CN112924555A - Method and device for detecting state and fault diagnosis of moving bed radial reactor by using acoustic emission - Google Patents
Method and device for detecting state and fault diagnosis of moving bed radial reactor by using acoustic emission Download PDFInfo
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Abstract
The invention discloses a method and a device for detecting the state and fault diagnosis of a radial reactor of a moving bed by using acoustic emission, and relates to the technical field of reactor fault diagnosis. Which comprises the following steps: an acoustic emission sensor connected with a waveguide rod or an acoustic emission sensor not connected with the waveguide rod is distributed on the outer wall surface and the inner member of the moving bed radial reactor, the acoustic emission sensor is connected with an acoustic emission signal acquisition system, and a software analysis system performs waveform analysis, parameter analysis and power spectrum analysis on the acoustic emission signals, judges the running state of the reactor according to the analysis result and diagnoses faults. The method for diagnosing the faults of the radial reactor of the moving bed by using acoustic emission has the characteristics of real-time online, convenience and sensitivity, and is a non-invasive nondestructive testing technology. The fault diagnosis device and the fault diagnosis method provided by the invention are beneficial to maintaining the long-term stable operation of the moving bed reactor and the whole operation unit.
Description
Technical Field
The invention relates to the technical field of reactor fault diagnosis, in particular to a method and a device for detecting the state of a radial reactor of a moving bed and diagnosing faults by using acoustic emission.
Background
The moving bed radial reactor is widely applied in the fields of catalytic reaction, environmental protection and the like, and is particularly successfully applied in catalytic reforming in the petroleum refining industry, propane dehydrogenation, toluene disproportionation, tail gas desulfurization and the like in the chemical industry. In the moving bed radial reactor, catalyst particles and gas flow in a cross flow mode, the catalyst particles flow downwards under the action of gravity, and the gas flows horizontally in a bed layer. When the air flow velocity is large, two abnormal operating states of cavity and wall attachment occur. The creation of cavities makes the distribution of the gas phase in the axial direction uneven until a short circuit is formed. The adherence is generated, a dead zone is formed in a granular layer, a catalyst in the dead zone cannot be timely moved out of a bed layer after inactivation to realize regeneration, so that the reaction conversion rate is reduced, and the whole catalyst bed layer is completely adhered to the wall when the reaction is serious, so that the reactor cannot be continuously operated.
The reactor detection and fault diagnosis method is based on the diagnosis method of measurable signal processing, and the characteristic signal from the system has some relation with fault source, such as sound wave signal, temperature, pressure, etc. Temperature and pressure signals used as traditional means can interfere with the structure and flow field of the reactor to a certain extent, and are difficult to obtain at some local positions. Acoustic signals are receiving more and more attention as a novel non-destructive monitoring means. The acoustic emission technology is a passive acoustic detection technology, which obtains the operation information of the system by detecting acoustic signals generated by various physical and chemical processes in the industrial process, unlike the active acoustic detection technology. As a non-invasive detection technology, the passive acoustic emission technology is suitable for various severe industrial environments, can accurately realize the detection of the key parameters of the process on line in real time, and has wide industrial application prospect.
Chinese patent CN 102338775a discloses a method for detecting the movement status of particles in a moving bed reactor, which adopts a vibration signal measurement technology, utilizes a vibration signal detection device to receive vibration signals generated during the movement of particles in the moving bed reactor, processes the vibration signals, and establishes a corresponding relationship between the vibration signals and the particle circulation rate, so as to be used as a basis for determining the movement status of particles in the moving bed reactor, and does not relate to the problem when abnormal conditions such as cavities and adherence occur in the reactor.
In fact, the circulation amount of the catalyst in the moving bed reactor does not correspond to the cavity and adherence state of the reactor one by one, and the circulation rate of the reactor can be changed by changing a plurality of factors, so that the existence of the cavity or adherence in the reactor cannot be determined by measuring the circulation rate of the catalyst only. The method adopts the acoustic emission technology to detect the state of the radial reactor of the moving bed, and detects and judges the faults of the reactor, and the obtained detection data, the processing method and the technical index of the data are completely different from the vibration signal detection method.
Disclosure of Invention
The invention aims to provide a method and a device for diagnosing faults of a moving bed radial reactor by using acoustic emission so as to solve the technical problems.
