CN113203296B - An online monitoring method for air leakage in flue of steel rolling heating furnace - Google Patents
An online monitoring method for air leakage in flue of steel rolling heating furnace Download PDFInfo
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- 238000010438 heat treatment Methods 0.000 title claims abstract description 35
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 20
- 238000005096 rolling process Methods 0.000 title claims abstract description 20
- 239000010959 steel Substances 0.000 title claims abstract description 20
- 238000000034 method Methods 0.000 title claims abstract description 14
- 238000012544 monitoring process Methods 0.000 title claims abstract description 11
- 239000003546 flue gas Substances 0.000 claims abstract description 52
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims abstract description 51
- 239000007789 gas Substances 0.000 claims abstract description 38
- 238000002485 combustion reaction Methods 0.000 claims abstract description 12
- 238000012360 testing method Methods 0.000 claims abstract description 11
- 238000002156 mixing Methods 0.000 claims abstract description 7
- 239000000203 mixture Substances 0.000 claims description 13
- 238000011084 recovery Methods 0.000 claims description 10
- 239000002918 waste heat Substances 0.000 claims description 10
- 239000000446 fuel Substances 0.000 claims description 8
- 238000004364 calculation method Methods 0.000 claims description 6
- 239000004215 Carbon black (E152) Substances 0.000 claims description 2
- 229930195733 hydrocarbon Natural products 0.000 claims description 2
- 150000002430 hydrocarbons Chemical class 0.000 claims description 2
- 238000012545 processing Methods 0.000 claims description 2
- 238000005065 mining Methods 0.000 claims 1
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 238000007726 management method Methods 0.000 abstract description 3
- 238000004458 analytical method Methods 0.000 abstract description 2
- 238000013461 design Methods 0.000 abstract description 2
- 239000000779 smoke Substances 0.000 abstract 4
- 238000012986 modification Methods 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000000571 coke Substances 0.000 description 1
- 238000013480 data collection Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000010943 off-gassing Methods 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F27—FURNACES; KILNS; OVENS; RETORTS
- F27D—DETAILS OR ACCESSORIES OF FURNACES, KILNS, OVENS OR RETORTS, IN SO FAR AS THEY ARE OF KINDS OCCURRING IN MORE THAN ONE KIND OF FURNACE
- F27D21/00—Arrangement of monitoring devices; Arrangement of safety devices
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Abstract
Description
技术领域Technical field
本发明涉及冶金行业轧钢加热炉的能效分析技术领域，尤其涉及一种轧钢加热炉烟道漏风量在线监测方法。The invention relates to the technical field of energy efficiency analysis of steel rolling heating furnaces in the metallurgical industry, and in particular to an online monitoring method for air leakage in the flue of steel rolling heating furnaces.
背景技术Background technique
轧钢加热炉是轧钢工序的主要耗能设备，提高加热炉热效率及合理利用加热炉排烟余热，可以避免能源的极大浪费，降低轧钢生产成本。由于加热炉炉膛内为正压，部分烟气在正压的作用下会从炉门和孔洞逸出，剩余烟气进入烟道内。烟道内一般安装会安装余热回收装置，空气预热器和煤气预热器。在引风机的作用下，烟道内为负压，导致漏入冷风使烟气量增大，烟气温度下降。此外，在炉膛出口一般设置掺冷风装置，防止空气预热器超温，掺冷风同样会使烟气量增加。因此，漏风量的准确测算是分析加热炉系统热平衡、评价烟气余热回收装置性能的重要基础。The steel rolling heating furnace is the main energy-consuming equipment in the steel rolling process. Improving the thermal efficiency of the heating furnace and rationally utilizing the exhaust heat of the heating furnace can avoid great waste of energy and reduce the cost of steel rolling production. Since there is positive pressure in the furnace of the heating furnace, part of the flue gas will escape from the furnace door and holes under the action of positive pressure, and the remaining flue gas will enter the flue. Waste heat recovery devices, air preheaters and gas preheaters are generally installed in the flue. Under the action of the induced draft fan, there is a negative pressure in the flue, which causes cold air to leak in, increasing the amount of flue gas and decreasing the temperature of the flue gas. In addition, a cold air mixing device is generally installed at the furnace outlet to prevent the air preheater from overheating. Cold air mixing will also increase the amount of flue gas. Therefore, the accurate measurement of air leakage is an important basis for analyzing the heat balance of the heating furnace system and evaluating the performance of the flue gas waste heat recovery device.
