Wear-resistant, anti-blocking and anti-leakage low-low-temperature coal economizer system

Abstract

The invention discloses a wear-resistant, anti-blocking and anti-leakage low-low-temperature economizer system which comprises a processor, and a heat exchange tube wear-resistant monitoring module, a dust monitoring module and a heat exchange tube leakage monitoring module which are connected with the processor, a heat exchange tube wear-resistant monitoring module monitors the wall thickness change of a heat exchange tube in real time, and when the real-time wall thickness is lower than a set threshold value, an alarm mechanism is automatically triggered, and an electric signal is sent to a processor; the dust monitoring module monitors the dust deposition condition of the heat exchange pipe wall in real time, and the working state of the soot blower is adjusted according to the dust deposition condition. By monitoring the wall thickness change, the wall dust deposition condition and the leakage condition of the heat exchange tube in real time, the wear resistance degree of the low-low-temperature economizer heat exchange tube can be improved, the leakage condition can be found in time, an alarm can be given, a leakage point can be positioned, the leakage point can be automatically isolated, liquid leakage is prevented, and the service life of the low-low-temperature economizer is prolonged. And the problems of low heat exchange efficiency, high energy consumption and flue blockage caused by excessive accumulated dust are prevented.

Description

Technical Field

[0001] The present application relates to the technical field of economizers, and in particular to a low-temperature economizer system. Background Art

[0002] Low-temperature economizer, also known as low-temperature economizer or flue gas cooler, is a device used in boiler systems to recover flue gas waste heat and heat boiler feed water. Low-temperature economizer is usually installed in the medium and low temperature section of the boiler tail flue. It heats the boiler feed water or condensate by recovering the waste heat in the flue gas. In this process, the heat in the flue gas is transferred to the feed water, which increases the feed water temperature and reduces the flue gas temperature. It can improve the thermal efficiency of the boiler and reduce flue gas heat loss. It is not only suitable for coal-fired power plants, but also widely used in chemical, steel and other industries.

[0003] A low-temperature economizer is disclosed in the prior art, which includes: a main body, a heat exchange component and an ash shielding component. The main body has a smoke inlet and a smoke outlet. The heat exchange component and the ash shielding component are arranged in an inner cavity of the main body. The heat exchange component is used for exchanging heat with the flue gas. Along the flow direction of the flue gas in the inner cavity, the ash shielding component is located upstream of the heat exchange component, and is used for preliminarily intercepting dust in the flue gas that enters the inner cavity and does not pass through the heat exchange component.

[0004] Although the low-temperature economizer in the above-mentioned prior art can improve the heat exchange effect, it is difficult to supervise the wear resistance, ash accumulation and leakage of the heat exchange tubes. As the use time goes by, the heat exchange tubes may show different degrees of wear. When the wear reaches a certain extent, it may cause the heat exchange tubes to leak, and it is also difficult to monitor the ash accumulation on the outer wall of the heat exchange tube. Ash accumulation will reduce the heat exchange efficiency and thus increase energy consumption. Excessive ash accumulation may also cause flue blockage and affect the normal operation of the boiler. Summary of the invention

[0005] To this end, the present application provides a wear-resistant, anti-blocking and anti-leakage low-temperature economizer system to solve the problem in the prior art that it is difficult to monitor the wear resistance, ash accumulation and leakage of the heat exchange tubes of the low-temperature economizer.

[0006] In order to achieve the above objectives, this application provides the following technical solutions:

[0007] A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system, comprising a processor, and a heat exchange tube wear-resistant monitoring module, a dust monitoring module and a heat exchange tube leakage monitoring module connected to the processor;

[0008] The heat exchange tube wear-resistance monitoring module monitors the change of the heat exchange tube wall thickness in real time. When the real-time wall thickness is lower than the set threshold, the alarm mechanism is automatically triggered and an electrical signal is sent to the processor.

