某集团循环水零排放模拟试验

1、某集团循环水零排放模拟实验一、实验目的试验我公司Fs-66、Fs-51高浓缩倍数缓蚀阻垢剂药剂在某集团循环水对设备产生腐蚀和结垢的情况，动态模拟试验是对药剂缓蚀阻垢效果的验证。二、技术条件设备使用条件：温度030C,空气相对湿度85%;循环水流态：湍流；日操作时数：24小时；供电电源：380V±1%整机功率：3kW占地面积：约2.5m2;蒸汽温度平均值：所在地区常压下的饱和蒸汽温度；实验要求：及可满足两组平行试验，又可满足单租毒理实验。三、试验装置介绍及试验流程1）实验装置介绍QYDM型智能动态模拟试验装置的的试验方法是依据中国化工部行业标准HG/T2060-2008冷却水动态模拟试

2、验方法执行，是在实验室给定条件下，用常压饱和蒸汽加热换热器，模拟生产现场的流速、流态、水质、金属材质、换热强度和饱和冷却水进、出口温度等主要参数，以评定水处理剂的缓蚀和阻垢性能。采用双水路流程，即可对同一配方进行平行对比试验，又可对不同配方进行性能筛选试验。装置对进口温度实行自动控制，实现系统对温度的稳定调节。采用高精度玻璃流量计对流量进行控制，确保系统流量的稳定。能实现对循环冷却水进口温度、出口温度、蒸汽温度、污垢热阻等参数的在线监控。能实现自动补水功能。采用无触点固态模块，能对加热功率实现无极调节。装置备有出口挂片器，通过透明的有机玻璃管能直接观测到水对挂片的腐蚀与结垢情况2）试验流程试验

3、用动态模拟试验装置流程图如下图所示:1锅炉水节水口72模拟换热器83挂片器94补水箱105入塔喷头116凉水塔12流量计阀门风机-集水池-浮球阀-水泵循环水循环过程：循环水由水泵从集水池打入模拟换热器进行换热，循环水被加热后再经入塔喷头喷淋进入凉水塔进行冷却，冷却后再次流入集水池。试验过程中，循环水流量由流量计控制，试验人员对流量实时监控；集水池液位由浮球控制，若水量蒸发，集水池液位下降，则浮球下落，阀门开启，由补水箱对集水池进行补水；试验人员在现场对模拟换热器进出口温差及换热管污垢热阻进行实时监控，并做详细记录；实验人员每天取样检测循环水指标，并做详细记录，检测结果双方确认。循环水中加入药剂

4、，模拟换热器中锅炉水升温到位后，试验正式开始。为了尽快将循环水的浓缩倍数提高到15倍，试验前期系统不排水，浓缩倍数到15倍后，根据每天补水量与补水水质，对系统进行定量排水，使循环水浓缩杯水在15倍平稳运行30天,30天后试验结束，在双方负责人监督下对设备进行拆卸，观察挂片及换热管的腐蚀与结垢情况。四、试验前准备1)挂片及不锈钢管的处理对挂片及不锈钢管用酒精擦拭，清洁表面的杂质及油污，然后把挂片与不锈钢管用冷风吹干，用滤纸包好在干燥箱内干燥24h,然后进行称重，并记录数据。2)实验设备清洗集水池中加入循环水循环2h,清洗设备管路中的尘土、油污；模拟换热器中加除盐水浸泡2h,清洗模拟换热器中杂质。

5、清洗结束后将循环水与除盐水放掉。3)水质监测对试验用的补水及循环水水质进行检测。4)挂片及不锈钢管的安装。五、初始数据及技术指标1)试验初始数据试验用水水质：总碱度(mg/l)总硬度(mg/l)钙硬(mg/l)Cl-(mg/l)循环水300640124560补水220510450挂片及锈钢管:系统种类型号质量(g)1#不锈钢挂片530220.7289530320.7619碳钢挂片108219.267108319.2781不锈钢管不锈钢170.57872#不锈钢挂片530020.7124530120.5657碳钢挂片108019.2213108119.251不锈钢管不锈钢270.62172）试验

6、装置技术指标流体介质管程（壳侧）冷却水壳程（管侧）饱和蒸汽进口水温C32±0.1出口水温C42±0.1模拟水流量l/h0-100,实际控制流量60l/h水流速m/s0-2,控制流速1m/s保有水量l13.81凉水塔15cm,h=120cm模拟温差C10±1换热管尺寸mm6X1挂片尺寸mm50X25X2出口挂片器尺寸mm60X150换热面积cnf/根99.85蒸汽发生器外形、规模mm550X500,SS304含保温总功耗kW3电压V3800电加热管形式、根数型号：220*21螺纹连接，220*1.5kW,2根1产生的蒸汽温度C100壳程壁温C&85蒸汽发生器

7、首次给补水方式人工补加蒸汽发生器给补水水质us/cm<10动态模拟试验装置的循环水量与系统保有水量之比：60/13.8=4.36;六、试验方法及试验控制标准试验方法参考化工行业标准冷却水动态模拟试验方法（HG/T2160-2008）进行,测定系统在一定浓缩倍率下动态模拟试验装置换热管污垢热阻的变化来判断所加入水处理剂的阻垢效果。测定系统在一定浓缩倍率下运行30天，挂片与不锈钢管的腐蚀情况来判定加入水处理剂的抗腐蚀效果。1）试验方法首先对试验系统的管路及模拟换热器进行清洗，清洗完毕后在集水池中加入循环水，模拟换热器中安装好不锈钢管，挂片器中安装好挂片，按照系统保有水量进行投药，先开启循环，

