System for predicting boiler reheater oxide skin generation based on oxidation-reduction potential method

Abstract

The invention discloses a system for predicting boiler reheater oxide skin generation based on an oxidation-reduction potential method.The system comprises an oxidation-reduction potential measuring unit and a data analysis unit, the oxidation-reduction potential measuring unit comprises at least one oxidation-reduction potential sensor, the oxidation-reduction potential sensor is installed on a boiler reheater, and the data analysis unit is connected with the oxidation-reduction potential sensor; the data analysis unit is used for detecting an oxidation-reduction potential value of a working medium in a boiler reheater and comprises an oxide skin generation prediction model; and the data analysis unit is used for receiving the oxidation-reduction potential value measured by the oxidation-reduction potential measurement unit and predicting the generation probability and the generation time of the oxide skin according to the oxide skin generation prediction model and the oxidation-reduction potential value. According to the system for predicting generation of the oxide skin of the boiler reheater based on the oxidation-reduction potential method, early prediction of the generation probability and generation time of the oxide skin in the boiler reheater can be achieved, and therefore the operation safety and reliability of the boiler reheater can be improved.

Description

Technical Field

[0001] The present invention relates to the field of boilers, and particularly to a system for predicting the formation of oxide scale on the reheater of a boiler based on the redox potential method. Background Art

[0002] The boiler reheater is a key component in the boiler system for increasing the steam temperature. Its long-term operation is easily affected by factors such as water quality, temperature, and pressure, resulting in oxidation on the surface of the reheater pipes, which will affect the operation efficiency and safety of the boiler. However, the boiler reheater is in a high-temperature, high-pressure, and complex chemical environment for a long time, and the metal material is extremely prone to oxidation reaction. The continuous formation and accumulation of oxide scale will seriously affect the heat transfer efficiency of the reheater. For example, the oxide scale will form a heat insulation layer on the pipe wall surface, preventing heat from being effectively transferred, causing the local temperature of the reheater to rise, and then affecting the thermal performance and operation stability of the entire boiler system. Moreover, the peeling of the oxide scale may also cause problems such as pipe blockage and wear, seriously threatening the safe operation of the boiler, increasing the maintenance cost and downtime.

[0003] There are many deficiencies in the current control means for the oxidation problem of the boiler reheater. The traditional methods mainly rely on regular manual inspections and maintenance, such as visual inspections of the appearance of the boiler reheater and wall thickness measurements. This method can only detect problems after the oxide scale has formed to a certain extent and cannot achieve early prediction. In addition, some prediction methods based on theoretical calculation models are difficult to provide a reliable basis for timely and effective adjustment of preventive measures because they do not take into account the complex and variable operating conditions in actual operation, such as temperature fluctuations and medium composition fluctuations. Therefore, it needs to be solved. Summary of the Invention

[0004] The present invention aims to solve at least one of the technical problems existing in the prior art. For this reason, an object of the present invention is to provide a system for predicting the formation of oxide scale on the reheater of a boiler based on the redox potential method. By providing a redox potential measurement unit to detect the redox potential value of the working medium in the boiler reheater, and through a data analysis unit to predict the formation probability and formation time of the oxide scale according to the oxide scale formation prediction model and the redox potential value, the formation probability and formation time of the oxide scale can be predicted more accurately. In this way, early prediction of the formation probability and formation time of the oxide scale in the boiler reheater can be achieved, and then a reliable basis can be provided for timely and effective adjustment of preventive measures to effectively inhibit the formation of the oxide scale, thereby being beneficial to improving the operation safety and reliability of the boiler reheater, reducing the maintenance cost and downtime risk caused by the oxide scale problem, and ensuring the stable and reliable operation of the boiler reheater.

[0005] A system for predicting the formation of oxide scale in a boiler reheater based on the redox potential method according to an embodiment of the present invention includes: a redox potential measurement unit, the redox potential measurement unit includes at least one redox potential sensor, and the redox potential sensor is installed in the boiler reheater to detect the redox potential value of the working medium in the boiler reheater; a data analysis unit, the redox potential measurement unit is electrically connected to the data analysis unit, the data analysis unit includes an oxide scale formation prediction model, and the data analysis unit is used to receive the redox potential value measured by the redox potential measurement unit and is used to predict the formation probability and formation time of the oxide scale according to the oxide scale formation prediction model and the redox potential value.

[0006] The system for predicting the formation of oxide scale in a boiler reheater based on the redox potential method according to an embodiment of the present invention detects the redox potential value of the working medium in the boiler reheater by providing a redox potential measurement unit, and predicts the formation probability and formation time of the oxide scale by the data analysis unit according to the oxide scale formation prediction model and the redox potential value, so that the formation probability and formation time of the oxide scale can be predicted more accurately. In this way, the early prediction of the formation probability and formation time of the oxide scale in the boiler reheater can be realized, and then a reliable basis can be provided for timely and effectively adjusting preventive measures to effectively inhibit the formation of the oxide scale, which is beneficial to improving the operation safety and reliability of the boiler reheater, reducing the maintenance cost and shutdown risk caused by the oxide scale problem, and ensuring the stable and reliable operation of the boiler reheater.

