Article(id=1236679388079641214, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1236679384321544791, articleNumber=null, orderNo=null, doi=10.19666/j.rlfd.202405100, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1715702400000, receivedDateStr=2024-05-15, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1772776942510, onlineDateStr=2026-03-06, pubDate=1735056000000, pubDateStr=2024-12-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1772776942510, onlineIssueDateStr=2026-03-06, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1772776942510, creator=13701087609, updateTime=1772776942510, updator=13701087609, issue=Issue{id=1236679384321544791, tenantId=1146029695717560320, journalId=1210938733613449225, year='2024', volume='53', issue='12', pageStart='1', pageEnd='160', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1772776941614, creator=13701087609, updateTime=1772777031740, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1236679762404504298, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1236679384321544791, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1236679762404504299, tenantId=1146029695717560320, journalId=1210938733613449225, issueId=1236679384321544791, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=112, endPage=119, ext={EN=ArticleExt(id=1236679388394214024, articleId=1236679388079641214, tenantId=1146029695717560320, journalId=1210938733613449225, language=EN, title=Deep recovery and optimization of waste heat and energy quality for coal-fired units, columnId=1211002405299294959, journalTitle=Thermal Power Generation, columnName=Thermal energy science research, runingTitle=null, highlight=null, articleAbstract=

In response to significant increase in energy consumption caused by low-grade waste heat and energy waste in coal-fired power plants, a 350 MW unit is selected as the research object, the Ebsilon software is used to model and simulate different deep recovery schemes for low-grated waste heat and residue. The operating data of the unit under two schemes of “organic Rankine cycle (ORC)” and “Heater” are calculated. The energy consumption characteristics, revenue characteristics and differences are analyzed, and the mechanism and optimization plan for deep recovery of waste heat and energy are obtained. The results show that, the energy consumption characteristics of the unit improve significantly under both schemes, and the “heater” scheme has lower energy consumption. As the organic working fluid flow rate increases, the power generation of the ORC system gradually increases, but the thermoelectric efficiency of the ORC system gradually increases at first and then tends to stabilize and has a downward trend, with a range of 6.94%~7.75%. The organic working fluid flow rate has a relatively small effect on circulation efficiency of the ORC system. Both schemes are technically and economically feasible. The “ORC” scheme can bring direct electricity benefits to the power plant, while the “Heater” scheme is slightly more economical.

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针对煤电机组低品位余热能质浪费问题,以某350 MW机组为研究对象,采用Ebsilon平台建模模拟研究不同的低品位余热能质深度回收方案,计算“有机朗肯循环(organic Rankine cycle,ORC)”和“加热器”2种方案对应机组运行数据,分析能耗特性、收益特性和差异性等,得到了余热能质深度回收的机理和优化方案。结果表明:2种方案下机组能耗特性均有明显提升,“加热器”方案能耗更低;随着有机工质流量增加,ORC系统发电量逐渐增大,ORC系统热电效率先逐渐增大后趋于平缓并有下降趋势,变化范围为6.94%~7.75%,有机工质流量对ORC系统循环效率影响较小;2种方案技术经济均可行,“ORC”方案可以为电厂带来直接电能收益,“加热器”方案经济性略好。

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邓佳(1990),女,硕士,高级工程师,主要研究方向为热能动力工程,

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邓佳(1990),女,硕士,高级工程师,主要研究方向为热能动力工程,

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Operating characteristics of the heaters under different load conditions in the “ORC” scheme

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运行工况QF/MWQX/MWTYJ/℃TYC/℃
THA-100%qa3.303.2491.0838.00
75%THA-100% qa3.303.2491.0838.00
50%THA-100% qa3.303.2491.0838.00
40%THA-100% qa3.303.2491.0838.00
30%THA-100% qa3.303.2491.0838.00
THA-100% qa3.303.2491.0838.00
THA-70% qa4.053.96102.9538.00
THA-50% qa4.544.45110.8938.00
THA-40% qa4.794.70114.8538.00
THA-30% qa5.044.94118.8138.00
), ArticleFig(id=1236679398808670342, tenantId=1146029695717560320, journalId=1210938733613449225, articleId=1236679388079641214, language=CN, label=表1, caption=

