A water beam tube fouling condition monitoring system and method for a steel rolling heating furnace

Abstract

The present application relates to a kind of rolling heating furnace water beam pipe fouling condition monitoring system and method, utilize the fouling simulation system simulation heating section and the fouling condition of water beam column in soaking section, the temperature in simulated water beam pipe in fouling simulation system is controlled according to the calculation value of water beam inner surface temperature calculation module, make the temperature in simulated water beam pipe in fouling simulation system and the temperature in water beam pipe deviation ≤3 ℃, periodically observe the fouling state in fouling simulation system, to realize the monitoring of the fouling situation in the water beam column of rolling heating furnace heating section and soaking section.The advantage is: the fouling situation monitoring of rolling heating furnace walking beam is realized, the import and export water temperature of walking beam, the monitoring of simulated water beam pipe inner cooling water PH value, hardness and fouling thickness can be carried out, and the influence of fouling on water beam heat transfer process is evaluated, effectively avoid the pipe burst accident of rolling heating furnace walking beam.

Description

Technical Field

[0001] This invention belongs to the field of heating furnace technology and relates to a system and method for monitoring scaling conditions in water beam pipes of steel rolling heating furnaces. Background Technology

[0002] Scaling of the walking beam in a steel rolling furnace is a complex process that can lead to tube rupture and disrupt furnace production in severe cases. Stable operation of the walking beam within the furnace faces several challenges: the impact and vibration of the slab lifting process, sufficient strength to support the weight of the slab, high temperatures at refractory material detachment points, and erosion from internal cooling water.

[0003] In the prior art, patent application number CN202410119197.4 discloses an intelligent centralized control device for a heating furnace, including: a data acquisition module, a data preprocessing module, a data storage module, a furnace efficiency analysis module, and a system display module; it may further include a condensate pipe risk early warning module, a scaling analysis module, a fault analysis module, an intelligent temperature control module, a centralized monitoring module, a production and consumption statistics module, an alarm management module, and a report management module. This invention judges the scaling situation of the heating furnace by temperature changes and displays the impact results. This method plays a certain positive role in the scaling prediction of the water pipes of the heating furnace, but due to its excessive dependence on temperature, it lacks a direct and accurate judgment of the scaling situation. Patent application number CN202410128629.8 discloses a low-temperature heat pump vacuum dehydration and drying device, including a support frame and internal evaporation components. This invention, by setting up an anti-scaling mechanism, simultaneously stirs and propels the sludge during the thermal drying process, further preventing sludge clumping and reduced drying efficiency. It also uses an arc-shaped scraper to simultaneously clean the inner wall of the evaporator, preventing sludge adhesion and scaling. This technology plays a positive role in many devices prone to scaling. However, for systems like steel rolling mills with replicated walking beams, the structure is too complex for installation, making this technology unsuitable for solving the scaling problem. Patent application number CN202320369712.5 discloses an anti-deposition and scaling baffle for furnace fire tubes, providing a novel anti-deposition and scaling baffle with several sets of baffles arranged according to the number of fire tubes in the furnace. However, this technology also cannot be used for steel rolling mills with replicated walking beams due to their complex structure and installation limitations.

[0004] The walking beam system of a steel rolling mill heating furnace is a complex system characterized by its intricate structure and variable operating conditions. Once scale builds up, it increases the thermal resistance of the walking beam water pipes, preventing heat from the high-temperature heat source from being transferred to the steam-water mixture inside the water beam in a timely manner. This creates localized high-temperature zones, and the increased temperature further exacerbates the scaling process, ultimately leading to a walking beam tube rupture and disrupting normal furnace production. Because the walking beam operates inside the furnace, there is a lack of online monitoring methods for scaling within it. Therefore, it is necessary to develop a monitoring system for the internal condition of the water beam pipes in a steel rolling mill heating furnace to monitor the scaling condition on the inner surface of the walking beam, enabling timely repair or replacement of problematic walking beams during furnace shutdowns to prevent accidents. Summary of the Invention

