基于电站锅炉排烟余热的机炉烟气回热循环理论与应用研究
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摘要
随着我国经济发展与能源、环境之间的矛盾日益突出,火电机组的节能减排成为一个备受关注的问题。大容量的超(超)临界机组的普及应用,为提高热系统经济性提供了一种有效的手段,同时,有效的利用机组余热也是机组节能的重要技术措施,其中锅炉排烟余热数量巨大,具备资源化利用的条件,但并未被充分利用。锅炉排烟余热属于低温余热,可做为回热热量引入蒸汽回热系统,用于加热汽轮机凝结水,或通过加热空气预热器进口冷空气以引入锅炉,但这两种锅炉排烟余热利用方式产生的经济性,由于机组冷源损失的变化和计算方法的差异性,导致对其评价一直存在争议。在这种背景下,急需把电站锅炉排烟余热回收利用中重要的节能理论问题搞清楚,以找到锅炉排烟余热利用经济性的合理评价方法和利用的最佳途径,提高排烟余热的能量转换效率,进一步降低发电能耗。
本文在机组原有蒸汽回热循环的基础上,通过引入烟气回热循环的概念,根据烟气余热的输入部位,建立了机侧烟气回热循环、炉侧烟气回热循环和机炉联合烟气回热循环的新概念。运用熵平衡原理及方法,建立了各种烟气回热循环的做功能力的热经济性评价模型,通过现场热力特性试验进行验证,系统地研究了锅炉烟气余热在机组内部利用过程中能量传递、转换的特性与机理,分析了锅炉烟气回热利用的热经济性评价机制,建立了机组中各热效率的有效的分析方法,澄清了学术界与工程界关于排烟余热机组内部回热利用评价的疑问。
本文首先总结了电站锅炉排烟余热利用的各种途径,指出各种利用方法中存在的问题与局限性,确定以排烟热量在机组内部回热利用的方式做为余热利用的基本方式,讨论了现有的各种排烟余热利用节能分析理论与方法,深入分析了各种方法的优势及其存在的问题,根据电站锅炉排烟余热利用的特点,确立以熵产分析法与等效热降法做为本文理论分析与计算的研究方法,以利用两种方法理论的特色与优势,深入研究锅炉排烟余热利用的热经济性问题。
在机组原有蒸汽回热循环的基础上,将回收的烟气余热做为回热热量用于蒸汽回热与空气回热中,提出了机侧烟气回热循环和炉侧烟气回热循环的概念。应用等效热降法对机侧烟气回热循环进行了局部定量分析,提出了抽汽热量实际做功效率与等效焓降当量增量的概念,并对原热经济性计算模型进行了整合,使其更易于理解与应用。依据三分仓回转空气预热器系统模型,对炉侧烟气回热循环进行了传热分析,通过引入烟气回热能量转换数的概念,确定了炉侧烟气回热循环的实际利用烟气热量,为准确分析其热经济性创造了前提条件。
运用熵平衡的原理,建立了外部热量输入温差传热系统的熵产模型,为烟气回热循环的热经济性分析提供了一种简化可行的分析方法,据此对烟气热量利用各环节进行了熵产分析,建立了两种烟气回热循环的做功能力模型。依据局部定量分析热力参数规定原则,应用于某300MW机组,并对烟气余热利用各环节的做功能力损失进行了分析,表明机侧烟气回热循环的热经济性受到电站锅炉原始排烟温度的限制,炉侧烟气回热循环通过降低空气预热器冷端的较大熵产,克服了锅炉排烟温度对其热经济性的制约,但实际利用烟气热量的减少导致其热经济性低于机侧烟气回热循环。计算分析还表明等效热降法与熵产分析法计算结果具有一致性,但熵产分析法能揭示烟气余热利用中产生的不可逆损失在热力系统中的分布特征,更容易查找影响系统热经济性的主要因素,可以为减小不可逆损失、系统优化指明方向。
运用机侧烟气回热循环热经济性评价模型,对分离式热管换热器与低压省煤器进行了热经济性分析比较,表明低压省煤器更具有节能优势；根据炉侧烟气回热循环的时段性特点,采用两种烟气回热循环在不同运行时段内单独运行的方式,对烟气回热循环系统进行了初步优化。
针对安装于300MW机组中的机侧烟气回热循环系统,现场进行了系统投用与切除的热耗率对比试验。通过建立凝汽器变工况传热模型,在试验值对排汽压力的回归修正中消除了机侧烟气回热循环使汽轮机排汽量增加的影响,并将投用状态的试验结果修正至计算基准状态,结果表明试验修正值与模型计算值相比偏差为1.83%,验证了以熵平衡原理为基础的研究方法的正确性及热经济性计算模型的准确性。
结合当前抗腐蚀的低温烟气换热元件应用研究取得显著进展的背景,在电站锅炉低温排烟余热深度利用中,从降低空气预热器冷端熵产与提高烟气利用能级的角度,将两种基本烟气回热循环有机结合,提出了机炉联合烟气回热循环(URC)的概念,并拓展为URC并联系统与URC串联系统。建立了机炉联合烟气回热循环的传热模型,通过引入回热能量转换数的概念,分析了机侧与炉侧两种烟气回热方式的联合机制,并建立了机炉联合烟气回热循环的热经济性评价模型。针对应用于某超临界600MW机组的计算结果,分析了烟气余热利用能级提升的机理,表明机炉联合烟气回热循环的热经济性高于机侧烟气回热循环,空气预热器单元熵产减少、热量做功能力增加是优化系统烟气利用能级提升的根本原因。
为进一步明确排烟回热利用对机组的各种热效率的影响,在传统热效率的基础上,应用局部定量分析的思想,将排烟余热利用过程进行独立考核,提出了排烟回热利用的各当量热效率的概念,并根据效率的热力学原始意义,定义了广义热效率,对各种烟气回热循环进行了广义热效率分析,表明其可使复杂余热利用的分析更加简捷方便,为复杂的烟气余热利用方式的热效率分析提供了一种简捷有效的新思路与新方法。
