某集團循環(huán)水零排放模擬試驗

1、某集團循環(huán)水零排放模擬實驗一、實驗目的試驗我公司Fs-66、Fs-51高濃縮倍數(shù)緩蝕阻垢劑藥劑在某集團循環(huán)水對設備產(chǎn)生腐蝕和結垢的情況，動態(tài)模擬試驗是對藥劑緩蝕阻垢效果的驗證。二、技術條件設備使用條件：溫度030C,空氣相對濕度85%;循環(huán)水流態(tài)：湍流；日操作時數(shù)：24小時；供電電源：380V±1%整機功率：3kW占地面積：約2.5m2;蒸汽溫度平均值：所在地區(qū)常壓下的飽和蒸汽溫度；實驗要求：及可滿足兩組平行試驗，又可滿足單租毒理實驗。三、試驗裝置介紹及試驗流程1）實驗裝置介紹QYDM型智能動態(tài)模擬試驗裝置的的試驗方法是依據(jù)中國化工部行業(yè)標準HG/T2060-2008冷卻水動態(tài)模擬試

2、驗方法執(zhí)行，是在實驗室給定條件下，用常壓飽和蒸汽加熱換熱器，模擬生產(chǎn)現(xiàn)場的流速、流態(tài)、水質(zhì)、金屬材質(zhì)、換熱強度和飽和冷卻水進、出口溫度等主要參數(shù)，以評定水處理劑的緩蝕和阻垢性能。采用雙水路流程，即可對同一配方進行平行對比試驗，又可對不同配方進行性能篩選試驗。裝置對進口溫度實行自動控制，實現(xiàn)系統(tǒng)對溫度的穩(wěn)定調(diào)節(jié)。采用高精度玻璃流量計對流量進行控制，確保系統(tǒng)流量的穩(wěn)定。能實現(xiàn)對循環(huán)冷卻水進口溫度、出口溫度、蒸汽溫度、污垢熱阻等參數(shù)的在線監(jiān)控。能實現(xiàn)自動補水功能。采用無觸點固態(tài)模塊，能對加熱功率實現(xiàn)無極調(diào)節(jié)。裝置備有出口掛片器，通過透明的有機玻璃管能直接觀測到水對掛片的腐蝕與結垢情況2）試驗流程試驗

3、用動態(tài)模擬試驗裝置流程圖如下圖所示:1鍋爐水節(jié)水口72模擬換熱器83掛片器94補水箱105入塔噴頭116涼水塔12流量計閥門風機-集水池-浮球閥-水泵循環(huán)水循環(huán)過程：循環(huán)水由水泵從集水池打入模擬換熱器進行換熱，循環(huán)水被加熱后再經(jīng)入塔噴頭噴淋進入涼水塔進行冷卻，冷卻后再次流入集水池。試驗過程中，循環(huán)水流量由流量計控制，試驗人員對流量實時監(jiān)控；集水池液位由浮球控制，若水量蒸發(fā)，集水池液位下降，則浮球下落，閥門開啟，由補水箱對集水池進行補水；試驗人員在現(xiàn)場對模擬換熱器進出口溫差及換熱管污垢熱阻進行實時監(jiān)控，并做詳細記錄；實驗人員每天取樣檢測循環(huán)水指標，并做詳細記錄，檢測結果雙方確認。循環(huán)水中加入藥劑

4、，模擬換熱器中鍋爐水升溫到位后，試驗正式開始。為了盡快將循環(huán)水的濃縮倍數(shù)提高到15倍，試驗前期系統(tǒng)不排水，濃縮倍數(shù)到15倍后，根據(jù)每天補水量與補水水質(zhì)，對系統(tǒng)進行定量排水，使循環(huán)水濃縮杯水在15倍平穩(wěn)運行30天,30天后試驗結束，在雙方負責人監(jiān)督下對設備進行拆卸，觀察掛片及換熱管的腐蝕與結垢情況。四、試驗前準備1)掛片及不銹鋼管的處理對掛片及不銹鋼管用酒精擦拭，清潔表面的雜質(zhì)及油污，然后把掛片與不銹鋼管用冷風吹干，用濾紙包好在干燥箱內(nèi)干燥24h,然后進行稱重，并記錄數(shù)據(jù)。2)實驗設備清洗集水池中加入循環(huán)水循環(huán)2h,清洗設備管路中的塵土、油污；模擬換熱器中加除鹽水浸泡2h,清洗模擬換熱器中雜質(zhì)。

