水泥分解炉结构参数优化与煤粉燃烧的数值模拟
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摘要
分解炉是新型干法水泥生产技术中的核心设备,对其结构参数进行优化一直是水泥工作者关注的重点。分解炉同时又是一个耗能设备,大量消耗煤炭资源。长期以来,我国干法水泥工业分解炉中使用的主要燃料是烟煤,低挥发分煤因具有着火点高、不易燃烬的特点,而在使用中会导致各种问题。现今,随着我国煤炭资源的日益紧张,烟煤的日益减少,使用低挥发分无烟煤甚至低挥发分高灰分劣质煤,已成为分解炉设计中必须解决的关键问题。本研究采用数值模拟的方法,结合定性与定量分析来研究分解炉内的流场结构并对其进行优化设计,通过研究气相停留时间、固相停留时间、固/气停留时间比、煤粉的燃烬时间等表征分解炉特性的参数来优化炉内的流场结构,并为分解炉内低挥发分无烟煤甚至低挥发分高灰分劣质煤的使用提供理论指导。
本研究选用了喷腾式、旋流式和旋—喷结合式三种典型结构的水泥分解炉进行数值模拟。对于每一种炉型,分别从气相流、气固二相流、煤粉燃烧的角度展开研究,采用的数学模型分别是标准k-ε双方程模型、离散相模型和混合分数方法结合简化的β-PDF模型。针对每一个方面分别进行最优化的设计,亦分别从不同的方面对三种不同的炉型进行对比分析,主要结论如下:
(1)在SLC-S型喷腾式分解炉内,气流场呈简单的喷腾状,只是在分解炉下部空间贴近壁面处有回流出现。炉内阻力损失很小,但生料在炉内分散不均匀,若增加一个与原生料进口的水平投影夹角大于或等于135°的新生料进口可以改善这种状况,且尤以157.5°为最佳。对煤粉燃烧的研究结果表明:该炉型对煤质的适应性很强,适合烧劣质煤,煤粉在该分解炉内的燃烬率很高。对低挥发分高灰分劣质煤燃烧进行优化设计的研究结论为:当三次风速率为30m/s、煤粉喷射角度向下,且当两煤粉进口的水平夹角为180°时最佳。
(2)在NST-I型旋流式分解炉内,气流在整个空间内呈螺旋式上升状,且在整个流场中形成了一系列围绕着分解炉中心轴旋转上升的涡。生料在整个炉膛内的分散状况极好,有效容积高。顺着三次风的旋转方向,当生料进口与三次风进口之间的水平夹角在45°～135°的范围内时较为适宜,且尤以135°为最佳。对煤粉燃烧的研究结果表明:进煤管方位对煤粉燃烬率的影响极大,其中在三次风进口附近且在三次风的初始运动方向上的煤粉流燃烬率很高,而远离三次风进口的煤粉流燃烬率则很低,因此煤粉的整体燃烬率不高。优化研究结果表明:当其中一个煤粉进口位于三次风进口附近时,建议将另外一个煤粉进口安置在避开三次风的初始运动方向的位置上。
(3)在TDF型旋—喷结合式分解炉中,下半柱体部分的流场以“旋流”效应为主,上半柱体部分的流场以“喷腾”效应为主。生料主要聚集在分解炉下半柱体部分生料进口这一侧,而在气流速率很高的中心区生料浓度较稀。对气固二相流场进行优化设计得到的优化方案为:保持烟气速度不变,当三次风速率在14m/s～20 m/s的范围内时,或者保持三次风速度不变,当烟气速率在20m/s～30m/s的范围内时较为合适;当生料入射角度在24°～34°的范围时较佳;同一高度的两个生料进口所形成的平面夹角越小越有利,当它们重合在一起时最佳。对煤粉燃烧的研究结果表明:该分解炉对煤质的适应性很好,有利于低挥发分高灰分劣质煤的燃烧。对劣质煤燃烧进行优化设计所得到的优化方案为:当同侧的两进煤管之间的夹角为90°时最佳,在此角度下三次风速率越大则煤粉燃烧越充分,尤以24m/s最为理想。
(4)对比研究结果表明:喷腾式分解炉和旋—喷结合式分解炉对煤质的适应性很强,皆有利于低挥发分高灰分劣质煤的燃烧,且通过调整参数能进一步地提高劣质煤在炉内的燃烬率;旋流式分解炉对煤质的适应潜力很大,但需要选择合适的进煤管方位。
Precalciner is not only a key equipment in cement industry on which the optimization of structure parameter are carried on frequently,but also an energy consumer.High-quality bituminous coal is commonly used in precalciners of cement industry in china for a long time.And low-volatile coal is almost not used since it is hard to be ignite and burnout.Recently,in order to reduce the energy consumption,more and more attentions have been paid on inferior coal combustion in precalciners.In this paper,combining qualitative studies and quantitative analysis, numerical simulations was carried out aiming at three actual precalciners under operational-based boundary conditions.What obtained from the analyzed result provides important theoretical information and significant referenced value for optimization of structure parameter and low-volatile or high ash inferior coal combustion in precalciners.
