Method and system for real-time monitoring of atomization effect and fault judgment of quench tower spray gun

Abstract

The application discloses a method and system for real-time monitoring of atomization effect and fault judgment of a quench tower spray gun, and belongs to the technical field of quench towers.The method comprises the following steps: obtaining an atomization effect value; if the atomization effect value is less than an atomization effect set value, switching to a backup spray gun; and if the atomization effect value is less than the atomization effect set value, performing first-time fault checking.The main purpose of the application is to convert the atomization effect in the quench tower spray gun system, which is difficult to monitor, into a visual atomization effect value, to realize real-time monitoring of the atomization effect of the spray gun; and according to the change of the atomization effect value, to judge the fault types, such as spray gun blockage, that may occur in the quench tower spray gun system, so that timely adjustment and maintenance can be performed, and the reaction time and judgment error of artificial judgment are reduced.

Description

Technical Field

[0001] This invention relates to the field of quench tower technology, and more specifically, to a method and system for real-time monitoring of atomization effect and fault diagnosis of quench tower spray guns. Background Technology

[0002] In metallurgical, solid waste incineration, and hazardous waste incineration processes, metallurgical furnaces and incinerators generate high-temperature flue gas. Before subsequent treatment such as dry dust removal, the high-temperature flue gas needs to be cooled. To prevent dioxin formation during cooling, quench towers are used to rapidly cool the high-temperature flue gas. However, current quench tower spray guns generally use the temperature parameters at the inlet and outlet of the quench tower to adjust the water spray volume to control the outlet temperature. Since the water spray volume can be monitored, but the atomization effect cannot, when the spray gun becomes clogged and the atomization effect deteriorates, the system increases the water spray volume to lower the flue gas temperature to the set range. This results in water dripping from the bottom of the quench tower and erosion and detachment of the bottom refrigeration material, increasing environmental pressure and the intensity of daily cleaning operations. Moreover, since the atomization effect of the spray guns in the quench tower cannot be monitored in real time, operators can only judge the blockage of the spray guns by phenomena such as overheating and dripping water, combined with experience. Therefore, the handling of the problem is delayed, which further aggravates the negative impact of the spray gun blockage.

[0003] Chinese patent CN214009234U discloses a novel spray gun system for a quench tower. In this system, the output end of a pneumatic regulating valve for the total cooling water flow is connected to a cooling water flow meter via a pipeline. One end of the cooling water flow meter is connected to six cooling water flow regulating ball valves via pipelines. Each spray gun can adjust the opening of its connected cooling water atomizing gas regulating ball valve according to its own opening degree and the atomizing gas pressure gauge, thereby controlling its own pressure to maintain within a set pressure range. This rapidly cools the flue gas to a certain temperature, preventing the formation of dioxins. Simultaneously, each spray gun is individually controlled, avoiding the phenomenon of a single spray gun spraying a large, unadjustable volume, thus preventing poor atomization and ash accumulation and agglomeration on the inner wall of the quench tower.

[0004] However, in the above scheme, the flow rate of cooling water in the spray gun is maintained by pressure gauges, but the atomization effect of the spray gun during use cannot be detected in a timely and effective manner, and the cooling effect of the flue gas cannot be determined in a timely manner. Moreover, faults in the system cannot be diagnosed in a timely and effective manner, resulting in the quench tower spray gun system not being used normally, the flue gas not being cooled in time, and thus generating a large amount of toxic and harmful gases and damaging subsequent flue gas treatment equipment. Summary of the Invention

[0005] The technical problem that the invention aims to solve

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a method and system for real-time monitoring of atomization effect and fault diagnosis of spray guns in quench towers. By converting the atomization effect of the spray guns in the quench tower into a visualized atomization effect value, the atomization effect of the spray guns can be monitored in real time. Based on the changes in the atomization effect value, possible faults such as spray gun blockage in the quench tower spray gun system can be identified, and timely maintenance can be carried out. This reduces the reaction time and judgment error of human judgment, so that the quench tower spray gun system can operate normally and the high-temperature flue gas can be cooled in a timely and effective manner.

[0007] Technical solution

[0008] To achieve the above objectives, the technical solution provided by the present invention is as follows:

[0009] The present invention provides a method for real-time monitoring of atomization effect and fault diagnosis of a quench tower spray gun, comprising:

[0010] Get the atomization effect value; if the atomization effect value is less than the atomization effect setting value, switch to the backup spray gun;

[0011] If the atomization effect value is less than the atomization effect setting value after switching to the backup spray gun, the first troubleshooting step will be performed.

[0012] Furthermore, the formula for calculating the atomization effect value is as follows:

[0013]

[0014] In the formula: N is the atomization effect value; Δh 理想 Δh represents the increase in enthalpy as water rapidly quenched to vapor under ideal conditions. 实际 This represents the increase in enthalpy as water rapidly cools and turns into water vapor in real-world conditions.

[0015] Furthermore, if the atomization effect value is less than the atomization effect setting value, the backup spray gun will be switched. Specifically, if the duration for which the N value is less than the atomization effect setting value is greater than the preset duration, the backup spray gun will be switched.

[0016] Furthermore, after obtaining the atomization effect value, if the N value is greater than the maximum effective value of the atomization effect, then the fault type is instrument fault.

