传热金属表面腐蚀结垢行为模拟及防腐阻垢技术研究
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摘要
传热金属表面腐蚀与结垢问题广泛存在于工业生产的多种过程中,严重妨碍换热设备的正常运行,造成巨大的能源浪费和经济损失,是一个经过长期研究而至今未能很好解决的问题。现有防腐阻垢技术基本上以添加缓蚀剂、阻垢剂和杀生剂为基础,对环境敏感并容易引起二次污染。本工作以实验室模拟试验和数值分析方法为基础,对传热金属表面的结垢和腐蚀问题进行了研究,结合计算机技术建立了循环冷却水系统模拟分析软件。并根据对传热面腐蚀结垢的机理分析,进行了改善传热面耐蚀、阻垢性能的研究。
在收集了实际生产运行数据、模拟实验数据和总结经验公式基础上,对碳钢在循环冷却水系统中的腐蚀行为进行了模拟研究。建立了氯离子、pH值、碱度、钙离子、硫酸根离子、溶解固体量(TDS)六种水质参数的动力学模型。以此为基础,利用离子联合作用公式推导了碳钢均匀腐蚀速率的数学模型,利用实验室数据确定了模型指前系数并进行了校正。
自制实验室污垢热阻测试仪器,在相同条件下利用人工硬水对不同的传热面材质进行了对比试验,得出污垢热阻随时间的变化关系。结果表明,材料表面特性对污垢形成有较大影响,材料的表面能越低,污垢沉积量越小。考察了传热表面温度、溶液pH值、碱度、硬度等影响因素对结垢行为的影响,分析了CaCO3在传热面结垢机理。提出了适用于CaCO3污垢的析晶-颗粒沉积混合污垢模型。以Hasson模型为基础,通过溶液离子和离子对平衡进行的校正,建立了析晶沉积速率模型。引入颗粒污垢沉积速率数学模型和污垢脱除数学模型,模拟了在析晶-颗粒沉积-脱除机制共同作用下的CaCO3垢生成过程。
以建立的腐蚀速率、结垢速率数学模型和水质参数动力学模型为基础,利用Flash为开发环境,以ActionScript为编程语言设计开发了一套循环冷却水系统模拟软件。软件以动画模拟循环冷却水系统运行过程,以坐标图形式反映系统运行期间水质参数的变化规律,并可对传热面的腐蚀与结垢进行预测。
通过对传热结垢、腐蚀机理的研究,探讨了通过表面无机膜的制备,以降低材料表面能的方法改善碳钢、不锈钢的防腐、阻垢性能的技术。采用溶胶-凝胶法在304不锈钢表面制备了锐钛矿晶型的TiO2膜；采用化学镀镍和溶胶-凝胶法在A3钢表面制备了Ni3P-TiO2膜层；采用溶胶-凝胶法在A3钢和304不锈钢表面制备了Si02膜。研究了催化剂、DMF添加剂、溶胶混配方式、烧结工艺等对成膜效果的影响,优化了各种无机膜制备工艺。测定了无机膜层的附着力、耐蚀、抗垢和杀菌性能。试验结果表明,在金属材料表面制备无机膜层可大大提高其防腐、阻垢性能。其中TiO2膜因其具有光催化性能,使其耐蚀性、抗垢和杀菌性能均优于Si02膜,且其制备工艺较简便,膜层附着力强,具有实际的应用价值。
The corrosion and fouling of metallic heat transfer surface were widely existed in many industrial processes. The problems that were unsolved up to the present hindered seriously the running of the heat exchanger and caused the great expense of the energe and the money. The actual technology of anticorrosion and fouling resistance mostly added the corrosion inhibitor, the scale inhibitor and the biocidal agent to the water, but these agents were sensitive for the ambience and brought on the environmental pollution. The paper studied on the corrosion and fouling behavior of the metallic heat transfer surface based on the simulation experiment of the laboratory and the numeric means. The simulation software of the recirculation cooling water system was established by the advanced computer technology. The improvement of the corrosion resistance and scale inhibition properties on the heat transfer surface were researched.
