Intermediate scale sample and preparation method and application thereof
Technical Field
The invention belongs to the technical field of surface treatment of catalytic cracking devices in the oil refining industry, and particularly relates to an intermediate scale sample and a preparation method and application thereof.
Background
In the oil refining industry, a catalytic cracking flue gas turbine (a smoke machine for short) is a power device which converts the heat energy of high-temperature flue gas into mechanical energy, drives a main fan or a generator to work and realizes energy conversion, the recovery efficiency can reach more than 130%, and the catalytic cracking flue gas turbine has a remarkable energy-saving effect.
The third stage cyclone separator (triple cyclone for short) is one of the key devices of the energy recovery system of the flue gas outlet of the catalytic cracking unit, and the normal use of the smoke machine is directly influenced by the efficiency in the operation process. Abnormal shutdown caused by excessive vibration of a main shaft of a range hood in an industrial operation process is one of common problems, and the root cause is abrasion of blades of the range hood and scaling of a catalyst. In recent years, with the continuous improvement of catalytic cracking process, the scaling problem of the cyclone and the smoke machine caused by the problems of the use of novel catalyst and the quality of raw oil is increasingly prominent, and the long-period operation of an energy recovery system is seriously influenced.
The problem of scaling inside the range hood, particularly scaling on the surfaces of movable blades of the range hood, is more and more serious, the dynamic balance of a rotor is seriously damaged, the range hood is slightly vibrated and stops at an excessive level, and the movable blades collide with the outer edge and are broken. The smoke machine of some oil refineries often stops for several months to remove scale, and cannot be synchronous with the overhaul of the whole equipment, so that the recycling efficiency of high-temperature smoke is reduced due to frequent stoppage of faults, the energy consumption is increased, and sometimes even the unplanned shutdown of the whole device is caused, thereby seriously influencing the economic benefit of enterprises and causing huge economic loss. Therefore, the development of the anti-scaling method for the flue gas turbine is of great significance.
The coating protection is one of the methods for treating the scale of the blades of the three-rotation single tube and the smoke turbine, and the preparation of the scale sample is the research basis for the interaction between the coating and the scale sample. The scale formation of the catalyst on a three-rotation single tube and a flue gas turbine usually takes several months, and the scale shape is irregular. If the regular sample of the scale sample can be prepared, the compatibility research of the coating and the scale sample is facilitated, and the screening of the protective coating is facilitated.
In the aspect of scale sample preparation, static high-temperature sintering experiments are carried out in a high-temperature electric furnace, a heating furnace simulates the working environment in a smoke machine, an equivalent catalyst sample at the inlet of a catalytic device smoke machine is placed on a test piece which is made of the same material as movable blades of the smoke machine, and the sintering experiments are carried out to prepare the scale sample. Hurenbo et al (Hurenbo, white, Zhao jin 32704m. et al. catalytic cracking triple-rotation catalyst fine powder sintering and scaling mechanism [ J ]. Chinese university of Petroleum institute (Nature science edition), 37(4), 2013, 169 and 173. all.) also selected the triple-rotation fine powder of a typical catalytic cracking device as a research object, and carried out roasting experiments on the triple-rotation fine powder at different temperatures, wherein the main components of the catalyst fine powder are alumina and silica. Although the composition is close to that of industrial scale, the above sintering method has disadvantages in that the scale itself is not high in cohesive strength and does not adhere to the base metal.
Disclosure of Invention
In order to overcome the disadvantages and drawbacks of the prior art, it is a primary object of the present invention to provide an intermediate scale sample.
Another object of the present invention is to provide a method for preparing the above intermediate soil sample.
It is a further object of the present invention to provide the use of the above intermediate soil sample.