[0005] To overcome the shortcomings of the existing technology, the purpose of this invention is to provide a monitoring system and method for scaling conditions of water beam tubes in steel rolling heating furnaces, enabling regular monitoring of scaling conditions in the walking beams, assessing the impact of scaling on the heat transfer of the walking beams, and promptly repairing or replacing problematic water beam tubes to prevent walking beam tube rupture accidents in steel rolling heating furnaces.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A method for monitoring scaling in water beam tubes of a steel rolling mill heating furnace is disclosed. This method utilizes a scaling simulation system to simulate the scaling conditions of the water beam columns in the heating and soaking sections. The simulated temperature inside the water beam tubes within the scaling simulation system is controlled based on the calculated value from the water beam inner surface temperature calculation module, ensuring that the deviation between the simulated temperature inside the water beam tubes and the actual temperature inside the water beam tubes is ≤3℃. The scaling status within the scaling simulation system is observed periodically, thereby enabling monitoring of the scaling conditions inside the water beam columns in the heating and soaking sections of the steel rolling mill heating furnace.

[0007] The periodic observation cycle for the scaling condition is as follows: once a month before scaling occurs, and once a week after scaling occurs, and the scaling thickness is measured. If the scaling layer thickness exceeds 3mm, the problematic walking beam is then shut down for inspection and confirmation.

[0008] A scaling monitoring system for water beam tubes in a steel rolling heating furnace includes a scaling simulation system, a data acquisition system, a water beam tube temperature detection thermocouple, a water beam inner surface temperature calculation module, a simulated water beam tube temperature control module, a pH detection probe, a water hardness detection probe, a pressure display module, and a steam / water ratio calculation module. The scaling simulation system is installed before the water inlet pipe of the water beam in the heating section and soaking section of the steel rolling furnace; The scaling simulation system includes simulated water beam pipes, which consist of steel pipes, insulation layers, and heaters. The insulation layer covers the outside of the steel pipes, and the heaters are placed between the insulation layer and the steel pipes. The number of simulated water beam pipes is the same as the number of water beam columns of the simulated steel rolling furnace, and the scaling situation of each water beam column of the steel rolling furnace can be simulated online. The simulated water beam pipes are placed vertically. The water beam tube temperature sensing thermocouple is used to detect the temperature of the water beam columns in the heating section and soaking section of the steel rolling furnace. pH and water hardness probes are used to detect the pH and hardness of the cooling water in the simulated water beam pipes of the scaling simulation system. The data acquisition system is used to collect and detect the temperature of the water beam columns in the heating section and soaking section of the steel rolling furnace, as well as the pH value and hardness of the cooling water in the scaling simulation system; The pressure display module is used to monitor and display the pressure in the simulated water beam pipe and the water beam pipe itself; the steam / water ratio calculation module is used to calculate the steam / water ratio in the simulated water beam pipe and the water beam pipe itself, and to adjust the flow rate and velocity in the simulated water beam pipe to ensure that the pressure and steam / water ratio deviation in the simulated water beam pipe and the water beam pipe does not exceed 5%; The data acquisition system communicates with the water beam inner surface temperature calculation module, which in turn communicates with the simulated water beam pipe temperature control module. The simulated water beam pipe temperature control module controls the heat output of the heater.

[0009] The flow velocity inside the simulated water beam pipe is controlled at 2.5 m / s to 3.2 m / s.

[0010] The diameter of the simulated water beam pipe is 30~50mm and the height is 500~800mm.

[0011] The temperature sensing thermocouple for the water beam pipe is installed between the water beam column and the insulation material in the heating section and soaking section of the steel rolling furnace, and the insulation material covers the outside of the water beam column.

[0012] The bottom of the water beam column is vertically connected to a detection tube, which is connected to the scaling simulation system. Within 500mm of the water beam column, there are 3 to 5 water beam tube temperature sensing couplers.

[0013] The simulated water beam pipes are connected in series.

[0014] The simulated water beam pipe is connected to the vaporization cooling return water system of the steel rolling heating furnace.