[0017] Furthermore, after switching to the backup spray gun, if the N value is less than the maximum effective value of the atomization effect but greater than the atomization effect setting value, the fault type is a primary spray gun fault.

[0018] Furthermore, the first troubleshooting step includes determining whether the compressed air pipeline pressure of the spray gun is lower than the preset value of the compressed air pipeline pressure of the spray gun. If the compressed air pipeline pressure is lower than the preset value of the compressed air pipeline pressure of the spray gun, the fault type is a compressed air pipeline fault of the spray gun.

[0019] If the compressed air pipeline pressure is not less than the preset value of the compressed air pipeline pressure of the spray gun, then determine whether it is an instrument failure. If it is not an instrument failure, then the failure type is that both the main spray gun and the standby spray gun have failed before and after the switch.

[0020] Furthermore, in practice, the enthalpy increase Δh due to the rapid cooling of water into water vapor is... 实际 The calculation formula is:

[0021]

[0022] Where: Δh 实际 V represents the increase in enthalpy as the quenched water turns into water vapor in actual conditions. 实际烟入 This represents the actual volume of imported flue gas; s 实际烟入 T represents the actual volumetric specific heat capacity of the imported flue gas. 实际烟入 The actual inlet flue gas temperature; s 实际烟出 T represents the actual volumetric specific heat capacity of the flue gas at the outlet; 实际烟出 This represents the actual outlet flue gas temperature; m 实际水 This refers to the actual quality of the quench water.

[0023] The present invention also provides a quench tower spray gun system for realizing real-time monitoring of atomization effect and fault diagnosis, including a quench tower, a spray gun, and a quench water tank, wherein the quench water tank is connected to the spray gun and the spray gun is installed inside the quench tower.

[0024] Imported flue gas monitoring components are used to monitor the temperature and volumetric flow rate of imported flue gas.

[0025] The outlet flue gas monitoring component is used to monitor the temperature of the outlet flue gas.

[0026] The quench water monitoring component is used to monitor the temperature and mass flow rate of the quench water.

[0027] Compressed air pressure monitoring component, used to monitor the pressure of the compressed air pipeline of the spray gun;

[0028] The controller is electrically connected to the spray gun, the inlet flue gas monitoring component, the outlet flue gas monitoring component, the quench water monitoring component, and the compressed air pressure monitoring component. It is used to acquire data and atomization effect values ​​and control the system to perform actions.

[0029] Further, the spray guns before and after the switch are interlocked.

[0030] Furthermore, it also includes a display for showing the real-time operating status information of each component in the system and the atomization effect value.

[0031] A further feature is that it also includes an alarm, which issues an alarm signal when the N value is not within the normal range.

[0032] Beneficial effects

[0033] Compared with the prior art, the technical solution provided by this invention has the following advantages:

[0034] (1) In this invention, the atomization effect that is difficult to monitor in the quench tower spray gun system is transformed into a visualized atomization effect value, so as to realize the real-time monitoring of the spray gun atomization effect, so as to monitor the usage status of the spray gun and the cooling effect of high temperature flue gas; and based on the change of the atomization effect value, the type of fault such as spray gun blockage that may occur in the quench tower spray gun system can be determined, which facilitates timely adjustment and maintenance, reduces the reaction time and judgment error of human judgment, so that the quench tower spray gun system can operate normally and the high temperature flue gas can be cooled in a timely and effective manner.

[0035] (2) The quench tower spray gun system of the present invention can automatically adjust according to the atomization effect value. When the atomization effect value is detected to be less than the atomization effect set value, it will automatically switch to the standby spray gun. After switching to the standby spray gun, the atomization effect value reaches the normal range, and the standby spray gun can continue to be used to cool the high temperature flue gas. This realizes the monitoring of the spray gun usage status and timely replacement of the spray gun. It avoids the generation of toxic and harmful gases due to poor atomization effect caused by the main spray gun being blocked or other faults.

[0036] (3) This invention monitors the atomization effect by atomization effect value, and can make automatic adjustments. Based on the magnitude of the atomization effect value, it can promptly identify possible fault types and eliminate fault points. Compared with the traditional method of troubleshooting and judging by manual experience, it reduces the lag time of manual handling and the complexity of manual troubleshooting. At the same time, it reduces the adverse effects caused by faults such as spray gun blockage, and reduces the operation and maintenance costs and environmental pressure of the quench tower.

[0037] (4) This invention realizes the visualization of atomization effect through thermodynamic principles, that is, converts it into atomization effect value, and does not require additional equipment or space. The structure is reasonably designed, safe, stable and reliable, and the principle is simple and easy to promote and use. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the quench tower spray gun system in this application.

[0039] The labels in the diagram are as follows: 1. Inlet flue gas monitoring component; 2. Outlet flue gas monitoring component; 3. Quenching water monitoring component; 4. Compressed air pressure monitoring component; 5. Controller; 6. Main spray gun; 7. Backup spray gun. Detailed Implementation

[0040] To further understand the content of this invention, a detailed description of the invention will be provided in conjunction with the accompanying drawings and embodiments.