The invention is realized by the following steps:
a method and a device for fault diagnosis of a moving bed radial reactor by using acoustic emission comprise the following steps: arranging acoustic emission sensors connected with wave guide rods or acoustic emission sensors not connected with the wave guide rods on the outer wall surface and the inner component of the moving bed radial reactor, connecting the acoustic emission sensors with an acoustic emission signal acquisition system to acquire acoustic emission signals of the moving bed radial reactor, analyzing the acquired acoustic emission signals by using at least one of the following methods by using a data software analysis system, and diagnosing faults according to the analysis result: waveform analysis, parametric analysis, and power spectrum analysis.
The invention adopts the acoustic emission detection technology to carry out real-time online detection on the motion conditions of gas and particles in the radial reactor of the moving bed, and has the characteristics of no invasion to a flow field, real-time online, convenience, sensitivity and the like. Acoustic emission signals directly measured by the outer wall surface and the inner component of the radial reactor of the moving bed are collected and are led out to a test software analysis system for waveform analysis, parameter analysis and power spectrum analysis. The signal characteristics of the moving state of the gas and the catalyst particles in the moving bed radial reactor can be obtained, and basis and means are provided for detection and fault diagnosis of the moving bed radial reactor.
Monitoring the moving state of gas and catalyst particles in the radial reactor of the moving bed has important significance for the safe and stable operation of the reactor, is favorable for improving the working efficiency of the moving bed reactor, ensures the stable operation of the whole operating device, and avoids the stop of the moving bed reactor.
In other embodiments, according to the temperature requirement of the reactor to be measured, a proper waveguide rod can be installed on the outer wall surface and the inner component of the reactor under a high-temperature condition, and an acoustic emission sensor can be installed at the other end of the waveguide rod. The signal conduction of the high-temperature device is realized through the waveguide rod, so that the real-time online detection and analysis of the acoustic signal are realized, the two-phase flow condition in the reactor is monitored, and the online monitoring, diagnosis and positioning of faults are carried out on the reactor. The acoustic emission signal source can be positioned by acoustic emission positioning, and the fault position can be identified according to the parameters of the acoustic emission positioning source when the reactor is abnormal.
Preferably, the waveguide rod is made of metal materials, the cross section of the waveguide rod can be in a circular shape, a rectangular shape, a polygonal shape and other geometric shapes, the diameter or the side length of the waveguide rod can be changed along the axial direction, the waveguide rod is in a conical shape and the like, and the waveguide rod has a proper length to match the transmission of the acoustic emission signals. One end of the waveguide rod is connected with the outer wall or the inner component of the reactor and is connected with the outer wall of the reactor by welding or fasteners so as to fix the waveguide rod on the outer wall of the reactor. The other end of the wave guide rod is provided with an expanding section and a connecting piece for installing the acoustic emission sensor, and the connecting piece is made of plastic or resin materials with low density.
The results of the waveform analysis, the parametric analysis and the power spectrum analysis are consistent with the observed experimental phenomena, and the three methods can be used for judging the running state of the reactor. In other embodiments, the location of the abnormality or fault may also be determined by calculation based on the acoustic emission signal, i.e. with a localization function.
In a preferred embodiment of the present invention, the analyzing the waveform of the acoustic emission signal includes: if the waveform is a stable signal, judging that the radial reactor of the moving bed normally operates; if the waveform shows a pulse shape, judging that the moving bed radial reactor is likely to generate a cavity phenomenon or an adherence phenomenon during operation.
According to the oscillogram of acoustic emission, namely the change relation of the voltage signal under various conditions along with time, the operation state of the reactor can be judged through the change of the waveform.
When the reactor is running normally, the waveform shows a stable signal. The waveform shows a pulse shape when the reactor is abnormal, the signal amplitude is between 10 and 300mV when the cavity phenomenon occurs, and the signal amplitude is more than 300mV when the reactor is attached to the wall phenomenon.
In the moving bed radial reactor, gas and catalyst particles flow in a cross flow mode, the catalyst particles flow downwards under the action of gravity, and the gas flows horizontally in the moving bed layer. When gas passes through the catalyst particle layer in the radial direction, drag force is generated on catalyst particles, and when the gas flow velocity is large enough, the catalyst particles leave the wall surface to form a cavity phenomenon in the bed layer; when the gas flow rate reaches a certain critical value, the friction force between the catalyst particles and the wall surface is greater than the gravity, so that a dead zone is formed on the catalyst bed layer, and the phenomenon of adherence occurs. When the cavity occurs, the gas flow is unevenly distributed along the axial direction, and gas channeling is formed in the bed layer when the gas flow is serious. When adherence occurs, the particles in the adherence zone are deactivated by the inability to move coke, rendering the moving bed incapable of normal operation and even leading to unplanned shutdowns.