[0015] The heater has a temperature detection function, and the temperature of the simulated water beam tube is fed back to the simulated water beam tube temperature control module. The simulated water beam tube temperature control module adjusts the heat output of the heater according to the temperature feedback value, so as to achieve accurate control of the temperature of the simulated water beam tube.

[0016] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention enables the monitoring of scaling on the walking beams of a steel rolling mill heating furnace. It can monitor the inlet and outlet water temperatures of the walking beams, the pH value, hardness, and scale thickness of the cooling water inside the simulated water beam tubes, and assess the impact of scaling on the heat transfer process of the water beams. When the scale thickness exceeds a warning value, the furnace is shut down for inspection and confirmation of the problematic walking beam. If necessary, repairs or replacement of the problematic water beam tubes are carried out, effectively preventing walking beam tube rupture accidents in steel rolling mill heating furnaces. This significantly improves the scientific and economic efficiency of scaling management in heating furnace water beam tubes, combining the comprehensive benefits of precise fault prevention and system sustainability.

[0017] 2. This invention uses simulated water beams (same number and flow rate) identical to the tested water beams to reproduce the actual scaling environment under strict temperature control (deviation ≤3℃). Combined with real-time monitoring of water quality parameters by pH / hardness probes, it achieves dynamic simulation and high-precision prediction of the scaling process.

[0018] 3. This invention achieves multi-dimensional data fusion and intelligent control, integrating temperature detection (3-5 water beam tube temperature detection thermocouples), pH and water hardness detection, water beam inner surface temperature calculation module and simulated water beam tube temperature control module to form a closed-loop feedback system, ensuring that the simulated conditions are highly synchronized with the actual working conditions, and improving the reliability of scaling status assessment.

[0019] 4. This invention adjusts the scaling observation frequency in stages (once a month → once a week), and combines the analysis of scale thickness and heat transfer impact to trigger boiler shutdown inspection in advance, effectively preventing tube rupture accidents and realizing the transformation from passive maintenance to predictive maintenance. Attached Figure Description

[0020] Figure 1 This is a flowchart for monitoring the scaling condition of the water beam pipes in a steel rolling heating furnace.

[0021] Figure 2 This is a schematic diagram of the scaling monitoring system for the water beam pipes of a steel rolling heating furnace.

[0022] Figure 3 This is a schematic diagram of the installation of a temperature sensing thermocouple for a water beam pipe. Figure 1 .

[0023] Figure 4 This is a schematic diagram of the installation of a temperature sensing thermocouple for a water beam pipe. Figure 2 .

[0024] In the diagram: 1-Water beam column three, 2-Water beam column two, 3-Water beam column one, 4-Water flow direction at the inlet of the stepping beam, 5-Water beam column six, 6-Flow direction of the steam-water mixture at the outlet of the stepping beam, 7-Water beam column five, 8-Water beam column four, 9-Cooling water supply pipe for the stepping beam, 10-Inlet pipe for the scaling simulation system, 11-Simulated water beam pipe one, 12-Simulated water beam pipe two, 13-Simulated water beam pipe three, 14-Simulated water beam pipe four, 15-Simulated water beam pipe five, 16-Simulated water beam pipe six, 17-Flow direction of the steam-water mixture at the outlet of the scaling simulation system, 201-Detection pipe, 202-Water beam pipe temperature detection thermocouple, 203-Insulation layer. Detailed Implementation

[0025] The present invention will now be described in detail with reference to the accompanying drawings, but it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0026] See Figure 1 A method for monitoring scaling in the water beam tubes of a steel rolling mill heating furnace is disclosed. This method utilizes a scaling simulation system to simulate the scaling conditions of the water beam columns in the heating and soaking sections. The simulated water beam tube temperature within the scaling simulation system is controlled based on the calculated value from the water beam inner surface temperature calculation module, ensuring the deviation between the simulated water beam tube temperature and the actual water beam tube temperature is ≤3℃. The scaling status within the scaling simulation system is observed periodically, thereby achieving monitoring of scaling conditions in the water beam columns of the heating and soaking sections of the steel rolling mill heating furnace. The periodic observation cycle for scaling status is: once a month before scaling occurs, and once a week after scaling occurs. The scaling thickness is measured, and the problematic walking beams are then inspected and confirmed during furnace shutdown. This allows for timely repair or replacement of problematic walking beams during furnace shutdown, effectively preventing walking beam tube rupture accidents in the steel rolling mill heating furnace. The steam-water mixture generated by the scaling simulation system enters the steam cooling return water system, pressure display module, and steam / water ratio calculation module of the steel rolling mill heating furnace.

