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Article(id=1213164444016890782, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1213164438232941220, articleNumber=null, orderNo=null, doi=10.19666/j.rlfd.202308130, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1691769600000, receivedDateStr=2023-08-12, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1767170542958, onlineDateStr=2025-12-31, pubDate=1711296000000, pubDateStr=2024-03-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1767170542958, onlineIssueDateStr=2025-12-31, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1767170542958, creator=13701087609, updateTime=1767170542958, updator=13701087609, issue=Issue{id=1213164438232941220, tenantId=1146029695717560320, journalId=1210938733613449225, year='2024', volume='53', issue='3', pageStart='1', pageEnd='182', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1767170541580, creator=13701087609, updateTime=1767775374880, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1215701293012796069, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1213164438232941220, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1215701293012796070, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1213164438232941220, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=153, endPage=160, ext={EN=ArticleExt(id=1213164444234994596, articleId=1213164444016890782, tenantId=1146029695717560320, journalId=1210938733613449225, language=EN, title=Numerical simulation and experimental research on oil sludge co-firing in a 330 MW pulverized-coal boiler at low load condition, columnId=1211002409397129992, journalTitle=Thermal Power Generation, columnName=Power generation technology forum, runingTitle=null, highlight=null, articleAbstract=

A method was proposed to solve the problem of oil sludge treatment environmentally by sending the pretreated oil sludge into a 330 MW pulverized coal boiler co-firing with coal. The combustion characteristics of the oil sludge were studied by thermogravimetric analysis, and it was proved to be easy to ignite with a high calorific value close to coal, which could improve the boiler’s low-load stable combustion ability. Numerical simulation results showed that the combustion center shifted downward slightly after the oil sludge was sent into the boiler, while the NOx content decreased. The experimental results proved that the minimum stable combustion load rate can be 20.00% by the benefit of oil sludge co-firing. The temperature at the coal-burner layer increased by 30~50 ℃ and the carbon content of the fly ash decreased from 4.79% to 3.80%. The fire detection analog signal of the coal burner was found to be more stable which validated the positive effect of the oil sludge co-firing at low load condition. The boiler efficiency increased by 0.23 percentage point which reduced the net coal consumption rate by 0.7 g/(kW·h). Moreover, about 3.7 t/h coal was saved at 120 MW load. The method was verified to have a significant energy-saving effect.

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针对含油污泥的无害化处置问题，提出预处理后送入煤粉锅炉与煤粉耦合燃烧的技术路线，在330 MW机组四角切圆锅炉上做了改造，并进行了含油污泥的热重分析及含油污泥入炉后的数值模拟，开展了油污泥入炉低负荷稳燃试验。结果表明：含油污泥具有易着火且热值接近动力煤的特点，可提高锅炉低负荷稳燃能力；含油污泥入炉后火焰中心略微下移，排放的烟气NOx量有所降低；锅炉最低稳燃负荷率可低至20.00%，对应燃烧器层炉膛温度上升30~50 ℃，煤粉燃烧器火检信号更稳定，飞灰含碳量从4.79%降至3.80%，证明了油污泥对低负荷工况下煤粉燃烧的促进作用；120 MW负荷下含油污泥入炉后，锅炉效率提高约0.23百分点，可降低供电煤耗率约0.7 g/(kW·h)，含油污泥热值可替代标准煤约3.7 t/h，节能效果显著。

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张光学（1982），男，博士，教授，主要研究方向为计算流体力学和燃料的高效清洁利用，。
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张海丹（1989），男，博士，高级工程师，主要研究方向为锅炉燃烧调整、生物质耦合等，。

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张海丹（1989），男，博士，高级工程师，主要研究方向为锅炉燃烧调整、生物质耦合等，。

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张海丹（1989），男，博士，高级工程师，主要研究方向为锅炉燃烧调整、生物质耦合等，。

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figureFileBig=AFmnSSok3Dpu8E05Icsz4Q==, tableContent=null), ArticleFig(id=1213164452078342468, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=图2, caption=油污泥、0号柴油、常用煤失重速率（DTG）曲线, figureFileSmall=nbRU2IpBOH765T1NOoZYCg==, figureFileBig=AFmnSSok3Dpu8E05Icsz4Q==, tableContent=null), ArticleFig(id=1213164452162228559, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=EN, label=Fig.3, caption=Schematic diagram of the oil sludge feeding system, figureFileSmall=ZE7Ewlc2hxX3b5LWbJNHYA==, figureFileBig=AHG6GFP2TUE6s4LtdsVu/g==, tableContent=null), ArticleFig(id=1213164452271280469, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=图3, caption=油污泥入炉系统示意