[0007] According to some embodiments of the present invention, there are multiple redox potential sensors, and at least part of the redox potential sensors are arranged at the inlet, outlet and pipe sections prone to oxidation of the boiler reheater.

[0008] According to some embodiments of the present invention, the redox potential sensor is made of a high-temperature and high-pressure resistant material, and the probe of the redox potential sensor is coated with a protective coating, and the protective coating is a coating with anti-corrosion and anti-pollution functions; wherein, the temperature resistance performance of the high-temperature and high-pressure resistant material is ≥800 °C, and the pressure resistance performance of the high-temperature and high-pressure resistant material is ≥35 Mpa; the corrosion rate of the protective coating is lower than 0.01 mm / year in a standard corrosion environment.

[0009] According to some embodiments of the present invention, the acquisition frequency of the redox potential sensor is 1 to 10 times / min; wherein, the acquisition frequency of the redox potential sensor is configured such that when the load change rate of the boiler reheater exceeds 10% or the temperature change rate of the boiler reheater exceeds 5 °C / min, the acquisition frequency of the redox potential sensor is adjusted to 8 times / min.

[0010] According to some embodiments of the present invention, it further includes: a parameter acquisition unit, which is electrically connected to the data analysis unit, and the parameter acquisition unit is used to detect the operating parameters of the boiler reheater; wherein, the parameter acquisition unit includes: a temperature sensor, a pressure sensor, and a flow sensor, the temperature sensor is used to detect the temperature inside the boiler reheater, the pressure sensor is used to detect the pressure inside the boiler reheater, and the flow sensor is used to detect the flow rate inside the boiler reheater.

[0011] According to some embodiments of the present invention, the oxide scale formation prediction model is used to predict the oxide scale thickness according to the oxidation kinetics model, time, and the operating parameters of the boiler reheater measured by the parameter acquisition unit, and the oxide scale thickness formula is: Δx = k·t n , where Δx is the oxide scale thickness, k is the rate constant, n is the reaction order of the oxidation-reduction reaction, and t is the time.

[0012] According to some embodiments of the present invention, the preset measurement errors of the temperature sensor, the pressure sensor, and the flow sensor are ±0.5%; when the measurement errors of the temperature sensor, the pressure sensor, and the flow sensor exceed the preset measurement errors, the data analysis unit reports a fault.

[0013] According to some embodiments of the present invention, the parameter acquisition unit further includes: a concentration sensor, which is electrically connected to the data analysis unit and is used to detect the change in the concentration of the working medium component inside the boiler reheater.

[0014] According to some embodiments of the present invention, it further includes: an early warning and display unit, which is communicatively connected to the oxidation-reduction potential measurement unit and the data analysis unit. The early warning and display unit determines whether the probability of oxide scale formation inside the boiler reheater exceeds a preset threshold according to the data predicted by the data analysis unit, so as to issue an early warning message when the probability of oxide scale formation exceeds the preset threshold, and is used to display the oxidation-reduction potential value detected by the oxidation-reduction potential measurement unit and the data predicted by the data analysis unit.

[0015] According to some embodiments of the present invention, the warning information includes: acoustic and optical warning, and the acoustic and optical warning includes at least one of volume, frequency, and light color; the volume includes a low-level volume and a high-level volume, the frequency includes a low-level frequency and a high-level frequency, and the light color includes a low-level light color and a high-level light color; wherein, the low-level volume range is 60 dB to 70 dB, the high-level volume range is 80 dB to 90 dB; the low-level frequency range is 1 Hz to 2 Hz, the high-level frequency range is 3 Hz to 5 Hz; the low-level light color is yellow, and the high-level light color is red.

[0016] Additional aspects and advantages of the present invention will be given in part in the following description, will become apparent in part from the following description, or will be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The above and / or additional aspects and advantages of the present invention will become apparent and be readily understood from the description of the embodiments in conjunction with the following drawings, in which:

[0018] Figure 1 is a schematic diagram of a system for predicting the formation of oxide scale on the boiler reheater based on the redox potential method according to some embodiments of the present invention.

[0019] REFERENCE SIGNS:

[0020] 100, system;

[0021] 10, redox potential measurement unit; 20, data analysis unit; 30, parameter acquisition unit; 40, warning and display unit. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] Embodiments of the present invention will be described in detail below. Examples of the embodiments are shown in the drawings, where the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the drawings are exemplary only for explaining the present invention and should not be construed as limiting the present invention.

