新型CFB工业锅炉气固流动与热平衡、物料平衡特性研究
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摘要
随着国内燃煤供应的日渐紧张及节能环保要求的不断加强，循环流化床(CFB)燃烧技术以其良好的燃料适应性、媲美煤粉炉的高效燃烧性能及环境友好的污染物排放特性，被越来越多的应用于大型电站锅炉领域，并朝着大容量、高参数方向迅速发展。与此同时，在国内的工业锅炉领域内，CFB燃烧技术也同样取得了长足的进步，多种各具特色的CFB工业锅炉被开发出来，并被用于新建或改造原有的层燃或鼓泡床工业锅炉。
但受到锅炉容量尺寸及工质相变特性等因素的影响，对于小型CFB工业锅炉而言，其较低的炉膛高度减少了燃煤在炉内的一次停留及燃尽时间，而用于控制炉内热平衡的埋管蒸发面则长期工作在表观气速较高，且物料粒径较大的炉膛密相区域内，因此普遍存在燃烧效率相对较低、埋管磨损严重的问题，降低了锅炉的运行经济性和可靠性。本文以解决上述问题为出发点，首次提出了一种返料换热型CFB工业锅炉的布置方案(发明专利号：ZL200810232860.2)，采用一个兼具残炭燃尽功能及埋管换热功能的返料换热器取代传统回料阀，以解决中低压CFB工业锅炉长期存在的技术难题，从而进一步提升锅炉运行的经济性和可靠性。
本文在重庆市科委科技攻关项目及合作企业资金支持下，建立了冷模、热态及半工业燃烧试验装置，通过系统的试验及数学模型计算对返料传热型CFB工业锅炉主循环回路及其关键部件(如布风装置、返料换热器等)的气固流动特性及热平衡、物料平衡特性进行了系统研究，并成功实现了工业化应用。本文的主要内容如下：
①返料换热型CFB工业锅炉布局方案的提出
通过分析我国能源背景及CFB燃烧技术发展现状，针对国内小型CFB工业锅炉长期存在的燃烧效率偏低、受热面布置不合理等技术难题，首次提出了一种返料换热型CFB工业锅炉的布置方案，并对其可行性及预期的运行效果进行了定性的论证分析。
②关键部件的气固流动特性及优化
1)返料换热器的气固流动特性研究
通过分析返料换热型CFB工业锅炉的特点，提出了一种结构简单，操作特性灵活简便，而又能够满足其性能要求的返料换热器布置方案。进而通过冷模试验，对其气固流动特性，包括：对物料循环流率的调节、系统压降分布、立管料位高度变化规律、侧向风和上回风对系统运行特性的影响等进行了深入研究。
2)布风装置的优化研究
分别通过试验及模拟的方法对钟罩型风帽的出口射流穿透深度及风帽阻力特性进行了系统研究。一方面基于试验数据拟合了CFB两种典型物料(炉内密相区物料、循环物料)床层内水平射流穿透深度的经验公式；而另一方面则对等流通截面积，不同结构特点的钟罩型风帽的阻力系数进行了数值计算。研究结果有助于优化返料换热型CFB工业锅炉钟罩型风帽的结构及排列布置方式。
③主循环回路的燃烧传热特性研究
设计并搭建了一台半工业的CFB燃烧试验台，并对其燃烧传热特性，包括：点火启动特性，主循环回路内燃烧份额的分配及影响因素，循环物料粒径及含碳量变化特性，炉膛稀相区烟气侧及返料换热器灰侧传热系数的变化特性等进行了系统的试验研究，以了解主循环回路各区域内热平衡及物料平衡的建立过程。
④返料换热器内的热平衡及物料平衡特性研究
沿返料换热器换热仓内物料横向流动方向建立了描述床内气固流动、焦炭燃烧、物料磨蚀及埋管换热过程的小室模型，通过求解各小室内的物料平衡及热平衡方程，得到了描述换热仓内床层温度分布、物性参数变化及燃烧、传热功率分布的特性曲线。通过对比模型计算结果及试验结果实现了对模型的验证，并通过改变模型中物料循环流率M cir及水冷换热面积Ahs的取值，分析了二者对各小室乃至整个换热仓内热平衡及物料平衡建立过程的影响。
⑤工业应用及工业试验研究
在试验及模型研究的基础上，成功设计并投运了一台11t/h的返料换热型CFB工业锅炉。对其点火特性，负荷变化对燃烧份额及传热份额分配的影响进行了工业试验；尤其对锅炉满负荷运行性能及低负荷条件下的埋管逆向传热现象进行了分析，基于锅炉水循环系统的布置方式，以保证低负荷条件下的水循环动力对锅炉的低负荷性能进行了估算和探讨。
With increases of the domestic coal consumption and strengthening requirementsof energy saving and environment protection, circulating fluidized bed (CFB)combustion technology is more and more applied in large power plant boiler field, andis being developed in the directon of larger capacity and higher parameters, because ofits great fuel adaptability、efficient combustion performance which can be compared topulverized coal boiler and the environment-friendly pollutant emission characteristics.Meanwhile, in the field of domestic industrial boilers, CFB combustion technology alsohas made considerable progress, and various CFB industrial boilers with differentfeatures have been developed for replacing or reconstructing the former bubblingfluidized bed boilers and grated-fired boilers.