201811418929.0发明公开了一种排气烟道阻力和漏风量测试系统，包括风量可调的风源，风量测量装置，第一气压计、第二气压计和第三气压计，其中排气烟道贯通多层建筑的第1至n个楼层，n为大于等于4的整数；风量测量装置分别与风源和位于第i层的排气烟道的进风口流体连通；第一气压计设置在第i+1层的排气烟道中，i为选自1至n-3的整数；第二气压计设置第j层的排气烟道中，j为选自大于等于i+2且小于等于n-1的整数；第三气压计设置在排气烟道的与进风口之间具有第一距离的侧壁上。这种通过风量测量的方法是一种很直接的测试方式，其存在的问题是需要额外设置传感器进行测量，需要额外的投资和管理，势必增加生产成本。The 201811418929.0 invention discloses an exhaust flue resistance and air leakage testing system, including an air source with adjustable air volume, an air volume measuring device, a first barometer, a second barometer and a third barometer, in which the exhaust flue is connected The 1st to nth floors of a multi-story building, n is an integer greater than or equal to 4; the air volume measuring device is fluidly connected to the air source and the air inlet of the exhaust flue located on the ith floor; the first barometer is set on the ith floor In the exhaust flue of the +1 layer, i is an integer selected from 1 to n-3; in the exhaust flue of the jth layer where the second barometer is set, j is an integer selected from greater than or equal to i+2 and less than or equal to n-1. an integer; the third barometer is disposed on the side wall of the exhaust flue with a first distance between the air inlet. This method of measuring air volume is a very direct test method. The problem is that it requires additional sensors for measurement, which requires additional investment and management, which will inevitably increase production costs.
因此目前轧钢加热炉运行监测数据普遍不能反映烟道漏风量的大小，不能及时发现烟道漏风及烟道余热回收装置性能是否处于正常水平，加热炉的耗能居高不下。Therefore, the current operation monitoring data of steel rolling heating furnaces generally cannot reflect the size of the flue air leakage, and cannot promptly detect whether the flue air leakage and the performance of the flue waste heat recovery device are at normal levels. The energy consumption of the heating furnace remains high.
发明内容Contents of the invention
本发明的目的是提供一种轧钢加热炉烟道漏风量在线监测方法，克服现有技术的不足，利用过量空气系数计算实际烟气量，烟道中实际烟气成分是进入烟道烟气和烟道漏风混合后的结果，通过及时检测漏风量，方便及时判断烟道漏风水平，解决余热回收装置效率低，空气、煤气预热温度不足，排烟热损失大等问题，为准确评价加热炉热平衡提供依据，从而找到提高加热炉热效率的措施。The purpose of the present invention is to provide an online monitoring method for air leakage in the flue of a steel rolling heating furnace, which overcomes the shortcomings of the existing technology and uses the excess air coefficient to calculate the actual flue gas amount. The actual flue gas components in the flue are the flue gas entering the flue and the flue gas. By detecting the air leakage amount in time, it is convenient to timely judge the level of flue air leakage and solve the problems of low efficiency of waste heat recovery device, insufficient preheating temperature of air and gas, and large exhaust heat loss. In order to accurately evaluate the heat balance of the heating furnace, Provide basis to find measures to improve the thermal efficiency of heating furnaces.
