Online monitoring method and system for slurry stirring effect of desulfurizing absorption tower

Abstract

The invention discloses an online monitoring method and system for the slurry stirring effect of a desulfurizing absorption tower, and relates to the technical field of absorption tower slurry stirring monitoring. The method comprises the following steps: acquiring tower wall temperature data under a normal working condition to establish a reference model containing a normal temperature range and a uniformity threshold value of each measuring point; during operation of the system, tower wall temperature and environment temperature data are collected in real time and subjected to compensation processing; comparing the processed data with a reference model, and performing grading judgment on the stirring effect based on the temperature deviation amplitude, the area proportion of the abnormal region and the duration time; and triggering corresponding early warning according to a judgment result and outputting diagnosis information. The system comprises a temperature monitoring unit, an environmental parameter acquisition unit, a data processing unit, a central processing unit, a man-machine interaction unit, an early warning execution unit and the like. According to the invention, real-time, online and visual monitoring and early warning of the stirring effect are realized, and the problems of strong subjectivity and early warning lagging of the traditional monitoring means are solved.

Description

An online monitoring method and system for the stirring effect of desulfurization absorption tower slurry. Technical Field

[0001] This invention relates to the field of absorption tower slurry stirring monitoring technology, specifically to an online monitoring method and system for the stirring effect of desulfurization absorption tower slurry. Background Technology

[0002] In wet desulfurization processes, the absorber tower is the core equipment, and the stirring effect of its bottom slurry tank directly affects the stable operation and desulfurization efficiency of the entire system. The slurry tank is typically equipped with multiple side-entry agitators, whose continuous operation aims to prevent the deposition and scaling of solid particles such as gypsum and limestone, ensuring uniform slurry composition and sufficient dispersion of oxidizing air, thereby maintaining a highly efficient chemical reaction environment.

[0003] Currently, the means of monitoring the working status and mixing effect of agitators are very limited, mainly relying on the following methods: First, through on-site inspections by operators, relying on experience to listen to the sound of the motor or touch the tower to sense vibrations, making subjective qualitative judgments. This method lacks quantitative basis and cannot achieve continuous monitoring. Second, stopping the tower and entering the interior for inspection during regular maintenance is a post-event verification, which cannot warn of early deposition risks, and unplanned shutdowns are costly. Third, through monitoring indirect electrical parameters such as agitator motor current, but changes in this signal are lagging, and usually only provide obvious indications when deposition is already quite serious or the equipment has suffered mechanical damage, thus having limited early warning function.

[0004] These existing technologies cannot achieve real-time, online, visualized, and quantitative evaluation of the mixing effect of the entire slurry tank, making it difficult for operators to promptly grasp the mixing blind spots and initial sedimentation state, and preventing intervention before problems worsen. Therefore, developing an online monitoring technology that can accurately reflect the actual mixing effect of the slurry and achieve early warning is of great significance for improving the reliability of desulfurization systems and reducing maintenance costs. Summary of the Invention

[0005] (I) Technical problems to be solved In view of the shortcomings of the existing technology, the present invention provides an online monitoring method and system for the stirring effect of desulfurization absorption tower slurry, which has the advantages of real-time online monitoring of the stirring effect of desulfurization absorption tower slurry and early warning of anomalies, and solves the problems of strong subjectivity, obvious lag and difficulty in achieving early warning of traditional monitoring methods.

[0006] (II) Technical Solution To achieve the above-mentioned objective of real-time and early warning of stirring effect, the present invention provides the following technical solution: The present invention provides an online monitoring method for the stirring effect of desulfurization absorption tower slurry, including the following steps: S1: Under the condition that the stirrer is working normally and there is no sediment in the tower, the tower wall temperature data is collected by a monitoring device deployed outside the absorption tower to establish a benchmark model including the normal temperature range of each measuring point and the overall temperature field uniformity threshold; S2: During system operation, the tower wall temperature data and environmental parameters are collected in real time, and the tower wall temperature data is subjected to environmental temperature compensation processing to obtain real temperature data; S3: The real temperature data after compensation processing is compared with the benchmark model, the temperature deviation and temperature field uniformity are calculated, and the stirring effect is graded based on the temperature deviation amplitude, the area ratio of abnormal region and the duration of abnormality; S4: According to the graded judgment result, the corresponding level of warning is triggered, and diagnostic information including abnormal location and handling suggestions is generated.

