Method and apparatus for monitoring the performance of a refractory material layer in a high temperature gas processing system

Abstract

The present invention relates to a method and a device for monitoring the performance of a refractory layer of a high temperature gas treatment system. The high temperature gas treatment system comprises a high temperature gas generating device and a cooling device connected downstream of the high temperature gas generating device, a cooling medium in the cooling device exchanging heat with the high temperature gas from the high temperature gas generating device, the method comprising the steps of: measuring in real time an operating parameter of the high temperature gas treatment system, calculating a heat loss J A of the high temperature gas, calculating a heat load J B of the cooling device, defining a performance index P of the refractory layer as: P=(J A -J B ) / J A , and determining the performance state of the refractory layer according to the magnitude of the P value.

Description

Technical Field

[0001] This invention relates to a method and apparatus for monitoring the performance of heat-resistant material layers in high-temperature gas handling systems. Background Technology

[0002] In the fields of coal chemical industry, petrochemical industry, and clean energy, high-temperature gas handling systems are one of the core process links. A typical high-temperature gas handling system includes a high-temperature gas generating unit, such as a combustion reactor or gasifier, and downstream cooling units connected to it, such as a syngas cooler or waste heat boiler. The high-temperature gas generating unit is usually equipped with a heat-resistant layer to isolate it from the high-temperature, high-pressure, and corrosive environment and protect the outer shell and surrounding equipment. Depending on the type of unit, the heat-resistant layer can be a refractory brick layer, such as the multi-layer structure of fire-facing bricks, backing bricks, and insulating bricks used in multi-nozzle gasifiers and GE gasifiers, or it can be a membrane water-cooled wall lining, such as the water-cooled wall structure used in Shell gasifiers.

[0003] The integrity and health of the heat-resistant layer directly affect the safe operation and service life of the high-temperature gas handling system. During long-term operation, the heat-resistant layer is subjected to erosion from high-temperature molten slag, repeated thermal stress, and chemical corrosion, leading to gradual thinning, cracking, peeling, or localized leaks. Once the heat-resistant layer fails, it can result in reduced thermal efficiency and reactor shutdown, or even a safety accident.

[0004] Therefore, effective and timely performance evaluation of the heat-resistant layer is directly related to the reliability and stability of the production equipment. Currently, the industry standard practice is to monitor the outer wall temperature of the main reactor using infrared thermography, thereby indirectly inferring the performance of the heat-resistant layer. However, infrared thermography has the following drawbacks: Infrared monitoring can only detect the result, not the process. In other words, it only reflects the temperature rise after the heat-resistant layer fails; it cannot detect the slow failure process of the heat-resistant layer, thus lacking predictability. Infrared detection can only monitor local areas and cannot provide comprehensive coverage.

[0005] Infrared detection can only provide qualitative assessments, not quantitative studies. Infrared detection is highly susceptible to environmental interference and has a high error rate, requiring manual screening to ensure the validity of the data.

[0006] Existing technologies lack a technical solution capable of online, continuous, and quantitative monitoring of the health status of the heat-resistant layer in a high-temperature gas handling system, providing early warnings of deterioration trends and guiding planned maintenance. Therefore, this invention aims to develop a monitoring method and device for the heat-resistant layer, which can intuitively and accurately assess the performance of the refractory brick layer, thereby guiding optimal production operation and maintenance solutions. This will have significant engineering application value and economic benefits. Summary of the Invention

[0007] To achieve the above objectives, in one aspect, the present invention provides a method for monitoring the performance of a heat-resistant material layer in a high-temperature gas handling system, comprising the following steps: Real-time measurement of operating parameters of high-temperature gas handling system Calculate the heat loss J of the high-temperature gas. A , Calculate the heat load J of the cooling device. B , The performance index P of the heat-resistant material layer is defined as: P = (J A -J B ) / J A ,as well as The performance status of the heat-resistant material layer is determined based on the value of P.

[0008] On the other hand, the present invention provides an intelligent control device for implementing the method, comprising: The data acquisition module is configured to measure and acquire the operating parameters of the high-temperature gas processing system in real time. Calculation module 1, configured to calculate the heat loss J of high-temperature gas. A ; Calculation module 2 is configured to calculate the heat load J of the cooling device. B , Calculation module 3 is configured to calculate the performance index P of the heat-resistant material layer. The calculation module 1 is electrically connected to the calculation module 3, and is used to calculate the heat loss J of the high-temperature gas. A The data is transmitted to the calculation module 3. The calculation module 2 is electrically connected to the calculation module 3, and is used to process the calculated heat load J of the cooling device. B The data is transmitted to the computing module 3.

