Dust collection system, dust collection method, water leakage / corrosion prediction system and water leakage / corrosion prediction method

Abstract

To provide a dust collection system which is provided with means of predicting the water leakage / corrosion of a prediction object in a smoke exhaust ventilation part from a furnace to a duct collection machine and, before the generation of water leakage in the prediction object, e.g., owing to its breakage caused by thickness reduction, can detect it and predict the breakage thereof to contribute to the predictive maintenance of equipment, a dust collection method, a water leakage / corrosion prediction system and a water leakage / corrosion prediction method.SOLUTION: A dust collection system comprises a prediction system for predicting at least one of the water leak and corrosion of a smoke exhaust ventilation part from a furnace to a dust collection machine. According to this invention, the dust collection system can predict at least one of the water leakage and corrosion of the prediction object, and, before water leakage in the smoke exhaust ventilation part from the furnace to the dust collection machine occurs or damage to a filter cloth occurs, can take the maintenance measures of the equipment in a planned manner.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a dust collection system, a dust collection method, a water leakage or corrosion prediction system, and a water leakage and corrosion prediction method. [Background technology]

[0002] Exhaust gas discharged from steelmaking electric furnaces, waste furnaces, etc. is sent to a dust collector through a flue gas duct, which is an exhaust gas ventilation member, where fly ash contained in the exhaust gas is collected and released into the atmosphere. Since the exhaust gas is hot, there are double-cylinder water-cooled exhaust gas vent members consisting of a metal outer cylinder and a metal inner cylinder, with the inside of the inner cylinder used as an exhaust gas passage and the space between the outer and inner cylinders used as a cooling water passage to cool the exhaust gas before sending it downstream.

[0003] Patent Document 1 describes a method for operating a water-cooled flue gas duct that can effectively suppress corrosion wear of the water-cooled flue gas duct without changing the structure or material of the water-cooled flue gas duct. This operating method is characterized in that in a double-cylinder water-cooled flue gas duct with a cooling water flow path between the outer and inner cylinders, a corrosive ash reforming operation in which the surface temperature of the inner surface of the inner cylinder, which serves as the exhaust gas flow path, is maintained at 250°C or higher for five minutes or more is performed at least once within 30 days for part or all of the exhaust gas flow path. This is said to have the effect of extending the life of the water-cooled smoke exhaust duct and reducing the frequency of operation shutdowns due to water leaks. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2007-278587 A Summary of the Invention [Problem to be solved by the invention]

[0005] When the operation of the furnace is stopped, for example, in the case of a double-tube water-cooled flue gas duct, the condensation of exhaust gas remaining in the exhaust gas passage inside the inner tube may cause the corrosion of the inner tube to progress, gradually thinning the wall thickness and causing thinning. If the inner tube is damaged due to thinning during operation of the furnace, water may leak from the damaged area, and moisture may adhere to the filter cloth of the dust collector located downstream, causing dust to adhere to the filter cloth, increasing the pressure loss of the filter cloth and causing the filter cloth to be damaged. There is also a problem that the moisture may damage the blower located downstream.

[0006] In order to avoid equipment downtime and improve productivity, it is desirable to detect signs of damage and perform maintenance before problems occur, rather than merely reducing the frequency of shutdowns due to water leaks as disclosed in the invention described in Prior Art Document 1. For example, a maintenance method such as predictive maintenance can be considered, in which the state of equipment is continuously monitored, the deterioration state of the equipment is grasped, and the deterioration is predicted, and parts are replaced or repaired.

[0007] Therefore, an object of the present invention is to provide a dust collection system, a dust collection method, a water leakage or corrosion prediction system, and a water leakage and corrosion prediction method which are equipped with a means for predicting water leakage or corrosion of a predicted object in the flue gas ventilation section from the furnace to the dust collector, and which can detect water leakage or corrosion in advance and predict damage to the predicted object before it occurs due to thinning leading to damage, etc., and which contribute to predictive maintenance of equipment. [Means for solving the problem]

[0008] As a result of intensive research into the above-mentioned problems, the inventors discovered that it is possible to obtain a dust collection system that is characterized by being equipped with a prediction system for predicting at least one of water leakage and corrosion in the flue gas ventilation section from the furnace to the dust collector, and that enables predictive maintenance of the equipment, and thus completed the present invention. That is, the present invention provides a dust collection system, a dust collection method, a water leakage or corrosion prediction system, and a water leakage and corrosion prediction method, characterized by the following.