[0009] The wear resistance of the heat exchange tube can also be significantly improved by selecting materials with high hardness and good wear resistance, such as ceramic oxide, silicon carbide and other composite materials to make the heat exchange tube, and the wear resistance of the heat exchange tube can be further improved by special treatment of the surface of the heat exchange tube, such as spraying wear-resistant coating, carburizing, nitriding, etc.

[0010] The dust monitoring module monitors the dust accumulation on the heat exchange tube wall in real time and adjusts the working state of the soot blower according to the dust accumulation;

[0011] The heat exchange tube leakage monitoring module monitors the leakage of the heat exchange tube in real time. When a leak is detected, an alarm is issued, the leak point is located, and the leak point is isolated to ensure the safe operation of the system.

[0012] Optionally, the heat exchange tube wear monitoring module includes

[0013] Data acquisition unit: deployed in the wear-prone part of the heat exchange tube to monitor the wall thickness change of the heat exchange tube in real time;

[0014] Data processing and analysis unit: Receives monitoring data from the data acquisition unit, and pre-processes, cleans and analyzes the data, extracts features related to the wear resistance of the heat exchange tube, such as wall thickness change rate, temperature distribution change, fluid flow rate, etc., to evaluate the wear resistance of the heat exchange tube, calculates the current wear resistance through the software embedded algorithm, uses historical data to train the selected algorithm to establish a wear resistance prediction model, and then optimizes the model. Finally, the real-time collected data is input into the trained model to calculate the current wear resistance value and compare it with the set threshold value;

[0015] Alarm and response unit: When the wear resistance is lower than the set threshold, the alarm is automatically triggered to remind the staff. At the same time, it provides alarm recording and report generation functions to facilitate subsequent analysis and processing by the staff. The staff responds quickly to inspect and repair the heat exchange tubes to avoid further wear and damage.

[0016] Optionally, the data acquisition unit uses an ultrasonic sensor or a laser ranging sensor, preferably an ultrasonic sensor, which is installed on the outer wall of the heat exchange tube. The ultrasonic pulses emitted by the ultrasonic sensor will pass through the wall of the heat exchange tube and measure the tube wall.

[0017] Optionally, the heat exchange tube wear monitoring module also includes a three-dimensional modeling unit, through which an accurate three-dimensional model is established for the heat exchange tube of the low-temperature economizer as a basis for subsequent wear calculation and monitoring.

[0018] Optionally, the dust monitoring module includes

[0019] Dust accumulation monitoring unit: The dust accumulation sensor is installed on the outer wall of the heat exchange tube to monitor the dust accumulation on the outside of the heat exchange tube in real time. The dust accumulation can be monitored based on optical principle, capacitance principle or weight sensing principle.

[0020] Intelligent sootblowing unit: According to the data from the soot accumulation monitoring unit, the working status of the sootblower is intelligently adjusted to determine whether the sootblower needs to be started, and the working frequency and intensity of the sootblower are adjusted;

[0021] The risk of ash accumulation can also be reduced by improving the flue structure and installing guide devices to guide the flue gas flow, reducing eddy currents and scouring effects.

[0022] Optionally, the heat exchange tube leakage monitoring module includes

[0023] Leakage monitoring unit: determines whether there is leakage by real-time monitoring of pressure and flow changes in the heat exchange tube;

[0024] Leakage warning and positioning unit: When the leakage monitoring unit determines that there is a leak, the leakage warning and positioning unit will sound an alarm and determine the location of the leak through the positioning algorithm;

[0025] Leakage processing unit: When the leakage warning and positioning unit sounds an alarm and locates the leakage point, the leakage processing unit automatically isolates the leakage point and transmits the isolation signal to the processor.

[0026] Optionally, the leakage monitoring unit includes a pressure sensor and a flow sensor, which are respectively installed inside the heat exchange tube, and determines whether there is a leakage by real-time monitoring of the pressure and flow in the pipeline.