不同负荷工况“ORC”方案加热器运行特性

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运行工况QF/MWQX/MWTYJ/℃TYC/℃
THA-100%qa3.303.2491.0838.00
75%THA-100% qa3.303.2491.0838.00
50%THA-100% qa3.303.2491.0838.00
40%THA-100% qa3.303.2491.0838.00
30%THA-100% qa3.303.2491.0838.00
THA-100% qa3.303.2491.0838.00
THA-70% qa4.053.96102.9538.00
THA-50% qa4.544.45110.8938.00
THA-40% qa4.794.70114.8538.00
THA-30% qa5.044.94118.8138.00
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Operating characteristics of the heaters under different load conditions in the “Heater” scheme

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运行工况QF/MWQX/MWTYJ/℃TYC/℃
THA5.795.67130.6338.00
75%THA5.795.67130.6338.00
50%THA5.795.67130.6338.00
40%THA5.795.67130.6338.00
30%THA5.795.67130.6338.00
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不同负荷工况“加热器”方案加热器运行特性

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运行工况QF/MWQX/MWTYJ/℃TYC/℃
THA5.795.67130.6338.00
75%THA5.795.67130.6338.00
50%THA5.795.67130.6338.00
40%THA5.795.67130.6338.00
30%THA5.795.67130.6338.00
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Investment income statement for waste heat energy and quality recovery

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项目“ORC”方案“换热器”方案
机组功率/MW350350
改前热耗/(kJ·(kW·h)–1)7 721.347 721.00
改后热耗/(kJ·(kW·h)–1)7 713.377 706.19
热耗下降/(kJ·(kW·h)–1)7.9614.81
节约标煤/(g·(kW·h)–1)0.270.51
年利用小时/h4 0714 071
年节煤量/t387720
标煤单价/(元·t–1)1 022.71 022.7
总节煤费用/万元39.673.7
总节水量/(t·a–1)467 319467 319
水价/(元·t–1)1010
总节水费用/万元467.3467.3
ORC汽轮机发电量/kW206
年新增发电量/(kW·h)839 554
上网电价/(元·(kW·h)–1)0.453
新增发电收益/万元38.0
总收益/万元544.9 541.0
总费用/万元703460
静态投资回收期/a1.290.85
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余热能质回收投资收益

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项目“ORC”方案“换热器”方案
机组功率/MW350350
改前热耗/(kJ·(kW·h)–1)7 721.347 721.00
改后热耗/(kJ·(kW·h)–1)7 713.377 706.19
热耗下降/(kJ·(kW·h)–1)7.9614.81
节约标煤/(g·(kW·h)–1)0.270.51
年利用小时/h4 0714 071
年节煤量/t387720
标煤单价/(元·t–1)1 022.71 022.7
总节煤费用/万元39.673.7
总节水量/(t·a–1)467 319467 319
水价/(元·t–1)1010
总节水费用/万元467.3467.3
ORC汽轮机发电量/kW206
年新增发电量/(kW·h)839 554
上网电价/(元·(kW·h)–1)0.453
新增发电收益/万元38.0
总收益/万元544.9 541.0
总费用/万元703460
静态投资回收期/a1.290.85
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煤电机组余热能质深度回收优化研究
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邓佳 1 , 许朋江 1 , 郑郝 2 , 刘雨恩 1 , 马汀山 1
热力发电 | 热能科学研究 2024,53(12): 112-119
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热力发电 | 热能科学研究 2024, 53(12): 112-119
煤电机组余热能质深度回收优化研究
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邓佳1 , 许朋江1, 郑郝2, 刘雨恩1, 马汀山1
作者信息
  • 1.西安热工研究院有限公司,陕西 西安 710054
  • 2.中国华能集团有限公司,北京 100031
  • 邓佳(1990),女,硕士,高级工程师,主要研究方向为热能动力工程,