[0009] The dust collection system of the present invention for solving the above problems is characterized by including a prediction system for predicting at least one of water leakage and corrosion in a flue gas vent section from a furnace to a dust collector. According to the dust collection system of the present invention, it is possible to predict at least one of water leakage and corrosion of the predicted object, and it is possible to provide a dust collection system that can take planned maintenance measures for the equipment before a situation occurs in which water leakage occurs in the flue gas ventilation section from the furnace to the dust collector or damages the filter cloth.

[0010] In addition, one embodiment of the dust collection system of the present invention is characterized by including a notification unit that notifies an administrator of the prediction result of the prediction system. According to this aspect, a dust collection system can be provided that can notify the prediction results of the prediction system to the equipment manager, thereby ensuring opportunities for the manager to carry out planned maintenance of the equipment at his or her discretion.

[0011] The water leakage or corrosion prediction system of the present invention, which is intended to solve the above problems, is characterized by predicting at least one of water leakage and corrosion in a flue gas ventilation section from a furnace to a dust collector. According to the water leakage or corrosion prediction system of the present invention, since it is provided with a prediction means for predicting at least one of water leakage and corrosion in the flue gas ventilation section from the furnace to the dust collector, it is possible to provide a water leakage or corrosion prediction system that contributes to predictive maintenance for avoiding equipment stoppage that would affect production plans before a water leakage occurs in the flue gas ventilation section from the furnace to the dust collector or before a situation occurs that would damage the filter cloth. In addition, by applying this prediction system to an existing dust collection system, the effects of the present invention can be obtained for the existing dust collection system as well.

[0012] The dust collection method of the present invention for solving the above problems is characterized by including a prediction step for predicting at least one of water leakage and corrosion in a flue gas vent section from a furnace to a dust collector. According to the present aspect, a dust collection method can be provided that includes a prediction step for predicting at least one of water leakage and corrosion in advance, and contributes to predictive maintenance of equipment to avoid equipment stoppages that would affect production plans before a water leakage occurs.

[0013] The water leakage or corrosion prediction method of the present invention for solving the above problem is characterized by including a prediction step for predicting at least one of water leakage and corrosion in a flue gas ventilation section from a furnace to a dust collector. According to the present aspect, a method for predicting water leakage or corrosion is provided, which includes a prediction step for predicting at least one of water leakage and corrosion in the flue gas ventilation section from the furnace to the dust collector, and contributes to predictive maintenance of equipment to avoid equipment stoppages that would affect production plans before a water leakage occurs. Effect of the Invention

[0014] According to the present invention, it is possible to provide a dust collection system, a dust collection method, a water leakage or corrosion prediction system, and a water leakage and corrosion prediction method that contribute to predictive maintenance of a flue gas vent section. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a schematic explanatory diagram showing an overall arrangement configuration of a dust collection system according to a first embodiment of the present invention. [Diagram 2] FIG. 1 is a schematic explanatory diagram showing a double-cylinder type smoke exhaust duct, which is one embodiment of a smoke exhaust ventilation section in a first embodiment of the present invention. [Diagram 3] FIG. 1 is a schematic explanatory diagram of a smoke exhaust vent having an identification portion in a first embodiment of the present invention. [Figure 4] FIG. 1 is a schematic explanatory diagram showing an overall configuration of a prediction system in a first embodiment of the present invention. [Diagram 5] FIG. 2 is a schematic explanatory diagram showing a hardware configuration of a prediction support unit of the prediction system in the first embodiment of the present invention. [Figure 6] 13 is a schematic explanatory diagram of a display example in which the predicted value obtained by the prediction information calculation unit in one embodiment of the present invention is a temperature distribution value. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, embodiments of the dust collection system, dust collection method, water leakage or corrosion prediction system, and water leakage and corrosion prediction method according to the present invention will be described in detail with reference to the drawings. Note that the description of the dust collection method and the water leakage and corrosion prediction method can be replaced with a description of the features and operation of the dust collection system and the water leakage or corrosion prediction system. Furthermore, the dust collection system, dust collection method, water leakage or corrosion prediction system and prediction method described in the embodiments are merely examples used to explain the dust collection system, dust collection method, water leakage or corrosion prediction system and water leakage and corrosion prediction method according to the present invention, and are not limited thereto.

