Condensation heat transfer on tubes in actual flue gas (Parametric study for condensation behavior)

In order to improve boiler efficiency, latent heat recovery from the flue gas is a very important concept. Condensation heat transfer on horizontal tubes was investigated experimentally by using flue gas from a natural gas boiler. The parametric studies concerning the effects of tube stages, gas velocities, SO₂ in the flue gas, and Teflon‐lined tubes were conducted at a wide range of tube surface temperature. The heat transfer was enhanced at the second stage due to the wake turbulence of the first stage. No significant decrease of the condensation in the second stage due to the condensate falling from the first stage could be observed. Even at the high gas velocity condition, the condensation pattern was similar to that observed in previous low gas velocity experiments. The effect of SO₂ in the flue gas on the condensation behavior could not be observed. The heat and mass transfer behaviors on stainless‐steel and Teflon‐lined surfaces were well predicted with the analogy correlation. The above results suggested that the heat and mass transfer were dominated by the convection and diffusion process on the gas side. © 2003 Wiley Periodicals, Inc. Heat Trans Asian Res, 32(2): 153–166, 2003; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.10079     

An experimental study on vapor condensation of wet flue gas in a plastic heat exchanger

An experimental system investigating condensation heat transfer of wet flue gas was set up, and the heat transfer performance of vapor‐gas mixture with vapor condensation was discussed. The experimental results of laminar flow in a plastic longitudinal spiral plate heat exchanger were obtained and are in good agreement with the modified classical film model. It is shown that the plastic air preheater can avoid acid corrosion in the low‐temperature field for the boiler using fuel containing sulfur and recover latent heat of the water vapor of the wet flue gas. Also some SO₂ was scrubbed during the vapor condensing process in the heat exchanger. © 2001 Scripta Technica, Heat Trans Asian Res, 30(7): 571–580, 2001     

低温烟气凝结换热及对天然气热效率的影响实验研究

为研究烟气露点附近及以下的低温烟气对流凝结换热规律与烟气换热对天然气利用热效率的影响,建立了烟气在翅片管换热器内对流凝结换热实验系统,研究了不同烟气温度、水蒸气含量对烟气凝结换热的影响,得出了烟气凝结换热实验准则关联式,分析对比了天然气利用热效率实验值与理论值.实验结果表明:当被加热水温度为23℃,烟气出口温度为73℃...     

增压富氧煤燃烧烟气凝结换热的计算

针对含有少量水蒸气的增压富氧煤燃烧产生的烟气在竖直管内的对流凝结换热进行了分析研究.利用修正的膜模型与Nusselt凝结理论建立了换热数学模型,并对不同壁面温度、不同雷诺数和不同水蒸气份额下烟气的凝结换热进行了计算.结果表明:壁面温度升高时,烟气的凝结速率、换热流率和凝结液膜的厚度均减小;混合气体的雷诺数增大时,烟气的凝结速率和换热流率增大,凝结液膜的厚度减小;烟气中水蒸气的份额减小时,烟气的凝结速率和换热流率减小,凝结液膜的厚度减小不明显.     

Analysis of two‐stage waste heat recovery based on natural gas‐fired boiler

Waste heat recovery (WHR) is crucial to the efficiency improvement of natural gas‐fired boiler systems. Two‐stage WHR systems based on the natural gas‐fired boiler were analyzed from the viewpoints of thermal efficiency and heat transfer irreversibility. An overall entransy dissipation‐based thermal resistance was derived to evaluate the irreversibility of WHR, including the entransy dissipations during condensation and in absorption heat pump (AHP). Compared with the basic WHR system, the two‐stage WHR systems have higher boiler efficiency and less irreversibility. The air‐humidified system recycles both the heat and vapor in flue gas, while the unutilized latent heat in the recovered vapor causes the boiler to be less efficient than the AHP system. Investigation on heat exchanger effectiveness of two‐stage WHR systems illustrated: in the two‐stage WHR system with air humidification, the increasing effectiveness of both heat exchangers could effectively increase boiler efficiency and reduce heat transfer irreversibility. In the two‐stage WHR system with AHP, boiler efficiency has a local optimum when the dew point occurs near the outlet of the first heat exchanger; increasing the second heat exchanger effectiveness is more efficient in improving boiler efficiency. The present work may provide available references and guidance for the design and optimization of the two‐stage WHR systems.     