[0041] The structures, proportions, and sizes illustrated in the accompanying drawings are merely for illustrative purposes and to aid those skilled in the art in understanding and reading the invention. They are not intended to limit the scope of the invention and therefore have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of the invention, should still fall within the scope of the technical content disclosed herein. Furthermore, terms such as "upper," "lower," "left," "right," and "middle" used in this specification are merely for clarity and not intended to limit the scope of implementation. Changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered within the scope of the invention's implementation.

[0042] The present invention will be further described below with reference to embodiments.

[0043] Example 1

[0044] Quenching towers rapidly cool high-temperature flue gas by spraying a mist of cooling water from spray guns. Currently, the water spray volume is adjusted based on the temperature of the flue gas exiting the quenching tower. When a spray gun becomes clogged, the cooling water cannot be effectively atomized, resulting in a higher outlet flue gas temperature. The water spray volume is then increased to lower the temperature to the set range. However, excessive cooling water that is not effectively atomized can lead to dripping water at the bottom of the quenching tower and erosion of the bottom refractory material, causing significant environmental pressure and increased daily cleaning workload. Furthermore, because the atomization effect of the spray guns in the quenching tower cannot be monitored in real time, workers often rely on observations of overheating and dripping, combined with experience, to diagnose clogging. This process is time-consuming and results in delayed troubleshooting. The unresolved problems hinder the cooling of the high-temperature flue gas, potentially leading to the generation of large amounts of toxic and harmful gases and damage to subsequent flue gas treatment equipment.

[0045] This embodiment of a method for real-time monitoring of atomization effect and fault diagnosis of a quench tower spray gun includes the following steps: Step S1: Obtain the atomization effect value; if the atomization effect value is less than the atomization effect set value, switch to the standby spray gun; Step S2: after switching to the standby spray gun, if the atomization effect value is less than the atomization effect set value, perform the first fault diagnosis.

[0046] The atomization effect value is calculated from the enthalpy increase of quenched water turning into water vapor under ideal conditions and the enthalpy increase of quenched water turning into water vapor under actual conditions. The specific calculation formula is as follows:

[0047]

[0048] In the formula: N is the atomization effect value; Δh 理想 Δh represents the increase in enthalpy (kJ / kg) of water rapidly cooled to vapor under ideal conditions.实际 The enthalpy increase, expressed in kJ / kg, represents the actual increase in enthalpy as water rapidly cools and transforms into water vapor.

[0049] This method transforms the atomization effect, which is difficult to monitor in the quench tower spray gun system, into a visualized atomization effect value, enabling real-time monitoring of the spray gun atomization effect and monitoring the cooling effect of high-temperature flue gas. It achieves simultaneous monitoring of the outlet flue gas temperature and its own atomization effect.

[0050] In a quench tower, high-temperature flue gas is rapidly cooled by spraying a mist of quenching water. The process involves heat exchange between the high-temperature flue gas and the quenching water. Ideally, the sprayed quenching water should reduce the temperature of the high-temperature flue gas to a set value, i.e., to the ideal outlet flue gas temperature, and the quenching water should just completely evaporate into water vapor at the same temperature as the ideal outlet flue gas. Therefore, the heat exchange in the quench tower is that the heat absorbed by the quenching water equals the heat released by the high-temperature flue gas, as shown in the formula:

[0051] Q 吸收 =Q 放出

[0052] In the formula, Q 放出 The high-temperature flue gas releases heat, kJ; Q 吸收 The amount of heat absorbed by the rapidly cooling water is kJ.

[0053] Furthermore, the formula for calculating the heat released by high-temperature flue gas is:

[0054] Q 放出 =V 烟入 (s 烟入 T 烟入 -s 烟出 T 烟出 ) / 1000

[0055] In the formula, Q 放出 The heat released by the high-temperature flue gas is kJ; V 烟入 The volume of the imported flue gas is m. 3 ;s 烟入 The specific heat capacity of the inlet flue gas is expressed in J / (m³). 3 ·K); T 烟入 The inlet flue gas temperature, K; s 烟出 The specific heat capacity of the outlet flue gas is J / (m³). 3 ·K); T 烟出 Let K be the outlet flue gas temperature.

[0056] The volumetric specific heat capacity of the inlet flue gas and the volumetric specific heat capacity of the outlet flue gas are both constants, which can be calculated based on the content and temperature of various gases in the inlet or outlet flue gas.

[0057] The formula for calculating the heat absorbed by quenched water is:

[0058] Q 吸收 =m 水 Δh 水

[0059] In the formula, Q 吸收 The heat absorbed by the quenched water, kJ; m 水 Mass of quenched water, kg; Δh 水 The enthalpy increase, expressed in kJ / kg, is the increase in enthalpy due to the rapid cooling of water into water vapor.

[0060] Therefore, the formula for calculating the increase in enthalpy when quenched water turns into water vapor at any given moment is:

[0061]

[0062] In the formula, Δh 水 V represents the increase in enthalpy (kJ / kg) as water rapidly cools and transforms into water vapor. 烟入 The volume of the imported flue gas is m. 3 ;s 烟入 The specific heat capacity of the inlet flue gas is expressed in J / (m³). 3 ·K); T 烟入 The inlet flue gas temperature, K; s 烟出 The specific heat capacity of the outlet flue gas is J / (m³). 3 ·K); T 烟出 The outlet flue gas temperature, K; m 水 The mass of the quenched water is expressed in kg.

