Automatic chemical adding corrosion prevention control method and system for heat exchanger

Abstract

The invention belongs to the technical field of corrosion prevention of industrial equipment, and particularly relates to an automatic dosing corrosion prevention control method and system for a heat exchanger. Receiving original data, and constructing an industry-scale-medium three-dimensional mapping model after preprocessing and feature extraction; then sensing the drug state in real time by means of a three-dimensional mapping model and working condition characteristics, and outputting type suggestions and effective correction parameters through adaptive calculation; on the basis, the dependence of a traditional dosing mode on artificial experience is effectively eliminated, precise dosing is achieved through collaborative operation of multi-dimensional perception and intelligent decision, meanwhile, dynamic fluctuation of the working condition of the heat exchanger can be responded in real time, and the stability of the anti-corrosion effect is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of industrial equipment corrosion prevention technology, specifically to an automatic chemical dosing corrosion prevention control method and system for heat exchangers. Background Technology

[0002] As a core heat transfer device in industrial production, the operational stability of heat exchangers directly determines the continuity of production and the service life of the equipment. Currently, the industrial sector commonly uses manual, timed chemical dosing for corrosion prevention. However, with the expansion of industrial production scale and the increase in the complexity of operating conditions, traditional corrosion prevention methods are no longer suitable for the precise corrosion prevention needs of diverse scenarios; specifically, the following problems exist:

[0003] 1. The accuracy of chemical dosing depends on human experience, and the risk of deviation is high: Traditional manual dosing requires operators to judge the dosage and frequency based on experience. For example, in a chemical plant, the petrochemical heat exchanger was corroded and leaked due to the operator's misjudgment of the corrosiveness of the medium and insufficient dosage, resulting in production stoppage losses. In another power plant, in order to avoid excessive corrosion, the amount of chemical waste per month reached 30%, which significantly increased operating costs.

[0004] 2. Lagging response to operating conditions and unstable corrosion protection effect: The operating conditions (temperature, pressure, medium concentration) of industrial heat exchangers fluctuate dynamically. For example, in the metallurgical industry, the medium temperature of the cooling system heat exchanger can rise sharply from 80℃ to 150℃ during the peak steelmaking period. Manual dosing cannot adjust the dosage in real time, resulting in insufficient corrosion protection during high-temperature periods and redundant agents during low-temperature periods. The fluctuation range of corrosion protection effect is more than 40%.

[0005] 3. Poor adaptability to multiple scenarios and insufficient versatility of solutions: The corrosion protection requirements of heat exchangers vary significantly across different industries, scales, and media types. For example, water-based media heat exchangers in small pharmaceutical plants require low-concentration, high-frequency dosing, while chemical media heat exchangers in large chemical enterprises require high-concentration, intermittent dosing. Traditional fixed dosing solutions cannot be adapted to these needs, resulting in waste of reagents in small equipment and increased corrosion risk in large equipment. Summary of the Invention

[0006] To address the aforementioned technical problems of dosing accuracy relying on manual experience, delayed response to operating conditions, and poor adaptability to various scenarios, this invention provides the following technical solution:

[0007] An automatic chemical dosing corrosion prevention control method for heat exchangers includes the following specific steps:

[0008] S1, Multi-dimensional Perception:

[0009] S11, Corrosion Status Sensing: Real-time acquisition of corrosion status parameters of the heat exchanger metal surface;

[0010] S12, Operating Parameter Acquisition: Acquire operating parameters;

[0011] S13, Equipment Status Monitoring: Monitor the vibration value of the heat exchanger during operation and the pressure change of the chemical dosing pipeline, and combine the operating parameters to determine whether the equipment is in an abnormal operating state.

[0012] S2, Data Processing and Modeling:

[0013] S21, Data preprocessing: After receiving the raw data from the multi-dimensional perception steps, noise reduction, completion, and standardization are performed.

[0014] S22, Feature Extraction: Extract corrosion features, operating condition features, and equipment features based on standardized data;

[0015] S23, Scene Adaptive Modeling: Utilize the extracted features to construct a three-dimensional mapping model of industry-scale-medium;

[0016] S3, Dynamic Adaptation of Drug Properties:

[0017] S31, Real-time sensing of drug status: Real-time acquisition of status parameters of drug concentrate and mixture;

[0018] S32, Agent-Operating Condition Adaptation Calculation: Based on agent status data, combined with a three-dimensional mapping model and operating condition characteristics, the effective dosage correction coefficient of the agent is calculated through an attenuation compensation algorithm;

[0019] S33, Drug type switching suggestion: Compare the correction coefficient with the preset threshold, and combine with the three-dimensional mapping model to output a drug type switching suggestion. At the same time, the correction coefficient and the switching suggestion are output synchronously.