[0007] In step S1, the monitoring device includes a temperature sensor array; establishing the benchmark model specifically includes: under the stable state of the stirrer running at rated speed, continuously collecting tower wall temperature data for a preset time through the temperature sensor, and statistically determining the normal temperature range of each measuring point and the uniformity threshold based on the data.

[0008] In step S2, the environmental parameters include ambient temperature; the ambient temperature compensation process specifically involves using the collected ambient temperature data to correct the tower wall temperature measurement deviation caused by environmental factors through a preset compensation algorithm.

[0009] The grading determination in step S3 specifically includes at least one of the following logics: when the temperature of a local area is continuously lower than the lower limit of its normal temperature range, and the area of ​​the local area exceeds a first threshold, it is determined that there is a risk of solid deposition; when the uniformity of the overall temperature field is continuously lower than the uniformity threshold, it is determined that the overall stirring effect is deteriorated.

[0010] The classification determination also includes logic for generating processing suggestions corresponding to the warning level; in step S4, when the warning is triggered, the warning signal is sent to the power plant DCS system through the relay module.

[0011] Another aspect of the present invention provides an online monitoring system for the stirring effect of desulfurization absorption tower slurry to implement the method described in the above aspect, comprising: a temperature monitoring unit, including multiple temperature sensors arranged on the outer wall of the slurry section of the absorption tower for collecting tower wall temperature data; an environmental parameter acquisition unit for collecting ambient temperature data; a data acquisition and processing unit, signal-connected to the temperature monitoring unit and the environmental parameter acquisition unit, for receiving and processing sensor data; a central processing unit, communicatively connected to the data acquisition and processing unit, configured to perform the following functions: establishing and storing the benchmark model, compensating for real-time temperature data, performing the graded judgment, and generating early warning instructions and diagnostic information; a human-machine interaction unit, connected to the central processing unit, for displaying temperature field information, judgment results, and diagnostic information; and an early warning execution unit, connected to the central processing unit, for executing alarm actions and signal output according to the early warning instructions.

[0012] The temperature sensor in the temperature monitoring unit is an infrared thermometer or a platinum resistance thermometer; the temperature sensors are arranged in at least three layers (upper, middle, and lower) along the height of the tower wall, with at least four sensors evenly arranged in each layer around the perimeter.

[0013] The early warning execution unit includes a field audible and visual alarm, as well as a relay module or communication interface module for communicating with the power plant's distributed control system (DCS).

[0014] It also includes a power supply unit that supplies power to each unit of the system, and the power supply unit includes an uninterruptible UPS power supply.

[0015] (III) Beneficial Effects Compared with the prior art, the present invention provides an online monitoring method and system for the stirring effect of desulfurization absorption tower slurry, which has the following beneficial effects: The online monitoring method and system for the stirring effect of desulfurization absorption tower slurry constructs a monitoring model based on the analysis of the tower wall temperature field and uses a sensor array to collect tower wall temperature data in real time; by comparing and analyzing the real-time collected data with the benchmark model, the stirring blind zone and solid deposition anomalies can be detected in a timely manner; the system automatically triggers the corresponding level of early warning and outputs diagnostic information according to the judgment result, realizing real-time, online, and visual monitoring and early warning of the stirring effect of absorption tower slurry, effectively solving the problems of strong subjectivity and delayed early warning of traditional monitoring methods. Attached Figure Description

[0016] Figure 1 is a schematic diagram of the method of the present invention; Figure 2 is a structural diagram of the system of the present invention. Detailed Implementation

[0017] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0018] Example 1 Please refer to Figure 1. The present invention provides an online monitoring method for the stirring effect of slurry in a desulfurization absorption tower, including the following steps: S1: Under the condition that the stirrer is working normally and there is no sediment in the tower, the tower wall temperature data is collected by a monitoring device installed on the outer wall of the absorption tower to establish a benchmark model that includes the normal temperature range of each measuring point and the overall temperature field uniformity threshold.