Deep recovery and optimization of waste heat and energy quality for coal-fired units
Jia DENG1 , Pengjiang XU1, Hao ZHENG2, Yuen LIU1, Tingshan MA1
Affiliations
  • 1.Xi’an Thermal Power Research Institute Co., Ltd., Xi’an 710054, China
  • 2.China Huaneng Group Co., Ltd., Beijing 100031, China
出版时间: 2024-12-25 doi: 10.19666/j.rlfd.202405100
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针对煤电机组低品位余热能质浪费问题,以某350 MW机组为研究对象,采用Ebsilon平台建模模拟研究不同的低品位余热能质深度回收方案,计算“有机朗肯循环(organic Rankine cycle,ORC)”和“加热器”2种方案对应机组运行数据,分析能耗特性、收益特性和差异性等,得到了余热能质深度回收的机理和优化方案。结果表明:2种方案下机组能耗特性均有明显提升,“加热器”方案能耗更低;随着有机工质流量增加,ORC系统发电量逐渐增大,ORC系统热电效率先逐渐增大后趋于平缓并有下降趋势,变化范围为6.94%~7.75%,有机工质流量对ORC系统循环效率影响较小;2种方案技术经济均可行,“ORC”方案可以为电厂带来直接电能收益,“加热器”方案经济性略好。

煤电机组  /  余热能质  /  深度回收  /  ORC  /  优化

In response to significant increase in energy consumption caused by low-grade waste heat and energy waste in coal-fired power plants, a 350 MW unit is selected as the research object, the Ebsilon software is used to model and simulate different deep recovery schemes for low-grated waste heat and residue. The operating data of the unit under two schemes of “organic Rankine cycle (ORC)” and “Heater” are calculated. The energy consumption characteristics, revenue characteristics and differences are analyzed, and the mechanism and optimization plan for deep recovery of waste heat and energy are obtained. The results show that, the energy consumption characteristics of the unit improve significantly under both schemes, and the “heater” scheme has lower energy consumption. As the organic working fluid flow rate increases, the power generation of the ORC system gradually increases, but the thermoelectric efficiency of the ORC system gradually increases at first and then tends to stabilize and has a downward trend, with a range of 6.94%~7.75%. The organic working fluid flow rate has a relatively small effect on circulation efficiency of the ORC system. Both schemes are technically and economically feasible. The “ORC” scheme can bring direct electricity benefits to the power plant, while the “Heater” scheme is slightly more economical.