[0027] The scaling monitoring system for water beam tubes in steel rolling heating furnaces includes a scaling simulation system, a data acquisition system, a water beam tube temperature detection thermocouple 202, a water beam inner surface temperature calculation module, a simulated water beam tube temperature control module, a pH detection probe, and a water hardness detection probe.

[0028] like Figure 2As shown, in this embodiment, the scaling simulation system includes: simulated water beam pipe one 11, simulated water beam pipe two 12, simulated water beam pipe three 13, simulated water beam pipe four 14, simulated water beam pipe five 15, simulated water beam pipe six 16, and the number of simulated water beam pipes is 6. The simulated water beam pipe consists of a steel pipe, an insulation layer 203, and a heater. The insulation layer 203 covers the outside of the steel pipe, and the heater is located between the insulation layer 203 and the steel pipe. The heater has a temperature monitoring function, and the temperature of the simulated water beam pipe is fed back to the simulated water beam pipe temperature control module. The simulated water beam pipe is placed vertically. A scaling simulation system is used to simulate the scaling situation of the water beam pipe in the rolling mill heating furnace. The simulation object is the water beam column of the rolling mill heating furnace, namely: water beam column 31, water beam column 22, water beam column 13, water beam column 65, water beam column 57, water beam column 48, and the number of water beam columns in the rolling mill heating furnace is 6. The number of simulated water beam pipes is the same as the number of water beam columns in the simulated rolling mill heating furnace. The scaling simulation system is installed as follows: the scaling simulation system inlet pipe 10 is installed on the cooling water supply pipe 9 of the walking beam before water beam column 13 in the heating section and soaking section of the rolling mill heating furnace. The flow process of cooling water inside the scaling simulation system is as follows: cooling water enters the scaling simulation system through the inlet pipe 10, and then flows through simulated water beam pipe 11, simulated water beam pipe 212, simulated water beam pipe 313, simulated water beam pipe 414, simulated water beam pipe 515 and simulated water beam pipe 616 respectively; the flow process of vaporization cooling water inside the water beam of the steel rolling heating furnace is as follows: vaporization cooling water flows into water beam column 13 along the inlet water flow direction 4 of the walking beam, and flows out in the direction 6 of the vapor-water mixture formed after flowing through water beam column 22, water beam column 13, water beam column 65, water beam column 7 and water beam column 48 respectively. The simulation system establishes the following correspondence between the simulated water beam pipes and the water beam columns of the rolling mill heating furnace: Simulated water beam pipe 11 simulates water beam column 13, simulated water beam pipe 212 simulates water beam column 22, simulated water beam pipe 313 simulates water beam column 31, simulated water beam pipe 414 simulates water beam column 48, simulated water beam pipe 515 simulates water beam column 57, and simulated water beam pipe 616 simulates water beam column 65; that is, it simulates the scaling condition of each water beam column of the rolling mill heating furnace online. The lower part of simulated water beam pipe 11 is connected to the inlet pipe 10 of the scaling simulation system, and the upper part is connected to the lower part of simulated water beam pipe 212, and so on until the upper part of simulated water beam pipe 515 is connected to simulated water beam pipe 616. Cooling water (from the walking beam cooling water supply pipe 9) flows through the simulated water beam pipes, and the flow rate is controlled at 3 m / s. All simulated water beam pipes have a diameter of 30~50mm and a height of 500~800mm (within this height range, the vertical pipes of the heating furnace water beam are prone to scale buildup).