[0020] S4, Intelligent Decision Control:

[0021] S41, Corrosion Level Assessment: By calling the three-dimensional mapping model and combining corrosion characteristics, the corrosion status of the heat exchanger is divided into three levels: mild, moderate and severe.

[0022] S42, Dynamic Dosage Calculation: Based on the corrosion level and real-time operating parameters, the optimal dosage is calculated using a multi-parameter fusion algorithm.

[0023] S43, Drug administration strategy optimization: Based on the calculated dose and combined with the three-dimensional mapping model, optimize the drug administration frequency and method;

[0024] S5, Precise Execution:

[0025] S51, Dosing Pump Unit Control: After receiving the dosing strategy, adjust the speed and start / stop time of the dosing pump;

[0026] S52, Drug Mixing Adjustment: Adjust the mixing ratio of the drug concentrate and the diluent according to the pump set operating status;

[0027] S53, Targeted drug delivery: Based on the medium flow direction data collected in the working condition parameter acquisition step and the mixed drug parameters in the drug mixing adjustment step, the drug delivery angle and position are controlled.

[0028] S6, end-to-end process control:

[0029] S61, Real-time feedback: Collects drug administration data for the targeted drug administration step and corrosion state change data for the corrosion state sensing step;

[0030] S62, Fault Diagnosis and Early Warning: Compare the feedback data of the real-time feedback step with the model threshold of the three-dimensional mapping model to achieve fault diagnosis and early warning;

[0031] S63, Remote Operation and Maintenance: Stores fault records of fault diagnosis and early warning steps, and provides real-time feedback on the operation data of the steps.

[0032] An automatic chemical dosing and corrosion prevention control system for heat exchangers includes:

[0033] The multi-dimensional sensing module is used to collect data on corrosion status, operating parameters, and equipment status.

[0034] The data processing and modeling module is used to receive the raw data from the multi-dimensional perception module, and after preprocessing and feature extraction, construct a three-dimensional mapping model of industry-scale-media.

[0035] The dynamic adaptation module for drug properties is used to sense the drug status in real time based on the three-dimensional mapping model and working condition characteristics of the data processing and modeling module, and output type suggestions and effective correction parameters through adaptation calculation.

[0036] The intelligent decision control module is used to integrate scenario models, reagent adaptation parameters and corrosion characteristics to complete corrosion level assessment, dynamic dosage calculation and dosing strategy optimization;

[0037] The precision execution module is used to respond to the dosing instructions from the intelligent decision control module. Through pump speed adjustment, drug mixing ratio optimization and targeted drug delivery control, the decision plan is transformed into actual dosing actions.

[0038] The end-to-end control module is used to collect actual dosing data from the precision execution module and status data from the multi-dimensional sensing module, and then provide real-time feedback, fault warnings, and remote operation and maintenance.

[0039] As a preferred embodiment of the automatic chemical dosing and corrosion prevention control system for heat exchangers described in this invention, the multi-dimensional sensing module includes:

[0040] The corrosion state sensing unit is used to collect corrosion state parameters of the metal surface of the heat exchanger in real time.

[0041] Operating condition parameter acquisition unit, used to acquire operating condition parameters;

[0042] The equipment status monitoring unit is used to monitor the vibration value of the heat exchanger during operation and the pressure change of the chemical dosing pipeline, and, in combination with the operating parameters, to determine whether the equipment is in an abnormal operating state.

[0043] As a preferred embodiment of the automatic chemical dosing and corrosion prevention control system for heat exchangers described in this invention, the data processing and modeling module includes:

[0044] The data preprocessing unit is used to perform noise reduction, completion, and standardization processing on the raw data received from the multi-dimensional perception module.

[0045] The feature extraction unit is used to extract corrosion features, operating condition features, and equipment features based on standardized data.

[0046] The scene adaptation modeling unit is used to construct a three-dimensional mapping model of industry-scale-media by utilizing the extracted features.

[0047] As a preferred embodiment of the automatic chemical dosing and corrosion prevention control system for heat exchangers described in this invention, the chemical characteristic dynamic adaptation module includes:

[0048] The real-time drug status sensing unit is used to collect the status parameters of the drug concentrate and mixture in real time;

[0049] The drug-operating condition adaptation calculation unit is used to calculate the effective dosage correction coefficient of the drug based on the drug status data, combined with the three-dimensional mapping model and operating condition characteristics, through the attenuation compensation algorithm.