为实现上述目的，本发明的技术方案为：In order to achieve the above objects, the technical solution of the present invention is:
S1：保持轧钢加热炉运行工况稳定，烟道空气预热器入口处掺冷风阀门关闭；S1: Keep the operating conditions of the steel rolling heating furnace stable, and close the cold air valve at the entrance of the flue air preheater;
S2：测试开始后，记录炉膛压力pl，煤气量Vm，空气量Vk；在煤气输送管道直管段选点测定煤气成分；测定炉头、炉尾处炉气成分；测定空气预热器入口、空气预热器出口烟道直管段的烟气成分；S2: After the test starts, record the furnace pressure p l , gas volume V m and air volume V k ; select points in the straight section of the gas delivery pipeline to measure the gas composition; measure the furnace gas composition at the furnace head and furnace tail; measure the air preheater Flue gas components at the inlet and outlet flue straight sections of the air preheater;
S3：利用公式1和公式2计算炉膛燃烧实际过量空气系数αl；S3: Use Formula 1 and Formula 2 to calculate the actual excess air coefficient α l of furnace combustion;
式中：L0——理论空气量，m3/m3；——燃料的可燃成分体积含量，％；m,n为碳氢化合物组成系数；In the formula: L 0 ——Theoretical air volume, m 3 /m 3 ; ——The volume content of combustible components of the fuel, %; m, n are the hydrocarbon composition coefficients;
S4：利用公式3计算炉膛燃烧产生的烟气量：S4: Use formula 3 to calculate the amount of flue gas generated by furnace combustion:
式中：Vs——炉膛燃烧产生的实际烟气量，m3/m3；——燃料的不可燃成分体积含量，％；gk——干空气含水量，g/m3；In the formula: V s - the actual amount of flue gas produced by furnace combustion, m 3 /m 3 ; ——Volume content of non-combustible components of fuel, %; g k ——Moisture content of dry air, g/m 3 ;
S5：利用公式4估算炉膛在炉门处和孔洞处的漏风量Vl；S5: Use formula 4 to estimate the air leakage volume V l of the furnace at the furnace door and holes;
式中：Vl——通过炉门、孔洞的逸气量，m3/h；pl——炉门、孔洞底部的炉气表压，Pa；ρc——环境温度下的空气密度，kg/m3；ρy——环境温度下的空气密度，kg/m3；H——炉门、孔洞底部的炉气表压，Pa；μ——流量系数，后墙，薄墙；b——炉门孔洞的平均宽度，m；τ——炉门、孔洞1h内的开启时间，h；pc——大气压，Pa；tyl——炉门、孔洞处的炉气温度，℃；In the formula: V l - the amount of escape gas through the furnace door and holes, m 3 /h; p l - the furnace gas gauge pressure at the bottom of the furnace door and holes, Pa; ρc - the air density at ambient temperature, kg/ m 3 ; ρy——air density at ambient temperature, kg/m 3 ; H——furnace gas gauge pressure at the bottom of furnace door and hole, Pa; μ——flow coefficient, back wall, thin wall; b——furnace The average width of the door hole, m; τ - the opening time of the furnace door and hole within 1 hour, h; pc - atmospheric pressure, Pa; tyl - the furnace gas temperature at the furnace door and hole, ℃;
S6：轧钢加热炉进入烟道中的实际烟气量可通过炉膛中燃料燃烧产生的烟气量减去逸气量来确定，利用公式(5)计算炉膛进入烟道的烟气流量；S6: The actual amount of flue gas entering the flue of the steel rolling heating furnace can be determined by subtracting the amount of escape gas from the amount of flue gas generated by fuel combustion in the furnace. Use formula (5) to calculate the flue gas flow rate of the furnace entering the flue;
Vyg＝Vs·Vm-Vl(公式5)V yg =V s ·V m -V l (Formula 5)
式中：Vyg——考虑炉膛逸气条件下的烟道进气量，m3/h；In the formula: V yg - flue air intake volume considering furnace outgas conditions, m 3 /h;
S7：利用过量空气系数计算实际烟气量Vs，而烟道中实际烟气成分是进入烟道烟气和烟道漏风混合后的结果，为了保证漏风量计算基准一致，利用公式(6)计算进入烟道烟气中对应的折算燃气量；S7: Use the excess air coefficient to calculate the actual flue gas volume V s . The actual flue gas composition in the flue is the result of mixing the flue gas entering the flue and the flue air leakage. In order to ensure that the air leakage calculation benchmark is consistent, formula (6) is used to calculate The corresponding converted gas volume entering the flue gas;
式中：Vzm——进入烟道烟气中含有的折算煤气量；In the formula: V zm - the converted gas volume contained in the flue gas entering the flue;
S8：根据测试得到的烟道处烟气成分，基于公式7，计算含有漏风后的烟道过量空气系数αy；根据公式8，计算烟道漏风系数；S8: According to the flue gas composition obtained through the test and based on Formula 7, calculate the flue excess air coefficient α y after air leakage; based on Formula 8, calculate the flue air leakage coefficient;
式中：——烟道烟气成分体积含量，％；In the formula: ——Volume content of flue gas components, %;
αlf＝αy-αl (公式8)α lf = α y - α l (Formula 8)