[0009] The method and apparatus of this invention, by calling real-time online data from the DCS and the basic physical property database corresponding to the process medium, can effectively and quantitatively calculate the performance index of the heat-resistant material layer in real time, and display it on the DCS human-machine interface in real time, thus forming a long-term monitoring trend. This invention realizes online, continuous, and quantitative monitoring of the performance of the heat-resistant material layer, can provide early warning of deterioration trends, guide planned maintenance, effectively extend equipment operating cycles, and reduce the risk of unplanned shutdowns. Attached Figure Description

[0010] Figure 1 A simplified schematic diagram of an exemplary high-temperature gas handling system is shown. Detailed Implementation

[0011] This invention is based on the understanding that for a high-temperature gas processing system with a defined structure, which typically includes a high-temperature gas generating device and a cooling device connected downstream of the gas generating device, under its designed normal operating conditions (such as a defined load, raw material, and ambient temperature), the heat loss of the reactor's metal furnace wall is a relatively stable baseline value. However, when the performance of the heat-resistant material layer deteriorates, the heat loss will exhibit a certain trend. This invention, based on the law of conservation of energy, characterizes and monitors the performance of the heat-resistant material layer of the high-temperature gas processing system by using the real-time percentage of heat loss.

[0012] The method for monitoring the performance of heat-resistant material layers in a high-temperature gas handling system according to the present invention includes the following steps: S1. Real-time measurement of operating parameters of the high-temperature gas handling system Figure 1 A simplified schematic diagram of an exemplary high-temperature gas processing system is shown. The high-temperature gas processing system includes a high-temperature gas generating device, such as a combustion reactor, and a cooling device, such as a waste heat boiler, connected downstream of the high-temperature gas generating device. Figure 1 As shown, the cooling device includes a high-temperature gas outlet A', a cooling medium inlet B', and a cooling medium outlet B. The high-temperature gas generating device generates high-temperature gas that travels downwards to the initial high-temperature position A of the cooling device. This position is the high-temperature point where the high-temperature gas completes a heating or exothermic reaction during its travel path. This high-temperature position A serves as a starting point for the thermal state of the high-temperature gas and is used to calculate the heat loss of the processing system.

[0013] In one specific embodiment, the high-temperature gas is syngas, and the high-temperature gas treatment system is a syngas system comprising a gasifier and a syngas cooler, such as a water-cooled boiler, connected downstream of the gasifier. The gasifier includes at least one burner disposed at the top of the gasifier for injecting fuel and oxidant into the gasifier. The initial high-temperature syngas location A is located downstream of the burner outlet, i.e., in the area below the burner; therefore, this location is close to the area below the burner in the gasifier. The water-cooled boiler includes a syngas outlet A', a subcooled boiler water inlet B', and a saturated steam outlet B. The heat-resistant material layer may be a layer of refractory bricks arranged on at least a portion of the wall of the gasifier.

[0014] In this step, the operating parameters of the high-temperature gas processing system are measured in real time. These operating parameters may include the initial temperature t of the high-temperature gas at the initial location A. A The high-temperature gas outlet temperature t at the high-temperature gas outlet of the cooling device A’ Cooling medium inlet temperature t B’ Cooling medium outlet temperature t B or pressure p BHigh-temperature gas mass flow rate f of the high-temperature gas generating device A The mass flow rate f of the cooling medium outlet of the cooling device B and the mass flow rate f of the cooling medium inlet B’ In one specific implementation, the operating parameters include the initial syngas temperature t at point A in the gasifier. A Syngas outlet temperature t at the syngas outlet of the water-cooled boiler A’ , subcooled boiler water inlet temperature t B’ and saturated steam outlet temperature t B or pressure p B Syngas mass flow rate f of the gasifier A 1. Saturated steam outlet mass flow rate f of water-cooled boiler B and subcooled boiler water inlet mass flow rate f B’ .

[0015] These operating parameters can be measured in real time using online thermocouple thermometers, online pressure gauges, or online flow meters installed at the corresponding locations in the system.