[0050] The drug type switching suggestion unit is used to compare the correction coefficient with the preset threshold, and combined with the three-dimensional mapping model, outputs drug type switching suggestions, and outputs the correction coefficient and switching suggestions simultaneously.

[0051] As a preferred embodiment of the automatic chemical dosing and corrosion prevention control system for heat exchangers described in this invention, the intelligent decision control module includes:

[0052] The corrosion level assessment unit is used to call the three-dimensional mapping model and, in combination with corrosion characteristics, classify the corrosion status of the heat exchanger into three levels: mild, moderate, and severe.

[0053] The dynamic dosage calculation unit is used to calculate the optimal dosage based on the corrosion level and real-time operating parameters using a multi-parameter fusion algorithm.

[0054] The dosing strategy optimization unit is used to optimize the dosing frequency and administration method based on the calculated dose and a three-dimensional mapping model.

[0055] As a preferred embodiment of the automatic chemical dosing and corrosion prevention control system for heat exchangers described in this invention, the precise execution module includes:

[0056] The dosing pump control unit is used to adjust the speed and start / stop time of the dosing pump after receiving the dosing strategy.

[0057] The drug mixing and adjustment unit is used to adjust the mixing ratio of the drug concentrate and the diluent according to the operating status of the pump group;

[0058] The targeted drug delivery unit is used to control the drug delivery angle and position based on the medium flow direction data collected by the operating condition parameter acquisition unit and the mixed drug parameters of the drug mixing adjustment unit.

[0059] As a preferred embodiment of the automatic chemical dosing and corrosion prevention control system for heat exchangers described in this invention, the full-process control module includes:

[0060] A real-time feedback unit is used to collect drug delivery data from the targeted drug delivery unit and corrosion state change data from the corrosion state sensing unit.

[0061] The fault diagnosis and early warning unit is used to compare the feedback data of the real-time feedback unit with the model threshold of the three-dimensional mapping model to achieve fault diagnosis and early warning.

[0062] The remote operation and maintenance unit is used to store fault records from the fault diagnosis and early warning unit and provide real-time feedback on the unit's operational data.

[0063] Compared with existing technologies:

[0064] This invention effectively eliminates the reliance on manual experience in traditional chemical dosing methods. It achieves precise dosing through the collaborative operation of multi-dimensional perception and intelligent decision-making. At the same time, it can respond to the dynamic fluctuations of heat exchanger operating conditions in real time, ensuring the stability of the anti-corrosion effect. Its multi-scenario adaptation model can flexibly adapt to the anti-corrosion needs of heat exchangers of different industries, scales and media types, significantly improving the versatility of the solution. Moreover, relying on the full-process status monitoring and fault diagnosis and early warning mechanism, it can promptly detect operational anomalies and issue prompts, ensuring the timeliness of maintenance work. Overall, it solves the core pain points of traditional anti-corrosion methods and provides a reliable guarantee for the stable operation of heat exchangers. Attached Figure Description

[0065] Figure 1 This is a schematic diagram of the overall framework of the present invention;

[0066] Figure 2 This is a schematic diagram of the multi-dimensional perception module framework of the present invention;

[0067] Figure 3 This is a schematic diagram of the data processing and modeling module framework of the present invention;

[0068] Figure 4 This is a schematic diagram of the dynamic adaptation module framework for drug properties of the present invention;

[0069] Figure 5 This is a schematic diagram of the intelligent decision control module framework of the present invention;

[0070] Figure 6 This is a schematic diagram of the precise execution module framework of the present invention;

[0071] Figure 7 This is a schematic diagram of the overall process control module framework of the present invention. Detailed Implementation

[0072] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0073] This invention provides an automatic chemical dosing corrosion prevention control method for heat exchangers, comprising the following specific steps:

[0074] S1, Multi-dimensional Perception:

[0075] S11, Corrosion Status Sensing: An electrochemical sensor array is used to collect corrosion status parameters such as corrosion rate and corrosion current density on the metal surface of the heat exchanger in real time, with a resolution of 0.01 mm / a, providing basic data for subsequent corrosion degree judgment;

[0076] S12, Operating Parameter Acquisition: Adapt the corresponding sensor according to the medium type (pH sensor for water-based media, concentration sensor for chemical media) to acquire operating parameters such as temperature (measurement range -20℃~300℃), pressure (0~10MPa), medium concentration, and flow rate. The data sampling frequency is 10Hz.