Heat transfer characteristics in a small-scale fluidized bed boiler

Heat transfer characteristics in a small-scale fluidized bed boiler (2MW_th) were studied using lignite and corn cob as fuels. Depending on air velocity, the heat transfer rates from bed to water membrane wall and from hot flue gas to convective tube bank were in the ranges 75–55% and 25–45% of the total heat absorbed by the boiler, respectively. At designed capacity, the heat transfer flux based on bed cross sectional area and on water membrane wall area were about 0·45 and 0·15 MWm⁻², respectively. Under the conditions studied, it was found that the overall heat transfer coefficient between bed and water membrane wall was 100–300 W m⁻² K⁻¹, whereas that between flue gas and convective tube bank was 10–30 Wm⁻² K⁻¹. The study of heat transfer to a horizontal tube immersed in the bed as well as placed in the freeboard region were also studied. The effective heat transfer coefficients were found to be 300–800 W m⁻² K⁻¹ for in-bed tube and 30–150 W m⁻² K⁻¹ for the freeboard region, depending on air velocity. Comparison of these data with those predicted by both modelling and correlation reported in the literature was also made. For the immersed tube, good agreement was observed for low air velocity, while at high air velocity the experiment produced results twice those estimated from modelling and correlation. For the freeboard region, the model gave a fair prediction.     

燃煤锅炉三维CFD数值模型水冷壁热边界条件设定方法

目前,燃煤锅炉三维CFD数值模拟中对炉膛水冷壁传热分布的预测大都基于给定的壁面温度边界条件。然而,此方法无法体现锅炉运行状态对壁面传热与壁温分布的影响。提出了一种基于锅炉烟气侧放热与汽水侧吸热间热平衡关系的壁面传热计算方法,并重点讨论了壁面传热系数的物理意义及取值方法。研究发现,壁面传热系数基本由壁面结渣状态决定,因此可根据壁面渣层的传热系数确定。本文方法将影响壁面传热的关键因素合理地体现在计算过程中,同时在模型复杂性与工程适用性之间保持了合理的平衡。采用此方法对一台320 MW锅炉的燃烧与传热分布进行了数值模拟,水冷壁吸热量的预测结果与锅炉运行数据吻合良好。     

Modelling and analyses of heat exchangers in a biomass boiler plant

A boiler plant is presented, in which the fuel is dried before combustion in a silo with air. The drying air is heated in a recuperative heat exchanger by the heat of flue gases. Hot air is then blown through the bed of fuel in the drying silo, while the fuel dries and the air cools down and becomes humidified. Heat of the moist exhaust air of the silo is recovered for the drying air and combustion air by a recuperative heat exchanger. Modelling of the thermal behaviour of the plant helps in understanding complex interdependencies of the two heat exchangers, the boiler and the dryer. The models of the heat exchangers and applications in analysing the boiler system are described in this paper. Calculating the combinations of extreme operational conditions gives the input data needed in comparing different types of heat exchangers, dimensioning the heat transfer area, choosing the control strategy and selecting the operating parameters and set‐values of the control system. Results of verification measurements and practical operation at a 40 kW_th pilot plant and a 500 kW_th demonstration plant are also discussed. Using engineering correlation formulas for heat and mass transfer, an adequate accuracy between the model and the measurements was achieved. Fouling was detected to be a major problem with the flue gas heat exchanger. However, in absence of condensation, the increase of a fouling layer with respect to time was observed to be low. Fouling was also a problem with the drying exhaust gas heat exchanger, but after the installation of a simple dust collector, a reasonable cleaning period was achieved. A mixed‐flow configuration was found to be the most appropriate for the flue gas heat exchanger. In order to avoid condensation of the flue gas the drying exhaust gas heat exchanger is indispensable in Finnish climate in the considered system. In addition to this, it decreases the need of fuel. A parallel‐flow type was found the most appropriate as the drying exhaust gas heat exchanger. Copyright © 2004 John Wiley & Sons, Ltd.     