5、清洗結束后將循環(huán)水與除鹽水放掉。3)水質(zhì)監(jiān)測對試驗用的補水及循環(huán)水水質(zhì)進行檢測。4)掛片及不銹鋼管的安裝。五、初始數(shù)據(jù)及技術指標1)試驗初始數(shù)據(jù)試驗用水水質(zhì)：總堿度(mg/l)總硬度(mg/l)鈣硬(mg/l)Cl-(mg/l)循環(huán)水300640124560補水220510450掛片及銹鋼管:系統(tǒng)種類型號質(zhì)量(g)1#不銹鋼掛片530220.7289530320.7619碳鋼掛片108219.267108319.2781不銹鋼管不銹鋼170.57872#不銹鋼掛片530020.7124530120.5657碳鋼掛片108019.2213108119.251不銹鋼管不銹鋼270.62172）試驗

6、裝置技術指標流體介質(zhì)管程（殼側(cè)）冷卻水殼程（管側(cè)）飽和蒸汽進口水溫C32±0.1出口水溫C42±0.1模擬水流量l/h0-100,實際控制流量60l/h水流速m/s0-2,控制流速1m/s保有水量l13.81涼水塔15cm,h=120cm模擬溫差C10±1換熱管尺寸mm6X1掛片尺寸mm50X25X2出口掛片器尺寸mm60X150換熱面積cnf/根99.85蒸汽發(fā)生器外形、規(guī)模mm550X500,SS304含保溫總功耗kW3電壓V3800電加熱管形式、根數(shù)型號：220*21螺紋連接，220*1.5kW,2根1產(chǎn)生的蒸汽溫度C100殼程壁溫C&85蒸汽發(fā)生器

7、首次給補水方式人工補加蒸汽發(fā)生器給補水水質(zhì)us/cm<10動態(tài)模擬試驗裝置的循環(huán)水量與系統(tǒng)保有水量之比：60/13.8=4.36;六、試驗方法及試驗控制標準試驗方法參考化工行業(yè)標準冷卻水動態(tài)模擬試驗方法（HG/T2160-2008）進行,測定系統(tǒng)在一定濃縮倍率下動態(tài)模擬試驗裝置換熱管污垢熱阻的變化來判斷所加入水處理劑的阻垢效果。測定系統(tǒng)在一定濃縮倍率下運行30天，掛片與不銹鋼管的腐蝕情況來判定加入水處理劑的抗腐蝕效果。1）試驗方法首先對試驗系統(tǒng)的管路及模擬換熱器進行清洗，清洗完畢后在集水池中加入循環(huán)水，模擬換熱器中安裝好不銹鋼管，掛片器中安裝好掛片，按照系統(tǒng)保有水量進行投藥，先開啟循環(huán)，

8、利用循環(huán)泵將藥劑攪拌均勻，再開啟蒸汽發(fā)生器直至使循環(huán)水入口溫度達到32C,記錄此時的污垢熱阻，動態(tài)試驗開始進行，試驗初始時，系統(tǒng)不排污，當濃縮倍率達到15倍時，對系統(tǒng)定量排水，按照每天補水量與補水水質(zhì)計算排污量，保證系統(tǒng)循環(huán)水在濃縮倍數(shù)為15倍的條件下平穩(wěn)運行，整個實驗過程現(xiàn)場實驗人員每隔兩個小時記錄溫差及瞬時污垢熱阻的變化，并且每天取樣測定pH值、堿度、硬度、鈣硬、C。2）控制標準不銹鋼腐蝕速率00.005mm/a；碳鋼腐蝕速率00.075mm/a；年污垢熱阻值03.44X10-4m2K/W七、計算方法1）污垢熱阻的計算：a.清潔管污垢熱阻的測定:當系統(tǒng)蒸汽溫度、冷卻水流量、冷卻水進口溫度達