[0029] The 202 water beam tube temperature sensing thermocouple is used to detect the temperature of the water beam columns in the heating and soaking sections of the rolling mill heating furnace. The pH and water hardness probes are used to detect the pH and hardness of the cooling water in the simulated water beam tubes of the scaling simulation system. A pH and water hardness probe are installed in each simulated water beam tube to monitor the pH and hardness of the cooling water in real time. The data acquisition system is used to collect data on the temperature of the water beam columns in the heating and soaking sections of the rolling mill heating furnace, as well as the pH, hardness, pressure, and steam / water ratio of the cooling water in the scaling simulation system.

[0030] The data acquisition system communicates with the water beam inner surface temperature calculation module, which in turn communicates with the simulated water beam pipe temperature control module. The simulated water beam pipe temperature control module controls the heater's heat output based on the temperature feedback from the heater, thereby achieving accurate temperature control of the simulated water beam.

[0031] The data acquisition system collects the temperature of the water beam columns in the heating and soaking sections of the rolling mill heating furnace, as well as the pH value and hardness of the cooling water in the scaling simulation system. The system transmits the water beam column temperature to the water beam inner surface temperature calculation module. This module calculates the water beam inner surface temperature (the average value detected by the water beam tube temperature sensing thermocouple 202) and transmits it to the simulated water beam tube temperature control module. The water beam tube temperature control module controls the heat output of the heater, ensuring that the deviation between the simulated water beam tube inner surface temperature and the simulated walking beam column inner surface temperature is ≤3℃. The pressure display module monitors and displays the pressure within the simulated water beam tube. The steam / water ratio calculation module calculates the steam / water ratio within the simulated water beam tube, adjusting the flow rate and velocity to ensure that the pressure and steam / water ratio deviation within the simulated water beam tube do not exceed 5%.

[0032] See Figure 4 Taking water beam column 2 as an example, the installation method of the temperature sensing couple is explained. Insulation material is wrapped around the outside of water beam column 2. The water beam pipe temperature sensing coupler 202 is installed between water beam column 2 and the insulation material to ensure the accuracy of the detected temperature. See... Figure 3 A detection tube 201 is vertically connected to the bottom of the water beam column. The detection tube 201 is connected to the scaling simulation system. Temperature sensing couplers 202 are evenly distributed within 500mm of the detection tube 201 on the water beam column. There are 3-5 temperature sensing couplers 202, evenly distributed along the column height. Combined with the insulation layer 203, this design accurately captures temperature gradient changes, enhancing the accuracy of internal surface temperature calculation. In this embodiment, the water beam columns requiring temperature sensing couplers include: Water Beam Column 1 (3), Water Beam Column 2 (2), Water Beam Column 1 (1), Water Beam Column 6 (5), Water Beam Column 5 (7), and Water Beam Column 4 (8). The steam-water mixture generated by the simulation system is recycled to the vaporization cooling return water system, achieving energy reuse while reducing the impact on the external environment.

[0033] Through the above specific embodiments, those skilled in the art can easily implement the present invention. However, it should be understood that the present invention is not limited to the specific embodiments described above. Based on the disclosed embodiments, those skilled in the art can arbitrarily combine different technical features to achieve different technical solutions. Due to space limitations and for the sake of brevity, each of these combined solutions has not been described in detail. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for monitoring scaling conditions in the water beam pipes of a steel rolling heating furnace, characterized in that, The scaling simulation system is used to simulate the scaling conditions of the water beam columns in the heating and soaking sections. The temperature inside the simulated water beam pipes in the scaling simulation system is controlled according to the calculated value of the water beam inner surface temperature calculation module, so that the temperature deviation between the simulated water beam pipes and the actual water beam pipe temperature is ≤3℃. The scaling status in the scaling simulation system is observed regularly, thereby realizing the monitoring of the scaling conditions inside the water beam columns in the heating and soaking sections of the steel rolling furnace.