[0016] S2. Calculate the heat loss J of the high-temperature gas respectively. A and the heat load of the cooling device J B Heat loss of high-temperature gas J A It can be calculated using the following formula: J A =(H A -H A’ )×f A , Where H A H is the enthalpy of the high-temperature gas at the initial location A of the high-temperature gas. A’ f is the mass enthalpy of the high-temperature gas outlet. A This refers to the mass flow rate of the high-temperature gas generated by the high-temperature gas generating device.

[0017] The enthalpy of a high-temperature gas can be calculated based on the gas's temperature and composition data using a preset thermodynamic function. In a specific implementation, H... A The enthalpy of the syngas at the high-temperature starting position A is based on the syngas starting temperature t. A The composition data of the synthesis gas are obtained through a preset thermodynamic function H. A =f(t A The calculated value of H is... A’ The enthalpy of syngas outlet in a water-cooled boiler is based on the syngas outlet temperature t in the water-cooled boiler. A’ The composition data of the synthesis gas are used to perform the calculation using a preset thermodynamic function H. A’ =f(t A’) was calculated.

[0018] The composition data of the syngas are pre-determined constant values, or can be obtained in real time during operation using an online gas analyzer. The thermodynamic functional relationships are derived from the physical state data tables of high-temperature gases such as syngas and computer-integrated simulations, and have been widely used in engineering practice.

[0019] The heat load J of the cooling device B It can be calculated using the following formula: J B =H B ×f B -H B’ ×f B’ , Where H B H is the enthalpy of the outlet cooling medium. B’ f is the mass enthalpy of the cooling medium inlet. B The mass flow rate of the outlet cooling medium and f B’ This represents the inlet mass flow rate of the cooling medium.

[0020] In one specific implementation, the cooling device is a water-cooled boiler, and the cooling medium at the inlet of the water-cooled boiler is water, while the cooling medium at the outlet of the water-cooled boiler is saturated steam. B The enthalpy of saturated steam is based on the outlet pressure p of saturated steam in a water-cooled boiler. B or outlet temperature t B Through the preset thermodynamic function H B =f(p B ) or H B =f(t B The calculated value of H is... B’ The mass enthalpy of subcooled boiler water is based on the inlet temperature t of the subcooled boiler water in a water-cooled boiler. B’ Through the preset thermodynamic function H B’ =f(t B’ ) was calculated.

[0021] Under ideal operating conditions, all the inlet cooling water is converted into saturated steam. According to the law of conservation of mass, the mass flow rate f of the outlet steam is... B equal to the mass flow rate f of the imported cooling water B’ The heat load of the cooling device J B J can be calculated using the following formula: B =f B’ × (H B -H B’ ).

[0022] The enthalpy of saturated steam as a function of pressure or temperature, and the enthalpy of subcooled water as a function of temperature, are deterministic functional relationships that can be obtained based on water's physical state data and computer-integrated simulations.

[0023] S3. Calculate the percentage of heat loss in the high-temperature gas generation system. In this invention, the percentage of heat loss in the high-temperature gas generation system is calculated using the following formula, and this percentage of heat loss is used to characterize the performance index P of the heat-resistant material layer: P=(J A -J B ) / J A .

[0024] According to the method of the present invention, the performance status of the heat-resistant material layer can be determined based on the calculated P value.

[0025] After the high-temperature gas handling system is first put into operation or the heat-resistant layer is replaced, under stable operating conditions, the equipment heat loss data is collected over a continuous period of time. Statistical processing yields the baseline P value (P0). 基准 When the calculated P value is less than or equal to P 基准 When the value is 3 times the value of P, the heat-resistant material layer is considered to have stable performance; when the P value is greater than 3 times the value of P, the heat-resistant material layer is considered to have stable performance. 基准 When the value is reached, the heat-resistant material layer is determined to have failed, and a shutdown and maintenance process needs to be triggered.

[0026] In one specific implementation scheme, for a syngas system, P 基准 For example, it can be selected as 0.01, or selected according to the system's design parameters.