[0017] [Embodiments] [Dust collection system] FIG. 1 is a schematic explanatory diagram showing the overall arrangement of a dust collection system 100 according to a first embodiment of the present invention. The dust collection system 100 includes a furnace 101, a combustion tower 102, an exhaust gas cooling tower 103, a dust collector 104, and a prediction system 3. Exhaust gas discharged from the furnace 101 flows through the ventilation section to the combustion tower 102, passes through the exhaust gas ventilation section 10, is sent to the exhaust gas cooling tower 103, and flows to the dust collector 104. The exhaust gas cooled in the exhaust gas cooling tower 103 is captured by a filter cloth in the dust collector 104, and the dust-removed exhaust gas is released to the atmosphere. The flue gas ventilation section 10 has the function of directing flue gas from the furnace 101 to the combustion tower 102, the flue gas cooling tower 103, and then to the dust collector 104. The prediction system 3 has a function of predicting at least one of water leakage and corrosion of the flue gas ventilation section 10.

[0018] The furnace 101 may be an electric furnace or any other type of industrial furnace such as a combustion furnace, a gasifier, or an incinerator. In this specification, the flue gas vent refers to an airtight member having a hollow portion that can serve as a flow path for the flue gas, but is not limited thereto, and may be any portion that comes into contact with the flue gas, including, for example, the inside of a combustion tower or a cooling tower, and the inside of a dust collector up to the portion where the flue gas is filtered. Specifically, it may be a duct, a piping material such as a steel pipe of a certain diameter, or a steel plate or the like inside a combustion tower, a cooling tower, or a dust collector. In this specification, the material of the flue gas vent is assumed to be metal, but it may also be plastic as long as it is a material that can maintain airtightness.

[0019] [Smoke exhaust ventilation section] One embodiment of the flue gas ventilation section 10 that connects the combustion tower 102 and the flue gas cooling tower 103 as a flue gas flow path is a double-cylinder type flue gas duct 11 shown in Fig. 2. The double-cylinder type flue gas duct 11 has a double-cylinder structure composed of an outer cylinder 11a and an inner cylinder 11b. The inside of the inner cylinder 11b serves as the flue gas flow path, and the space between the outer cylinder 11a and the inner cylinder 11b serves as a cooling water flow path.

[0020] Both ends of the outer cylinder 11a and the inner cylinder 11b are closed by flange members 11c having a hollow portion with the same diameter as the inner diameter of the inner cylinder 11b to close the cooling water flow path between the outer cylinder 11a and the inner cylinder 11b. Cooling water nozzles 11d and 11e are provided near the flange members 11c at both ends of the outer cylinder 11a so as to protrude outward from the outer cylinder 11a. Cooling water is supplied from one of the cooling water nozzles 11d and 11e, and discharged from the other. The exhaust gas flowing inside the inner cylinder 11b is cooled by heat exchange with the cooling water on the inner surface of the inner cylinder 11b.

[0021] In the double-cylinder type smoke exhaust duct 11 having a water-cooled cooling structure, when water leaks from the inner cylinder 11b, moisture adheres to the filter cloth of the dust collector located downstream, and dust adheres to the filter cloth, causing an increase in pressure loss and damage to the filter cloth. On the other hand, it is difficult to grasp from the outside the thinning caused by the progression of corrosion that causes water leakage from the inner cylinder 11b. Even if maintenance is performed after a problem associated with damage due to thinning occurs, if downtime has already occurred, it will have a significant impact on production plans.

