CN110823946B - Experimental method and device for simulating corrosion of furnace wall of high-temperature reaction furnace - Google Patents
Experimental method and device for simulating corrosion of furnace wall of high-temperature reaction furnace Download PDFInfo
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Abstract
The invention discloses an experimental method and a device for simulating corrosion of a furnace wall of a high-temperature reaction furnace, which comprises an outer cylinder, an inner cylinder, an upper flange cover plate, a lower flange cover plate, a temperature observation point, a temperature sensor, a heating device I, a heating device II, a temperature controller, a temperature signal converter, a bus signal converter and a data acquisition processor, wherein the outer cylinder and the inner cylinder are used for preparing the simulated furnace wall, the temperature observation point is laid between the inner surface and the outer surface of the simulated furnace wall in the same horizontal section, the temperature sensor is arranged at the central position of the bottom of a furnace cylinder and is used for representing the temperature of a high-temperature medium in the furnace, the heating device I is used for preparing the wall surface of the simulated furnace cylinder, the heating device II is used for locally heating an internal fluid, and the temperature controller, the temperature signal converter, the bus signal converter and the data acquisition processor are connected with the heating device II and are arranged in a data acquisition box, and have a serial communication interface and a man-machine interaction function. The invention can simulate the phenomenon that the furnace wall of the high-temperature reaction furnace is eroded by the high-temperature medium in the operation process, and verify the reliability and accuracy of various algorithms for solving the problem of furnace wall erosion by the data of the temperature observation point and the result of the practical experiment.
Description
Technical Field
The invention relates to the field of safety diagnosis of chemical and metallurgical equipment, in particular to an experimental method and device for simulating corrosion of a furnace wall of a high-temperature reaction furnace, which are provided for the reaction furnace with high-temperature fluid inside.
Background
In the chemical and metallurgical fields, high-temperature fluid flows exist in some process equipment for a long time, the wall surfaces of the equipment are usually subjected to high temperature or high pressure, and once the temperature or the pressure exceeds the critical value which can be born by the wall surfaces in the long-term operation process, the furnace wall can be gradually eroded and thinned, even broken, and the production safety is seriously influenced. The blast furnace is a typical representative device of such high temperature reaction furnaces, and generally, a steel plate is used as a furnace shell, refractory bricks are built in the shell as an inner lining, and the inner lining at the hearth part close to a tap hole is subjected to the effects of high temperature molten iron scouring, thermal stress and the like for a long time, so that the erosion phenomenon of the furnace wall of the part occurs earlier.
In order to solve the problem of safe operation of the furnace wall of the high-temperature reaction furnace, most of the current methods propose a method capable of monitoring the position of a profile line of a lining of the furnace wall on line, such as an ultrasonic flaw detection technology, a ray flaw detection technology, an indirect flaw detection technology based on a surface infrared thermography and the like. The method has the advantages that operators can know the current corrosion condition of the furnace wall clearly theoretically, but most methods are still in the theoretical research level due to the limitation of conditions such as safety, cost, technology and the like, and few monitoring systems which can be applied practically have the problems of large measurement error, long calculation time, unstable calculation result and the like. Therefore, in the theoretical research process, besides a great amount of numerical simulation is carried out on the erosion positions of the furnace wall of the high-temperature reaction furnace under different conditions, the real erosion dynamic trend of the furnace wall needs to be investigated by combining certain practical conditions, so that the establishment of the high-temperature reaction furnace for simulating the furnace wall erosion in the laboratory environment is necessary.
In a high-temperature sealed reaction furnace similar to an iron-making blast furnace, temperature is one of important parameters for safe operation, and generally, a temperature sensor is embedded in certain positions in a furnace wall according to design specifications in the process of building a furnace wall to monitor the temperature change condition of the reaction furnace in the operation process in real time. Under experimental conditions, corresponding thermocouple temperature sensors are also required to be embedded at appropriate positions when the simulated furnace cylinder wall is manufactured, and the erosion state of the furnace wall is monitored through data measured by the temperature sensors. At present, no well-established experimental method, device or system which can be used for simulating the corrosion of the furnace wall of the high-temperature reaction furnace exists.