According to the waveform performance, the flowing conditions of the catalyst and the gas in the reactor can be judged, and further the running condition of the moving bed radial reactor is obtained.
In a preferred embodiment of the present invention, the analyzing the acoustic emission signal includes: the average signal level, amplitude and energy of the acoustic emission signal are analyzed.
Single parameter analysis indicates that the root mean square voltage (RMS) of the signal is small when the reactor is operating normally and that the RMS value increases when an anomaly occurs. Likewise, the Average Signal Level (ASL) is low during normal operation and increases when the reactor is operating abnormally. When the adherence phenomenon occurs, the amplitude, the average signal level and the energy are further increased, so that the running state of the reactor can be judged according to the change of the parameters.
In a preferred embodiment of the present invention, when performing parameter analysis on the acoustic emission signal, if the average signal level of the moving bed radial reactor is less than or equal to 20dB, the operating amplitude of the reactor is 35-45dB, and the maximum energy is less than 10, then determining that the moving bed radial reactor is operating normally; when the average signal level of the moving bed radial reactor is 20-40dB, the operation amplitude of the reactor is 35-65dB, and the maximum energy is 1000-; when the average signal level of the moving bed radial reactor is 30-60dB, the operation amplitude of the reactor is 35-75dB, and the maximum energy is more than 20000, judging that the moving bed radial reactor has adherence phenomenon.
In a preferred embodiment of the present invention, the analyzing the power spectrum of the acoustic emission signal includes: when the frequency range of the acoustic emission signal is widened compared with the normal operation, the cavity phenomenon or the wall adhesion phenomenon of the radial reactor of the moving bed is judged.
Performing power spectrum analysis on the acoustic emission signal, including: when the peak frequency of the acoustic emission signal is within the range of 50-150kHz, the moving bed radial reactor has a cavity phenomenon; when the peak frequency of the acoustic emission signal is in the range of 50-150kHz and a shoulder exists in the range of 100-200kHz, adherence phenomenon occurs in the radial reactor of the moving bed.
In an embodiment of the invention, before the acoustic emission signal is collected in the moving bed radial reactor, a lead-breaking test is performed to calibrate the acoustic emission signal collection system. If the signal acquisition of the acoustic emission signal acquisition system is in a problem, the subsequent analysis result is greatly discounted, so that the calibration of the signal acquisition of the acoustic emission signal acquisition system is very important.
In a preferred embodiment of the present invention, when the acoustic emission signal is collected in the moving bed radial reactor, the sampling time, the sampling frequency, the amplifier gain and the threshold value of the acoustic emission signal collection system are set, and the impact definition time and the impact blocking time are set.
In a preferred embodiment of the invention, when the acoustic emission signal is collected in the moving bed radial reactor, the sampling time of the acoustic emission signal collection system is set to be 0-60s, and the sampling frequency is set to be 0.1-1 MHz.
In a preferred embodiment of the present invention, the moving bed radial reactor is a moving bed radial reactor on any one of the following apparatuses: a continuous reforming device, a hydrocarbon dehydrogenation device, a continuous moving bed desulfurization process device, a toluene disproportionation device, a moving bed coal gasification process device, a moving bed aromatization process device and a laboratory moving bed cold die device.
A device for detecting the running state of a radial reactor of a moving bed and diagnosing faults by using acoustic emission comprises the radial reactor of the moving bed, an emission signal acquisition system and a test software analysis system, wherein acoustic emission sensors are distributed on the outer wall surface and the inner component of the radial reactor of the moving bed, the reactor with high wall surface temperature also comprises a waveguide rod for connecting the outer wall and the inner component of the radial reactor of the moving bed and the acoustic emission sensors, one end of the waveguide rod is fixed on the outer wall surface and the inner component of the reactor, the acoustic emission sensors are arranged at the other end of the waveguide rod, and the acoustic emission sensors are sequentially connected with the emission signal acquisition system and the test software analysis system.
The wave guide rod is made of high-temperature-resistant materials, the cross section of the wave guide rod is circular or polygonal, and the top of the wave guide rod is provided with an expansion section for installing the acoustic emission sensor. The diameter or the side length of the waveguide rod along the axial direction can be adjusted in a self-adaptive mode according to needs. The waveguide rod can improve the sensitivity of the sensor and reduce the cost.
The moving bed radial reactor consists of a shell, a central cylinder and a fan-shaped cylinder, wherein the shell is made of organic glass and comprises two plane plates and an arc panel, the arc panel is provided with an arc surface less than 360 degrees, the plane plates and the arc panel are enclosed to form a cylinder structure with a cavity, and an inner member of the reactor is arranged in the cavity; preferably, the cambered plate is a polygonal cylindrical surface.