1—油污泥输送泵；2—油污泥母管隔离阀；3—油污泥回油阀；4—1号角进油污泥前隔离阀；5—1号角进油污泥后隔离阀；6—2号角进油污泥前隔离阀；7—2号角进油污泥后隔离阀；8—3号角进油污泥前隔离阀；9—3号角进油污泥后隔离阀4；10—4号角进油污泥前隔离阀；11—4号角进油污泥后隔离阀。

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Compositional analysis of pretreated oil sludge

, figureFileSmall=null, figureFileBig=null, tableContent=
样品工业分析/%Qnet,ar/(kJ·kg–1)元素分析/%
war(M)war(A)war(V)war(FC)war(C)war(H)war(N)wt,ar(S)war(O)
油污泥12.410.465.012.218 00055.65.30.50.215.7
), ArticleFig(id=1213164453642817967, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=表1, caption=

预处理后油污泥成分分析

, figureFileSmall=null, figureFileBig=null, tableContent=
样品工业分析/%Qnet,ar/(kJ·kg–1)元素分析/%
war(M)war(A)war(V)war(FC)war(C)war(H)war(N)wt,ar(S)war(O)
油污泥12.410.465.012.218 00055.65.30.50.215.7
), ArticleFig(id=1213164453709926836, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=EN, label=Tab.2, caption=

Quality analysis for designed and calibrated coal

, figureFileSmall=null, figureFileBig=null, tableContent=
项目工业分析/%Qnet,ar/(kJ·kg–1)元素分析/%
war(M)war(A)wdaf(V)war(FC)war(C)war(H)war(N)wt,ar(S)war(O)
设计煤种12.014.036.047.423 00060.03.51.00.88.7
校核煤种20.022.039.041.521 00054.03.61.00.98.5
), ArticleFig(id=1213164453798007225, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=表2, caption=

设计煤种和校核煤种煤质分析

, figureFileSmall=null, figureFileBig=null, tableContent=
项目工业分析/%Qnet,ar/(kJ·kg–1)元素分析/%
war(M)war(A)wdaf(V)war(FC)war(C)war(H)war(N)wt,ar(S)war(O)
设计煤种12.014.036.047.423 00060.03.51.00.88.7
校核煤种20.022.039.041.521 00054.03.61.00.98.5
), ArticleFig(id=1213164453894476220, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=EN, label=Tab.3, caption=

Low load test conditions

, figureFileSmall=null, figureFileBig=null, tableContent=
试验工况实际负荷/MW总煤量/(t·h–1)油污泥量/(t·h–1)磨煤机组合
工况112056无B、C、D
工况21205110B、C、D
工况3684010B、C
), ArticleFig(id=1213164454003528129, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=表3, caption=

低负荷试验工况

, figureFileSmall=null, figureFileBig=null, tableContent=
试验工况实际负荷/MW总煤量/(t·h–1)油污泥量/(t·h–1)磨煤机组合
工况112056无B、C、D
工况21205110B、C、D
工况3684010B、C
), ArticleFig(id=1213164454125162955, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=EN, label=Tab.4, caption=

Quality analysis for the test coal

, figureFileSmall=null, figureFileBig=null, tableContent=
项目工业分析/%Qnet,ar/(kJ·kg–1)元素分析/%
war(M)war(A)wdaf(V)war(FC)war(C)war(H)war(N)wt,ar(S)war(O)
数值12.415.344.740.05 18055.73.931.070.6310.9
), ArticleFig(id=1213164454234214863, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=表4, caption=

试验煤种煤质分析

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项目工业分析/%Qnet,ar/(kJ·kg–1)元素分析/%
war(M)war(A)wdaf(V)war(FC)war(C)war(H)war(N)wt,ar(S)war(O)
数值12.415.344.740.05 18055.73.931.070.6310.9
), ArticleFig(id=1213164454355849683, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=EN, label=Tab.5, caption=