从实际运行的角度,对机炉联合烟气回热循环的各影响因素展开分析。依据磨煤机进口风温的调节原理,分析得到保证锅炉燃烧稳定性的条件。分析了URC并联系统在额定工况运行调节下与变工况运行时的热经济性变化规律,表明旁路烟气份额的调节可满足系统季节性调节的需求,为URC并联系统的运行调节提供了理论依据。进行了各烟气回热循环的热经济性对锅炉原始排烟温度的敏感性分析,表明URC串联系统与机侧烟气回热循环系统对原始排烟温度的敏感性高于URC并联系统,并由此确定了各种烟气回热循环的原始排烟温度适用区域,有利于设计中烟气余热利用形式的合理选择。相对于机组的厂用电率,通过引入烟气余热新增功率的当量厂用电率的概念,对各烟气回热循环对全厂净效率的影响进行了分析,为评价烟气余热利用系统的供电热经济性指标提供了依据。
With the increasingly prominent contradiction between economy development and energy and environment in China, energy conservation and emission reduction of thermal power units becomes an issue of great concern. The current wide use of large-capacity super criticality units provides an effective means of improving thermal efficiency. Meanwhile, to utilize the waste heat is an important measure to save energy. The huge amount of boiler flue gas waste heat can be used but haven't been fully used. The flue gas heat has a low temperature and can be conducted into either regenerative system to heat the condensate water or the boiler through heating the inlet air of air preheater. However, the economy of the two ways of boiler flue gas waste heat utilization (BFGWHU) is disputed due to the disagreement over the calculation methods of cold source loss. In this context, it's urgent to figure out the theoretical questions and find out exact evaluation methodology and best ways to utilize it, thus we can improve the energy conversion efficiency of flue gas waste heat and lower the energy consumption rate accordingly.
Based on the original steam regenerative cycle, the concepts of flue gas regenerative cycles which include turbine side regenerative cycle (TRC), boiler side regenerative cycle (BRC) and united regenerative cycle (URC) are presented according to the inputting location of flue gas waste heat. Following the entropy equilibrium principle, working ability models of all the flue gas regenerative cycles which can evaluate thermal economy are built and verified by field tests. So the energy transfer mechanism of flue gas heat during utilization is systematically studied and the effective analytical method is put forward, thus the doubt in the evaluation of BFGWHU is clarified.