The invention has the following beneficial effects:
the method and the device for diagnosing the state and the fault of the radial reactor of the moving bed by using acoustic emission have the characteristics of real-time online, convenience, sensitivity, safety and environmental protection, are a non-invasive nondestructive detection technology, and do not need an additional emission source. By continuously detecting the running state of the moving bed radial reactor on line, the movement state of particles in the moving bed radial reactor can be detected at any time. Acoustic emission waveform analysis, parameter analysis and power spectrum analysis can be used for judging the running state of the reactor, and further diagnosing the faults of the cavity, the wall adhesion and the like of the radial reactor of the moving bed. The invention accurately carries out on-line analysis on the motion state of particles in the moving bed reactor, is beneficial to maintaining the long-term stable operation of the moving bed reactor and the whole operation unit, can carry out fault monitoring and diagnosis on the radial reactor in time and avoids the unplanned shutdown of the moving bed reactor. In addition, a device for diagnosing faults of the radial reactor of the moving bed is provided, and the device is simple and feasible.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings needed to be used in the embodiments will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and for those skilled in the art, other related drawings can be obtained according to the drawings without inventive efforts.
FIG. 1 is a diagram of an acoustic emission fault diagnosis system provided in embodiment 1 of the present invention;
FIG. 2 is a schematic diagram showing the time variation of an acoustic emission signal in the detection method provided in example 1 of the present invention;
FIG. 3 is a schematic diagram showing the variation of ASL with operating conditions in example 1 of the present invention;
FIG. 4 is a schematic diagram showing the variation of energy with operating conditions in example 1 of the present invention;
FIG. 5 is a graph showing the absolute energy according to the operating conditions in example 1 of the present invention;
FIG. 6 is a graph showing the variation of the number of hits depending on the operating conditions in embodiment 1 of the present invention;
FIG. 7 is a schematic diagram showing the variation of an acoustic emission signal with frequency in example 1 of the present invention;
FIG. 8 is a schematic view of the acoustic emission signal detection process in example 7.
Reference numerals: 1-a reactor riser; 2-a reactor lower hopper; 3-a signal processing system; 4-a signal acquisition system; 5-an acoustic emission sensor; 6-waveguide rod; 7-a reactor; 8-reactor discharge pipe; 9-reactor upper hopper; 10-a reactor riser; 11-a separation hopper; 12-a lock hopper; 13-a regenerator; 14-regenerator down pipe; 15-regenerator lower hopper; 16-a regenerator lifter; 17-a regenerator riser; 18-a gas distributor; 19-a flow meter; 20-a cold mould hopper; 21-cold mould reactor inlet; 22-cold mould reactor; 23-a cold die sensor; 24-a cold die signal acquisition system; 25-a cold mold signal processing system; 26-cold mould reactor outlet; 27-cold die blanking pipe; 28-cold die lifter; 29-cold mould riser.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. The examples, in which specific conditions are not specified, were conducted under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products available commercially.
The features and properties of the present invention are described in further detail below with reference to examples.
Example 1
Referring to fig. 1, the acoustic emission detection reactor operating state and fault diagnosis system (apparatus) provided in this embodiment detects the mutual moving state of the gas and the catalyst particles in the moving bed radial reactor by the fault diagnosis system shown in fig. 1, and performs acquisition of an acoustic emission signal of a continuous reforming apparatus and fault diagnosis. In this example, the continuous reforming apparatus had four moving bed radial reactors and a moving bed regenerator of different diameters, wherein the first reactor had an inner diameter of 2500mm and the catalytic reforming catalyst had an average particle size of 1.5 mm. Only one of the moving bed radial reactors and regenerators and the catalyst circulation system are shown in the flow diagram of fig. 1.
In the acoustic emission detection reactor operation state and fault diagnosis system, oil gas from a heating furnace enters a reactor 7 from an inlet, radially passes through a catalyst particle bed layer, and then goes to the next reactor from an outlet of a top reactor. The catalyst flows downwards from the upper hopper 9 of the reactor through the lower pipe 8 of the reactor to the reactor 7, flows out from the lower hopper 2 of the reactor, and is lifted to the separation hopper 11 along the riser 10 of the reactor through the riser 1 of the reactor. The catalyst is separated and then enters a regenerator 13, after the catalyst is in cross flow contact with the coke-burning gas in the regenerator for burning, the catalyst sequentially moves, is subjected to chlorination calcination, enters a lock hopper 12 through a regenerator blanking pipe 14 and then enters a regenerator lower hopper 15, and is lifted to a reactor upper hopper 9 (or a reduction section) through a regenerator lifting pipe 17 by a regenerator lifter 16.