Impacted by the boiler dimentison and the phase transition characteristics of worksubstance, the buring time of coal in the riser isn’t adequate, and the evaporatingimmersed tubes are always installed in the emulsion zone with higher fluidizingvelocity and larger particle size. As results, the boiler combustion efficiency is relativelylower, and the erosion problem of the immersed tubes is serious. The economicalefficiency and reliability of the CFB industrial boiler are both reduced consequently. Inthis paper, for solving the above problems, the CFB industrial boiler with recycle heatexchanger (Patent No.: ZL200810232860.2), in which the raditioanl recycle valve wasreplace by a recycle heat exchanger (RHE) with the functions of carbon burnout andheat transfer from circulating solids to evaporating immersed tubes, was put forward forsolving the existent problems of the CFB industrial boilers with lower operatingpressure, and hence increasing the boilers’ economical efficiency and reliability.
Under the support of the research fund of Chongqing Science and TechnologyCommission and cooperative enterprise, the correlative cold and hot test rig, as well as asemi-industrial combustion test rig was built for carrying out the experimental studies,and corresponding mathematical models was also established. By employing the aboveresearch methods, the gas-solids flow characteristics and the heat balance, materialbalance characteristics of the main circulating loop and its key components (such as airdistributior and recycle heat exchanger, etc.) had been systemlly investigated, and a11t/h CFB industrial boiler with RHE was successuffly put into operation finally. Maincontents of this paper are listed as follows:
①Proposition of the CFB boiler with recycle heat exchanger(RHE)
According to the national energy background and the development status of CFBcombustion technology, the CFB boiler with recycle heat exchanger was put forward forthe first time to solve the problems existing in the small-scale CFB industrial boiler,such as the lower combustion efficiency and unconscionable arrangement of heattransfer surface, etc.. The feasibility and expected operating performance of this type ofCFB industrial boiler were also qualitatively analyzed.
②Gas-solid flow characteristics and optimization of key components
1) Gas-solid flow characteristics of recycle heat exchanger
The required performance of recycle heat exchanger (RHE) was proposed byanalyzing the inherent features of CFB industrial boiler with RHE. The one with novelconfiguration was put forward and its gas-solids flow characteristics, such as theregulation of solids circulating rate, the system pressures distribution, the variation ruleof solids height in the standpipe, and the impacts of vertical air into the standpip and theup-return air from the recycle chamber, were systemely investigated in a cold test rig.