In this paper,aiming at spouted precalciner,swirling precalciner and swirling-spouted precalciner,the gas flow field,gas-solid flow field and coal combustion are simulated respectively with the k-εmodel,the Discrete Phase Model and theβ-PDF modle used.The optimum performance parameters for gas-solid flow field and low-volatile combustion were presented,and also the differences between the three types were studied with the strongpoint or shortcoming of each type illustrated legibly.Results are as follows:
(1)There is a simple spraying-liked flow field only with reversed-flow appears near the wall at the bottom in the spouted precalciner.Though the pressure drop from the tertiary inlet to the outlet is low,there is an ununiform particle dispersion condition.The dispersion condition can be improved by adding a new raw meal inlet to this type of precalciner,and the optimal horizontal projection angle between the two raw meal pipes is larger than or equal to 135°,especially at 157.5°.The research results of coal combustion show that this type of precalciner has a good adaptability for different quality coal combustion,and it is suitable for inferior coal combustion. The researches of low-volatile coal combustion for optimum condition show that it is optimum when the tertiary air velocity is 30 m/s with the incident angle of coal particles downward and with the angle between the two coal pipes is 180°.
(2)There is a high-velocity stream rising spirally near the wall with a series of spirally rising vortexes exist around the center axis in the swirling precalciner. Particles disperse uniform throughout the precalciner.By changing the initial tertiary air velocity but fixing the initial flue gas velocity-and vice versa-the predicted results were compared.It is advised to set the raw meal inlet along the direction of the initial tertiary air with the horizontal projection angle between the raw meal inlet and the tertiary air inlet is in the range of 45°and 135°,especially, 135°is the best.The research results of coal combustion show that the coal burn-off rate is high coming from the coal pipe located on the same side of the tertiary air inlet,while it is quite low coming from the coal pipe located on the different side of the tertiary air inlet,resulting in a low total coal burn-off rate,indicating the importance of the location of coal pipe.It is suggusted that when one of the coal pipe is near the tertiary air inlet and have the same initial moving direction with the tertiary air,it is better to keep the other coal flow out of the initial direction of the tertiary air.
(3)There is a very complex and turbulent flow field in the swirling-spouted precalciner:in the half down-body of the precalciner,there is a high velocity region in the center while two series of "c-shaped" low-velocity regions occur around the center;at the center-body,there appear two high-velocity vortexes cause by the "neck",resulting in a spraying-liked flow field with a uniform velocity in the half up-body;in the top space,a bracket-shaped vortex appears caused by both the two outlets located on the same side and the coping on the top.The simulation results of the gas solid flow filed show that there are many particles near the raw meal inlets but few in the center of high gas velocity region.With the the fixed initial tertiary air velocity,it is optimum when the flue gas velocity is between 20m/s and 30m/s.It is optimum when the angle between the raw meal pipe and the precalciner body is in the range of 24°and 34°.The better,the smaller of the angle between two raw meal inlets on the same side,and it is optimum when the angle is 0°in this research.The research results of coal combustion show that this type of precalciner has a good adaptability for different quality coal combustion,and it is suitable for low-volatile inferior coal combustion.The optimum researches results show that it is beneficial when the angle between the two coal pipes on the same side is 40°;with the angle of 90°,the larger the velocity is,the higher the coal burn-off rate is,and it is optimum when the tertiary air velocity is 24 m/s.
