1 , site profile
SP furnace waste heat boiler contains a lot of dust in hot flue gas, and the dust is fine, it is easy to accumulate ash on the heated surface of the boiler, affect the heat transfer effect of the boiler heating surface, resulting in reduced boiler output, reduced power generation, the current site using mechanical rapping method. In the long-term use process, the mechanical rapping method has summarized the following three significant problems:
(a) Sealing
The principle of mechanical rapping is that the motor drives the mechanical transmission part to rotate, relying on the impact force of the hammer head for cleaning, and the principle is not a sealed structure, in particular, the outdoor temperature in winter is low, and the temperature loss in the furnace is large.
(II) Limitations of cleaning range
The mechanical vibration cleaning method determines that the cleaning effect is better when the hammer is closer to the striking hammer. The cleaning effect is not obvious or almost has no effect from the distance from the hammer. The mechanical vibration method is used in the cleaning furnace. The tube bundles are not evenly stressed, and even some locations have leaks in the heat pipe bundles.
(C) Higher costs of electricity consumption and maintenance costs
The company uses a total of 11 medium-pressure heat recovery boilers with mechanical rapping equipment on each floor. The power of a radon motor for a waste heat boiler on the 1st line is approximately 1.1 KW. Calculated on a yearly basis for 300 days, the average annual power consumption is calculated as :
Average annual power consumption = 300 days * 24 hours / day * 1.1KW * 11 * 2 = 174240KWh (degrees)
There are 11 layers of waste heat boiler on the 2nd line, and the power of the vibrating motor on each layer is 1.1KW. Each set of vibrating hammers is equipped with two sets of vibrating hammers. Calculated according to 300 days of work per year, the average annual power consumption is calculated as follows:
Average annual power consumption = 300 days * 24 hours / day * 1.1KW * 11 * 2 = 174240KWh (degrees)
Total annual power consumption: 174240KWh+174240KWh=348480KWh
In addition equipment maintenance, lubricants, hammer replacement, labor, etc. is also a small fortune
2. Introduction and application of sonic cleaning technology
Acoustic wave cleaning technology is a cutting-edge technology in the field of international and domestic cleaning. It uses a 0.4-0.6 Mpa compressed air as a power source to oscillate the high-strength titanium alloy diaphragm inside the sounding body and oscillate it in the resonant cavity. Generates vibration, converts the potential energy of the compressed air into low-frequency sound energy, emits low-frequency, high-energy sound waves, and magnifies through the sound reinforcement cylinder, and the air medium transmits the sound energy to the corresponding swelling point, and directly acts on the molecular structure of the material. The intermolecular cohesion force of the material is changed from compact to loose, and it is detached from the surface of the attached body under the action of gravity or fluid media, and the purpose of effective cleaning is achieved. Compared with the traditional mechanical vibration cleaning method, it has the following three advantages:
A fully sealed structure
Acoustic wave cleaning device uses compressed air to pass into the sounding body to make the diaphragm produce low-frequency vibration. The sound reinforcement tube is introduced into the boiler for cleaning. When the work is stopped, the electromagnetic valve is automatically closed, and no smoke or dust is leaked. It is a fully sealed structure.
Two 360-degree dead-end comprehensive cleaning
Because the sound waves have the characteristics of reflection and refraction, high-frequency low-frequency sound waves will cause low-frequency vibration in the entire boiler after entering the boiler along the sound reinforcement tube, and the dust adhered to the heat-conducting tube bundle will be peeled off to exert negative pressure or gravity. Next, leave the surface of the heat pipe, and the heat pipe is subjected to uniform force, and there will be no problems such as cracking of the heat pipe or dead corner of the cleaning.
Small maintenance costs are low
The sound wave cleaner has no movable parts (excluding the diaphragm), so it requires little manual care during use, which greatly reduces the labor intensity. Compared to the traditional mechanical vibration cleaning method, the power consumption of the compressed air generated by the air compressor operation required for the sonic cleaning method is calculated as follows:
The working mode of the acoustic wave cleaning device is generally 30 minutes vibration once, vibration for 10-15 seconds, and the compressed air volume of 0.4 MPa required is about 0.75 cubic meters. The common frequency converter controls the screw air compressor generated by the permanent magnet motor. 1 cubic meter 0.6MPa compressed air power consumption is about 0.08KWh, due to the nonlinear relationship between compressed air production and power consumption, temporarily budgeted to produce 1 cubic meter 0.4MPa of compressed air power consumption of 0.06KWh, the same Under the conditions, the annual power consumption using the sonic cleaning method is calculated as follows:
Annual average power consumption of two lines: 300 days*24 hours/day*2 times per hour*0.045kwh*44 units=28512KWh
That is, using the sonic cleaning method can save power consumption in the year: 348480KWh-28512KWh=319968KWh
According to the industrial electricity standard, the minimum per kilowatt power is 0.8 yuan, which means that the electricity cost can be saved annually 319968*0.8=255975 yuan
In addition to the traditional mechanical cleaning method, the annual maintenance cost of the hammerhead and the motor (a SP furnace is calculated based on 20,000 yuan) can save a total annual cost of about 300,000 yuan.
3 , the main factors that should be considered in selecting the sonic ash eliminator
1 ) The range of sound waves;
2 ) The volume and structure of the equipment;
3 ) The required frequency and sound intensity of different types of dust;
4 ) On-site installation location
The correct installation position is the most important for the effective operation of the acoustic wave cleaner. It will directly affect the range of acoustic radiation and the efficiency of acoustic wave transmission, thus affecting the actual effect of cleaning. Different parts of the coke powder, blocking materials with working conditions such as the size of the humidity, etc., have different adhesion, it is necessary to effectively remove the coke powder from the surface of its attachment, you need to clear the most distant point of the object The required sound pressure level and working conditions of the propagation medium, the structural characteristics of the action space, the distance from the sound source, and the attenuation characteristics of the sound waves are used to comprehensively determine the installation position and number of the acoustic wave cleaning device, and the corresponding operating frequency is designed. .
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To use cobalt-based alloy powders for PTAW, the powder is typically fed into the plasma arc using a powder feeder. The powder is then melted by the high-temperature plasma arc and deposited onto the workpiece, forming a weld bead. The specific welding parameters, such as arc current, travel speed, and powder feed rate, will depend on the specific alloy and application requirements.
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