Damper opening of the secondary air

, figureFileSmall=null, figureFileBig=null, tableContent=
项目SOFA4燃尽风SOFA3燃尽风SOFA2燃尽风SOFA1燃尽风OFA燃尽风EF二次风E燃烧器周界风DE二次风
数值10010010010090501210
项目D周界风CD二次风C周界风BC二次风B周界风AB二次风A燃烧器周界风AA二次风
数值1410301030101250
), ArticleFig(id=1213164454477484506, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=表5, caption=

二次风小风门挡板开度

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项目SOFA4燃尽风SOFA3燃尽风SOFA2燃尽风SOFA1燃尽风OFA燃尽风EF二次风E燃烧器周界风DE二次风
数值10010010010090501210
项目D周界风CD二次风C周界风BC二次风B周界风AB二次风A燃烧器周界风AA二次风
数值1410301030101250
), ArticleFig(id=1213164455718998496, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=EN, label=Tab.6, caption=

Operating parameters of the boiler

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项目工况1工况2工况3
机组负荷/MW12012068
总煤量/(t·h–1)565140
总风量/(t·h–1)714715650
一次风比例/%26.828.122.3
二次风比例/%73.271.977.7
热一次风温度/℃252251247
热二次风温度/℃246245240
油污泥量/(t·h–1)08~108~10
主蒸汽流量/(t·h–1)301297175
主/再热蒸汽温度/℃425/407414/402402/384
主/再热蒸汽压力/MPa7.10/1.576.70/1.524.10/1.52
A/B侧原烟气NOx质量浓度（φ(O2)=6%）/(mg·m–3)425376343
A/B侧脱硝反应器进口烟气温度/℃283282273
A/B侧脱硝反应器进口氧量/%6.77.311.4
A/B侧空气预热器出口温度/℃121116109
), ArticleFig(id=1213164455815467493, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=表6, caption=

炉侧运行参数

, figureFileSmall=null, figureFileBig=null, tableContent=
项目工况1工况2工况3
机组负荷/MW12012068
总煤量/(t·h–1)565140
总风量/(t·h–1)714715650
一次风比例/%26.828.122.3
二次风比例/%73.271.977.7
热一次风温度/℃252251247
热二次风温度/℃246245240
油污泥量/(t·h–1)08~108~10
主蒸汽流量/(t·h–1)301297175
主/再热蒸汽温度/℃425/407414/402402/384
主/再热蒸汽压力/MPa7.10/1.576.70/1.524.10/1.52
A/B侧原烟气NOx质量浓度（φ(O2)=6%）/(mg·m–3)425376343
A/B侧脱硝反应器进口烟气温度/℃283282273
A/B侧脱硝反应器进口氧量/%6.77.311.4
A/B侧空气预热器出口温度/℃121116109
), ArticleFig(id=1213164455916130792, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=EN, label=Tab.7, caption=

Boiler efficiency calculation

, figureFileSmall=null, figureFileBig=null, tableContent=
项目工况1工况2
排烟温度/℃121.00116.00
飞灰含碳量/%4.793.80
干烟气热损失/%5.505.51
燃料燃烧生成水蒸气的热损失/%0.290.31
燃料固有水蒸气热损失/%0.100.10
空气中水蒸气的热损失/%0.120.12
气体未完全燃烧热损失/%0.010.01
固体未完全燃烧热损失/%1.200.94
锅炉散热损失/%0.380.38
灰渣物理显热损失/%0.120.12
其他热损失/%0.350.35
外来热源占比/%－0.02－0.02
实测锅炉效率/%91.9092.13
), ArticleFig(id=1213164456033571312, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1213164444016890782, language=CN, label=表7, caption=