[0077] S13, Equipment Status Monitoring: Monitor the vibration value of the heat exchanger and the pressure change of the chemical dosing pipeline through vibration sensors and current sensors, and combine them with operating parameters to determine whether the equipment is in an abnormal operating state (e.g., if the operating parameters are normal but the vibration value exceeds the standard, it indicates that scale has formed inside the heat exchanger).

[0078] S2, Data Processing and Modeling:

[0079] S21, Data Preprocessing: After receiving the raw data from the multi-dimensional sensing steps, noise reduction (removing sensor interference signals), completion (using interpolation algorithms to repair missing data) and standardization are performed to convert parameters of different dimensions into a unified data format, providing standardized data for subsequent modeling.

[0080] S22, Feature Extraction: Based on standardized data, extract corrosion features (such as the slope of corrosion rate change), operating condition features (such as the amplitude of temperature fluctuation), and equipment features (such as the peak value of vibration frequency), and screen key feature variables that are strongly correlated with the anti-corrosion effect;

[0081] S23, Scene Adaptation Modeling: Utilize the extracted features to construct a three-dimensional mapping model of industry-scale-medium. For example, the chemical industry-large-scale equipment-chemical medium corresponds to a "high concentration-low frequency" dosing model, and the power industry-small and medium-sized units-water-based medium corresponds to a "low concentration-high frequency" dosing model, so as to achieve accurate adaptation of multiple scenarios.

[0082] S3, Dynamic Adaptation of Drug Properties:

[0083] S31, Real-time sensing of reagent status: Using a near-infrared spectroscopy sensor and a viscosity sensor, it collects real-time status parameters such as the content of active ingredients, viscosity, and stability of the reagent stock solution and mixture (e.g., the detection accuracy of active ingredients reaches 0.1%), and simultaneously receives operating condition data (temperature, medium concentration), and adjusts the detection frequency accordingly (e.g., detecting the activity decay rate every 5 seconds under high temperature conditions, and every 30 seconds under normal temperature conditions) to provide real-time reagent status data for subsequent adaptation calculations;

[0084] S32, Agent-Operating Condition Adaptation Calculation: Based on agent state data, combined with a three-dimensional mapping model (such as chemical industry-chemical medium scenario) and operating condition characteristics (such as temperature fluctuation range, media corrosivity), the effective dosage correction coefficient of the agent is calculated through an attenuation compensation algorithm. For example, if the agent activity decreases by 30% under high temperature (>150℃) conditions, the correction coefficient is set to 1.43 to ensure that the actual effect of the agent meets the decision-making expectations.

[0085] S33, Agent Type Switching Suggestion: Compare the correction coefficient with the preset threshold (e.g., if the correction coefficient > 2.0, it means that the current agent can no longer meet the anti-corrosion requirements through dosage adjustment), and combine with the three-dimensional mapping model to output agent type switching suggestions (e.g., in acidic media scenarios, if the current neutral agent is not suitable, it is recommended to switch to an acid-resistant special agent). At the same time, the correction coefficient and switching suggestions are output synchronously, providing core basis for subsequent dosing dosage decisions and strategy optimization from the agent dimension;

[0086] S4, Intelligent Decision Control:

[0087] S41, Corrosion Level Assessment: By calling the three-dimensional mapping model and combining corrosion characteristics, the corrosion status of the heat exchanger is divided into three levels: mild (corrosion rate < 0.1 mm / a), moderate (0.1~0.3 mm / a), and severe (> 0.3 mm / a), providing a basis for chemical dosage decisions;

[0088] S42, Dynamic Dosage Calculation: Based on the corrosion level and real-time operating parameters, the optimal dosage is calculated using a multi-parameter fusion algorithm. For example, under moderate corrosion and high temperature (>120℃) conditions, the dosage is increased by 20% from the base dosage.

[0089] S43, Dosing Strategy Optimization: Based on the calculated dose and combined with the three-dimensional mapping model, optimize the dosing frequency and administration method (continuous or intermittent dosing). For example, small equipment uses "micro-volume continuous dosing" and large equipment uses "batch intermittent dosing" to ensure that the strategy is highly matched with the scenario and dosage.

[0090] S5, Precise Execution:

[0091] S51, Dosing Pump Unit Control: After receiving the dosing strategy, adjust the speed of the dosing pump (control the flow rate) and the start-stop time (control the frequency). For example, when following the "high concentration-low frequency" strategy, the pump unit runs at high speed for 10 minutes and then stops for 2 hours.

