Analysis of flue gas deep waste heat recovery with cooperative flue gas pressure control for alkane dehydrogenation heating furnace

doi:10.16085/j.issn.1000-6613.2023-0750

Abstract

Abstract:

The refinery heating furnace is one of the high energy consumption and high carbon emission equipment in the petroleum refining process. Flue gas waste heat recovery of the refinery heating furnace plays an important role in reducing pollutants and carbon emissions for petrochemical industry, but low-temperature flue gas condensate can corrode heat exchanger, and the flue gas condensing heat exchanger (FGCHE) added at the rail of heating furnace increases flue gas pressure drop, affecting refinery production process and the combustion efficiency of the heating furnace. The anti-corrosion, high-efficiency and low-pressure-drop FGCHE with cooperative flue gas pressure control become technical challenges to improve the maximizing energy efficiency of flue gas heat recovery and utilization system. Taking alkane dehydrogenation heating furnace in the refining plant as an example, the low-temperature flue gas deep waste heat recovery with cooperative flue gas pressure control system (FGHR-PCS) was proposed, and its demonstration project was established, then the FGHR-PCS under the working conditions both of stepped and no-stepped heat transfer was tested on site. Energy-saving operating characteristics were analyzed and compared with the theoretical value. The results showed that the accuracy of flue gas pressure in the heating furnace chamber control reached (-35±6.4)Pa, meeting the requirement of the production process. Meanwhile, the flue gas temperature of the alkane dehydrogenation heating furnace was reduced from 178.3—178.7℃ to 54.3—78.7℃, the energy saving efficiency reached 4.75%—6.9%, the flue gas waste heat recovery ratio reached 28.1%—40.4%, the flue gas heat recovery amount in the stepped heat transfer stage was 43.8% higher than that in the no-stepped heat transfer stage, and the exergy efficiency of the FGCHE reached 52.8%—63.7%. At the same time, the flue gas energy saving of the FGHR-PCS was beneficial to reduce carbon and pollutant emissions (NO _x and SO₂), and the carbon reduction emissions could reach 2884.5—4197.9t/a, which provided the FGHR-PCS had remarkable benefits on energy saving, pollution emission and carbon reduction. It can provide a practical application reference for the technology development and application of the low-temperature deep waste heat recovery from refining heating furnaces.

Key words: heating furnace, flue gas waste heat, waste heat recovery, stepped heat transfer, flue gas pressure control

摘要：

炼化装置加热炉为石油炼化生产工艺中高能耗、高碳排放设备之一，但低温下烟气冷凝水会腐蚀换热设备，增设排烟余热回收换热设备还会增加烟气系统阻力，对生产工艺造成影响，降低加热炉燃烧效率。排烟余热回收利用系统的防腐、高效、低阻力及烟压控制是余热回收系统能效最大化技术难题。本文以炼化装置加热炉为对象，以烷烃脱氢加热炉为例，提出加热炉低温排烟余热深度回收协同炉膛烟压控制系统方案，采用自主研发的防腐、高效、低阻力排烟余热回收设备，建立加热炉低温排烟余热回收利用节能改造示范工程，并跟踪实测，将实测值与理论值进行对比。结果表明：该系统可将炉膛烟压控制在满足生产工艺要求范围内，控制精度达(-35±6.4)Pa；排烟温度由178.3~178.7℃降至54.3~78.7℃，系统节能率达4.75%~6.9%，烟气余热回收率达28.1%~40.4%，其中梯级换热比单级换热性能提高43.8%，㶲效率可达52.8%~63.7%，并减少CO₂排放2884.5~4197.9t/a，且降低NO _x 和SO₂等污染物排放，节能、减污、降碳效果显著。为炼化装置加热炉的排烟低温余热利用技术开发与应用提供了参考和示范。

关键词: 加热炉, 排烟余热, 余热回收, 梯级换热, 烟压控制

CLC Number:

TE08

MU Lianbo, WANG Suilin, LU Junhui, LIU Guichang, ZHAO Liqiu, LIU Jincheng, HAO Anfeng, ZHANG Tong. Analysis of flue gas deep waste heat recovery with cooperative flue gas pressure control for alkane dehydrogenation heating furnace[J]. Chemical Industry and Engineering Progress, 2024, 43(6): 3029-3041.

穆连波, 王随林, 鲁军辉, 刘贵昌, 赵立秋, 刘锦程, 郝安峰, 张彤. 烷烃脱氢加热炉排烟余热深度回收协同烟压控制性能分析[J]. 化工进展, 2024, 43(6): 3029-3041.

Figures/Tables 16

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燃料气成分	体积分数/%
CH₄	16.88
C₂H₆	13.19
C₂H₄	5.65
C₃H₈	0.94
C₃H₆	0.39
n-C₄H₁₀	0.09
i-C₄H₁₀	1.66
C₄H₈	0.08
n-C₅H₁₂	0.03
C₆H₁₄	0.01
O₂	1.88
N₂	14.04
H₂	44.62
CO	0.44
CO₂	0.09
H₂S	≤0.01

燃料气成分	体积分数/%
CH₄	16.88
C₂H₆	13.19
C₂H₄	5.65
C₃H₈	0.94
C₃H₆	0.39
n-C₄H₁₀	0.09
i-C₄H₁₀	1.66
C₄H₈	0.08
n-C₅H₁₂	0.03
C₆H₁₄	0.01
O₂	1.88
N₂	14.04
H₂	44.62
CO	0.44
CO₂	0.09
H₂S	≤0.01

排烟温度/℃	过量空气系数	烟气成分的体积分数
排烟温度/℃	过量空气系数	N₂/%	H₂O/%	CO₂/%	O₂/%	NO _x （标准状况）/mg·m^-3	SO₂（标准状况）/mg·m^-3
176~185	1.1~1.3	71~72.5	16~18.5	7.1~8.2	1.7~4.3	36~132	≤6.3

排烟温度/℃	过量空气系数	烟气成分的体积分数
排烟温度/℃	过量空气系数	N₂/%	H₂O/%	CO₂/%	O₂/%	NO _x （标准状况）/mg·m^-3	SO₂（标准状况）/mg·m^-3
176~185	1.1~1.3	71~72.5	16~18.5	7.1~8.2	1.7~4.3	36~132	≤6.3

名称	梯级换热工况	单级换热工况
标准状况下燃料气总流量/m³·h^-1	6100	6100
标准状况下烟气流量/m³·h^-1	54439	54439
烟气进口温度/℃	180	180
烟气出口温度/℃	55	80
被加热介质	热媒水，低温除盐水	热媒水
被加热水流量/m³·h^-1	热媒65，低温除盐17	100
进水温度/℃	热媒75，低温除盐20	75
出水温度/℃	热媒98.3，低温除盐91	95
引风机额定功率/kW	52	52
排烟余热量/kW	8297	8297
烟气余热回收量/kW	3166	2329
烟气余热回收率/%	34.2	25.1
节能率/%	6.8	4.9