A corrosion-resistant and wear-resistant economizer and its preparation method

Abstract

The present invention discloses a corrosion-resistant and wear-resistant economizer, comprising a water inlet pipe, a water outlet pipe, and a heat exchange pipe. The water inlet pipe is connected to the water outlet pipe via the heat exchange pipe, and a water inlet valve is installed on the water inlet pipe. A rotatable dust cleaning component is installed on the heat exchange pipe, and raised reversing bumps are provided on both end sides of the heat exchange pipe. The dust cleaning component comprises a support frame, three sets of brush plates provided on the support frame, and air scoops installed on the brush plates. A method for preparing a corrosion-resistant and wear-resistant economizer comprises the following steps: Step 1: Material preparation; Step 2: Component fabrication and assembly; Step 3: Overall assembly and commissioning. The brush of the dust cleaning component can effectively remove dust and solid particles from the pipe wall. The rational design of the air scoop and the automatic reversal function of the dust cleaning component ensure comprehensive cleaning of the pipe wall. The dust cleaning component automatically rotates and reverses through exhaust gas blowing, eliminating the need for frequent manual operation for dust cleaning.

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] Economizers are essential heat exchange devices widely used in thermal systems, particularly boilers. Their core function is to utilize the waste heat from flue gases discharged from the boiler's exhaust to preheat the boiler's feedwater. In this way, economizers significantly improve the boiler system's thermal efficiency and effectively reduce fuel consumption, playing a crucial role in energy conservation. Preheating the feedwater also reduces the water's heating time within the boiler, thereby alleviating thermal stress on the boiler, which is crucial for extending the boiler's service life.

[0003] In boiler operation, economizers face a complex corrosive environment. Flue gas typically contains acidic gases such as sulfur dioxide and sulfur trioxide. These gases combine with water vapor to form acidic substances such as sulfuric acid, which can severely corrode the metal surfaces of economizers.

[0004] Corrosion can cause the metal tube walls of economizers to gradually thin, reducing their mechanical strength and pressure-bearing capacity. Severe corrosion can cause perforations in the tube walls, leading to water leaks that can 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 economizer cleaning methods 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 with 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 a water inlet pipe, a water outlet pipe and a heat exchange pipe, the water inlet pipe is connected to the water outlet pipe through the heat exchange pipe, and a water inlet valve is installed on the water inlet pipe, and a water outlet valve and a pressure relief valve are respectively installed at both ends of the water outlet pipe, a rotatable cleaning assembly is installed on the heat exchange pipe, and raised reversal bumps are provided 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 can rotate on the brush plate. At the same time, a positioning component is provided on the rotating shaft. The positioning component is composed of a spring and balls at both ends, and the balls at the front end of the positioning component are clamped in the groove of the brush plate for positioning.

[0010] Furthermore, the ash cleaning component rotates along the heat exchange tube under the blowing of exhaust gas, and the ash cleaning component rotates until one end of the heat exchange tube contacts the reversal protrusion, and the air scoop provided on the ash cleaning component rotates, and the ash 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:

[0012] Step 1: Material preparation;

[0013] 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, and rust removal, to ensure the surface of the materials is clean;

[0014] Step 2: Component production and assembly;

[0015] Use the pretreated metal material to make an inlet pipe, an outlet pipe and a heat exchange pipe, connect the inlet pipe to the outlet pipe through the heat exchange pipe, install an inlet valve on the inlet pipe, and install an outlet valve and a pressure relief valve at both ends of the outlet pipe;

[0016] The support frame is made of a C-shaped metal structure with corrosion and wear resistance. The metal material of 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.

[0017] 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 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 are clamped in the groove of the brush plate for positioning;

[0018] Step 3: Overall assembly and debugging;

[0019] Install the prepared dust cleaning assembly onto the heat exchange tube so that the dust cleaning assembly can rotate on the heat exchange tube. Set raised reversing bumps on both ends of the heat exchange tube. The reversing bumps are made of wear-resistant material.

[0020] Debug the assembled economizer, check whether the connections between the components 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 air scoop 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.

[0021] Furthermore, during the material preparation stage, for pre-treatment operations, ultrasonic cleaning technology is used to clean the metal materials to 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 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.