[0027] The method of this invention can be performed in a DCS system. The calculation of the P value typically relies on the real-time scanning cycle of the DCS system. A typical scanning cycle for a DCS controller is 0.2 to 1 second. Within this cycle, the system continuously reads the instantaneous values ​​of field instruments (such as temperature, pressure, flow rate, etc.) and calculates the heat loss percentage P in real time based on the above formula. This calculation process is synchronized with the control scanning of the DCS, accurately reflecting the instantaneous fluctuations in heat loss. Depending on the capabilities of specific sensors, computing, and storage devices, the calculation cycle for the P value can be reasonably set. For example, the operating parameters of the high-temperature gas handling system required for calculating the P value can be read every second, and the P value can be calculated accordingly. This calculation cycle for the P value can be extremely short, and this high-frequency data can be used for real-time monitoring and instantaneous alarms. For example, when the P value is greater than 3 times P... 基准 When the value is reached, the heat-resistant material layer is determined to have failed, an instantaneous alarm is triggered, and a shutdown and maintenance process is initiated.

[0028] In the method of this invention, the performance index P of the heat-resistant material layer can also be recorded and analyzed over a long period. In one embodiment, the method of this invention further includes the following steps: acquiring the performance index P at a certain trend sampling period, generating a trend curve, and calculating the derivative of the performance index P with respect to time t to obtain the real-time rate of change K of the performance index P. The trend sampling period refers to the time interval between extracting data points from the high-frequency instantaneously calculated P value and storing them in a historical database, so as to fit a curve of P value with time t, and to perform long-term trend analysis and real-time rate of change calculation.

[0029] Furthermore, based on the performance index P value and its real-time rate of change K value, and compared with multiple preset thresholds, the performance degradation state of the heat-resistant layer can be automatically identified. Based on the identified degradation state, an alarm signal of the corresponding level is triggered, and matching maintenance suggestions are output. Therefore, in a preferred embodiment, the method of the present invention further includes determining the performance degradation state of the heat-resistant material layer and providing multi-level early warnings based on the performance index P and the real-time rate of change K. Specifically: When P 基准 <P<1.5×P 基准 When 0≤K≤alarm threshold, a first-level warning is issued to determine that the performance of the heat-resistant material layer has shown initial signs of deterioration, and the planned process conditions of the high-temperature gas treatment system are adjusted accordingly. When P 基准 <P<1.5×P 基准 When K > alarm threshold, a secondary warning is issued, indicating a rapid deterioration in the performance of the heat-resistant material layer. The system then enters a special protection operation phase for the high-temperature gas treatment system and prepares spare parts. When 1.5×P 基准 <P<3×P 基准 When K>0, a level 3 warning is issued, indicating that the performance of the heat-resistant material layer has entered the late stage of its service life, and a shutdown for maintenance is planned in the near future.

[0030] The alarm threshold for K can be set according to factors such as the specific equipment's process conditions and expected service life.

[0031] In some embodiments, the method according to the invention further includes calculating the derivative N of the real-time rate of change K of the performance index P with respect to time t. When N > 0 or K is absent at a certain time t, an additional warning is issued to immediately introduce human intervention. On the one hand, when N > 0, it can be determined that the performance of the heat-resistant material layer is deteriorating rapidly for some reason, even if the P value has not yet exceeded P0. 基准 Multiples or P 基准This itself also requires immediate attention. On the other hand, when K is absent at a certain time t, it can be determined that the performance of the heat-resistant material layer has suddenly deteriorated due to discontinuous changes over time. As an example, this may only be a localized detachment of the refractory brick layer, and human intervention can be introduced to use, for example, infrared thermography to find the localized heating point of the gasifier, which is a high-temperature gas generating device, thereby confirming the existence or non-existence of localized detachment of the refractory brick layer.

[0032] Compared with the prior art, the method of the present invention has the following beneficial effects: 1. Online continuous monitoring: The performance status of the heat-resistant layer can be obtained in real time without shutting down the furnace, avoiding production losses.

[0033] 2. Early warning: By further monitoring the rate of change of the heat-resistant layer performance index, early signs of deterioration can be identified before the percentage of heat loss exceeds the standard, thus buying time for proactive maintenance.

[0034] 3. Tiered early warning and maintenance decision-making: The deterioration state of the heat-resistant layer is quantified into several stages, and different levels of alarms and maintenance suggestions are matched for different stages, realizing the transformation from "post-event maintenance" to "condition-based maintenance", which significantly extends the equipment operation cycle.