9、到規(guī)定值，并穩(wěn)定2h6h后，控制柜電腦可實時測量冷卻水進出口溫度和蒸汽溫度，測量時應嚴格的將流量、入口水溫、蒸汽溫度控制在規(guī)定值，求出算術平均值，計算清潔管的熱阻（式（1）:一'，'冗idl父3600T-t進1r;二一二4186.8父G、t出t進2f_''0.86ndJT-1進1=-(1)G、t出-t進2式（1）中:di換熱管內(nèi)徑（mG-循環(huán)水量（kg/h）r監(jiān)測管熱阻（m2-K/WJl換熱管換熱長度（項4186.8水的熱容CP（J/kgC）3600-從小時換算為秒的數(shù)值T'清潔管蒸汽溫度（C）t進循環(huán)水進水溫度（C）t出循環(huán)水出水溫度（C）b.瞬時污垢

10、熱阻的測定：測定監(jiān)測管熱阻后，每2小時按照a中的方法測定一次瞬時污垢熱阻，按照式（2）計算0.86二dilGT-t進it出-t進一一一f.一'，(2)0.86ndilT-t進T-t進Gt出一t進t出一t進式（2）中-換熱管換熱長度（mj）循環(huán)水量（kg/h）'清潔管蒸汽溫度（C）出一循環(huán)水出水溫度（C）出一循環(huán)水出水溫度（C）r*瞬時污垢熱阻（m2-K/WJldi換熱管內(nèi)徑（mj）GT蒸汽溫度（C）Tt進一循環(huán)水進水溫度（C）tt進循環(huán)水進水溫度（C）tc.年污垢熱阻：按b測出的瞬時污垢熱阻用數(shù)理統(tǒng)計的方法舍去異常值，以瞬時污垢熱阻的最高值乘以1.1即為年污垢熱阻。3）腐蝕率的

11、計算：在整個試驗過程中，腐蝕試驗采用掛片測失重法。當試驗達到一定時間后，取出試驗模擬換熱管及腐蝕掛片，觀察換熱器管表面腐蝕及沉積情況，對腐蝕掛片進行處理并稱重，測腐蝕速率。腐蝕速率的測定：以年腐蝕舉（mm/a表小，計算方法如下:B=KGATD3式中：K3.65X10G試樣失重（g）T試驗時間（天）試樣面積（cm2）一金屬密度（g/cm3）不銹鋼密度7.92g/cm3;碳銹鋼密度7.86g/cm3。八、實驗結果動態(tài)模擬實驗結果試驗結束后水質(zhì)分析結果PH堿度(mg/l)硬度(mg/l)鈣離子（mg/l）氯離子（mg/l）19.33210036001208150一9.170%”,J50年可柘除阻80

12、瞬日、府垢垮220今力1里（ppm）小小1才干(X10m?K/W)(X10m2?K/W)30014.950.5120.56330015.080.6710.738污垢熱阻阻垢劑腐蝕率試驗報告TestingReportofCorrosion報告編號：20170123-1委托人信源電廠產(chǎn)品(項目)編號中水廠水、目前循環(huán)水補水試樣材質(zhì)碳鋼、304不銹鋼，試樣狀態(tài)動態(tài)規(guī)格件數(shù)8試驗標準水處理劑緩蝕性能的測定GB/T18175-2014合格判定GB50050-2007試驗方法動態(tài)循環(huán)水掛片表1ASTMA923Ct腐蝕試驗試樣編號表面積,2、(cm)腐蝕前稱重(g)重(g)失重(g)腐蝕速率mm/a標準要求

13、mm/a結論53002820.712420.71230.00010.0000320.005合格53012820.565720.56560.00010.0000320.005合格53022820.728920.72800.00090.0000290.005合格53032820.761920.76140.00050.000160.005合格10802819.221319.02620.19510.0630.075合格10812819.25119.04870.20230.06580.075合格10822819.26719.04650.22050.07170.075合格10832819.278119.0

14、5110.22700.07380.075合格結論：合格/、合格掛片1082/1083;5302/5303在現(xiàn)場補水添加1號藥劑配方緩蝕阻垢劑中懸掛53天，掛片1080/1081;5300/5301在現(xiàn)場補水添加2號藥劑配方緩蝕阻垢劑中懸掛53天，在同樣的試驗條件下從試驗數(shù)據(jù)可以得出結論，我公司的緩蝕阻垢劑防腐效果優(yōu)于信源電廠目前使用的阻垢劑。備注使用藥劑為Fs-51Fs-66試驗者日期審核日期2017年1月23日九、結論及建議1）動態(tài)模擬試驗裝置模擬換熱管內(nèi)循環(huán)水流速為0.85m/s,比實際運行流速低，條件更為惡劣，易于結垢和粘泥的沉積。2）本次試驗在接近現(xiàn)場甚至比現(xiàn)場情況更惡劣的條件下，年污

