Heat exchanger scale monitoring and treatment methods

Abstract

The present invention relates to the technical field of industrial data processing, and in particular to a method for monitoring and processing scale in a heat exchanger. The method obtains a variety of industrial data of a heat exchanger pipeline. The degree of scale adhesion in the heat exchanger pipeline is obtained by analyzing the calcium and magnesium ion content, water flow rate and descaling time in the heat exchanger. Further, the heat exchange effect evaluation of the heat exchanger in the current analysis period is obtained based on the stability of the thickness sequence of the heat exchanger pipeline and the stability of the water flow rate in the pipeline. The heat exchange performance of the heat exchanger is evaluated through the heat exchange effect evaluation, and the focus sampling time of the heat exchanger affected by scale is determined according to the element size in the descaling time sequence in the analysis period, and the descaling strategy of the focus sampling time is adjusted in the next analysis period. By analyzing a variety of heat exchanger industrial data, the present invention realizes the monitoring of the impact of scale on the heat exchanger and makes reasonable adjustments to the descaling and cleaning strategy.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial data processing, and in particular to a method for monitoring and processing scale in a heat exchanger. Background Art

[0002] A heat exchanger is a device that transfers part of the heat of a hot fluid to a cold fluid. It plays an important role in many industrial productions such as chemical, petroleum, power, and food.

[0003] There are many types of heat exchangers, but each one achieves heat exchange through inlet and outlet water pipes. When water flows through the heat exchanger pipes, calcium and magnesium ions in the water will adhere to the inner wall of the heat exchanger pipes, which can easily cause pipe blockage, reduce the heat exchange effect of the heat exchanger, affect industrial production efficiency, shorten the service life of the heat exchanger, and increase industrial costs. Therefore, it is necessary to descale and clean the heat exchanger pipes. In large-scale industrial scenarios with high workloads, due to the long service life and high utilization rate of heat exchangers, if the cleaning strategy is not adjusted according to the scale status in the heat exchanger, it will still cause problems that affect production efficiency. Summary of the Invention

[0004] In order to solve the above technical problems, the purpose of the present invention is to provide a heat exchanger scale monitoring and treatment method, the technical solution adopted is as follows:

[0005] The present invention proposes a heat exchanger scale monitoring and treatment method, the method comprising:

[0006] Obtaining a preset analysis cycle and preset sampling time for the heat exchanger; wherein the sampling time includes at least one descaling process; collecting the calcium and magnesium ion content in the water at the heat exchanger inlet, the water flow in the heat exchanger pipe, and the pipe thickness of the heat exchanger pipe at each sampling time to obtain a calcium and magnesium ion content sequence, a water flow sequence, and a pipe thickness sequence; the descaling time of each descaling process within the analysis cycle constitutes a descaling time sequence;

[0007] The scale adhesion degree is obtained according to the calcium and magnesium ion content sequence, the water flow sequence and the descaling time sequence; the pipeline stability degree is obtained according to the difference between adjacent elements in the pipeline thickness sequence; and the water flow stability degree is obtained according to the difference between adjacent elements in the water flow sequence;

[0008] A heat exchange effect evaluation of the heat exchanger is obtained based on the degree of scale adhesion, the pipeline stability, and the water flow stability; if the heat exchange effect evaluation is less than a preset evaluation threshold, the heat exchanger is considered to be a heat exchanger affected by scale; based on the size of the elements in the descaling time series of the heat exchanger affected by scale, the focus sampling time with high descaling pressure in the analysis cycle is obtained, and the descaling frequency corresponding to the focus sampling time is increased in the next analysis cycle.

[0009] Furthermore, obtaining the preset analysis period and preset sampling time of the heat exchanger includes:

[0010] The analysis period is one year, and the sampling time is once a month.

[0011] Furthermore, obtaining the scale adhesion degree according to the calcium and magnesium ion content sequence, the water flow sequence, and the descaling time sequence includes:

[0012] The scale adhesion degree is obtained according to a scale adhesion degree formula, and the scale adhesion degree formula includes:

[0013]

[0014] in, is the scale adhesion degree, is the calcium and magnesium ion content sequence, is the water flow sequence, is the descaling time series, is the mean value function, is the maximum value function, is the minimum function, is a natural constant.