2) Air distributor optimization
The bell type blast cap’s outlet horizontal jet penetration characteristics andresistance characteristics were investigated in experimental and modeling approachesrespectively. On one hand, regression analysis towards experimental data acquired incoarse solids bed (corresponding to solids in the furnace) and fine solids bed(corresponding to solids in the external circulation loop) were carried out respectivelyfor extracting correlations predicting the horizontal jet penetration depth in static bed;and on the other hand, the resistance coefficients of the bell type blast caps withdifferent inner structures were numerical calculated. The study results were able to beemployed for optimazing the bell type blast caps installed in the small-scale CFBindustrial boiler
③Study on combustion and heat transfer characteristics of main circulating loop
A semi-industrial combustion test rig was designed and built for investigating thecombustoion and heat transfer characteristics of the CFB main circulating loop forlearing the establishment processes of the systems’ heat balance and material balance.The major studies were conducted in the following aspects: the combustion fractionsdistribution in the main circulating loop, the changes of mean diameter and carboncontent of the circulating solids, the heat transfer coffecients in the riser dilution zoneand in the RHE.
④Study on heat balance and material balance characteristics of RHE
In the heat transfer chamber of the RHE, a small room model was established fordescribing the mechanisms of gas-solids flow、carbon combustion、solids erosion andheat transfer from the circulating solids to the immersed tubes. By solving the equationsof heat balance and material balance of each small chamber, the distributions of bedtemperature、gas component、solids physical parameters、combusiton and heat transferpowers along the solids horizontal moving direction were acquired, and the model wasalso validated by comparing the calculating values and test values. By regulating thegiven values ofM cirandAhs, the impacts of them on the heat and material balances ineach small chamber and the whole heat transfer chambers were stuied.
⑤Industrial application and industrial experiments
Based on the experimental and modeling investigation, an11t/h CFB industrialboiler with RHE was successfully put into operation. Its ignition characteristics, as wellas the load impacts on the combustion and evaporation fractions distribusions in themain circulating loop, were investigated. The boiler performance at full load, as well asthe phenomenon of heat transfer from the immersed tubes to the circulating solids atlower load was specially investigated. And based on the arrangement of watercirculation system, the low load operating performance of the boiler, at which thecirculating force of the water could be ensured, was estimated and discussed.
但受到锅炉容量尺寸及工质相变特性等因素的影响，对于小型CFB工业锅炉而言，其较低的炉膛高度减少了燃煤在炉内的一次停留及燃尽时间，而用于控制炉内热平衡的埋管蒸发面则长期工作在表观气速较高，且物料粒径较大的炉膛密相区域内，因此普遍存在燃烧效率相对较低、埋管磨损严重的问题，降低了锅炉的运行经济性和可靠性。本文以解决上述问题为出发点，首次提出了一种返料换热型CFB工业锅炉的布置方案(发明专利号：ZL200810232860.2)，采用一个兼具残炭燃尽功能及埋管换热功能的返料换热器取代传统回料阀，以解决中低压CFB工业锅炉长期存在的技术难题，从而进一步提升锅炉运行的经济性和可靠性。