Disclosure of Invention
The invention aims to solve the problem that the erosion of the furnace wall of the high-temperature reaction furnace is mainly caused by the thermal stress and the circular flow scouring action of an internal high-temperature medium and is accompanied by certain factors such as chemical corrosion, oxidation and the like. During the erosion process of the furnace wall of the high-temperature reaction furnace, the temperature data measured by the temperature sensor in the furnace wall changes to a certain extent, and the current erosion position of the furnace hearth can be calculated by using the data. The invention accordingly proposes an experimental method for simulating erosion.
Technical scheme
An experimental device for simulating erosion of a furnace wall of a high-temperature reaction furnace comprises an outer cylinder for preparing a simulated furnace wall, an inner cylinder positioned in an inner cavity of the outer cylinder, a phase-change material for preparing the furnace wall, and an upper flange cover plate and a lower flange cover plate which play roles in loading, unloading and sealing; at least one temperature sensor for representing the temperature of a high-temperature medium in the furnace is arranged at the bottom of a furnace cylinder formed by the outer cylinder and the inner cylinder; a plurality of temperature sensors are pre-buried and arranged in an annular cavity formed by the outer cylinder and the inner cylinder, so that temperature observation points in the same horizontal section between the inner surface of the simulated furnace wall and the outer surface of the simulated furnace wall are formed; the phase change material for preparing the furnace wall is placed in the annular cavity; wherein a heating device is inserted into the phase change material to heat the phase change material; wherein the second heating device is inserted into the inner cavity of the prepared simulated furnace wall; the temperature observation point and a temperature sensor in the temperature sensor are connected with a temperature signal converter in the data acquisition box, the first heating device and the second heating device are connected with a temperature controller in the data acquisition box, and the temperature controller and the temperature signal converter are connected to a data acquisition processor with a serial communication interface and a human-computer interaction function through a bus signal converter.
An experimental method for simulating corrosion of a furnace wall of a high-temperature reaction furnace comprises the following steps:
1) and (4) embedding a furnace wall temperature sensor. Arranging a temperature sensor in an annular cavity between the outer cylinder and the inner cylinder, and respectively selecting N horizontal sections P on different heights of the furnace wall in consideration of the existence of vertical temperature differencei(i ═ 1,2, …, N), M points Q were determined on each horizontal sectionj(j-1, 2, …, M) for mounting temperature sensors, forming observation points for the temperature in the furnace wall, each measurement point being at a specific time τkIs recorded as
2) Embedding a furnace bottom temperature sensor in advance; at least one temperature sensor for representing the temperature of a high-temperature medium in the furnace is arranged at the bottom of a furnace cylinder formed by the outer cylinder and the inner cylinder, and the measured temperature data is recorded;
3) and preparing a simulated hearth wall surface. Putting the prepared phase-change material into an annular cavity between the outer cylinder and the inner cylinder, heating and melting the phase-change material by using a heating device, stopping heating after the phase-change material is completely melted into a liquid state, and cooling and solidifying the phase-change material into a solid state so as to form the required furnace wall;
4) taking out the inner cylinder, pouring corresponding fluid medium into the formed simulated furnace wall, heating the simulated furnace wall by using a heating device to form high-temperature medium, and melting a local furnace wall by adjusting the position of a heating device II to manufacture local erosion of the furnace wall;
5) connecting temperature sensors in a temperature observation point and a temperature sensor with a temperature signal converter (10) in a data acquisition box, connecting a heating device I and a heating device II with a temperature controller (9) in the data acquisition box (8), and connecting the temperature controller (9) and the temperature signal converter (10) to a data acquisition processor (12) with a serial communication interface and a human-computer interaction function through a bus signal converter (11) to form a monitoring network capable of controlling temperature and continuously measuring temperature;