[0015] Furthermore, obtaining the pipeline stability according to the difference between adjacent elements in the pipeline thickness sequence includes:

[0016] The pipeline stability is obtained according to a stability formula, wherein the stability formula includes:

[0017]

[0018] in, is the stability of the pipeline, is the length of the thickness sequence, is the thickness sequence The thickness of the pipe, is the thickness sequence The thickness of the pipe, is the absolute value function, is a natural constant;

[0019] The obtaining of the water flow stability according to the difference between adjacent elements in the water flow sequence comprises:

[0020] The water flow stability is obtained according to a stability formula.

[0021] Furthermore, the heat exchange effect evaluation of the heat exchanger obtained according to the scale adhesion degree, the pipeline stability and the water flow stability includes:

[0022] The heat exchange effect evaluation is obtained according to a heat exchange effect evaluation formula, wherein the heat exchange effect evaluation formula includes:

[0023]

[0024] in, For the evaluation of the heat exchange effect, is the stability of the pipeline, is the water flow stability, is the scale adhesion degree, is a natural constant.

[0025] Furthermore, obtaining the sampling time of interest with high descaling pressure in the analysis period according to the element size in the descaling time series of the heat exchanger affected by scale includes:

[0026] An element mean value in the descaling time series is obtained, and a sampling time corresponding to an element in the descaling time series that is greater than the element mean value is used as the focused sampling time.

[0027] The present invention has the following beneficial effects:

[0028] The embodiment of the present invention obtains a sequence of state data of the heat exchanger pipe within an analysis cycle based on a preset analysis cycle and a preset sampling time. The degree of scale adhesion in the current heat exchanger pipe, the degree of pipe stability, and the degree of water flow stability are determined through various state data of the heat exchanger pipe, and the heat exchange effect evaluation of the heat exchanger within an analysis cycle is further obtained. The calcium and magnesium ion content indicates the water quality state in the heat exchanger pipe, the water flow indicates the scale adhesion state in the heat exchanger pipe, the descaling time indicates the amount and degree of scale adhesion, and the pipe thickness indicates the corrosive effect of scale on the pipe. A heat exchange effect evaluation with a strong reference value is obtained by jointly analyzing the above-mentioned multiple state data. The descaling strategy of the next analysis cycle is adjusted according to the size of the heat exchange effect evaluation, so as to realize a scientific heat exchanger cleaning process in a large-scale industrial environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solutions and advantages of the embodiments of the present invention or the prior art, the following briefly introduces the drawings required for use in the embodiments or the prior art descriptions. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0030] Figure 1This is a flow chart of a heat exchanger scale monitoring and treatment method provided by one embodiment of the present invention. DETAILED DESCRIPTION

[0031] To further illustrate the technical means and effectiveness of the present invention in achieving its intended objectives, the following, in conjunction with the accompanying drawings and preferred embodiments, provides a detailed description of the specific implementation, structure, features, and effectiveness of a heat exchanger scale monitoring and treatment method proposed in accordance with the present invention. In the following description, references to "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment. Furthermore, specific features, structures, or characteristics of one or more embodiments may be combined in any suitable manner.

[0032] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0033] The specific scheme of the heat exchanger scale monitoring and treatment method provided by the present invention is described in detail below with reference to the accompanying drawings.

[0034] See also Figure 1 , which shows a flow chart of a heat exchanger scale monitoring and treatment method provided by one embodiment of the present invention, the method comprising:

[0035] Step S1: Obtain a preset analysis cycle and a preset sampling time for the heat exchanger; the sampling time includes at least one descaling process; collect the calcium and magnesium ion content in the water at the heat exchanger inlet, the water flow in the heat exchanger pipe, and the pipe thickness of the heat exchanger pipe at each sampling time to obtain a calcium and magnesium ion content sequence, a water flow sequence, and a pipe thickness sequence; the descaling time of each descaling process within the analysis period constitutes a descaling time sequence.