[0019] Specifically, this step is carried out when both the stirring system and the desulfurization system are in a stable and healthy operating state. The monitoring device includes a temperature sensor array for the outer wall of the absorber slurry section. Establishing the baseline model specifically includes: under stable conditions where the stirrer is running continuously at its rated speed, the slurry concentration and level are within the normal design range, and maintenance confirms that there is no gypsum or other solid matter deposited in the tower, the tower wall temperature data is continuously collected for a preset duration (e.g., 72 hours) using the temperature sensor array. During the collection process, the operating status of the stirrer (e.g., running / stopping, current, etc.) and key process parameters (e.g., slurry pH, density, level, etc.) are recorded simultaneously to ensure the validity of the data. Based on this data, the normal temperature range of each measuring point is statistically determined, specifically by calculating the average temperature value T of each measuring point. i With standard deviation σ i and its normal temperature range is defined as [T i -nσ i ,T i +nσ i Typically, n can be 2 or 3. The overall temperature field uniformity threshold is defined based on the dispersion of temperature values ​​at all valid measuring points at the same time. For example, the "standard deviation of temperatures at all measuring points" or the "difference between the highest and lowest measuring point temperatures" can be used as the uniformity evaluation index.

[0020] S2: During system operation, tower wall temperature data and environmental parameters are collected in real time, and the tower wall temperature data is processed for environmental temperature compensation to obtain the true temperature value.

[0021] The environmental parameters include at least ambient temperature. Because the exposed portion of the absorber wall is affected by ambient temperature, its measured value will deviate from the actual temperature transmitted to the tower wall by the slurry. The ambient temperature compensation process specifically involves: using historical data collected synchronously over a long period to establish a measurement temperature (T) system for each measuring point on the tower wall. measured ), ambient temperature (T) env ) and the compensated true temperature (T) real The relationship model between T and T. A typical pre-defined compensation algorithm is a linear regression model: T real =T measured -k i *(T env -T a ), where k iT represents the compensation coefficient for the i-th measurement point obtained by fitting historical data. a This serves as the reference ambient temperature (or average ambient temperature) for establishing the baseline model. During system operation, the data acquisition and processing unit reads the temperature values ​​from each sensor and the data from the ambient temperature and humidity sensors in real time. Based on this model, it compensates and corrects the real-time measurement values ​​at each measuring point, thereby eliminating or reducing the impact of environmental fluctuations and obtaining a more accurate tower wall temperature value that reflects the internal state of the slurry.

[0022] S3: Compare the real-time temperature data after compensation with the benchmark model, calculate the temperature deviation and temperature field uniformity, and classify the stirring effect based on the temperature deviation amplitude, the area ratio of abnormal regions and the duration of abnormality.

[0023] Specifically, the comparative analysis is performed at a fixed period (e.g., every minute). First, it is calculated whether the real-time compensated temperature value at each measuring point exceeds its corresponding reference normal temperature range. Second, the uniformity index J of the entire temperature field at the current moment is calculated. current For example, the standard deviation of the temperature at all measuring points. Then, the following logic is used to classify and determine the level: Level 1 warning (mild abnormality / attention): When the temperature of a single or a few adjacent measuring points is consistently (e.g., for 3 consecutive cycles) slightly lower than the lower limit of its normal range, but the deviation is less than ΔT1 (e.g., 2℃), and the area of ​​the abnormal region is small (e.g., <2%), it is judged as a potential sign of imbalance.

[0024] Level 2 warning (moderate anomaly / warning): When the temperature of a local continuous area (composed of adjacent abnormal measuring points) is consistently lower than the lower limit of its normal range, with a deviation between ΔT1 and ΔT2 (e.g., 5°C), and the area of ​​this region exceeds the first threshold (e.g., 5%), and the duration exceeds t1 (e.g., 5 minutes), it is determined that there is a risk of solid deposition or insufficient local stirring intensity.

[0025] Level 3 Warning (Severe Anomaly / Alarm): When a large area experiences a sustained and significantly lower temperature than the lower limit of the normal range (deviation > ΔT2), or when the overall temperature field uniformity J... current Continuously below the uniformity threshold J th Furthermore, if the degree of deterioration is obvious and the duration exceeds t2 (e.g., 10 minutes), it is judged as a serious overall deterioration of the stirring effect, with a high risk of large-scale deposition or stirrer failure.

[0026] The classification judgment also includes the logic for generating handling suggestions corresponding to the warning level. For example, for a level 1 warning, it is recommended to pay attention to the corresponding area during inspection; for a level 2 warning, it is recommended to adjust the corresponding agitator operating parameters or prepare for process adjustment; for a level 3 warning, it is recommended to immediately check the mechanical status of the agitator and consider arranging a shutdown for dredging.

[0027] S4: Trigger the corresponding level of warning based on the grading judgment result, and generate diagnostic information output including anomaly location and handling suggestions.

