适应锅炉调峰运行的水冷壁高温腐蚀预测模型

doi:10.16085/j.issn.1000-6613.2023-0268

摘要/Abstract

摘要：

随着可再生能源大规模并网，传统火电机组作为调配能源的地位显著增强，这对锅炉灵活调峰运行的安全稳定性提出了更高要求。本文耦合烟气侧与工质侧传热，结合管壁温计算，形成水冷壁壁温分布耦合计算方法。同时，建立了用于确定还原性气氛下的燃料硫释放以及含硫组分的相互转化过程的SO _x 生成模型。综合炉膛数值模拟、水冷壁壁温耦合计算以及包含时间维度的管壁高温腐蚀模型，提出了一种适应锅炉调峰运行的水冷壁高温腐蚀预测模型并基于Matlab GUI开发了对应软件。选取一台超临界600MW四角切圆燃煤锅炉为研究对象，结果表明：采用壁温耦合计算模型和SO _x 生成模型得到水冷壁的壁温分布和近壁面H₂S浓度分布准确度高，为水冷壁高温腐蚀的准确预测提供了良好基础。不同负荷下水冷壁高温腐蚀特征存在差异，壁面腐蚀程度整体上随负荷降低而降低。100%BMCR与75%THA负荷下前墙水冷壁燃烧器与SOFA之间的区域腐蚀最为严重，最大年腐蚀深度分别为276μm和233μm；50%THA与35%BMCR负荷下高温腐蚀深度在燃烧器区域的上部迅速增加至最大值，分别为224μm和256μm。多工况运行水冷壁高温腐蚀状态表现为各工况腐蚀状态的时空叠加。运用水冷壁高温腐蚀预测模型可实现通过锅炉运行参数和运行时间预测多工况下水冷壁高温腐蚀状态程度的时空分布。

关键词: 调峰运行, 水冷壁, 高温腐蚀, 数值模拟, 壁温计算

Abstract:

With large-scale renewable power integrated into the grid, the status of traditional thermal power units as energy allocation has been significantly enhanced. The safety and stability of boiler peak-shaving operation become more and more important. This work coupled the heat absorption with the hydrodynamic characteristics and forms the temperature calculation model of water-cooled wall. Meanwhile, a SO _x generation model was developed to determine the process of the fuel sulfur release in a reducing atmosphere and the mutual transformation of sulfur components. Based on the numerical simulation of furnace, the temperature calculation model of water-cooled wall and the tube wall high-temperature corrosion model with time dimension, a high-temperature corrosion prediction model of water-cooled wall for boiler peak-shaving operation was proposed. The corresponding software was also developed using the Matlab GUI platform. A supercritical 600MW tangentially coal-fired boiler was selected as the research object. The results showed that the accuracies of the wall temperature distribution and H₂S concentration distribution near the wall obtained by coupling calculation of wall temperature and SO _x generation model were high, which provided a good basis for accurate prediction of high-temperature corrosion. The high-temperature corrosion characteristics of the water-cooled wall under different loads were different. The corrosion degree of the water-cooled wall decreases with the decrease of the boiler loaded as a whole. The area of front wall between the burner zone and SOFA zone was the most severely corroded under 100% BMCR and 75% THA load, with maximum corrosion depths of 276μm and 233μm per year, respectively. The high-temperature corrosion depths under 50% THA and 35% BMCR load rapidly increased to a maximum in the top of the burner zone, which were 224μm and 256μm per year, respectively. The high-temperature corrosion state of the water-cooled wall under multiple working operation was manifested as the spatio-temporal superposition of the corrosion state of each working condition. The spatio-temporal distribution of the high-temperature corrosion state of water-cooled wall could be predicted by boiler operation parameters and operation time through the prediction software.

Key words: peak-shaving operation, water-cooled wall, high-temperature corrosion, numerical simulation, wall temperature calculation

中图分类号:

TK224.9

邓磊, 袁茂博, 杨家辉, 岳洋, 姜家豪, 车得福. 适应锅炉调峰运行的水冷壁高温腐蚀预测模型[J]. 化工进展, 2024, 43(2): 925-936.

DENG Lei, YUAN Maobo, YANG Jiahui, YUE Yang, JIANG Jiahao, CHE Defu. High-temperature corrosion prediction model of water-cooled wall for boiler peak regulation[J]. Chemical Industry and Engineering Progress, 2024, 43(2): 925-936.