[0023] Reference is made below to Figure 1 describe a system 100 for predicting the formation of oxide scale on the boiler reheater based on the redox potential method according to an embodiment of the present invention.

[0024] Reference is made to Figure 1, according to the system 100 for predicting the formation of oxide scale on the boiler reheater based on the redox potential method according to an embodiment of the present invention, it includes a redox potential measurement unit 10 and a data analysis unit 20. The redox potential measurement unit 10 includes at least one redox potential sensor, and the redox potential sensor is installed on the boiler reheater to detect the redox potential value of the working medium in the boiler reheater. The redox potential measurement unit 10 is electrically connected to the data analysis unit 20. The data analysis unit 20 includes an oxide scale formation prediction model. The data analysis unit 20 is used to receive the redox potential value measured by the redox potential measurement unit 10 and to predict the formation probability and formation time of the oxide scale according to the oxide scale formation prediction model and the redox potential value.

[0025] The redox potential measurement unit 10 includes at least one redox potential sensor, and the redox potential sensor is installed on the boiler reheater to detect the redox potential value of the working medium in the boiler reheater. During the operation of the boiler reheater, the redox potential sensor continuously collects the information of the redox potential value of the working medium, and can measure the redox potential value of the working medium in the boiler reheater in real time and accurately. For example, the collection frequency can be dynamically adjusted according to the boiler operation conditions to ensure the timeliness and effectiveness of the data.

[0026] For example, relevant personnel clean and inspect the redox potential sensor of the redox potential measurement unit 10 once a month. Use special cleaning tools and reagents to remove the dirt on the surface of the redox potential sensor probe, check the sealing performance of the redox potential sensor and whether the connection part is loose, and ensure that the redox potential measurement unit 10 can accurately and timely measure the redox potential value of the working medium in the boiler reheater. And, clean and maintain the hardware equipment of the data analysis unit 20, such as checking whether the circuit board, communication interface, etc. are normal, updating the virus library and security patches of the software system 100, etc., to ensure the stable operation of the system 100.

[0027] The redox potential measurement unit 10 is electrically connected to the data analysis unit 20. The data analysis unit 20 includes an oxide scale formation prediction model. The data analysis unit 20 is used to receive the redox potential value measured by the redox potential measurement unit 10 and to predict the formation probability and formation time of the oxide scale according to the oxide scale formation prediction model and the redox potential value. After receiving the redox potential value, the data analysis unit 20 uses the oxide scale formation prediction model for real-time analysis to predict the formation probability and formation time of the oxide scale.

[0028] For example, the oxide scale formation prediction model comprehensively considers the relationships between operating parameters such as temperature, flow rate, and working medium composition in the boiler reheater and the redox potential value. By analyzing the redox potential value and other operating parameters, the probability and time of oxide scale formation are predicted, thereby realizing the early prediction of the probability and time of oxide scale formation in the boiler reheater. Furthermore, it can provide a reliable basis for timely and effective adjustment of preventive measures to effectively inhibit the formation of oxide scale, which is beneficial to improving the operating safety and reliability of the boiler reheater, reducing the maintenance cost and shutdown risk caused by oxide scale problems, and ensuring the stable and reliable operation of the boiler reheater.

[0029] For example, the data analysis unit 20 predicts the probability and time of oxide scale formation according to the oxide scale formation prediction model and the redox potential value at preset time intervals, such as once every 10 minutes. It can predict the probability and time of oxide scale formation more timely and accurately, and further provide a reliable basis for timely and effective adjustment of preventive measures to effectively inhibit the formation of oxide scale.

[0030] According to the system 100 for predicting the formation of oxide scale in a boiler reheater based on the redox potential method according to an embodiment of the present invention, the redox potential measurement unit 10 is provided to detect the redox potential value of the working medium in the boiler reheater, and the data analysis unit 20 predicts the probability and time of oxide scale formation according to the oxide scale formation prediction model and the redox potential value. It can more accurately predict the probability and time of oxide scale formation, so as to realize the early prediction of the probability and time of oxide scale formation in the boiler reheater. Furthermore, it can provide a reliable basis for timely and effective adjustment of preventive measures to effectively inhibit the formation of oxide scale, which is beneficial to improving the operating safety and reliability of the boiler reheater, reducing the maintenance cost and shutdown risk caused by oxide scale problems, and ensuring the stable and reliable operation of the boiler reheater.

[0031] Refer to Figure 1 , according to some embodiments of the present invention, there are multiple redox potential sensors, and at least some of the redox potential sensors are arranged at the inlet, outlet, and pipe sections prone to oxidation of the boiler reheater. Since the inlet, outlet, and pipe sections prone to oxidation of the boiler reheater are more likely to be oxidized to form oxide scale, by arranging at least some of the redox potential sensors at the inlet, outlet, and pipe sections prone to oxidation of the boiler reheater, effective prediction can be carried out for these parts more likely to form oxide scale. Furthermore, preventive measures for these parts can be adjusted timely and effectively to effectively inhibit the formation of oxide scale, reduce the maintenance cost and shutdown risk caused by oxide scale problems, and ensure the stable and reliable operation of the boiler reheater.