6) inputting a sampling time interval delta tau and a total sampling duration tau from a human-computer interaction interface of a data processor (12)mHeating temperature ThAnd a start instruction;
7) processing the temperature observation point and the temperature measured by each temperature sensor on the temperature sensor for representing the temperature of the high-temperature medium in the furnace by a data processor, and calculating tau in a set time windowmThe erosion position of the inner surface of the furnace wall at the moment is specifically calculated as
(a) Let τ bemThe erosion position of the inner surface of the furnace wall is r0The temperature data which should be measured by the temperature sensor at the temperature observation point at the assumed erosion position is obtained by calculating the heat conduction equation of the furnace wall
(calculating temperature);
(b) the temperature data actually measured by the temperature observation point
And calculating the temperature
Comparing, if the error of the two is in the set range, then tau can be obtainedmThe erosion position of the inner surface of the furnace wall at the moment is r0；
(c) If the accuracy is not reached, the assumed erosion position is adjusted to rn(n 1,2, 3.) and then solving the furnace wall heat transfer equation to calculate the temperature data measured at the temperature observation point at the assumed erosion location
(d) When the error between the measured temperature and the calculated temperature is sufficiently small, τ can be obtainedmTime of erosion position r of inner surface of furnace walln。
8) Opening the upper flange cover plate to each horizontal section PiAnd taking X reference points, respectively measuring the erosion positions of the reference points, comparing the experimental result with the calculation result, and verifying the accuracy of the algorithm.
Has the advantages that: the experimental method and the device for simulating the corrosion of the furnace wall of the high-temperature reaction furnace, provided by the invention, can not only simulate the phenomenon that the furnace wall is corroded by an internal high-temperature medium in the operation process of the high-temperature reaction furnace, but also verify the reliability and the accuracy of various algorithms for solving the problem of the corrosion of the furnace wall at present by combining the data of the temperature observation point and the result of an actual experiment, and provide a brand-new experimental simulation platform for scientific researchers engaged in the research of the problem of the corrosion of the furnace wall. Meanwhile, the system provided by the invention has the advantages of simple structure and convenience in operation, and manufacturing materials are common devices in the market and are easy to obtain.
Drawings
FIG. 1 shows a schematic diagram of the experimental setup of the present invention;
FIG. 2 shows temperature measurement data of a temperature sensor during an experiment in the experimental apparatus of the present invention;
fig. 3 shows the data processing calculation results of the experimental setup of the present invention.
Wherein: 1. the device comprises an outer cylinder 2, an inner cylinder 3, an upper flange cover plate 4, a lower flange cover plate 5, a furnace wall internal temperature observation point 6, a temperature sensor 7-1 representing the temperature of a medium in the furnace, a first heating device 7-2, a second heating device 8, a data acquisition box 9, a temperature controller 10, a temperature signal converter 11, a bus signal converter 12, a data acquisition processor 13, a furnace wall inner surface 14 and a furnace wall outer surface.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
One embodiment of the typical system is shown in figure 1, stainless steel materials are adopted to manufacture an outer cylinder 1, an inner cylinder 2, an upper flange cover plate 3 and a lower flange cover plate 4, and 60# fully refined paraffin is selected as phase change materials for preparing a simulated furnace wall; the temperature observation point 5 and the temperature sensor 6 for representing the temperature of the high-temperature medium in the furnace adopt armored K-type thermocouples, the compensation wires with the same graduation number are used as lead wires to connect thermocouple signals into the data acquisition box 8, and the temperature signal converter 10 in the data acquisition box 8 adopts an ICP-7018 distributed thermoelectric even data acquisition module of Hongge company to acquire temperature data; the first heating device 7-1 and the second heating device 7-2 adopt 5 independent stainless steel single-end straight through long electric heating pipes, the rated power of each electric heating pipe is 400W, and an independent temperature signal sensor is arranged to connect the temperature control signals of the heating pipes into a data acquisition box 8.