[0036] In intelligent industrial scenarios, industrial Internet of Things technology can be used to detect and transmit the status data of heat exchanger pipelines through various detectors and sensors in the Internet of Things.

[0037] In normal industrial scenarios, heat exchanger operation is affected by environmental factors such as seasonal temperature. Therefore, a year can be considered as the data analysis cycle for a heat exchanger. Therefore, with one year as the analysis cycle for the heat exchanger, data sampling is performed monthly to collect heat exchanger pipeline data. Because the present invention is targeted at large-scale industrial production environments with high heat exchanger utilization, an initial fixed descaling strategy is set to descaling once a month. Through data analysis of the heat exchanger, the number of descaling cycles in a particular month can be appropriately increased in the next analysis cycle to adjust the heat exchanger pipeline cleaning strategy. Therefore, at least one descaling process is included between sampling times.

[0038] Scale, also known as water rust or water limescale, refers to the white, lumpy or powdery substance that gradually forms in a container after boiling water with high hardness due to the minerals contained therein. Its main components include calcium carbonate, magnesium hydroxide, magnesium carbonate, calcium sulfate, magnesium sulfate, calcium chloride, and magnesium chloride. In other words, the higher the calcium and magnesium ion content in the water within the heat exchanger pipes, the harder the water, which is more likely to cause scale accumulation. Therefore, in the embodiments of the present invention, a calcium and magnesium ion concentration detector is used to obtain the calcium and magnesium ion content within the heat exchanger pipes at each sampling time, and further obtain a calcium and magnesium ion content sequence for the entire analysis period. That is, the length of the calcium and magnesium ion content sequence is 12, and each element in the sequence represents the calcium and magnesium ion content of the water within the heat exchanger for the corresponding entire month.

[0039] The water flow rate reflects the utilization rate of the heat exchanger, that is, the greater the water flow rate in the heat exchanger pipe, the greater the utilization rate of the heat exchanger. The higher the utilization level, the easier it is to form scale. Therefore, in an embodiment of the present invention, a surface-mounted pipe flow meter is used to measure the water flow rate in the heat exchanger pipe. The surface-mounted pipe flow meter uses the ultrasonic time difference method to measure the time difference of upstream and downstream ultrasonic transmission to obtain a measurement method of the flow rate in the pipe. Its main advantage is that it can obtain accurate flow data by installing an external clamp-on sensor to measure the transmission and reception time difference of the upstream and downstream transmission signals without breaking the pipe or stopping the water supply, and then obtain the water flow sequence of the heat exchanger pipe during the entire analysis period. That is, the length of the water flow sequence is 12, and each element in the sequence represents the water flow rate in the heat exchanger for the corresponding entire month.

[0040] Scale deposits on heat exchanger pipes can corrode the inner walls, causing unevenness and potholes, which can affect the lifespan of the heat exchanger. Therefore, in this embodiment, an ultrasonic thickness gauge is used to analyze pipe thickness using a spectrum analyzer. Ten monitoring points are set up along the entire pipe, generating 10 data points. The average of these 10 data points is used as the pipe thickness at the current time, generating a pipe thickness sequence. The length of the pipe thickness sequence is 12, with each element representing the heat exchanger pipe thickness for the corresponding month.

[0041] In industrial scenarios with high workloads and loads, regular descaling and cleaning are necessary to maintain heat exchange efficiency in heat exchangers. In this embodiment of the present invention, the initial fixed descaling and cleaning strategy is monthly. This fixed strategy will be used in the subsequent description of this embodiment. In this embodiment of the present invention, a sampling electronic descaling instrument is used to descaling heat exchangers. The basic principle of this electronic descaling instrument is to change the physical molecular structure that causes scale formation. It uses magnetic composite ripples to modify the surrounding environmental conditions to break the bonds between ions and form stable, non-scaling substances. Its core is a modulation signal generator. Using unique integrated circuit and signal processing technology, it generates a complex frequency modulation signal. This modulation signal is applied to the pipeline via a signal cable, creating a dynamic molecular interference field within the pipeline. This field acts on the fluid and dissolved salt molecules in the pipeline, producing a nucleation effect. Therefore, the electronic descaling instrument is suitable for descaling heat exchanger pipelines in large-scale industrial scenarios. The descaling time is obtained for each descaling process. All descaling times within an analysis cycle constitute a descaling time series. Because the initial fixed descaling cleaning strategy is used, the length of the descaling time series is 12. Each element in the series represents the descaling time of the descaling process in the corresponding month. The longer the descaling time, the more scale has accumulated.