15、垢熱阻值和腐蝕率遠低于國家標準：不銹鋼腐蝕率00.005mm/a；碳鋼腐蝕率00.075mm/a污垢熱阻值03.44X10-4m2K/皿完全能夠滿足系統(tǒng)運行要求。3）由于貴廠補水水質(zhì)變化較大，我司會根據(jù)具體補水情況調(diào)整加藥量，建議貴廠穩(wěn)定補水水質(zhì)。4）根據(jù)運行結果，我司選擇1號藥劑配方作為貴廠的最佳配方，在以后正常運行過程中，我司會根據(jù)實際情況適當調(diào)整加藥量，在保證滿足技術要求的情況下，最大限度地為貴廠節(jié)約成本。十、動態(tài)試驗附表補水加藥量記錄表天數(shù)時間補加水量(ml)加藥量(g)1號2號Fs-66Fs-511號2號1號2號12016.12.310:5513800138005.525.5212.

16、312:00（到溫）4000400012.316:203000300012.319:4540004000212.43:305000500012.49:004000400012.416:004000400012,423:0040004000312.58:305000500012.517:0050005000412.60:003000300012.611:305000500013.812.617:3013.8512.70:004000400012.710:302.11.5712.711:305000500012.722:0040004000612.89:000.1260.0842.11.5712.

17、812:004000400012.822:0050006000712.99:000.1260.0842.11.5712.912:004000400012.917:002000200012.922:0020003000812.109:000.1260.0841.571.5712.1011:454000400012.1022:0030003000912.119:000.1260.0842.362.3612.1112:004000400012.1122:00400040001012.129:000.1260.0843.673.6712.1212:004000400012.1222:003000400

18、01112.139:000.1260.0843.673.67天數(shù)時間補加水量(ml)加藥量(g)1號2號Fs-66Fs-511號2號1號2號1112.1314:005000500012.1323:00200030001212.149:000.126P0.0843.673.6712.1419:00400012.1423:00200020001312.159:000.126P0.0843.673.6712.1517:00600060001412.169:000.1260.0843.673.6712.1611:00200012.1617:00400050001512.179:00200040000.

19、1260.0843.673.6712.1717:00400050001612.189:00400040000.126:0.0843.673.6712.1817:00200050001712.199:00400040000.1260.0843.673.6712.1917:00200040001812.2010:00300040000.126P0.0843.673.6712.2017:00200020001912.219:000.126P0.0843.673.6712.2111:004000400012.2117:00100030002012.229:000.1260.0843.673.6712.

20、2211:004000500012.2217:00200020002112.239:000.1260.0843.673.6712.2311:002000400012.2317:00200030002212.249:000.1260.0843.673.6712.2411:004000500012.2417:00100020002312.259:000.1260.0843.673.6712.2511:002000400012.2516:00200040002412.269:000.1260.0843.673.67天數(shù)時間補加水量(ml)加藥量(g)1號2號Fs-66Fs-511號2號1號2號241

21、2.2611:002000400012.2616:00200020002512.279:000.1260.0843.673.6712.2711:00200012.2716:00300040002612.289:000.1260.0843.673.6712.2811:002000400012.2816:00200030002712.299:000.1260.0843.673.6712.2911:002000400012.2916:00100020002812.309:00400060000.1260.0843.673.6712.3017:002000400012.3021:00100020002

22、912.319:000.1260.0843.673.6712.3110:004000600012.3121:3030005000302017.1.19:00400060000.1260.0843.673.672017.1.116:30200040002017.1.122:3020004000312017.1.29:00400060000.1260.1683.673.672017.1.217:00200030002017.1.222:3020003000322017.1.39:00400060000.126P0.1683.673.672017.1.317:00200040002017.1.322

