均混预热电石熔炼新工艺的能耗特征与热经济成本分析

doi:10.16085/j.issn.1000-6613.2022-1129

摘要/Abstract

摘要：

传统电石生产以块状生石灰和块状焦炭为原料，在电石炉内电热高温（2000℃以上）作用下完成电石熔炼反应。均混预热电石熔炼新工艺以低阶煤粉和生石灰粉为原料，增加压球和热解工序，以期获得降低成本和节能降耗效果。本文建立了两种工艺的能质平衡模型，分别对两种工艺在相同电石出炉条件下进行物质流和能量流的模拟，探讨新工艺的能源替代效果；基于㶲流和㶲单价，建立了热经济学成本分析模型，对比两种工艺的热经济特性。结果表明，在新工艺中，每吨电石需消耗低阶煤粉810.0kg，热解过程产生副产能源206.2kg，其碳质能源的净消耗与传统工艺耗量（583.5kg焦炭）基本相当，新工艺具有“以煤代焦”特性；热解出炉球团的物理热通过热送热装直接带入电石炉，可节约加热电耗约11.2%，具有“以热代电”的按质用能效果；传统工艺和新工艺的吨电石热经济学成本分别为2208元和1919元，新工艺电石成本下降主要源于电力消耗降低、副产气净产量提高和低阶原料替代，其贡献度分别为8.7%、6.0%和3.5%；新工艺的设备成本偏高，其热经济性优势会在后续工艺推广中逐步展现。

关键词: 电石, 电石炉, 球团, 能源替代, 热经济成本

Abstract:

Traditional calcium carbide production takes lumpy quicklime and lumpy coke as raw materials and completes the smelting reaction of calcium carbide under the high temperature of electric heating (above 2000℃) in submerged arc furnace. A newly proposed smelting process with homogenization and preheating takes low-grade pulverized coal and quicklime powder as raw materials, and adds the processes of pelletizing and pyrolysis before smelting, in order to achieve the effect of cost reduction and energy saving. In this paper, the mass and energy balance models of the two processes were constructed, and the material and energy flows were simulated under the same calcium carbide discharge conditions to discuss the energy substitution effect of the new process. Based on exergy flow and unit price of exergy, a thermoeconomic cost analysis model was established to compare the thermal economy of the two processes. The results showed that, for 1 ton of calcium carbide produced by the new process, 810.0kg of low-grade pulverized coal needed to be consumed, and 206.2kg of by-product energy was generated in the pyrolysis process. Its net consumption of carbonaceous energy was basically equivalent to that of the traditional process (583.5 kg coke). The characteristic of "replacing coke with coal" of the new process was reflected. The physical enthalpy of hot pellets was directly brought into the furnace through hot delivery and hot charging, which can save about 11.2% heating power consumption, and had the effect of "replacing electricity with heat". The thermoeconomic cost per ton of calcium carbide for the traditional process and the new process was 2208CNY and 1919CNY, respectively. The cost reduction of the new process mainly came from the reduction of power consumption, the increase of net by-product gas generation and the substitution of low-grade raw materials, whose contribution were 8.7%, 6.0% and 3.5%, respectively. The current equipment cost of the new process was relatively high, and its thermal economy advantage will be gradually displayed in the follow-up process promotion.

Key words: calcium carbide, submerged arc furnace, pellet, energy substitution, thermoeconomic cost

中图分类号:

TQ161

耿书阳, 姜泽毅, 张欣茹. 均混预热电石熔炼新工艺的能耗特征与热经济成本分析[J]. 化工进展, 2023, 42(4): 1787-1796.

GENG Shuyang, JIANG Zeyi, ZHANG Xinru. Analysis of energy consumption and thermoeconomic cost for a novel calcium carbide smelting process with homogenization and preheating[J]. Chemical Industry and Engineering Progress, 2023, 42(4): 1787-1796.

图/表 16

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物质	状态	标准化学焓 /kJ·mol^-1	标准化学㶲 /kJ·mol^-1	基准物
C	s	412.25	34353.83	CO₂
CaO	s	123.79	2210.46	CaCO₃
CaC₂	s	1491.07	23297.89	CaCO₃
H₂	g	274.16	137079.00	H₂O
H₂O	g	64.87	3603.94	H₂O
CO	g	334.26	11937.82	CO₂
CH₄	g	885.96	55372.63	CO₂
C₂H₄	g	1425.31	50903.86	CO₂
O₂	g	65.03	2032.06	O₂
N₂	g	57.74	2062.11	N₂
CO₂	g	83.77	1903.91	CO₂
MgCO₃	s	40.62	483.51	CaCO₃MgCO₃
MgO	s	57.94	1448.58	CaCO₃MgCO₃
S	s	610.74	19085.66	CaSO₄·2H₂O

物质	状态	标准化学焓 /kJ·mol^-1	标准化学㶲 /kJ·mol^-1	基准物
C	s	412.25	34353.83	CO₂
CaO	s	123.79	2210.46	CaCO₃
CaC₂	s	1491.07	23297.89	CaCO₃
H₂	g	274.16	137079.00	H₂O
H₂O	g	64.87	3603.94	H₂O
CO	g	334.26	11937.82	CO₂
CH₄	g	885.96	55372.63	CO₂
C₂H₄	g	1425.31	50903.86	CO₂
O₂	g	65.03	2032.06	O₂
N₂	g	57.74	2062.11	N₂
CO₂	g	83.77	1903.91	CO₂
MgCO₃	s	40.62	483.51	CaCO₃MgCO₃
MgO	s	57.94	1448.58	CaCO₃MgCO₃
S	s	610.74	19085.66	CaSO₄·2H₂O

物质	市场价
石灰石	150CNY/t
焦炭	760CNY/t
电极糊	2850CNY/t
电力	0.35CNY/kWh
煤粉	450CNY/t
生石灰粉	220CNY/t
黏结剂	40CNY/t
焦油	1500CNY/t
热解气	0.5CNY/m³
电石炉气	0.5CNY/m³

物质	市场价
石灰石	150CNY/t
焦炭	760CNY/t
电极糊	2850CNY/t
电力	0.35CNY/kWh
煤粉	450CNY/t
生石灰粉	220CNY/t
黏结剂	40CNY/t
焦油	1500CNY/t
热解气	0.5CNY/m³
电石炉气	0.5CNY/m³

设备	C_B/10⁶CNY	Q_B	M	Q	参考文献
压球机	6.29	5t/h	0.6	24t/h	[20]
热解炉	62	60m	0.6	40m	[10]
电石炉	33	33MVA	0.6	33MVA×2	[10]