The method is characterized in that 15 acoustic emission sensors 5 are arranged at the peripheral position of a reactor 7, 18 acoustic emission sensors 5 are arranged at the peripheral position of a regenerator 13, a waveguide rod 6 with proper length is arranged at different axial and circumferential positions of the outer wall surfaces of a moving bed radial reactor and a regenerator (and inner components of the moving bed radial reactor and the regenerator) when necessary due to the fact that the temperature of the outer wall surfaces of the reactor and the regenerator is high, the acoustic emission sensors 5 are installed at the top ends of the waveguide rods 6, 6 waveguide rods and acoustic emission sensors are respectively arranged on a discharging pipe and a lifting pipe of the reactor and the regenerator in order to comprehensively analyze the operation condition of the continuous reforming device, the acoustic emission sensors 5 are connected with a signal acquisition system 4, and the signal acquisition system 4 transmits collected signals to a signal processing system 3 for signal processing. And performing fault diagnosis and evaluation according to the data processing and analysis result.
The sampling time of the acoustic signal acquisition system 4 is set to 15s, the sampling frequency is set to 1MHz, the gain of the preamplifier is set to 40dB, and the threshold value is set to 35 dB. The strike signal timing parameters are set to a peak definition time of 1000 mus, a strike definition time of 2000 mus, and a strike dwell time of 20000 mus.
Before acoustic emission detection is carried out on the reactor and the regenerator 13, a lead breaking test is carried out to calibrate the acoustic signal acquisition system 4. Collecting acoustic emission signals of the moving bed radial reactor 7 and the regenerator 13, and performing waveform analysis, parameter analysis and power spectrum analysis on the acoustic emission signals. The signal processing system 3 is turned on. The signals are processed in real time.
Acoustic emission signal variation over time referring to fig. 2, when the reactor and regenerator 13 is operating normally, the waveform of fig. 2a appears as a stationary signal; when the running state of the reactor and the regenerator 13 is abnormal, such as the adherence of a cavity occurs, the waveform is in a pulse shape, and the signal amplitude is 10-300mV when the cavity phenomenon occurs, as shown in figure 2 b; the amplitude of the signal was greater than 300mV when adherence occurred, see FIG. 2 c.
And opening a signal processing system, and performing ASL (amplitude shift keying), energy, absolute energy, impact number and other parameter analysis on acoustic emission signals of the outer wall surfaces and the inner members of the reactor and the regenerator. Results of ASL analysis referring to FIG. 3, the acoustic emission signal ASL is small (left side of vertical line in FIG. 3) and is substantially 20dB when the reactor is in normal operation; when the reactor operating state is abnormal, such as the adherence of a cavity, the acoustic emission signal ASL is increased remarkably (at the vertical line of FIG. 3). Fig. 4, fig. 5 and fig. 6 are graphs of the change of the acoustic emission signal energy, the absolute energy and the impact number with time, which are consistent with the trend of the acoustic emission signal ASL with time, respectively, and when the running state of the reactor and the regenerator is abnormal, such as the cavity adheres to the wall, the acoustic emission signal energy, the absolute energy and the impact number are increased greatly (at vertical lines of fig. 4-fig. 6).
Carrying out power spectrum analysis on acoustic emission signals of the reactor, the outer wall surface of the regenerator and the inner component, and referring to fig. 7, when a cavity phenomenon occurs in the reactor, the peak frequency is between 50 and 150kHz (fig. 7 a); when the adherence phenomenon occurs, the frequency range of the acoustic emission signal is widened, the shape of the power spectrum is changed between 0 and 250kHz, and a shoulder peak (figure 7b) appears in the range of 100 to 200 kHz.
The Average Signal Level (ASL), which is the average of the signal levels over the sampling time, can be used to evaluate the degree of interaction between the gas and the catalyst particles. When the reactor and regenerator 13 adhere to each other, the Average Signal Level (ASL) increases significantly, and the average of the root mean square voltage (RMS) also increases significantly. Therefore, the detection of the running state of the radial reactor of the moving bed and the diagnosis of the fault can be carried out. The other acoustic emission signals (energy, amplitude, count, rise time, duration and the like) on the outer wall surface of the reactor are subjected to parameter analysis, and the detection of the running state of the radial reactor of the moving bed and the regenerator 13 and the diagnosis of faults can be carried out according to the acoustic emission signal parameter analysis.