图/表 16

图1 锅炉布置简图

表1 不同负荷下锅炉运行参数

负荷	给煤量/t·h^-1	燃烧器层数（摆角）	过量空气系数（主燃区）	一次风率
35% BMCR	95.7	B-C（20^o）	1.47（1.00）	0.18
50% THA	113.0	A-C（10^o）	1.37（0.95）	0.20
75% THA	164.4	B-E（0^o）	1.33（(0.90）	0.24
100% BMCR	240.0	A-E（-10^o）	1.20（0.85）	0.22

表2 煤样的工业分析与元素分析

工业分析/%				元素分析/%					Q_net,ar/MJ·kg^-1
w_ar(FC)	w_ar(M)	w_daf(V)	w_ar(A)	w_ar(C)	w_ar(N)	w_ar(S)	w_ar(O)	w_ar(H)	Q_net,ar/MJ·kg^-1
50.38	14.50	35.00	8.00	62.83	0.70	0.41	9.94	3.62	22.76

表3 含硫组分相互转化反应方程[17]

序号	总包反应	反应速率
1	H₂S+1.5O₂ $→$ SO₂+H₂O	r₁
2	H₂S+2H₂O $→$ SO₂+3H₂	r₂
3	H₂S+CO₂ $→$ COS+H₂O	r₃
4	H₂S+CO $→$ COS+H₂	r₄
5	COS+1.5O₂ $→$ SO₂+CO₂	r₅
6	COS+H₂ $→$ H₂S+CO	r₆
7	COS+2CO₂ $→$ SO₂+3CO	r₇
8	COS+H₂O $→$ H₂S+CO₂	r₈
9	SO₂+3H₂ $→$ H₂S+2H₂O	r₉
10	SO₂+3CO $→$ COS+2CO₂	r₁₀

表3 含硫组分相互转化反应方程[17]

序号	总包反应	反应速率
1	H₂S+1.5O₂ $→$ SO₂+H₂O	r₁
2	H₂S+2H₂O $→$ SO₂+3H₂	r₂
3	H₂S+CO₂ $→$ COS+H₂O	r₃
4	H₂S+CO $→$ COS+H₂	r₄
5	COS+1.5O₂ $→$ SO₂+CO₂	r₅
6	COS+H₂ $→$ H₂S+CO	r₆
7	COS+2CO₂ $→$ SO₂+3CO	r₇
8	COS+H₂O $→$ H₂S+CO₂	r₈
9	SO₂+3H₂ $→$ H₂S+2H₂O	r₉
10	SO₂+3CO $→$ COS+2CO₂	r₁₀

图2 网格无关性验证

表4 100% BMCR负荷下实炉测量结果与模拟结果对比

项目	水冷壁吸热量/MW	炉膛出口氧体积分数/%	后屏出口烟温/K	前墙中心H₂S浓度/μL∙L^-1
项目	水冷壁吸热量/MW	炉膛出口氧体积分数/%	后屏出口烟温/K	25m	29m	35m
实测值	610	3.72	1356	348	134	203
模拟值	659	3.62	1291	321	145	186
偏差/%	7.50	2.76	4.79	7.76	8.21	8.37

图3 螺旋管圈展开与重构示意图

图4 100%BMCR负荷下螺旋管圈水冷壁出口温度分布对比

图5 水冷壁高温腐蚀预测模型示意图

图6 水冷壁高温腐蚀预测GUI界面

表5 壁温计算函数汇总

函数	功能	输入与输出
deal_data	对Fluent导出的三维热流密度分布数据进行重构处理	输入:热流密度分布/锅炉结构参数/水动力单元密度
deal_data	对Fluent导出的三维热流密度分布数据进行重构处理	输出:重构热流密度矩阵/重构前热流密度坐标参数
equs	设置一维水动力计算方程组	输入:总质量流量/水动力单元密度/管壁结构参数/压降初值/回路的物性参数
equs	设置一维水动力计算方程组	输出:用于判断方程收敛的一维数组
super_sumdv sub_sumdv	超临界和亚临界工况下水动力回路物性参数计算	输入:流量/水动力网格密度/工作压力/工质初始焓值
super_sumdv sub_sumdv	超临界和亚临界工况下水动力回路物性参数计算	输出:所有单元内工质密度和比体积
solve_newton	离散牛顿法求解水动力方程组	输入:初始解/步长/工质物性参数/管壁结构参数
solve_newton	离散牛顿法求解水动力方程组	输出:水动力方程组的一组解以及迭代次数
super_massflow sub_massflow	超临界和亚临界工况下各回路质量流量计算	输入:deal_data输出的热流密度/solve_newton的输入
super_massflow sub_massflow	超临界和亚临界工况下各回路质量流量计算	输出:各回路质量流量和总压降
super_temp sub_temp	超临界和亚临界工况下水冷壁壁温分布计算	输入:deal_data的输出/各回路质量流量/管壁结构参数
super_temp sub_temp	超临界和亚临界工况下水冷壁壁温分布计算	输出:水冷壁壁温分布

图7 100%BMCR负荷水冷壁前墙壁温分布、H2S浓度分布以及年腐蚀深度分布

图8 不同负荷下水冷壁前墙壁温分布

图9 不同负荷下水冷壁前墙H2S浓度分布

图10 不同负荷下水冷壁前墙高温腐蚀状态

图11 调峰运行下水冷壁高温腐蚀状态

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