IGCC热力性能的发展潜力分析
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摘要
整体煤气化联合循环(IGCC)是集成煤气化与燃气轮机的超清洁、高效发电技术,效率提升途径多,潜力大。本文研究了集成中高温干法脱硫、高温离子膜分离(ITM)、先进燃气轮机等新型先进单元技术的IGCC系统及热力性能提升潜力,分析了气化技术对IGCC系统热力性能的影响。主要内容和结果如下：
1.集成中高温干法净化的IGCC
分析了氧化锌干法脱硫温度、再生氧气浓度、脱硫效率对IGCC系统热力性能的影响,比较了集成不同净化技术的IGCC系统。结果表明,中温干法净化(脱硫温度350℃)比全湿法净化IGCC供电效率高1.77个百分点,其中干法除尘技术贡献约1个百分点；干法净化温度从200℃升高至650℃,IGCC供电效率提高0.74个百分点,但如考虑燃烧室注蒸汽保持燃烧室相同的当量绝热火焰温度,IGCC供电效率仅上升约0.3个百分点。
2.集成高温离子膜分离技术(ITM)的IGCC
研究了集成ITM空分、深冷空分的IGCC热力性能,分析了整体化ITM的氧气分离率、氮气回注温度对IGCC热力性能的影响。结果表明：IGCC供电效率随ITM空分与燃气轮机集成度增加而上升,100%集成度的ITM空分与完全独立ITM空分相比可提高IGCC供电效率1.81个百分点,与完全整体化深冷空分的IGCC相比供电效率高1.11个百分点。
3.先进燃气轮机IGCC的热力性能
建立并校验了准一维燃气轮机透平冷却模型。研究了透平冷却技术、材料、热障涂层以及冷却介质对燃气轮机联合循环的影响。
以F级“冷却-材料”水平为基准,提高燃烧室出口温度,燃机简单循环和联合循环效率先升高后降低,联合循环效率在初温约1700℃,压比约25时最高：提高透平“冷却-材料”水平,相同燃烧室出口温度下,联合循环效率提高,随燃烧室出口温度的提高,提高“冷却-材料”水平对提高联合循环效率的作用越明显。
GE9G燃机如采用透平首级喷嘴蒸汽冷却,联合循环效率相比于目前透平空气冷却可提高0.6个百分点,采用透平前两级蒸汽冷却(9H)效率可再提高1.7个百分点,如采用透平全蒸汽冷却可进一步提高效率1.1个百分点。
采用M701G2、9H、M701J燃机的IGCC相比于采用PG9351FA燃机IGCC供电效率分别高2.8、3.3和4.2个百分点。对于1700℃级燃机IGCC系统,如“冷却-材料”水平与M701J燃机相同时,系统供电效率较M701J级燃机IGCC高0.6个百分点；如提高“冷却-材料”水平使冷却空气量与M701J相同时,效率可再提高0.7个百分点,如进一步提高“冷却-材料”水平使冷却空气量相比于M701J下降10%时,可继续提高IGCC系统供电效率0.3个百分点。
4.气化技术对IGCC系统热力性能的影响
研究分析了空气气化和纯氧气化的气化温度、碳转化率、汽煤比对IGCC系统热力性能的影响。结果表明：对于氧气气化与空气气化IGCC系统,气化温度每提高100℃,系统供电效率分别下降约0.32～0.49和0.67～0.77个百分点；蒸汽煤比每提高0.1,系统供电效率分别下降0.28-0.36和0.29～0.52个百分点,C转化率每提高1个百分点,系统供电效率分别提高约0.42～0.45和0.41～0.43个百分点。
空气气化与氧气气化IGCC系统的气化压力对系统热力性能影响显著,其中,常压氧气气化的系统效率明显低于加压氧气气化2.6～3.2个百分点；常压空气气化IGCC系统效率明显低于加压空气气化3.9～4.2个百分点。空气气化的增压流程会影响IGCC供电效率约1.7个百分点。
5. IGCC热力性能发展潜力预测
相比于F级燃机、水煤浆气化炉、湿法脱硫、深冷空分IGCC系统,集成了1700℃燃机、干法给料气化、中温干法净化、膜分离空分的IGCC系统供电效率提升约9.6个百分点,达54.8%；进一步集成合成气回热加热气化剂(氧气和水蒸汽)、高温干法净化技术的IGCC可再提升系统供电效率1.5个百分点。
Integrated Gasification Combined Cycle(IGCC) is a kind of super clean and high efficiency power generation technology. There are many ways and huge potential to improve the net efficiency of IGCC. The present work explores how much IGCC can benefit from technologies of warm gas desulfurization, Ion Transport Membrane(ITM), and advanced gas turbine. Influences of key gasification parameters on thermodynamic performance of IGCC plants have been analyzed. The main contents and results are presented as follows:
1. IGCC integrated with warm gas clean-up(WGCU)
Four IGCC systems with different gas clean-up processes based on the model of ZnO-desulfurization are established and compared. Impacts of key parameters of WGD on thermodynamic performance of IGCC plants including desulfurization temperature, oxygen concentration in regeneration stream, and H2S removal efficiency are discussed. It is found that the net efficiency of IGCC with full WGCU increases1.77percentage points compared with IGCC with cold gas clean-up(CGCU), among which the dry ash removal contributes about1percentage point. The net efficiency will increase0.74percentage point when the desulfurization temperature increases from200℃to650℃. However, if the way of steam injection were considered to control the same SFT, the net efficiency increases only0.3percentage point.