(4)Comparing research indicates that both the spouted precalciner and the swirling precalciner in this research have a good adaptability for coal combustion with different quality,and it is suitable for low-volatile inferior coal combustion.If adjust parameters properly,the coal burn-off rate will increase greatly.There is a great potential for inferior coal combustion in the swirling-spouted precalciner if the position and direction of the coal pipes are adjusted suitably.
本研究选用了喷腾式、旋流式和旋—喷结合式三种典型结构的水泥分解炉进行数值模拟。对于每一种炉型,分别从气相流、气固二相流、煤粉燃烧的角度展开研究,采用的数学模型分别是标准k-ε双方程模型、离散相模型和混合分数方法结合简化的β-PDF模型。针对每一个方面分别进行最优化的设计,亦分别从不同的方面对三种不同的炉型进行对比分析,主要结论如下:
(1)在SLC-S型喷腾式分解炉内,气流场呈简单的喷腾状,只是在分解炉下部空间贴近壁面处有回流出现。炉内阻力损失很小,但生料在炉内分散不均匀,若增加一个与原生料进口的水平投影夹角大于或等于135°的新生料进口可以改善这种状况,且尤以157.5°为最佳。对煤粉燃烧的研究结果表明:该炉型对煤质的适应性很强,适合烧劣质煤,煤粉在该分解炉内的燃烬率很高。对低挥发分高灰分劣质煤燃烧进行优化设计的研究结论为:当三次风速率为30m/s、煤粉喷射角度向下,且当两煤粉进口的水平夹角为180°时最佳。
(2)在NST-I型旋流式分解炉内,气流在整个空间内呈螺旋式上升状,且在整个流场中形成了一系列围绕着分解炉中心轴旋转上升的涡。生料在整个炉膛内的分散状况极好,有效容积高。顺着三次风的旋转方向,当生料进口与三次风进口之间的水平夹角在45°～135°的范围内时较为适宜,且尤以135°为最佳。对煤粉燃烧的研究结果表明:进煤管方位对煤粉燃烬率的影响极大,其中在三次风进口附近且在三次风的初始运动方向上的煤粉流燃烬率很高,而远离三次风进口的煤粉流燃烬率则很低,因此煤粉的整体燃烬率不高。优化研究结果表明:当其中一个煤粉进口位于三次风进口附近时,建议将另外一个煤粉进口安置在避开三次风的初始运动方向的位置上。
(3)在TDF型旋—喷结合式分解炉中,下半柱体部分的流场以“旋流”效应为主,上半柱体部分的流场以“喷腾”效应为主。生料主要聚集在分解炉下半柱体部分生料进口这一侧,而在气流速率很高的中心区生料浓度较稀。对气固二相流场进行优化设计得到的优化方案为:保持烟气速度不变,当三次风速率在14m/s～20 m/s的范围内时,或者保持三次风速度不变,当烟气速率在20m/s～30m/s的范围内时较为合适;当生料入射角度在24°～34°的范围时较佳;同一高度的两个生料进口所形成的平面夹角越小越有利,当它们重合在一起时最佳。对煤粉燃烧的研究结果表明:该分解炉对煤质的适应性很好,有利于低挥发分高灰分劣质煤的燃烧。对劣质煤燃烧进行优化设计所得到的优化方案为:当同侧的两进煤管之间的夹角为90°时最佳,在此角度下三次风速率越大则煤粉燃烧越充分,尤以24m/s最为理想。
(4)对比研究结果表明:喷腾式分解炉和旋—喷结合式分解炉对煤质的适应性很强,皆有利于低挥发分高灰分劣质煤的燃烧,且通过调整参数能进一步地提高劣质煤在炉内的燃烬率;旋流式分解炉对煤质的适应潜力很大,但需要选择合适的进煤管方位。
Precalciner is not only a key equipment in cement industry on which the optimization of structure parameter are carried on frequently,but also an energy consumer.High-quality bituminous coal is commonly used in precalciners of cement industry in china for a long time.And low-volatile coal is almost not used since it is hard to be ignite and burnout.Recently,in order to reduce the energy consumption,more and more attentions have been paid on inferior coal combustion in precalciners.In this paper,combining qualitative studies and quantitative analysis, numerical simulations was carried out aiming at three actual precalciners under operational-based boundary conditions.What obtained from the analyzed result provides important theoretical information and significant referenced value for optimization of structure parameter and low-volatile or high ash inferior coal combustion in precalciners.