Example 2
The embodiment provides a method for diagnosing the faults of a moving bed hydrocarbon dehydrogenation device by using acoustic emission, which detects the mutual motion state of gas and catalyst particles in a moving bed radial reactor. An acoustic emission failure diagnosis system similar to that of example 1 was used, and acoustic emission sensors were installed on the outer wall and the inner member of the moving bed hydrocarbon dehydrogenation apparatus. If necessary, a waveguide rod can be additionally arranged, and an acoustic emission sensor is arranged at one end of the waveguide rod.
And setting the sampling time of the acoustic emission signal acquisition system to be 15s and the sampling frequency to be 1MHz, and acquiring the acoustic signal of the outer wall surface of the hydrocarbon dehydrogenation reactor of the moving bed. And opening a signal processing system, performing ASL (amplitude shift keying), energy, absolute energy, impact number and other parameter analysis on the acoustic emission signals of the hydrocarbon dehydrogenation reactor of the moving bed, performing power spectrum analysis on the acoustic emission signals, and processing the signals in real time. The detection of the running state of the hydrocarbon dehydrogenation reactor of the moving bed and the diagnosis of the fault can be carried out according to the analysis of the acoustic emission signals.
Example 3
The embodiment provides a method for diagnosing the faults of a moving bed aromatization process device by adopting acoustic emission. In this example, the aromatization process unit had 2 moving bed radial reactors of different diameters. Acoustic emission sensors are respectively arranged on the outer wall surface of the radial reactor of the moving bed and the inner component in different axial and circumferential positions and are connected with a signal amplification acquisition and processing system.
And setting the sampling time of the acoustic emission signal acquisition system to be 15s and the sampling frequency to be 1MHz, and acquiring the acoustic signal of the outer wall surface of the hydrocarbon dehydrogenation reactor of the moving bed. And opening a signal processing system, performing ASL (amplitude shift keying), energy, absolute energy, impact number and other parameter analysis on the acoustic emission signals of the hydrocarbon dehydrogenation reactor of the moving bed, performing power spectrum analysis on the acoustic emission signals, and processing the signals in real time. The detection of the running state of the hydrocarbon dehydrogenation reactor of the moving bed and the diagnosis of the fault can be carried out according to the analysis of the acoustic emission signals.
Example 4
The embodiment provides a method for diagnosing faults of a moving bed coal gasification process device by using acoustic emission. The state of mutual movement of the gas and the catalyst particles in the radial reactor of the moving bed is detected. In this example, the coal gasification process apparatus had 3 moving bed radial reactors with different diameters. Acoustic emission sensors are respectively arranged on the outer wall surface of the radial reactor of the moving bed and the inner component in different axial and circumferential positions and are connected with a signal amplification acquisition and processing system.
And setting the sampling time of the acoustic emission signal acquisition system to be 15s and the sampling frequency to be 1MHz, and acquiring the acoustic signal of the outer wall surface of the hydrocarbon dehydrogenation reactor of the moving bed. And opening a signal processing system, performing ASL (amplitude shift keying), energy, absolute energy, impact number and other parameter analysis on the acoustic emission signals of the hydrocarbon dehydrogenation reactor of the moving bed, performing power spectrum analysis on the acoustic emission signals, and processing the signals in real time. The detection of the running state of the hydrocarbon dehydrogenation reactor of the moving bed and the diagnosis of the fault can be carried out according to the analysis of the acoustic emission signals.
Example 5
The embodiment provides a method for diagnosing faults of a moving bed toluene disproportionation device by adopting acoustic emission. The method is used for monitoring and diagnosing the mutual movement state of gas and catalyst particles in a radial reactor of the moving bed toluene disproportionation device. In this example, the toluene disproportionation unit had three moving bed radial reactors of different diameters.
Acoustic emission sensors are respectively arranged on the outer wall surface of the radial reactor of the moving bed and the inner component at different axial and circumferential positions. Because the temperature of the reactor is high, a waveguide rod with proper length is arranged if necessary, and an acoustic emission sensor is arranged at the top end of the waveguide rod and connected with a signal amplification acquisition and processing system.
And setting the sampling time of the acoustic emission signal acquisition system to be 15s and the sampling frequency to be 1MHz, and acquiring the acoustic signal of the outer wall surface of the hydrocarbon dehydrogenation reactor of the moving bed. And opening a signal processing system, performing ASL (amplitude shift keying), energy, absolute energy, impact number and other parameter analysis on the acoustic emission signals of the hydrocarbon dehydrogenation reactor of the moving bed, performing power spectrum analysis on the acoustic emission signals, and processing the signals in real time. The detection of the running state of the hydrocarbon dehydrogenation reactor of the moving bed and the diagnosis of the fault can be carried out according to the analysis of the acoustic emission signals.