In this thesis, various means of BFGWHU in power station are summarized, the drawbacks and limitations of which are discussed. Flue gas waste heat being regeneratively utilized inside the unit is determined as the basic mode. The main saving energy analysis theories and methods of BFGWHU in thermal plants are discussed, and the advantages and problems are analyzed. According to the characteristics of BFGWHU in power station, the entropy generation analysis and equivalent enthalpy drop method are used as the research basis of theoretical analysis and calculation. By combining the advantages of the two methods, the thermal economy of BFGWHU is deeply studied.
On the basis of steam regenerative cycle, the recovered flue gas waste heat is used in steam regeneration and air regeneration, and the concepts of TRC and BRC are presented. TRC is quantitatively analyzed using the equivalent enthalpy drop method. The concepts of extraced steam actual working efficiency and equivalent increment of equivalent enthalpy drop are put forward. The original thermal economy computing model is modified for better understand and application. Based on trisector air preheater system model, the heat transfer of BRC is analyzed. Through the concept of flue gas regenerative heat recovery conversion numbers, the actual amount of utilized flue gas heat is determined, which lays the fundation of exact thermal economy analysis.
Based on the entropy equilibrium principle, entropy generation model of external heat entering temprature difference heat-transfer system is built, which supplies a simplified and feasible method of thermal economy analysis. Working ability models of TRC&BRC are built using this method. Subject to the thermal parameter regulation of partial quantitative analysis, the application in a300MW unit shows that the thermal economy of TRC is confined by the original temperature of boiler flue gas while BRC is free of it, but the reduction in actual amount of utilized flue heat leads to lower thermal economy than TRC. Calculation shows that equivalent enthalpy drop method has good uniformity with entropy generation method. However, the latter can reveal the distribution characteristics of the irreversible loss in thermal system and can more easily find the key factor to affect thermal economy, thus can indicate the way to decrease the irreversible loss and optimize the system.
Using the thermal economy evaluation models of TRC, the thermal economy of separated type heat pipe and low pressure economizer are respectively analyzed, which shows that the latter is better at energy saving. According to the time-interval feature of BRC, two flue gas regenerative cycles are combined in the manner of running separately in respective time-interval, the BFGWHU system is preliminarily optimized.
The heat rate field tests with TRC on and off is conducted in a300MW unit. Except for the errer actor of the exhaust steam pressure change by TRC, the test result is corrected to calculation standard through variable working condition computing model of condenser. Comparison between the test and the calculated result shows that the deviation is1.83%, thus validating the accuracy of the research method and the thermal economy computing models.
Currently the application research about low temperature flue gas heat transfer elements has made great progress. According to the analysis conclusion has been obtained, the concept of united regenerative cycle (URC) on boiler and turbine is presented to deeply utilize low temperature flue gas waste heat, which is a combination of TRC&BRC. URC can be extended to series system and parallel system. The heat transfer model of URC is built. The coupling mechanism of TRC&BRC is analyzed and thermal economy evaluation models are built through the concept of heat recovery conversion numbers. Considering the calculated results of a600MW unit, the mechanism of the flue gas heat energy level increasing is analyzed. It shows that the thermal economy of URC is higher than that of TRC, the root cause of which is the entropy generation reducing and the working ability increasing of the air preheater.
To further learn the influence of BFGWHU on unit thermal efficiency, the BFGWHU process is discussed independently using the partial quantitative analysis thought, and the concept of equivalent unit efficiency of BFGWHU is presented. According to the original thermodynamic meaning of efficiency, the generalized unit efficiency is defined on the basis of traditional unit efficiency and analyzed with the use of BFGWHU system. This efficiency analysis provides a new simple and effective way for researches into more complex BFGWHU systems.