[0035] On the other hand, the present invention also provides an intelligent control device for implementing the method described herein, preferably a DCS system, comprising: The data acquisition module is configured to measure and acquire the operating parameters of the high-temperature gas processing system in real time; Calculation module 1, configured to calculate the heat loss J of high-temperature gas. A ; Calculation module 2 is configured to calculate the heat load J of the cooling device. B , Calculation module 3 is configured to calculate the performance index P of the heat-resistant material layer. The calculation module 1 is electrically connected to the calculation module 3, and is used to calculate the heat loss J of the high-temperature gas. A The data is transmitted to the calculation module 3. The calculation module 2 is electrically connected to the calculation module 3, and is used to process the calculated heat load J of the cooling device. B The data is transmitted to the computing module 3.

[0036] In a preferred embodiment, the intelligent control device of the present invention further includes a trend generation module, configured to acquire the performance index P of the heat-resistant material layer at a certain trend sampling period, generate a trend curve of P changing with time t, and calculate the derivative of the performance index P with respect to time t based on the real-time acquired performance index P data to obtain the real-time rate of change K of the performance index. The trend generation module can also be further configured to calculate the derivative N of the real-time rate of change K of the performance index P with respect to time t.

[0037] In another preferred embodiment, the intelligent control device further includes an alarm module configured to generate multi-level early warning signals based on changes in the performance index P and the real-time rate of change K, and, if present, changes in the derivative N.

[0038] The method of the present invention will be illustrated below using a syngas system as an example.

[0039] like Figure 1 As shown, the syngas system includes a gasifier 1 and a water-cooled boiler 2 connected downstream of the gasifier. The syngas system at point A is the high-temperature side of the syngas system (i.e., near the gasifier burner). The instantaneous temperature at this point can be accurately measured in real time using an online thermocouple thermometer, denoted by t. A This indicates that point A' is the low-temperature side of the synthesis gas, and the instantaneous temperature at this point can be accurately measured in real time using an online thermocouple thermometer, denoted by t. A’ This indicates that the pressure drop in the syngas system from point A to A' is almost zero. In actual operation, the pressure P varies depending on the gasifier's process, generally ranging from 2.0 MPa to 6.0 MPa. Taking P as an example of 3.0 MPa, the enthalpy of the syngas system at point A is: H A =1×10 -14 t A 5 -8×10 -11 t A 4 +2×10 -7 t A 3 +1×10 -4 t A 2 +1.4622t A -9381.3 At point A', the mass enthalpy of the synthesis gas system is: H A′ =4×10 -13 t A' 5 -7×10 -10 t A' 4 +5×10 -7 t A' 3 +5×10 -5 t A' 2 +1.4271t A' -9366.7 The heat loss of the synthesis gas system is: J A =(HA -H A′ )×f A .

[0040] In a water-cooled boiler, the subcooled boiler water absorbs heat from the syngas to produce saturated steam. At the saturated steam outlet B, the instantaneous pressure can be accurately measured in real time using an online pressure gauge, denoted as p. B This indicates that the pressure range is typically 2.0 MPa to 5.0 MPa, and the enthalpy of saturated steam has a definite functional relationship with the corresponding pressure. At the subcooled boiler water inlet B', under a fixed pressure, the mass enthalpy of the subcooled boiler water is related to the temperature t. B’ A definite functional relationship exists. Given a specific gasifier and steam generator, the corresponding subcooled boiler water pressure is also definite; here, 7.5 MPa is used as an example. The saturated steam output can be measured in real-time using an online flow meter, expressed as f. B This indicates that the mass flow rate of subcooled boiler water can also be measured in real time using an online flow meter, using f B’ This indicates that at point B, the enthalpy of the saturated vapor is: H B = 0.0258p B 5 - 0.5591p B 4 + 5.0656p B 3 - 25.693p B 2 + 68.216p B - 13241 At point B', the enthalpy of the subcooled boiler water is: H B' = 2×10 -10 t B' 5 - 1×10 -7 t B' 4 + 4×10 -5 t B' 3 - 0.0053t B' 2 + 4.5332t B' - 15974 The heat load J of the water-cooled boiler B For: J B =H B ×f B -H B’ ×f B’ .

