

[0097] (3) System Restoration and Trial Operation: Remove the temporary cleaning circuit, restore the original system piping connections, and install or replace components removed during cleaning, such as instruments and valves. Inject qualified cooling water, preferably treated soft water or reclaimed water, and start the circulation pump for trial operation. At this time, an appropriate amount of pre-filming corrosion inhibitor, low-concentration zinc phosphate, compound organic phosphate, etc., can be added to further enhance the protective film (film-protecting agents: phosphate / zinc + molybdate + organophosphorus / polycarboxylic acid: 1–3 mg / L as P; 0.5–1.5 mg / L as Mo; dispersant 5–15 mg / L, not for film formation, but for site adsorption and inhibition of cation / cathode reactions, significantly slowing down the electrochemical corrosion and redeposition of exposed pipe walls). Monitor the pH, iron ions, and turbidity of the operating water. Initially, there may be slightly high iron ions, which may be due to a small amount of residual rust being washed away. Appropriate discharge can be carried out until normal is restored. After checking that there are no leaks at all connections, the system can be put back into operation under load.

[0098] (4) Subsequent Operation Protection Strategy: After cleaning and resumption of operation, this invention is equipped with a complete set of water quality stabilization and monitoring maintenance measures to ensure long-term scale and corrosion prevention. These mainly include: Adjust the makeup water quality and pH: Minimize the content of corrosive ions in the makeup water, and soften / deaerate the makeup water if necessary; maintain the pH of the circulating water in a slightly alkaline range of 7.5–8.5 to avoid an acidic corrosive environment. The pH can be adjusted by adding lime slurry or alkaline agents, and automatic control should be set.

[0099] Add corrosion and scale inhibitors (film-protecting agents): phosphate / zinc + molybdate + organophosphorus / polycarboxylic acid: 1–3 mg / L as P; 0.5–1.5 mg / L as Mo; 5–15 mg / L as dispersant. It does not form a film, but it can occupy sites for adsorption, inhibit cation / cathode reactions, significantly slow down the electrochemical corrosion and redeposition of exposed pipe walls, and inhibit rust precipitation.

[0100] Side-flow filtration and backwashing: During operation, the side-flow filter is activated to continuously filter out suspended iron oxide particles and impurities in the water. The side-flow filtration rate is generally 5–10% of the total circulation flow to gradually purify the water. In addition, a small amount of circulating water is periodically backwashed according to the concentration ratio to control Cl. - SO4 2- Plasma concentration. Maintaining Cl - Concentrations below 100 mg / L, SO4 2- Below 200 mg / L, total iron <0.5–1.0 mg / L (if total iron continues to rise, it indicates corrosion, and the dosage of side-filter and corrosion inhibitor should be increased).

[0101] Online monitoring and early warning: Install and utilize existing DCS systems in key areas to monitor the pressure difference between cooling water inlet and outlet, flow rate, temperature difference between inlet and outlet water, and water quality indicators (pH, conductivity, iron ion concentration, etc.) in real time. Establish early warning thresholds: a pressure difference increase of more than 20% compared to the initial clean state, total iron exceeding 1.0 mg / L, flow rate decrease exceeding 15%, and abnormal increase in temperature difference in a certain section indicate a potential scaling trend. Issue an early warning promptly and arrange for inspection or small-scale online cleaning. A low-dose citric acid corrosion inhibitor mixture (concentration 0.5–1%) can be added under continuous flow conditions for light online cleaning to remove initial deposits. Simultaneously investigate and correct the causes of water quality abnormalities (such as changes in makeup water quality, interruption of chemical treatment, etc.).