The temperature controller 9 in the data acquisition box 8 adopts a GR818 digital temperature control meter produced by Vigorboom corporation to independently control the temperature of each heating pipe, the modules are connected in series through a shielded twisted pair to form an RS-485 bus, ICP-7520 is adopted as a bus signal converter 11, and the data acquisition processor 12 adopts an embedded industrial personal computer PPC-3100S with a touch screen; wherein, the bus signal converter 11 is connected with an RS-232 serial port on the data acquisition processor 12 to form an acquisition control system which can continuously measure temperature and control heating temperature; the industrial software on the data acquisition processor 12 is compiled in C language, realizing the functions of acquisition, control, display, etc., and realizing the proposed erosion location calculation algorithm.
The second typical system embodiment is shown in fig. 1, an outer cylinder 1, an inner cylinder 2, an upper flange cover plate 3 and a lower flange cover plate 4 are made of engineering plastics, and ice is selected as a phase change material for preparing a simulated furnace wall;
the temperature observation point 5 and the temperature sensor 6 for representing the temperature of the high-temperature medium in the furnace adopt armored J-type thermocouples, the compensation wires with the same division number are used as leads to connect thermocouple signals into the data acquisition box 8, and the temperature signal converter 10 in the data acquisition box 8 adopts an ADAM-4018 distributed thermoelectric even data acquisition module of the Mowa company to acquire temperature data;
the heating device I7-1 and the heating device II 7-2 adopt 4 independent stainless steel single-head U-shaped through long heating pipes, the rated power of each heating pipe is 500W, an independent temperature signal sensor is arranged, temperature control signals of the heating pipes are connected into a data acquisition box 8, a temperature controller 9 in the data acquisition box 8 adopts an ANTHONE LU-900U electronic temperature controller produced by Andon company to independently control the temperature of each heating pipe, the modules are connected in series through a shielded twisted pair to form an RS-485 bus, ADAM-4520 is adopted as a bus signal converter 11, and an embedded industrial personal computer PPC-3100S with a touch screen is adopted as a data acquisition processor 12; wherein, the bus signal converter 11 is connected with an RS-232 serial port on the data acquisition processor 12 to form an acquisition control system which can continuously measure temperature and control heating temperature; the industrial software on the data acquisition processor 12 is compiled in C language to realize the functions of acquisition, control, display, etc., and the erosion position calculation algorithm can be compiled on MATLAB and realize calculation by calling functions.
Referring to fig. 1, a third typical system embodiment is shown, wherein a stainless steel outer cylinder 1 and an inner cylinder 2 are made of the engineering material according to one of the typical system embodiments, the inner diameter of the outer cylinder is 400mm, the outer diameter of the inner cylinder is 240mm, 60# fully refined paraffin is used as a phase change material for preparing a simulated hearth ratio, and before the paraffin is put into an annular cavity between the outer cylinder 1 and the inner cylinder 2, the inner cylinder 2 is shifted to one side by 10mm to form an irregular inner wall surface position. Liquid paraffin is put into the furnace, a heating device is used for heating at constant temperature, the temperature is kept at 85 ℃, the data acquisition interval is 4s, and the temperature history data measured by the temperature sensor embedded in the furnace wall is the data measured by the temperature observation point shown in figure 2.
Calculating the position and shape of the inner wall surface of the paraffin by using the set of measured data, and adopting two optimization algorithms of a Conjugate Gradient Method (CGM) and a Powell Method, wherein the calculation result is shown in FIG. 3; experimental data calculation results:
as can be obtained from the figure, the average relative error of the calculation result of the Powell method is 1.9 percent, and the average relative error of the calculation result of the CGM is 2.7 percent, therefore, the experimental device and the method provided by the invention can effectively verify the accuracy and the reliability of various algorithms under the actual measurement environment.