[0092] S52, Drug Mixing Adjustment: Adjust the mixing ratio of drug concentrate and diluent according to the pump group's operating status. For example, increase the proportion of concentrate when high dose requirements are needed (80% concentrate + 20% diluent), and decrease the proportion of concentrate when low dose requirements are needed (30% concentrate + 70% diluent) to ensure that the drug concentration after mixing meets the calculation requirements.

[0093] S53, Targeted drug delivery: Based on the medium flow direction data collected in the working condition parameter acquisition step and the mixed agent parameters in the agent mixing adjustment step, the angle and position of the drug delivery nozzle are controlled to ensure that the agent is accurately sprayed to the high corrosion area of ​​the heat exchanger (such as the tube bundle interface), thereby improving the targeted nature of corrosion prevention.

[0094] S6, end-to-end process control:

[0095] S61, Real-time Feedback: Collects drug administration data (actual dosage and mixing ratio) from the targeted drug administration step and corrosion state change data from the corrosion state sensing step to form a feedback loop and provide real-time basis for decision-making adjustments;

[0096] S62, Fault Diagnosis and Early Warning: By comparing the feedback data of the real-time feedback step with the model threshold of the three-dimensional mapping model, fault diagnosis and early warning can be achieved. For example, when the deviation between the sensor data and the feedback data exceeds 5%, the sensor is judged to be faulty; when the operating current of the dosing pump does not match the instructions of the dosing pump group control step, the pump group is judged to be abnormal and an audible and visual alarm is issued in time.

[0097] S63, Remote Operation and Maintenance: Stores fault records of fault diagnosis and early warning steps, provides real-time feedback on the operation data of the steps, and supports remote viewing, parameter adjustment and fault troubleshooting. For example, the enterprise headquarters can remotely adjust the dosing strategy of heat exchangers in multiple plants and optimize the scenario model based on historical data.

[0098] Please refer to the following: An automatic chemical dosing and corrosion prevention control system for heat exchangers. Figure 1 ,include:

[0099] The multi-dimensional sensing module is used to collect data on corrosion status, operating parameters, and equipment status.

[0100] The data processing and modeling module is used to receive the raw data from the multi-dimensional perception module, and after preprocessing and feature extraction, construct a three-dimensional mapping model of industry-scale-media.

[0101] The dynamic adaptation module for drug properties is used to sense the drug status in real time based on the three-dimensional mapping model and working condition characteristics of the data processing and modeling module, and output type suggestions and effective correction parameters through adaptation calculation.

[0102] The intelligent decision control module is used to integrate scenario models, reagent adaptation parameters and corrosion characteristics to complete corrosion level assessment, dynamic dosage calculation and dosing strategy optimization;

[0103] The precision execution module is used to respond to the dosing instructions from the intelligent decision control module. Through pump speed adjustment, drug mixing ratio optimization and targeted drug delivery control, the decision plan is transformed into actual dosing actions.

[0104] The end-to-end control module is used to collect actual dosing data from the precision execution module and status data from the multi-dimensional sensing module, and then provide real-time feedback, fault warnings, and remote operation and maintenance.

[0105] Please see Figure 2 The multi-dimensional perception module includes:

[0106] The corrosion state sensing unit is used to collect corrosion state parameters such as corrosion rate and corrosion current density on the metal surface of the heat exchanger in real time using an electrochemical sensor array, with a resolution of 0.01 mm / a, providing basic data for subsequent corrosion degree judgment.

[0107] The operating condition parameter acquisition unit is used to adapt to the corresponding sensor according to the medium type (pH sensor for water-based media, concentration sensor for chemical media) to acquire operating condition parameters such as temperature (measurement range -20℃~300℃), pressure (0~10MPa), medium concentration, and flow rate. The data sampling frequency is 10Hz.

[0108] The equipment status monitoring unit is used to monitor the vibration value of the heat exchanger and the pressure change of the dosing pipeline through vibration sensors and current sensors, and combined with the operating parameters, to determine whether the equipment is in an abnormal operating state (such as when the operating parameters are normal but the vibration value exceeds the standard, it indicates that scale has formed inside the heat exchanger).

[0109] Please see Figure 3The data processing and modeling module includes:

[0110] The data preprocessing unit is used to perform noise reduction (removing sensor interference signals), completion (using interpolation algorithms to repair missing data) and standardization processing after receiving the raw data from the multi-dimensional perception module. It converts parameters of different dimensions into a unified data format to provide standardized data for subsequent modeling.