coal-fired power unit  /  wasted heat and substance  /  deep recycling  /  ORC  /  optimization
邓佳, 许朋江, 郑郝, 刘雨恩, 马汀山. 煤电机组余热能质深度回收优化研究. 热力发电, 2024 , 53 (12) : 112 -119 . DOI: 10.19666/j.rlfd.202405100
Jia DENG, Pengjiang XU, Hao ZHENG, Yuen LIU, Tingshan MA. Deep recovery and optimization of waste heat and energy quality for coal-fired units[J]. Thermal Power Generation, 2024 , 53 (12) : 112 -119 . DOI: 10.19666/j.rlfd.202405100
《中共中央国务院关于完整准确全面贯彻新发展理念做好碳达峰碳中和工作的意见》(2021年)、《全国煤电机组改造升级实施方案》(发改运行〔2021〕1519号)等一系列政策文件共同指出,煤炭清洁高效利用是深入推进能源革命的重要一环[1],“双碳”目标下,坚持节能优先的能源发展战略,大力推动煤电节能降碳改造[2],进一步深挖煤电机组的节能潜力,既是对节能减排政策的响应,又提高了火电机组在新型电力系统中的生存能力,缓解煤电机组经营生存困境[3-7]
提高机组低温余热能质深度梯级利用回收能力可以缓解燃煤发电正面临的重大急迫需求。对电厂低品位余热的深度挖掘,如烟气余热[8-11]、循环水余热[12-17]、除氧器连续排汽[18-19]、灰斗加热蒸汽疏水等,是煤电机组进一步节能提效的有效途径。目前电厂的烟气余热和循环水余热分别通过低温省煤器[8-11]、旁路烟道[10]、原煤烟气预干燥[10]、高背压供热[12]、热泵[12-17]等技术加以利用,提高了机组运行的热经济性,减少了一次能源的消耗。然而,除氧器连续排汽、灰斗疏水、暖管蒸汽疏水等余热长期以来一直被忽视,余热能质持续浪费已成为煤电机组普遍存在共性问题。余热能质浪费一方面造成电厂的经济性下降,同时增加了碳排放指标和用水指标[20-21],另一方面造成白色雾气视觉污染,产生了不良的社会影响[22-23]。如何对这些低品位余热进行深度的回收利用,是煤电机组节能降碳进入深水区的技术难题。目前,对于煤电机组深度余热利用的研究较少[24-26],尤其是灰斗伴热疏水等余热能质回收的研究更少。
利用有机朗肯循环(organic rankine cycle,ORC)系统进行低温余热发电具有节能、环保等特点,符合能源梯级利用的要求。目前,利用ORC技术回收低品位工业废热(低于350 ℃)的发电设备装置容量已经超过了400 MW(主要位于欧美等国家),ORC技术逐渐成熟,其主要应用在内燃机、燃气轮机、天然气压缩机站等大型设备或者行业的废热回收发电。ORC系统在火电行业的应用目前还属于空白。煤电机组的低温余热资源丰富多样,具有很大的回收价值。
针对煤电机组低品位余热能质浪费引起机组能耗升高、运行经济性变差、视觉污染严重的问题,本文以某电厂350 MW机组为研究对象,采用Ebsilon平台建模模拟研究不同的低品位余热能质深度回收方案,计算“ORC”和“加热器”2种方案对应不同负荷、不同有机工质流量下机组运行数据,分析能耗特性、收益特性和差异性等,得到余热能质深度回收的机理和优化方案,掌握不同余热能质深度回收方案对机组运行经济性的影响规律。
本文汽轮机计算模型为东方电气CC350-24.2/ 4.05/1.3/566/566型双抽可调供热纯凝式机组。设计额定蒸汽流量1 029.7 t/h,热耗7 638 kJ/(kW·h),背压4.9 kPa。
采用Ebsilon平台进行建模,计算模型包括汽轮机、发电机、凝汽器、凝结水泵组、低压加热器、除氧器、汽动给水泵组、高压加热器、锅炉及汽水管道等。汽轮机组变工况运行方式为滑压运行,以汽轮机组阀全开工况热平衡特性为计算基准,分别模拟ORC和热交换器换热的余热能质回收利用方案。“ORC”方案利用余热回收储罐把ORC与蒸汽动力循环结合起来,再利用换热器深度梯级利用废热,最后可直接回收工质,具体如图1所示。“加热器”方案利用余热回收储罐回收余热,然后通过换热器直接加热凝结水深度回收余热,最后可直接回收工质,具体如图2所示。
