锌精馏炉砖砌式换热室数值模拟与场协同优化

doi:10.11949/0438-1157.20241439

摘要/Abstract

摘要：

砖砌式换热室是塔式锌精馏炉的关键设备，主要用于预热入炉空气和回收烟气余热。由于砖砌式换热室的结构限制，其存在气体流速分布不均、换热效率低等问题。因此，以锌精馏炉砖砌式换热室为研究对象，利用CFD技术对换热室进行全面的数值研究，并基于场协同理论，以积分中值协同角、体积加权平均协同角、综合强化传热性能系数等为评价指标，评估并获得了结构优化方案。研究表明，烟气侧速度分布不均的现象集中在换热流程的连接口，空气侧流速不均的现象集中在底层空气道；结构优化应重点关注底层东侧空气道；拓宽空气道入口可有效强化筒形砖内空气流量的均匀性，相对标准偏差仅为17.5%，并改善换热室的综合传热性能；底层东侧空气道入口的最佳宽度为435 mm。

关键词: 锌精馏炉, 砖砌式换热室, 数值模拟, 场协同, 优化, 对流

Abstract:

Brick-built heat exchange chamber is a key equipment of tower zinc distillation furnace, which is mainly used for preheating incoming air and recovering flue gas waste heat. Due to the structural limitations of the brick-built heat exchange chamber, it has problems such as uneven gas velocity distribution and low heat transfer efficiency. Therefore, a brick-built heat exchange chamber of the zinc refining furnace is taken as the research subject in this paper, a comprehensive numerical study of the chamber is conducted by using CFD technology. Based on the field synergy theory, the evaluation is carried out by using indicators such as integral median synergistic angle, volume weighted average synergistic angle and comprehensive heat transfer enhancement coefficient, leading to the identification of an optimized structural solution. The study indicates that the uneven velocity distribution on the flue gas side is concentrated at the junctions of the heat exchange process, while the uneven velocity distribution on the air side is primarily observed in the bottom air ducts. Structural optimization should focus on the air ducts on the eastern side at the bottom layer. Expanding the air duct inlets can effectively enhance the uniformity of air flow within the chimney checkers, with the relative standard deviation reduced to only 17.5%, improving the overall performance of the heat exchange chamber. The optimal width for the air duct inlets on the eastern side at the bottom layer is 435 mm.

Key words: zinc refining furnace, brick-built heat exchange chamber, numerical simulation, field synergy, optimization, convection

中图分类号:

TK 172

黄正宗, 刘科成, 李泽方, 曾平生, 刘永富, 闫红杰, 刘柳. 锌精馏炉砖砌式换热室数值模拟与场协同优化[J]. 化工学报, 2025, 76(9): 4425-4439.

Zhengzong HUANG, Kecheng LIU, Zefang LI, Pingsheng ZENG, YongFu LIU, Hongjie YAN, Liu LIU. Numerical simulation and field synergy optimization of brick-built heat exchange chamber in zinc refining furnace[J]. CIESC Journal, 2025, 76(9): 4425-4439.

图/表 20

图1 砖砌式换热室几何模型

Fig.1 Geometric model of the brick-built heat exchange chamber

图2 换热室内不同特征截面的结构示意图

Fig.2 Schematic structure of different characteristic sections in the heat exchange chamber

表1 锌精馏炉墙体的物性参数

Table 1 Physical parameters of the wall of a zinc refining furnace

材料	密度/(kg/m³)	比热容/(J/(kg∙K))	热导率/(W/(m∙K))	吸收系数/m^-1	散射系数/m^-1
墙体	2200	750	1.5	3.7	50.88

图3 换热室C排筒形砖空气出口的质量流量与温度的柱状图

Fig.3 Histogram of the mass flow and temperature at the air outlet of the chimney checker in row C for the heat exchange chamber

表2 换热室烟气及空气温度计算值与测试值对比

Table 2 Comparison of calculated and measured flue gas and air temperatures in the heat exchange chamber

序号	测点位置	测试值/K	计算值/K	相对误差/%
1	换热室烟气出口	825.13	882.46	6.9
2	换热室空气出口	1070.85	1001.23	6.5

图4 砖砌式换热室的烟气速度云图

Fig.4 Velocity contours of flue gas in the brick-built heat exchange chamber

图5 砖砌式换热室筒形砖空气出口的速度云图

Fig.5 Velocity contour of air outlets at the chimney checker of the brick-built heat exchange chamber.

图6 砖砌式换热室内不同排筒形砖的空气质量流量柱状图

Fig.6 Histogram of air mass flow for different rows of the chimney checker in the brick-built heat exchange chamber

图7 砖砌式换热室内底层空气道水平截面的速度云图

Fig.7 Velocity contour of horizontal section of the bottom air duct in the brick-built heat exchange chamber

图8 砖砌式换热室不同监测截面的温度云图

Fig.8 Temperature contours at different monitoring sections of the brick-built heat exchange chamber

图9 筒形砖出口截面的空气温度云图

Fig.9 Air temperature contour of the outlet cross-section of the chimney checkers

图10 砖砌式换热室不同排筒形砖内壁面的平均温度柱状图

Fig.10 Average temperature histogram of the inner wall surfaces of different rows of the chimney checker in the brick-built heat exchange chamber

图11 空气道入口的结构示意图

Fig.11 Schematic diagram of the structure of the air duct inlet.

表3 底层东侧空气道入口的水平宽度

Table 3 Horizontal width of air duct inlet on east side at bottom layer

工况	Case-1	Case-2	Case-3	Case-4
数值/mm	240	305	370	435

图12 空气道不同入口宽度时筒形砖空气出口的速度云图

Fig.12 Velocity contours of air outlets at the chimney checkers for different inlet widths of air duct

图13 空气道不同入口宽度时不同排筒形砖的空气质量流量及其相对标准偏差的柱状图

Fig.13 Histograms of air mass flows and their relative standard deviations for different rows of chimney checkers at different inlet widths of air duct

图14 砖砌式换热室l1截面的局部传热协同角云图

Fig.14 Local heat transfer synergy angle contour at the l1 cross-section of the brick-built heat exchange chamber

图15 空气道不同入口宽度时换热室局部传热协同角云图的对比

Fig.15 Comparison of local heat transfer synergy angle contours of the heat exchanger chamber for different inlet widths of the air channel

图16 空气道不同入口宽度时积分中值协同角与体积协同角的对比

Fig.16 Comparison of integral-averaged and volumetric synergistic angles for different inlet widths of air duct

图17 Case-4与Case-1的综合性能对比

Fig.17 Comparison of the comprehensive performance of Case-4 and Case-1

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