锅炉效率计算

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项目工况1工况2
排烟温度/℃121.00116.00
飞灰含碳量/%4.793.80
干烟气热损失/%5.505.51
燃料燃烧生成水蒸气的热损失/%0.290.31
燃料固有水蒸气热损失/%0.100.10
空气中水蒸气的热损失/%0.120.12
气体未完全燃烧热损失/%0.010.01
固体未完全燃烧热损失/%1.200.94
锅炉散热损失/%0.380.38
灰渣物理显热损失/%0.120.12
其他热损失/%0.350.35
外来热源占比/%－0.02－0.02
实测锅炉效率/%91.9092.13
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330 MW机组煤粉锅炉耦合油污泥低负荷燃烧数值模拟与试验研究
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张海丹 1, 2 , 张凡志 3 , 方仙明 3 , 梁震 3 , 张光学 4
热力发电 | 发电技术论坛 2024,53(3): 153-160
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热力发电 | 发电技术论坛 2024, 53(3): 153-160
330 MW机组煤粉锅炉耦合油污泥低负荷燃烧数值模拟与试验研究
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张海丹1, 2 , 张凡志3, 方仙明3, 梁震3, 张光学4
作者信息
  • 1.浙江浙能技术研究院有限公司，浙江　杭州　311121
  • 2.浙江省火力发电高效节能与污染物控制技术研究重点实验室，浙江　杭州　311121
  • 3.浙江浙能电力股份有限公司台州发电厂，浙江　台州　318016
  • 4.中国计量大学能源工程研究所，浙江　杭州　310018

    • 张海丹（1989），男，博士，高级工程师，主要研究方向为锅炉燃烧调整、生物质耦合等，。

通讯作者:

张光学（1982），男，博士，教授，主要研究方向为计算流体力学和燃料的高效清洁利用，。
Numerical simulation and experimental research on oil sludge co-firing in a 330 MW pulverized-coal boiler at low load condition
Haidan ZHANG1, 2 , Fanzhi ZHANG3, Xianming FANG3, Zhen LIANG3, Guangxue ZHANG4
Affiliations
  • 1.Zhejiang Energy R&D Institute Co., Ltd., Hangzhou 311121, China
  • 2.Zhejiang Key Laboratory of Energy Conservation & Pollutant Control Technology for Thermal Power, Hangzhou 311121, China
  • 3.Taizhou Power Plant of Zhejiang Zheneng Electric Power Co., Ltd., Taizhou 318016, China
  • 4.Institute of Energy Engineering, China Jiliang University, Hangzhou 310018, China
出版时间: 2024-03-25 doi: 10.19666/j.rlfd.202308130
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摘要
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针对含油污泥的无害化处置问题，提出预处理后送入煤粉锅炉与煤粉耦合燃烧的技术路线，在330 MW机组四角切圆锅炉上做了改造，并进行了含油污泥的热重分析及含油污泥入炉后的数值模拟，开展了油污泥入炉低负荷稳燃试验。结果表明：含油污泥具有易着火且热值接近动力煤的特点，可提高锅炉低负荷稳燃能力；含油污泥入炉后火焰中心略微下移，排放的烟气NOx量有所降低；锅炉最低稳燃负荷率可低至20.00%，对应燃烧器层炉膛温度上升30~50 ℃，煤粉燃烧器火检信号更稳定，飞灰含碳量从4.79%降至3.80%，证明了油污泥对低负荷工况下煤粉燃烧的促进作用；120 MW负荷下含油污泥入炉后，锅炉效率提高约0.23百分点，可降低供电煤耗率约0.7 g/(kW·h)，含油污泥热值可替代标准煤约3.7 t/h，节能效果显著。

含油污泥  /  锅炉  /  耦合燃烧  /  低负荷稳燃

A method was proposed to solve the problem of oil sludge treatment environmentally by sending the pretreated oil sludge into a 330 MW pulverized coal boiler co-firing with coal. The combustion characteristics of the oil sludge were studied by thermogravimetric analysis, and it was proved to be easy to ignite with a high calorific value close to coal, which could improve the boiler’s low-load stable combustion ability. Numerical simulation results showed that the combustion center shifted downward slightly after the oil sludge was sent into the boiler, while the NOx content decreased. The experimental results proved that the minimum stable combustion load rate can be 20.00% by the benefit of oil sludge co-firing. The temperature at the coal-burner layer increased by 30~50 ℃ and the carbon content of the fly ash decreased from 4.79% to 3.80%. The fire detection analog signal of the coal burner was found to be more stable which validated the positive effect of the oil sludge co-firing at low load condition. The boiler efficiency increased by 0.23 percentage point which reduced the net coal consumption rate by 0.7 g/(kW·h). Moreover, about 3.7 t/h coal was saved at 120 MW load. The method was verified to have a significant energy-saving effect.

