Corrosion-resistant and wear-resistant economizer and preparation method thereof

Abstract

The corrosion-resistant and wear-resistant economizer comprises a water inlet pipe, a water outlet pipe and a heat exchange pipe, the water inlet pipe is connected with the water outlet pipe through the heat exchange pipe, a water inlet valve is installed on the water inlet pipe, a rotatable ash removal assembly is installed on the heat exchange pipe, and protruding reverse rotation protruding blocks are arranged on the side faces of the two ends of the heat exchange pipe correspondingly; the ash removal assembly comprises a supporting frame, three sets of brush plates arranged on the supporting frame and air scoops installed on the brush plates, and a preparation method of the corrosion-resistant and wear-resistant economizer comprises the following steps that firstly, materials are prepared; step 2, manufacturing and assembling components; step 3, integrally assembling and debugging; and a brush of the dust removal assembly can effectively remove dust and solid particles on the pipe wall. The reasonable design of the air scoop and the automatic reverse rotation function of the ash removal assembly ensure comprehensive cleaning of the pipe wall, the ash removal assembly automatically rotates and reversely rotates through waste gas blowing, and frequent manual operation is not needed for ash removal.

Description

Technical Field

[0001] The present invention relates to the technical field related to economizers, and in particular to a corrosion-resistant and wear-resistant economizer and a preparation method thereof. Background Art

[0002] Economizer is an important heat exchange device widely used in thermal systems, especially in boiler systems. Its core function is to use the waste heat of flue gas discharged from the tail of the boiler to preheat the feed water entering the boiler. In this way, the economizer significantly improves the thermal efficiency of the boiler system and effectively reduces fuel consumption, thus playing a vital role in energy conservation. At the same time, preheating the feed water can also reduce the heating time of water in the boiler, thereby reducing the thermal stress on the boiler, which is of great significance for extending the service life of the boiler.

[0003] In the boiler operating environment, economizers face a complex corrosive environment. Flue gas usually contains acidic gases such as sulfur dioxide and sulfur trioxide. These gases will form acidic substances such as sulfuric acid when combined with water vapor, which will have a strong corrosive effect on the metal surface of the economizer.

[0004] Corrosion will cause the metal tube wall of the economizer to gradually become thinner, thereby reducing its mechanical strength and pressure bearing capacity. Severe corrosion may cause perforation of the tube wall and cause water leakage, which will directly affect the normal operation of the boiler.

[0005] During the operation of the economizer, a large amount of solid particles carried in the flue gas, such as dust and fly ash, will wash the pipe wall at a high speed. As the pipe wall wears, its thickness will continue to decrease, which not only reduces the strength and pressure-bearing capacity of the pipe wall, but may also cause the pipe wall to rupture. In order to reduce the deposition of solid particles on the pipe wall, the economizer needs to be cleaned regularly. The existing cleaning methods of economizers are mainly regular manual cleaning or the use of some simple mechanical cleaning equipment. Manual cleaning is inefficient and it is difficult to ensure the consistency of cleaning quality. Although mechanical cleaning equipment has improved the cleaning efficiency to a certain extent, there may be problems such as incomplete cleaning and additional wear on the pipe wall. Summary of the invention

[0006] The object of the present invention is to provide a corrosion-resistant and wear-resistant economizer and a preparation method thereof, so as to solve the problems raised in the above-mentioned background technology.

[0007] To achieve the above-mentioned objectives, the present invention provides the following technical solutions: a corrosion-resistant and wear-resistant economizer, comprising an inlet pipe, an outlet pipe and a heat exchange pipe, the inlet pipe is connected to the outlet pipe through the heat exchange pipe, and an inlet valve is installed on the inlet pipe, and an outlet valve and a pressure relief valve are respectively installed at both ends of the outlet pipe, a rotatable cleaning assembly is installed on the heat exchange pipe, and raised reversal bumps are arranged on the side surfaces of both ends of the heat exchange pipe, the cleaning assembly comprises a support frame, three groups of brush plates arranged on the support frame and a wind bucket installed on the brush plate, and brushes are evenly arranged on both sides of the brush plate.

[0008] Furthermore, the support frame adopts a C-shaped metal structure, and four groups of balls are evenly arranged inside the support frame, and three groups of brush plates are evenly arranged on the support frame.

[0009] Furthermore, the wind bucket is connected to the brush plate through a rotating shaft at the front end, and the wind bucket is rotatable on the brush plate. At the same time, a positioning assembly is provided on the rotating shaft. The positioning assembly is composed of a spring and balls at both ends, and the balls at the front end of the positioning assembly are clamped in the groove of the brush plate for positioning.

[0010] Furthermore, the cleaning component rotates along the heat exchange tube under the blowing of exhaust gas, and the cleaning component rotates until one end of the heat exchange tube contacts the reversal protrusion, and the wind bucket arranged on the cleaning component rotates, and the cleaning component rotates in the opposite direction on the heat exchange tube.