[0111] The feature extraction unit is used to extract corrosion features (such as the slope of corrosion rate change), operating condition features (such as the temperature fluctuation amplitude), and equipment features (such as the peak vibration frequency) from standardized data, and to screen key feature variables that are strongly correlated with the anti-corrosion effect.

[0112] The scenario adaptation modeling unit is used to construct a three-dimensional mapping model of industry-scale-medium using the extracted features. For example, the chemical industry-large-scale equipment-chemical medium corresponds to the "high concentration-low frequency" dosing model, and the power industry-small and medium-sized units-water-based medium corresponds to the "low concentration-high frequency" dosing model, so as to achieve accurate adaptation of multiple scenarios.

[0113] Please see Figure 4 The drug characteristic dynamic adaptation module includes:

[0114] The real-time drug status sensing unit uses near-infrared spectroscopy sensors and viscosity sensors to collect real-time status parameters such as active ingredient content, viscosity, and stability of the drug stock solution and mixture (e.g., active ingredient detection accuracy reaches 0.1%), and simultaneously receives operating condition data (temperature, medium concentration), and adjusts the detection frequency accordingly (e.g., detecting the activity decay rate every 5 seconds under high temperature conditions, and every 30 seconds under normal temperature conditions) to provide real-time drug status data for subsequent adaptation calculations.

[0115] The agent-condition adaptation calculation unit is used to calculate the effective dosage correction coefficient of the agent based on the agent state data, combined with the three-dimensional mapping model (such as the chemical industry-chemical medium scenario) and the condition characteristics (such as temperature fluctuation range and media corrosivity), through the attenuation compensation algorithm. For example, if the agent activity decreases by 30% under high temperature (>150℃) conditions, the correction coefficient is set to 1.43 to ensure that the actual effect of the agent meets the decision-making expectations.

[0116] The agent type switching suggestion unit is used to compare the correction coefficient with the preset threshold (e.g., when the correction coefficient is > 2.0, it means that the current agent can no longer meet the anti-corrosion requirements through dosage adjustment). Combined with the three-dimensional mapping model, it outputs agent type switching suggestions (e.g., in acidic media scenarios, when the current neutral agent is not suitable, it is recommended to switch to an acid-resistant special agent). At the same time, the correction coefficient and switching suggestions are output synchronously, providing core basis for subsequent dosing dosage decisions and strategy optimization from the agent dimension.

[0117] Please see Figure 5 The intelligent decision control module includes:

[0118] The corrosion level assessment unit is used to call the three-dimensional mapping model and combine corrosion characteristics to classify the corrosion state of the heat exchanger into three levels: mild (corrosion rate < 0.1 mm / a), moderate (0.1~0.3 mm / a), and severe (> 0.3 mm / a), providing a basis for chemical dosage decisions;

[0119] The dynamic dosage calculation unit is used to calculate the optimal dosage based on the corrosion level and real-time operating parameters using a multi-parameter fusion algorithm. For example, under moderate corrosion and high temperature (>120℃) conditions, the dosage is increased by 20% from the base dosage.

[0120] The dosing strategy optimization unit is used to optimize the dosing frequency and administration method (continuous or intermittent dosing) based on the calculated dose and combined with the three-dimensional mapping model. For example, small equipment uses "micro-volume continuous dosing" and large equipment uses "batch intermittent dosing" to ensure that the strategy is highly matched with the scenario and dosage.

[0121] Please see Figure 6 The precise execution module includes:

[0122] The dosing pump control unit is used to adjust the speed (control flow rate) and start / stop time (control frequency) of the dosing pump after receiving the dosing strategy. For example, when the "high concentration-low frequency" strategy is followed, the pump unit runs at high speed for 10 minutes and then stops for 2 hours.

[0123] The drug mixing and adjustment unit is used to adjust the mixing ratio of the drug concentrate and diluent according to the pump group's operating status. For example, when a high dose is required, the proportion of concentrate is increased (80% concentrate + 20% diluent), and when a low dose is required, the proportion of concentrate is decreased (30% concentrate + 70% diluent) to ensure that the drug concentration after mixing meets the calculation requirements.

[0124] The targeted drug delivery unit is used to control the angle and position of the drug delivery nozzle based on the medium flow direction data collected by the operating condition parameter acquisition unit and the mixed agent parameters of the agent mixing and adjustment unit, so that the agent is accurately sprayed to the high corrosion area of ​​the heat exchanger (such as the tube bundle interface), thereby improving the targeted nature of corrosion prevention.