2. The method for monitoring scaling conditions in the water beam pipes of a steel rolling heating furnace according to claim 1, characterized in that, The periodic observation cycle for the scaling condition is as follows: once a month before scaling occurs, and once a week after scaling occurs, and the scaling thickness is measured. If the scaling layer thickness exceeds 3mm, the problematic walking beam is then shut down for inspection and confirmation.

3. A system for monitoring scaling conditions in the water beam pipes of a steel rolling heating furnace, implementing the monitoring method of claim 1 or 2, characterized in that, It includes a scaling simulation system, a data acquisition system, a water beam tube temperature detection thermocouple, a water beam inner surface temperature calculation module, a simulated water beam tube temperature control module, a pH detection probe, a water hardness detection probe, a pressure display module, and a steam / water ratio calculation module; The scaling simulation system is installed before the water inlet pipe of the water beam in the heating section and soaking section of the steel rolling furnace. The scaling simulation system includes simulated water beam pipes, which consist of steel pipes, insulation layers, and heaters. The insulation layer covers the outside of the steel pipes, and the heaters are placed between the insulation layer and the steel pipes. The number of simulated water beam pipes is the same as the number of water beam columns of the simulated steel rolling furnace, and the scaling situation of each water beam column of the steel rolling furnace can be simulated online. The simulated water beam pipes are placed vertically. The water beam tube temperature sensing thermocouple is used to detect the temperature of the water beam columns in the heating section and soaking section of the steel rolling furnace. pH and water hardness probes are used to detect the pH and hardness of the cooling water in the simulated water beam pipes of the scaling simulation system. The data acquisition system is used to collect and detect the temperature of the water beam columns in the heating section and soaking section of the steel rolling furnace, as well as the pH value and hardness of the cooling water in the scaling simulation system; The pressure display module is used to monitor and display the pressure in the simulated water beam pipe and the water beam pipe itself; the steam / water ratio calculation module is used to calculate the steam / water ratio in the simulated water beam pipe and the water beam pipe itself, and to adjust the flow rate and velocity in the simulated water beam pipe to ensure that the pressure and steam / water ratio deviation in the simulated water beam pipe and the water beam pipe does not exceed 5%; The data acquisition system communicates with the water beam inner surface temperature calculation module, which in turn communicates with the simulated water beam pipe temperature control module. The simulated water beam pipe temperature control module controls the heat output of the heater.

4. The scaling monitoring system for water beam pipes in a steel rolling heating furnace according to claim 3, characterized in that, The flow velocity inside the simulated water beam pipe is controlled at 2.5 m / s to 3.2 m / s.

5. The scaling monitoring system for water beam pipes in a steel rolling heating furnace according to claim 3, characterized in that, The diameter of the simulated water beam pipe is 30~50mm and the height is 500~800mm.

6. The scaling monitoring system for water beam pipes in a steel rolling heating furnace according to claim 3, characterized in that, The temperature sensing thermocouple for the water beam pipe is installed between the water beam column and the insulation material in the heating section and soaking section of the steel rolling furnace, and the insulation material covers the outside of the water beam column.

7. A scaling monitoring system for water beam pipes in a steel rolling heating furnace according to claim 6, characterized in that, The bottom of the water beam column is vertically connected to a detection tube, which is connected to the scaling simulation system. Within 500mm of the water beam column, there are 3 to 5 water beam tube temperature sensing couplers.

8. A scaling monitoring system for water beam pipes in a steel rolling heating furnace according to claim 3, characterized in that, The simulated water beam pipes are connected in series.

9. A scaling monitoring system for water beam pipes in a steel rolling heating furnace according to claim 3, characterized in that, The simulated water beam pipe is connected to the vaporization cooling return water system of the steel rolling heating furnace.

10. A scaling monitoring system for water beam pipes in a steel rolling heating furnace according to claim 3, characterized in that, The heater has a temperature detection function, and the temperature of the simulated water beam tube is fed back to the simulated water beam tube temperature control module. The simulated water beam tube temperature control module adjusts the heat output of the heater according to the temperature feedback value, so as to achieve accurate control of the temperature of the simulated water beam tube.

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