熔渣气化炉喷嘴燃烧区行为的数值模拟研究

doi:10.11949/0438-1157.20230681

摘要/Abstract

摘要：

燃烧区是熔渣气化炉的重要区域，其对熔渣气化炉的工作状态具有明显影响。基于双欧拉模型探究了燃烧区的速度场、温度场和组分场的分布特征及燃烧区空腔的形成过程。研究发现：工业级熔渣气化炉燃烧区呈“羽”状，其先向炉中心延伸再斜向上发展；气体在熔渣气化炉中心区域的流动速度为2.5 m/s 左右，但未形成“高速对撞区”；高温区出现在燃烧空腔外表面附近特别是正对喷嘴且靠近炉中心的区域，该区域的温度可以达到约2000℃；氧气主要分布在气化剂喷嘴前端约0.5 m的空腔内，一氧化碳的分布区域与水蒸气在空间上有较大程度重叠，二氧化碳主要在喷嘴前端空腔外壳附近生成，氢气浓度较高的区域则出现在燃烧区对应空腔的上沿；沿喷嘴轴线方向，气体温度呈先升至峰值再逐渐下降的趋势。随着气化剂流量的增大，燃烧温度极大值出现的位置逐渐朝炉中心处移动，并呈较明显的线性变化规律。

关键词: 熔渣气化炉, 煤气化, 燃烧区形状, 合成气, 数学模拟, 反应动力学

Abstract:

The combustion zone is an important region in a slagging gasifier, as it determines the working state of a coal gasifier. This study applies the Eulerian-Eulerian model to study the gas-coal behaviors in this region in an industrial-scale coal gasifier. The model considers the flow, heat transfer and chemical reactions for both gas and coal phases. The model is also used to explore the formation process of the combustion zone and the distribution of velocity, temperature, and species in and around it. It is found that the combustion zone is of a plume-like shape, extending to the centre of the gasifier and then towards the top obliquely; the gas velocity is about 2.5 m/s in the central regions of the gasifier, without forming a high-speed collision zone; the high-temperature zone appears near the surface of the combustion zone, especially that facing the nozzle and near the centre of the gasifier, where the temperature can reach as high as 2000℃. Besides, it is found that oxygen is mainly distributed at about 0.5 m in front of the nozzle, while the distribution of carbon monoxide and water vapor overlap in space to a large extent; carbon dioxide is mainly generated near the outer surface of the combustion region while a higher concentration of hydrogen appears above the combustion region. Along the direction of the nozzle axis, the gas temperature first increases to a peak and then gradually decreases. With increasing gasification agent flow rate, the position where the maximum value of combustion temperature appears gradually moves to the centre of the gasifier, showing an obvious linear change pattern.

Key words: slagging gasifier, coal gasification, combustion zone profile, syngas, mathematical modeling, reaction kinetics

中图分类号:

TK 6

王学云, 郁肖兵, 彭万旺, 沈岩松. 熔渣气化炉喷嘴燃烧区行为的数值模拟研究[J]. 化工学报, 2024, 75(2): 659-674.

Xueyun WANG, Xiaobing YU, Wanwang PENG, Yansong SHEN. Numerical study on combustion zone behaviors of a slagging gasifier[J]. CIESC Journal, 2024, 75(2): 659-674.