[0027] Optionally, the leakage warning and positioning unit uses a negative pressure wave positioning method to locate the leakage point. The specific formula is as follows:

[0028] x=(L+aΔt) / 2

[0029] Among them, x is the distance between the leakage point and the pressure measuring point of the upstream station, L is the distance between the upstream and downstream monitoring workstations, a is the propagation speed of the negative pressure wave, and Δt is the time difference between the pressure mutation time of the upstream station and the pressure mutation time of the downstream station.

[0030] Optionally, the leakage processing unit includes an isolation valve installed on the heat exchange tube, and the number of the isolation valves is multiple and evenly distributed along the length direction of the heat exchange tube;

[0031] When the leakage warning and positioning unit sounds an alarm and determines the leakage point, the execution instruction is sent to the isolation valve upstream of the leakage point through the heat exchange tube leakage monitoring module. After the isolation valve receives the instruction, its actuator will start quickly and push the valve to close. When the isolation valve is closed, the leakage monitoring unit automatically detects the fluid pressure or flow change at the leakage point to confirm whether the leakage point has been successfully isolated. If the isolation is successful, the staff will be notified to carry out maintenance. If the isolation fails, the nearest isolation valve upstream of the leakage point will be closed and the operation can be repeated.

[0032] Compared with the prior art, this application has at least the following beneficial effects:

[0033] (1) By monitoring the wall thickness changes of the heat exchange tubes in real time, the wear degree of the heat exchange tubes can be controlled in real time. When the real-time wall thickness of the heat exchange tubes is lower than the preset threshold, an alarm is triggered and sent to the system background through the processor, so that the staff can inspect and replace the heat exchange tubes in time, thereby improving the wear resistance of the low-temperature economizer heat exchange tubes;

[0034] (ii) By real-time monitoring of the ash accumulation on the heat exchange tube wall, the blowing frequency, blowing intensity, blowing time and other parameters of the soot blower can be adjusted according to the real-time ash accumulation data to remove the ash accumulation on the outer wall of the heat exchange tube, prevent the problems of low heat exchange efficiency, high energy consumption and blockage of the flue caused by excessive ash accumulation, thereby ensuring the normal operation of the boiler;

[0035] (III) By real-time monitoring of the leakage of the heat exchange tube, the leakage can be discovered in time, an alarm can be sounded and the leakage point can be located, so that the leakage point can be automatically isolated to prevent liquid leakage, thereby ensuring the normal operation of the low-temperature economizer, and also facilitating the staff to inspect and repair the leakage point. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more intuitively illustrate the prior art and the present application, exemplary drawings are given below. It should be understood that the specific shapes and structures shown in the drawings should not generally be regarded as limiting conditions for implementing the present application; for example, those skilled in the art are capable of easily making conventional adjustments or further optimizations to the addition / reduction / attribution division, specific shapes, positional relationships, connection methods, dimensional ratios, etc. of certain units (components) based on the technical concepts and exemplary drawings disclosed in the present application.

[0037] Figure 1 This is a principle block diagram of a wear-resistant, anti-blocking and anti-leakage low-temperature economizer system provided in this application. DETAILED DESCRIPTION

[0038] The present application is further described below in detail through specific embodiments in conjunction with the accompanying drawings.

[0039] like Figure 1 As shown, a wear-resistant, anti-blocking, and anti-leakage low-temperature economizer system includes a processor, and a heat exchange tube wear-resistant monitoring module, a dust monitoring module, and a heat exchange tube leakage monitoring module connected to the processor;

[0040] The heat exchange tube wear monitoring module monitors the change of the heat exchange tube wall thickness in real time. When the real-time wall thickness is lower than the set threshold, the alarm mechanism is automatically triggered and an electrical signal is sent to the processor. The processor encapsulates the electrical signal data into a data packet and transmits it to the system background. Finally, it is converted into an optical signal and displayed on the display. It can be displayed in the form of pictures, data or various parameter tables.