The purpose of the invention is realized by the following technical scheme:
an intermediate soil sample comprising a component base powder (JCF) and a binder;
the basic powder comprises the following components in parts by mass:
the binder is preferably aluminum dihydrogen phosphate (chemical formula Al (H)2PO4)3);
The dosage of the aluminum dihydrogen phosphate is preferably 30-50% of the total mass of the binder and the base powder;
the preparation standard of the MMC-2 catalyst is preferably Q/SH 3610236-2015;
the preparation method of the intermediate scale sample comprises the following steps:
(1) mixing calcium chloride, ferrous sulfate, nickel sulfate and an MMC-2 catalyst to obtain basic powder (JCF);
(2) mixing the base powder (JCF) prepared in the step (1) with a binder to obtain a blended powder (GHF), and then adding water to obtain a blended slurry (GHLJ);
(3) sintering the blended slurry prepared in the step (2) at a high temperature, and cooling to obtain an intermediate scale sample;
the water in the step (2) is preferably distilled water;
the amount of water used in step (2) is preferably: the water adding amount of each 100g of the blended powder is 55-65 mL;
the sintering condition in the step (3) is preferably 680-750 ℃, and the temperature is kept for 2-4 h;
the intermediate scale sample is applied to the field of screening of anti-scale coatings;
a method of screening for antifouling coatings comprising the steps of:
(1) mixing calcium chloride, ferrous sulfate, nickel sulfate and an MMC-2 catalyst to obtain basic powder (JCF);
(2) mixing the base powder (JCF) prepared in the step (1) with a binder to obtain a blended powder (GHF), and then adding water to obtain a blended slurry (GHLJ);
(3) coating the blend slurry prepared in the step (2) on a coating sample, sintering at high temperature, and cooling to obtain an intermediate scale sample, wherein if the intermediate scale sample is not bonded with the coating sample, the coating sample has an anti-scaling effect; if the intermediate scale sample is bonded with the coating sample, the coating sample does not have the scale prevention effect;
the water in the step (2) is preferably distilled water;
the amount of water used in step (2) is preferably: the water adding amount of each 100g of the blended powder is 55-65 mL;
the sintering condition in the step (3) is preferably 680-750 ℃, and the temperature is kept for 2-4 h;
the principle of the invention is as follows:
the method comprises the steps of firstly preparing basic powder (JCF for short), enabling the powder to be basically the same as industrial scale sample components after high-temperature sintering, preparing blended powder (GHF for short) by adopting a mode of blending the basic powder (JCF) and aluminum dihydrogen phosphate, adding a proper amount of water to form blended slurry (GHLJ for short), and sintering the blended slurry GHLJ to form an intermediate scale sample. For the coating, if a certain coating is not adhered to an intermediate scale sample with higher viscosity before sintering and higher strength after sintering, the coating can be inferred to be not adhered to industrial scale, namely, the coating has the anti-scaling effect under industrial conditions, and the coating can be further screened by industrial tests at a later stage. The intermediate scale sample can indirectly realize the primary screening of the catalytic cracking unit surface coating material in the oil refining industry under simple sintering conditions.
Compared with the prior art, the invention has the following advantages and effects:
(1) the blended slurry prepared by the invention is easy to form block dirty samples after being sintered, is difficult to break by hands, has high cohesive strength, and improves the condition that basic powder (JCF) is sintered and then is lightly twisted to form powder.
(2) The JCF is not scaled, so that the anti-scaling capability of the coating cannot be judged by the JCF; if a coating X prevents the adhesion of the intermediate scale to its surface, the adhesion of the JCF to the coating is prevented with great probability. And the preliminary screening of the coating can be realized by adopting a middle dirt sample mode.
Drawings
FIG. 1 is a graph showing the appearance and morphology of an intermediate soil sample prepared in example 1.
FIG. 2 is a graph showing the appearance and morphology of an intermediate soil sample prepared in example 2.
FIG. 3 is a graph showing the appearance and appearance of an intermediate soil sample obtained in example 3.
FIG. 4 is a graph showing the appearance and morphology of the scale sample prepared in comparative example 1.
FIG. 5 is a graph showing the appearance and morphology of the scale sample prepared in comparative example 2.
Detailed Description
The present invention will be described in further detail with reference to examples and drawings, but the present invention is not limited thereto.
Example 1
(1) 0.88g of calcium chloride, 2.77g of ferrous sulfate, 2.81g of nickel sulfate and 93.54g of MMC-2 catalyst (powder preparation standard Q/SH 3610236-2015) are mixed to obtain basic powder (JCF);
(2) mixing 14g of the base powder (JCF) prepared in the step (1) with 6g of binder aluminum dihydrogen phosphate to obtain blended powder (GHF), and then adding 12ml of distilled water to obtain blended slurry (GHLJ-1);
(3) preparing a 304 stainless steel sample with a specification of 50mm multiplied by 50mm, and placing a 304 stainless steel square frame (the outer dimension is 50mm multiplied by 5mm, the inner dimension is 45mm multiplied by 5mm) on the surface of the sample; coating the blending slurry (GHLJ-1) prepared in the step (2) on the surface of a sample, filling the slurry into a square frame, sintering the sample coated with the slurry in a sintering furnace at the sintering temperature of 700 ℃, and preserving heat for 2 hours; and then closing the heat preservation program, and cooling the sample along with the furnace to room temperature to obtain an intermediate scale sample.
As shown in FIG. 1, the intermediate-scale-like product is hard to be broken by an adult and has high strength by itself.
Example 2
(1) 0.88g of calcium chloride, 2.77g of ferrous sulfate, 2.81g of nickel sulfate and 93.54g of MMC-2 catalyst (powder preparation standard Q/SH 3610236-2015) are mixed to obtain basic powder (JCF);
(2) mixing 12g of the base powder (JCF) prepared in the step (1) with 8g of binder aluminum dihydrogen phosphate to obtain blended powder (GHF), and then adding 11ml of distilled water to obtain blended slurry (GHLJ-2);
(3) preparing a 304 stainless steel sample with the specification of 50 multiplied by 5mm, placing a 304 stainless steel square frame (the outer dimension is 50 multiplied by 50mm multiplied by 5mm, the inner dimension is 45 multiplied by 45mm multiplied by 5mm) on the surface of the sample, coating the blended slurry (GHLJ-2) prepared in the step (2) on the surface of the sample, filling the square frame with the slurry, placing the sample coated with the slurry in a sintering furnace for sintering, wherein the sintering temperature is 750 ℃, and preserving heat for 4 hours; then closing the heat preservation program, and cooling the sample to room temperature along with the furnace to obtain an intermediate scale sample;
as shown in FIG. 2, the blended slurry forms a lump-like intermediate scale after sintering, which is difficult to be broken by both hands of an adult and has high strength.