Based on the data collected from the running circulating cooling water system, the laboratory experimental results and some relevant formulaes, the paper simulated the corrosion behavior of the carbon steel heat exchanger. The kinetic models of parameters which included pH value, alkalinity, concentration rate, concentration of calcium and sulphate, total dissolved solids were discussed and verified. The corrosion rate of carbon steel was inferred by the ion associated effect formula and revised.
The comparison experiments of the different heat transfer material were carried out on the same conditions using the laboratory fouling resistance apparatus and the man-made hardness water. The relation of the fouling rasistance and the time was obtained from the experiment. The results showed that the formation of the fouling was closely related with the characteristic of heat transfer surface. The surface energy of material was lower, the CaCO3 deposit was smaller. The factors included of the surface temperature, pH value, alkalinity and hardness affected the fouling behavior were investigated. According to the CaCO3 fouling formation mechanism, a model was proposed for CaCO3 fouling which took into account both the crystallization and particulate fouling. Based on the hasson model, the crystallization rate model was set up concerning the ion and the ion-pairs equilibrium relationship in the solution. The particulate fouling model and the removal fouling model were introduced, then the CaCO3 fouling formation was simulated with the deposition-removal mechanism.
The simulation software of the circulating cooling water system was developed by using ActionScript 3.0 as the development tool and Adobe Flash CS4 Professional as the development environment. The software performed the running process of the circulating cooling water system and calculated parameters by using the mathematical models imitating professional numerical calculating softwares, especially the point-by-point survey. In addition, computations of corrosion rate about the carbon steel and the trend of scaling were presented.
The inorganic films had been prepared on the metallic heat transfer surface to improve the corrosion resistance and scale inhibition properties according to the theory of reduced the surface energy. The works mainly included as followings:the anatase phase TiO2 films had been prepared on 304 stainless steel by sol-gel method; the Ni3P-TiO2 composite films had been prepared on carbon steel by electroless plating and sol-gel method; the amorphism SiO2 films had been prepared on 304 stainless steel and carbon steel. The factors including catalyzer, DMF additive, different mixed sol ways, sinter technics were discussed to effect the films formation on the substrates, then the best preparation process was determined. These films'properties of anticorrosion, antifouling and antibiosis were measured. The results proved that the inorganic films on the metal surface can greatly improve the performances of anticorrosion, antifouling and antibiosis. The TiO2 films had the better characteristic than SiO2 film because of the TiO2 films' photoelectricity effect. Moreover, the preparation of TiO2 film was simple and the adhesion with the substrate was strong so that the film was worth for application.
在收集了实际生产运行数据、模拟实验数据和总结经验公式基础上,对碳钢在循环冷却水系统中的腐蚀行为进行了模拟研究。建立了氯离子、pH值、碱度、钙离子、硫酸根离子、溶解固体量(TDS)六种水质参数的动力学模型。以此为基础,利用离子联合作用公式推导了碳钢均匀腐蚀速率的数学模型,利用实验室数据确定了模型指前系数并进行了校正。
自制实验室污垢热阻测试仪器,在相同条件下利用人工硬水对不同的传热面材质进行了对比试验,得出污垢热阻随时间的变化关系。结果表明,材料表面特性对污垢形成有较大影响,材料的表面能越低,污垢沉积量越小。考察了传热表面温度、溶液pH值、碱度、硬度等影响因素对结垢行为的影响,分析了CaCO3在传热面结垢机理。提出了适用于CaCO3污垢的析晶-颗粒沉积混合污垢模型。以Hasson模型为基础,通过溶液离子和离子对平衡进行的校正,建立了析晶沉积速率模型。引入颗粒污垢沉积速率数学模型和污垢脱除数学模型,模拟了在析晶-颗粒沉积-脱除机制共同作用下的CaCO3垢生成过程。
以建立的腐蚀速率、结垢速率数学模型和水质参数动力学模型为基础,利用Flash为开发环境,以ActionScript为编程语言设计开发了一套循环冷却水系统模拟软件。软件以动画模拟循环冷却水系统运行过程,以坐标图形式反映系统运行期间水质参数的变化规律,并可对传热面的腐蚀与结垢进行预测。
通过对传热结垢、腐蚀机理的研究,探讨了通过表面无机膜的制备,以降低材料表面能的方法改善碳钢、不锈钢的防腐、阻垢性能的技术。采用溶胶-凝胶法在304不锈钢表面制备了锐钛矿晶型的TiO2膜；采用化学镀镍和溶胶-凝胶法在A3钢表面制备了Ni3P-TiO2膜层；采用溶胶-凝胶法在A3钢和304不锈钢表面制备了Si02膜。研究了催化剂、DMF添加剂、溶胶混配方式、烧结工艺等对成膜效果的影响,优化了各种无机膜制备工艺。测定了无机膜层的附着力、耐蚀、抗垢和杀菌性能。试验结果表明,在金属材料表面制备无机膜层可大大提高其防腐、阻垢性能。其中TiO2膜因其具有光催化性能,使其耐蚀性、抗垢和杀菌性能均优于Si02膜,且其制备工艺较简便,膜层附着力强,具有实际的应用价值。