oil sludge  /  boiler  /  co-firing  /  low load stable combustion
张海丹, 张凡志, 方仙明, 梁震, 张光学. 330 MW机组煤粉锅炉耦合油污泥低负荷燃烧数值模拟与试验研究. 热力发电, 2024 , 53 (3) : 153 -160 . DOI: 10.19666/j.rlfd.202308130
Haidan ZHANG, Fanzhi ZHANG, Xianming FANG, Zhen LIANG, Guangxue ZHANG. Numerical simulation and experimental research on oil sludge co-firing in a 330 MW pulverized-coal boiler at low load condition[J]. Thermal Power Generation, 2024 , 53 (3) : 153 -160 . DOI: 10.19666/j.rlfd.202308130
正文
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浙江省沿海地区的工业企业、港口、油罐、加油站、船舶等在清仓、清理过程中会掺烧大量的含油污泥及含油废水，本文研究对象主要是石油炼制、油罐清理过程中产生的含油污泥。我国已明确将这类含油污泥定义为危险废物，危险废物代码主要为废矿物油和含矿物油废物（HW08）[1]。这类含油污泥主要由乳化油、水、固体悬浮物等混合而成，具有危害大、处理难度高、处理时效性强等特点[2]。由于含油污泥成分复杂，没有任何一种处置方法可以处理所有类型的含油污泥[3-6]。目前，我国的油污泥处置方法主要有机械分离[7]、热解[8]、热化学清洗[9]、电化学处理[10]、脱水法[11]、生物处理[12]以及焚烧法[13]这几种。焚烧法作为热处理法的一种，是一种高效的含油污泥减量化技术，可以将含油污泥中的石油资源转化为热能[14]，通常具有处理效率高、场地要求低等特点，但需对焚烧过程中产生的废气、废渣做进一步处理[15]。
国内外已有很多学者通过热重或热重红外联用等技术在实验室对油污泥的热解、燃烧过程展开研究，同时也分析了含油污泥与煤、半焦等燃料的混合燃烧特性[16]。宋薇等[17]分析了油污泥的热解机理，提出油污泥的热解过程主要包括水分挥发、轻质油挥发、重质油热解、半焦炭化与矿物质分解5种反应；谢磊等[18]通过热重分析研究了含油污泥的热解反应动力学，并分析了粒径的影响；周雄等[19]通过热重-红外联用（FTIR）研究含油污泥在N2/CO2气氛下的热解特性；吉树鹏等[20]分析了不同配比下油污泥和煤混合燃料的挥发份析出特性、着火特性和燃尽性能，结果表明随油污泥比例增加，燃料的着火、燃尽温度逐渐降低，油污泥比例为40%时稳燃特性最好；赵瑞东等[21]通过热重-红外联用研究了低阶煤热解半焦与油污泥混合燃料的燃烧特性，试验表明油污泥的加入可以改善低挥发分的煤半焦着火，但另一方面也促进了NOx的生成。
油污泥与其他燃料耦合燃烧技术在国内有一些小规模应用[22]。贾勇军等[23]制定了含油污泥无害化处置方案，在4 t/h工业锅炉上完成了含油污泥与煤的掺烧试验；赵帅等[24]将含油污泥与水、煤粉和分散剂混合制备含油污泥煤浆，并以水煤浆为参考，研究了掺配含油污泥对水煤浆浆体性能及燃烧性能的影响；林炳丞等[25]在小型流化床试验台上将含油污泥与煤混烧，试验结果表明油污泥在小型流化床上的燃烧不充分，导致CO排放质量浓度以及飞灰含碳量偏高；张文武等[26]将高水分的含油污泥雾化后送入220 t/h容量的煤粉锅炉中燃烧，分析了含水率的影响以及锅炉效率的变化。上述研究主要用于小容量的工业锅炉中，且部分燃料的指标更接近于传统污泥[27]，相比燃煤电厂常规的污泥掺烧，本文研究对象为含油污泥。其燃烧特性与污泥完全不同，将经过预处理的含油污泥送入330 MW机组煤粉锅炉中与煤粉耦合燃烧，达到危废无害化处置的目的，同时也高效利用了油污泥的热值，提高锅炉低负荷稳燃能力，满足深度调峰需求。
1　油污泥燃料特性