[0011] A method for preparing a corrosion-resistant and wear-resistant economizer comprises the following steps: Step 1: Material preparation; Select corrosion-resistant and wear-resistant metal materials to make water inlet pipes, water outlet pipes and heat exchange pipes, and pre-treat the selected metal materials, including cleaning, degreasing, rust removal and other operations to ensure the cleanliness of the material surface; Step 2: Component production and assembly; The pretreated metal material is used to make an inlet pipe, an outlet pipe and a heat exchange pipe, the inlet pipe is connected to the outlet pipe through the heat exchange pipe, an inlet valve is installed on the inlet pipe, and an outlet valve and a pressure relief valve are installed at both ends of the outlet pipe; The support frame is made of a C-shaped metal structure with corrosion resistance and wear resistance. The metal material used to make the support frame is cut, bent and processed. Four sets of ball bearings are evenly arranged inside the support frame. The ball bearings are made of wear-resistant materials. Three sets of brush plates are evenly arranged on the support frame. The brush plates are made of corrosion-resistant materials. Brushes are evenly arranged on both sides of the brush plates. The brushes are made of wear-resistant and high-temperature resistant materials. The wind bucket is connected to the brush plate through the rotating shaft at the front end. The wind bucket is made of corrosion-resistant and wear-resistant materials. A positioning component is set on the rotating shaft. The positioning component is composed of a spring and balls at both ends. When making the spring, it must be ensured to have good elasticity and corrosion resistance. The balls are made of wear-resistant materials, and the balls at the front end of the positioning component are clamped in the groove of the brush plate for positioning; Step 3: Overall assembly and debugging; Install the prepared dust cleaning assembly onto the heat exchange tube so that the dust cleaning assembly can rotate on the heat exchange tube. Protruding reversing bumps are arranged on the sides of both ends of the heat exchange tube. The reversing bumps are made of wear-resistant materials. Debug the assembled economizer, check whether the connections of various parts are tight, whether the ash cleaning assembly rotates smoothly, and whether the ash cleaning assembly can rotate along the heat exchange tube under the blowing of exhaust gas. When the ash cleaning assembly rotates to one end of the heat exchange tube and contacts the reversal bump, check whether the wind bucket set on the ash cleaning assembly can rotate 180 degrees, and whether the ash cleaning assembly can rotate in the opposite direction on the heat exchange tube.

[0012] Furthermore, in the material preparation stage, for the pretreatment operation, ultrasonic cleaning technology is used to clean the metal material, which can more thoroughly remove surface oil and impurities; during the degreasing process, a special metal degreasing agent can be used, and when removing rust, a combination of chemical rust removal and mechanical rust removal is used. First, an acidic rust remover is used to remove rust, and then sandpaper is used to polish the material surface to make it smoother; In the component manufacturing and assembly process, CNC laser cutting and CNC bending equipment are used for cutting and bending operations of the support frame to ensure accuracy; in the production of balls, heat treatment is performed on the wear-resistant materials to improve their hardness and wear resistance; when making brush plates, an electroplating process can be used to add a wear-resistant metal layer on the surface of the corrosion-resistant material; for the wind scoop, computer simulation can be performed based on the principles of fluid mechanics to optimize its shape; During the overall assembly and commissioning phase, high-precision positioning instruments are used to ensure accurate positioning of the cleaning components when they are installed. During the commissioning process, thermal imagers are used to detect the temperature distribution of each economizer component to determine whether abnormal heating occurs so that timely adjustments can be made.

[0013] Furthermore, in the material preparation stage, after the metal material is selected, a microstructure analysis is performed on it, and its crystal structure and defects are observed using an electron microscope; if defects exist, they can be repaired through a special heat treatment process; during the pretreatment process, a biodegradable cleaning agent is used for cleaning; at the same time, plasma treatment technology is used on the material surface to enhance the activity of the material surface and improve its bonding with subsequent coatings; In the process of component manufacturing and assembly, the support frame can adopt a new composite material structure, such as carbon fiber reinforced metal matrix composite material, which has both high strength and corrosion resistance; the ball can be a ceramic ball, and a layer of lubricant is coated on its surface to improve its rotation flexibility; the brush plate can be designed as a multi-layer structure, with a corrosion-resistant metal layer as the bottom layer, a buffer layer in the middle, and a wear-resistant coating on the top layer; the wind scoop can be made of deformable material, which can automatically adjust its shape according to the exhaust gas flow and pressure; During the overall assembly and debugging stage, intelligent assembly equipment is used to automatically identify and install each component. During the debugging process, intelligent sensors are used to monitor the rotation angle and speed of the cleaning components, as well as the operating parameters of the economizer, and problems are discovered and optimized in a timely manner through data analysis.

[0014] Furthermore, during the material preparation stage, the resource sustainability of the materials is considered when selecting the materials, and recyclable metal materials are given priority; the selected materials are marked so that they can be easily recycled after the products are scrapped; during the pretreatment process, high-pressure water jet cleaning technology is used, which has high cleaning efficiency and does not damage the materials; at the same time, the surface of the material is micro-arc oxidized to form a ceramic film to improve its corrosion resistance; In the process of component manufacturing and assembly, the water inlet pipe, water outlet pipe and heat exchange pipe can adopt a double-layer structure design, with the inner layer being a corrosion-resistant metal layer and the outer layer being a wear-resistant coating; when making the support frame, 3D printing technology is used to quickly manufacture support frames with complex shapes, and they can be customized according to design requirements; the ball bearings can be made of nanostructured materials with higher hardness and wear resistance; the brush plate can be made of self-cleaning materials to reduce dust adhesion; the wind bucket can be designed to be an asymmetric shape according to the flow direction of the exhaust gas to improve its rotation efficiency; During the overall assembly and commissioning stage, the magnetic installation method is used to install the cleaning components, which is convenient, fast and accurate in positioning. During the commissioning process, virtual reality technology is used to simulate the operating environment of the economizer, evaluate and optimize its performance, and monitor the operating status of each component to detect and handle problems in a timely manner. Furthermore, in the material preparation stage, for corrosion-resistant and wear-resistant metal materials, surface modification treatment is carried out after pretreatment; ion implantation technology is used to implant specific ions into the material surface to change its surface chemical composition and physical properties, thereby improving its corrosion and wear resistance; at the same time, high-temperature aging tests are carried out on the materials to test their performance stability in high-temperature environments; In the process of component manufacturing and assembly, the support frame can adopt a multi-layer nested structure, each layer has different functions, the outermost layer is a wear-resistant layer, the middle layer is a support layer, and the innermost layer is a corrosion-resistant layer; the ball can be a high-precision ceramic ball with a dimensional accuracy within ±0.05mm to improve its rotation flexibility and wear resistance; the brush plate can be made of high-temperature wear-resistant material; During the overall assembly and commissioning stage, when installing the cleaning components on the heat exchange tubes, ensure that the installation position is accurate and firm; during the commissioning process, use high-temperature testing equipment to measure various parameters of the economizer, and monitor the cleaning effect of the cleaning components at the same time, and make timely adjustments and optimizations; Furthermore, in the material preparation stage, when selecting metal materials, the chemical compatibility with the surrounding environment is considered; metal materials that are not easy to react with chemical substances in the environment are selected; at the same time, the material is surface treated by using a chemical plating method to coat a protective film on the surface of the material to improve its chemical stability; In the process of component manufacturing and assembly, the support frame can adopt intelligent structural design, the ball bearing can be made of self-lubricating material to reduce friction; the brush plate can be made of antibacterial material to prevent microorganisms from growing on its surface; the wind scoop can be made of material with optical sensors to sense the flow direction and speed of the exhaust gas, so as to better adjust its shape and rotation direction; During the overall assembly and debugging stage, when the cleaning component is installed on the heat exchange tube, an intelligent positioning system is used to ensure its accurate installation position; during the debugging process, an intelligent monitoring system is used to monitor the various parameters of the economizer in real time, including temperature, pressure, and flow. Through data analysis, it is determined whether its operating status is normal, and problems are discovered and handled in a timely manner.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: the corrosion-resistant and wear-resistant economizer and its preparation method, in the material preparation stage, the present invention selects corrosion-resistant and wear-resistant metal materials for making the key components of the water inlet pipe, the water outlet pipe and the heat exchange tube. At the same time, the selected metal materials are subjected to a variety of pretreatment operations, ultrasonic cleaning technology is used to more thoroughly remove surface oil and impurities, a special metal degreasing agent is used in the degreasing process, and a combination of chemical and mechanical rust removal is used for rust removal, so that the material surface is smoother. These treatment measures lay a good foundation for the subsequent corrosion resistance.