[0028] When an alert is triggered, the system will simultaneously perform the following actions: highlight the abnormal area in the human-computer interaction unit (e.g., use different colors to indicate different alert levels), and pop up a diagnostic information window. The information will clearly state the abnormal level, possible cause, specific location (e.g., "lower layer, east side 30°, 60° sector"), and recommended handling measures.

[0029] Based on the warning level, the warning execution unit is activated: Level 1 warnings may only log and display a prompt on the interface; Level 2 warnings activate the on-site audible and visual alarm, which flashes yellow; Level 3 warnings activate the red audible and visual alarm and keep it constantly lit.

[0030] The warning signal (usually a passive dry contact signal or a standard communication protocol message) is sent to the power plant's distributed control system (DCS) through a relay module or communication interface module, so that the operators in the main control room can be informed and coordinate with other systems.

[0031] In this embodiment, the temperature sensor array is arranged in multiple layers along the height direction of the outer side of the slurry section of the absorption tower, preferably in three layers (upper, middle, and lower) to cover the main slurry reaction zone. Multiple temperature sensors are evenly spaced along the circumference of each layer, for example, eight sensors per layer at 45° intervals. The sensor type can be a platinum resistance temperature sensor (PT100) for direct contact measurement, which is accurate and stable; or an infrared temperature sensor for non-contact measurement, which can be mounted on the ground using an adjustable bracket for more flexible installation.

[0032] Example 2 (Referring to Figure 2) This invention provides an online monitoring system for the stirring effect of desulfurization absorption tower slurry to implement the method described in Example 1 above. The system includes a temperature monitoring unit comprising multiple temperature sensors arranged on the outer wall of the slurry section of the absorption tower for collecting tower wall temperature data. The temperature sensor array is arranged in multiple layers along the height direction of the outer side of the slurry section of the absorption tower, preferably in upper, middle, and lower layers to cover the main slurry reaction zone. Multiple temperature sensors are evenly spaced along the circumference of each layer, for example, eight sensors per layer, spaced 45° apart. Preferably, the temperature sensors are waterproof and corrosion-resistant platinum resistance temperature sensors (PT100), which are in close contact with the tower wall through thermally conductive putty or welded temperature-measuring sleeves, or infrared temperature sensors, enabling non-contact measurement. They are mounted on the ground using adjustable brackets for more flexible installation.

[0033] The environmental parameter acquisition unit is used to collect ambient temperature data. This unit typically includes a temperature transmitter with a protective shield, installed near the absorption tower in a well-ventilated location that represents the overall environmental conditions.

[0034] The data acquisition and processing unit, connected to the temperature monitoring unit and environmental parameter acquisition unit, is used to receive and process sensor data. This unit typically includes a multi-channel temperature acquisition module (such as an RTD input module) and an analog / digital input module, responsible for converting the sensor's resistance or current signals into digital quantities, performing preliminary filtering and packaging, and uploading the data via fieldbus (such as RS-485 / Modbus) or industrial Ethernet.

[0035] The central processing unit, which communicates with the data acquisition and processing unit, is typically an industrial computer or embedded industrial control computer with dedicated monitoring software installed. It is configured to perform the following core functions: store historical data and establish and update baseline models; call environmental compensation algorithms to process real-time temperature data; execute the grading judgment logic; and generate early warning instructions of different levels, along with detailed diagnostic information including anomaly location, cause analysis, and handling suggestions.

[0036] The human-machine interface unit, connected to the central processing unit, is used to display temperature field information, judgment results, and diagnostic information. This unit typically includes an industrial touch screen or monitor, providing a graphical interface that can dynamically display three-dimensional or unfolded two-dimensional temperature cloud maps of the absorption tower, trend curves, real-time data from measuring points, a list of warning statuses, and historical record queries.

[0037] The early warning execution unit, connected to the central processing unit, is used to execute alarm actions and output signals according to the early warning command. This unit includes a local audible and visual alarm (different colors and sound modes correspond to different levels), and a relay module (outputting passive contact signals) or a standard communication interface module (such as supporting OPC, Modbus TCP, etc.) for communicating with the power plant's distributed control system (DCS).

[0038] The power supply unit provides a stable and reliable power supply to all system units (sensors, data acquisition modules, processors, alarms, etc.). Considering the power plant environment and the system's importance, the power supply unit includes an uninterruptible power supply (UPS) to ensure the system can continue to operate and shut down safely during brief power outages.