The influencing factors of URC are analyzed from the perspective of actual running. According to the adjusting principle of air inlet temprature of coal mill, the conditions of ensuring boiler combustion stability are obtained. The thermal economy variation of URC parallel system operation adjustment under rated conditions and variable conditions is analyzed, which reveals that the adjustment of flue gas bypass portion is able to meet the requirement of seasonal characteristics. The sensitivities of various BFGWHU systems to original boiler exhaust gas temperature are analyzed, which shows that the sensitivity of URC series system and TRC is higher than that of URC parallel system, and the suitable original exhaust temperature range of each flue gas regenerative system is determined. The influences of flue gas regenerative systems on whole plant net efficiency are analyzed through the concept of equivalent auxiliary power rate, which provides foudation for evaluating the power supply thermal efficiency indices of BFGWHU systems.
本文在机组原有蒸汽回热循环的基础上,通过引入烟气回热循环的概念,根据烟气余热的输入部位,建立了机侧烟气回热循环、炉侧烟气回热循环和机炉联合烟气回热循环的新概念。运用熵平衡原理及方法,建立了各种烟气回热循环的做功能力的热经济性评价模型,通过现场热力特性试验进行验证,系统地研究了锅炉烟气余热在机组内部利用过程中能量传递、转换的特性与机理,分析了锅炉烟气回热利用的热经济性评价机制,建立了机组中各热效率的有效的分析方法,澄清了学术界与工程界关于排烟余热机组内部回热利用评价的疑问。
本文首先总结了电站锅炉排烟余热利用的各种途径,指出各种利用方法中存在的问题与局限性,确定以排烟热量在机组内部回热利用的方式做为余热利用的基本方式,讨论了现有的各种排烟余热利用节能分析理论与方法,深入分析了各种方法的优势及其存在的问题,根据电站锅炉排烟余热利用的特点,确立以熵产分析法与等效热降法做为本文理论分析与计算的研究方法,以利用两种方法理论的特色与优势,深入研究锅炉排烟余热利用的热经济性问题。
在机组原有蒸汽回热循环的基础上,将回收的烟气余热做为回热热量用于蒸汽回热与空气回热中,提出了机侧烟气回热循环和炉侧烟气回热循环的概念。应用等效热降法对机侧烟气回热循环进行了局部定量分析,提出了抽汽热量实际做功效率与等效焓降当量增量的概念,并对原热经济性计算模型进行了整合,使其更易于理解与应用。依据三分仓回转空气预热器系统模型,对炉侧烟气回热循环进行了传热分析,通过引入烟气回热能量转换数的概念,确定了炉侧烟气回热循环的实际利用烟气热量,为准确分析其热经济性创造了前提条件。
运用熵平衡的原理,建立了外部热量输入温差传热系统的熵产模型,为烟气回热循环的热经济性分析提供了一种简化可行的分析方法,据此对烟气热量利用各环节进行了熵产分析,建立了两种烟气回热循环的做功能力模型。依据局部定量分析热力参数规定原则,应用于某300MW机组,并对烟气余热利用各环节的做功能力损失进行了分析,表明机侧烟气回热循环的热经济性受到电站锅炉原始排烟温度的限制,炉侧烟气回热循环通过降低空气预热器冷端的较大熵产,克服了锅炉排烟温度对其热经济性的制约,但实际利用烟气热量的减少导致其热经济性低于机侧烟气回热循环。计算分析还表明等效热降法与熵产分析法计算结果具有一致性,但熵产分析法能揭示烟气余热利用中产生的不可逆损失在热力系统中的分布特征,更容易查找影响系统热经济性的主要因素,可以为减小不可逆损失、系统优化指明方向。
运用机侧烟气回热循环热经济性评价模型,对分离式热管换热器与低压省煤器进行了热经济性分析比较,表明低压省煤器更具有节能优势；根据炉侧烟气回热循环的时段性特点,采用两种烟气回热循环在不同运行时段内单独运行的方式,对烟气回热循环系统进行了初步优化。
针对安装于300MW机组中的机侧烟气回热循环系统,现场进行了系统投用与切除的热耗率对比试验。通过建立凝汽器变工况传热模型,在试验值对排汽压力的回归修正中消除了机侧烟气回热循环使汽轮机排汽量增加的影响,并将投用状态的试验结果修正至计算基准状态,结果表明试验修正值与模型计算值相比偏差为1.83%,验证了以熵平衡原理为基础的研究方法的正确性及热经济性计算模型的准确性。
结合当前抗腐蚀的低温烟气换热元件应用研究取得显著进展的背景,在电站锅炉低温排烟余热深度利用中,从降低空气预热器冷端熵产与提高烟气利用能级的角度,将两种基本烟气回热循环有机结合,提出了机炉联合烟气回热循环(URC)的概念,并拓展为URC并联系统与URC串联系统。建立了机炉联合烟气回热循环的传热模型,通过引入回热能量转换数的概念,分析了机侧与炉侧两种烟气回热方式的联合机制,并建立了机炉联合烟气回热循环的热经济性评价模型。针对应用于某超临界600MW机组的计算结果,分析了烟气余热利用能级提升的机理,表明机炉联合烟气回热循环的热经济性高于机侧烟气回热循环,空气预热器单元熵产减少、热量做功能力增加是优化系统烟气利用能级提升的根本原因。
为进一步明确排烟回热利用对机组的各种热效率的影响,在传统热效率的基础上,应用局部定量分析的思想,将排烟余热利用过程进行独立考核,提出了排烟回热利用的各当量热效率的概念,并根据效率的热力学原始意义,定义了广义热效率,对各种烟气回热循环进行了广义热效率分析,表明其可使复杂余热利用的分析更加简捷方便,为复杂的烟气余热利用方式的热效率分析提供了一种简捷有效的新思路与新方法。