[0102] Regular Inspection and Maintenance: It is recommended to schedule a shutdown inspection every six months to one year, opening and inspecting key parts of the pipeline, such as elbows and headers, to assess for rust and scale regeneration. If slight thin rust is found, it can be treated by online chemical dosing without shutting down the system; if significant deposits are found, targeted CIP cleaning or full system circulation cleaning should be performed again during planned maintenance. However, due to the above comprehensive protective measures, the cleaning cycle is expected to be shortened from the original quarterly to 6–12 months or even longer. Practical results show that within one year of implementing the cleaning and protection plan, the total iron concentration in the system remained below 0.5 mg / L, and the pressure differential and flow rate remained stable, requiring no unplanned shutdowns. Through neutralization, passivation, and continuous water quality control during operation, this invention achieves long-term protection of the smelting cooling water system after one cleaning. The beneficial effects of cleaning and descaling are maintained, preventing the re-exacerbation of pipeline corrosion and scaling problems. The entire system enters a virtuous cycle: stable water quality—controlled corrosion—no large amount of new rust and scale generated—long-term stable heat exchange efficiency, thereby ensuring the safe, efficient and continuous operation of smelting production.

[0103] The cleaning and protection method provided by this invention enables phased rust and scale removal treatment of the smelting furnace water cooling system, significantly restoring the effective flow cross-section of the pipeline and noticeably improving the circulating water volume and flow smoothness. The increased flow velocity of cooling water on the heating surface enhances the heat transfer coefficient, significantly reduces the furnace shell and water jacket wall temperature, eliminates existing high-temperature hotspots, and transforms the overall temperature field of the equipment from localized anomalies to uniform and stable operation. With increased cooling margin, core equipment such as the smelting furnace can maintain stable operation under higher smelting intensities, simultaneously improving smelting thermal efficiency and the heat transfer effect of the flue gas waste heat boiler, resulting in an overall improvement in the system's energy utilization and production efficiency.

[0104] Improved safety and extended operating cycle: Through an integrated solution of cleaning, passivation pre-filming, and water quality control, this invention effectively breaks the vicious cycle of scaling and blockage—reduced flow—increased wall temperature—localized pressure anomalies leading to pipe rupture and failure. After cleaning, the temperature difference between the cooling water inlet and outlet returns to normal, the furnace shell / water jacket wall temperature stabilizes within a safe range, and the risk of cooling wall overheating is significantly reduced. A uniform and dense passivation film forms inside the pipe, and with the help of corrosion inhibitors, the corrosion rate of the carbon steel substrate is greatly reduced, simultaneously extending equipment life and continuous operating time, resulting in significant indirect economic benefits.

[0105] Comprehensive performance optimization and energy saving: After cleaning and protection are implemented, the circulating water quality and system operating parameters are under long-term control. The cleaning process of this invention restores the hydraulic performance of the pipeline to near-new condition, significantly reduces pressure drop, and decreases pump power consumption at the same flow rate, thus contributing to energy saving.

[0106] Figure 8 This is a schematic diagram illustrating the effect of elemental and phase composition analysis in rust and scale samples of the present invention. Figure 1 ; Figure 9 This is a schematic diagram illustrating the effect of elemental and phase composition analysis in rust and scale samples of the present invention. Figure 2 ; Table 1. Elemental and phase composition analysis results of rust and scale samples

[0107] Table 2. Analysis results of water samples before rust removal.

[0108] In summary, the method provided by this invention can completely eliminate the cooling bottleneck caused by rust and scale blockage, restore and improve equipment operating efficiency; and through passivation pre-filming and water quality optimization, it achieves long-term protection, significantly extending the cleaning and maintenance cycle and equipment life; while ensuring safe production, it saves a lot of maintenance and energy costs, which has significant economic and safety significance.

[0109] The specific embodiments of the invention have been described in detail above, but these are merely examples, and the invention is not limited to the specific embodiments described above. For those skilled in the art, any equivalent modifications or substitutions to the invention are also within the scope of this invention. Therefore, all equivalent transformations, modifications, and improvements made without departing from the spirit and principles of this invention should be included within the scope of this invention.