[0063] In practical applications, the enthalpy increase Δh of the rapid cooling water turning into water vapor can be obtained. 实际 The calculation formula is:

[0064]

[0065] Where: Δh 实际 The enthalpy increase (kJ / kg) of quenched water turning into water vapor in actual conditions; V 实际烟入 The actual volume of imported flue gas, in m 3 ;s 实际烟入 The actual volumetric specific heat capacity of the imported flue gas, J / (m³) 3 ·K); T 实际烟入 The actual temperature of the inlet flue gas, in K; s 实际烟出 The actual specific heat capacity of the flue gas at the outlet is expressed in J / (m³). 3 ·K); T 实际烟出 The actual outlet flue gas temperature, K; m 实际水 The actual mass of the quench water is in kg.

[0066] Actual outlet flue gas temperature T 实际烟出 Actual inlet flue gas temperature T 实际烟出Actual imported flue gas volume V 实际烟入 Actual quench water mass m 实际水 All of these can be directly obtained from relevant instruments and meters. Among them, the flue gas and quench water react simultaneously in the quench tower; therefore, the actual inlet flue gas volume V per unit time is... 实际烟入 and the mass of quenched water m 实际水 The data can be directly obtained from the measurement data of instruments that measure the actual inlet flue gas volume flow rate and the actual quench water mass flow rate.

[0067] Actual outlet flue gas volumetric specific heat capacity s 实际烟出 Actual imported flue gas volumetric specific heat capacity s 实际烟入 It is a constant and can be determined based on the actual conditions, such as the temperature of the inlet flue gas and the content of various gases.

[0068] In this embodiment, the temperature of the quench water after absorbing heat under ideal conditions is a constant, i.e., the ideal outlet flue gas temperature set by the quench tower. The enthalpy h of the water vapor transformed from the ideal quench water can then be obtained. 急冷水水蒸气 Then, based on the quench water temperature, obtain the enthalpy h of the quench water. 急冷水 To further obtain the enthalpy increase Δh of the quenched water turning into water vapor under ideal conditions. 理想 The specific calculation formula is as follows:

[0069] Δh 理想 =h 急冷水水蒸气 -h 急冷水

[0070] In the formula, Δh 理想 The enthalpy increase of quenched water turning into water vapor under ideal conditions, kJ / kg; h 急冷水水蒸气 The enthalpy of water vapor transformed from quenched water under ideal conditions, expressed in kJ / kg; h. 急冷水 Δ is the enthalpy of quenched water, expressed in kJ / kg.

[0071] As one implementation method of this embodiment, the quench water temperature can be set to a default room temperature value, such as 25°C. Based on the default room temperature value, the enthalpy h of the quench water can be directly obtained without measurement. 急冷水 This allows us to directly obtain the enthalpy increase Δh from the ideal state of quenched water turning into water vapor. 理想 The effect of quench water temperature on the N value is no longer considered, making the calculation of the N value simpler.

[0072] In this embodiment, the enthalpy increase of quenched water turning into water vapor in actual application is obtained through thermodynamic principles, thereby visualizing the atomization effect and converting it into an atomization effect value. The principle is simple and will not have any negative impact on the quench tower system.

[0073] The atomization effect setting value refers to the minimum range within which the high-temperature flue gas can be cooled to the ideal outlet flue gas temperature. If the atomization effect value is less than the atomization effect setting value, it means that the flue gas cannot be cooled to the ideal outlet flue gas temperature, and in this case, it is necessary to switch spray guns. The maximum effective atomization effect value refers to the maximum range within which the atomization effect value can be varied when the high-temperature flue gas is cooled to the ideal outlet flue gas temperature.

[0074] It should be further explained that the ideal state mentioned above, that is, the theoretical state or the calibration state, is that the quenched water absorbs heat and turns into water vapor, and the temperature of the water vapor is the outlet flue gas temperature, which is the set value, i.e., the set temperature.

[0075] For ease of explanation and understanding, in this embodiment, the maximum effective value of atomization effect is taken as 100%, and the set value of atomization effect is taken as 90%. It should be noted that 100% and 90% here are only for illustrative purposes and do not impose any further limitations on the values ​​of the set value of atomization effect and the maximum effective value of atomization effect. The set value of atomization effect and the maximum effective value of atomization effect can be taken according to the actual production and operation conditions to obtain higher economic efficiency.

[0076] Furthermore, during use, different values ​​can be set for the atomization effect and the maximum effective value of the atomization effect multiple times, and the economic effect obtained after each value is recorded to determine the atomization effect value and the maximum effective value of the atomization effect that achieve the best economic efficiency.

[0077] After obtaining the atomization effect value, i.e., the N value, compare the N value with the preset atomization effect value of 90% and the maximum atomization effect value of 100%. If the N value is greater than or equal to 90% and less than or equal to 100%, it is within the normal range, which means that the atomization effect of the main spray gun is normal and the system is operating normally.