从实际运行的角度,对机炉联合烟气回热循环的各影响因素展开分析。依据磨煤机进口风温的调节原理,分析得到保证锅炉燃烧稳定性的条件。分析了URC并联系统在额定工况运行调节下与变工况运行时的热经济性变化规律,表明旁路烟气份额的调节可满足系统季节性调节的需求,为URC并联系统的运行调节提供了理论依据。进行了各烟气回热循环的热经济性对锅炉原始排烟温度的敏感性分析,表明URC串联系统与机侧烟气回热循环系统对原始排烟温度的敏感性高于URC并联系统,并由此确定了各种烟气回热循环的原始排烟温度适用区域,有利于设计中烟气余热利用形式的合理选择。相对于机组的厂用电率,通过引入烟气余热新增功率的当量厂用电率的概念,对各烟气回热循环对全厂净效率的影响进行了分析,为评价烟气余热利用系统的供电热经济性指标提供了依据。
With the increasingly prominent contradiction between economy development and energy and environment in China, energy conservation and emission reduction of thermal power units becomes an issue of great concern. The current wide use of large-capacity super criticality units provides an effective means of improving thermal efficiency. Meanwhile, to utilize the waste heat is an important measure to save energy. The huge amount of boiler flue gas waste heat can be used but haven't been fully used. The flue gas heat has a low temperature and can be conducted into either regenerative system to heat the condensate water or the boiler through heating the inlet air of air preheater. However, the economy of the two ways of boiler flue gas waste heat utilization (BFGWHU) is disputed due to the disagreement over the calculation methods of cold source loss. In this context, it's urgent to figure out the theoretical questions and find out exact evaluation methodology and best ways to utilize it, thus we can improve the energy conversion efficiency of flue gas waste heat and lower the energy consumption rate accordingly.
Based on the original steam regenerative cycle, the concepts of flue gas regenerative cycles which include turbine side regenerative cycle (TRC), boiler side regenerative cycle (BRC) and united regenerative cycle (URC) are presented according to the inputting location of flue gas waste heat. Following the entropy equilibrium principle, working ability models of all the flue gas regenerative cycles which can evaluate thermal economy are built and verified by field tests. So the energy transfer mechanism of flue gas heat during utilization is systematically studied and the effective analytical method is put forward, thus the doubt in the evaluation of BFGWHU is clarified.
In this thesis, various means of BFGWHU in power station are summarized, the drawbacks and limitations of which are discussed. Flue gas waste heat being regeneratively utilized inside the unit is determined as the basic mode. The main saving energy analysis theories and methods of BFGWHU in thermal plants are discussed, and the advantages and problems are analyzed. According to the characteristics of BFGWHU in power station, the entropy generation analysis and equivalent enthalpy drop method are used as the research basis of theoretical analysis and calculation. By combining the advantages of the two methods, the thermal economy of BFGWHU is deeply studied.