[0016] The support frame of the cleaning component adopts a corrosion-resistant C-shaped metal structure, the brush plate is made of corrosion-resistant materials, and the wind bucket is also made of corrosion-resistant and wear-resistant materials. This overall application of corrosion-resistant materials and structural design enables the economizer to maintain good performance in a complex corrosive environment, reducing problems such as thinning of the tube wall, perforation, and reduced heat exchange efficiency caused by corrosion, extending the service life of the economizer and ensuring the normal operation of the boiler.

[0017] Four groups of balls are evenly arranged inside the support frame. The balls are made of wear-resistant material, which can reduce friction during the rotation of the cleaning component and reduce wear on its own structure and the wall of the heat exchange tube.

[0018] Brushes are evenly arranged on both sides of the brush plate. The brushes are made of wear-resistant and high-temperature resistant materials, which can effectively remove dust and solid particles on the wall of the heat exchange tube, and are not easy to wear. The wind bucket can rotate on the brush plate, which can better utilize the flow energy of the exhaust gas for cleaning and reduce the additional wear on the tube wall caused by improper cleaning methods.

[0019] The cleaning component rotates along the heat exchange tube under the blowing of exhaust gas. When one end of the heat exchange tube contacts the reversing bump, the wind bucket rotates 180 degrees, and the cleaning component rotates in the opposite direction on the heat exchange tube. This automatic reversing cleaning method can ensure that all parts of the heat exchange tube wall can be effectively cleaned.

[0020] The brush of the cleaning component can effectively remove dust and solid particles on the tube wall. The reasonable design of the air scoop and the automatic reversal function of the cleaning component ensure the comprehensive cleaning of the tube wall, and there will be no partial incomplete cleaning, so that the heat exchange tube wall always maintains a good clean state, which is conducive to the efficient heat exchange.

[0021] The cleaning component of the present invention rotates and reverses automatically through the blowing of exhaust gas, and does not require frequent manual operations for cleaning. Compared with the manual cleaning method in the prior art, which is inefficient and difficult to ensure the consistency of cleaning quality, and the mechanical cleaning equipment may not clean thoroughly and cause additional wear to the pipe wall. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the development of the structure of the present invention; Figure 2 This is a schematic diagram of the installation of the dust cleaning component of the structure of the present invention; Figure 3 This is a schematic diagram of the wind scoop connection structure of the present invention; Figure 4 The figure is a top view schematic diagram of the dust cleaning component of the structure of the present invention.

[0023] In the figure: 1. water inlet pipe; 2. water outlet pipe; 3. heat exchange tube; 4. water inlet valve; 5. water outlet valve; 6. pressure relief valve; 7. dust cleaning component; 71. brush plate; 72. brush; 73. air scoop; 74. support frame; 741. ball bearing; 75. rotating shaft; 76. positioning component; 8. reversing bump. DETAILED DESCRIPTION

[0024] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0025] See also Figure 1-4 The present invention provides a technical solution: a corrosion-resistant and wear-resistant economizer and a preparation method thereof, and the implementation method is as follows: 1. Material preparation stage Metal material selection and pretreatment First, according to the use environment and performance requirements of the economizer, corrosion-resistant and wear-resistant metal materials are selected to make the water inlet pipe 1, the water outlet pipe 2 and the heat exchange tube 3. These metal materials need to have good corrosion resistance, be able to resist the erosion of acidic gases in the flue gas such as sulfur dioxide, sulfur trioxide, etc. and corrosive components dissolved in water such as oxygen and chloride ions, etc., and have sufficient wear resistance to withstand the erosion of solid particles in the flue gas.

[0026] During the pretreatment process, a variety of methods are used to ensure the cleanliness and performance of the material surface.