Example 3
(1) 0.88g of calcium chloride, 2.77g of ferrous sulfate, 2.81g of nickel sulfate and 93.54g of MMC-2 catalyst (powder preparation standard Q/SH 3610236-2015) are mixed to obtain basic powder (JCF);
(2) mixing 10g of the base powder (JCF) prepared in the step (1) with 10g of binder aluminum dihydrogen phosphate to obtain blended powder (GHF), and then adding 13ml of distilled water to obtain blended slurry (GHLJ-3);
(3) preparing a 304 stainless steel sample with a specification of 50 x 5mm, the surface of which is sprayed with a NiCr-Cr3C2 coating, placing a 304 stainless steel square box (the outer dimension of which is 50mm x 5mm, the inner dimension of which is 45mm x 5mm) on the surface of the coating sample, coating the mixed slurry (GHLJ-3) prepared in the step (2) on the surface of the NiCr-Cr3C2 coating sample, filling the square box with the slurry, placing the coating sample coated with the slurry in a sintering furnace for sintering, wherein the sintering temperature is 680 ℃, and keeping the temperature for 3 h; then closing the heat preservation program, and cooling the sample to room temperature along with the furnace to obtain an intermediate scale sample;
as shown in fig. 3, the blended slurry forms a lump-like intermediate scale sample after sintering, the scale sample is firmly adhered to the metal frame and is difficult to remove, and the scale sample is difficult to be broken off by hands of adults and has high strength. After testing, the intermediate scale sample was found to adhere to the NiCr-Cr3C2 coating, indicating that the NiCr-Cr3C2 coating was not scale inhibiting, which is consistent with the situation in an industrial range hood.
Comparative example 1
(1) 0.88g of calcium chloride, 2.77g of ferrous sulfate, 2.81g of nickel sulfate and 93.54g of MMC-2 catalyst (powder preparation standard Q/SH 3610236-2015) are mixed to obtain basic powder (JCF);
(2) adding 12ml of distilled water into 20g of the base powder (JCF) prepared in the step (1) to form slurry (LJ-0);
(3) preparing a 304 stainless steel sample with the specification of 50 multiplied by 5mm, placing a 304 stainless steel square frame (the outer dimension is 50 multiplied by 50mm multiplied by 5mm, the inner dimension is 45 multiplied by 45mm multiplied by 5mm) on the surface of the sample, coating the slurry (LJ-0) prepared in the step (2) on the surface of the sample, filling the square frame with the slurry, placing the sample coated with the slurry in a sintering furnace for sintering, wherein the sintering temperature is 700 ℃, and preserving heat for 4 hours; and then closing the heat preservation program, and cooling the sample to room temperature along with the furnace.
As shown in FIG. 4, the slurry was sintered to a loose powder, not to a scale-like mass, having a powder composition as shown in Table 1, similar to the composition of a scale sample from the cigarette-making industry (see Table 2).
TABLE 1X-ray spectral composition of basic powder (JCF) after sintering at 700 deg.C
TABLE 2X-ray spectral composition of industrial scale samples
Comparative example 2
(1) 0.88g of calcium chloride, 2.77g of ferrous sulfate, 2.81g of nickel sulfate and 93.54g of MMC-2 catalyst (powder preparation standard Q/SH 3610236-2015) are mixed to obtain basic powder (JCF);
(2) blending 18g of the base powder (JCF) prepared in the step (1) with 2g of binder aluminum dihydrogen phosphate to prepare blended powder (GHF), and then adding 12ml of distilled water to obtain blended slurry (GHLJ-4);
(3) preparing a 304 stainless steel sample with a specification of 50mm multiplied by 5mm, placing a 304 stainless steel square frame (the outer dimension is 50mm multiplied by 5mm, the inner dimension is 45mm multiplied by 5mm) on the surface of the sample, coating the prepared blended slurry (GHLJ-4) on the surface of the sample, and filling the square frame with the slurry; placing the sample coated with the slurry into a sintering furnace for sintering, wherein the sintering temperature is 720 ℃, and preserving heat for 4 hours; and then closing the heat preservation program, and cooling the sample to room temperature along with the furnace.
As shown in fig. 5, the blended slurry was a loose powder after sintering, not a scale-like mass.
The above embodiments are preferred embodiments of the present invention, but the present invention is not limited to the above embodiments, and any other changes, modifications, substitutions, combinations, and simplifications which do not depart from the spirit and principle of the present invention should be construed as equivalents thereof, and all such changes, modifications, substitutions, combinations, and simplifications are intended to be included in the scope of the present invention.