2. IGCC integrated with ITM
The thermodynamic performance of IGCC with different ways of integration between ITM and gas turbine is discussed. In comparison to IGCC system with cryogenic air separation, the net efficiency of IGCC with full integration of ITM technology experiences an improvement of1.11percentage points, and is higher than that of the IGCC with independent ITM by1.81percentage points. In addition, in view of the full integration IGCC, influences of O2separation rate and the N2reinjection temperature on IGCC net efficiency are evaluated.
3. IGCC with advanced gas turbine
A quasi-1D turbine cooling model is built and validated. Impacts of turbine cooling techniques such as convection cooling and film cooling, blade material, thermal barrier coating and coolant medium on the thermal performance of GTCC and IGCC are studied.
With constant "cooling-material" technology(F class), the efficiency of simple gas turbine cycle and combined cycle increases first and then decreases with the increase of combustor exit temperature. For combined cycle, the maximum efficiency appears on the point where the combustor exit temperature is1700℃and the pressure ratio is about25. With constant combustor exit temperature, the net efficiency of GTCC increases following the improvement of the "cooling-material" technology. When the combustor exit temperature increases, the effect of improving "cooling-material" technology on improving the net efficiency of GTCC becomes more obvious.
Taking GE9G as an example, the performance of turbine adopting steam as the coolant medium is discussed. According to results, the net efficiency of IGCC, which adopts9G gas turbine but steam is taken as the coolant of first nozzle, is higher than that of the IGCC with9G gas turbine by0.6percentage point. When the first two stages adopt steam cooling, the IGCC net efficiency can be further improved by1.7percentage points. Additional1.1percentage points of net efficiency improvement can be obtained by taking steam as coolant of whole turbine.
The net efficiency of IGCC employing M701G2、9H、M701J gas turbines is higher than that of IGCC employing PG9351FA by2.8、3.3、4.2percentage points respectively. If the "cooling-material" technology of1700℃class gas turbine keeps constant with the M701J, the net efficiency of IGCC with1700℃class gas turbine is higher than that of the M701J-IGCC by0.6percentage point. And if the "cooling-material" technology is improved in order to keep the cooling flow same to the M701J, the net efficiency can be further improved by0.7percentage point. Additional0.3percentage point of net efficiency improvement can be obtained by improving the "cooling-material" technology which can decrease the cooling flow by10%with respect to M701J.
4. Influences of gasification on thermodynamic performance of IGCC
Influences of key parameters, including gasification temperature, C conversion, the mass ratio of steam to coal, on thermodynamic performance of IGCC are assessed in view of the air and oxygen blown gasification. Results show that, when the gasification temperature dropped by100℃, the IGCC net efficiency decrease by0.32-0.49and0.67～0.77percentage point respectively for IGCC systems with air and oxygen blown gasification. When the mass ratio of steam to coal increases by0.1, the IGCC net efficiency decreases by0.28～0.36and0.29～0.52percentage point respectively for IGCC systems with air and oxygen blown gasification. When the C conversion efficiency is improved by1percentage point, the IGCC net efficiency can be improved by0.42～0.45and0.41～0.43percentage point respectively for IGCC systems with air-and oxygen gasification.
There is an obvious advantage in the view of thermal performance for IGCC systems with pressurized gasification with respect to the atmospheric gasification. The IGCC net efficiency of pressurized oxygen blown gasification is higher than that of atmospheric oxygen gasification by2.6～3.2percentage points, and the IGCC net efficiency of pressurized air blown gasification is higher than that of atmospheric air gasification by3.9-4.2percentage points. For pressurized air blown gasification, an efficiency gap about1.7percentage points can be affected by adopting various ways of compression.
5. Calculating the thermodynamic performance potential of IGCC
The net efficiency of IGCC system whose key components include1700℃class gas turbine, dry-feed gasifier, warm gas clean-up and ITM air separation unit can reach54.8%, which is higher than the IGCC system integrated by technologies of F class gas turbine, slurry-feed gasifier, cold gas clean-up and cryogenic air separation unit by9.6percentage points. Another1.5percentage points can be further improved by integrating with syngas recirculation and high gas clean-up.
