吴剑恒. “双碳”目标下燃煤背压机组锅炉烟气余热深度利用研究[J]. 电力学报, 2022, 37(5): 384-421. DOI: 10.13357/j.dlxb.2022.049
引用本文: 吴剑恒. “双碳”目标下燃煤背压机组锅炉烟气余热深度利用研究[J]. 电力学报, 2022, 37(5): 384-421. DOI: 10.13357/j.dlxb.2022.049
WU Jian-heng. Study on Deep Utilization of Flue Gas Waste Heat of Coal-Fired Back Pressure Boiler under Double Carbon Target[J]. Journal of Electric Power, 2022, 37(5): 384-421. DOI: 10.13357/j.dlxb.2022.049
Citation: WU Jian-heng. Study on Deep Utilization of Flue Gas Waste Heat of Coal-Fired Back Pressure Boiler under Double Carbon Target[J]. Journal of Electric Power, 2022, 37(5): 384-421. DOI: 10.13357/j.dlxb.2022.049

“双碳”目标下燃煤背压机组锅炉烟气余热深度利用研究

Study on Deep Utilization of Flue Gas Waste Heat of Coal-Fired Back Pressure Boiler under Double Carbon Target

  • 摘要: 在“二氧化碳排放力争于2030年前达到峰值,努力争取2060年前实现碳中和”的“双碳”目标下,我国将进一步推进以煤炭为主的能源结构调整,构建以风电、太阳能发电等新能源为主体的清洁低碳安全高效的能源体系,燃煤发电机组将逐渐从处于基础地位和起到支撑作用的主体电源转变为基荷电源与调节电源并重,并且起到基础支撑和安全兜底作用,同时实现清洁高效先进节能,而燃煤锅炉烟气余热深度利用是节能降碳、减排降污、提质增效的重要措施。介绍了我国燃煤锅炉烟气余热利用的三个主要阶段及其主要技术特点,分析了无低压(小于背压排汽压力)低真空回热系统的背压机组与具有多级完善回热系统的抽凝机组、纯凝机组在烟气余热深度回收利用中的区别。以拥有2台背压机组的某燃煤热电厂为例,介绍了其中两台循环流化床锅炉增设低低温省煤器的设计选型、运行实践与优化改进,根据能量平衡、质量平衡和等效焓降原理,从锅炉烟气余热回收经验公式中推导出符合生产需要的经济技术指标简化计算公式,5年多的生产运行实践证明这些简化计算公式与常用经验公式得出的经济技术指标基本一致,可以用来指导运行操作。该热电厂两台循环流化床锅炉增设低低温省煤器后,在锅炉100%BMCR和80%BMCR负荷工况下可分别回收锅炉烟气热量6 100.5 kW、4 381.4 kW;而这些热量可用于加热低温的除盐补充水,可排挤替代9 519.6 kg/h、6 837.0 kg/h较高品质的背压排汽。