S9：在确定烟道过量空气系数基础上，基于公式3，将炉膛出口过量空气系数替换为烟道处过量空气系数，计算烟道中实际烟气流量Vyg1；S9: After determining the excess air coefficient in the flue, based on Formula 3, replace the excess air coefficient at the furnace outlet with the excess air coefficient at the flue, and calculate the actual flue gas flow rate V yg1 in the flue;
S10：确定炉膛出口和烟道处的烟气量后，根据公式(9)计算烟道的平均漏风量；S10: After determining the amount of flue gas at the furnace outlet and flue, calculate the average air leakage of the flue according to formula (9);
Vlk＝Vyg1-Vyg (公式9)V lk =V yg1 -V yg (Formula 9)
与现有技术相比，本发明技术方案的有益效果是：对于由于运行年限较长，存在掺冷风阀门不严、烟道漏风严重的现象的加热炉，可通过及时检测漏风量，及时发现漏风情况，解决余热回收装置效率低，空气、煤气预热温度不足，排烟热损失大等问题，本发明仅需在烟道设置氧量计或其他烟气成分测试仪器，就可配合炉膛运行数据，在监测调节炉膛燃烧工况的同时，准确判断烟道漏风情况并实现定量测算，过程参数中不采集风量参数，无需额外投资，该计算过程可准确确定漏风量，可以为准确评价加热炉热平衡提供依据，从而找到提高加热炉热效率的措施，对加热炉的生产管理和改进设计都具有积极的意义。Compared with the existing technology, the beneficial effects of the technical solution of the present invention are: for heating furnaces with long operating years, lax valves for mixing cold air and serious air leakage in the flue, the air leakage can be discovered in time by detecting the amount of air leakage in time. situation, solving the problems of low efficiency of the waste heat recovery device, insufficient preheating temperature of air and gas, and large exhaust heat loss. The present invention only needs to install an oxygen meter or other flue gas component testing instruments in the flue to coordinate with the furnace operation data. , while monitoring and adjusting the combustion conditions of the furnace, it can accurately determine the flue air leakage and achieve quantitative calculation. The air volume parameters are not collected in the process parameters, and no additional investment is required. This calculation process can accurately determine the air leakage volume, which can accurately evaluate the heat balance of the heating furnace. Provide a basis to find measures to improve the thermal efficiency of heating furnaces, which has positive significance for the production management and improved design of heating furnaces.
附图说明Description of the drawings
图1本发明实施例计算过程流程图；Figure 1 is a flow chart of the calculation process of the embodiment of the present invention;
图2本发明实施例中加热炉体参数采集位置图。Figure 2 is a diagram of the acquisition location of parameters of the heating furnace body in the embodiment of the present invention.
图中：1－加热炉体、2－炉门炉气测点、3－炉尾炉气测点、4－空预器入口测点、5－空预器出口测点。In the figure: 1-heating furnace body, 2-furnace door gas measuring point, 3-furnace tail gas measuring point, 4-air preheater entrance measuring point, 5-air preheater outlet measuring point.
具体实施方式Detailed ways
下面将结合本发明实施方式中的附图，对本发明的实施方式中的技术方案进行清楚、完整的描述，显然，所描述的实施方式仅仅是作为例示，并非用于限制本发明。The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only for illustration and are not intended to limit the present invention.
下面结合实例及附图对本发明的实施步骤做具体说明：The implementation steps of the present invention will be described in detail below with reference to examples and drawings:
以某钢铁企业轧钢加热炉为端进端出常规步进式为例，设计年产量70万吨，燃料为高炉煤气和焦炉煤气混合煤气，煤气、配置空气双预热烟气余热回收系统。由于运行年限较长，存在掺冷风阀门不严、烟道漏风严重的现象，造成余热回收装置效率低，空气、煤气预热温度不足，排烟热损失大等问题。漏风量的测算实施步骤如下：Taking the rolling heating furnace of a steel company as an end-in and end-out conventional stepping type as an example, the designed annual output is 700,000 tons. The fuel is a mixture of blast furnace gas and coke oven gas. The gas and air dual preheating flue gas waste heat recovery system is equipped. Due to the long operating life, there are problems such as loose cold air mixing valves and serious air leakage in the flue, resulting in low efficiency of the waste heat recovery device, insufficient air and gas preheating temperatures, and large exhaust heat loss. The steps to calculate air leakage are as follows:
S1：测试时间为2020年7月份，数据采集及测试开始前一个小时，保持轧钢加热炉运行稳定，不更换物料规格，处理物料量维持在24块/h。S1: The test time is July 2020, one hour before the start of data collection and testing. The steel rolling heating furnace is kept running stably, the material specifications are not changed, and the material processing volume is maintained at 24 pieces/h.