[0032] Refer to Figure 1, According to some embodiments of the present invention, the redox potential sensor is made of a high-temperature and high-pressure resistant material, and the probe of the redox potential sensor is coated with a protective coating, which is a coating with anti-corrosion and anti-pollution functions. Among them, the temperature resistance of the high-temperature and high-pressure resistant material is ≥800 °C, and the pressure resistance of the high-temperature and high-pressure resistant material is ≥35 Mpa; the corrosion rate of the protective coating is less than 0.01 mm / year in a standard corrosion environment. By coating the probe of the redox potential sensor with a coating having anti-corrosion and anti-pollution functions, it is possible to prevent the redox potential sensor from being corroded or the working medium in the boiler reheater from contaminating the redox potential sensor, resulting in the failure of the redox potential sensor.

[0033] For example, when installing the redox potential sensor, it is necessary to ensure that the probe of the redox potential sensor is completely immersed in the working medium, while avoiding direct impact from the medium flow to prevent affecting the measurement accuracy. After installation, each redox potential sensor needs to be calibrated, and calibration operations are carried out using a standard buffer solution under simulated working temperature and pressure conditions to ensure the accuracy of the redox potential sensor measurement.

[0034] For example, clean and inspect the redox potential sensor once a month. Use special cleaning tools and reagents to remove dirt and scale on the surface of the sensor probe, and check the sealing performance of the redox potential sensor and whether the connection parts are loose.

[0035] For example, the temperature resistance of the high-temperature and high-pressure resistant material can be 800 °C, 850 °C, 900 °C, 950 °C, 1000 °C, etc., and the pressure resistance of the high-temperature and high-pressure resistant material can be 35 Mpa, 40 Mpa, 45 Mpa, 50 Mpa, 55 Mpa, etc. The corrosion rate of the protective coating in a standard corrosion environment can be 0.002 mm / year, 0.005 mm / year, 0.007 mm / year, 0.009 mm / year, 0.01 mm / year, etc. By having the temperature resistance of the high-temperature and high-pressure resistant material ≥800 °C, the pressure resistance of the high-temperature and high-pressure resistant material ≥35 Mpa; and the corrosion rate of the protective coating being less than 0.01 mm / year in a standard corrosion environment, the redox potential sensor can detect the redox potential value more stably and reliably, effectively reducing or avoiding the possibility of the redox potential sensor being corroded or the working medium in the boiler reheater contaminating the redox potential sensor, resulting in the failure of the redox potential sensor.

[0036] Refer to Figure 1, according to some embodiments of the present invention, the acquisition frequency of the redox potential sensor is 1 to 10 times / min. For example, the acquisition frequency of the redox potential sensor can be 1 time / min, 3 times / min, 5 times / min, 7 times / min, 10 times / min, etc. By setting the acquisition frequency of the redox potential sensor to 1 to 10 times / min, the redox potential value of the working medium in the boiler reheater can be detected in a relatively timely manner, ensuring the timeliness and effectiveness of the data. Furthermore, it can ensure that the data analysis unit 20 can predict the generation probability and generation time of oxide scale in a relatively timely and accurate manner.

[0037] Among them, the acquisition frequency of the redox potential sensor is configured such that when the load change rate of the boiler reheater exceeds 10% or the temperature change rate of the boiler reheater exceeds 5°C / min, the acquisition frequency of the redox potential sensor is adjusted to 8 times / min. For example, the acquisition frequency of the redox potential sensor can be dynamically adjusted according to the operating conditions of the boiler reheater. When the load change rate of the boiler reheater exceeds 10% or the temperature change rate of the boiler reheater exceeds 5°C / min, it indicates that the pressure in the boiler reheater increases too fast or the temperature rises too fast. At this time, by adjusting the acquisition frequency of the redox potential sensor to 8 times / min, the redox potential value of the working medium in the boiler reheater can be detected in a relatively timely manner, ensuring the timeliness and effectiveness of the data. This can ensure that the data analysis unit 20 can predict the generation probability and generation time of oxide scale in a relatively timely and accurate manner, and further provide a reliable basis for timely and effective adjustment of preventive measures, thereby effectively inhibiting the generation of oxide scale.