[0027] Ultrasonic cleaning technology is used to clean metal materials. Ultrasonic cleaning uses the cavitation effect of ultrasonic waves in liquids to generate a strong impact force to remove dirt from the surface of the material. This cleaning method can more thoroughly remove surface oil and impurities. Compared with traditional cleaning methods, its cleaning effect is better and can penetrate into the tiny gaps and holes on the surface of the material to remove the dirt hidden therein.

[0028] During the degreasing process, a special metal degreasing agent is used. This degreasing agent has good emulsifying properties and can break down grease into tiny particles, making it easier to clean. At the same time, the degreasing agent also has certain corrosion inhibition properties and will not corrode metal materials during the degreasing process.

[0029] When removing rust, a combination of chemical and mechanical rust removal is used. First, use an acidic rust remover to remove rust. The acidic rust remover can react chemically with the rust and dissolve it. Then use sandpaper to polish. Sandpaper polishing can further remove rust and uneven parts on the surface, making the surface of the material smoother. This combined method can more effectively remove rust and ensure the flatness of the material surface, providing a good foundation for subsequent processing and use.

[0030] Material microstructure analysis and repair For some application scenarios with higher requirements, metal materials can be selected and then subjected to microstructural analysis. The crystal structure and defects are observed using an electron microscope. Electron microscopes can provide high-resolution images that clearly show the crystal structure and possible defects inside the material, such as dislocations and grain boundary defects.

[0031] If defects are found, they can be repaired through special heat treatment processes. For example, for some metal materials, annealing can be used to eliminate internal stress and repair defects. Annealing is to heat the metal material to a certain temperature and then slowly cool it. During this process, the atoms inside the material will rearrange, eliminate stress and repair defects, thereby improving the performance of the material.

[0032] Material surface treatment During the material preparation stage, a variety of surface treatments can be performed to further improve the material's performance.

[0033] Plasma treatment is used to treat the surface of materials. Plasma is a partially ionized gas with high energy and activity. When plasma comes into contact with the surface of a material, it changes the chemical composition and physical properties of the surface. For example, plasma treatment can increase the activity of the surface of the material, improve its bonding with subsequent coatings, and also improve the roughness of the surface of the material, making it more conducive to heat transfer.

[0034] A protective film is plated on the surface of the material by chemical plating. Chemical plating is a method of depositing metal or alloy on the surface of a material by chemical reaction. By selecting the appropriate chemical plating solution and process conditions, a protective film with good chemical stability can be plated on the surface of the material. For example, a nickel-phosphorus alloy film can be plated, which has good corrosion resistance and wear resistance and can effectively protect the surface of the material from corrosion and grinding. Micro-arc oxidation treatment forms a ceramic film. Micro-arc oxidation is a method of in-situ growth of a ceramic film on the surface of a metal material under the action of high voltage. The ceramic film has good corrosion resistance, wear resistance and insulation, and can significantly improve the performance of the material. During the micro-arc oxidation process, the thickness and performance of the ceramic film can be adjusted by controlling parameters such as voltage, current and time.

[0035] 2. Component production and assembly Water inlet pipe, water outlet pipe and heat exchange pipe production The pre-treated metal material is used to make the water inlet pipe 1, the water outlet pipe 2 and the heat exchange pipe 3. During the manufacturing process, the dimensional accuracy and surface quality of the pipes must be ensured. Advanced processing equipment and processes, such as CNC machining centers, can be used to ensure the manufacturing quality of the pipes.

[0036] For some special design requirements, the water inlet pipe 1, the water outlet pipe 2 and the heat exchange pipe 3 can be designed with a double-layer structure. The inner layer is a corrosion-resistant metal layer, and the outer layer is a wear-resistant coating. For example, a stainless steel material with good corrosion resistance can be used in the inner layer, and a ceramic coating or a metal ceramic coating with good wear resistance can be used in the outer layer. Through this double-layer structure design, the corrosion resistance and wear resistance of the pipeline can be improved at the same time.

[0037] Support frame production The support frame 74 is made of a C-shaped metal structure with corrosion resistance and wear resistance. During the manufacturing process, the metal material of the support frame 74 is subjected to cutting, centering, bending and other processing operations.

[0038] For the cutting and bending operations of the support frame 74, CNC laser cutting and CNC bending equipment can be used to ensure accuracy. CNC laser cutting has the advantages of high cutting accuracy, narrow incision, and small heat-affected zone, which can ensure the dimensional accuracy and shape accuracy of the support frame 74. CNC bending equipment can accurately control the bending angle and radius so that the support frame 74 meets the design requirements.

[0039] Four groups of balls 741 are evenly arranged inside the support frame 74, and the balls 741 are made of wear-resistant material. The function of the balls 741 is to reduce the friction between the support frame 74 and the heat exchange tube 3, so that the dust cleaning component 7 can rotate more smoothly. For the production of the balls 741, the wear-resistant material can be heat-treated to improve its hardness and wear resistance. For example, a heat treatment process such as quenching and tempering can be used to make the hardness of the balls 741 meet certain requirements while maintaining good toughness.

[0040] The support frame 74 can adopt a new composite material structure. For example, the support frame 74 is made of a carbon fiber reinforced metal matrix composite material. Carbon fiber has the advantages of high strength, low density and good corrosion resistance, while the metal matrix composite material has good processing performance and toughness. By combining carbon fiber with metal matrix composite material, a support frame 74 with both high strength and corrosion resistance can be produced.

[0041] The support frame 74 may adopt a multi-layer nested structure. For example, the outermost layer is a wear-resistant layer, the middle layer is a support layer, and the innermost layer is a corrosion-resistant layer. This multi-layer structure can optimize the wear resistance, support and corrosion resistance performance according to different usage requirements, thereby improving the comprehensive performance of the support frame 74.

[0042] Brush plate production Three groups of brush plates 71 are evenly arranged on the support frame 74, and the brush plates 71 are made of corrosion-resistant materials. Brushes 72 are evenly arranged on both sides of the brush plates 71, and the brushes 72 are made of wear-resistant and high-temperature-resistant materials.