本文在重庆市科委科技攻关项目及合作企业资金支持下，建立了冷模、热态及半工业燃烧试验装置，通过系统的试验及数学模型计算对返料传热型CFB工业锅炉主循环回路及其关键部件(如布风装置、返料换热器等)的气固流动特性及热平衡、物料平衡特性进行了系统研究，并成功实现了工业化应用。本文的主要内容如下：
①返料换热型CFB工业锅炉布局方案的提出
通过分析我国能源背景及CFB燃烧技术发展现状，针对国内小型CFB工业锅炉长期存在的燃烧效率偏低、受热面布置不合理等技术难题，首次提出了一种返料换热型CFB工业锅炉的布置方案，并对其可行性及预期的运行效果进行了定性的论证分析。
②关键部件的气固流动特性及优化
1)返料换热器的气固流动特性研究
通过分析返料换热型CFB工业锅炉的特点，提出了一种结构简单，操作特性灵活简便，而又能够满足其性能要求的返料换热器布置方案。进而通过冷模试验，对其气固流动特性，包括：对物料循环流率的调节、系统压降分布、立管料位高度变化规律、侧向风和上回风对系统运行特性的影响等进行了深入研究。
2)布风装置的优化研究
分别通过试验及模拟的方法对钟罩型风帽的出口射流穿透深度及风帽阻力特性进行了系统研究。一方面基于试验数据拟合了CFB两种典型物料(炉内密相区物料、循环物料)床层内水平射流穿透深度的经验公式；而另一方面则对等流通截面积，不同结构特点的钟罩型风帽的阻力系数进行了数值计算。研究结果有助于优化返料换热型CFB工业锅炉钟罩型风帽的结构及排列布置方式。
③主循环回路的燃烧传热特性研究
设计并搭建了一台半工业的CFB燃烧试验台，并对其燃烧传热特性，包括：点火启动特性，主循环回路内燃烧份额的分配及影响因素，循环物料粒径及含碳量变化特性，炉膛稀相区烟气侧及返料换热器灰侧传热系数的变化特性等进行了系统的试验研究，以了解主循环回路各区域内热平衡及物料平衡的建立过程。
④返料换热器内的热平衡及物料平衡特性研究
沿返料换热器换热仓内物料横向流动方向建立了描述床内气固流动、焦炭燃烧、物料磨蚀及埋管换热过程的小室模型，通过求解各小室内的物料平衡及热平衡方程，得到了描述换热仓内床层温度分布、物性参数变化及燃烧、传热功率分布的特性曲线。通过对比模型计算结果及试验结果实现了对模型的验证，并通过改变模型中物料循环流率M cir及水冷换热面积Ahs的取值，分析了二者对各小室乃至整个换热仓内热平衡及物料平衡建立过程的影响。
⑤工业应用及工业试验研究
在试验及模型研究的基础上，成功设计并投运了一台11t/h的返料换热型CFB工业锅炉。对其点火特性，负荷变化对燃烧份额及传热份额分配的影响进行了工业试验；尤其对锅炉满负荷运行性能及低负荷条件下的埋管逆向传热现象进行了分析，基于锅炉水循环系统的布置方式，以保证低负荷条件下的水循环动力对锅炉的低负荷性能进行了估算和探讨。
With increases of the domestic coal consumption and strengthening requirementsof energy saving and environment protection, circulating fluidized bed (CFB)combustion technology is more and more applied in large power plant boiler field, andis being developed in the directon of larger capacity and higher parameters, because ofits great fuel adaptability、efficient combustion performance which can be compared topulverized coal boiler and the environment-friendly pollutant emission characteristics.Meanwhile, in the field of domestic industrial boilers, CFB combustion technology alsohas made considerable progress, and various CFB industrial boilers with differentfeatures have been developed for replacing or reconstructing the former bubblingfluidized bed boilers and grated-fired boilers.
Impacted by the boiler dimentison and the phase transition characteristics of worksubstance, the buring time of coal in the riser isn’t adequate, and the evaporatingimmersed tubes are always installed in the emulsion zone with higher fluidizingvelocity and larger particle size. As results, the boiler combustion efficiency is relativelylower, and the erosion problem of the immersed tubes is serious. The economicalefficiency and reliability of the CFB industrial boiler are both reduced consequently. Inthis paper, for solving the above problems, the CFB industrial boiler with recycle heatexchanger (Patent No.: ZL200810232860.2), in which the raditioanl recycle valve wasreplace by a recycle heat exchanger (RHE) with the functions of carbon burnout andheat transfer from circulating solids to evaporating immersed tubes, was put forward forsolving the existent problems of the CFB industrial boilers with lower operatingpressure, and hence increasing the boilers’ economical efficiency and reliability.