燃气锅炉烟气在滴型管外传热特性的数值分析

在回收燃气锅炉烟气余热时,采用特殊管型强化传热以吸收烟气中大量的水蒸气所携带的显热和潜热,可以降低锅炉的排烟温度,提高锅炉的热效率。对滴型管和圆管烟气侧传热特性进行数值计算,通过对计算结果的分析比较,探讨了影响传热的因素,得出滴型管的传热特性优于圆管的结论,为特殊管型在冷凝换热器中的应用提供参考。     

有机热载体炉烟气余热回收技术浅析

长期以来,有机热载体炉排烟温度偏高,造成大量的能源浪费,严重影响了锅炉运行的经济性。为减少热能损失,对烟气余热回收技术的可行性方案、工程应用实例进行了阐述;并指出通过锅炉烟气余热利用技术回收排烟中的显热和潜热,可以大大提高有机热载体炉的热效率,实现节能降耗。     

燃气锅炉尾部烟气余热回收冷凝型节能器的实验研究

针对常规节能器不能有效回收燃气锅炉尾部烟气中水蒸气凝结所释放的汽化潜热、节能器系统阻力大等问题,介绍了一种低阻燃气锅炉尾部烟气余热回收冷凝型节能器的结构和实验研究情况,研究了液气比与锅炉排烟温度的关系、锅炉热效率与排烟温度的关系和节能器系统阻力与烟气流速的关系.     

分离式冷凝锅炉冷凝水处理方案设计

在分离式冷凝锅炉的换热装置系统中处理烟气中,处理冷凝水的方法通常是通过净化处理再利用。本文的分离式冷凝锅炉冷凝水处理方案是将冷凝水经系统处理作为锅炉的给水,将冷凝换热装置节约的能量直接反馈回锅炉,由于锅炉负荷的波动带来烟气温度与给水流量的变化,导致冷凝率不稳定,所以本文中采用理论方法计算冷凝水量。     

300MW循环流化床锅炉屏式受热面传热系数计算及其变化规律

根据300MW循环流化床（CFB）锅炉现场测试数据并结合以往CFB锅炉传热系数的研究成果,建立了屏式受热面烟气侧的传热模型,包括辐射传热模型和对流传热半经验公式．利用该模型对某300MWCFB锅炉在94％锅炉最大连续蒸发量（BMCR）工况下炉膛内屏式受热面的传热系数进行了计算,分析了屏式受热面管间节距、炉膛温度、工质温度、壁面黑度及烟气速度等因素对传热系数的影响．结果表明：烟气速度、炉膛温度和壁面黑度对传热系数的影响较大,所建立的传热模型能够合理地反映主要因素对CFB锅炉屏式受热面传热的影响．     

Evaluation of retrofitting a conventional natural gas fired boiler into a condensing boiler

The exit flue gas temperature of a conventional gas fired boiler is usually high and a great amount of heat energy is lost to the environment. If both sensible heat and latent heat can be recovered by adding a condensing heat exchanger, the efficiency of the boiler can be increased by as much as 10%. In this paper, based on combustion and heat transfer calculations, the recoverable heat and the efficiency improvement potential of different heat recovery schemes at various exit flue gas temperatures are presented by performing design calculations. The payback period method has been used to analyze the feasibility of retrofitting a conventional gas fired boiler into a condensing boiler in a heating system in detail. The results show that the most economical exit flue gas temperature is 40–55 °C when a conventional natural gas fired boiler is retrofitted into a condensing boiler simply by adding a condensing heat exchanger. It is feasible to use the return water of a heating system as the cooling medium of the condensing heat exchanger because the return temperature varies with the ambient temperature and is lower than the dew point of the water vapor in the flue gas in most periods of a heating season in some regions, which has been verified by retrofitted case.     