[0043] For the production of the brush plate 71, a wear-resistant metal layer can be added on the surface of the corrosion-resistant material by electroplating. The electroplating process can deposit a layer of metal, such as nickel, chromium, etc., on the surface of the brush plate 71 to increase the wear resistance of the brush plate 71. At the same time, the electroplating layer can also improve the surface hardness and smoothness of the brush plate 71, making it more conducive to dust cleaning.

[0044] The brush plate 71 can be designed as a multi-layer structure. For example, the bottom layer is a corrosion-resistant metal layer, the middle layer is a buffer layer, and the upper layer is a wear-resistant coating. This multi-layer structure can optimize the corrosion resistance, buffering and wear resistance according to different usage requirements, thereby improving the comprehensive performance of the brush plate 71.

[0045] The clapper board 71 can be made of self-cleaning materials. For example, a material with self-cleaning function, such as a nano material or a material with a special surface structure, is used to make the brush board 71. This self-cleaning material can reduce the adhesion of dust on the brush board 71 and improve the dust cleaning efficiency.

[0046] Wind bucket production The wind scoop 73 is connected to the brush plate 71 through a rotating shaft 75 at the front end. The wind scoop 73 is made of corrosion-resistant and wear-resistant materials.

[0047] The shape of the wind scoop 73 can be optimized by computer simulation based on the principle of fluid mechanics. The force and flow characteristics of the wind scoop 73 under different airflow conditions can be analyzed by computer simulation, so as to optimize the shape of the wind scoop 73 so that it is more conducive to using the flow energy of the exhaust gas for dust removal.

[0048] The air scoop 73 can be made of a deformable material. For example, the air scoop 73 can be made of a shape memory alloy or a material with elastic deformation ability. Such a deformable material can automatically adjust its shape according to the exhaust gas flow and pressure, thereby improving the rotation efficiency and dust cleaning effect of the air scoop 73.

[0049] The wind scoop 73 can be made of a material with an optical sensor. For example, the wind scoop 73 can be made of a plastic or ceramic material with an optical sensor function. Such a material can sense the flow direction and speed of the exhaust gas so as to better adjust the shape and improve the rotation efficiency and dust removal effect of the wind scoop.

[0050] The wind scoop 73 can be made of a material with an optical sensor. For example, the wind scoop 73 can be made of a plastic or ceramic material with an optical sensor function. Such a material can sense the flow direction and speed of the exhaust gas so as to better adjust its shape and rotation direction and improve the dust removal effect.

[0051] A positioning assembly 76 is provided on the rotating shaft 75. The positioning assembly 76 is composed of a spring and balls at both ends, and the balls at the front end of the positioning assembly 76 are clamped in the groove of the brush plate for positioning.

[0052] When manufacturing the positioning assembly 76, the spring must be made to have good elasticity and corrosion resistance. Special spring materials and manufacturing processes can be used, such as stainless steel spring wire, which is subjected to appropriate heat treatment and surface treatment to ensure the elasticity and corrosion resistance of the spring.

[0053] For the production of the ball, wear-resistant materials such as ceramic balls or metal ceramic balls can be used. The dimensional accuracy and surface finish of the ball must meet the requirements to ensure the positioning accuracy of the positioning component.

[0054] 3. Overall assembly and debugging stage Installation of dust cleaning components The prepared cleaning component 7 is installed on the heat exchange tube 3 so that the cleaning component 7 can rotate on the heat exchange tube 3 .

[0055] When installing the dust cleaning component 7, different installation methods are available.

[0056] For example, a magnetic attraction installation method is adopted, and a magnetic attraction structure is provided to improve the convenience and accuracy of installing the dust cleaning component 7 on the heat exchange tube 3. The magnetic attraction structure can be a magnet with opposite magnetic properties provided on the support frame 74 of the dust cleaning component 7 and the heat exchange tube 3, respectively, and the dust cleaning component 7 can be quickly and accurately positioned on the heat exchange tube 3 by using the magnetic adsorption effect. At the same time, during the magnetic attraction process, the position and strength of the magnet can be adjusted to ensure that the relative position between the dust cleaning component 7 and the heat exchange tube 3 meets the design requirements, for example, to ensure that the brush 72 of the dust cleaning component 7 can fully contact the surface of the heat exchange tube 3, so as to better perform the dust cleaning operation.

[0057] Alternatively, a high-precision positioning instrument can be used to ensure its accurate position. For example, a laser locator or an optical locator can be used to measure and adjust the position of the cleaning component 7 on the heat exchange tube 3 to ensure that its installation position is accurate and the deviation is within ±0.5mm. When using a laser locator, first install the laser locator in a suitable position so that it can accurately illuminate the positioning marks on the cleaning component 7 and the heat exchange tube 3. Then, by observing the position of the laser spot on the positioning mark, adjust the position of the cleaning component 7 until the laser spot completely overlaps with the positioning mark. For optical locators, the principle is similar. Through optical imaging and measurement technology, the position information of the cleaning component 7 and the heat exchange tube 3 is obtained, and precise adjustments are made.

[0058] Reverse bump installation Raised inversion bumps 8 are arranged on the side surfaces of both ends of the heat exchange tube 3, and the inversion bumps 8 are made of wear-resistant material.

[0059] For the installation of the reversal protrusion 8 , welding or high-strength bolt connection can be adopted to ensure that the reversal protrusion 8 will not loosen or fall off when hit by the dust cleaning component 7 .