[0022] During component manufacturing and assembly, CNC laser cutting and CNC bending equipment are used to ensure precision in the cutting and bending of support frames. In ball production, wear-resistant materials are heat-treated to improve their hardness and wear resistance. When manufacturing brush plates, an electroplating process is used to add a wear-resistant metal layer to the surface of corrosion-resistant materials. For the air scoop, computer simulation is performed based on fluid mechanics principles to optimize its shape.

[0023] During the overall assembly and commissioning phase, high-precision positioning instruments are used to ensure the accurate positioning of the dust removal components when installing them. 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.

[0024] Furthermore, during the material preparation stage, after selecting the metal material, a microstructural 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, 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.

[0025] During component manufacturing and assembly, the support frame can adopt a new composite material structure, such as carbon fiber reinforced metal matrix composite materials, which have both high strength and corrosion resistance. The ball bearings can be ceramic ball bearings, and a layer of lubricant is coated on their surface to improve their rotational 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 a deformable material, automatically adjusting its shape according to the exhaust gas flow and pressure.

[0026] During the overall assembly and commissioning phase, intelligent assembly equipment is used to automatically identify and install components. During the commissioning 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.

[0027] Furthermore, during the material preparation stage, the sustainability of the resources is taken into consideration when selecting materials, with recyclable metal materials being given priority. The selected materials are marked to facilitate recycling after the product is scrapped. During the pretreatment process, high-pressure water jet cleaning technology is used, which is highly efficient and harmless to the material. At the same time, the surface of the material is micro-arc oxidized to form a ceramic film to improve its corrosion resistance.

[0028] During component manufacturing and assembly, the water inlet pipe, outlet pipe, and heat exchange tube 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. 3D printing technology is used in the production of support frames, which can quickly produce support frames with complex shapes and can be customized according to design requirements. The ball bearings can be made of nanostructured materials with higher hardness and wear resistance. The brush plates can be made of self-cleaning materials to reduce dust adhesion. The air scoop can be designed with an asymmetric shape according to the direction of exhaust gas flow to improve its rotation efficiency.

[0029] During the overall assembly and commissioning phase, magnetic installation was used to install the dust removal components, which was convenient, quick, and accurate in positioning. During the commissioning process, virtual reality technology was used to simulate the economizer's operating environment, evaluate and optimize its performance, and monitor the operating status of each component to promptly identify and address any problems.

[0030] Furthermore, during the material preparation stage, corrosion-resistant and wear-resistant metal materials are subjected to surface modification 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 performed on the materials to examine their performance stability in high-temperature environments.

[0031] During the component manufacturing and assembly process, the support frame can adopt a multi-layer nested structure, with each layer having 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 balls can be high-precision ceramic balls with a dimensional accuracy within ±0.05mm to improve their rotation flexibility and wear resistance. The brush plate can be made of high-temperature wear-resistant materials.

[0032] During the overall assembly and commissioning phase, when installing the cleaning components onto the heat exchange tubes, ensure that the installation position is accurate and secure. During the commissioning process, high-temperature testing equipment is used to measure various parameters of the economizer and monitor the cleaning effect of the cleaning components, allowing for timely adjustments and optimization.

[0033] Furthermore, during the material preparation stage, when selecting metal materials, the chemical compatibility with the surrounding environment is considered; metal materials that are less likely 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;

[0034] During the component manufacturing and assembly process, the support frame can adopt an intelligent structural design, the ball bearings can be made of self-lubricating materials to reduce friction; the brush plate can be made of antibacterial materials to prevent microorganisms from growing on its surface; the air scoop can be made of materials with optical sensors to sense the flow direction and speed of the exhaust gas, so as to better adjust its shape and rotation direction;

[0035] During the overall assembly and commissioning phase, when installing the ash cleaning assembly onto the heat exchange tube, an intelligent positioning system is used to ensure its accurate installation position. During the commissioning process, an intelligent monitoring system is used to monitor the various parameters of the economizer in real time, including temperature, pressure, and flow. Data analysis is used to determine whether its operating status is normal, and problems are discovered and addressed in a timely manner.