[0038] Refer to Figure 1 , according to some embodiments of the present invention, it further includes a parameter acquisition unit 30. The parameter acquisition unit 30 is electrically connected to the data analysis unit 20. The parameter acquisition unit 30 is used to detect the operating parameters of the boiler reheater. Among them, the parameter acquisition unit 30 includes a temperature sensor, a pressure sensor, and a flow sensor. The temperature sensor is used to detect the temperature in the boiler reheater, the pressure sensor is used to detect the pressure in the boiler reheater, and the flow sensor is used to detect the flow rate in the boiler reheater. By using the temperature sensor to detect the temperature in the boiler reheater, the pressure sensor to detect the pressure in the boiler reheater, and the flow sensor to detect the flow rate in the boiler reheater, it is convenient for the data analysis unit 20 to combine the received redox potential value and the operating parameters measured by the parameter acquisition unit 30, such as temperature, pressure, and flow rate, etc., and use the oxide scale generation prediction model for comprehensive analysis. In this way, the generation probability and generation time of oxide scale can be predicted more accurately.

[0039] Refer to Figure 1, according to some embodiments of the present invention, the oxide scale formation prediction model is used to predict the oxide scale thickness based on the oxidation kinetics model, time, and the operating parameters of the boiler reheater measured by the parameter acquisition unit 30. The oxide scale thickness formula is Δx = k·t n , where Δx is the oxide scale thickness in micrometers (μm), k is the rate constant, n is the reaction order of the oxidation-reduction reaction, and t is the time in hours (h). By enabling the oxide scale formation prediction model to generate the oxide scale thickness formula based on the oxidation kinetics model, time, and the operating parameters of the boiler reheater, this oxide scale thickness formula comprehensively considers the relationships between various operating parameters of the boiler reheater, such as temperature, pressure, flow rate, and working medium composition, and the oxidation-reduction potential value. By analyzing the real-time oxidation-reduction potential data and the operating parameters of the boiler reheater, the oxide scale thickness can be predicted relatively quickly and accurately, thereby predicting the formation probability and formation time of the oxide scale relatively quickly and accurately.

[0040] Among them, the oxide scale formation prediction model is a machine learning-based prediction method, mainly dynamically optimizing the rate constant k and the reaction order n of the oxidation-reduction reaction by training the model with historical data. The data used for training the historical data training model covers the operating data of at least 50 different types of boiler reheaters under different operating years (1 - 20 years), different fuel types, and different water quality conditions (pH 6 - 9, hardness 50 - 500 mg / L) to ensure the generality of the oxide scale formation prediction model. For example, in a high oxidation-reduction potential environment, the k value is adjusted through the machine learning model to reflect the accelerated oxidation reaction rate.

[0041] For example, according to the actual operating conditions of the boiler reheater and long-term monitoring data, relevant personnel regularly (such as once a quarter) update the parameters of the oxide scale formation prediction model. For example, if it is found during operation that a certain new medium component has a significant impact on the formation of the oxide scale, or the operating load mode of the boiler has changed, the parameters related to these factors in the oxide scale formation prediction model are adjusted accordingly; and during the update process, a data verification mechanism is adopted to verify the effectiveness of the new parameters to ensure that the performance of the updated model is not lower than that before the update. At the same time, the parameter update history is recorded to facilitate tracing and analyzing the reasons for changes in the model performance. The parameter update history record is saved for no less than 5 years.

[0042] For another example, it can also be to optimize key parameters such as the relationship parameters between the oxidation-reduction potential value, the formation probability of the oxide scale, and the formation time according to new experimental data or the latest research results in the industry. After updating the parameters, a simulation test is carried out on the system 100 to ensure that the system 100 can operate normally under the new parameters and can more effectively predict the formation probability and formation time of the oxide scale.

[0043] Refer toFigure 1 , according to some embodiments of the present invention, the preset measurement errors of the temperature sensor, the pressure sensor, and the flow sensor are ±0.5%. When the measurement errors of the temperature sensor, the pressure sensor, and the flow sensor exceed the preset measurement errors, the data analysis unit 20 reports a fault.

[0044] Since the temperature sensor, the pressure sensor, and the flow sensor are all high-precision sensors, for example, when the system 100 detects that the measurement error of the temperature sensor or the pressure sensor or the flow sensor exceeds the preset measurement error, the temperature sensor or the pressure sensor or the flow sensor can automatically send a fault signal and transmit it to the data analysis unit 20; it can also be that the temperature sensor, the pressure sensor, and the flow sensor have a self-diagnosis function and can monitor their own working states in real time. When it detects that its own measurement error exceeds the preset measurement error, the temperature sensor or the pressure sensor or the flow sensor can automatically send a fault signal and transmit it to the data analysis unit 20.

[0045] For another example, when there is a hardware fault in the temperature sensor or the pressure sensor or the flow sensor, the temperature sensor or the pressure sensor or the flow sensor can automatically send a fault signal and transmit it to the data analysis unit 20.

[0046] In some embodiments, relevant personnel regularly inspect and calibrate the temperature sensor, the pressure sensor, and the flow sensor, etc., to ensure that the measurement accuracies of the temperature sensor, the pressure sensor, and the flow sensor are within the specified range. The calibration process uses an automatic calibration device, which can quickly complete the calibration operation according to a preset program, improve the maintenance efficiency, and the calibration time does not exceed 30 minutes / sensor.