[0022] The water leakage or corrosion prediction system and water leakage and corrosion prediction method in this embodiment are particularly effective in dust collection systems having a smoke exhaust ventilation section, such as the double-tube type smoke exhaust duct 11, where the progression of thinning due to corrosion that causes water leakage cannot be detected from the outside.

[0023] [Water leakage and corrosion prediction system] The configuration of the water leakage and corrosion prediction system in this embodiment is shown in Fig. 4. Fig. 4 is a schematic diagram showing the entire water leakage and corrosion prediction system. Note that the water leakage and corrosion prediction system described in the embodiment is merely exemplified to explain the prediction system, and is not limited thereto. In this prediction system, prediction information refers to information that can be directly detected from the flue gas ventilation section 10, such as the electrical resistance value of the components, temperature distribution value, exhaust gas component values, change in the amount of cooling water, impedance measured between electrodes, polarization resistance of the components, and other information of the flue gas ventilation section 10 that is the subject of prediction. Also, in this prediction system, prediction value refers to a numerical value used for predicting water leakage and corrosion, which is obtained by calculation in the prediction information calculation unit 303 based on the prediction information.

[0024] As shown in FIG. 4, the water leakage and corrosion prediction system 3 includes the smoke exhaust ventilation section 10 to be predicted, a prediction support section 30, a display section (manager) 31, and a display section (maintenance person) 32. The flue gas ventilation unit 10 is a target for predicting water leakage and corrosion. The prediction support unit 30 calculates the predicted information of water leakage and corrosion obtained from the flue gas ventilation unit 10 to obtain predicted values ​​for predictive maintenance. The predicted values ​​obtained by the prediction support unit 30 are notified to a display unit (manager) 31 and a display unit (maintenance person) 32. FIG. 4 shows an example in which the display unit (maintenance person) 32 is located where the dust collection system is located, and since the display unit (maintenance person) 32 is remote, notification is made via the Internet.

[0025] 5 is a hardware configuration diagram of the water leakage and corrosion prediction support unit 30. As shown in FIG. 5, the prediction support unit 30 is composed of a prediction information detection unit 301, a prediction information accumulation unit 302, a prediction information calculation unit 303, and a prediction information notification unit 304. The prediction information detection unit 301 detects prediction information of water leakage and corrosion in the flue gas ventilation unit 10. The prediction information of water leakage and corrosion acquired by the prediction information detection unit 301 is accumulated in the prediction information accumulation unit 302. The prediction information accumulated in the prediction information accumulation unit 302 is sent to the prediction information calculation unit 303. The prediction information calculation unit 303 calculates a prediction value for predicting at least one of water leakage and corrosion based on the prediction information sent from the prediction information accumulation unit 302. The prediction value for predicting at least one of water leakage and corrosion calculated by the prediction information calculation unit 303 is returned to the prediction information accumulation unit 302. The prediction value for predicting at least one of water leakage and corrosion returned to the prediction information accumulation unit 302 is sent to the prediction information notification unit 304.

[0026] The predicted value for predicting at least one of water leakage and corrosion, sent to the prediction information notification unit 304, is sent to the display unit (manager) 31 and the display unit (maintenance person) 32, and is thereby notified to the manager and the maintainer. The manager is the person in charge of the operation of the dust collection system according to this embodiment. The maintainer is the person involved in the maintenance of the dust collection system who is located in a remote location from the dust collection system. The predicted value for predicting at least one of water leakage and corrosion is also notified to the maintainer remotely via a network or the like, and the manager and the maintainer can monitor the equipment together.

[0027] The flue gas vent 10 has an identification unit 12 for identifying the type of the flue gas vent 10. Information on the type of the flue gas vent 10 is read from the identification unit 12, and the type of the flue gas vent 10 is recognized. This enables the prediction system 3, which is applied to the flue gas vent 10 and is used to predict at least one of water leakage and corrosion, to operate normally. In addition, the prediction system 3 can be managed according to the type of the flue gas vent 10.