[0036] Compared with the prior art, the present invention has the following advantages: During the material preparation stage, the present invention selects corrosion-resistant and wear-resistant metal materials for the key components of the water inlet pipe, water outlet pipe, and heat exchange tube. Furthermore, the selected metal materials undergo various pretreatment operations, including ultrasonic cleaning technology to more thoroughly remove surface oil and impurities, the use of a dedicated metal degreasing agent during the degreasing process, and the use of a combination of chemical and mechanical rust removal methods to achieve a smoother material surface. These treatments lay a good foundation for subsequent corrosion resistance.

[0037] The support frame of the ash cleaning assembly utilizes a corrosion-resistant C-shaped metal structure, the brush plate is made of corrosion-resistant materials, and the air scoop is also made of corrosion-resistant and wear-resistant materials. This integrated use of corrosion-resistant materials and structural design enables the economizer to maintain excellent performance in complex corrosive environments, reducing problems such as tube wall thinning, perforation, and reduced heat exchange efficiency caused by corrosion, extending the economizer's service life and ensuring normal boiler operation.

[0038] There are four sets of balls evenly arranged inside the support frame. The balls are made of wear-resistant material, which enables the cleaning component to reduce friction during rotation and reduce wear on its own structure and the wall of the heat exchange tube.

[0039] Brushes are evenly spaced on both sides of the brush plate. Made from wear-resistant and high-temperature-resistant materials, they effectively remove dust and solid particles from the heat exchange tube walls while also being self-resistant to wear. The air scoops rotate on the brush plate, better utilizing the exhaust gas flow energy for cleaning and reducing additional wear on the tube walls caused by improper cleaning methods.

[0040] The cleaning assembly rotates along the heat exchange tube under the influence of exhaust gas. When one end of the heat exchange tube contacts the reversing bump, the air bucket rotates 180 degrees, and the cleaning assembly rotates in the opposite direction on the heat exchange tube. This automatic reversing cleaning method ensures that all parts of the heat exchange tube wall are effectively cleaned.

[0041] The brushes in the cleaning assembly effectively remove dust and solid particles from the tube walls. The rational design of the air scoop and the automatic reversal function of the cleaning assembly ensure comprehensive cleaning of the tube walls, preventing partial cleaning. This keeps the heat exchange tube walls consistently clean, facilitating efficient heat exchange.

[0042] The cleaning assembly of the present invention automatically rotates and reverses through exhaust gas, eliminating the need for frequent manual cleaning. This compares to existing manual cleaning methods, which are inefficient and difficult to ensure consistent cleaning quality, and mechanical cleaning equipment, which may not clean thoroughly and cause additional wear on the pipe wall. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 It is a schematic diagram of the expansion of the structure of the present invention;

[0044] Figure 2 This is a schematic diagram of the installation of the dust cleaning component of the structure of the present invention;

[0045] Figure 3 This is a schematic diagram of the wind scoop connection structure of the present invention;

[0046] Figure 4 This is a top view schematic diagram of the dust cleaning component of the structure of the present invention.

[0047] 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 assembly; 71. Brush plate; 72. Brush; 73. Air scoop; 74. Support frame; 741. Ball bearing; 75. Rotating shaft; 76. Positioning assembly; 8. Reversing bump. DETAILED DESCRIPTION

[0048] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. 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 making creative efforts are within the scope of protection of the present invention.

[0049] See also Figure 1-4 The present invention provides a technical solution: a corrosion-resistant and wear-resistant economizer and a preparation method thereof, the implementation method is as follows:

[0050] 1. Material preparation stage

[0051] Metal material selection and pretreatment

[0052] First, based on the economizer's operating environment and performance requirements, corrosion- and wear-resistant metal materials are selected for the water inlet pipe 1, water outlet pipe 2, and heat exchange tubes 3. These metal materials must possess excellent corrosion resistance to withstand erosion by acidic gases in flue gas, such as sulfur dioxide and sulfur trioxide, and corrosive components dissolved in water, such as oxygen and chloride ions. They must also possess sufficient wear resistance to withstand the erosion of solid particles in the flue gas.