[0060] For example, the reversed protrusion 8 is firmly welded to the heat exchange tube 3 by welding methods such as argon arc welding or carbon dioxide gas shielded welding. Before welding, the welding part needs to be cleaned and pretreated to remove impurities such as oil stains and rust on the surface to ensure the welding quality. During welding, it is necessary to control the welding parameters, such as welding current, voltage, welding speed, etc., to ensure that the weld is uniform and firm, without defects such as pores and slag inclusions. After welding is completed, the weld needs to be inspected and tested, such as by non-destructive testing methods such as ultrasonic testing and radiographic testing, to ensure that the weld quality meets the requirements.

[0061] Alternatively, use high-strength bolts, such as 8.8-grade or 10.8-grade bolts, to fix the reverse lug 8 to the heat exchange tube 3. When using bolts for connection, first drill appropriate bolt holes on the heat exchange tube 3 and the reverse lug 8 to ensure that the bolts can pass through accurately. Then, apply an appropriate amount of thread locking agent on the bolts to prevent the bolts from loosening during use. When installing the bolts, use a suitable torque wrench to tighten the bolts according to the specified torque value to ensure a firm connection.

[0062] Economizer commissioning Debug the assembled economizer, check whether the connections of each component are tight, whether the cleaning assembly 7 rotates smoothly, and observe whether the cleaning assembly 7 can rotate along the heat exchange tube 3 under the blowing of exhaust gas. When the cleaning assembly 7 rotates to one end of the heat exchange tube 3 and contacts the reversal protrusion 8, check whether the wind scoop 73 provided on the cleaning assembly 7 can rotate 180 degrees, and whether the cleaning assembly 7 can rotate in the opposite direction on the heat exchange tube 3.

[0063] Different debugging methods and equipment can be used according to different debugging contents.

[0064] To check whether the connections between the components are tight, a combination of manual inspection and instrument inspection can be used. Manual inspection is to manually touch and observe the connection parts of the components to determine whether there is looseness or gap. For example, check the connection between the water inlet pipe 1 and the heat exchange tube 3, shake it gently with your hand to feel whether there is any looseness; observe the connection between the water outlet valve 5 and the water outlet pipe 2 to see if there is any water leakage, so as to determine whether the connection is tight. Instrument inspection can use ultrasonic flaw detectors, magnetic particle flaw detectors, etc. to detect the internal structure and connection conditions of each component to ensure that each component is tightly connected. For example, use an ultrasonic flaw detector to detect the connection between the heat exchange tube 3 and the support frame 74, and by analyzing the ultrasonic echo signal, determine whether there are defects in the connection, such as incomplete welding, cracks, etc.

[0065] To check whether the rotation of the cleaning component 7 is smooth, a combination of observation and instrument detection can be used. The observation method is to observe the rotation of the cleaning component 7 with the naked eye to determine whether there is any jamming or unsmoothness. For example, under the blowing of exhaust gas, observe the rotation trajectory of the cleaning component 7 on the heat exchange tube 3 to see if there is any sudden pause or jump. The instrument detection method can use encoders, angular velocity sensors, etc. to measure the rotation angle and speed of the cleaning component 7 to ensure its smooth rotation. For example, an encoder is installed on the rotating shaft 75 of the cleaning component 7, and the rotation angle information of the cleaning component 7 is obtained through the encoder to determine whether its rotation meets the design requirements.

[0066] Under the blowing of exhaust gas, observe whether the cleaning component 7 can rotate along the heat exchange tube 3. When the cleaning component 7 rotates to one end of the heat exchange tube 3 and contacts the reversal protrusion 8, observe whether the wind bucket 73 provided on the cleaning component 7 can rotate 180 degrees, and whether the cleaning component 7 can rotate in the opposite direction on the heat exchange tube 3. This part of the debugging can be observed on site, and recorded and analyzed in combination with video monitoring equipment. For example, during the operation of the economizer, install video monitoring equipment, align the cleaning component 7 and the heat exchange tube 3, and record the rotation of the cleaning component 7 and the contact with the reversal protrusion 8 in real time. By analyzing the video data, it is judged whether the cleaning component 7 can be reversed normally and whether the wind bucket 73 can rotate 180 degrees correctly.

[0067] Use a thermal imager to detect the temperature distribution of each component of the economizer to determine whether there is abnormal heating so that timely adjustments can be made. The thermal imager can quickly and accurately detect the temperature of each component. By analyzing the temperature distribution, it can be found whether there is local overheating or poor heat dissipation, so as to adjust the operating parameters of the economizer or check related components in time. For example, if it is found that the temperature of a certain part of the heat exchange tube 3 is too high, it may be due to incomplete cleaning of this part, resulting in obstruction of heat transfer. At this time, it is necessary to check the working status of the cleaning component 7 and focus on cleaning this part; if the temperature of the water inlet valve 4 is found to be abnormal, it may be due to blockage or leakage inside the valve. The water inlet valve 4 needs to be repaired.

[0068] Intelligent sensors are used to monitor the rotation angle and speed of the cleaning component 7, as well as the operating parameters of the economizer, and problems are discovered and optimized in a timely manner through data analysis. Intelligent sensors can collect data in real time and transmit the data to a computer or control system. By analyzing the data, it can be found whether there is any abnormal rotation of the cleaning component 7 or whether the operating parameters of the economizer meet the design requirements, so as to timely adjust and optimize the operating status of the economizer. For example, if the intelligent sensor monitors that the rotation speed of the cleaning component 7 is too fast, it may lead to incomplete cleaning or excessive wear on the heat exchange tube 3. At this time, it is necessary to adjust the flow rate of the exhaust gas or optimize the structure of the cleaning component 7; if the water inlet temperature of the economizer is monitored to be too high, it may be necessary to check whether the water inlet pipe 1 is blocked or has other problems, and to deal with the water inlet pipe 1 accordingly.