[0125] Please see Figure 7 The full-process management module includes:

[0126] The real-time feedback unit is used to collect the drug administration data (actual dosage and mixing ratio) from the targeted drug delivery unit and the corrosion state change data from the corrosion state sensing unit, forming a feedback loop to provide real-time basis for decision-making and adjustment.

[0127] The fault diagnosis and early warning unit is used to compare the feedback data of the real-time feedback unit with the model threshold of the three-dimensional mapping model to realize fault diagnosis and early warning. For example, when the deviation between the sensor data and the feedback data exceeds 5%, the sensor is judged to be faulty; when the operating current of the dosing pump does not match the command of the dosing pump group control unit, the pump group is judged to be abnormal and an audible and visual alarm is issued in time.

[0128] The remote operation and maintenance unit is used to store fault records from the fault diagnosis and early warning unit, provide real-time feedback on the unit's operating data, and support remote viewing, parameter adjustment, and fault diagnosis. For example, the enterprise headquarters can remotely adjust the dosing strategy of heat exchangers in multiple plants and optimize the scenario model based on historical data.

[0129] Although the present invention has been described above with reference to embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, as long as there is no structural conflict, the features in the disclosed embodiments can be combined with each other in any manner. The lack of an exhaustive description of these combinations in this specification is merely for the sake of brevity and resource conservation. Therefore, the present invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. An automatic chemical dosing and corrosion prevention control method for heat exchangers, characterized in that, The specific steps are as follows: S1, Multi-dimensional Perception: S11, Corrosion Status Sensing: Real-time acquisition of corrosion status parameters of the heat exchanger metal surface; S12, Operating Parameter Acquisition: Acquire operating parameters; S13, Equipment Status Monitoring: Monitor the vibration value of the heat exchanger during operation and the pressure change of the chemical dosing pipeline, and combine the operating parameters to determine whether the equipment is in an abnormal operating state. S2, Data Processing and Modeling: S21, Data preprocessing: After receiving the raw data from the multi-dimensional perception steps, noise reduction, completion, and standardization are performed. S22, Feature Extraction: Extract corrosion features, operating condition features, and equipment features based on standardized data; S23, Scene Adaptive Modeling: Utilize the extracted features to construct a three-dimensional mapping model of industry-scale-medium; S3, Dynamic Adaptation of Drug Properties: S31, Real-time sensing of drug status: Real-time acquisition of status parameters of drug concentrate and mixture; S32, Agent-Operating Condition Adaptation Calculation: Based on agent status data, combined with a three-dimensional mapping model and operating condition characteristics, the effective dosage correction coefficient of the agent is calculated through an attenuation compensation algorithm; S33, Drug type switching suggestion: Compare the correction coefficient with the preset threshold, and combine with the three-dimensional mapping model to output a drug type switching suggestion. At the same time, the correction coefficient and the switching suggestion are output synchronously. S4, Intelligent Decision Control: S41, Corrosion Level Assessment: By calling the three-dimensional mapping model and combining corrosion characteristics, the corrosion status of the heat exchanger is divided into three levels: mild, moderate and severe. S42, Dynamic Dosage Calculation: Based on the corrosion level and real-time operating parameters, the optimal dosage is calculated using a multi-parameter fusion algorithm. S43, Drug administration strategy optimization: Based on the calculated dose and combined with the three-dimensional mapping model, optimize the drug administration frequency and method; S5, Precise Execution: S51, Dosing Pump Unit Control: After receiving the dosing strategy, adjust the speed and start / stop time of the dosing pump; S52, Drug Mixing Adjustment: Adjust the mixing ratio of the drug concentrate and the diluent according to the pump set operating status; S53, Targeted drug delivery: Based on the medium flow direction data collected in the working condition parameter acquisition step and the mixed drug parameters in the drug mixing adjustment step, the drug delivery angle and position are controlled. S6, end-to-end process control: S61, Real-time feedback: Collects drug administration data for the targeted drug administration step and corrosion state change data for the corrosion state sensing step; S62, Fault Diagnosis and Early Warning: Compare the feedback data of the real-time feedback step with the model threshold of the three-dimensional mapping model to achieve fault diagnosis and early warning; S63, Remote Operation and Maintenance: Stores fault records of fault diagnosis and early warning steps, and provides real-time feedback on the operation data of the steps.