Example 6
The embodiment provides a method for diagnosing the faults of a device in a continuous moving bed desulfurization process by using acoustic emission. The state of mutual movement of the gas and the catalyst particles in the radial reactor of the moving bed is detected. In this example, the dehydrogenation unit had two moving bed radial reactors of different diameters. Acoustic emission sensors are respectively arranged on the outer wall surface of the radial reactor of the moving bed and the different axial and circumferential positions of the inner component, because the temperature of the outer wall of the reactor is high, a waveguide rod with proper length can be arranged for improving the sensitivity of the sensor and reducing the cost, the acoustic emission sensor is arranged at the top end of the waveguide rod and is connected with a signal amplification acquisition and processing system.
And setting the sampling time of the acoustic emission signal acquisition system to be 15s and the sampling frequency to be 1MHz, and acquiring the acoustic signal of the outer wall surface of the hydrocarbon dehydrogenation reactor of the moving bed. And opening a signal processing system, performing ASL (amplitude shift keying), energy, absolute energy, impact number and other parameter analysis on the acoustic emission signals of the hydrocarbon dehydrogenation reactor of the moving bed, performing power spectrum analysis on the acoustic emission signals, and processing the signals in real time. The detection of the running state of the hydrocarbon dehydrogenation reactor of the moving bed and the diagnosis of the fault can be carried out according to the analysis of the acoustic emission signals.
Example 7
The embodiment provides an acoustic emission signal detection method and a fault diagnosis method for a laboratory moving bed cold die device, which are used for detecting the mutual motion state of gas and catalyst particles in a moving bed radial reactor. In this embodiment, the moving bed reactor housing is made of plexiglass for viewing. The outer wall surface of the reactor is a cylindrical surface or a polygonal cylindrical surface formed by a plane plate and a semicircle with the diameter of 2000mm, or a cylindrical surface or a polygonal cylindrical surface formed by 1/4 circles, or a cylindrical surface or a polygonal cylindrical surface formed by an arc with the angle less than 360 degrees, so that the flow state and the interaction of gas and solid phases in the reactor can be directly observed conveniently, particularly the direct observation is carried out, and the appearance and the development of a cavity and an adherence wall are shot and recorded, and the height is 1500 mm. The average particle size was 1.5 mm.
Figure 8 shows a flow diagram of a moving bed radial reactor cold die apparatus. The shell of the moving bed cold mould reactor is made of organic glass, the outer wall surface of the reactor is a cavity formed by two plane plates and a cylindrical surface or a polygonal cylindrical surface formed by arc surfaces (or polygonal surfaces), and the arc surfaces are semi-circular arc surfaces (or 1/4 arc surfaces), so that the flowing state and interaction of gas and solid phases in the reactor can be directly observed conveniently, and particularly, the appearance and development of shooting and recording cavities and adherence walls can be directly observed.
The gas is distributed into a plurality of paths through the gas distributor 18, one path of the gas enters the cold die reactor 22 from the inlet 21 of the cold die reactor through the flow meter 19, the two paths of the gas enter the cold die lifter 28, the catalyst is lifted along the cold die lifting pipe 29 and enters the cold die hopper 20, the gas is separated from catalyst particles and then discharged, and the catalyst particles enter the cold die reactor 22. A cold die reactor outlet 26 is provided in the upper portion of the cold die reactor 22, gas is discharged from the cold die reactor outlet 26, and catalyst flows out of the reactor through a cold die discharge pipe 27.
And 9 cold die sensors 23 are respectively arranged on the wall surface of the radial reactor of the moving bed in different axial directions and circumferential directions. In order to analyze the operating conditions of the cold die device in general, 2 cold die sensors 23 are arranged on the catalyst offtake and riser of the reactor. And opening the cold mold signal acquisition system 24, sampling for 15s at the sampling frequency of 1MHz, and acquiring the signal of the cold mold reactor 22. And opening the cold mould signal processing system 25, performing ASL (amplitude shift keying), energy, absolute energy, impact number and other parameter analysis on the acoustic emission signals of the reactor, performing power spectrum analysis on the acoustic emission signals on the outer wall surface of the reactor, and processing the signals in real time. The detection of the running state of the radial reactor of the moving bed and the diagnosis of the fault can be carried out according to the parameter analysis of the acoustic emission signal of the outer wall surface of the cold die reactor 22.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (12)
1. A method for moving bed radial reactor condition detection using acoustic emission, comprising the steps of: arranging acoustic emission sensors connected with wave guide rods or acoustic emission sensors not connected with the wave guide rods on the outer wall surface and the inner component of the moving bed radial reactor, connecting the acoustic emission sensors with an acoustic emission signal acquisition system to acquire acoustic emission signals of the moving bed radial reactor, analyzing the acquired acoustic emission signals by using at least one of the following methods by using a data software analysis system, and diagnosing faults according to the analysis result: waveform analysis, parametric analysis, and power spectrum analysis.