[0053] During the pretreatment process, various methods are used to ensure the cleanliness and performance of the material surface.

[0054] Ultrasonic cleaning technology is used to clean metal materials. Ultrasonic cleaning utilizes the cavitation effect of ultrasound waves in a liquid, generating a powerful impact force that removes dirt from the surface of the material. This cleaning method can more thoroughly remove surface oil and impurities. Compared with traditional cleaning methods, it is more effective and can penetrate deep into the tiny cracks and holes on the surface of the material to remove hidden dirt.

[0055] During the degreasing process, a specialized metal degreaser is used. This degreaser has excellent emulsifying properties, breaking down grease into tiny particles, making it easier to clean. It also has corrosion-inhibiting properties, preventing it from corroding the metal during the degreasing process.

[0056] Rust removal uses a combination of chemical and mechanical methods. First, use an acidic rust remover to remove rust, which reacts chemically with the rust and dissolves it. Sanding is then performed to further remove rust and surface irregularities, resulting in a smoother surface. This combined approach effectively removes rust while ensuring surface smoothness, providing a good foundation for subsequent processing and use.

[0057] Material microstructure analysis and repair

[0058] For more demanding applications, metal materials can be selected and subjected to microstructural analysis. Electron microscopy is used to observe the crystal structure and defects. Electron microscopy provides high-resolution images that clearly reveal the material's internal crystal structure and possible defects, such as dislocations and grain boundary defects.

[0059] If defects are found, they can be repaired through specialized heat treatment processes. For example, annealing can be used to eliminate internal stress and repair defects in certain metal materials. Annealing involves heating the metal to a certain temperature and then slowly cooling it. During this process, the atoms within the material rearrange themselves, eliminating stress and repairing defects, thereby improving the material's performance.

[0060] Material surface treatment

[0061] During the material preparation stage, a variety of surface treatments can be performed to further improve the material's performance.

[0062] Plasma treatment is used to treat the surface of a material. Plasma is a partially ionized gas with high energy and activity. When plasma comes into contact with a material surface, it alters the chemical composition and physical properties of the surface. For example, plasma treatment can increase the surface activity, improving its adhesion to subsequent coatings, while also reducing the surface roughness, making it more conducive to heat transfer.

[0063] A protective film is plated on the surface of the material by chemical plating. Chemical plating is a method of depositing metals or alloys on the surface of a material by chemical reaction. By selecting appropriate chemical plating solutions 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 growing 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 properties, 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.

[0064] 2. Component production and assembly

[0065] Production of water inlet pipes, water outlet pipes and heat exchange pipes

[0066] The pretreated metal material is used to make the water inlet pipe 1, water outlet pipe 2, and 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 quality of the pipes.

[0067] For special design requirements, the water inlet pipe 1, water outlet pipe 2, and heat exchange pipe 3 can adopt a double-layer structure. The inner layer is a corrosion-resistant metal layer, and the outer layer is a wear-resistant coating. For example, the inner layer can be made of stainless steel, which has excellent corrosion resistance, and the outer layer can be made of ceramic coating or metal ceramic coating, which has excellent wear resistance. This double-layer design can simultaneously improve the corrosion and wear resistance of the pipeline.

[0068] Support frame production

[0069] The support frame 74 is made of a C-shaped metal structure having corrosion resistance and wear resistance. During the manufacturing process, the metal material of the support frame 74 is subjected to processing operations such as cutting, centering, and bending.

[0070] CNC laser cutting and bending equipment can be used to ensure precision during the cutting and bending of support frame 74. CNC laser cutting offers advantages such as high cutting accuracy, narrow kerfs, and a minimal heat-affected zone, ensuring the dimensional and shape accuracy of support frame 74. CNC bending equipment can accurately control the bending angle and radius, ensuring that support frame 74 meets design requirements.

[0071] Four sets of balls 741 are evenly distributed within the support frame 74. These balls 741 are made of a wear-resistant material. These balls 741 reduce friction between the support frame 74 and the heat exchange tubes 3, enabling smoother rotation of the dust removal assembly 7. The balls 741 can be manufactured by heat-treating the wear-resistant material to increase its hardness and wear resistance. For example, heat treatment processes such as quenching and tempering can be used to achieve a desired hardness while maintaining good toughness.