若所有运行锅炉已在BMCR工况运行或者背压机组已在满负荷工况运行仍无法满足热用户需求时,这些排汽可用以对外增加供热,在锅炉100%BMCR和80%BMCR负荷工况下可分别增加供热蒸汽质量流量9 888.6 kg/h、7 102.0 kg/h,同时减少脱硫系统水耗量9 204.4 kg/h、6 610.6 kg/h,燃料综合热效率分别提高1.85百分点、1.66百分点;按年运行5 000 h计算,在扣除辅机功率增加电费和维修检查清洗费用后,每年可增加不含税收入890.9万元,静态投资回收期不到1年;同时,每年可分别减少SO2排放量2 158.9 t、NOx排放量2 251.3 t、粉尘排放量438.7 t、CO2排放量57 613.4 t,减少碳排放量15 712.7 t,节能减排降碳效果明显。若该热电厂运行背压机组能够随时满足工业园区所有热用户需求,回收烟气余热可减少锅炉主蒸汽产出,在锅炉100%BMCR和80%BMCR负荷工况下可分别节约煤炭量(设计煤种)1 139.4 kg/h、829.4 kg/h,燃料综合热效率提高2.63百分点、2.35百分点;每年可节省支出203.7万元,SO2、NOx、粉尘、CO2、碳排放的减少量分别为697.0 t、726.8 t、141.6 t、4 474.4 t、1 220.3 t。若运用背压机驱动电机或者螺杆发电技术等热功联产方式,将除盐补充水从环境温度加热到低低温省煤器进水温度75℃左右所需背压排汽的热量梯级、深度、合理利用,在锅炉100%BMCR和80%BMCR负荷工况下可分别通过热功联产装置增加发电功率1 631.3 kW、1 186.1 kW的同时,增加供热蒸汽质量流量6 243.0 kg/h、4 462.2 kg/h或者节约煤炭量(设计煤种)719.4 kg/h、521.1 kg/h,燃料综合热效率提高1.39百分点以上,每年可增加收入791.4万元或者节省支出358.4万元;同时,每年可分别减少SO2排放量2 553.6 t、1 632.4 t,减少NOx排放量2 662.9 t、1 702.2 t,减少粉尘排放量518.9 t、2 374.4 t,减少CO2排放量41 653.3 t、8 166.6 t,减少碳排放量11 360.0 t、2 227.3 t,节能降耗减碳效果更加明显,经济效益、生态效益和社会效益更加显著。该热电厂5年多的运行实践证明,增加供热与节省煤炭是交融进行的,实际增收节支在两者之间。同时,根据现场实际对低低温省煤器运行中存在的腐蚀、磨损、积灰等问题进行不断完善改进,该热电厂考虑到不同锅炉负荷工况选择合理的烟气速度,优化了低低温省煤器换热管结构,提出并实施了控制低低温省煤器的进水温度、出口烟气温度以及增加自动控制与保护逻辑回路,在低低温省煤器上部设置一排防磨假管并在前三排换热管上设置防磨瓦,取得了良好的效果,为燃煤背压机组烟气余热深度回收利用的优化设计、改进完善提供切实的借鉴参考和实践佐证。