图/表 28

图1 熔渣气化炉及其燃烧区喷嘴布局结构示意图

Fig.1 Schematics of the coal gasifier and burner distribution

图2 熔渣气化炉燃烧区模型所用几何和网格示意图

Fig.2 Schematics of the geometry and mesh used in the MEKL combustion zone model

表1 熔渣气化炉燃烧区模型所用数据

Table 1 The data used in the MEKL combustion zone model

熔渣气化炉参数	数值
熔渣气化炉炉膛内径/ mm	3600
熔渣气化炉炉膛高度 (不计渣池)/mm	10500
熔渣气化炉气化剂喷嘴个数/个	6
熔渣气化炉气化剂喷嘴出口（喷口）内径/mm	18
熔渣气化炉气化剂喷嘴轴线与水平线夹角/(°)	19
熔渣气化炉气化剂喷嘴轴线延长线交点距渣池上表面距离/mm	130
熔渣气化炉气化剂喷嘴水平伸入长度/mm	215
氧气质量流量所有喷嘴总计/(kg/h)	13718
水蒸气质量流量所有喷嘴总计/(kg/h)	12621
气化剂给气温度/K	513
气化剂给气压强/MPa	4.6
熔渣气化炉运行压强/MPa	4.0
熔渣气化炉炉顶煤气压强/MPa	4.0
熔渣气化炉给煤速率/(kg/h)	30000
熔渣气化炉给煤粒度/mm	6~50
熔渣气化炉给煤密度/(kg/m³)	1400
熔渣气化炉给煤成分（质量分数）	全水（9.4%）；灰分ash（8.3%）；挥发分（35.44%）；固定碳（55%）；内水（1.26%）；低位热值（6333 kcal/kg）
熔渣气化炉壁面冷却条件	冷却水流量6 m³/h（标准工况），温差6℃，壁面温度350~500℃

表2 熔渣气化炉喷嘴燃烧区模型设置

Table 2 MEKL combustion zone model settings

项目	参数
主相	相材料名称：混合物气体混合物组成：氧气，二氧化碳，水蒸气，氮气，一氧化碳，氢气反应模型：涡耗散（eddy-dissipation）气体状态：理想气体方程热容模型：混合律（mixing-law）热导率：混合律（mass-weighted-mixing-law）黏度：1.72×10^-5 kg/(m·s) 质量扩散系数：2.88×10^-5 m²/s
次相（颗粒相）	相名称：碳密度：用户自定义密度模型UDF 粒度：用户自定义粒度模型UDF 颗粒动力黏度 (kinetic viscosity)：Gidaspow 颗粒黏度 (bulk viscosity)：Lun 摩擦黏度 (frictional visosity)：schaeffer 内摩擦角：30.00007 摩擦压力：based-ktgf 摩擦模量：derived 摩擦填充极限：0.62 颗粒相温度模型：phase property 颗粒相温度求解：algebraic 固相压力：Lun 径向分布：Lun 弹性模量：derived 填充极限：0.63
边界条件设置	气化剂入口：UDF 炉顶气体出口：UDF 渣池上液面： UDF
其他计算参数	时间步长：10^-4 s 计算总时长：10 s