ORC是以低沸点有机物为工质的朗肯循环,主要由蒸发器(换热器)、膨胀机、冷凝器和工质泵4大部分组成[27-29]。本文中的“ORC”方案采用带有回热系统的ORC,利用余热回收装置回收系统余热,有机工质在蒸发器中从余热流中吸收热量,生成具一定压力和温度的蒸汽,蒸汽进入膨胀机做功,从而带动发电机发电。从膨胀机排出的蒸汽在回热加热器中向冷却后的有机工质放热,然后进一步在冷凝器中向冷却水放热,凝结成液态后,借助工质泵回到回热加热器吸热,最后重新回到蒸发器,如此完成一个循环。ORC发电设备占地规模小,自动化程度高,投入的人力成本较低,是一种比较理想的低品位热能回收利用技术[30-32]图3为以ORC为核心的余热回收原理。
热耗r是指汽轮发电机组每生产1 kW·h的电能所需要的热量,反应了发电厂的热经济性,是发电厂重要的经济性指标之一[27]。机组不对外供热时的热耗,即纯凝工况机组热耗rcn,计算见式(1)。
rcn=QcnP
式中:rcn为纯凝工况机组热耗,kJ/(kW·h);Qcn为纯凝工况介质的锅炉吸热量,kJ/h;P为机组发电功率,kW。
ORC系统的热电效率η是指ORC系统的净功率与ORC系统蒸发器的吸热量之比。
本文采用Ebsilon软件对350 MW机组的实际运行状态进行建模模拟,以机组VWO工况热平衡计算为建模计算的基准工况,VWO工况计算收敛性如图4所示。从图4可知,该VWO工况模拟计算的焓值、流量、压力的残差呈下降趋势,最终趋于稳定,经过35步迭代、39 ms的运行计算结果收敛,说明该模型的计算结果稳定、收敛,可以作为后续其他工况计算的基础。
通过Ebsilon软件分别模拟机组现状、“ORC”方案和“加热器”方案3种模型在100%THA、75%THA、50%THA、40%THA和30%THA不同负荷工况下汽轮机的热耗特性r,具体如图5所示。从图5可知:100%THA、75%THA、50%THA、40%THA和30%THA工况下,机组现状的热耗分别为7 721、7 949、8 306、8 522、8 814 kJ/(kW·h);采用“ORC”方案机组热耗分别为7 713、7 939、8 292、8 504、8 791 kJ/(kW·h);采用“加热器”方案机组热耗分别为7 706、7 928、8 276、8 484、8 764 kJ/(kW·h)。综上可知,随着负荷降低机组热耗逐渐增大。同一工况下,汽轮机组现状热耗>“ORC”方案热耗>“加热器”方案热耗。
机组余热流量53 t/h,焓值549 kJ/kg,“ORC”方案中配置带回热系统的ORC系统回收机组余热,然后通过换热器深度梯级利用ORC系统蒸发器的余热。额定工况下ORC系统的运行状况如图6所示,ORC系统采用有机工质五氟丙烷R245fa。从图6可知,蒸发器内有机工质的吸热量为2 487.07 kW,ORC系统的发电量为206.23 kW,ORC系统的发电效率约为7.75%。
不同有机工质流量q下,ORC系统的运行特性如图7所示。从图7可知,随着有机工质流量q的逐渐增大,ORC系统输出的电功率Peva逐渐增大。ORC系统的输出功率主要受限于热源温度、热源流量、冷源温度、冷源流量、膨胀机效率等。热源温度越高、热源流量越大、冷源温度越低、冷源流量越大、膨胀机效率越高,则ORC系统输出电功率越大。
不同有机工质流量q下,ORC系统的热电效率η特性如图8所示。从图8可知,随着工质流量的增大,ORC系统的热电效率曲线呈下开口抛物线趋势,变化范围为6.94%~7.75%,有机工质流量对ORC系统循环效率的影响较小。结合图7图8可知,有机工质的流量与ORC系统输出电功率成正比,与ORC系统循环效率呈抛物线变化,因此在ORC系统设计时,存在最优流量兼顾ORC系统的效率和输出功率。
“ORC”方案中,加热器在额定工况的运行参数如图9所示。不同工况下余热能质的放热量QF和凝结水的吸热量QX、余热进水温度TYJ和余热出水温度TYC表1。从图9表1可知,加热器的换热损失为2%,从蒸发器出来的余热温度约为91 ℃,经加热器加热凝结水后温度降到38 ℃,最终回到水处理系统进行余质回收。改变机组工况、ORC系统有机工质流量为100%qaqa为额定工况有机工质流量)时,加热器放热量为定值3.30 MW,凝结水吸热量为定值3.24 MW。机组THA工况、改变ORC系统有机工质流量,则随着有机工质流量的逐渐减小,加热器的放热量逐渐增大,凝结水的吸热量相应增加,这与ORC系统的耗热量逐渐减少有关。余热能量守恒,ORC系统余热利用量减少,则加热器系统余热利用量增加。
“加热器”方案中,加热器在额定工况的运行参数如图10所示。不同工况下余热能质放热量QF和凝结水吸热量QX、余热进水温度TYJ和余热出水温度TYC表2。从图10表2可知,加热器的换热损失为2%,余热储热装置出口温度约为131 ℃,经加热器加热凝结水后温度降到38 ℃,然后回到水处理系统进行余质回收。机组改变工况时,加热器放热量为定值5.79 MW,凝结水吸热量为定值5.67 MW,当余热的能质稳定时,“加热器”方案可以深度梯级利用余热,并回收余质。