[0047] Refer to Figure 1 , according to some embodiments of the present invention, the parameter acquisition unit 30 further includes a concentration sensor, which is electrically connected to the data analysis unit 20 and is used to detect the change in the concentration of the working medium component in the boiler reheater. The concentration sensor can detect the change in the concentration of the working medium component in the boiler reheater in real time, and transmit the measured data to the data analysis unit 20, providing more comprehensive information for predicting the probability and time of oxide scale formation.

[0048] For example, the concentration sensor can detect the change in the concentration of oxygen content, pH value, etc. in the boiler reheater in real time. The preset range of the oxygen content is 0-20%, and the preset range of the pH value is 4-10. When the oxygen content or the pH value exceeds the corresponding preset range, the concentration sensor can promptly transmit the information to the data analysis unit 20.

[0049] Refer to Figure 1, according to some embodiments of the present invention, it further includes an early warning and display unit 40. The early warning and display unit 40 is communicatively connected to the redox potential measurement unit 10 and the data analysis unit 20. The early warning and display unit 40 determines whether the probability of oxide scale formation in the boiler reheater exceeds a preset threshold according to the data predicted by the data analysis unit 20, so as to issue a warning message when the probability of oxide scale formation exceeds the preset threshold, and the early warning and display unit 40 is used to display the redox potential value detected by the redox potential measurement unit 10 and the data predicted by the data analysis unit 20.

[0050] The early warning and display unit 40 can be connected to the redox potential measurement unit 10 and the data analysis unit 20 through various communication methods, such as Ethernet, wireless communication, etc. If it is determined that the probability of oxide scale formation predicted by the data analysis unit 20 exceeds the preset threshold, the early warning and display unit 40 issues a warning message and displays the redox potential data measured by the redox potential measurement unit 10, the probability of oxide scale formation predicted by the data analysis unit 20, the formation time and other information.

[0051] For another example, the early warning and display unit 40 is communicatively connected to a remote terminal. The early warning and display unit 40 and the remote terminal can be connected through various communication methods, such as Ethernet, wireless communication, etc., to transmit the warning message to the remote terminal and support various display methods, such as in the form of graphics, tables, texts, etc.

[0052] In some embodiments, the early warning and display unit 40 is communicatively connected to the parameter acquisition unit 30, and can transmit the operating parameters of the boiler reheater measured by the parameter acquisition unit 30 to the remote terminal, and display them in an intuitive manner on the monitoring interface of the remote terminal for the convenience of the operator to view.

[0053] Refer to Figure 1 , according to some embodiments of the present invention, the warning message includes an audible and visual warning. The audible and visual warning includes at least one of volume, frequency, and light color. The volume includes a low-level volume and a high-level volume. The frequency includes a low-level frequency and a high-level frequency. The light color includes a low-level light color and a high-level light color. Among them, the low-level volume range is 60 dB - 70 dB, the high-level volume range is 80 dB - 90 dB, the low-level frequency range is 1 Hz - 2 Hz, the high-level frequency range is 3 Hz - 5 Hz, the low-level light color is yellow, and the high-level light color is red.

[0054] The warning and display unit 40 can timely send warning messages to the operator, clearly display relevant data and prediction results, facilitate the operator to quickly grasp the situation, make reasonable decisions, and improve the convenience and efficiency of operation management. The warning messages include audible and visual alarms at different levels and push messages to the terminals designated by the operator. Different levels of warning messages correspond to different probabilities of scale formation. The volume, frequency of the audible and visual alarms, and the color of the lights can be personalized according to different levels of warning messages, facilitating the operator to quickly distinguish the warning levels.

[0055] For example, the low-level volume can be 60dB, 62dB, 65dB, 67dB, 70dB, etc., and the high-level volume can be 80dB, 82dB, 85dB, 87dB, 90dB, etc. By setting the low-level volume range to 60dB - 70dB and the high-level volume range to 80dB - 90dB, the difference between different levels of volume can be made larger, which is convenient for the operator to quickly distinguish the warning levels.

[0056] For another example, the low-level frequency can be 1Hz or 2Hz, etc., and the high-level frequency can be 3Hz, 4Hz or 5Hz, etc., which can make the difference between different levels of frequency larger, facilitating the operator to quickly distinguish the warning levels.

[0057] Next, refer to Figure 1 the system 100 for predicting the formation of scale in the boiler reheater based on the redox potential method according to some embodiments of the present invention.

[0058] In this embodiment, the redox potential measurement unit 10, the data analysis unit 20, the parameter acquisition unit 30, and the warning and display unit 40 are installed and connected according to the design of the system 100 to ensure that the communication lines between the units are firmly connected and the data transmission is stable and reliable.