In the measurement and calculation process by using the experimental device, the method comprises the following steps:
1) and (4) embedding a furnace wall temperature sensor. Arranging a temperature sensor in an annular cavity between the outer drum 1 and the inner drum 2, selecting N horizontal sections Pi (i is 1,2, …, N) at different heights of the furnace wall respectively in consideration of the existence of vertical temperature difference, determining M points Qj (j is 1,2, …, M) on each horizontal section for mounting the temperature sensor, forming temperature observation points 5 in the furnace wall, and determining a specific time tau at each measurement pointkIs recorded as
2) And (4) embedding a furnace bottom temperature sensor. At least one temperature sensor 6 for representing the temperature of a high-temperature medium in the furnace is arranged at the bottom of a furnace cylinder formed by the outer cylinder 1 and the inner cylinder 2, and the measured temperature data is recorded;
3) and preparing a simulated hearth wall surface. Putting the prepared phase-change material into an annular cavity between the outer cylinder 1 and the inner cylinder 2, heating and melting the phase-change material by using a first heating device 7-1, stopping heating after the phase-change material is completely melted into a liquid state, and cooling and solidifying the phase-change material into a solid state so as to form a required furnace wall;
4) taking out the inner cylinder 2, pouring corresponding fluid medium into the formed simulated furnace wall, heating the simulated furnace wall by using a second heating device 7-2 to form high-temperature medium, and manufacturing local erosion of the furnace wall by adjusting the position of the heater;
5) connecting temperature sensors in the temperature observation point 5 and the temperature sensor 6 with a temperature signal converter 10 in a data acquisition box 8, connecting a first heating device 7-1 and a second heating device 7-2 with a temperature controller 9 in the data acquisition box 8, and connecting the temperature controller 9 and the temperature signal converter 10 to a data acquisition processor 12 with a serial communication interface and a human-computer interaction function through a bus signal converter 11 to form a monitoring network capable of controlling temperature and continuously measuring temperature;
6) inputting the sampling time interval delta tau and the total sampling time tau from the human-computer interaction interface of the data processor 12mHeating temperature ThAnd a start instruction;
7) the temperature measured by each temperature sensor on the temperature observation point 5 and the temperature sensor 6 for representing the temperature of the high-temperature medium in the furnace is processed by the data processor 12, and tau is calculated in a set time windowmThe erosion position of the inner surface of the furnace wall at the moment is specifically calculated as
(a) Let τ bemThe erosion position of the inner surface of the furnace wall is r0The temperature data which should be measured by the temperature sensor at the temperature observation point 5 at the assumed erosion position is obtained by calculating the heat conduction equation of the furnace wall
(calculating temperature);
(b) the temperature data actually measured by the temperature observation point
And calculating the temperature
Comparing, if the error of the two is in the set range, then tau can be obtainedmThe erosion position of the inner surface of the furnace wall at the moment is r0；
(c) If the accuracy is not reached, the assumed erosion position is adjusted to rn(n 1,2, 3..) then the antipyretic conduction equation calculates the number of temperatures measured at the temperature observation point at the assumed erosion locationAccording to
(d) When the error between the measured temperature and the calculated temperature is sufficiently small, τ can be obtainedmTime of erosion position r of inner surface of furnace walln。
8) And opening the upper flange cover plate 3, taking X reference points on each horizontal section Pi, respectively measuring erosion positions of the reference points, comparing an experimental result with a calculation result, and verifying the accuracy of the algorithm.