[0041] By monitoring the wall thickness changes of the heat exchange tubes in real time, the wear degree of the heat exchange tubes can be controlled in real time. When the real-time wall thickness of the heat exchange tubes is lower than the preset threshold, an alarm is triggered and sent to the system background through the processor, so that the staff can inspect and replace the heat exchange tubes in time, thereby improving the wear resistance of the low-temperature economizer heat exchange tubes;

[0042] The following dust accumulation and leakage conditions can be displayed on the monitor through the system background;

[0043] The dust monitoring module monitors the dust accumulation on the heat exchange tube wall in real time and adjusts the working state of the soot blower according to the dust accumulation;

[0044] Through real-time monitoring of the soot accumulation on the heat exchange tube wall, the soot blower's blowing frequency, blowing intensity, blowing time and other parameters can be adjusted according to the real-time soot accumulation data to remove the soot accumulation on the outer wall of the heat exchange tube, and prevent the problems of low heat exchange efficiency, high energy consumption and flue blockage caused by excessive soot accumulation, thereby ensuring the normal operation of the boiler;

[0045] The heat exchange tube leakage monitoring module monitors the leakage of the heat exchange tube in real time. When a leak is detected, an alarm is issued and the leak point is located and isolated to ensure the safe operation of the system.

[0046] By monitoring the leakage of the heat exchange tube in real time, the leakage can be discovered in time, an alarm can be issued and the leakage point can be located, so that the leakage point can be automatically isolated to prevent liquid leakage, thereby ensuring the normal operation of the low-temperature economizer, and also making it convenient for staff to inspect and repair the leakage point.

[0047] Optionally, the heat exchange tube wear monitoring module includes

[0048] Data acquisition unit: deployed in the wear-prone part of the heat exchange tube to monitor the wall thickness change of the heat exchange tube in real time;

[0049] Data processing and analysis unit: Receives monitoring data from the data acquisition unit, and pre-processes, cleans and analyzes the data, extracts features related to the wear resistance of the heat exchange tube, such as wall thickness change rate, temperature distribution change, fluid flow rate, etc., to evaluate the wear resistance of the heat exchange tube. The software embedded algorithm can calculate the current wear resistance. Common algorithms include machine learning algorithms (such as support vector machines, neural networks, decision trees, etc.) and statistical methods (such as regression analysis, variance analysis, etc.). Use historical data to train the selected algorithm to establish a wear resistance prediction model, and then optimize the model (through cross-validation, grid search, etc.). Finally, input the real-time collected data into the trained model to calculate the current wear resistance value and compare it with the set threshold value;

[0050] Alarm and response unit: When the wear resistance is lower than the set threshold, the alarm is automatically triggered through various means such as sound, light and electricity to remind the staff. At the same time, it provides alarm recording and report generation functions to facilitate subsequent analysis and processing by the staff. The staff responds quickly to inspect and repair the heat exchange tubes to avoid further wear and damage.

[0051] Optionally, the data acquisition unit uses an ultrasonic sensor or a laser ranging sensor, preferably an ultrasonic sensor. The ultrasonic sensor is installed on the outer wall of the heat exchange tube. The ultrasonic pulses emitted by the ultrasonic sensor will pass through the wall of the heat exchange tube and measure the wall of the tube. Although it may be affected by factors such as the material, thickness, and coating of the tube wall, when installed externally, it only takes the selection of appropriate measurement methods and calibration techniques to ensure the accuracy and reliability of the measurement results.

[0052] Optionally, the heat exchange tube wear monitoring module further includes a three-dimensional modeling unit, through which an accurate three-dimensional model is established for the heat exchange tube of the low-temperature economizer as a basis for subsequent wear calculation and monitoring. The three-dimensional model establishment steps are as follows:

[0053] (1) Input basic information of the heat exchange tube, such as size, shape, and material properties;

[0054] (2) Create a three-dimensional model of the heat exchange tube using selected modeling technology (such as CAD);

[0055] The three-dimensional model can be used to simulate the wear of the heat exchange tube under different working conditions. Through the simulation results, the wear resistance of the heat exchange tube can be calculated and its service life can be predicted. By combining the real-time wall thickness monitoring data with the three-dimensional model, the wear of the heat exchange tube can be discovered in time by analyzing these data, and corresponding maintenance measures can be taken.