[0059] In the parameter acquisition unit 30, temperature sensors, pressure sensors, flow sensors, concentration sensors, etc. are installed, debugged, and calibrated to ensure that they can accurately collect the corresponding operating parameter data; and the warning and display unit 40 is configured to set parameters such as preset thresholds and display formats.

[0060] In the data analysis unit 20, the basic parameters of the boiler reheater, such as design temperature, pressure, rated flow, initial composition of the working medium, etc. are input; and according to theoretical calculations and previous experimental data, the initial parameters of the scale formation prediction model are set, including the relationship parameters between the redox potential values and the possibility of scale formation under different working conditions, the influence weights of various operating parameters of the boiler reheater on scale formation, etc., and the warning and display unit 40 is initialized to set parameters such as access rights to the remote terminal, data update frequency, and display interface layout.

[0061] During the normal operation of the boiler reheater, the redox potential measurement unit 10 continuously collects the redox potential values of the working medium, and the parameter collection unit 30 simultaneously collects the operating parameters of the boiler reheater such as temperature, pressure, and flow rate, and transmits them to the data analysis unit 20 respectively.

[0062] The data analysis unit 20 analyzes and processes the data at a preset time interval (such as once every 10 minutes). Combining various operating parameters obtained in real time, it uses the oxide scale generation prediction model to calculate the probability and generation time of oxide scale generation. If the calculation result shows that the probability of oxide scale generation is lower than the preset threshold, the system 100 maintains the current operating state, and the warning and display unit 40 does not issue a warning.

[0063] When the data analysis unit 20 detects that the probability of oxide scale generation reaches or exceeds the preset threshold, it generates warning signals of different levels according to the predicted severity. For example, if the probability of oxide scale generation is at a low level, a first-level warning is issued, and only a prompt message is displayed on the monitoring interface; if the probability of oxide scale generation is at a high level, a second-level warning is issued, accompanied by an audible and visual alarm and a push message to the operator's terminal. Moreover, information such as the redox potential data, the predicted oxide scale generation situation (such as generation probability, generation location, generation time, etc.), and relevant operating parameters are displayed in detail on the monitoring interface, so that the operator can take measures in a timely manner. For example, it can be to adjust the operating parameters of the boiler reheater, strengthen inspections, or prepare a maintenance plan.

[0064] If an abnormal situation occurs during the operation of the boiler reheater, such as a failure of the temperature sensor, pressure sensor, or flow sensor, a communication interruption, or an error in the data analysis unit 20, the system 100 will automatically start the corresponding fault handling program. For a failure of the temperature sensor, pressure sensor, or flow sensor, the system 100 will switch to a backup sensor (if any) or issue an alarm to prompt the operator to replace the faulty sensor in a timely manner.

[0065] During a communication interruption, the system 100 will attempt to re-establish the connection and save the local data, and upload it after the communication is restored. At the same time, the warning and display unit 40 supports the remote monitoring function, and the operator can view the operating data and prediction results of the system 100 in real time through the remote terminal, so as to timely grasp the situation and make decisions when not on site.

[0066] By adopting the redox potential value in combination with the operating parameters of the boiler reheater, since various complex operating conditions during the operation of the boiler reheater are considered, the system 100 can accurately predict the probability of oxide scale formation under different changes in temperature, pressure, flow rate, and working medium concentration. By comprehensively considering a variety of operating parameters and advanced data analysis models, the accuracy of the prediction is improved, and protective measures can be taken in advance to inhibit the formation of oxide scale.

[0067] Through the timely and accurate prediction and early warning of the probability and formation time of oxide scale, it is convenient for operators to take measures in advance to inhibit the formation and development of oxide scale, reduce safety hazards such as pipeline blockage and local overheating caused by oxide scale, and reduce the possibility of equipment damage and shutdown for maintenance. This not only ensures the safe operation of the boiler reheater, but also reduces the maintenance cost and shutdown time, and improves the economic efficiency of the operation of the boiler reheater.

[0068] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc. is based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention.

[0069] In the description of the present invention, the "first feature" and "second feature" may include one or more of such features.

[0070] In the description of the present invention, the meaning of "a plurality" is two or more.

[0071] In the description of the present invention, the first feature being "above" or "below" the second feature may include the first and second features being in direct contact, or may include the first and second features not being in direct contact but being in contact through additional features therebetween.

[0072] In the description of the present invention, the first feature being "above", "above the top", and "on the upper surface" of the second feature includes the first feature being directly above and obliquely above the second feature, or merely indicating that the first feature has a higher horizontal height than the second feature.

[0073] In the description of this specification, the description referring to terms such as "one embodiment", "some embodiments", "schematic embodiments", "examples", "specific examples", or "some examples", etc. means that the specific features, structures, materials, or characteristics described in connection with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in a suitable manner in any one or more embodiments or examples.