表3 熔渣气化炉喷嘴燃烧区模型控制方程

Table 3 Governing equations of the MEKL combustion zone model

方程	公式
连续性方程	$\frac{\partial}{\partial t} (α_{q} ρ_{q}) + \nabla \cdot (α_{q} ρ_{q} v_{q}) = S_{q} + \sum_{p = 1}^{n} (m_{p q} - m_{q p})$
动量方程	$\frac{\partial}{\partial t} (α_{q} ρ_{q} v_{q}) + \nabla \cdot (α_{q} ρ_{q} v_{q} v_{q}) = - α_{q} \nabla p + \nabla \cdot {\bar{\bar{τ}}}_{q} + α_{q} ρ_{q} g + \sum_{p = 1}^{n} (R_{p q} + m_{p q} v_{p q} - m_{q p} v_{q p}) + (F_{q} + F_{l i f t, q} + F_{w l, q} + F_{v m, q} + F_{t d, q})$ $\frac{\partial}{\partial t} (α_{s} ρ_{s} v_{s}) + \nabla \cdot (α_{s} ρ_{s} v_{s} v_{s}) = - α_{s} \nabla p - \nabla p_{s} + \nabla \cdot {\bar{\bar{τ}}}_{s} + α_{s} ρ_{s} g + \sum_{p = 1}^{n} (R_{p s} + m_{p s} v_{p s} - m_{s p} v_{s p}) + (F_{s} + F_{l i f t, s} + F_{v m, q} + F_{t d, s})$
能量方程	$\frac{\partial}{\partial t} (α_{q} ρ_{q} h_{q}) + \nabla \cdot (α_{q} ρ_{q} v_{q} h_{q}) = α_{q} \frac{\partial p_{q}}{\partial t} + {\bar{\bar{τ}}}_{q} : \nabla v_{q} - \nabla \cdot q_{q} + S_{q} + \sum_{p = 1}^{n} (Q_{p q} + m_{p q} h_{p q} - m_{q p} h_{q p})$
组分传输方程	$\frac{\partial}{\partial t} (α_{q} ρ_{q} Y_{i, q}) + \nabla \cdot (α_{q} ρ_{q} v_{q} Y_{i, q}) = - \nabla \cdot α_{q} J_{i, q} + α_{q} R_{i, q} + α_{q} S_{i, q} + \sum_{p = 1}^{n} (m_{i, p \to q} - m_{q \to p . i}) + R$
气体状态方程	$ρ = \frac{p_{o p} + p}{\frac{R}{M_{w e i g h t}} T}$
湍流模型	$\frac{\partial}{\partial t} (α_{q} ρ_{q} k_{q}) + \nabla \cdot (α_{q} ρ_{q} U_{q} k_{q}) = \nabla \cdot [α_{q} (μ_{q} + \frac{μ_{t, q}}{σ_{k}}) \nabla k_{q}] + α_{q} G_{k, q} - α_{q} ρ_{q} ε_{q} + α_{q} ρ_{q} Π_{k_{q}}$ $\frac{\partial}{\partial t} (α_{q} ρ_{q} ε_{q}) + \nabla \cdot (α_{q} ρ_{q} U_{q} ε_{q}) = \nabla \cdot [α_{q} (μ_{q} + \frac{μ_{t, q}}{σ_{ε}}) \nabla ε_{q}] + α_{q} \frac{ε_{q}}{k_{q}} (C_{1 ε} G_{k, q} - C_{2 ε} ρ_{q} ε_{q}) + α_{q} ρ_{q} Π_{ε_{q}}$
气固动量交换方程	$K_{s l} = ψ K_{s l - E r g u n} + (1 - ψ) K_{s l - W e n & Y u}$
固相黏度方程	$μ_{s} = μ_{s, c o l} + μ_{s, k i n} + μ_{s, f r}$
气固换热方程	$h_{p q} = \frac{κ_{q} N u_{p}}{d_{p}}$
颗粒相温度方程	$\frac{3}{2} [\frac{\partial}{\partial t} (α_{s} ρ_{s} θ_{s}) + \nabla \cdot (α_{s} ρ_{s} v_{s} θ_{s})] = (- p_{s} \bar{\bar{I}} + {\bar{\bar{τ}}}_{s}) : \nabla v_{s} + \nabla \cdot (k_{θ_{s}} \nabla θ_{s}) - γ_{θ_{s}} + ϕ_{l s}$