[0056] Optionally, the dust monitoring module includes a dust accumulation monitoring unit and an intelligent soot blowing unit;

[0057] The dust accumulation monitoring unit uses a dust accumulation sensor, and the dust accumulation sensor is installed on the outer wall of the heat exchange tube. The dust accumulation sensor monitors the dust accumulation on the outside of the heat exchange tube based on optical principles, capacitance principles or weight sensing principles;

[0058] The optical dust accumulation sensor detects dust accumulation by emitting a light beam and receiving the reflected light. When the dust accumulation increases, the intensity of the reflected light changes, and the sensor determines the severity of the dust accumulation based on this change.

[0059] The capacitive dust accumulation sensor detects dust accumulation by measuring the capacitance change caused by dust accumulation. When dust accumulates on the sensor surface, the capacitance value changes, and the sensor determines the dust accumulation situation accordingly.

[0060] The weight-sensing dust accumulation sensor assesses the degree of dust accumulation by detecting the weight change caused by dust accumulation;

[0061] The intelligent sootblowing unit intelligently adjusts the working status of the sootblower according to the data of the soot accumulation monitoring unit, determines whether the sootblower needs to be started, and adjusts the working frequency and intensity of the sootblower;

[0062] The risk of ash accumulation can also be reduced by improving the flue structure and installing guide devices to guide the flue gas flow, reducing eddy currents and scouring effects.

[0063] Optionally, the heat exchange tube leakage monitoring module includes a leakage monitoring unit, a leakage warning and positioning unit, and a leakage processing unit;

[0064] The leakage monitoring unit monitors the pressure and flow changes in the heat exchange tube in real time to determine whether there is a leak. When the leakage monitoring unit determines that there is a leak, the leakage warning and positioning unit issues an alarm and determines the location of the leak through a positioning algorithm. After the leakage warning and positioning unit issues an alarm and locates the leak, the leakage processing unit automatically isolates the leak and transmits an isolation signal to the processor, which controls the actuator for isolation. The actuator is preferably an isolation valve.

[0065] Optionally, the leakage monitoring unit includes a pressure sensor and a flow sensor, which are respectively installed inside the heat exchange tube, and determines whether there is a leakage by real-time monitoring of the pressure and flow in the pipeline.

[0066] Optionally, the leakage warning and positioning unit uses a negative pressure wave positioning method to locate the leakage point. The specific formula is as follows:

[0067] x=(L+aΔt) / 2

[0068] Among them, x is the distance between the leakage point and the pressure measuring point of the upstream station, L is the distance between the upstream and downstream monitoring workstations, a is the propagation speed of the negative pressure wave, and Δt is the time difference between the pressure mutation time of the upstream station and the pressure mutation time of the downstream station.

[0069] Optionally, the leakage processing unit includes an isolation valve installed on the heat exchange tube. The number of the isolation valves is multiple and evenly distributed along the length direction of the heat exchange tube, so as to achieve multi-point isolation and facilitate subsequent inspection and maintenance operations;

[0070] When the leakage warning and positioning unit sounds an alarm and determines the leakage point, the execution instruction is sent to the isolation valve upstream of the leakage point through the heat exchange tube leakage monitoring module. After the isolation valve receives the instruction, its actuator will start quickly and push the valve to close. When the isolation valve is closed, the leakage monitoring unit automatically detects the fluid pressure or flow change at the leakage point to confirm whether the leakage point has been successfully isolated. If the isolation is successful, the staff will be notified to carry out maintenance. If the isolation fails, the nearest isolation valve upstream of the leakage point will be closed and the operation can be repeated.

[0071] The technical features of the above embodiments may be arbitrarily combined (as long as there is no contradiction in the combination of these technical features). To make the description concise, not all possible combinations of the technical features in the above embodiments are described; these embodiments that are not explicitly written should also be considered to be within the scope of this specification.

