Online leakage detection system of heat exchange device

Abstract

The utility model discloses an on-line leakage detection system of a heat exchange device. The heat exchange device comprises an isothermal conversion furnace and a steam generator, according to the online leakage checking system, the isothermal transformation furnace is connected with a steam pocket, the steam pocket is connected with a first separator through a first circulating water cooler, the first separator is connected with a first air cooling separator pipeline, and the first air cooling separator is connected with a carbon monoxide analysis meter through a first electromagnetic stop valve; the steam generator is connected with a second separator through a second circulating water cooler, the second separator is connected with a second air cooling separator, and the second air cooling separator is connected with a carbon monoxide analysis meter through a second electromagnetic stop valve. According to the utility model, gas in the heat exchange device is sampled, cooled and detected respectively, whether the heat exchange device leaks or not is accurately judged in real time, and meanwhile, automatic switching is realized through the electromagnetic stop valve, so that the safety is improved, and the instrument equipment is simplified.

Description

Technical Field

[0001] This utility model belongs to the field of coal chemical leakage detection technology, specifically relating to an online leak detection system for a heat exchange device. Background Art

[0002] Coal chemical processes generally include coal gasification, carbon monoxide conversion, coal gas purification, and product gas synthesis. During the high-temperature gasification, conversion, and syngas cooling processes, a significant amount of industrial waste heat can be utilized. Currently, waste heat in coal chemical processes is typically addressed by using isothermal shift reactors or steam generators to generate steam and remove the heat. Isothermal shift reactors primarily utilize hot water tube bundles embedded within the catalyst bed to convert the reaction heat of the catalyst bed and excess system heat into steam. This effectively reduces the catalyst bed temperature, increases the reaction driving force, and extends the catalyst's lifespan. They also offer advantages such as flexible temperature control, lower catalyst bed temperature, higher conversion rate, and lower catalyst usage. Steam generators utilize the heat energy of fuel or other energy sources to heat water and generate steam. They offer advantages such as high thermal energy utilization, wide application range, low operating difficulty, and low cost.

[0003] However, isothermal converters have complex structures and large individual units, especially with numerous internal heat exchange tubes. Improper operation can easily damage these internal components, leading to leaks and adverse effects on the catalyst, thus impacting system stability. The complex structure of the isothermal converter also makes leak detection and maintenance extremely difficult. Steam generator pipe joints operate in a high-temperature environment for extended periods, and are prone to cracking and leaks due to crack corrosion and stress corrosion. Furthermore, the continuous gas-liquid conversion process also causes wear and corrosion of internal components, resulting in leaks. Currently, the coal chemical industry commonly uses a method of adding a cooler to the downstream unit to cool the generated steam, then collecting the cooled gas and manually sending it to an analytical testing center to analyze its composition and determine if leaks exist in the isothermal converter and steam generator. However, this method is time-consuming and labor-intensive, and cannot detect leaks promptly, potentially leading to safety accidents and affecting the stable operation of the equipment and system. Summary of the Invention

[0004] To address the aforementioned technical problems, this utility model provides an online leak detection system for heat exchange devices. By installing an air cooling separator after heat exchange devices such as isothermal converters and steam generators to remove moisture, and using high-purity nitrogen to guide non-condensable components to an online carbon monoxide analyzer, the system enables online real-time analysis and inspection of the gas components flowing out of the heat exchange device. Furthermore, the system achieves remote automatic switching of airflow through an electromagnetic shut-off valve, resulting in a high degree of automation.

[0005] To achieve the above objectives, this utility model provides an online leak detection system for a heat exchange device, the heat exchange device including an isothermal converter and a steam generator; the online leak detection system includes the isothermal converter connected to a steam drum, the steam drum connected to a first separator via a first circulating water cooler, the first separator connected to a first air-cooled separator via a pipeline, the first air-cooled separator connected to a carbon monoxide analyzer via a first electromagnetic shut-off valve; the steam generator connected to a second separator via a second circulating water cooler, the second separator connected to a second air-cooled separator, and the second air-cooled separator connected to a carbon monoxide analyzer via a second electromagnetic shut-off valve.

[0006] Preferably, a first pressure reducing valve is provided on the pipeline connecting the first separator and the first air-cooled separator.

[0007] Preferably, a second pressure reducing valve is provided on the pipeline connecting the second separator and the second air-cooled separator.

[0008] Preferably, the first air cooling separator and the first electromagnetic shut-off valve are connected to a high-purity nitrogen storage tank via a pipeline.

[0009] Preferably, the second air cooling separator and the second electromagnetic shut-off valve are connected to a high-purity nitrogen storage tank via a pipeline.

[0010] The beneficial effects of the present invention are:

[0011] 1. A gas sampling, cooling, and detection device was designed for the isothermal converter and the steam generator, respectively. The device includes a circulating water cooler, a classifying gas separator, and an air cooling separator. Gas samples are taken from both. After two cooling cycles and moisture separation, the non-condensable gas components are transported to a carbon monoxide analyzer for online analysis under the guidance of high-purity nitrogen. The sample gas components are detected, which allows for real-time determination of whether there are any leaks in the isothermal converter and the steam generator.