2. The method of claim 1, wherein performing a waveform analysis on the acoustic emission signal comprises: if the waveform is a stable signal, judging that the radial reactor of the moving bed normally operates; if the waveform shows a pulse shape, judging that the moving bed radial reactor is likely to generate a cavity phenomenon or an adherence phenomenon during operation.
3. The method as claimed in claim 2, wherein, in the waveform analysis of the acoustic emission signal, if the waveform shows a pulse shape and the signal amplitude is in the range of 10-300mV, it is determined that the moving bed radial reactor is operated to generate the cavitation; if the waveform shows a pulse shape and the signal amplitude is more than 300mV, judging that the moving bed radial reactor operates to generate adherence phenomenon.
4. The method of claim 1, wherein performing parametric analysis on the acoustic emission signals comprises: the average signal level, amplitude and energy of the acoustic emission signal are analyzed.
5. The method as claimed in claim 4, wherein, when the acoustic emission signal is subjected to parameter analysis, if the average signal level of the moving bed radial reactor is less than or equal to 20dB, the reactor operation amplitude is 35-45dB, and the maximum energy is less than 10, the moving bed radial reactor is judged to be normally operated; when the average signal level of the moving bed radial reactor is 20-40dB, the operation amplitude of the reactor is 35-65dB, and the maximum energy is 1000-; when the average signal level of the moving bed radial reactor is 30-60dB, the operation amplitude of the reactor is 35-75dB, and the maximum energy is more than 20000, judging that the moving bed radial reactor has adherence phenomenon.
6. The method of claim 1, wherein performing a power spectral analysis of the acoustic emission signal comprises: when the peak frequency of the acoustic emission signal is within the range of 50-150kHz, the moving bed radial reactor has a cavity phenomenon; when the peak frequency of the acoustic emission signal is in the range of 50-150kHz and a shoulder exists in the range of 100-200kHz, adherence phenomenon occurs in the radial reactor of the moving bed.
7. The method of claim 1, further comprising calibrating the acoustic emission signal acquisition system by performing a lead break test before the acoustic emission signal acquisition is performed on the moving bed radial reactor.
8. The method according to claim 7, wherein when the acoustic emission signal is collected from the moving bed radial reactor, the sampling time of the acoustic emission signal collecting system is set to 0-60s, and the sampling frequency is set to 0.1-1 MHz.
9. The process of claim 1, wherein the moving bed radial reactor is a moving bed radial reactor on any one of the following devices: the device comprises a continuous reforming device, a hydrocarbon dehydrogenation device, a toluene disproportionation device, a moving bed aromatization process device, a continuous moving bed desulfurization device, a moving bed coal gasification device and a laboratory moving bed cold die device.
10. A device for carrying out fault diagnosis on a moving bed radial reactor by using acoustic emission is characterized by comprising the moving bed radial reactor, an emission signal acquisition system and a test software analysis system, wherein acoustic emission sensors are distributed on the outer wall surface and the inner component of the moving bed radial reactor, the reactor with high wall surface temperature also comprises a waveguide rod used for connecting the outer wall surface and the inner component of the moving bed radial reactor and the acoustic emission sensors, one end of the waveguide rod is fixed on the outer wall surface and the inner component of the reactor, the acoustic emission sensors are installed at the other end of the waveguide rod, and the acoustic emission sensors are sequentially connected with the emission signal acquisition system and the test software analysis system.
11. The device of claim 10, wherein the waveguide is made of a high temperature resistant material, the waveguide has a circular or polygonal cross-section, and the top of the waveguide is provided with an enlarged section for mounting the acoustic emission sensor.
12. The apparatus according to claim 10, characterized in that the moving bed radial reactor is composed of a shell, a central cylinder and a sector cylinder, and for the moving bed radial reactor cold mould apparatus, the shell is made of organic glass, the shell comprises two flat plates and an arc plate, the arc plate has an arc surface less than 360 degrees, the flat plates and the arc plate enclose a column structure with a chamber, and the inner component of the reactor is arranged in the chamber; preferably, the cambered plate is a polygonal cylindrical surface.
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