对比图9图10可知:“ORC”方案中,ORC系统利用了一部分余热,所以加热器有效利用的热量相对较少,仅为3.24 MW;“加热器”方案中,余热直接进入加热器中,所以加热器有效利用的热量相对较多,为5.67 MW。
2种方案回收余热后,余质均回到水处理系统进行回收。“ORC”方案会产生电、煤、水3种收益,其中电能可以为企业直接带来收益。“加热器”方案会产生煤、水2种收益。2种深度余热能质回收方案的投资收益见表3。从表3可以看出:“ORC”方案新增发电收益38万元/年,节煤收益39.6万元/年,节水收益467.3万元/年,总收益为544.9万元/年;“换热器”方案节煤收益73.7万元/年,节水收益467.3万元/年,总收益为541万元/年。
“ORC”方案主要由废热回收系统、ORC系统和回热系统组成,总投资约703万元,该方案的静态投资回收期为1.29年,技术经济性良好。“加热器”方案主要由废热回收系统和回热系统组成,总投资约460万元,该方案的静态投资回收期为0.85年,技术经济性良好。通过以上对比分析可知,“ORC”方案利用ORC系统吸收电厂低温废热发电,后采用换热器对余热进行进一步的梯级利用,最后回收工质,不仅可以减少企业的碳排放,还可以提供可观的电能,技术创新性相对较强。“加热器”方案采用换热器对余热进行充分的梯级利用,并回收工质,可以提高循环热效率,减少企业碳排放,该方案较为传统。2个方案的投资收益均良好,均可以对电厂的余热、余质进行深度的回收,技术经济均可行。
针对煤电机组低品位余热能质浪费引起机组能耗大幅升高,导致电厂热经济性下降的问题。本文以某350 MW机组为研究对象,采用Ebsilon平台建模模拟研究不同低品位余热能质深度回收方案,计算“ORC”和“加热器”2种方案在不同负荷、不同有机工质流量下机组运行状态,分析能耗特性、收益特性和差异性等,得到了余热能质深度回收的机理和优化方案。掌握了不同余热能质深度回收方案对机组运行经济性的影响规律,研究总结如下。
1)“ORC”方案系统的热效率低于“加热器”方案系统的热效率,故“ORC”方案机组的热耗率高于“加热器”方案,随着负荷降低机组的热耗逐渐增大。
2)ORC系统的发电效率约为7.75%。有机工质的流量与ORC系统输出电功率成正比,与ORC系统循环效率呈抛物线变化,因此在ORC系统设计时,存在最优流量兼顾ORC系统的效率和输出功率。
3)“ORC”方案中,ORC系统利用了一部分余热,故加热器有效利用热量相对较少,仅为3.24 MW;“加热器”方案中,余热直接进入加热器中,故加热器有效利用热量相对较多,为5.67 MW。“ORC”方案总余热利用效率低于“加热器”方案。
4)“ORC”方案和“加热器”方案的投资收益均良好,均可以对电厂的余热能质进行深度的回收,技术经济均可行,“ORC”方案可以为电厂带来直接电能收益,“加热器”方案经济性略好。建议电厂进行余热能质深度回收利用改造时,根据电厂的实际情况,进行经济性论证,以使机组的运行经济性处于最优。
  • 西安西热节能技术有限公司科技项目(GB-24-TZK11)
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2024年第53卷第12期
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doi: 10.19666/j.rlfd.202405100
  • 接收时间:2024-05-15
  • 首发时间:2026-03-06
  • 出版时间:2024-12-25
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  • 收稿日期:2024-05-15
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Science and Technology Project of Xi’an Xire Energy Saving Technology Co., Ltd.(GB-24-TZK11)
西安西热节能技术有限公司科技项目(GB-24-TZK11)
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    1.西安热工研究院有限公司,陕西 西安 710054
    2.中国华能集团有限公司,北京 100031
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