[0069] Virtual reality technology is used to simulate the operating environment of the economizer, evaluate and optimize its performance, monitor the operating status of each component, and promptly identify and handle problems. Virtual reality technology can create a virtual economizer operating environment, evaluate the performance of the economizer by simulating different working conditions and operating parameters, and optimize it according to the evaluation results. At the same time, in the virtual environment, the operating status of each component can be monitored in real time, and problems can be discovered and handled in a timely manner. For example, in a virtual environment, the situation of the economizer under high load operation is simulated, the stress and temperature changes of each component are observed, and the structure of the economizer is optimized according to the simulation results, such as adjusting the structure of the support frame 74 or strengthening the strength of certain components; at the same time, through the monitoring system in the virtual environment, the rotation of the cleaning component 7 and the operating parameters of the economizer are monitored in real time, and problems are promptly handled. For example, when it is found that the wind bucket 73 of the cleaning component 7 rotates abnormally in the virtual environment, the wind bucket 73 is checked and adjusted in the actual equipment.

[0070] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A corrosion-resistant and wear-resistant economizer, comprising a water inlet pipe (1), a water outlet pipe (2) and a heat exchange tube (3), characterized in that: The water inlet pipe (1) is connected to the water outlet pipe (2) via a heat exchange pipe (3), and a water inlet valve (4) is installed on the water inlet pipe (1). The two ends of the water outlet pipe (2) are respectively installed with a water outlet valve (5) and a pressure relief valve (6). A rotatable dust cleaning component (7) is installed on the heat exchange pipe (3), and raised reversing protrusions (8) are provided on the side surfaces of both ends of the heat exchange pipe (3). The dust cleaning component (7) comprises a support frame (74), three groups of brush plates (71) arranged on the support frame (74), and a wind bucket (73) installed on the brush plate (71), and brushes (72) are evenly arranged on both sides of the brush plate (71).

2. The corrosion-resistant and wear-resistant economizer according to claim 1, characterized in that: The support frame (74) adopts a C-shaped metal structure, and four groups of rolling balls (741) are evenly arranged inside the support frame (74), while three groups of brush plates (71) are evenly arranged on the support frame (74).

3. The corrosion-resistant and wear-resistant economizer according to claim 1, characterized in that: The wind scoop (73) is connected to the brush plate (71) via a rotating shaft (75) at the front end, and the wind scoop (73) is rotatable on the brush plate (71). A positioning assembly (76) is provided on the rotating shaft (75). The positioning assembly (76) is composed of a spring and balls at both ends. The balls at the front end of the positioning assembly (76) are clamped in a groove of the brush plate (71) for positioning.

4. The corrosion-resistant and wear-resistant economizer according to claim 1, characterized in that: The ash cleaning component (7) rotates along the heat exchange tube (3) under the blowing of the exhaust gas, and the ash cleaning component (7) rotates until one end of the heat exchange tube (3) contacts the reversing protrusion (8), and the air scoop (73) provided on the ash cleaning component (7) rotates (180) degrees, and the ash cleaning component (7) rotates in the opposite direction on the heat exchange tube (3).

5. A method for preparing a corrosion-resistant and wear-resistant economizer according to any one of claims 1 to 4, characterized in that: The following steps are involved: Step 1: Material preparation; Selecting corrosion-resistant and wear-resistant metal materials for making the water inlet pipe (1), the water outlet pipe (2) and the heat exchange pipe (3), and pre-treating the selected metal materials, including cleaning, degreasing, derusting and other operations, to ensure that the surface of the materials is clean; Step 2: Component production and assembly; Using the pretreated metal material to make a water inlet pipe (1), a water outlet pipe (2) and a heat exchange pipe (3), connecting the water inlet pipe (1) to the water outlet pipe (2) via the heat exchange pipe (3), installing a water inlet valve (4) on the water inlet pipe (1), and installing a water outlet valve (5) and a pressure relief valve (6) at both ends of the water outlet pipe (2); A support frame (74) is made of a C-shaped metal structure having corrosion resistance and wear resistance. The metal material used to make the support frame (74) is subjected to cutting, bending and other processing operations. Four groups of balls (741) are evenly arranged inside the support frame (74). The balls (741) are made of wear-resistant materials. Three groups of brush plates (71) are evenly arranged on the support frame (74). The brush plates (71) are made of corrosion-resistant materials. Brushes (72) are evenly arranged on both sides of the brush plates (71). The brushes (72) are made of wear-resistant and high-temperature-resistant materials. The wind bucket (73) is connected to the brush plate (71) through the rotating shaft (75) at the front end. The wind bucket (73) is made of corrosion-resistant and wear-resistant materials. A positioning component (76) is arranged on the rotating shaft (75). The positioning component (76) is composed of a spring and balls at both ends. When making the spring, it is necessary to ensure that it has good elasticity and corrosion resistance. The balls are made of wear-resistant materials, and the balls at the front end of the positioning component (76) are clamped in the groove of the brush plate (71) for positioning; Step 3: Overall assembly and debugging; The prepared cleaning component (7) is mounted on the heat exchange tube (3) so that the cleaning component (7) can rotate on the heat exchange tube (3), and raised reversing bumps (8) are provided on the side surfaces of both ends of the heat exchange tube (3), wherein the reversing bumps (8) are made of wear-resistant material; The assembled economizer is debugged to check whether the components are tightly connected and whether the cleaning assembly (7) rotates smoothly. Under the blowing of exhaust gas, it is observed whether the cleaning assembly (7) can rotate along the heat exchange tube (3). When the cleaning assembly (7) rotates to the point where one end of the heat exchange tube (3) contacts the reversing protrusion (8), it is observed whether the air scoop (73) provided on the cleaning assembly (7) can rotate 180 degrees and whether the cleaning assembly (7) can rotate in the opposite direction on the heat exchange tube (3).

6. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 5, characterized in that: In the material preparation stage, for pretreatment operations, ultrasonic cleaning technology is used to clean metal materials to more thoroughly remove surface oil and impurities; During the degreasing process, a special metal degreasing agent can be used. When removing rust, a combination of chemical and mechanical rust removal is used. First, use an acidic rust remover to remove rust, and then use sandpaper to polish to make the material surface smoother. In the component manufacturing and assembly process, for the cutting and bending operations of the support frame (74), CNC laser cutting and CNC bending equipment are used to ensure accuracy; in the production of the ball (741), the wear-resistant material is heat treated to improve its hardness and wear resistance; when the brush plate (71) is produced, a wear-resistant metal layer can be added on the surface of the corrosion-resistant material by electroplating; for the wind scoop (73), its shape can be optimized by computer simulation based on the principles of fluid mechanics; During the overall assembly and commissioning phase, when installing the dust removal component (7), use a high-precision positioning instrument to ensure its accurate position; During the debugging process, a thermal imager is used to detect the temperature distribution of each economizer component to determine whether there is abnormal heating so that timely adjustments can be made.

7. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 5, characterized in that: In the material preparation stage, after selecting the metal material, the microstructure is analyzed and its crystal structure and defects are observed using an electron microscope; if defects exist, they can be repaired through special heat treatment processes; During the pretreatment process, biodegradable cleaning agents are used for cleaning; at the same time, plasma treatment technology is used on the material surface to enhance the activity of the material surface and improve its bonding with subsequent coatings; In the component manufacturing and assembly process, the support frame (74) can adopt a new composite material structure, such as a carbon fiber reinforced metal matrix composite material, which has both high strength and corrosion resistance; the ball (741) can adopt a ceramic ball, and a layer of lubricant is coated on its surface to improve its rotation flexibility; The brush plate (71) may be designed as a multi-layer structure, with a bottom layer being a corrosion-resistant metal layer, a middle layer being a buffer layer, and an upper layer being a wear-resistant coating; the wind scoop (73) may be made of a deformable material and automatically adjust its shape according to the exhaust gas flow and pressure; During the overall assembly and commissioning phase, intelligent assembly equipment is used to automatically identify and install each component; During the debugging process, intelligent sensors are used to monitor the rotation angle and speed of the cleaning assembly (7) and the operating parameters of the economizer, and problems are discovered and optimized in a timely manner through data analysis.

8. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 5, characterized in that: During the material preparation stage, the resource sustainability of materials is considered when selecting materials, and recyclable metal materials are given priority; the selected materials are marked so that they can be easily recycled after the product is scrapped; During the pretreatment process, high-pressure water jet cleaning technology is used, which has high cleaning efficiency and does not damage the material. At the same time, the surface of the material is subjected to micro-arc oxidation treatment to form a ceramic film to improve its corrosion resistance. In the process of component manufacturing and assembly, the water inlet pipe (1), the water outlet pipe (2) and the heat exchange tube (3) can adopt a double-layer structure design, wherein the inner layer is a corrosion-resistant metal layer and the outer layer is a wear-resistant coating; when manufacturing the support frame (74), 3D printing technology is adopted to quickly manufacture a support frame with a complex shape, and the support frame can be customized according to design requirements; the ball (741) can be made of a nanostructured material with higher hardness and wear resistance; the brush plate (71) can be made of a self-cleaning material to reduce dust adhesion; the wind bucket (73) can be designed to be an asymmetric shape according to the flow direction of the exhaust gas to improve its rotation efficiency; During the overall assembly and commissioning stage, a magnetic installation method is used when installing the cleaning component (7), which is convenient, fast and accurate in positioning. During the commissioning process, virtual reality technology is used to simulate the operating environment of the economizer, evaluate and optimize its performance, and monitor the operating status of each component to promptly identify and handle problems.

9. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 5, characterized in that: In the material preparation stage, for corrosion-resistant and wear-resistant metal materials, surface modification treatment is carried out after pretreatment; Ion implantation technology is used to implant specific ions into the surface of the material to change its surface chemical composition and physical properties, and improve its corrosion resistance and wear resistance. At the same time, high-temperature aging tests are performed on the material to test its performance stability in high-temperature environments. In the component manufacturing and assembly process, the support frame (74) can adopt a multi-layer nested structure, each layer has different functions, the outermost layer is a wear-resistant layer, the middle layer is a support layer, and the innermost layer is a corrosion-resistant layer; the ball (741) can adopt a high-precision ceramic ball with a dimensional accuracy within ±0.05mm to improve its rotation flexibility and wear resistance; the brush plate (71) can be made of high-temperature wear-resistant material; During the overall assembly and commissioning stage, when the cleaning component (7) is installed on the heat exchange tube (3), ensure that the installation position is accurate and firm; during the commissioning process, high-temperature testing equipment is used to measure various parameters of the economizer, and at the same time, the cleaning effect of the cleaning component (7) is monitored, and timely adjustments and optimizations are made.

10. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 5, characterized in that: In the material preparation stage, when selecting metal materials, consider their chemical compatibility with the surrounding environment; select metal materials that are not easy to react with chemical substances in the environment; at the same time, the material is surface treated by chemical plating to coat a protective film on the surface of the material to improve its chemical stability; In the component manufacturing and assembly process, the support frame (74) can adopt an intelligent structural design, and the ball (741) can be made of a material with a self-lubricating function to reduce friction; The brush plate (71) may be made of a material having an antibacterial function to prevent microorganisms from growing on its surface; the wind scoop (73) may be made of a material having an optical sensor to sense the flow direction and speed of the exhaust gas so as to better adjust its shape and rotation direction; During the overall assembly and commissioning stage, when the cleaning assembly (7) is installed on the heat exchange tube (3), an intelligent positioning system is used to ensure that its installation position is accurate; during the commissioning process, an intelligent monitoring system is used to monitor various parameters of the economizer in real time, including temperature, pressure, and flow, and to determine whether its operating status is normal through data analysis, so that problems can be discovered and handled in a timely manner.

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