1.集成中高温干法净化的IGCC
分析了氧化锌干法脱硫温度、再生氧气浓度、脱硫效率对IGCC系统热力性能的影响,比较了集成不同净化技术的IGCC系统。结果表明,中温干法净化(脱硫温度350℃)比全湿法净化IGCC供电效率高1.77个百分点,其中干法除尘技术贡献约1个百分点；干法净化温度从200℃升高至650℃,IGCC供电效率提高0.74个百分点,但如考虑燃烧室注蒸汽保持燃烧室相同的当量绝热火焰温度,IGCC供电效率仅上升约0.3个百分点。
2.集成高温离子膜分离技术(ITM)的IGCC
研究了集成ITM空分、深冷空分的IGCC热力性能,分析了整体化ITM的氧气分离率、氮气回注温度对IGCC热力性能的影响。结果表明：IGCC供电效率随ITM空分与燃气轮机集成度增加而上升,100%集成度的ITM空分与完全独立ITM空分相比可提高IGCC供电效率1.81个百分点,与完全整体化深冷空分的IGCC相比供电效率高1.11个百分点。
3.先进燃气轮机IGCC的热力性能
建立并校验了准一维燃气轮机透平冷却模型。研究了透平冷却技术、材料、热障涂层以及冷却介质对燃气轮机联合循环的影响。
以F级“冷却-材料”水平为基准,提高燃烧室出口温度,燃机简单循环和联合循环效率先升高后降低,联合循环效率在初温约1700℃,压比约25时最高：提高透平“冷却-材料”水平,相同燃烧室出口温度下,联合循环效率提高,随燃烧室出口温度的提高,提高“冷却-材料”水平对提高联合循环效率的作用越明显。
GE9G燃机如采用透平首级喷嘴蒸汽冷却,联合循环效率相比于目前透平空气冷却可提高0.6个百分点,采用透平前两级蒸汽冷却(9H)效率可再提高1.7个百分点,如采用透平全蒸汽冷却可进一步提高效率1.1个百分点。
采用M701G2、9H、M701J燃机的IGCC相比于采用PG9351FA燃机IGCC供电效率分别高2.8、3.3和4.2个百分点。对于1700℃级燃机IGCC系统,如“冷却-材料”水平与M701J燃机相同时,系统供电效率较M701J级燃机IGCC高0.6个百分点；如提高“冷却-材料”水平使冷却空气量与M701J相同时,效率可再提高0.7个百分点,如进一步提高“冷却-材料”水平使冷却空气量相比于M701J下降10%时,可继续提高IGCC系统供电效率0.3个百分点。
4.气化技术对IGCC系统热力性能的影响
研究分析了空气气化和纯氧气化的气化温度、碳转化率、汽煤比对IGCC系统热力性能的影响。结果表明：对于氧气气化与空气气化IGCC系统,气化温度每提高100℃,系统供电效率分别下降约0.32～0.49和0.67～0.77个百分点；蒸汽煤比每提高0.1,系统供电效率分别下降0.28-0.36和0.29～0.52个百分点,C转化率每提高1个百分点,系统供电效率分别提高约0.42～0.45和0.41～0.43个百分点。
空气气化与氧气气化IGCC系统的气化压力对系统热力性能影响显著,其中,常压氧气气化的系统效率明显低于加压氧气气化2.6～3.2个百分点；常压空气气化IGCC系统效率明显低于加压空气气化3.9～4.2个百分点。空气气化的增压流程会影响IGCC供电效率约1.7个百分点。
5. IGCC热力性能发展潜力预测
相比于F级燃机、水煤浆气化炉、湿法脱硫、深冷空分IGCC系统,集成了1700℃燃机、干法给料气化、中温干法净化、膜分离空分的IGCC系统供电效率提升约9.6个百分点,达54.8%；进一步集成合成气回热加热气化剂(氧气和水蒸汽)、高温干法净化技术的IGCC可再提升系统供电效率1.5个百分点。
Integrated Gasification Combined Cycle(IGCC) is a kind of super clean and high efficiency power generation technology. There are many ways and huge potential to improve the net efficiency of IGCC. The present work explores how much IGCC can benefit from technologies of warm gas desulfurization, Ion Transport Membrane(ITM), and advanced gas turbine. Influences of key gasification parameters on thermodynamic performance of IGCC plants have been analyzed. The main contents and results are presented as follows:
1. IGCC integrated with warm gas clean-up(WGCU)
Four IGCC systems with different gas clean-up processes based on the model of ZnO-desulfurization are established and compared. Impacts of key parameters of WGD on thermodynamic performance of IGCC plants including desulfurization temperature, oxygen concentration in regeneration stream, and H2S removal efficiency are discussed. It is found that the net efficiency of IGCC with full WGCU increases1.77percentage points compared with IGCC with cold gas clean-up(CGCU), among which the dry ash removal contributes about1percentage point. The net efficiency will increase0.74percentage point when the desulfurization temperature increases from200℃to650℃. However, if the way of steam injection were considered to control the same SFT, the net efficiency increases only0.3percentage point.