[0078] If the N value is greater than 100%, it indicates an instrument malfunction, meaning the instrument is faulty and cannot measure properly, resulting in abnormal measured values ​​that are either too high or too low. The obtained data, after a series of data processing steps, will yield an N value greater than the maximum effective value for atomization. The enthalpy increase Δh from the actual conversion of quenched water into water vapor is also considered. 实际 Calculations show that the actual inlet flue gas volume V 实际烟入 The measured value is too high, and the actual mass of quenched water is m 实际水 The measured value is too low, and the actual outlet flue gas temperature T 实际烟出 Inaccurate measurements can lead to an increase in the enthalpy Δh of the rapidly cooled water turning into water vapor. 实际 If the value is too high, the N value will exceed 100%. In this case, staff should check these instrument components.

[0079] If the N value is less than 90%, it indicates that the atomization effect of the main spray gun has deteriorated. In this case, the main spray gun should be turned off, and the standby spray gun should be turned on to spray water for cooling. If the N value is between 90% and 100% (greater than or equal to 90% and less than or equal to 100%), the fault type is a main spray gun malfunction, such as a clogging issue. The switched-off standby spray gun has normal atomization effect, the system is operating normally, and the high-temperature flue gas can be reduced to the set temperature (set value).

[0080] The high-temperature flue gas treated by the quench tower contains a large amount of dust. After cooling, the high-temperature flue gas is transported to a dust collector for dust removal. The quench water atomization process is roughly as follows: compressed air pushes the quench water into the spray gun, where it is dispersed into a water mist through the small orifices of the nozzle. Therefore, during the cooling of high-temperature flue gas containing a large amount of dust, the spray gun is prone to clogging and other malfunctions, resulting in a poor atomization effect of the quench water, which in turn fails to effectively reduce the flue gas temperature. Therefore, when the atomization effect deteriorates, it is considered that the main spray gun is clogged or malfunctioning, and the system is switched to the backup spray gun.

[0081] When the main spray gun malfunctions and causes poor atomization of the quenching water, compared to the traditional method of controlling the outlet flue gas temperature by adjusting the spray volume based on the outlet flue gas temperature, problems such as water dripping at the bottom of the quenching tower and overheating occur, affecting the service life of the quenching tower. In this application, when the main spray gun of the quenching tower malfunctions and causes poor atomization, the atomization effect value can be reflected in a timely manner, allowing for the adjustment to shut down the main spray gun and switch to the backup spray gun. The backup spray gun can continue to be used to quench and cool the high-temperature flue gas. By monitoring the atomization effect of the spray gun, the problem of poor atomization when the main spray gun malfunctions and causes poor atomization can be avoided, preventing the high-temperature flue gas from being cooled in a timely and effective manner and generating toxic and harmful gases. At the same time, the problems of water dripping at the bottom of the tower and overheating that occur in the traditional method are avoided. Moreover, after confirming the malfunction of the main spray gun, it can be repaired or replaced in a timely manner.

[0082] After switching spray guns, obtain the N value. If the N value is greater than 100%, the fault type is instrument failure, meaning the instrument is malfunctioning and cannot measure properly, resulting in abnormal measured values ​​that are either too high or too low. The obtained data, after a series of data processing steps, will yield an N value greater than the maximum effective value for atomization. The enthalpy increase Δh from the actual conversion of quenched water into water vapor is also considered. 实际 Calculations show that the actual inlet flue gas volume V 实际烟入 The measured value is too high, and the actual mass of quenched water is m 实际水 The measured value is too low, and the actual outlet flue gas temperature T 实际烟出 Inaccurate measurements can lead to an increase in the enthalpy Δh of the rapidly cooled water turning into water vapor. 实际If the value is too high, the N value will exceed 100%. In this case, staff should check these instrument components.

[0083] If the N value remains less than 90% after switching spray guns, the first troubleshooting step is performed. This first step includes determining if the compressed air pipeline pressure is lower than the preset pressure value for the spray gun's compressed air pipeline. If the pressure is lower, the fault type is a compressed air pipeline malfunction. To further explain, the quenching water in the spray gun needs to be pressurized by compressed air to form a mist when sprayed through the nozzle, allowing for sufficient contact with the high-temperature flue gas and heat exchange. The preset compressed air pipeline pressure is the minimum pressure required for proper atomization of the cooling water. If the pressure is lower than this preset value, it indicates a compressed air pipeline malfunction, meaning insufficient pressure prevents the compressed air from atomizing the quenching water. This reduces the contact area between the quenching water and the high-temperature flue gas, resulting in insufficient heat exchange and inadequate cooling of the flue gas. Consequently, the actual outlet flue gas temperature exceeds the ideal outlet flue gas temperature.

[0084] If the compressed air pipeline pressure is not less than the preset value of the compressed air pipeline pressure for the spray gun, it is necessary to further determine whether the fault is an instrument malfunction. If it is an instrument malfunction, resulting in the inability to obtain normal measurement values, the measured flue gas volume V will be incorrect. 实际烟入 The value is too small, and the mass of the quench water is too small. 实际水 The value is too high, and the outlet flue gas temperature T 实际烟出 A value that is too high will lead to an increase in the actual enthalpy Δh of the quenched water vapor. 实际 If the value is too small, resulting in an N value of less than 90%, the faulty instrument should be repaired.