Claims (1)
1. An experimental method for simulating the erosion of a furnace wall of a high-temperature reaction furnace is characterized by comprising the following steps:
the device is realized by an experimental device for simulating the erosion of the furnace wall of the high-temperature reaction furnace, and comprises an outer cylinder (1) for preparing a simulated furnace wall, an inner cylinder (2) positioned in the inner cavity of the outer cylinder (1), phase-change materials for preparing the furnace wall, and upper and lower flange cover plates (3 and 4) for loading, unloading and sealing; at least one temperature sensor (6) for representing the temperature of a high-temperature medium in the furnace is arranged at the bottom of a furnace cylinder formed by the outer cylinder (1) and the inner cylinder (2); a plurality of temperature sensors are pre-buried and arranged in an annular cavity formed by the outer cylinder (1) and the inner cylinder (2), so that a temperature observation point (5) in the same horizontal section between the inner surface (13) of the simulated furnace wall and the outer surface (14) of the simulated furnace wall is formed; the phase change material for preparing the furnace wall is placed in the annular cavity; wherein the first heating device (7-1) is inserted into the phase-change material to heat the phase-change material; wherein the second heating device (7-2) is inserted into the inner cavity of the prepared simulated furnace wall; wherein the temperature observation point (5) and the temperature sensor (6) are connected with a temperature signal converter (10) in the data acquisition box (8), the heating device I (7-1) and the heating device II (7-2) are connected with a temperature controller (9) in the data acquisition box (8), and the temperature controller (9) and the temperature signal converter (10) are connected to a data acquisition processor (12) with a serial communication interface and a human-computer interaction function through a bus signal converter (11);
the method comprises the following steps:
1) embedding a furnace wall temperature sensor in advance; in the outer cylinder (1) and the inner cylinder (2)A temperature sensor is arranged in the annular cavity between the two, and N horizontal sections P are respectively selected on different heights of the furnace wall in consideration of the existence of vertical temperature differenceiI 1,2, …, N, M points Q being determined on each horizontal sectionj1,2, …, M being used to mount temperature sensors, forming observation points (5) of the temperature in the furnace wall, each measurement point being at a specific time τkIs recorded as
2) Embedding a furnace bottom temperature sensor in advance; at least one temperature sensor (6) for representing the temperature of a high-temperature medium in the furnace is arranged at the bottom of a furnace cylinder formed by the outer cylinder (1) and the inner cylinder (2), and the measured temperature data is recorded;
3) preparing a simulated hearth wall surface; putting the prepared phase-change material into an annular cavity between the outer cylinder (1) and the inner cylinder (2), heating and melting the phase-change material by using a first heating device (7-1), stopping heating after the phase-change material is completely melted into a liquid state, and cooling and solidifying the phase-change material into a solid state so as to form a required furnace cylinder wall;
4) taking out the inner cylinder (2), pouring a corresponding fluid medium into the formed simulated furnace wall, heating the simulated furnace wall by using a second heating device (7-2) to form a high-temperature medium, and melting a local furnace wall by adjusting the position of the second heating device (7-2) to manufacture local erosion of the furnace wall;
5) connecting a temperature observation point (5) and a temperature sensor (6) at the bottom of a hearth with a temperature signal converter (10) in a data acquisition box (8), connecting a first heating device (7-1) and a second heating device (7-2) with a temperature controller (9) in the data acquisition box (8), and connecting the temperature controller (9) and the temperature signal converter (10) to a data acquisition processor (12) with a serial communication interface and a man-machine interaction function through a bus signal converter (11) to form a monitoring network capable of controlling temperature and continuously measuring temperature;
6) inputting a sampling time interval delta tau and a total sampling duration tau from a human-computer interaction interface of a data acquisition processor (12)mHeating temperature ThAnd a start instruction;
7) will warm upThe temperature measured by the temperature observation point (5) and the temperature sensor (6) for representing the temperature of the high-temperature medium in the furnace are processed by a data acquisition processor (12), and tau is calculated in a set time windowmThe erosion position of the inner surface of the furnace wall at the moment is specifically calculated as
(a) Let τ bemThe erosion position of the inner surface of the furnace wall is r0The temperature data which should be measured by the temperature sensor at the temperature observation point (5) at the assumed erosion position is obtained by calculating the heat conduction equation of the furnace wall
(b) The temperature data actually measured by the temperature observation point
And calculating the temperature
Comparing, if the error of the two is in the set range, then tau can be obtainedmThe erosion position of the inner surface of the furnace wall at the moment is r0；
(c) If the accuracy is not reached, the assumed erosion position is adjusted to rnN is 1,2,3, …, and then calculating the temperature data measured at the temperature observation point at the assumed erosion location by solving the furnace wall heat transfer equation
(d) When the error between the measured temperature and the calculated temperature is sufficiently small, τ can be obtainedmTime of erosion position r of inner surface of furnace walln；
8) Opening the upper flange cover plate (3) and forming a horizontal section PiAnd taking X reference points, respectively measuring the erosion positions of the reference points, comparing the experimental result with the calculation result, and verifying the accuracy of the algorithm.
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