[0072] Support frame 74 can be constructed using a novel composite material. For example, support frame 74 can be made of a carbon fiber reinforced metal matrix composite material. Carbon fiber offers advantages such as high strength, low density, and excellent corrosion resistance, while metal matrix composite materials offer excellent processing properties and toughness. By combining carbon fiber and metal matrix composite materials, a support frame 74 with both high strength and corrosion resistance can be produced.

[0073] The support frame 74 can 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 wear resistance, support, and corrosion resistance according to different usage requirements, thereby improving the overall performance of the support frame 74.

[0074] Brush plate production

[0075] 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.

[0076] The brush plate 71 can be manufactured by electroplating a wear-resistant metal layer on the surface of a corrosion-resistant material. This process deposits a layer of metal, such as nickel or chromium, on the surface of the brush plate 71, increasing its wear resistance. The electroplating layer also improves the surface hardness and finish of the brush plate 71, making it more suitable for cleaning.

[0077] 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 top layer is a wear-resistant coating. This multi-layer structure can optimize corrosion resistance, buffering, and wear resistance according to different usage requirements, thereby improving the overall performance of the brush plate 71.

[0078] The brush plate 71 can be made of a self-cleaning material. For example, a material with a self-cleaning function, such as a nano material or a material with a special surface structure, can be used to make the brush plate 71. This self-cleaning material can reduce the adhesion of dust on the brush plate 71 and improve the cleaning efficiency.

[0079] Wind scoop production

[0080] 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.

[0081] The shape of the scoop 73 can be optimized through computer simulation based on the principles of fluid mechanics. This simulation can analyze the force and flow characteristics of the scoop 73 under different airflow conditions, thereby optimizing the shape of the scoop 73 to better utilize the flow energy of the exhaust gas for dust removal.

[0082] The scoop 73 can be made of a deformable material. For example, a shape memory alloy or a material with elastic deformation capability can be used to make the scoop 73. This deformable material can automatically adjust its shape according to the exhaust gas flow rate and pressure, thereby improving the rotation efficiency and dust removal effect of the scoop 73.

[0083] The scoop 73 can be made of a material with optical sensors. For example, plastic or ceramic materials with optical sensing capabilities can be used to make the scoop 73. Such materials can sense the flow direction and speed of the exhaust gas, allowing for better shape adjustment and improving the scoop's rotation efficiency and dust removal performance.

[0084] The air scoop 73 can be made of a material with optical sensors. For example, plastic or ceramic materials with optical sensing capabilities can be used to make the air scoop 73. Such materials can sense the flow direction and speed of the exhaust gas, allowing for better adjustment of its shape and rotation direction to improve the cleaning effect.

[0085] 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 ball at the front end of the positioning assembly 76 is clamped in the groove of the brush plate for positioning.

[0086] 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 spring wire, which is subjected to appropriate heat treatment and surface treatment to ensure the elasticity and corrosion resistance of the spring.

[0087] For the production of balls, wear-resistant materials such as ceramic balls or metal ceramic balls can be used. The dimensional accuracy and surface finish of the balls must meet the requirements to ensure the positioning accuracy of the positioning component.

[0088] 3. Overall assembly and debugging stage

[0089] Cleaning component installation

[0090] The prepared dust cleaning component 7 is installed on the heat exchange tube 3 so that the dust cleaning component 7 can rotate on the heat exchange tube 3 .

[0091] When installing the dust cleaning component 7, different installation methods can be used.

[0092] For example, a magnetic installation method can be used, with a magnetic structure, to improve the ease and accuracy of installing the dust cleaning assembly 7 on the heat exchange tube 3. The magnetic structure can be achieved by installing magnets with opposite magnetic properties on the support frame 74 of the dust cleaning assembly 7 and the heat exchange tube 3, respectively. This structure utilizes magnetic attraction to quickly and accurately position the dust cleaning assembly 7 on the heat exchange tube 3. Furthermore, during the magnetic attraction process, the position and strength of the magnets can be adjusted to ensure that the relative position between the dust cleaning assembly 7 and the heat exchange tube 3 meets design requirements. For example, this ensures that the brush 72 of the dust cleaning assembly 7 is in full contact with the surface of the heat exchange tube 3, facilitating a more efficient dust cleaning operation.