23、:0010002000332017.1.49:00200060000.1260.1683.673.672017.1.417:00400040002017.1.422:0020002000342017.1.59:00400050000.1260.1683.673.672017.1.511:00100020002017.1.521:0060006000352017.1.69:00500060000.1260.1683.673.672017.1.611:0020004000天數(shù)時間補加水量(ml)加藥量(g)1號2號Fs-66Fs-511號2號1號2號2017.1.623:0040006000362

24、017.1.79:00400060000.126P0.1683.673.672017.1.711:00200020002017.1.717:00200050002017.1.723:0040005000372017.1.89:00400060000.126P0.1683.673.672017.1.811:00200020002017.1.817:00200040002017.1.8230030005000382017.1.99:00400060000.1260.1683.673.672017.1.917:00400060002017.1.922:0020005000392017.1.109:0

25、0400060000.126r0.1682.974.712017.1.1017:00600060002017.1.1022:0020005000402017.1.119:00400060000.126r0.1262.984.362017.1.1117:00400060002017.1.1123:0040004000412017.1.129:00400060000.126r0.1263.14.832017.1.1217:00400060002017.1.1223:0020004000422017.1.139:00200060000.1260.1263.244.62017.1.1317:00600

26、060002017.1.1323:0040005000432017.1.149:00600060000.1260.1262.264.762017.1.1417:00200060002017.1.1423:0040004000442017.1.159:00600060000.1260.1263.564.692017.1.1517:00200060002017.1.1523:0020004000452017.1.169:00600060000.1260.1263.814.22017.1.1617:00200040002017.1.1623:00300050002017.1.179:00400060

27、000.1260.1263.064.55天數(shù)時間補加水量(ml)加藥量(g)1號2號Fs-66Fs-511號2號1號2號462017.1.1717:00200040002017.1.1723:0040005000472017.1.189:00400060000.1260.1262.84.12017.1.1817:00400050002017.1.1823:0020004000482017.1.199:00600060000.1260.1262.373.882017.1.1917:00200040002017.1.1923:0020004000492017.1.219:00400040000.1

28、260.1263.053.92017.1.2117:00200020002017.1.2123:0020004000502017.1.229:00400050000.1260.1262.373.382017.1.2217:00200040002017.1.2223:0040004000溫差、污垢熱阻數(shù)據(jù)表日期時間入口溫度出口溫度溫差加熱溫度瞬時污垢熱阻12121212121201612.48:0031.93239.839.97.97.999.699.6-0.199-0.21510:003131.639.639.18.67.599.699.5-0.219-0.212:0030.932.239.7

29、39.88.87.699.699.6-0.219-0.21514:0030.131.339.339.19.27.899.699.6-0.24-0.23216:0031.831.940.439.38.67.499.599.8-0.24-0.24818:0030.831.839.841.199.399.699.6-0.24-0.2322201612.58:0031.232.439.741.18.58.799.799.6-0.219-0.18410:0031.930.242.34110.410.899.699.7-0.206-0.093P12:0031.831.842.142.710.310.999

30、.699.6-0.195-0.04314:0032.132.142.54310.410.999.599.6-0.206-0.043P16:0031.73142.142.110.411.199.899.6-0.217-0.04318:0030.830.241.441.610.611.499.899.8-0.217-0.0833201612.6P8:0031.631.742.742.911.111.299.699.6-0.217-0.08310:0031.530.741.940.610.49.999.699.6-0.217-0.083P12:0030.731.239.639.98.98.799.6

31、99.6-0.217-0.08314:003230.939.842.17.811.299.699.6-0.217-0.083P16:0032.130.239.741.17.610.999.699.6-0.217-0.08318:0030.93241.34110.4999.799.6-0.217-0.0834201612.7P8:003131.140.239.89.28.799.799.6-0.0410.00110:0030.832.141.239.910.47.899.799.7-0.0410.001P12:0031.130.740.440.49.39.799.699.6-0.0410.073

32、14:0031.831.440.840.999.599.799.6-0.010.07316:0031.531.240.241.18.79.999.699.6-0.0410.07318:0032.231.241.3419.19.899.899.7-0.0410.0485201612.88:0032.131.740.841.28.79.599.799.60.0190.07310:0031.931.640.641.48.79.899.899.70.0520.07312:0031.230.240.9429.711.899.799.60.0350.08614:0032.231.240.740.58.59