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对预处理后的油污泥进行取样化验，按动力煤元素分析及工业分析标准分析了其燃料成分，结果见表1。预处理后油污泥挥发分质量分数极高，计算其干燥无灰基挥发分Vdaf质量分数达到84.2%左右，判断其具有易着火、易燃尽的特点。收到基灰分约为10.4%，可见预处理工艺中已将大部分固体油污泥渣去除，最终送入炉膛的为燃烧特性较好的液态油污泥。
为进一步了解预处理后油污泥的燃烧特性，对油污泥样品进行热重分析，并与0号柴油以及电厂常用烟煤进行对比，燃料的失重（TG）曲线和失重速率（DTG）曲线如图1和图2所示。采用美国EPA2050B标准消解法测定油污泥燃烧产生的灰渣中重金属含量，所有重金属元素浸出质量浓度均低于《危险废物鉴别标准浸出毒性鉴别》（GB 5085.3—2007）。因此，燃煤锅炉掺烧含油污泥后产生飞灰不属于危废范畴，不会影响飞灰品质。
从图1中可以看出，预处理后油污泥失重曲线与柴油更接近，与常用煤相比失重曲线显著提前。相比0号柴油，油污泥成分更复杂，含有较多重质烃类以及固定碳，因此图2中有多处失重峰，对应温度分别为159、177、323、455 ℃，其中159 ℃和177 ℃处的失重峰最为突出，相比0号柴油的失重峰（231 ℃）更为提前，可以认为油污泥的着火点甚至比0号柴油更低，但是燃尽时间更长，油污泥的燃尽温度约为500 ℃，而0号柴油在300 ℃之前已基本燃烧完全。根据油污泥热值接近动力煤，着火温度低的特点，考虑将其作为锅炉低负荷运行的替代燃料，提高锅炉低负荷运行稳燃特性，同时达到节省燃煤的节能效果。
2　研究对象
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2.1　锅炉概况
本文研究对象为1台330 MW机组亚临界四角切圆锅炉，设计煤种为烟煤。锅炉采用一次中间再热、单炉膛、燃烧器摆动调温、平衡通风、固态排渣、全钢悬吊结构、半露天布置。炉膛上部布置墙式再热器和大节距的过热器分隔屏和后屏，炉膛折焰角上方布置屏式再热器，水平烟道处布置了末级再热器和末级过热器。尾部烟道转向室内布置立式低温过热器，下部布置水平低温过热器和省煤器。锅炉设计煤种和校核煤种均为烟煤，煤质参数见表2。磨煤机采用正压直吹碗式中速磨煤机，主燃烧器区域配置5层（A—E）共20只双尺度低NOx燃烧器。上层燃烧器上方布置1层燃尽风（OFA）和4层分离型燃尽风（SOFA）。
2.2　油污泥入炉系统
为达到油污泥与煤粉耦合燃烧的目的，对炉膛主燃烧器区域进行油污泥入炉改造，将预处理后的油污泥分为4路同时送入炉膛的4个角，高度方向上位于C、D层燃烧器中间的二次风喷口处。图3为改造后油污泥入炉系统以及油枪位置示意。该系统设计年处理油污泥5万t，满负荷工况下处置油污泥热量可占锅炉总输入热量5%左右。
进厂油污泥经过筛分、调剂、过滤、沉降等一系列预处理工艺后，将其中高热值液态部分贮存在油污泥日用罐中。整个油污泥储存、输送系统通过伴热装置维持温度在80 ℃，降低油污泥黏度，满足正常流动需求。油污泥输送系统通过2台并联的油污泥泵（1用1备）将物料输送至炉膛的4个角。油污泥母管安装了油压及流量测量装置，实时监测油污泥压力及流量。油污泥枪采用压缩空气雾化方式将油污泥雾化后送入炉膛燃烧，其雾化粒径、喷嘴大小采用特殊设计，以保证油污泥的流动性。该系统配置了回油管路以及蒸汽吹扫，防止管道堵塞。
3　数值模拟
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采用Ansys Fluent 2019 R3软件平台对锅炉掺烧油污泥的低负荷工况进行数值模拟，主要研究掺烧油污泥前后炉膛温度、氧量以及NOx质量浓度变化。首先利用Fluent meshing软件划分为多面体网格，几何模型及网格如图4所示。