[0041] The performance parameter P of the refractory brick layer can be determined as P=(JA -J B ) / J A 。

[0042] It should be understood that the above is only an exemplary calculation process of the performance parameter P for the syngas system including the gasifier 1 and the water-cooled boiler 2 connected downstream of the gasifier. When the high-temperature gas treatment system consists of other high-temperature gas generating devices and cooling devices, the heat loss ratio of the heat-resistant material layer can be calculated accordingly using the flow rate of the medium (e.g., volume flow rate or mass flow rate) and the enthalpy per unit (volume or mass) flow rate, so as to reflect the heat preservation performance of the heat-resistant material layer.

[0043] The P of this gasifier system 基准 is 0.01. The calculated P values are sampled and monitored at intervals of, for example, every second to generate a trend curve P = f(t), and its derivative K = f’(t) is obtained based on this trend curve.

[0044] When 0.01 < P < 0.015 and 0 ≤ K ≤ the alarm threshold, a first-level early warning is given, indicating that there are signs of deterioration in the refractory brick layer and process conditions need to be adjusted planfully. When 0.01 < P < 0.015 and K > the alarm threshold, a second-level early warning is given, indicating that there are signs of rapid deterioration in the performance of the refractory brick layer and the device enters the special care operation stage. With the cooperation of an infrared imaging instrument, the local performance deterioration points can be located, and spare parts are prepared simultaneously. When 0.015 < P < 0.03 and K > 0, a third-level early warning is given, indicating that the performance of the refractory brick layer has entered the late stage of its life, and recent shutdown and maintenance preparations are arranged according to the plan.

[0045] According to the method of the present invention, the alarm threshold of K, which is constant or variable, can be set based on information such as the process conditions and design life of the gasifier system. For example, when it is expected that under normal operating conditions, the P value will increase from the reference value of 0.01 to 0.015 basically at a uniform speed over two years, the expected average change rate of P during these two years is 0.0025 / year. Accordingly, the alarm threshold of K can be set to a constant 0.0025 / year or a value close thereto to reflect whether the deterioration speed of the heat preservation performance of the refractory bricks of the gasifier meets the expectation, and further determine whether an early warning needs to be generated. In other examples, if it is expected that the P value will change non-uniformly under normal operating conditions, the alarm threshold of K can also be set as a value that changes with time according to the prediction. For example, when it is expected that at the start of the operation of the gasifier, the P value rapidly increases from the reference value to a certain value and then slowly increases basically at a uniform speed, the alarm threshold of K in the initial operation stage of the gasifier can be set appropriately higher, and the later alarm threshold can be set lower.

[0046] The above description, using a syngas system as an example, is merely illustrative and does not limit the application of this method. Those skilled in the art, upon reading the context, should understand that the method of this application can be applied to evaluate the performance changes of heat-resistant insulation materials in other systems with heat exchange between high-temperature gases and cooling media.

Claims

1. A method for monitoring the performance of a heat-resistant material layer in a high-temperature gas handling system, the high-temperature gas handling system comprising a high-temperature gas generating device and a cooling device connected downstream of the high-temperature gas generating device, wherein a cooling medium in the cooling device exchanges heat with high-temperature gas from the high-temperature gas generating device, the method comprising the following steps: Real-time measurement of operating parameters of high-temperature gas handling system Calculate the heat loss J of the high-temperature gas. A , Calculate the heat load J of the cooling device. B , The performance index P of the heat-resistant material layer is defined as: P = (J A -J B ) / J A ,as well as The performance status of the heat-resistant material layer is determined based on the value of P.

2. The method according to claim 1, wherein: When P is less than or equal to P 基准 When the value is reached, the heat-resistant material layer is judged to have good performance; and When P is greater than 3×P 基准 When the value is reached, the heat-resistant material layer is determined to have failed, and a shutdown and maintenance process needs to be triggered.

3. The method according to claim 2, wherein P 基准 The value is 0.

01.

4. The method according to claim 1 or 2, wherein the cooling device includes a high-temperature gas inlet, a high-temperature gas outlet, a cooling medium inlet, and a cooling medium outlet, the high-temperature gas generating device includes a high-temperature gas travel start position, wherein the operating parameters include the high-temperature gas start temperature at the high-temperature gas start position, the high-temperature gas outlet temperature at the high-temperature gas outlet of the cooling device, the cooling medium inlet temperature, the cooling medium outlet temperature or pressure, the high-temperature gas mass flow rate of the high-temperature gas generating device, the cooling medium outlet mass flow rate of the cooling device, and the cooling medium inlet mass flow rate, wherein the high-temperature gas start position is the position where the high-temperature gas completes the heating or exothermic reaction in its travel path.