S2：记录供入炉膛的煤气量和空气量，Vm＝20200m3/h，Vk＝48000m3/h；测试燃料成分， S2: Record the amount of gas and air supplied to the furnace, V m =20200m 3 /h, V k =48000m 3 /h; test the fuel composition,
S3：根据公式(1)和(2)计算炉膛过量空气系数αl＝1.237；S3: Calculate the furnace excess air coefficient α l =1.237 according to formulas (1) and (2);
S4：根据公式(3)计算炉膛燃烧产生的烟气量Vs＝64229m3/h；S4: Calculate the amount of flue gas generated by furnace combustion according to formula (3) Vs = 64229m 3 /h;
为了确定炉门处逸气量，记录炉门处的温度，炉头处炉气温度tyl,lt＝1100℃，炉尾处炉气温度tyl,lw＝600℃；炉门每次开启时间55s；记录炉膛压力pl＝5Pa；炉门开启宽度b＝8000mm。In order to determine the amount of outgassing at the furnace door, record the temperature at the furnace door. The furnace gas temperature at the furnace head is t yl,lt = 1100℃, and the furnace gas temperature at the furnace tail is t yl,lw = 600℃; the furnace door is opened for 55 seconds each time. ;Record the furnace pressure p l =5Pa; the furnace door opening width b =8000mm.
S5：根据公式(4)，计算炉门逸气量Vl＝13121m3/h；S5: According to formula (4), calculate the furnace door gas escape volume V l =13121m 3 /h;
S6：根据公式(5)，计算从炉膛进入烟道的烟气量Vyg＝51108m3/h；S6: According to formula (5), calculate the amount of flue gas entering the flue from the furnace V yg = 51108m 3 /h;
S7：根据公式(6)，计算折算煤气量Vzm＝16073m3/h；S7: According to formula (6), calculate the converted gas volume V zm = 16073m 3 /h;
S8：如图2所示，在烟道空气预热器入口处测试烟气成分，O2＝6.2％，N2＝80.05％，CO2＝13.75％；根据公式(7)，计算空预器入口处过量空气系数ay＝1.5114；根据公式(8)，计算烟道漏风系数alf＝0.2744；S8: As shown in Figure 2, test the flue gas composition at the inlet of the flue air preheater, O 2 =6.2%, N 2 =80.05%, CO 2 =13.75%; according to formula (7), calculate the air preheater The excess air coefficient at the inlet a y =1.5114; according to formula (8), calculate the flue air leakage coefficient a lf =0.2744;
S9：根据公式(4)和公式(5)计算烟道中空气预热器入口实际烟气流量Vyg1＝60722m3/h；S9: Calculate the actual flue gas flow V yg1 = 60722m 3 /h at the inlet of the air preheater in the flue according to formula (4) and formula (5);
S10：根据公式(9)，计算炉膛出口至空气预热器入口烟道处漏风量Vlk＝9614m3/h，漏风率达到18.8％；S10: According to formula (9), calculate the air leakage volume V lk from the furnace outlet to the air preheater inlet flue = 9614m 3 /h, and the air leakage rate reaches 18.8%;
经过测算，烟道漏风系数为0.2744，漏风率达到18.8％，明显高于正常漏风系数0.02-0.03，判断烟道漏风是比较严重。通过查找原因，发现掺冷风处的阀门无法关严，导致漏风严重。大量的漏风使烟气温度降低，空预器的余热回收效率下降。确定漏风量为准确评价加热炉热平衡提供了依据，从而找到提高加热炉热效率的措施。After calculation, the air leakage coefficient of the flue is 0.2744, and the air leakage rate reaches 18.8%, which is significantly higher than the normal air leakage coefficient of 0.02-0.03. It is judged that the air leakage of the flue is relatively serious. After searching for the cause, it was found that the valve at the place where the cold air was mixed could not be closed tightly, resulting in serious air leakage. A large amount of air leakage reduces the flue gas temperature and reduces the waste heat recovery efficiency of the air preheater. Determining the amount of air leakage provides a basis for accurately evaluating the heat balance of the heating furnace, thereby finding measures to improve the thermal efficiency of the heating furnace.
当然，本发明还可以有其它多种实施例，在不背离本发明精神及其实质的情况下，熟悉本领域的技术人员可根据本发明作出各种相应的改变与变形，但这些相应的改变与变形都应属于本发明权利要求的保护范围。Of course, the present invention can also have various other embodiments. Without departing from the spirit and essence of the present invention, those skilled in the art can make various corresponding changes and modifications according to the present invention. However, these corresponding changes All modifications and modifications shall fall within the protection scope of the claims of the present invention.
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