[0028] The information about the type of the smoke exhaust vent 10 identified by the identification unit 12 is, for example, information that it is a genuine product, the manufacturer, the model number, the production lot, the date of production, etc. The identification unit 12 can distinguish between smoke exhaust vents that are suitable for the water leakage or corrosion prediction system of the present invention and those that are not suitable. The information on the type of the smoke exhaust ventilation section 10 of the identification section 12 may be, for example, an IC tag, a barcode, etc. Alternatively, the type of filler may be identified by a physical shape, such as a key and a keyhole. The position of the recognition unit 12 may be located at the upper right of the smoke exhaust ventilation unit 10 as shown in FIG. 13, or may be located at the center of the smoke exhaust ventilation unit 10.

[0029] The information on the type of the smoke exhaust ventilation unit 10 from the identification unit 12 is automatically or manually input to the prediction information accumulation unit 302 of the prediction support unit 30 depending on the identification means. The prediction information calculation unit 303 is pre-programmed to take in the information of the identification unit 12 from the prediction information accumulation unit 302 and to call a calculation module of a prediction value based on the type of the smoke exhaust ventilation unit 10 to perform calculations. The calculation module of a prediction value based on the type of the smoke exhaust ventilation unit 10 may be stored in a memory area of ​​the prediction information calculation unit 303 in advance, or the calculation module stored in the identification unit 12 may be automatically loaded into the prediction information calculation unit 303.

[0030] The prediction information calculation unit 303 calculates the prediction values ​​of water leakage and corrosion by combining a calculation module based on the information of the identification unit 12 with a calculation module corresponding to the detection means of the prediction information described below. The information contained in the identification unit 12 may include information on the detection means of the specified prediction information in addition to information on the type of the flue gas vent unit 10. In this way, when the information of the identification unit 12 is read, the specified calculation module is automatically called, and the prediction information calculation unit 303 can calculate the prediction values. The calculation module corresponding to the detection means for the specified prediction information may be stored in advance in the memory area of ​​the prediction information calculation unit 303, or the calculation module stored in the identification unit 12 may be automatically loaded into the prediction information calculation unit 303.

[0031] It should be noted that a smoke exhaust ventilation unit that does not have the identification unit 12 may be attached to the dust collection system, but in this case, the prediction support unit 30 will not function or the prediction accuracy will be reduced, thereby preventing the use of non-genuine products and ensuring proper maintenance. Reducing the prediction accuracy means, for example, managing on the safe side by shortening the set value of the product life, thereby ensuring proper maintenance.

[0032] [Methods of detecting predictive information] As an example of prediction information of water leakage and corrosion detected in the flue gas ventilation section 10, the electrical resistance value of the members constituting the flue gas ventilation section 10 can be used as the prediction information. In this method, electrodes are provided at least at both ends of the flue gas ventilation section 10 when viewed in the longitudinal direction, and the change in resistance value when electricity is passed through the electrodes is regarded as thinning of the prediction object. The resistance value is detected by the prediction information detection section 301 of the prediction support section 30, accumulated by the prediction information accumulation section 302, and converted into a prediction value for thinning by calculation in the prediction information calculation section 303. The converted prediction information is returned to the prediction information accumulation section 302, and then sent to the display section (manager) 31 and the display section (maintenance person) 32 via the prediction information notification section 304 and notified. The resistance value increases as the cross-sectional area of ​​the plate decreases. Thinning can be predicted by the amount of change in this increase in resistance value.