[0085] However, if the instrument is not malfunctioning, it indicates that both the main spray gun and the standby spray gun are malfunctioning, such as being clogged. In such cases, the main spray gun and the standby spray gun should be repaired immediately to prevent the high-temperature flue gas from being unable to be rapidly cooled down during continued use, which could lead to the generation of large amounts of toxic and harmful gases such as dioxins, causing air pollution and endangering the health and lives of workers.

[0086] Therefore, this application visualizes the atomization effect of the quenching water sprayed from the quench tower spray gun by converting the enthalpy change of the quenching water into water vapor into an atomization effect value. Furthermore, it also enables real-time monitoring of the spray gun's atomization effect, allowing for real-time monitoring of the spray gun's operating status and the cooling effect on the high-temperature flue gas.

[0087] Furthermore, based on multi-level judgment of atomization effect values, the type of fault occurring in the quench tower spray gun system can be identified, such as inlet flue gas overheating, main spray gun blockage, and instrument malfunction. This facilitates timely fault detection and identification of the cause, enabling adjustments and repairs to ensure the normal operation of the quench tower. Simultaneously, it reduces the lag caused by human judgment reaction time and errors, making fault detection and resolution during operation more timely and effective. This leads to better cooling of high-temperature flue gas and prevents the generation of large amounts of toxic and harmful gases due to inadequate quenching.

[0088] On the other hand, compared with the traditional method of troubleshooting and judging based on manual experience, the method of judging faults based on atomization effect values ​​and the atomization effect values ​​can reduce the operation and maintenance costs and environmental pressure of quench towers.

[0089] Example 2

[0090] This embodiment is based on Embodiment 1, and its difference from Embodiment 1 is as follows:

[0091] In chemical production processes, numerous factors can affect the normal operation of instrumentation equipment. In actual chemical production, the instrumentation equipment in use may be momentarily affected by a certain factor, causing instantaneous changes. However, this does not affect the overall normal operation of the instrumentation equipment and the process, nor its subsequent normal use. To further avoid the instantaneous impact of accidental factors on the N-value of related instrumentation equipment, when the N-value is less than 90% or equal to 100%, and the duration of the N-value being less than 90% or equal to 100% exceeds a set duration, operations such as switching to a backup spray gun are performed. This reduces the impact of accidental factors on process production and the maintenance costs of the instrumentation equipment.

[0092] For ease of explanation and understanding, the duration is set to 3 seconds in this embodiment. It should be noted that this 3 seconds is merely an example and does not impose any further limitations on the set duration. For instance, if the N value is less than 90%, and the duration of N values ​​less than 90% exceeds 3 seconds (i.e., exceeds the set duration), then the spray gun needs to be switched, and further judgment is required. However, if the N value is less than 90%, and the duration of N values ​​less than 90% does not exceed 3 seconds, then there is no need to switch to the backup spray gun.

[0093] In addition, the duration set here can be adjusted according to the actual production situation, such as the fluctuation of flue gas temperature and flue gas flow rate under the operating conditions.

[0094] In another implementation of this embodiment, to avoid the influence of accidental factors, timing begins when the N value first falls below 90%. If the interval between two occurrences of an N value below 90% is less than a set interval, then the spray gun is switched and further fault type determination is performed. This method is also used for cases where the N value is greater than 100%. Similarly, this reduces the impact of accidental factors and prevents disruptions to the production process.

[0095] Example 3

[0096] Combination Figure 1 A quench tower spray gun system for real-time monitoring of atomization effect and fault diagnosis includes: a quench tower, a spray gun, and a quench water tank. The quench water tank is connected to the spray gun, and the spray gun is installed inside the quench tower. An inlet flue gas monitoring component 1 is used to monitor the actual inlet flue gas temperature and actual inlet flue gas volumetric flow rate. Temperature sensors and volumetric flow sensors can be used for measurement to meet computational processing requirements. Furthermore, the inlet flue gas monitoring component 1 can be installed near the end of the quench tower to obtain data that more closely approximates the actual state of the high-temperature flue gas at the inlet. An outlet flue gas monitoring component 2 is used to monitor the actual outlet flue gas temperature. A temperature sensor can be used. Similarly, the outlet flue gas monitoring component 2 can be installed near the end of the quench tower to obtain data that more closely approximates the actual state of the high-temperature flue gas at the outlet. A quench water monitoring component 3 is used to monitor the quench water temperature and actual quench water mass flow rate. Temperature sensors and mass flow sensors can be used for measurement. A compressed air pressure monitoring component 4 is used to monitor the pressure in the compressed air pipeline of the spray gun.

[0097] Controller 5 is electrically connected to the spray gun, inlet flue gas monitoring component 1, outlet flue gas monitoring component 2, quench water monitoring component 3, and compressed air pressure monitoring component 4. It is used to acquire data such as actual inlet flue gas temperature, actual inlet flue gas volumetric flow rate, actual outlet flue gas temperature, actual quench water mass flow rate, and compressed air pipeline pressure. The actual inlet flue gas volumetric specific heat capacity and actual outlet flue gas volumetric specific heat capacity can be calculated based on the temperature. The enthalpy increase of quench water turning into water vapor under ideal conditions can be calculated based on the quench water temperature and the ideal outlet temperature of the quench tower, i.e., the set value. The acquired data is processed to obtain the actual enthalpy increase of quench water turning into water vapor and the atomization effect value, i.e., the N value, to achieve the above-mentioned real-time monitoring of atomization effect. Based on the comparison of the atomization effect value with the atomization effect set value and the maximum effective value of the atomization effect, the above-mentioned fault judgment method is implemented, and the system executes actions such as shutting down the main spray gun 6 and switching to the backup spray gun 7.