[0042] Step S2: obtaining the scale adhesion degree according to the calcium and magnesium ion content sequence, the water flow sequence and the descaling time sequence; obtaining the pipeline stability degree according to the difference between adjacent elements in the pipeline thickness sequence; and obtaining the water flow stability degree according to the difference between adjacent elements in the water flow sequence.

[0043] The scale adhesion degree is obtained according to the scale adhesion degree formula, which includes:

[0044]

[0045] in, is the degree of scale adhesion, is the calcium and magnesium ion content sequence, is the water flow sequence, is the descaling time series, is the mean value function, is the maximum value function, is the minimum function, is a natural constant.

[0046] In the scale adhesion degree formula, It is the average value of calcium and magnesium ion content within an analysis period. The larger the average value, the more calcium and magnesium ion content in the water used in the current industrial scenario, the higher the water hardness, and the more prone to scale formation. It is the relative change of water flow within an analysis period. The greater the relative change, the more unstable the water flow in the pipeline and the higher the degree of scale adhesion. It represents the mean value of the elements in the descaling sequence. The larger the mean value, the longer the descaling time required and the higher the degree of scale adhesion.

[0047] Furthermore, considering that scale adhesion inside the heat exchanger pipe will affect the pipe thickness and water flow rate, the pipe stability is obtained based on the difference between adjacent elements in the pipe thickness sequence, and the water flow stability is obtained based on the difference between adjacent elements in the water flow sequence. Specifically, the following are included:

[0048] The stability of the pipeline is obtained according to the stability formula, which includes:

[0049]

[0050] in, is the pipeline stability, is the length of the thickness sequence, is the thickness sequence Pipe thickness, is the thickness sequence Pipe thickness, is the absolute value function, is a natural constant.

[0051] In the stability formula, This represents the difference between the mean value between the current and initial time points and the mean value between the previous and initial time points. If there is no corrosion within the heat exchanger pipe, the differences in the stability formula will all approach zero, and the pipe stability will approach 1. Conversely, if the pipe is corroded by scale, causing data to vary at different times, indicating significant differences in the stability formula, the pipe stability will approach 0.

[0052] Similar to the pipeline stability, the water flow sequence in the heat exchanger pipeline is analyzed according to the stability formula to obtain the water flow stability.

[0053] Step S3: Obtain a heat exchange effect evaluation of the heat exchanger based on the degree of scale adhesion, pipeline stability, and water flow stability; if the heat exchange effect evaluation is less than a preset evaluation threshold, the heat exchanger is considered to be affected by scale; based on the element size in the descaling time series of the heat exchanger affected by scale, obtain the focus sampling time with high descaling pressure in the analysis cycle, and increase the descaling frequency between the corresponding focus sampling times in the next analysis cycle.

[0054] The greater the stability of the heat exchanger pipe, the less scale corrosion or corrosion inside the pipe, the higher the heat exchanger's working efficiency and the better the heat exchange effect. The more stable the water flow in the heat exchanger pipe, the better the heat exchange working environment of the pipe, the higher the heat exchanger's working efficiency and the better the heat exchange effect. The less scale adhesion, the less the impact of scale on the heat exchanger, the higher the heat exchanger's working efficiency and the better the heat exchange effect. Therefore, the heat exchange effect of the heat exchanger can be evaluated based on the scale adhesion, pipe stability and water flow stability, including:

[0055] The heat transfer effect evaluation is obtained according to the heat transfer effect evaluation formula, which includes:

[0056]

[0057] in, To evaluate the heat transfer effect, is the pipeline stability, is the stability of water flow, is the degree of scale adhesion, is a natural constant.