[0093] 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.

[0094] Reverse bump installation

[0095] Raised inversion bumps 8 are provided on both end sides of the heat exchange tube 3 , and the inversion bumps 8 are made of wear-resistant material.

[0096] For the installation of the reversal projection 8 , welding or high-strength bolt connection can be adopted to ensure that the reversal projection 8 will not loosen or fall off when impacted by the dust cleaning component 7 .

[0097] For example, argon arc welding or CO2 gas shielded welding is used to securely weld the inverted bump 8 to the heat exchange tube 3. Before welding, the weld area needs to be cleaned and pre-treated to remove surface impurities such as oil, rust, and other impurities to ensure weld quality. During welding, welding parameters such as welding current, voltage, and welding speed must be carefully controlled to ensure a uniform, secure weld without defects such as pores and slag inclusions. After welding, the weld needs to be inspected and tested, using non-destructive testing methods such as ultrasonic testing and radiographic testing to ensure that the weld quality meets requirements.

[0098] Alternatively, use high-strength bolts, such as grade 8.8 or 10.8 bolts, to secure the reversing projection 8 to the heat exchange tube 3. When using bolts, first drill appropriate bolt holes in the heat exchange tube 3 and reversing projection 8 to ensure the bolts can pass through accurately. Then, apply an appropriate amount of threadlocker to the bolts to prevent loosening during use. When installing the bolts, use an appropriate torque wrench and tighten them to the specified torque value to ensure a secure connection.

[0099] Economizer commissioning

[0100] Debug the assembled economizer, check whether the connections between the components are tight, whether the ash cleaning assembly 7 rotates smoothly, and observe whether the ash cleaning assembly 7 can rotate along the heat exchange tube 3 under the blowing of exhaust gas. When the ash cleaning assembly 7 rotates to one end of the heat exchange tube 3 and contacts the reversal protrusion 8, check whether the air scoop 73 set on the ash cleaning assembly 7 can rotate 180 degrees, and whether the ash cleaning assembly 7 can rotate in the opposite direction on the heat exchange tube 3.

[0101] Depending on the debugging content, different debugging methods and equipment can be used.

[0102] To check whether the connections between components are tight, a combination of manual inspection and instrument inspection can be used. Manual inspection involves manually touching and observing the connection points of each component to determine whether there are any looseness or gaps. For example, check the connection between the water inlet pipe 1 and the heat exchange tube 3 by gently shaking it with your hand to feel for 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 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 inspect the connection between the heat exchange tube 3 and the support frame 74, and by analyzing the ultrasonic echo signal, determine whether the connection has defects, such as incomplete welding, cracks, etc.

[0103] To check whether the dust cleaning component 7 rotates smoothly, a combination of observation and instrument detection can be used. The observation method is to observe the rotation of the dust cleaning component 7 with the naked eye to determine whether there is any jamming or unevenness. For example, under the blowing of exhaust gas, observe the rotation trajectory of the dust 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 dust cleaning component 7 to ensure its smooth rotation. For example, an encoder is installed on the rotating shaft 75 of the dust cleaning component 7, and the rotation angle information of the dust cleaning component 7 is obtained through the encoder to determine whether its rotation meets the design requirements.

[0104] Under the influence of exhaust gas, observe 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, observe whether the air scoop 73 installed 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. This part of the debugging can be observed on site, combined with video monitoring equipment for recording and analysis. For example, during economizer operation, install video monitoring equipment, align the cleaning assembly 7 with the heat exchange tube 3, and record the rotation of the cleaning assembly 7 and its contact with the reversing protrusion 8 in real time. By analyzing the video data, determine whether the cleaning assembly 7 can reverse normally and whether the air scoop 73 can rotate 180 degrees correctly.