8、利用循环泵将药剂搅拌均匀，再开启蒸汽发生器直至使循环水入口温度达到32C,记录此时的污垢热阻，动态试验开始进行，试验初始时，系统不排污，当浓缩倍率达到15倍时，对系统定量排水，按照每天补水量与补水水质计算排污量，保证系统循环水在浓缩倍数为15倍的条件下平稳运行，整个实验过程现场实验人员每隔两个小时记录温差及瞬时污垢热阻的变化，并且每天取样测定pH值、碱度、硬度、钙硬、C。2）控制标准不锈钢腐蚀速率00.005mm/a；碳钢腐蚀速率00.075mm/a；年污垢热阻值03.44X10-4m2K/W七、计算方法1）污垢热阻的计算：a.清洁管污垢热阻的测定:当系统蒸汽温度、冷却水流量、冷却水进口温度达

9、到规定值，并稳定2h6h后，控制柜电脑可实时测量冷却水进出口温度和蒸汽温度，测量时应严格的将流量、入口水温、蒸汽温度控制在规定值，求出算术平均值，计算清洁管的热阻（式（1）:一'，'冗idl父3600T-t进1r;二一二4186.8父G、t出t进2f_''0.86ndJT-1进1=-(1)G、t出-t进2式（1）中:di换热管内径（mG-循环水量（kg/h）r监测管热阻（m2-K/WJl换热管换热长度（项4186.8水的热容CP（J/kgC）3600-从小时换算为秒的数值T'清洁管蒸汽温度（C）t进循环水进水温度（C）t出循环水出水温度（C）b.瞬时污垢

10、热阻的测定：测定监测管热阻后，每2小时按照a中的方法测定一次瞬时污垢热阻，按照式（2）计算0.86二dilGT-t进it出-t进一一一f.一'，(2)0.86ndilT-t进T-t进Gt出一t进t出一t进式（2）中-换热管换热长度（mj）循环水量（kg/h）'清洁管蒸汽温度（C）出一循环水出水温度（C）出一循环水出水温度（C）r*瞬时污垢热阻（m2-K/WJldi换热管内径（mj）GT蒸汽温度（C）Tt进一循环水进水温度（C）tt进循环水进水温度（C）tc.年污垢热阻：按b测出的瞬时污垢热阻用数理统计的方法舍去异常值，以瞬时污垢热阻的最高值乘以1.1即为年污垢热阻。3）腐蚀率的

11、计算：在整个试验过程中，腐蚀试验采用挂片测失重法。当试验达到一定时间后，取出试验模拟换热管及腐蚀挂片，观察换热器管表面腐蚀及沉积情况，对腐蚀挂片进行处理并称重，测腐蚀速率。腐蚀速率的测定：以年腐蚀举（mm/a表小，计算方法如下:B=KGATD3式中：K3.65X10G试样失重（g）T试验时间（天）试样面积（cm2）一金属密度（g/cm3）不锈钢密度7.92g/cm3;碳锈钢密度7.86g/cm3。八、实验结果动态模拟实验结果试验结束后水质分析结果PH碱度(mg/l)硬度(mg/l)钙离子（mg/l）氯离子（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污垢热阻阻垢剂腐蚀率试验报告TestingReportofCorrosion报告编号：20170123-1委托人信源电厂产品(项目)编号中水厂水、目前循环水补水试样材质碳钢、304不锈钢，试样状态动态规格件数8试验标准水处理剂缓蚀性能的测定GB/T18175-2014合格判定GB50050-2007试验方法动态循环水挂片表1ASTMA923Ct腐蚀试验试样编号表面积,2、(cm)腐蚀前称重(g)重(g)失重(g)腐蚀速率mm/a标准要求

13、mm/a结论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合格结论：合格/、合格挂片1082/1083;5302/5303在现场补水添加1号药剂配方缓蚀阻垢剂中悬挂53天，挂片1080/1081;5300/5301在现场补水添加2号药剂配方缓蚀阻垢剂中悬挂53天，在同样的试验条件下从试验数据可以得出结论，我公司的缓蚀阻垢剂防腐效果优于信源电厂目前使用的阻垢剂。备注使用药剂为Fs-51Fs-66试验者日期审核日期2017年1月23日九、结论及建议1）动态模拟试验装置模拟换热管内循环水流速为0.85m/s,比实际运行流速低，条件更为恶劣，易于结垢和粘泥的沉积。2）本次试验在接近现场甚至比现场情况更恶劣的条件下，年污

15、垢热阻值和腐蚀率远低于国家标准：不锈钢腐蚀率00.005mm/a；碳钢腐蚀率00.075mm/a污垢热阻值03.44X10-4m2K/皿完全能够满足系统运行要求。3）由于贵厂补水水质变化较大，我司会根据具体补水情况调整加药量，建议贵厂稳定补水水质。4）根据运行结果，我司选择1号药剂配方作为贵厂的最佳配方，在以后正常运行过程中，我司会根据实际情况适当调整加药量，在保证满足技术要求的情况下，最大限度地为贵厂节约成本。十、动态试验附表补水加药量记录表天数时间补加水量(ml)加药量(g)1号2号Fs-66Fs-511号2号1号2号12016.12.310:5513800138005.525.5212.

16、312:00（到温）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天数时间补加水量(ml)加药量(g)1号2号Fs-66Fs-511号2号1号2号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天数时间补加水量(ml)加药量(g)1号2号Fs-66Fs-511号2号1号2号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天数时间补加水量(ml)加药量(g)1号2号Fs-66Fs-511号2号1号2号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天数时间补加水量(ml)加药量(g)1号2号Fs-66Fs-511号2号1号2号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温差、污垢热阻数据表日期时间入口温度出口温度温差加热温度瞬时污垢热阻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日期时间入口温度出口温度温差加热温度瞬时污垢热阻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日期时间入口温度出口温度温差加热温度瞬时污垢热阻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