Claims

1. A cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns, characterized in that, The cleaning control method for rust removal and scale dissolution in the water-cooled pipeline of the metallurgical furnace includes: collecting pipeline flow cross-section and rust and scale characteristic data, determining the blockage level, and outputting a cleanable trigger signal; upon receiving the cleanable signal, adaptively selecting the start program from mechanical pretreatment and chemical cleaning according to the blockage level, and sequentially executing the chemical cleaning, neutralization passivation, and pre-film protection processes. During the cleaning process, the concentration of iron ions, pH value, temperature, flow rate and corrosion rate of the substrate in the cleaning solution are monitored in real time. When the concentration of iron ions tends to stabilize and the pH rises to the set threshold, the system automatically switches from chemical cleaning to neutralization and passivation. When the corrosion rate approaches the safety limit, the current cleaning is automatically interrupted and the system is forced to switch to neutralization and passivation. Heating, circulation and chemical dosing are adjusted in real time to keep the temperature, flow rate and chemical concentration dynamically within the target range.

2. The cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns according to claim 1, characterized in that, When a trigger signal indicating that the cleaning state is received, the program selects one of the mechanical pretreatment program and the chemical scale removal program as the start program according to the preset program; then the neutralization and passivation program and the pre-film protection program or the chemical scale removal program, the neutralization and passivation program and the pre-film protection program are started in sequence. Sensors and sampling points are deployed throughout the four cleaning processes to collect real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate, and weight loss of the corrosion test piece; based on preset thresholds, it is determined whether the current state deviates from the safe range, and control commands are dynamically generated.

3. The cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns according to claim 1, characterized in that, The process of setting up the default program includes the following steps: When the clogging level is low, a trigger command is generated to directly start the chemical scale removal cleaning program, and the trigger command is output to the start end of the chemical scale removal cleaning program; when the clogging level is medium or high, a sequence control command is generated to first start the mechanical pretreatment program, and then start the chemical scale removal cleaning program after the mechanical pretreatment program is completed, and the sequence control command is output to the start end of the mechanical pretreatment program and the delayed start end of the chemical scale removal cleaning program. Based on the type of trigger instruction or sequence control instruction, the corresponding program chain template is retrieved from the preset program chain template library. There are two types of program chain templates: the first type consists of a chemical scale removal and cleaning program, a neutralization and passivation program, and a pre-film protection program connected in series; the second type consists of a mechanical pretreatment program, a chemical scale removal and cleaning program, a neutralization and passivation program, and a pre-film protection program connected in series. According to the program sequence in the program chain template, start signals are sent sequentially to the actuators corresponding to each program. When the program chain template is the first type, a start signal is first sent to the actuator of the chemical scale removal and cleaning program. After receiving the completion signal of the chemical scale removal and cleaning program, a start signal is then sent to the actuator of the neutralization and passivation program. After receiving the completion signal of the neutralization and passivation program, a start signal is finally sent to the actuator of the pre-film protection program. When the program chain template is the second type, a start signal is first sent to the actuator of the mechanical pretreatment program. After receiving the completion signal of the mechanical pretreatment program, a start signal is then sent to the actuator of the chemical scale removal and cleaning program. After receiving the completion signal of the chemical scale removal and cleaning program, a start signal is then sent to the actuator of the neutralization and passivation program. After receiving the completion signal of the neutralization and passivation program, a start signal is finally sent to the actuator of the pre-film protection program.

4. The cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns according to claim 3, characterized in that, The process of retrieving the corresponding program chain template from the preset program chain template library includes the following steps: Extract the type identifier carried in the trigger instruction or sequence control instruction, and match the type identifier with the preset instruction type lookup table. When the matching result is a trigger instruction type, output the first type code; when the matching result is a sequence control instruction type, output the second type code. The received first type code and second type code are compared one by one with the pre-set associated codes of each template in the program chain template library; when the type code matches the associated code of the first template in the program chain template library, the storage address of the first template is located in the program chain template library; when the type code matches the associated code of the second template in the program chain template library, the storage address of the second template is located in the program chain template library. The corresponding template content is read from the program chain template library according to the storage address. The read template content is encapsulated into a template output data packet containing program sequence identifier and program connection order fields, and then sent to the program execution controller.