In this paper,aiming at spouted precalciner,swirling precalciner and swirling-spouted precalciner,the gas flow field,gas-solid flow field and coal combustion are simulated respectively with the k-εmodel,the Discrete Phase Model and theβ-PDF modle used.The optimum performance parameters for gas-solid flow field and low-volatile combustion were presented,and also the differences between the three types were studied with the strongpoint or shortcoming of each type illustrated legibly.Results are as follows:
(1)There is a simple spraying-liked flow field only with reversed-flow appears near the wall at the bottom in the spouted precalciner.Though the pressure drop from the tertiary inlet to the outlet is low,there is an ununiform particle dispersion condition.The dispersion condition can be improved by adding a new raw meal inlet to this type of precalciner,and the optimal horizontal projection angle between the two raw meal pipes is larger than or equal to 135°,especially at 157.5°.The research results of coal combustion show that this type of precalciner has a good adaptability for different quality coal combustion,and it is suitable for inferior coal combustion. The researches of low-volatile coal combustion for optimum condition show that it is optimum when the tertiary air velocity is 30 m/s with the incident angle of coal particles downward and with the angle between the two coal pipes is 180°.
(2)There is a high-velocity stream rising spirally near the wall with a series of spirally rising vortexes exist around the center axis in the swirling precalciner. Particles disperse uniform throughout the precalciner.By changing the initial tertiary air velocity but fixing the initial flue gas velocity-and vice versa-the predicted results were compared.It is advised to set the raw meal inlet along the direction of the initial tertiary air with the horizontal projection angle between the raw meal inlet and the tertiary air inlet is in the range of 45°and 135°,especially, 135°is the best.The research results of coal combustion show that the coal burn-off rate is high coming from the coal pipe located on the same side of the tertiary air inlet,while it is quite low coming from the coal pipe located on the different side of the tertiary air inlet,resulting in a low total coal burn-off rate,indicating the importance of the location of coal pipe.It is suggusted that when one of the coal pipe is near the tertiary air inlet and have the same initial moving direction with the tertiary air,it is better to keep the other coal flow out of the initial direction of the tertiary air.
(3)There is a very complex and turbulent flow field in the swirling-spouted precalciner:in the half down-body of the precalciner,there is a high velocity region in the center while two series of "c-shaped" low-velocity regions occur around the center;at the center-body,there appear two high-velocity vortexes cause by the "neck",resulting in a spraying-liked flow field with a uniform velocity in the half up-body;in the top space,a bracket-shaped vortex appears caused by both the two outlets located on the same side and the coping on the top.The simulation results of the gas solid flow filed show that there are many particles near the raw meal inlets but few in the center of high gas velocity region.With the the fixed initial tertiary air velocity,it is optimum when the flue gas velocity is between 20m/s and 30m/s.It is optimum when the angle between the raw meal pipe and the precalciner body is in the range of 24°and 34°.The better,the smaller of the angle between two raw meal inlets on the same side,and it is optimum when the angle is 0°in this research.The research results of coal combustion show that this type of precalciner has a good adaptability for different quality coal combustion,and it is suitable for low-volatile inferior coal combustion.The optimum researches results show that it is beneficial when the angle between the two coal pipes on the same side is 40°;with the angle of 90°,the larger the velocity is,the higher the coal burn-off rate is,and it is optimum when the tertiary air velocity is 24 m/s.
(4)Comparing research indicates that both the spouted precalciner and the swirling precalciner in this research have a good adaptability for coal combustion with different quality,and it is suitable for low-volatile inferior coal combustion.If adjust parameters properly,the coal burn-off rate will increase greatly.There is a great potential for inferior coal combustion in the swirling-spouted precalciner if the position and direction of the coal pipes are adjusted suitably.
引文
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