[0012] 2. Electromagnetic shut-off valves are installed on the pipelines of the isothermal converter and steam generator before the sampling gas enters the detection instrument. The electromagnetic shut-off valves are controlled by a remote automation system to automatically switch between the opening and closing states of the two electromagnetic shut-off valves, thereby enabling separate online detection of the sampling gas in different heat exchange devices.

[0013] 3. This utility model can make accurate judgments when the leakage is at a very small level, preventing the leakage accident from escalating further. It overcomes the problems of missed judgments and inaccurate judgments of micro-leakages in conventional manual analysis, and also has real-time performance. Attached Figure Description

[0014] Figure 1This is a schematic diagram of the structure of the present invention. In the figure, 1 is an isothermal conversion furnace, 2 is a steam drum, 3 is a first circulating water cooler, 4 is a first separator, 5 is a first pressure reducing valve, 6 is a first air cooling separator, 7 is a high-purity nitrogen storage tank, 8 is a first electromagnetic shut-off valve, 9 is a carbon monoxide analyzer, 10 is a steam generator, 11 is a second circulating water cooler, 12 is a second separator, 13 is a second pressure reducing valve, 14 is a second air cooling separator, and 15 is a second electromagnetic shut-off valve. Detailed Implementation

[0015] The technical solution of this utility model will be further explained below with reference to the accompanying drawings and specific embodiments. It is worth noting that the following embodiments are only preferred embodiments of this utility model and should not be construed as limiting this utility model. The protection scope of this utility model should be determined by the content of the claims. Modifications or substitutions made by those skilled in the art to the technical solution of this utility model without creative effort all fall within the protection scope of this utility model.

[0016] Example 1

[0017] like Figure 1 As shown, an online leak detection system for a heat exchange device includes an isothermal converter 1 and a steam generator 10 connected in parallel. The isothermal converter 1 is connected to a steam drum 2, which is connected to a first circulating water cooler 3 via pipeline. The isothermal converter 1 and the steam drum 2 are used to cool samples taken online from the isothermal converter 1 and the steam drum 2, and to condense the water vapor contained therein. The first circulating water cooler 3 is connected to a first separator 4 via pipeline, which separates the condensate and non-condensable components in the cooled sample. The non-condensable components are depressurized by a pressure reducing valve 5 and then transported through a pipeline to a first air cooling separator 6 for further separation of water and non-condensable gas components. The pipeline from which the non-condensable gas components flow is connected to a high-purity nitrogen storage tank 7. Guided by high-purity nitrogen, the non-condensable gas components flow through a first electromagnetic shut-off valve 8 into a carbon monoxide analyzer 9 for gas composition analysis. The analysis detects the carbon monoxide content in the non-condensable gas components to determine whether there is a leak in the isothermal converter 1.

[0018] The steam generator 10 outlet is connected to the second circulating water cooler 11, which samples and cools the gas in the steam generator 10. The cooled gas is then transported through a pipeline to the second separator 12 for further cooling and moisture separation. The remaining non-condensable components are depressurized by the second pressure reducing valve 13 and then transported to the second air cooling separator 14 for further cooling and moisture separation to obtain non-condensable gas components. The pipeline from which the non-condensable gas components flow is connected to the high-purity nitrogen storage tank 7. Guided by high-purity nitrogen, the non-condensable gas components flow through the opened second electromagnetic shut-off valve 15 into a carbon monoxide analyzer for analysis. The carbon monoxide content is detected to determine whether there is a leak in the steam generator 10.

[0019] When checking for leaks in the isothermal converter 1, the first electromagnetic shut-off valve 8 is opened and the second electromagnetic shut-off valve 15 is closed via the remote control system; when checking for leaks in the steam generator 10, the second electromagnetic shut-off valve 15 is opened and the first battery shut-off valve 8 is closed via the remote control system, achieving automatic switching and online leak checking for different heat exchange devices.

Claims

1. An online leak detection system for a heat exchange device, characterized in that: The isothermal conversion furnace (1) is connected to a steam drum (2), the steam drum (2) is connected to a first separator (4) via a first circulating water cooler (3), the first separator (4) is connected to a first air cooling separator (6) via a pipeline, the first air cooling separator (6) is connected to a carbon monoxide analysis meter (9) via a first electromagnetic shut-off valve (8); the steam generator (10) is connected to a second separator (12) via a second circulating water cooler (11), the second separator (12) is connected to a second air cooling separator (14), and the second air cooling separator (14) is connected to a carbon monoxide analysis meter (9) via a second electromagnetic shut-off valve (15).

2. The online leak detection system for a heat exchange device according to claim 1, characterized in that: A first pressure reducing valve (5) is provided on the pipeline connecting the first separator (4) and the first air cooling separator (6).

3. The online leak detection system for a heat exchange device according to claim 1, characterized in that: A second pressure reducing valve (13) is provided on the pipeline connecting the second separator (12) and the second air cooling separator (14).

4. The online leak detection system for a heat exchange device according to claim 1, characterized in that: The first air cooling separator (6) and the first electromagnetic shut-off valve (8) are connected to a high-purity nitrogen storage tank (7) via a pipeline.

5. The online leak detection system for a heat exchange device according to claim 1, characterized in that: The second air cooling separator (14) and the second electromagnetic shut-off valve (15) are connected to a high-purity nitrogen storage tank (7) via a pipeline.

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