[0033] As an example of prediction information of water leakage and corrosion detected in the flue gas ventilation section 10, the temperature distribution value of the flue gas ventilation section 10 can be used as the prediction information (FIG. 6). Two or more thermometers are installed along the longitudinal direction of the prediction object. Since the temperature of the exhaust gas flowing inside the prediction object normally gradually decreases from upstream to downstream, the surface temperature of the prediction object also gradually decreases from upstream to downstream. This method captures changes such as the gradient of the change in the surface temperature of the prediction object becoming gentler or steeper in relation to thinning of the prediction object. The temperature value is detected by the prediction information detection section 301 of the prediction support section 30, accumulated by the prediction information accumulation section 302, and converted into a prediction value for thinning by calculation in the prediction information calculation section 303. The converted prediction value is returned to the prediction information accumulation section 302, and then sent to the display section (manager) 31 and the display section (maintenance person) 32 via the prediction information notification section 304 and notified.

[0034] Exhaust gas component values ​​can be used as an example of prediction information for water leakage and corrosion detected in the flue gas ventilation section 10. For example, at least one of a SOx analyzer that measures the concentration of sulfur oxides, which are exhaust gas components, an HCL analyzer that measures the concentration of hydrogen chloride, and a moisture meter that measures the concentration of moisture is provided, and the corrosion rate is predicted according to the measurement result of at least one of the sulfur oxide concentration, hydrogen chloride concentration, and moisture concentration. When estimating the corrosion rate, there is a method that takes into account at least one of the measured sulfur oxide concentration, hydrogen chloride concentration, and water concentration, and extrapolates the predicted corrosion depth from the relationship between the integrated exhaust gas concentration and the corrosion rate. If the concentration is high, the corrosion rate is predicted to be high. Also, if the concentration and the integrated time are known, the prediction of corrosion or water leakage can be made more accurately.

[0035] As an example of prediction information of water leakage and corrosion detected in the flue gas ventilation unit 10, the change in the amount of cooling water can be used as the prediction information. The double-tube flue gas ventilation member is composed of an outer tube and an inner tube, the inside of the inner tube is an exhaust gas flow path, and the space between the outer tube and the inner tube is a cooling water flow path, and the exhaust gas is cooled by heat exchange between the exhaust gas and the cooling water. If there is a difference between the inflow and outflow of the cooling water, the difference is considered to be a water leakage. The values ​​of the inflow and outflow of the cooling water are detected by the prediction information detection unit 301 of the prediction support unit 30, accumulated by the prediction information accumulation unit 302, and converted into prediction information about thinning by calculation in the prediction information calculation unit 303. The converted prediction information is returned to the prediction information accumulation unit 302, and then sent to the display unit (manager) 31 and the display unit (maintenance person) 32 via the prediction information notification unit 304 and notified. [Explanation of symbols]

[0036] 3...Prediction system, 10...Smoke exhaust ventilation section, 11...Double-cylinder smoke exhaust duct, 11a...Outer tube, 11b...Inner tube, 11c...Flange, 11d...Cooling water nozzle, 11e...Cooling water nozzle, 12...Identification section, 30...Prediction support section, 31...Display section (manager), 32...Display section (maintenance person), 100...Dust collection system, 101...Furnace, 102...Combustion tower, 103...Cooling tower, 104...Dust collector, 301...Prediction information detection section, 302...Prediction information accumulation section, 303...Prediction information calculation section, 304...Prediction information notification section, 311...Example of temperature distribution in smoke exhaust ventilation section

Claims

1. A dust collection system comprising a prediction system for predicting at least one of water leakage and corrosion in a flue gas ventilation section from a furnace to a dust collector.

2. The dust collection system according to claim 1 , further comprising a notification unit that notifies a manager or a maintenance person of a prediction result of the prediction system.

3. A water leakage or corrosion prediction system for predicting at least one of water leakage and corrosion in a flue gas ventilation section from a furnace to a dust collector.

4. A dust collection method comprising a prediction step for predicting at least one of water leakage and corrosion in a flue gas ventilation section from a furnace to a dust collector.

5. A method for predicting water leakage or corrosion, comprising a prediction step for predicting at least one of water leakage and corrosion in a flue gas ventilation section from a furnace to a dust collector.

6. 2. The dust collection system according to claim 1, wherein the smoke vent has an identification section for identifying an installation state or a type of the smoke vent.

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