[0074] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A system for predicting boiler reheater scale formation based on redox potential method, characterized in that: include: An oxidation-reduction potential measuring unit, the oxidation-reduction potential measuring unit comprising at least one oxidation-reduction potential sensor, the oxidation-reduction potential sensor being installed in a boiler reheater to detect an oxidation-reduction potential value of a working medium in the boiler reheater; A data analysis unit, wherein the oxidation-reduction potential measurement unit is electrically connected to the data analysis unit, the data analysis unit comprises an oxide scale generation prediction model, the data analysis unit is used to receive the oxidation-reduction potential value measured by the oxidation-reduction potential measurement unit and to predict the probability and time of oxide scale generation according to the oxide scale generation prediction model and the oxidation-reduction potential value.

2. The system for predicting boiler reheater scale formation based on oxidation-reduction potential method according to claim 1, characterized in that: There are multiple oxidation-reduction potential sensors, and at least some of the oxidation-reduction potential sensors are arranged at the inlet, outlet and pipe section prone to oxidation of the boiler reheater.

3. The system for predicting boiler reheater scale formation based on oxidation-reduction potential method according to claim 1, characterized in that: The oxidation-reduction potential sensor is made of a high-temperature and high-pressure resistant material, and the probe of the oxidation-reduction potential sensor is coated with a protective coating, which is a coating with anti-corrosion and anti-pollution functions; Wherein, the temperature resistance of the high temperature and high pressure resistant material is ≥800°C, and the pressure resistance of the high temperature and high pressure resistant material is ≥35Mpa; The corrosion rate of the protective coating is less than 0.01 mm / year under a standard corrosion environment.

4. The system for predicting boiler reheater scale formation based on oxidation-reduction potential method according to claim 1, characterized in that: The acquisition frequency of the redox potential sensor is 1 to 10 times / min; The acquisition frequency of the redox potential sensor is configured to be adjusted to 8 times / min when the load change rate of the boiler reheater exceeds 10% or the temperature change rate of the boiler reheater exceeds 5°C / min.

5. The system for predicting boiler reheater scale formation based on oxidation-reduction potential method according to claim 1, characterized in that: Also includes: A parameter acquisition unit, the parameter acquisition unit is electrically connected to the data analysis unit, and the parameter acquisition unit is used to detect the operating parameters of the boiler reheater; Wherein, the parameter acquisition unit includes: a temperature sensor, a pressure sensor and a flow sensor, the temperature sensor is used to detect the temperature in the boiler reheater, the pressure sensor is used to detect the pressure in the boiler reheater, and the flow sensor is used to detect the flow in the boiler reheater.

6. The system for predicting boiler reheater scale formation based on the oxidation-reduction potential method according to claim 5, characterized in that: The oxide scale generation prediction model is used to predict the oxide scale thickness according to the oxidation kinetics model, time and the operating parameters of the boiler reheater measured by the parameter acquisition unit. The oxide scale thickness formula is: Δx = k·t n , where Δx is the oxide scale thickness, k is the rate constant, n is the reaction order of the redox reaction, and t is the time.

7. The system for predicting boiler reheater scale formation based on oxidation-reduction potential method according to claim 5, characterized in that: The preset measurement errors of the temperature sensor, the pressure sensor and the flow sensor are ±0.5%; When the measurement errors of the temperature sensor, the pressure sensor, and the flow sensor exceed the preset measurement errors, the data analysis unit reports a fault.

8. The system for predicting boiler reheater scale formation based on oxidation-reduction potential method according to claim 6, characterized in that: The parameter acquisition unit further includes: a concentration sensor, which is electrically connected to the data analysis unit and is used to detect concentration changes of working medium components in the boiler reheater.

9. The system for predicting boiler reheater scale formation based on oxidation-reduction potential method according to claim 1, characterized in that: Also includes: An early warning and display unit, wherein the early warning and display unit is communicatively connected with the redox potential measuring unit and the data analysis unit, and the early warning and display unit determines whether the probability of scale formation in the boiler reheater exceeds a preset threshold value based on the data predicted by the data analysis unit, so as to issue an early warning message when the probability of scale formation exceeds the preset threshold value, and is used to display the redox potential value detected by the redox potential measuring unit and the data predicted by the data analysis unit.

10. The system for predicting boiler reheater scale formation based on oxidation-reduction potential method according to claim 9, characterized in that: The warning information includes: sound and light warning, the sound and light warning includes at least one of volume, frequency and light color; The volume includes a low-level volume and a high-level volume, the frequency includes a low-level frequency and a high-level frequency, and the light color includes a low-level light color and a high-level light color; The low-level volume range is 60dB to 70dB, and the high-level volume range is 80dB to 90dB. The low-level frequency range is 1 Hz to 2 Hz, and the high-level frequency range is 3 Hz to 5 Hz; The color of the low-level light is yellow, and the color of the high-level light is red.

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