[0058] In a fixed operating scenario, the heat exchanger's heat transfer efficiency should be guaranteed to meet the operating standard. Therefore, an evaluation threshold can be set to conduct comparative analysis of the heat transfer efficiency evaluation. In this embodiment of the present invention, considering that the reasons for the reduced heat transfer efficiency of the heat exchanger include not only the influence of scale but also the aging of the heat exchanger itself, the same analysis method is used to analyze the data of a new heat exchanger to obtain the heat transfer efficiency evaluation of the new heat exchanger, and 90% of the heat transfer efficiency evaluation of the new heat exchanger is used as the evaluation threshold.

[0059] If the heat exchange effect evaluation is not less than the evaluation threshold, it indicates that the heat exchange effect of the current heat exchanger is good, and the existing descaling and cleaning strategy can be maintained unchanged to proceed to the next analysis cycle. If the heat exchange effect evaluation is less than the evaluation threshold, it indicates that the descaling and cleaning strategy of the current analysis cycle is unreasonable, causing scale to affect the heat exchange efficiency, and the heat exchanger is considered to be affected by scale. In order to adjust the descaling and cleaning strategy for heat exchangers affected by scale, it is necessary to collect data within the current analysis cycle and determine the sampling time with high descaling pressure in the current analysis cycle as the sampling time of interest based on the element size in the descaling time series. Specifically, it includes:

[0060] The element mean in the descaling time series is obtained, and the sampling time corresponding to the element in the descaling time series that is greater than the element mean is used as the focus sampling time.

[0061] The months corresponding to the sampling time of interest are the months with the highest workload in the current working scenario. For example, in winter, when temperatures are low and heat loss is high, the workload of the heat exchanger will increase compared to other months. Therefore, the descaling frequency may need to be increased during the sampling time of interest. For example, the descaling frequency may be increased from once a month to twice a month during the sampling time of interest. The specific setting can be based on the cost budget of the working scenario and is not a constraint here.

[0062] For sampling times that are not of concern, the existing descaling and cleaning strategy can be maintained, and only the descaling frequency of sampling times of concern can be adjusted to monitor and treat scale in the heat exchanger.

[0063] It should be noted that if you choose to increase the descaling frequency for a certain month in the next analysis cycle, the length of the corresponding descaling time series in the next analysis cycle will increase. For example, if you need to change the descaling frequency in December to twice a month in the next analysis cycle, the corresponding descaling time series length will be 13, where the sampling time in December corresponds to two descaling times. By analyzing the heat exchanger data in the next analysis cycle, the descaling and cleaning strategies in subsequent analysis cycles can be further analyzed and adjusted. If the descaling and cleaning strategy of the heat exchanger cannot be adjusted, that is, the cleaning frequency cannot be increased due to the cost budget, and the heat exchange effect of the heat exchanger is still not ideal, it means that the life of the current heat exchanger is about to reach its limit. In order to ensure work efficiency, the heat exchanger needs to be replaced.

[0064] In summary, the embodiment of the present invention obtains a variety of industrial data of the heat exchanger pipeline. The degree of scale adhesion in the heat exchanger pipeline is obtained by analyzing the calcium and magnesium ion content, water flow rate and descaling time in the heat exchanger. Further, the heat exchange effect evaluation of the heat exchanger in the current analysis period is obtained based on the stability of the heat exchanger pipeline thickness sequence and the stability of the water flow rate in the pipeline. The heat exchange performance of the heat exchanger is evaluated through the heat exchange effect evaluation, and the focus sampling time of the heat exchanger affected by scale is determined according to the element size in the descaling time sequence in the analysis period, and the descaling strategy of the focus sampling time is adjusted in the next analysis period. The embodiment of the present invention realizes the monitoring of scale and makes reasonable adjustments to the descaling and cleaning strategy by analyzing a variety of heat exchanger industrial data.