5. The cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns according to claim 4, characterized in that, The process of extracting the type identifier carried in trigger instructions or sequence control instructions includes the following steps: Receive the output trigger command or sequence control command, and separate the command header area and command payload area from the data packet of the trigger command or sequence control command; Read the congestion level code value from the fixed field bit in the instruction header area; at the same time, read the preset verification parameter corresponding to the congestion level code value from the instruction payload area, compare the congestion level code value with the preset verification parameter for consistency, and when the comparison result is consistent, mark the congestion level code value as a valid level code. The valid level code is matched with the preset level and type mapping table. When the valid level code corresponds to a low congestion level, the trigger instruction type identifier is output; when the valid level code corresponds to a medium or high congestion level, the sequence control instruction type identifier is output; the trigger instruction type identifier or the sequence control instruction type identifier is output to the preset instruction type lookup table.

6. The cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns according to claim 5, characterized in that, The process of separating the instruction header region and the instruction payload region from the data packet of trigger instructions or sequence control instructions includes the following steps: The system receives and outputs data packets containing trigger commands or sequence control commands. The data packets consist of a fixed-length command header containing a blockage level code and a cleaning program identifier, and a variable-length command body containing a mechanical pretreatment completion signal verification field and a chemical scale removal cleaning start delay parameter. After storing the data packets in a buffer, the system compares them byte by byte in the buffer with a preset command start identifier. When consecutive comparison results are completely consistent with the command start identifier, the starting position of the consecutive bytes is recorded as the data packet start boundary. Based on the recorded data packet start boundary, locate the byte position in the buffer at the preset header length field offset from the data packet start boundary, and read the header length value stored at the byte position; extract a continuous byte sequence from the buffer with the data packet start boundary as the starting point and the header length value as the truncation length, and output the extracted continuous byte sequence as the instruction header area; the instruction header area contains the congestion level code and the cleaning program identifier, which is used to read the congestion level code value; Based on the byte length occupied by the output instruction header area, the payload start boundary is obtained by adding the byte length to the data packet start boundary. From the payload start boundary to the end of the data packet in the buffer, the remaining continuous byte sequence is extracted and output as the instruction payload area. The instruction payload area contains the mechanical preprocessing completion signal verification field and the chemical scale removal cleaning start delay parameter, which are used to read the preset verification parameters. The instruction header area and the instruction payload area are output.

7. The cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns according to claim 6, characterized in that, The process of extracting the remaining consecutive byte sequence includes the following steps: Based on the output instruction header area, read the cleaning program identifier bit from the instruction header area. Based on the program type corresponding to the cleaning program identifier bit, obtain the first offset position and first field length of the mechanical pretreatment completion signal verification field, as well as the second offset position and second field length of the chemical scale dissolution cleaning start delay parameter from the preset load field configuration table. Output the obtained first offset position, first field length, second offset position, and second field length to the load extraction control terminal. Based on the first offset position and the first field length of the output, and taking the determined load start boundary as a reference, the load start boundary is offset backward by the first offset position to obtain the starting byte position of the mechanical preprocessing completion signal verification field; starting from the starting byte position, a byte sequence of the first field length is continuously extracted, and the byte sequence is used as the value of the mechanical preprocessing completion signal verification field; at the same time, the value of the mechanical preprocessing completion signal verification field is compared with the preset mechanical preprocessing completion standard check code. When the comparison is consistent, a load valid confirmation mark is generated; when the comparison is inconsistent, a load abnormality mark is generated and subsequent extraction is stopped. Based on the output second offset position and the second field length, and assuming the load valid confirmation flag is generated, the load start boundary is shifted backward by the second offset position to obtain the starting byte position of the chemical scale removal start delay parameter, using the load start boundary as a reference. A byte sequence of the second field length is continuously extracted from the starting byte position, and the byte sequence is used as the chemical scale removal start delay parameter value. The extracted mechanical preprocessing completion signal verification field value and the extracted chemical scale removal start delay parameter value are merged and encapsulated to form the instruction load area output.