2. IGCC integrated with ITM
The thermodynamic performance of IGCC with different ways of integration between ITM and gas turbine is discussed. In comparison to IGCC system with cryogenic air separation, the net efficiency of IGCC with full integration of ITM technology experiences an improvement of1.11percentage points, and is higher than that of the IGCC with independent ITM by1.81percentage points. In addition, in view of the full integration IGCC, influences of O2separation rate and the N2reinjection temperature on IGCC net efficiency are evaluated.
3. IGCC with advanced gas turbine
A quasi-1D turbine cooling model is built and validated. Impacts of turbine cooling techniques such as convection cooling and film cooling, blade material, thermal barrier coating and coolant medium on the thermal performance of GTCC and IGCC are studied.
With constant "cooling-material" technology(F class), the efficiency of simple gas turbine cycle and combined cycle increases first and then decreases with the increase of combustor exit temperature. For combined cycle, the maximum efficiency appears on the point where the combustor exit temperature is1700℃and the pressure ratio is about25. With constant combustor exit temperature, the net efficiency of GTCC increases following the improvement of the "cooling-material" technology. When the combustor exit temperature increases, the effect of improving "cooling-material" technology on improving the net efficiency of GTCC becomes more obvious.
Taking GE9G as an example, the performance of turbine adopting steam as the coolant medium is discussed. According to results, the net efficiency of IGCC, which adopts9G gas turbine but steam is taken as the coolant of first nozzle, is higher than that of the IGCC with9G gas turbine by0.6percentage point. When the first two stages adopt steam cooling, the IGCC net efficiency can be further improved by1.7percentage points. Additional1.1percentage points of net efficiency improvement can be obtained by taking steam as coolant of whole turbine.
The net efficiency of IGCC employing M701G2、9H、M701J gas turbines is higher than that of IGCC employing PG9351FA by2.8、3.3、4.2percentage points respectively. If the "cooling-material" technology of1700℃class gas turbine keeps constant with the M701J, the net efficiency of IGCC with1700℃class gas turbine is higher than that of the M701J-IGCC by0.6percentage point. And if the "cooling-material" technology is improved in order to keep the cooling flow same to the M701J, the net efficiency can be further improved by0.7percentage point. Additional0.3percentage point of net efficiency improvement can be obtained by improving the "cooling-material" technology which can decrease the cooling flow by10%with respect to M701J.
4. Influences of gasification on thermodynamic performance of IGCC
Influences of key parameters, including gasification temperature, C conversion, the mass ratio of steam to coal, on thermodynamic performance of IGCC are assessed in view of the air and oxygen blown gasification. Results show that, when the gasification temperature dropped by100℃, the IGCC net efficiency decrease by0.32-0.49and0.67～0.77percentage point respectively for IGCC systems with air and oxygen blown gasification. When the mass ratio of steam to coal increases by0.1, the IGCC net efficiency decreases by0.28～0.36and0.29～0.52percentage point respectively for IGCC systems with air and oxygen blown gasification. When the C conversion efficiency is improved by1percentage point, the IGCC net efficiency can be improved by0.42～0.45and0.41～0.43percentage point respectively for IGCC systems with air-and oxygen gasification.
There is an obvious advantage in the view of thermal performance for IGCC systems with pressurized gasification with respect to the atmospheric gasification. The IGCC net efficiency of pressurized oxygen blown gasification is higher than that of atmospheric oxygen gasification by2.6～3.2percentage points, and the IGCC net efficiency of pressurized air blown gasification is higher than that of atmospheric air gasification by3.9-4.2percentage points. For pressurized air blown gasification, an efficiency gap about1.7percentage points can be affected by adopting various ways of compression.
5. Calculating the thermodynamic performance potential of IGCC
The net efficiency of IGCC system whose key components include1700℃class gas turbine, dry-feed gasifier, warm gas clean-up and ITM air separation unit can reach54.8%, which is higher than the IGCC system integrated by technologies of F class gas turbine, slurry-feed gasifier, cold gas clean-up and cryogenic air separation unit by9.6percentage points. Another1.5percentage points can be further improved by integrating with syngas recirculation and high gas clean-up.
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