2. An automatic chemical dosing and corrosion prevention control system for heat exchangers, characterized in that, include: The multi-dimensional sensing module is used to collect data on corrosion status, operating parameters, and equipment status. The data processing and modeling module is used to receive the raw data from the multi-dimensional perception module, and after preprocessing and feature extraction, construct a three-dimensional mapping model of industry-scale-media. The dynamic adaptation module for drug properties is used to sense the drug status in real time based on the three-dimensional mapping model and working condition characteristics of the data processing and modeling module, and output type suggestions and effective correction parameters through adaptation calculation. The intelligent decision control module is used to integrate scenario models, reagent adaptation parameters and corrosion characteristics to complete corrosion level assessment, dynamic dosage calculation and dosing strategy optimization; The precision execution module is used to respond to the dosing instructions from the intelligent decision control module. Through pump speed adjustment, drug mixing ratio optimization and targeted drug delivery control, the decision plan is transformed into actual dosing actions. The end-to-end control module is used to collect actual dosing data from the precision execution module and status data from the multi-dimensional sensing module, and then provide real-time feedback, fault warnings, and remote operation and maintenance.

3. The automatic chemical dosing and corrosion prevention control system for heat exchangers according to claim 2, characterized in that, The multi-dimensional perception module includes: The corrosion state sensing unit is used to collect corrosion state parameters of the metal surface of the heat exchanger in real time. Operating condition parameter acquisition unit, used to acquire operating condition parameters; The equipment status monitoring unit is used to monitor the vibration value of the heat exchanger during operation and the pressure change of the chemical dosing pipeline, and, in combination with the operating parameters, to determine whether the equipment is in an abnormal operating state.

4. The automatic chemical dosing and corrosion prevention control system for heat exchangers according to claim 2, characterized in that, The data processing and modeling module includes: The data preprocessing unit is used to perform noise reduction, completion, and standardization processing on the raw data received from the multi-dimensional perception module. The feature extraction unit is used to extract corrosion features, operating condition features, and equipment features based on standardized data. The scene adaptation modeling unit is used to construct a three-dimensional mapping model of industry-scale-media by utilizing the extracted features.

5. The automatic chemical dosing and corrosion prevention control system for heat exchangers according to claim 2, characterized in that, The dynamic adaptation module for drug properties includes: The real-time drug status sensing unit is used to collect the status parameters of the drug concentrate and mixture in real time; The drug-operating condition adaptation calculation unit is used to calculate the effective dosage correction coefficient of the drug based on the drug status data, combined with the three-dimensional mapping model and operating condition characteristics, through the attenuation compensation algorithm. The drug type switching suggestion unit is used to compare the correction coefficient with the preset threshold, and combined with the three-dimensional mapping model, outputs drug type switching suggestions, and outputs the correction coefficient and switching suggestions simultaneously.

6. The automatic chemical dosing and corrosion prevention control system for heat exchangers according to claim 2, characterized in that, The intelligent decision-making and control module includes: The corrosion level assessment unit is used to call the three-dimensional mapping model and, in combination with corrosion characteristics, classify the corrosion status of the heat exchanger into three levels: mild, moderate, and severe. The dynamic dosage calculation unit is used to calculate the optimal dosage based on the corrosion level and real-time operating parameters using a multi-parameter fusion algorithm. The dosing strategy optimization unit is used to optimize the dosing frequency and administration method based on the calculated dose and a three-dimensional mapping model.

7. The automatic chemical dosing and corrosion prevention control system for heat exchangers according to claim 2, characterized in that, The precise execution module includes: The dosing pump control unit is used to adjust the speed and start / stop time of the dosing pump after receiving the dosing strategy. The drug mixing and adjustment unit is used to adjust the mixing ratio of the drug concentrate and the diluent according to the operating status of the pump group; The targeted drug delivery unit is used to control the drug delivery angle and position based on the medium flow direction data collected by the operating condition parameter acquisition unit and the mixed drug parameters of the drug mixing adjustment unit.

8. The automatic chemical dosing and corrosion prevention control system for heat exchangers according to claim 2, characterized in that, The full-process control module includes: A real-time feedback unit is used to collect drug delivery data from the targeted drug delivery unit and corrosion state change data from the corrosion state sensing unit. The fault diagnosis and early warning unit is used to compare the feedback data of the real-time feedback unit with the model threshold of the three-dimensional mapping model to achieve fault diagnosis and early warning. The remote operation and maintenance unit is used to store fault records from the fault diagnosis and early warning unit and provide real-time feedback on the unit's operational data.

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