The corrosion and fouling of metallic heat transfer surface were widely existed in many industrial processes. The problems that were unsolved up to the present hindered seriously the running of the heat exchanger and caused the great expense of the energe and the money. The actual technology of anticorrosion and fouling resistance mostly added the corrosion inhibitor, the scale inhibitor and the biocidal agent to the water, but these agents were sensitive for the ambience and brought on the environmental pollution. The paper studied on the corrosion and fouling behavior of the metallic heat transfer surface based on the simulation experiment of the laboratory and the numeric means. The simulation software of the recirculation cooling water system was established by the advanced computer technology. The improvement of the corrosion resistance and scale inhibition properties on the heat transfer surface were researched.
Based on the data collected from the running circulating cooling water system, the laboratory experimental results and some relevant formulaes, the paper simulated the corrosion behavior of the carbon steel heat exchanger. The kinetic models of parameters which included pH value, alkalinity, concentration rate, concentration of calcium and sulphate, total dissolved solids were discussed and verified. The corrosion rate of carbon steel was inferred by the ion associated effect formula and revised.
The comparison experiments of the different heat transfer material were carried out on the same conditions using the laboratory fouling resistance apparatus and the man-made hardness water. The relation of the fouling rasistance and the time was obtained from the experiment. The results showed that the formation of the fouling was closely related with the characteristic of heat transfer surface. The surface energy of material was lower, the CaCO3 deposit was smaller. The factors included of the surface temperature, pH value, alkalinity and hardness affected the fouling behavior were investigated. According to the CaCO3 fouling formation mechanism, a model was proposed for CaCO3 fouling which took into account both the crystallization and particulate fouling. Based on the hasson model, the crystallization rate model was set up concerning the ion and the ion-pairs equilibrium relationship in the solution. The particulate fouling model and the removal fouling model were introduced, then the CaCO3 fouling formation was simulated with the deposition-removal mechanism.
The simulation software of the circulating cooling water system was developed by using ActionScript 3.0 as the development tool and Adobe Flash CS4 Professional as the development environment. The software performed the running process of the circulating cooling water system and calculated parameters by using the mathematical models imitating professional numerical calculating softwares, especially the point-by-point survey. In addition, computations of corrosion rate about the carbon steel and the trend of scaling were presented.
The inorganic films had been prepared on the metallic heat transfer surface to improve the corrosion resistance and scale inhibition properties according to the theory of reduced the surface energy. The works mainly included as followings:the anatase phase TiO2 films had been prepared on 304 stainless steel by sol-gel method; the Ni3P-TiO2 composite films had been prepared on carbon steel by electroless plating and sol-gel method; the amorphism SiO2 films had been prepared on 304 stainless steel and carbon steel. The factors including catalyzer, DMF additive, different mixed sol ways, sinter technics were discussed to effect the films formation on the substrates, then the best preparation process was determined. These films'properties of anticorrosion, antifouling and antibiosis were measured. The results proved that the inorganic films on the metal surface can greatly improve the performances of anticorrosion, antifouling and antibiosis. The TiO2 films had the better characteristic than SiO2 film because of the TiO2 films' photoelectricity effect. Moreover, the preparation of TiO2 film was simple and the adhesion with the substrate was strong so that the film was worth for application.
引文
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