根据网格无相关性试验，最终确定网格数量为267万，锅炉燃烧器喷口布置如图5所示。采用Realizable k-ε模型计算气相湍流；煤粉颗粒及油污泥液滴的运动、传热及燃烧过程采用双向耦合的离散相模型（DPM），其中挥发分析出采用双方程竞争模型，焦炭表面燃烧采用扩散/动力控制模型；考虑三原子气体的辐射效应、颗粒与气体之间的辐射换热，炉内高温辐射采用DO模型。气相燃烧采用非预混燃烧（PDF）模型，燃料为煤、油污泥。求解器中压力-速度耦合方式采用基于压力的SIMPLE算法，对流项采用二阶迎风离散格式，并采用亚松弛的方式加强计算稳定性，迭代至能量及辐射方程残差低于10–6，其余方程残差低于10–3为止。
数值模拟共分3个工况：1）120 MW不投油污泥工况；2）120 MW投油污泥工况；3）投油污泥70 MW最低稳燃负荷工况。工况设置与后续低负荷油污泥掺烧试验对应。
图6、图7分别代表3个工况下的炉膛温度和NOx分布计算结果。模拟结果表明，工况2掺烧了油污泥，主燃区燃煤量减少了5 t/h，火焰中心与工况1相比略微下移，故高温燃烧产物在还原区停留时间增加，同时高温区面积也相应减小，最终使工况2生成的NOx质量浓度降低至376 mg/m3（标准状态，下同），而未掺烧油污泥的工况1生成的NOx质量浓度则为401 mg/m3。工况3机组负荷进一步降至70 MW时，主燃区高温区面积变得非常小，相应生成的NOx质量浓度降至336 mg/m3，不过燃烧器区域温度仍正常，可维持稳定燃烧。数值模拟的计算结果为低负荷下油污泥对燃烧的促进作用提供了依据，相关参数可与后续低负荷试验数据做对比。
4　低负荷稳燃试验
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4.1　试验工况
为验证低负荷工况下数值模拟的计算结果，研究油污泥入炉燃烧对低负荷燃烧稳定性、经济性的实际影响，探索掺烧油污泥后锅炉的不投油稳燃极限，开展了油污泥入炉低负荷稳燃试验。试验工况与上节数值模拟工况相同，实际负荷、各工况下的燃料比例以及磨煤机组合见表3。试验内容主要有炉膛温度测量，飞灰、炉渣含碳量检测，锅炉运行参数对比等。试验期间工况1与工况2锅炉均采用B、C、D磨煤机组合运行，工况3在减负荷过程中煤量持续下降后，停运D磨煤机，采用B、C磨煤机组合运行。试验所用煤种煤质指标见表4，干燥无灰基挥发分wdaf(V)达到44.7%，着火特性较好。试验所用油污泥化验低位发热量在5 180 kJ/kg左右。各工况下二次风小风门挡板开度保持不变，为了降低低负荷下烟气NOx质量浓度，燃尽风保持全开，主燃烧器区域二次风挡板开度设置较低，二次风挡板设置见表5。
4.2　试验结果
4.2.1　锅炉侧主要运行参数
试验期间锅炉侧主要运行参数见表6。工况2与工况3试验期间投油污泥，因投料期间油压一直无法稳定，显示油污泥流量在8~10 t/h波动，导致锅炉运行参数同步波动，锅炉侧运行参数为一段时间内的平均值。根据试验结果，认为工况3达到最低稳燃极限，负荷约为68 MW（对应负荷率约20.00%），该工况下炉膛燃烧稳定，锅炉可正常稳定运行，但受限于脱硝进口温度过低，两侧平均值仅271.5 ℃，为满足环保要求，不再继续降低负荷。对比工况1和工况2，掺烧油污泥后NOx质量浓度从425 mg/m3降至376 mg/m3，与数值模拟结果一致。还有一部分原因可能是油污泥燃料含氮量低，替代燃煤后生成的燃料型NOx有所减少。
4.2.2　掺烧油污泥低负荷稳燃分析
试验期间测量了C层燃烧器、D层燃烧器、SOFA风下方以及屏式过热器下方4个高度位置的炉膛温度，同时观察燃烧器层煤粉气流着火情况，验证低负荷燃烧工况的安全性。图8为炉膛温度实测值与数值模拟结果对比。由图8可见，炉膛各截面的温度实测结果与数值模拟计算结果接近，对比工况1和工况2，在相同负荷下，掺烧油污泥后燃烧器C、D层的炉膛温度有所上升，上升幅度为30~50 ℃，屏式过热器下方位置炉膛温度差异不大。原因主要是投入油污泥虽然热值比燃煤低，但挥发分高，着火温度低，燃烧特性更接近油类燃料，油污泥与煤粉混合燃烧使着火提前，主燃烧区域温度上升。工况3机组负荷仅68 MW，同时D磨煤机停止运行，炉膛温度相比工况1与工况2显著降低，但就地观察火焰仍可保持正常稳定燃烧，炉膛温度可维持在1 000 ℃以上，满足低负荷稳燃的要求。
图9为1号角B、C层掺烧油污泥前后火检模拟量强度变化。由图9可见，120 MW负荷下（投油污泥后因油污泥流量波动，造成负荷波动）投油污泥前火检信号不太稳定，B层火检在90%~100%波动，C层火检在55%~68%波动；而掺烧油污泥后，B层火检基本稳定在100%，C层火检稳定在68%，波动频次显著减少。
