Optimization of burner layout parameters and operating parameters of oxy-thermal entrained-flow calcium carbide reactor

doi:10.16085/j.issn.1000-6613.2024-0120

Abstract

Abstract:

In order to make the oxygen thermal entrained-flow calcium carbide reactor meet the design requirements of high calcium carbide yield and low energy consumption, the burner layout parameters and operating parameters of the designed calcium carbide reactor were optimized by Fluent software. Firstly, only the non-premixed combustion model of pulverized coal was added to the reactor to study the uniformity of temperature field in the reactor. Under the condition that the number of nozzles was 4 and the particle size of pulverized coal was 120 μm, the orthogonal experiment of three factors and three levels was designed with the highest uniformity of temperature field as the goal. The response surface method was used to optimize the layout parameters of the nozzle (nozzle axial angle, nozzle tangential angle and nozzle height). The result showed that changing the layout parameters will have a greater impact on the uniformity of the temperature field. The optimal layout parameters were the axial angle of 46°, the tangential angle of 32°, and the nozzle height of 0.56m. The calculated temperature field uniformity was 61.25%, which was 28.79% higher than the original model, and the optimization effect was obvious. Then, in the reactor with the optimal structure, a double reaction model of pulverized coal non-premixed combustion and calcium carbide synthesis was added. With the highest yield of calcium carbide as the goal, a three-factor three-level orthogonal experiment was designed. The response surface method was used to optimize the operating parameters of the reactor (feed particle size, feed temperature and oxygen temperature). The optimized operating parameters were beneficial to the improvement of the yield. The optimized operating parameters were: feed particle size 138μm, feed temperature 1432K, oxygen temperature 769K, and calcium carbide yield 58.36%, which was 16.68% higher than that before optimization.

Key words: calcium carbide synthesis, coal combustion, granular materials, multiphase reactor, numerical simulation, optimization

摘要：

使用Fluent软件对氧热法气流床电石反应器的烧嘴布置参数和操作参数进行优化。首先在反应器反应段中只加载煤粉非预混燃烧模型，对反应段内温度场均匀度进行研究。在烧嘴数量为4、煤粉粒径为120μm的条件下，以温度场均匀度最高为目标，采用响应曲面法对烧嘴布置参数（轴向夹角、切向夹角和烧嘴高度）进行优化。最优布置参数为轴向夹角46°、切向夹角32°、烧嘴高度0.56m；计算得温度场均匀度为61.25%，比原始模型提高了28.79%，优化效果明显。然后在最优结构反应段中，加载煤粉非预混燃烧和电石合成耦合反应模型，以电石产率最高为目标，采用响应曲面法对操作参数（进料粒径、进料温度和氧气温度）进行优化。最佳操作参数为：进料粒径138μm、进料温度1432K、氧气温度769K，计算得电石产率为58.36%，比优化前提高了16.68%。

关键词: 电石合成, 煤燃烧, 颗粒物料, 多相反应器, 数值模拟, 优化

CLC Number:

TK229.6

QIAO Lei, ZHANG Yaxin, WEI Bo, RAN Wenshen, MA Jingrong, WANG Feng. Optimization of burner layout parameters and operating parameters of oxy-thermal entrained-flow calcium carbide reactor[J]. Chemical Industry and Engineering Progress, 2025, 44(1): 145-157.

乔磊, 张亚新, 魏博, 冉文燊, 马金荣, 王峰. 氧热法气流床电石反应器烧嘴布置参数及操作参数优化[J]. 化工进展, 2025, 44(1): 145-157.

Figures/Tables 25

参数	数值	参数	数值
反应段总高度H₁	4.37m	烧嘴数量n	4
加热区高度H₂	4.0m	烧嘴直径d	0.01m
加热区直径D₁	1.5m	烧嘴高度h	0.6m
反应区高度H₃	0.37m	轴向夹角α	30°
底部直径D₂	0.8m	切向夹角β	0°

动力学参数	煤粉非预混燃烧反应	电石合成反应
A/s^-1	2.119×10¹¹	983333
E_a/J·mol^-1	2.027×10⁸	353000

工业分析/%					元素分析/%
M_ar	V_ar	FC_ar	A_ar		C_ar	H_ar	O_ar	N_ar	S_ar
10.8	30.06	50.40	8.7		88.10	5.08	3.72	1.24	1.86

原料	CaO/%	MgO/%	SiO₂/%	R₂O₃/%
氧化钙	96	1.5	0.7	1.8

反应物	∆H $_{298}^{⊖}$ /kJ·mol^-1	∆S $_{298}^{⊖}$ /J·mol^-1·K^-1	∆G $_{298}^{⊖}$ /kJ·mol^-1
CaO	-635.09	39.75	-604.3
C	0	5.74	0
CO	-110.525	197.674	-137.168
CO₂	-393.509	213.74	-394.359
O₂	0	205.138	0
CaC₂	-59.8	69.96	-64.9

反应物	∆H $_{298}^{⊖}$ /kJ·mol^-1	∆S $_{298}^{⊖}$ /J·mol^-1·K^-1	∆G $_{298}^{⊖}$ /kJ·mol^-1
CaO	-635.09	39.75	-604.3
C	0	5.74	0
CO	-110.525	197.674	-137.168
CO₂	-393.509	213.74	-394.359
O₂	0	205.138	0
CaC₂	-59.8	69.96	-64.9