[0039] In summary, this online monitoring method and system for the stirring effect of desulfurization absorber slurry constructs a monitoring model based on tower wall temperature field analysis and utilizes a sensor array to collect tower wall temperature data in real time. It improves data reliability through environmental temperature compensation technology and compares the real-time collected data with a benchmark model to promptly detect stirring blind spots and abnormal solid deposition. The system automatically triggers corresponding level early warnings and outputs diagnostic information based on the judgment results, achieving real-time, online, and visualized monitoring and early warning of the absorber slurry stirring effect. This effectively solves the problems of strong subjectivity and delayed early warning in traditional monitoring methods, providing a strong guarantee for the safe, stable, and efficient operation of the desulfurization system.

[0040] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. An online monitoring method for the stirring effect of slurry in a desulfurization absorption tower, characterized in that, include: S1: Under normal operating conditions of the stirrer and no sedimentation inside the tower, the tower wall temperature data is collected by the monitoring device installed outside the absorption tower to establish a benchmark model that includes the normal temperature range of each measuring point and the overall temperature field uniformity threshold; S2: During system operation, the tower wall temperature data and environmental parameters are collected in real time, and the tower wall temperature data is processed by environmental temperature compensation to obtain real temperature data. S3: Compare the compensated real temperature data with the benchmark model, calculate the temperature deviation and temperature field uniformity, and classify the stirring effect based on the temperature deviation amplitude, the area ratio of abnormal regions and the duration of abnormality; S4: Trigger the corresponding level of warning according to the classification judgment result, and generate diagnostic information output including abnormality location and handling suggestions.

2. The method according to claim 1, characterized in that, In step S1, the monitoring device includes a temperature sensor array; establishing the benchmark model specifically includes: under the stable state of the stirrer running at the rated speed, continuously collecting tower wall temperature data for a preset time through the temperature sensor, and statistically determining the normal temperature range of each measuring point and the uniformity threshold based on the data.

3. The method according to claim 2, characterized in that, In step S2, the environmental parameters include ambient temperature; the ambient temperature compensation process specifically involves using the collected ambient temperature data to correct the tower wall temperature measurement deviation caused by environmental factors through a preset compensation algorithm.

4. The method according to claim 1, characterized in that, The grading determination in step S3 specifically includes at least one of the following logics: when the temperature of a local area is continuously lower than the lower limit of its normal temperature range, and the area ratio of the local area exceeds a first threshold, it is determined that there is a risk of solid deposition; when the uniformity of the overall temperature field is continuously lower than the uniformity threshold, it is determined that the overall stirring effect is deteriorated.

5. The method according to claim 4, characterized in that, The classification determination also includes logic for generating processing suggestions corresponding to the warning level; in step S4, while triggering the warning, the warning signal is sent to the power plant DCS system through the relay module.

6. An online monitoring system for the stirring effect of desulfurization absorption tower slurry in implementing the method according to any one of claims 1 to 5, characterized in that, include: The temperature monitoring unit includes multiple temperature sensors installed on the outer wall of the slurry section of the absorption tower to collect tower wall temperature data. Environmental parameter acquisition unit, used to collect ambient temperature data; A data acquisition and processing unit, signal-connected to the temperature monitoring unit and the environmental parameter acquisition unit, is used to receive and process sensor data; a central processing unit, communicatively connected to the data acquisition and processing unit, is configured to perform the following functions: establish and store the benchmark model, perform compensation processing on real-time temperature data, execute the graded judgment, and generate early warning instructions and diagnostic information; a human-machine interaction unit, connected to the central processing unit, is used to display temperature field information, judgment results, and diagnostic information; and an early warning execution unit, connected to the central processing unit, is used to execute alarm actions and output signals according to the early warning instructions.

7. The system according to claim 6, characterized in that, The temperature sensor in the temperature monitoring unit is an infrared thermometer or a platinum resistance thermometer; the temperature sensors are arranged in at least three layers along the height of the tower wall, with at least four sensors evenly arranged in each layer around the perimeter.

8. The system according to claim 6, characterized in that, The early warning execution unit includes a field audible and visual alarm, as well as a relay module or communication interface module for communicating with the power plant's distributed control system (DCS).

9. The system according to claim 6, characterized in that, It also includes a power supply unit that supplies power to each unit of the system, the power supply unit including an uninterruptible UPS power supply.

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