综合分析掺烧油污泥前后的炉膛温度及火检强度变化，可得出掺烧油污泥可促进煤粉燃烧，加强着火稳定性，提高主燃区炉膛温度，降低锅炉稳燃极限，与数值模拟计算结果吻合。
4.2.3　掺烧油污泥低负荷经济性分析
1）提高锅炉效率。表7为工况1和工况2的实测锅炉效率。120 MW掺烧油污泥后实测锅炉效率为92.13%，相比掺烧油污泥前锅炉效率提高了约0.23百分点，降低供电煤耗率约0.7 g/(kW·h)。这是由于掺烧油污泥后，飞灰含碳量从4.79%降至3.80%，固体未完全燃烧热损失减少。
2）节省燃煤量。根据表6数据，120 MW负荷下掺烧油污泥后总煤量可降低约5 t/h（折算成标准煤约3.7 t/h）。这部分热值由入炉的油污泥替代。
3）带来油污泥处置费收入。含油污泥属于危险废弃物，一般每吨可获得上千元的处置费用。
5　结论
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本文提出将含油污泥经过预处理后送入330 MW机组煤粉锅炉中与煤粉耦合燃烧的技术路线，不仅可以利用电厂现有锅炉设备及配套的烟气净化系统达到危险废弃物无害化处置的目的，同时也利用油污泥易着火燃尽的特点，提高锅炉低负荷稳燃能力。
1）含油污泥具有较高热值、易着火的特点，可作为锅炉低负荷运行的替代燃料，提高锅炉低负荷稳燃特性。
2）根据现场试验结果，掺烧油污泥后机组最低稳燃负荷可低至20.00%左右，受限因素主要是脱硫系统反应器进口烟温过低。
3）低负荷掺烧油污泥后，对应的燃烧器层炉膛温度上升30~50 ℃，屏式过热器下方位置炉膛温度差异不大，煤粉火检信号更稳定。
4）120 MW负荷下，掺烧油污泥后锅炉效率提高约0.23百分点，可降低供电煤耗率约0.7 g/(kW·h)。油污泥热值可替代标准煤约3.7 t/h，同时考虑危废处置费收入，经济效益显著。
基金
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  • 浙能集团科技项目资助(ZNKJ-2022-015)
文献
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doi: 10.19666/j.rlfd.202308130
  • 接收时间：2023-08-12
  • 首发时间：2025-12-31
  • 出版时间：2024-03-25
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  • 收稿日期：2023-08-12
基金
Scientific and Technological Projects of Zheneng Group(ZNKJ-2022-015)
浙能集团科技项目资助(ZNKJ-2022-015)
作者信息
    1.浙江浙能技术研究院有限公司，浙江　杭州　311121
    2.浙江省火力发电高效节能与污染物控制技术研究重点实验室，浙江　杭州　311121
    3.浙江浙能电力股份有限公司台州发电厂，浙江　台州　318016
    4.中国计量大学能源工程研究所，浙江　杭州　310018

通讯作者:

张光学（1982），男，博士，教授，主要研究方向为计算流体力学和燃料的高效清洁利用，。
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https://castjournals.cast.org.cn/joweb/rlfd/CN/10.19666/j.rlfd.202308130
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2种不同金属材料的力学参数
科
Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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