边界条件	温度 /K	速度 /m·s^-1	湍流强度/%	进料流量 /kg·s^-1	内部辐射系数
氧化钙	1800	0.1	—	0.0146	0.6
煤粉	1800	0.1	—	0.0803	0.6
氧气入口	300	—	10	—	0.6
压力出口	300	—	0.1	—	0.6

网格尺寸/m	0.04	0.05	0.06
网格数量	670796	502385	419634

因素	编号	水平
因素	编号	1	2	3
烧嘴轴向夹角/(°)	A₁	40	45	50
烧嘴切向夹角/(°)	B₁	20	30	40
烧嘴高度/m	C₁	0.5	0.6	0.7

序号	A₁	B₁	C₁	Y_T/%
1	45	40	0.7	30.08
2	45	30	0.6	59.77
3	45	20	0.5	36.88
4	40	40	0.6	33.33
5	45	30	0.6	59.77
6	40	30	0.5	-8.66
7	50	30	0.7	12.89
8	50	20	0.6	17.51
9	45	30	0.6	59.77
10	45	30	0.6	59.77
11	45	20	0.7	23.13
12	40	30	0.7	51.55
13	50	30	0.5	50.50
14	50	40	0.6	24.73
15	40	20	0.6	16.31
16	45	40	0.5	43.43
17	45	30	0.6	59.77

方差来源	平方和	自由度	均方	F值	P值
模型	0.6484	9	0.072	12.02	0.0017
A₁	0.0021	1	0.0021	0.3581	0.5684
B₁	0.0177	1	0.0177	2.95	0.1293
C₁	0.0002	1	0.0002	0.0402	0.8467
A₁B₁	0.0024	1	0.0024	0.4005	0.547
A₁C₁	0.2393	1	0.2393	39.92	0.0004
B₁C₁	2.09×10^-6	1	2.09×10^-6	0.0003	0.9856
	0.2004	1	0.2004	33.44	0.0007
B $_{1}^{2}$	0.0945	1	0.0945	15.77	0.0054
C $_{1}^{2}$	0.0545	1	0.0545	9.1	0.0195
残差	0.042	7	0.006	—	—
失拟项	0.042	3	0.014
纯误差	0	4	0
总和	0.6903	16	—

方差来源	平方和	自由度	均方	F值	P值
模型	0.6484	9	0.072	12.02	0.0017
A₁	0.0021	1	0.0021	0.3581	0.5684
B₁	0.0177	1	0.0177	2.95	0.1293
C₁	0.0002	1	0.0002	0.0402	0.8467
A₁B₁	0.0024	1	0.0024	0.4005	0.547
A₁C₁	0.2393	1	0.2393	39.92	0.0004
B₁C₁	2.09×10^-6	1	2.09×10^-6	0.0003	0.9856
	0.2004	1	0.2004	33.44	0.0007
B $_{1}^{2}$	0.0945	1	0.0945	15.77	0.0054
C $_{1}^{2}$	0.0545	1	0.0545	9.1	0.0195
残差	0.042	7	0.006	—	—
失拟项	0.042	3	0.014
纯误差	0	4	0
总和	0.6903	16	—

因素	编号	水平
因素	编号	1	2	3
进料粒径/μm	A₂	120	140	160
进料温度/K	B₂	1200	1400	1600
氧气温度/K	C₂	500	800	1100

水平	A₂	B₂	C₂	Y_p/%
1	160	1600	800	46.0756
2	120	1400	500	52.5889
3	160	1400	1100	43.5116
4	160	1400	500	51.1943
5	140	1400	800	55.6441
6	120	1200	800	41.9578
7	140	1200	1100	45.1369
8	140	1400	800	55.6441
9	140	1400	800	55.6441
10	140	1400	800	55.6441
11	160	1200	800	48.5747
12	140	1200	500	53.1574
13	140	1600	500	43.979
14	140	1400	800	55.6441
15	120	1600	800	48.0226
16	120	1400	1100	51.9964
17	140	1600	1100	48.692

方差来源	平方和	自由度	均方	F值	P值
模型	330.43	9	36.71	6.41	0.0114
A₂	3.39	1	3.39	0.5922	0.4667
B₂	0.5292	1	0.5292	0.0924	0.7700
C₂	16.77	1	16.77	2.93	0.1308
A₂B₂	18.34	1	18.34	3.20	0.1167
A₂C₂	12.57	1	12.57	2.19	0.1821
B₂C₂	40.54	1	40.54	7.08	0.0325
A $_{2}^{2}$	57.72	1	57.72	10.08	0.0156
B $_{2}^{2}$	140.86	1	140.86	24.59	0.0016
C $_{2}^{2}$	18.90	1	18.90	3.30	0.1121
残差	40.10	7	5.73
失拟项	40.10	3	13.37
纯误差	0.0000	4	0.0000
总和	370.53	16	—

方差来源	平方和	自由度	均方	F值	P值
模型	330.43	9	36.71	6.41	0.0114
A₂	3.39	1	3.39	0.5922	0.4667
B₂	0.5292	1	0.5292	0.0924	0.7700
C₂	16.77	1	16.77	2.93	0.1308
A₂B₂	18.34	1	18.34	3.20	0.1167
A₂C₂	12.57	1	12.57	2.19	0.1821
B₂C₂	40.54	1	40.54	7.08	0.0325
A $_{2}^{2}$	57.72	1	57.72	10.08	0.0156
B $_{2}^{2}$	140.86	1	140.86	24.59	0.0016
C $_{2}^{2}$	18.90	1	18.90	3.30	0.1121
残差	40.10	7	5.73
失拟项	40.10	3	13.37
纯误差	0.0000	4	0.0000
总和	370.53	16	—

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