On the basis of steam regenerative cycle, the recovered flue gas waste heat is used in steam regeneration and air regeneration, and the concepts of TRC and BRC are presented. TRC is quantitatively analyzed using the equivalent enthalpy drop method. The concepts of extraced steam actual working efficiency and equivalent increment of equivalent enthalpy drop are put forward. The original thermal economy computing model is modified for better understand and application. Based on trisector air preheater system model, the heat transfer of BRC is analyzed. Through the concept of flue gas regenerative heat recovery conversion numbers, the actual amount of utilized flue gas heat is determined, which lays the fundation of exact thermal economy analysis.
Based on the entropy equilibrium principle, entropy generation model of external heat entering temprature difference heat-transfer system is built, which supplies a simplified and feasible method of thermal economy analysis. Working ability models of TRC&BRC are built using this method. Subject to the thermal parameter regulation of partial quantitative analysis, the application in a300MW unit shows that the thermal economy of TRC is confined by the original temperature of boiler flue gas while BRC is free of it, but the reduction in actual amount of utilized flue heat leads to lower thermal economy than TRC. Calculation shows that equivalent enthalpy drop method has good uniformity with entropy generation method. However, the latter can reveal the distribution characteristics of the irreversible loss in thermal system and can more easily find the key factor to affect thermal economy, thus can indicate the way to decrease the irreversible loss and optimize the system.
Using the thermal economy evaluation models of TRC, the thermal economy of separated type heat pipe and low pressure economizer are respectively analyzed, which shows that the latter is better at energy saving. According to the time-interval feature of BRC, two flue gas regenerative cycles are combined in the manner of running separately in respective time-interval, the BFGWHU system is preliminarily optimized.
The heat rate field tests with TRC on and off is conducted in a300MW unit. Except for the errer actor of the exhaust steam pressure change by TRC, the test result is corrected to calculation standard through variable working condition computing model of condenser. Comparison between the test and the calculated result shows that the deviation is1.83%, thus validating the accuracy of the research method and the thermal economy computing models.
Currently the application research about low temperature flue gas heat transfer elements has made great progress. According to the analysis conclusion has been obtained, the concept of united regenerative cycle (URC) on boiler and turbine is presented to deeply utilize low temperature flue gas waste heat, which is a combination of TRC&BRC. URC can be extended to series system and parallel system. The heat transfer model of URC is built. The coupling mechanism of TRC&BRC is analyzed and thermal economy evaluation models are built through the concept of heat recovery conversion numbers. Considering the calculated results of a600MW unit, the mechanism of the flue gas heat energy level increasing is analyzed. It shows that the thermal economy of URC is higher than that of TRC, the root cause of which is the entropy generation reducing and the working ability increasing of the air preheater.
To further learn the influence of BFGWHU on unit thermal efficiency, the BFGWHU process is discussed independently using the partial quantitative analysis thought, and the concept of equivalent unit efficiency of BFGWHU is presented. According to the original thermodynamic meaning of efficiency, the generalized unit efficiency is defined on the basis of traditional unit efficiency and analyzed with the use of BFGWHU system. This efficiency analysis provides a new simple and effective way for researches into more complex BFGWHU systems.
The influencing factors of URC are analyzed from the perspective of actual running. According to the adjusting principle of air inlet temprature of coal mill, the conditions of ensuring boiler combustion stability are obtained. The thermal economy variation of URC parallel system operation adjustment under rated conditions and variable conditions is analyzed, which reveals that the adjustment of flue gas bypass portion is able to meet the requirement of seasonal characteristics. The sensitivities of various BFGWHU systems to original boiler exhaust gas temperature are analyzed, which shows that the sensitivity of URC series system and TRC is higher than that of URC parallel system, and the suitable original exhaust temperature range of each flue gas regenerative system is determined. The influences of flue gas regenerative systems on whole plant net efficiency are analyzed through the concept of equivalent auxiliary power rate, which provides foudation for evaluating the power supply thermal efficiency indices of BFGWHU systems.
引文
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