[0065] It should be noted that the order in which the embodiments of the present invention are described above is for illustrative purposes only and does not necessarily represent the superiority or inferiority of the embodiments. The processes depicted in the accompanying drawings do not necessarily require the specific order or sequential order shown to achieve the desired results. In certain embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0066] The various embodiments in this specification are described in a progressive manner, and the same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on the differences from other embodiments.

[0067] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A heat exchanger scale monitoring and treatment method, characterized in that: The method comprises: Obtaining a preset analysis cycle and preset sampling time for the heat exchanger; wherein the sampling time includes at least one descaling process; collecting the calcium and magnesium ion content in the water at the heat exchanger inlet, the water flow in the heat exchanger pipe, and the pipe thickness of the heat exchanger pipe at each sampling time to obtain a calcium and magnesium ion content sequence, a water flow sequence, and a pipe thickness sequence; the descaling time of each descaling process within the analysis cycle constitutes a descaling time sequence; The scale adhesion degree is obtained according to the calcium and magnesium ion content sequence, the water flow sequence and the descaling time sequence; the pipeline stability degree is obtained according to the difference between adjacent elements in the pipeline thickness sequence; and the water flow stability degree is obtained according to the difference between adjacent elements in the water flow sequence; A heat exchange effect evaluation of the heat exchanger is obtained based on the degree of scale adhesion, the pipeline stability, and the water flow stability; if the heat exchange effect evaluation is less than a preset evaluation threshold, the heat exchanger is considered to be a heat exchanger affected by scale; based on the size of the elements in the descaling time series of the heat exchanger affected by scale, the focus sampling time with high descaling pressure in the analysis cycle is obtained, and the descaling frequency corresponding to the focus sampling time is increased in the next analysis cycle.

2. A heat exchanger scale monitoring and treatment method according to claim 1, characterized in that: The method of obtaining the preset analysis period and preset sampling time of the heat exchanger includes: The analysis period is one year, and the sampling time is once a month.

3. A heat exchanger scale monitoring and treatment method according to claim 1, characterized in that: The obtaining of the scale adhesion degree according to the calcium and magnesium ion content sequence, the water flow sequence and the descaling time sequence includes: The scale adhesion degree is obtained according to a scale adhesion degree formula, and the scale adhesion degree formula includes: in, is the scale adhesion degree, is the calcium and magnesium ion content sequence, is the water flow sequence, is the descaling time series, is the mean value function, is the maximum value function, is the minimum function, is a natural constant.

4. A heat exchanger scale monitoring and treatment method according to claim 1, characterized in that: Obtaining the pipeline stability according to the difference between adjacent elements in the pipeline thickness sequence includes: The pipeline stability is obtained according to a stability formula, wherein the stability formula includes: in, is the stability of the pipeline, is the length of the thickness sequence, is the thickness sequence The thickness of the pipe, is the thickness sequence The thickness of the pipe, is the absolute value function, is a natural constant; The obtaining of the water flow stability according to the difference between adjacent elements in the water flow sequence comprises: The water flow stability is obtained according to a stability formula.

5. The heat exchanger scale monitoring and treatment method according to claim 1, characterized in that: The heat exchange effect evaluation of the heat exchanger obtained according to the scale adhesion degree, the pipeline stability degree and the water flow stability degree includes: The heat exchange effect evaluation is obtained according to a heat exchange effect evaluation formula, wherein the heat exchange effect evaluation formula includes: in, For the evaluation of the heat exchange effect, is the stability of the pipeline, is the water flow stability, is the scale adhesion degree, is a natural constant.

6. A heat exchanger scale monitoring and treatment method according to claim 1, characterized in that: The obtaining of the sampling time of interest with high descaling pressure in the analysis period according to the element size in the descaling time series of the heat exchanger affected by scale comprises: An element mean value in the descaling time series is obtained, and a sampling time corresponding to an element in the descaling time series that is greater than the element mean value is used as the focused sampling time.

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