Under the support of the research fund of Chongqing Science and TechnologyCommission and cooperative enterprise, the correlative cold and hot test rig, as well as asemi-industrial combustion test rig was built for carrying out the experimental studies,and corresponding mathematical models was also established. By employing the aboveresearch methods, the gas-solids flow characteristics and the heat balance, materialbalance characteristics of the main circulating loop and its key components (such as airdistributior and recycle heat exchanger, etc.) had been systemlly investigated, and a11t/h CFB industrial boiler with RHE was successuffly put into operation finally. Maincontents of this paper are listed as follows:
①Proposition of the CFB boiler with recycle heat exchanger(RHE)
According to the national energy background and the development status of CFBcombustion technology, the CFB boiler with recycle heat exchanger was put forward forthe first time to solve the problems existing in the small-scale CFB industrial boiler,such as the lower combustion efficiency and unconscionable arrangement of heattransfer surface, etc.. The feasibility and expected operating performance of this type ofCFB industrial boiler were also qualitatively analyzed.
②Gas-solid flow characteristics and optimization of key components
1) Gas-solid flow characteristics of recycle heat exchanger
The required performance of recycle heat exchanger (RHE) was proposed byanalyzing the inherent features of CFB industrial boiler with RHE. The one with novelconfiguration was put forward and its gas-solids flow characteristics, such as theregulation of solids circulating rate, the system pressures distribution, the variation ruleof solids height in the standpipe, and the impacts of vertical air into the standpip and theup-return air from the recycle chamber, were systemely investigated in a cold test rig.
2) Air distributor optimization
The bell type blast cap’s outlet horizontal jet penetration characteristics andresistance characteristics were investigated in experimental and modeling approachesrespectively. On one hand, regression analysis towards experimental data acquired incoarse solids bed (corresponding to solids in the furnace) and fine solids bed(corresponding to solids in the external circulation loop) were carried out respectivelyfor extracting correlations predicting the horizontal jet penetration depth in static bed;and on the other hand, the resistance coefficients of the bell type blast caps withdifferent inner structures were numerical calculated. The study results were able to beemployed for optimazing the bell type blast caps installed in the small-scale CFBindustrial boiler
③Study on combustion and heat transfer characteristics of main circulating loop
A semi-industrial combustion test rig was designed and built for investigating thecombustoion and heat transfer characteristics of the CFB main circulating loop forlearing the establishment processes of the systems’ heat balance and material balance.The major studies were conducted in the following aspects: the combustion fractionsdistribution in the main circulating loop, the changes of mean diameter and carboncontent of the circulating solids, the heat transfer coffecients in the riser dilution zoneand in the RHE.
④Study on heat balance and material balance characteristics of RHE
In the heat transfer chamber of the RHE, a small room model was established fordescribing the mechanisms of gas-solids flow、carbon combustion、solids erosion andheat transfer from the circulating solids to the immersed tubes. By solving the equationsof heat balance and material balance of each small chamber, the distributions of bedtemperature、gas component、solids physical parameters、combusiton and heat transferpowers along the solids horizontal moving direction were acquired, and the model wasalso validated by comparing the calculating values and test values. By regulating thegiven values ofM cirandAhs, the impacts of them on the heat and material balances ineach small chamber and the whole heat transfer chambers were stuied.
⑤Industrial application and industrial experiments
Based on the experimental and modeling investigation, an11t/h CFB industrialboiler with RHE was successfully put into operation. Its ignition characteristics, as wellas the load impacts on the combustion and evaporation fractions distribusions in themain circulating loop, were investigated. The boiler performance at full load, as well asthe phenomenon of heat transfer from the immersed tubes to the circulating solids atlower load was specially investigated. And based on the arrangement of watercirculation system, the low load operating performance of the boiler, at which thecirculating force of the water could be ensured, was estimated and discussed.
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