5. The method according to claim 1 or 2, wherein the heat loss J of the high-temperature gas is calculated. A The steps include according to formula J A =(H A -H A’ )×f A Calculate the heat loss of high-temperature gas J A H A H is the enthalpy of the initial mass of the high-temperature gas. A’ For the high-temperature gas outlet mass enthalpy, f A This refers to the mass flow rate of the high-temperature gas generated by the high-temperature gas generating device.

6. The method according to claim 1 or 2, wherein the heat load J of the cooling device is calculated. B The steps include according to formula J B =H B ×f B -H B’ ×f B’ Calculate the heat load J of the cooling device B H B H is the mass enthalpy of the outlet cooling medium. B’ f is the mass enthalpy of the cooling medium inlet. B For the mass flow rate of the outlet cooling medium and f B’ This represents the inlet mass flow rate of the cooling medium.

7. The method according to claim 1 or 2, wherein the method further comprises obtaining the performance index P at a certain trend sampling period and calculating the derivative of the performance index P with respect to time t to obtain the real-time rate of change K of the performance index P.

8. The method according to claim 7, wherein the method further comprises determining the performance degradation state of the heat-resistant material layer and providing multi-level early warning based on the magnitude of the performance index P and the real-time change rate K, wherein: When P 基准 <P<1.5×P 基准 When 0≤K≤alarm threshold, a Level 1 warning is issued, indicating that the performance of the heat-resistant material layer has shown initial signs of deterioration; When P 基准 <P<1.5×P 基准 When K > alarm threshold, a secondary warning is issued, indicating a rapid deterioration in the performance of the heat-resistant material layer; and When 1.5×P 基准 <P<3×P 基准 When K>0, a level 3 warning is issued, indicating that the performance of the heat-resistant material layer has entered the late stage of its lifespan.

9. The method according to claim 7, wherein the method further comprises calculating the derivative N of the real-time rate of change K of the performance index P with respect to time t, and issuing an additional warning when N>0 or N is discontinuous at a certain time t, and determining that the performance of the heat-resistant material layer has accelerated deterioration when N>0, and determining that the performance of the heat-resistant material layer has suddenly deteriorated when N is discontinuous at a certain time t.

10. The method according to claim 1, wherein the high-temperature gas processing system is a syngas system, the high-temperature gas generating device is a gasifier and the high-temperature gas is syngas, the high-temperature gas starting position is near the burner below the gasifier, the cooling device is a water-cooled boiler and the cooling medium at the inlet of the water-cooled boiler is water, the cooling medium at the outlet of the water-cooled boiler is saturated steam, and the heat-resistant material layer is a refractory brick layer arranged on at least a portion of the wall of the gasifier.

11. An intelligent control device for implementing the method according to any one of claims 1-10, comprising: The data acquisition module is configured to measure and acquire the operating parameters of the high-temperature gas processing system in real time; Calculation module 1, configured to calculate the heat loss J of high-temperature gas. A ; Calculation module 2 is configured to calculate the heat load J of the cooling device. B , Calculation module 3 is configured to calculate the performance index P of the heat-resistant material layer. The calculation module 1 is electrically connected to the calculation module 3, and is used to calculate the heat loss J of the high-temperature gas. A The data is transmitted to the calculation module 3. The calculation module 2 is electrically connected to the calculation module 3, and is used to process the calculated heat load J of the cooling device. B The data is transmitted to the computing module 3.

12. The intelligent control device according to claim 11, further comprising a trend generation module, configured to acquire the performance index P of the heat-resistant material layer at a certain trend sampling period, generate a trend curve of P changing with time t, and calculate the derivative of the performance index P with respect to time t based on the real-time acquired performance index P data to obtain the real-time rate of change K of the performance index.

13. The intelligent control device according to claim 12, wherein the trend generation module is further configured to calculate the derivative N of the real-time rate of change K of the performance index P with respect to time t.

14. The intelligent control device according to claim 12 or 13, further comprising an alarm module configured to generate multi-level early warning signals based on changes in the performance index P and the real-time rate of change K, and optionally changes in N.

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