Claims

1. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system, comprising a processor, characterized in that: Also included is a processor connected Heat exchange tube wear monitoring module, used to monitor the change of heat exchange tube wall thickness in real time. When the real-time wall thickness is lower than the set threshold, the alarm mechanism is automatically triggered; The dust monitoring module is used to monitor the dust accumulation on the heat exchange tube wall in real time and adjust the working state of the soot blower according to the dust accumulation; The heat exchange tube leakage monitoring module is used to monitor the leakage of the heat exchange tube in real time. When a leak is detected, an alarm is issued and the leak point is located and isolated to ensure the safe operation of the system.

2. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system according to claim 1, characterized in that: Heat exchange tube wear monitoring module includes Data acquisition unit: deployed in the wear-prone part of the heat exchange tube to monitor the wall thickness change of the heat exchange tube in real time; Data processing and analysis unit: receives monitoring data from the data acquisition unit, pre-processes, cleans and analyzes the data, extracts features related to the wear resistance of the heat exchange tube, evaluates and calculates the wear resistance of the heat exchange tube, and compares the real-time wear resistance with the set threshold value; Alarm and response unit: When the wear resistance falls below the set threshold, an alarm is automatically triggered to alert staff, while also providing alarm recording and report generation functions.

3. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system according to claim 2, characterized in that: The data acquisition unit uses an ultrasonic sensor or a laser ranging sensor.

4. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system according to claim 2, characterized in that: The heat exchange tube wear monitoring module also includes a three-dimensional modeling unit, through which an accurate three-dimensional model is established for the heat exchange tube of the low-temperature economizer as the basis for subsequent wear calculation and monitoring.

5. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system according to claim 1, characterized in that: Dust monitoring module includes Dust accumulation monitoring unit: uses dust accumulation sensor and is installed on the outer wall of the heat exchange tube to monitor the dust accumulation on the outside of the heat exchange tube in real time; Intelligent sootblowing unit: According to the data from the soot accumulation monitoring unit, it intelligently adjusts the working status of the sootblower, determines whether the sootblower needs to be started, and adjusts the working frequency and intensity of the sootblower.

6. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system according to claim 1, characterized in that: Heat exchange tube leakage monitoring module includes Leakage monitoring unit: determines whether there is leakage by real-time monitoring of pressure and flow changes in the heat exchange tube; Leakage warning and positioning unit: When the leakage monitoring unit determines that there is a leak, the leakage warning and positioning unit will sound an alarm and determine the location of the leak through the positioning algorithm; Leakage processing unit: When the leakage warning and positioning unit sounds an alarm and locates the leakage point, the leakage processing unit will automatically isolate the leakage point.

7. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system according to claim 6, characterized in that: The leakage monitoring unit includes a pressure sensor and a flow sensor, which are respectively installed inside the heat exchange tube. The pressure sensor and the flow sensor are used to determine whether there is a leakage by real-time monitoring of the pressure and flow in the pipeline.

8. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system according to claim 6, characterized in that: The leakage warning and positioning unit uses the negative pressure wave positioning method to locate the leakage point. The specific formula is as follows: x=(L+aΔt) / 2 Among them, x is the distance between the leakage point and the pressure measuring point of the upstream station, L is the distance between the upstream and downstream monitoring workstations, a is the propagation speed of the negative pressure wave, and Δt is the time difference between the pressure mutation time of the upstream station and the pressure mutation time of the downstream station.

9. A wear-resistant, anti-blocking and anti-leakage low-temperature economizer system according to claim 6, characterized in that: The leakage handling unit includes an isolation valve installed on the heat exchange tube, and the number of the isolation valves is multiple and evenly distributed along the length direction of the heat exchange tube; When the leakage warning and positioning unit sounds an alarm and determines the leakage point, the execution instruction is sent to the isolation valve upstream of the leakage point through the heat exchange tube leakage monitoring module. After the isolation valve receives the instruction, its actuator will start quickly and push the valve to close. When the isolation valve is closed, the leakage monitoring unit automatically detects the fluid pressure or flow change at the leakage point to confirm whether the leakage point has been successfully isolated.

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