8. The cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns according to claim 7, characterized in that, The process of using a byte sequence as a mechanical preprocessor to complete the signal verification field value includes the following steps: Based on the first offset position and the first field length of the output, and taking the determined load start boundary as a reference, the load start boundary is shifted backward by the first offset position to obtain the starting byte position of the mechanical preprocessing completion signal verification field. Starting from the starting byte position, the first field length bytes are read sequentially according to the preset byte-by-byte reading method. The read byte sequence is stored in the temporary verification buffer area and output as the original verification byte sequence. According to the preset verification field structure template, the mechanical preprocessing program type identifier and the mechanical preprocessing completion timestamp field are separated from the original verification byte sequence; the separated mechanical preprocessing program type identifier is matched with the preset mechanical preprocessing type lookup table; when the match is consistent, the mechanical preprocessing completion timestamp field is compared with the timestamp verification segment in the preset mechanical preprocessing completion standard verification code; when the absolute value of the difference is within the preset allowable range, a valid field structure identifier is generated. Under the premise of generating a valid identifier for the field structure, the original check byte sequence is summed and compared with the checksum field in the preset mechanical preprocessing completion standard check code. When the sum of the original check byte sequence matches the checksum field, the original check byte sequence is marked as a valid mechanical preprocessing completion signal check field value.

9. The cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns according to claim 1, characterized in that, It receives online monitoring data in the cleaning fluid, compares it with preset process parameters, and automatically executes control logic; The control logic includes: when the iron ion concentration tends to stabilize and the pH rises to the set threshold during the chemical scale dissolution stage, the stage switching is automatically triggered, and the process switches to neutralization and passivation. When the corrosion rate monitoring value approaches the safety limit, the current cleaning is automatically interrupted and forced to switch to the neutralization stage; the heating device, circulation pump frequency and dosing pump output are adjusted in real time to dynamically converge the key parameters of temperature, flow rate and reagent concentration to the target range, so as to achieve closed-loop optimization control of the whole process.

10. A cleaning and control system for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns, applied to the cleaning and control method for rust removal and scale removal in water-cooled pipelines of metallurgical furnaces and kilns as described in any one of claims 1 to 9, characterized in that, The cleaning and control system for rust removal and scale removal in the water-cooled pipelines of the metallurgical furnace includes: The blockage detection module is used to collect pipeline flow cross-sectional data, rust and scale quality and distribution characteristics, comprehensively analyze and determine the blockage level, and output a trigger signal for cleanable or non-cleanable status; providing a classification basis for mechanical pretreatment procedures. The rust and scale removal cleaning module is used to select one of the mechanical pretreatment program and the chemical scale removal cleaning program as the start program when a trigger signal indicating that the cleaning state is available is received. Then, it sequentially starts the neutralization and passivation program and the pre-film protection program, or the chemical scale removal cleaning program, the neutralization and passivation program and the pre-film protection program. Sensors and sampling points are deployed throughout the cleaning process of the four programs to collect real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate and weight loss of corrosion test pieces. Based on preset thresholds, it judges whether the current state deviates from the safe range and dynamically generates control commands. The online monitoring and control module is used to deploy sensors and sampling points throughout the entire cleaning process of the four procedures to collect real-time online monitoring data on iron ion concentration, pH value, temperature, flow rate, and weight loss of the corrosion test piece; it determines whether the current state deviates from the safe range based on preset thresholds and dynamically generates control commands. The closed-loop feedback control module is used to receive online monitoring data, compare it with preset process parameters, and automatically execute control logic.

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