新型燃气锅炉尾部烟气余热回收节能器的应用研究

针对常规节能器不能有效回收燃气锅炉烟气中水蒸气凝结所释放的汽化潜热、系统阻力大等问题,介绍了一种新型低阻燃气锅炉尾部烟气余热回收节能器的结构和实际应用研究情况,分析了影响节能器换热效果的主要因素,研究了液气比与锅炉排烟温度的关系、锅炉热效率与排烟温度的关系和节能器系统阻力与烟气流速的关系.     

An Experimental Study on Latent Heat Recovery of Exhaust Wet Flue Gas

The experiment was conducted to investigate the heat transfer performance of wet flue gas in a vertical tube. The factors influencing the convective condensation of wet flue gas were experimentally investigated. The measured results indicate that the convective heat transfer of bulk flow and condensation heat transfer of vapor have significant contribution to the total heat transfer and the dominant transport mechanism is dependent upon the vapor fraction in mixture.     

含湿混合气体水平管外对流冷凝换热实验研究

回收烟气中的潜热和显热在提高锅炉效率和环境保护方面都具有重要意义。主要针对含湿混合气体在水平单管管外的对流冷凝换热进行了实验研究。通过对实验数据的分析，得到了烟气进口温度、冷却水进口温度、水蒸气的质量分数以及Re的变化对含湿混合气体在水平单管管外冷凝换热的影响。     

Techno-economic analysis of a novel hybrid heat pump system to recover waste heat and condensate from the low-temperature boiler exhaust gas

This paper is based on the proposal of a new waste heat recovery (WHR) system, which can be utilized to heat the boiler return water, boiler supply air, and building heating air. The system is the combination of an indirect contact condensing unit (IDCCU), a mechanical compression heat pump, and two air preheaters. The system is modeled on the basis of mass and energy balance and then thermodynamically analyzed. Improved performance results were obtained in the form of an increase in the boiler's energy efficiency of about 10.47%, with 4.87% increase in exergy efficiency. The coefficient of performance (COP) of the heat pump was increased from 1.23 to 1.45 by the addition of an air heater in the conventional heat pump. The exergy destruction in each component is calculated. Sensitivity analysis was performed to check the influence of different operating parameters on the performance of the WHR system and boiler. It can be observed from the results that for a specific refrigerant temperature and a calculated amount of mass, flow rate can maximize the condensation efficiency of IDCCU by decreasing the flue gas temperature, while the use of the air heater can further reduce the flue gas temperature, and a stream of hot air can be utilized for space heating. A comparison is made with the other system on a performance basis. The results shows a clear difference in efficiencies and profit earned.     

天然气热利用率及影响因素

用热力学理论和燃烧理论建立了天然气排烟温度与热利用率的计算模型,计算得出了天然气热利用率与排烟温度的关系曲线,可供实际工程参考.对影响天然气热利用率的因素(排烟温度、过剩空气系数和烟气冷凝温度)的主要影响因素(燃烧空气含湿量)进行了定量分析,提出了提高天然气热利用率的措施,可使天然气的热利用效率提高1000/~2000/.     

Consteel电炉余热锅炉的热平衡计算方法研究

针对Consteel电炉余热锅炉烟气入口参数不稳定的特点,得到了余热锅炉的各项热损失、锅炉效率、有效利用热量和蒸发量的计算公式。对65t Consteel电炉炼钢设备余热锅炉进行了热平衡计算,计算表明,锅炉的排烟热损失随烟气入口温度的降低而增加,而锅炉效率、有效利用热量和蒸发量随烟气入口温度的降低而降低,锅炉的平均蒸发量为23．1t／h。