     

    Abstract: Under the“double carbon”goal of“carbon dioxide emissions striving to reach its peak by 2030 and striving to achieve carbon neutrality by 2060”, China will further promote the adjustment of energy structure based on coal, and build a clean, low-carbon, safe and efficient energy system with new energy sources such as wind power and solar power generation as the main body. Coal-fired generating units will gradually change from the main power supply which is in the basic position and plays a supporting role to the basic load power supply and the regulating power supply, and play the role of basic support and safety, while achieving clean, efficient,advanced and energy-saving. The deep utilization of flue gas waste heat of coal-fired boiler is an important measure to save energy, reduce carbon emissions, reduce pollution, improve quality and efficiency. The three main stages of flue gas waste heat utilization of coal-fired boilers in China,and their main technical characteristics have been introduced, and the difference between the back pressure unit without low pressure(less than back pressure exhaust pressure) and low vacuum regenerative system,and the extraction condensing unit and pure condensing unit with multi-stage perfect regenerative system in the deep recovery and utilization of flue gas waste heat have been analyzed. Taking a coal-fired thermal power plant with two back pressure units as an example, this paper introduces the design selection, operation practice and optimization improvement of adding ultra low temperature economizer to two circulating fluidized bed boilers. According to the principle of energy balance, mass balance and equivalent enthalpy drop, the simplified calculation formula of economic and technical indicators that meet the production needs is derived from the empirical formula of boiler flue gas waste heat recovery. More than five years of production and operation practice has proved that these simplified calculation formulas are basically consistent with the economic and technical indicators obtained by common empirical formulas, which can be used to guide operation.After adding ultra low temperature economizers to two circulating fluidized bed boilers in the thermal power plant, the boiler flue gas heat can be recovered by 6 100.5 kW and4 381.4 kW respectively under 100% BMCR and 80% BMCR load conditions. These heats can be used to heat low-temperature desalted make-up water, which can be squeezed out to replace the 9 519.6 kg/h, 6 837.0 kg/h higher quality back pressure exhaust.If all the operating boilers have been operated under BMCR conditions or the back pressure units have been operated under full load conditions and still cannot meet the needs of heat users, these exhaust steams are used to increase heating. Under 100% BMCR and 80% BMCR load conditions,the mass flow of heating steam can be increased by 9 888.6 kg/h and 7 102.0 kg/h respectively, and the water consumption of desulfurization system can be reduced by 9 204.4 kg/h and 6 610.6 kg/h, and the comprehensive thermal efficiency of fuel can be increased by 1.85% and 1.66% respectively. Calculated on an annual basis of 5 000 hours of operation, after deducting the auxiliary power to increase the cost of electricity and maintenance, inspection and cleaning, the annual non-tax revenue can be increased by 8.909 million yuan, with a static investment recovery period of less than 1 year;At the same time, each year can reduce SO2emissions 2 158.9 t,NOx emissions 2 251.3 t, dust emissions 438.7 t, CO2emissions 57 613.4 t, reduce carbon emissions 15 712.7t, energy saving and emission reduction effect is obvious. If the operation of the thermal power plant back pressure unit can meet the needs of all heat users in the industrial park at any time, the recovery of flue gas waste heat can reduce the boiler main steam output, in the boiler 100% BMCR and 80% BMCR load conditions can save coal( design coal)1 139.4 kg/h, 829.4 kg/h, fuel comprehensive thermal efficiency increased by 2.63%,2.35%; annual expenditure can be saved 2.037 million yuan, SO2, NOx, dust, CO2, carbon emissions reductions were 697.0 t, 726.8 t,141.6 t, 4 474.4 t, 1 220.3 t.If the back pressure machine is used to drive the motor or screw power generation technology and other thermal power cogeneration methods, the heat of the back pressure exhaust steam required to heat the desalting water from the ambient temperature to the ultra low temperature economizer inlet temperature of about 75 °C is stepped, deeply and rationally utilized. Under the 100% BMCR and 80% BMCR load conditions of the boiler, the power generation power can be increased by 1 631.3 kW and 1 186.1 kW through the thermal power cogeneration device, respectively. Increase heating steam mass flow6 243.0 kg/h, 4 462.2 kg/h or save the amount of coal( design coal) 719.4 kg/h, 521.1 kg/h, fuel integrated thermal efficiency increased by more than 1.39%, the annual income of 7.914 million yuan or save spending3.584 million yuan;At the same time, the annual reduction of SO2emissions 2 553.6 t, 1 632.4 t, NOx emissions 2 662.9 t, 1 702.2 t, dust emissions 518.9 t, 2 374.4 t, CO2emissions 41 653.3 t, 8 166.6 t, carbon emissions 11 360.0 t, 2 227.3 t, energy saving and carbon reduction effect is more obvious, more significant economic, ecological and social benefits.The operation practice of the thermal power plant for more than 5 years has proved that increasing heat supply and saving coal are integrated, and the actual income and expenditure are between the two. At the same time, according to the actual situation of the site, the problems of corrosion, wear and ash accumulation in the operation of the ultra low temperature economizer are continuously improved. The thermal power plant selects reasonable flue gas velocity considering different boiler load conditions, optimizes the heat exchange tube structure of the ultra low temperature economizer, proposes and implements the control of the inlet water temperature and outlet flue gas temperature of the ultra low temperature economizer, and increases the automatic control and protection logic circuit. A row of anti-wear false tubes is set on the upper part of the ultra low temperature economizer and an anti-wear tile is set on the first three rows of heat exchange tubes, which has achieved good results. It provides practical reference and practical evidence for the optimization design and improvement of flue gas waste heat deep recovery and utilization of coal-fired back pressure units.

     

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