33、.399.699.60.0350.08616:0032.331.940.841.58.59.699.699.60.0350.113P18:0032.131.241.940.69.89.499.699.70.0360.1136201612.98:0031.331.14240.710.79.699.799.60.110.113r10:0032.131.541.740.89.69.399.899.60.1230.1412:0031.630.541.5409.99.599.899.60.160.086r14:0031.431.24242.410.611.299.699.60.160.07316:003

34、1.230.541.140.29.99.799.699.80.160.073r18:0031.831.241.640.69.89.499.799.80.1360.1137201612.108:0030.930.540.740.29.89.799.899.60.110.086r10:0031.431.741.341.39.99.699.799.60.1230.12612:0030.830.740.540.69.79.999.899.60.1360.086r14:0031.130.941.140.7109.899.899.70.1230.09916:0039.231.240.940.91.79.7

35、99.699.60.1230.13318:003231.741.141.19.19.499.899.60.0970.14日期時間入口溫度出口溫度溫差加熱溫度瞬時污垢熱阻12121212128201612.118:0031.231.140.940.89.79.799.699.60.1360.09910:0031.431.341.340.59.99.299.699.80.1360.16912:0030.73140.840.610.19.699.899.70.1230.09914:0031.131.740.741.19.69.499.799.80.0760.09916:0031.331.741.14

36、1.19.89.499.699.70.1480.12618:0031.331.641.341.1109.599.799.80.1360.0999201612.128:0031.831.641.140.99.39.399.899.70.110.11310:0031.231.44140.89.89.499.699.70.070.099P12:0031.4314140.89.69.899.799.60.1360.09914:0031.531.640.740.59.28.999.799.80.110.126P16:0031.131.340.340.49.29.199.699.50.0840.76118

37、:0031.331.540.240.68.99.199.799.80.0750.11310201612.13P8:0031.331.54140.59.7999.799.50.070.1410:0031.131.440.940.69.89.299.799.80.0140.126P12:003230.941.540.19.59.299.899.80.0840.15514:0031.530.840.840.19.39.399.699.70.0970.126P16:0031.631.641.341.19.79.599.799.80.110.11318:003231.741.640.79.6999.89

38、9.90.084014P8:0031.631.341.340.69.79.399.799.70.0970.16910:0031.731.441.140.39.48.999.799.80.0840.155P12:003231.441.240.59.29.199.899.60.110.15514:003231.441.439.39.47.999.999.70.0970.19516:0031.631.641.339.19.77.599.799.70.070.14518:0032.131.741.639.19.57.499.999.70.084015

39、8:0031.931.641.139.19.27.599.799.60.070.14810:003231.740.238.98.27.299.599.40.0690.16512:0032.132.240.338.98.26.799.799.80.1030.16r14:0031.631.939.939.38.37.499.699.60.130.15716:0031.531.839.539.187.399.799.70.1230.142r18:0031.631.439.939.18.37.799.799.70.1650.12813201612.168:0031.731.540.139.38.47.

40、899.899.60.1350.135r10:0031.531.34039.28.57.999.799.50.1780.13912:0031.731.739.939.28.27.599.799.80.1570.145r14:0031.731.54039.38.37.899.799.80.1770.16916:0031.230.94040.28.89.399.699.70.1470.12r18:0031.431.34139.19.67.899.799.80.1880178:0031.531.140.139.18.6899.599.70.1920.165r10:0032.

41、131.940.339.68.27.799.899.60.1230.16212:003231.841.240.99.29.199.799.80.1130.15614:0031.932.140.7428.89.999.699.70.1990.13216:0031.73239.939.78.27.799.699.70.1320.15218:0031.331.240.34199.899.699.70.20.177日期時間入口溫度出口溫度溫差加熱溫度瞬時污垢熱阻121212121215201612.188:0031.631.140.139.68.58.599.799.80.2550.2310:0031.731.74039.58.37.899.699.70.2310.23512:0031.831.14039.68.28.599.799.80.2090.25314:003232.240.539.78.57.599.899.70.1960.25416:0032.13240.238.58.16.599.699.70.1910.24418:0031.931.840.138.58.26.799.699.70.2590.2616201612.198:0