[0098] The formula for calculating the atomization effect N is:

[0099]

[0100] In the formula: N is the atomization effect value; Δh 理想 Δh represents the increase in enthalpy (kJ / kg) of water rapidly cooled to vapor under ideal conditions. 实际 The enthalpy increase, expressed in kJ / kg, represents the actual increase in enthalpy as water rapidly cools and transforms into water vapor.

[0101] Among them, the enthalpy increase Δh of the quenching water turning into water vapor in the actual situation inside the quench tower. 实际 The calculation formula is:

[0102]

[0103] Where: Δh 实际 The enthalpy increase (kJ / kg) of quenched water turning into water vapor in actual conditions; V 实际烟入 The actual volume of imported flue gas, in m 3 ;s 实际烟入 The actual volumetric specific heat capacity of the imported flue gas, J / (m³) 3 ·K); T 实际烟入 The actual temperature of the inlet flue gas, in K; s 实际烟出 The actual specific heat capacity of the flue gas at the outlet, J / (m³). 3 ·K); T 实际烟出 The actual outlet flue gas temperature, K; m 实际水 The actual mass of the quenched water is in kg.

[0104] Ideally, the temperature of the quench water after absorbing heat is constant, which is the ideal outlet flue gas temperature set by the quench tower. The enthalpy h of the ideal quench water vapor can then be obtained. 急冷水水蒸气 Then, based on the quench water temperature, obtain the enthalpy h of the quench water. 急冷水 To further obtain the enthalpy increase Δh of the quenched water turning into water vapor under ideal conditions. 理想 The specific calculation formula is as follows:

[0105] Δh 理想 =h 急冷水水蒸气 -h 急冷水

[0106] In the formula, Δh 理想 The enthalpy increase of quenched water turning into water vapor under ideal conditions, kJ / kg; h 急冷水水蒸气 The enthalpy of water vapor transformed from quenched water under ideal conditions, expressed in kJ / kg; h. 急冷水 Δ is the enthalpy of quenched water, expressed in kJ / kg.

[0107] Furthermore, the quench water tank is connected to a main pipeline. The quench water monitoring component 3 and the compressed air pressure monitoring component 4 can be installed on the main pipeline, and corresponding mass sensors and pressure sensors can be used. The main pipeline is further divided into two pipelines: a main pipeline and a backup pipeline, which are connected to the main spray gun 6 and the backup spray gun 7, respectively. The main pipeline and the backup pipeline are respectively connected to main pipeline valves and backup pipeline valves. The controller 5 can control the opening and closing of the main and backup spray guns by controlling the opening and closing of the main and backup pipeline valves. It should be noted that the main pipeline and backup pipeline, as well as the main pipeline valves and backup pipeline valves, are only distinguished by naming. To ensure that the main spray gun 6 and the backup spray gun 7 have the same atomization effect, and to ensure the comparability of the N value obtained by the controller 5, the main pipeline and backup pipeline, as well as the main pipeline valves and backup pipeline valves, are essentially the same.

[0108] Additionally, the quench water monitoring component 3 allows users to choose whether to disable the quench water temperature sensor and set the quench water temperature to a default room temperature value, making the calculation of atomization effect values ​​more convenient. It should be further noted that the ideal state mentioned above, i.e., the theoretical state or calibration state, refers to the quench water absorbing heat and turning into water vapor, with the water vapor temperature being the outlet flue gas temperature, which is the set value, i.e., the set temperature.

[0109] Furthermore, the main spray gun 6 and the standby spray gun 7 are interlocked, meaning that when the main spray gun 6 is closed, the standby spray gun 7 is opened. In other words, the main pipeline valve and the standby pipeline valve are interlocked to allow the main spray gun 6 and the standby spray gun 7 to switch quickly.

[0110] Furthermore, multiple main spray guns 6 and multiple backup spray guns 7 are employed, configured as main spray gun groups and backup spray gun groups. The spray guns within each main and backup spray gun group are interlocked, meaning that spray guns within the same group open and close simultaneously. This facilitates rapid switching between the main and backup spray gun groups, enabling timely cooling of the high-temperature flue gas. For example, in a quench tower with 6 spray guns, 3 main spray guns 6 form the main spray gun group, and the other 3 backup spray guns 7 form the backup spray gun group.

[0111] Compared to traditional methods that solely control quenching water based on outlet flue gas temperature, this system addresses the issue of nozzle blockage preventing proper atomization. When the actual outlet flue gas temperature exceeds the set temperature, the water flow is increased to lower it, further hindering atomization and leading to problems like wet walls, wet bottoms, and sludge buildup in the quenching tower. This results in poor environmental performance and increased maintenance costs. Furthermore, manually identifying these faults through dripping or overheating is time-consuming and time-consuming, with delayed response and handling. However, this quenching tower spray gun system monitors atomization effectiveness using the N-value. When atomization is poor, it can switch to backup spray gun 7, avoiding the problems caused by increased water flow while simultaneously cooling the high-temperature flue gas to the set temperature.