[0105] Use a thermal imager to detect the temperature distribution of each economizer component to determine if there is abnormal heating so that timely adjustments can be made. A thermal imager can quickly and accurately detect the temperature of each component. By analyzing the temperature distribution, it can be determined whether there is local overheating or poor heat dissipation, allowing timely adjustments to the economizer's operating parameters or inspection of related components. For example, if the temperature of a certain part of the heat exchange tube 3 is found to be too high, it may be due to incomplete cleaning of that part, resulting in obstructed heat transfer. In this case, it is necessary to check the working status of the cleaning component 7 and focus on cleaning that part. If the temperature of the water inlet valve 4 is found to be abnormal, it may be due to problems such as blockage or leakage inside the valve, and the water inlet valve 4 needs to be repaired.

[0106] Smart 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 promptly discovered and optimized through data analysis. Smart 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 smart sensor detects 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. In this case, it is necessary to adjust the flow rate of the exhaust gas or optimize the structure of the cleaning component 7; if it is detected that the water inlet temperature of the economizer is too high, it may be necessary to check whether the water inlet pipe 1 is blocked or has other problems, and to perform corresponding treatment on the water inlet pipe 1.

[0107] Virtual reality technology is used to simulate the economizer's operating environment, evaluate and optimize its performance, and monitor the operating status of each component, enabling timely identification and resolution of issues. Virtual reality technology can create a virtual economizer operating environment. By simulating different operating conditions and parameters, economizer performance can be evaluated and optimized based on the evaluation results. Furthermore, within the virtual environment, the operating status of each component can be monitored in real time, allowing for timely identification and resolution of issues. For example, the economizer's high-load operation can be simulated in the virtual environment to observe the stress and temperature changes of each component. Based on the simulation results, the economizer's structure can be optimized, such as by adjusting the structure of the support frame 74 or strengthening certain components. Furthermore, the monitoring system within the virtual environment monitors the rotation of the ash cleaning assembly 7 and the economizer's operating parameters in real time, allowing timely resolution of any issues. For example, if the scoop 73 of the ash cleaning assembly 7 is found to be rotating abnormally in the virtual environment, it can be inspected and adjusted in the actual equipment.

[0108] While 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 these embodiments without departing from the principles and spirit of the invention, and that the scope of the 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 pipe (3), characterized in that: The water inlet pipe (1) is connected to the water outlet pipe (2) through the heat exchange pipe (3), and a water inlet valve (4) is installed on the water inlet pipe (1), and a water outlet valve (5) and a pressure relief valve (6) are installed at both ends of the water outlet pipe (2), respectively. A rotatable dust cleaning component (7) is installed on the heat exchange pipe (3), and raised reversing protrusions (8) are provided on both end sides of the heat exchange pipe (3). The dust cleaning component (7) includes a support frame (74), three groups of brush plates (71) provided on the support frame (74), and an air bucket (73) installed on the brush plate (71), and brushes (72) are evenly provided on both sides of the brush plate (71); 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).

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 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 bucket (73) is connected to the brush plate (71) through a rotating shaft (75) at the front end, and the wind bucket (73) is rotatable on the brush plate (71). At the same time, a positioning component (76) is provided on the rotating shaft (75). The positioning component (76) is composed of a spring and balls at both ends, and the balls at the front end of the positioning component (76) are clamped in the groove of the brush plate (71) for positioning.

4. A method for preparing a corrosion-resistant and wear-resistant economizer according to any one of claims 1 to 3, 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, and rust removal, to ensure that the material surface is clean; Step 2: Component production and assembly; The pretreated metal material is used to make a water inlet pipe (1), a water outlet pipe (2) and a heat exchange pipe (3), the water inlet pipe (1) is connected to the water outlet pipe (2) through the heat exchange pipe (3), a water inlet valve (4) is installed on the water inlet pipe (1), and a water outlet valve (5) and a pressure relief valve (6) are installed at both ends of the water outlet pipe (2); A C-shaped metal structure with corrosion resistance and wear resistance is used to make a support frame (74), and the metal material used to make the support frame (74) is cut, bent, and processed. Four groups of balls (741) are evenly arranged inside the support frame (74), and the balls (741) are made of wear-resistant material. Three groups of brush plates (71) are evenly arranged on the support frame (74), and the brush plates (71) are made of corrosion-resistant material. 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. The wind bucket (73) is connected to the brush plate (71) through the front end rotating shaft (75). The wind bucket (73) is made of corrosion-resistant and wear-resistant materials. A positioning component (76) is set on the rotating shaft (75). The positioning component (76) is composed of a spring with 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 dust cleaning component (7) is installed on the heat exchange tube (3) so that the dust 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), and the reversing bumps (8) are made of wear-resistant material; The assembled economizer is debugged to check whether the connections of the various components are tight and whether the ash cleaning assembly (7) rotates smoothly. Under the blowing of exhaust gas, observe whether the ash cleaning assembly (7) can rotate along the heat exchange tube (3). When the ash cleaning assembly (7) rotates to one end of the heat exchange tube (3) and contacts the reversing protrusion (8), check whether the air scoop (73) provided on the ash cleaning assembly (7) can rotate 180 degrees and whether the ash cleaning assembly (7) can rotate in the opposite direction on the heat exchange tube (3).

5. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 4, characterized in that: In the material preparation stage, for pre-treatment operations, ultrasonic cleaning technology is used to clean metal materials to more thoroughly remove surface oil and impurities; During the degreasing process, metal degreasing agents can be used. When removing rust, a combination of chemical and mechanical rust removal methods is used. First, use an acidic rust remover to remove rust, and then use sandpaper 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 (74) 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 to 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), a high-precision positioning instrument is used to ensure its accurate position; During the debugging process, a thermal imager is used 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.

6. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 4, characterized in that: During the material preparation stage, after selecting the metal material, a microstructural analysis is performed on it, and its crystal structure and defects are observed using an electron microscope. If defects are present, they can be repaired through 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 composite material structure, including 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) can 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) can 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 component (7) and the operating parameters of the economizer, and problems are discovered and optimized in a timely manner through data analysis.

7. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 4, characterized in that: During the material preparation stage, recyclable metal materials are selected; 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 micro-arc oxidized to form a ceramic film to improve its corrosion resistance. During the component manufacturing and assembly process, the water inlet pipe (1), the water outlet pipe (2) and the heat exchange pipe (3) can be designed with a double-layer structure, with the inner layer being a corrosion-resistant metal layer and the outer layer being a wear-resistant coating; when manufacturing the support frame (74), 3D printing technology is used 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 scoop (73) can be designed with an asymmetric shape according to the exhaust gas flow direction to improve its rotation efficiency; During the overall assembly and commissioning phase, a magnetic installation method is used when installing the dust cleaning component (7), which is convenient, quick and accurate in positioning. During the commissioning process, virtual reality technology is used to simulate the operating environment of the economizer to evaluate and optimize its performance, while monitoring the operating status of each component to promptly identify and handle problems.

8. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 4, 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 inject ions into the surface of the material to change its surface chemical composition and physical properties, thereby improving its corrosion resistance and wear resistance. At the same time, high-temperature aging tests are performed on the material to examine its performance stability in high-temperature environments. During the component manufacturing and assembly process, the support frame (74) can adopt a multi-layer nested structure, each layer having different functions, the outermost layer being a wear-resistant layer, the middle layer being a support layer, and the innermost layer being a corrosion-resistant layer; the ball (741) can adopt a high-precision ceramic ball with a dimensional accuracy within ±0.05 mm, thereby improving its rotation flexibility and wear resistance; the brush plate (71) can be made of a high-temperature wear-resistant material; During the overall assembly and commissioning phase, when the ash 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 ash cleaning effect of the ash cleaning component (7) is monitored, and timely adjustments and optimizations are made.

9. The method for preparing a corrosion-resistant and wear-resistant economizer according to claim 4, characterized in that: During the material preparation stage, when selecting metal materials, consider their chemical compatibility with the surrounding environment; select metal materials that are not likely to react with chemical substances in the environment; 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; During the component manufacturing and assembly process, the support frame (74) can be designed with an intelligent structure, and the ball (741) can be made of a material with a self-lubricating function to reduce friction; The brush plate (71) can be made of a material with antibacterial function to prevent microorganisms from growing on its surface; the wind scoop (73) can be made of a material with 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 phase, when the dust 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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