[0112] As one implementation method of this embodiment, the quench tower spray gun system can also be equipped with a display screen, which can display the working status information of each component in the system and the readings of each instrument in real time, such as the actual inlet flue gas temperature, the actual outlet flue gas temperature, the actual quench water mass flow rate, and the atomization effect N value, so that the staff can obtain information at any time. Moreover, when the N value is not within the normal range and a fault occurs, the fault type can be directly obtained from the display screen. In addition, when the fault type is an instrument fault, the faulty instrument can be identified based on the readings of each instrument displayed on the display screen, so that the faulty instrument can be directly repaired, etc., without having to check each instrument involved one by one, making the fault identification and resolution more accurate and timely. Compared with traditional manual fault diagnosis, the lag in fault handling is greatly reduced, and the processing efficiency of the quench tower is improved.

[0113] Furthermore, an alarm can be installed to sound an alarm when a malfunction occurs, alerting staff to the problem and further improving the response speed.

[0114] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the figures shown are only one embodiment of the present invention; the actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A method for real-time monitoring of atomization effect and fault diagnosis of a quench tower spray gun, characterized in that: Get the atomization effect value; if the atomization effect value is less than the atomization effect setting value, switch to the backup spray gun; If the atomization effect value is less than the atomization effect setting value after switching to the backup spray gun, the first troubleshooting step will be performed. The formula for calculating the atomization effect value is: In the formula: This represents the atomization effect value; This represents the increase in enthalpy as water rapidly cooled to vaporize under ideal conditions. This represents the increase in enthalpy as water rapidly cools and turns into water vapor in real-world conditions. In reality, the enthalpy increase when quenched water turns into water vapor The calculation formula is: In the formula: This represents the increase in enthalpy as water rapidly cools and turns into water vapor in real-world conditions. This represents the actual volume of imported flue gas. This refers to the actual volumetric specific heat capacity of the imported flue gas. This refers to the actual inlet flue gas temperature. This refers to the actual volumetric specific heat capacity of the flue gas at the outlet. This refers to the actual outlet flue gas temperature. This refers to the actual quality of the quench water; The increase in enthalpy when quenched water turns into water vapor under ideal conditions The calculation formula is: In the formula, The enthalpy increase of quenched water turning into water vapor under ideal conditions; The enthalpy value of water vapor transformed from rapidly cooled water under ideal conditions; This is the enthalpy value of quenched water.

2. The method for real-time monitoring of atomization effect and fault diagnosis of the quench tower spray gun according to claim 1, characterized in that: If the atomization effect value is less than the atomization effect setting value, then switch to the backup spray gun. Specifically, if the duration for which the N value is less than the atomization effect setting value is greater than the preset duration, then switch to the backup spray gun.

3. The method for real-time monitoring of atomization effect and fault diagnosis of the quench tower spray gun according to claim 1, characterized in that: After obtaining the atomization effect value, it is also included that if the N value is greater than the maximum effective value of the atomization effect, the fault type is instrument fault.

4. The method for real-time monitoring of atomization effect and fault diagnosis of the quench tower spray gun according to claim 1, characterized in that: After switching to the backup spray gun, if the N value is less than the maximum effective value of the atomization effect but greater than the atomization effect setting value, the fault type is a primary spray gun fault.

5. The method for real-time monitoring of atomization effect and fault diagnosis of the quench tower spray gun according to claim 1, characterized in that: The first troubleshooting step includes determining whether the compressed air pressure in the spray gun is lower than the preset value. If the compressed air pressure is lower than the preset value, the fault type is a compressed air pipeline fault. If the compressed air pipeline pressure is not less than the preset value of the compressed air pipeline pressure of the spray gun, then determine whether it is an instrument failure. If it is not an instrument failure, then the failure type is that both the main spray gun and the standby spray gun have failed before and after the switch.

6. A quench tower spray gun system for implementing the method of any one of claims 1-5, characterized in that: It includes a quench tower, a spray gun, and a quench water tank, wherein the quench water tank is connected to the spray gun, and the spray gun is installed inside the quench tower; Imported flue gas monitoring components are used to monitor the temperature and volumetric flow rate of imported flue gas. The outlet flue gas monitoring component is used to monitor the temperature of the outlet flue gas. The quench water monitoring component is used to monitor the temperature and mass flow rate of the quench water. Compressed air pressure monitoring component, used to monitor the pressure of the compressed air pipeline of the spray gun; The controller is electrically connected to the spray gun, the inlet flue gas monitoring component, the outlet flue gas monitoring component, the quench water monitoring component, and the compressed air pressure monitoring component. It is used to acquire data and atomization effect values ​​and control the system to perform actions.

7. The quench tower spray gun system according to claim 6, characterized in that: The spray guns before and after switching are interlocked.

8. The quench tower spray gun system according to claim 7, characterized in that: It also includes a display for showing the working status information of each component in the system and the atomization effect value in real time.

9. The quench tower spray gun system according to claim 8, characterized in that: It also includes an alarm that will issue an alarm signal when the N value is not within the normal range.

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