表3 熔渣气化炉喷嘴燃烧区模型控制方程

Table 3 Governing equations of the MEKL combustion zone model

方程	公式
连续性方程	$\frac{\partial}{\partial t} (α_{q} ρ_{q}) + \nabla \cdot (α_{q} ρ_{q} v_{q}) = S_{q} + \sum_{p = 1}^{n} (m_{p q} - m_{q p})$
动量方程	$\frac{\partial}{\partial t} (α_{q} ρ_{q} v_{q}) + \nabla \cdot (α_{q} ρ_{q} v_{q} v_{q}) = - α_{q} \nabla p + \nabla \cdot {\bar{\bar{τ}}}_{q} + α_{q} ρ_{q} g + \sum_{p = 1}^{n} (R_{p q} + m_{p q} v_{p q} - m_{q p} v_{q p}) + (F_{q} + F_{l i f t, q} + F_{w l, q} + F_{v m, q} + F_{t d, q})$ $\frac{\partial}{\partial t} (α_{s} ρ_{s} v_{s}) + \nabla \cdot (α_{s} ρ_{s} v_{s} v_{s}) = - α_{s} \nabla p - \nabla p_{s} + \nabla \cdot {\bar{\bar{τ}}}_{s} + α_{s} ρ_{s} g + \sum_{p = 1}^{n} (R_{p s} + m_{p s} v_{p s} - m_{s p} v_{s p}) + (F_{s} + F_{l i f t, s} + F_{v m, q} + F_{t d, s})$
能量方程	$\frac{\partial}{\partial t} (α_{q} ρ_{q} h_{q}) + \nabla \cdot (α_{q} ρ_{q} v_{q} h_{q}) = α_{q} \frac{\partial p_{q}}{\partial t} + {\bar{\bar{τ}}}_{q} : \nabla v_{q} - \nabla \cdot q_{q} + S_{q} + \sum_{p = 1}^{n} (Q_{p q} + m_{p q} h_{p q} - m_{q p} h_{q p})$
组分传输方程	$\frac{\partial}{\partial t} (α_{q} ρ_{q} Y_{i, q}) + \nabla \cdot (α_{q} ρ_{q} v_{q} Y_{i, q}) = - \nabla \cdot α_{q} J_{i, q} + α_{q} R_{i, q} + α_{q} S_{i, q} + \sum_{p = 1}^{n} (m_{i, p \to q} - m_{q \to p . i}) + R$
气体状态方程	$ρ = \frac{p_{o p} + p}{\frac{R}{M_{w e i g h t}} T}$
湍流模型	$\frac{\partial}{\partial t} (α_{q} ρ_{q} k_{q}) + \nabla \cdot (α_{q} ρ_{q} U_{q} k_{q}) = \nabla \cdot [α_{q} (μ_{q} + \frac{μ_{t, q}}{σ_{k}}) \nabla k_{q}] + α_{q} G_{k, q} - α_{q} ρ_{q} ε_{q} + α_{q} ρ_{q} Π_{k_{q}}$ $\frac{\partial}{\partial t} (α_{q} ρ_{q} ε_{q}) + \nabla \cdot (α_{q} ρ_{q} U_{q} ε_{q}) = \nabla \cdot [α_{q} (μ_{q} + \frac{μ_{t, q}}{σ_{ε}}) \nabla ε_{q}] + α_{q} \frac{ε_{q}}{k_{q}} (C_{1 ε} G_{k, q} - C_{2 ε} ρ_{q} ε_{q}) + α_{q} ρ_{q} Π_{ε_{q}}$
气固动量交换方程	$K_{s l} = ψ K_{s l - E r g u n} + (1 - ψ) K_{s l - W e n & Y u}$
固相黏度方程	$μ_{s} = μ_{s, c o l} + μ_{s, k i n} + μ_{s, f r}$
气固换热方程	$h_{p q} = \frac{κ_{q} N u_{p}}{d_{p}}$
颗粒相温度方程	$\frac{3}{2} [\frac{\partial}{\partial t} (α_{s} ρ_{s} θ_{s}) + \nabla \cdot (α_{s} ρ_{s} v_{s} θ_{s})] = (- p_{s} \bar{\bar{I}} + {\bar{\bar{τ}}}_{s}) : \nabla v_{s} + \nabla \cdot (k_{θ_{s}} \nabla θ_{s}) - γ_{θ_{s}} + ϕ_{l s}$

表4 熔渣气化炉燃烧模型涉及化学反应及速率

Table 4 Chemical reactions and kinetics of the MEKL combustion zone model

C + O₂

\overset{}{̿}

CO₂

指前因子：1.04×10⁵

温度指数β：1.0

活化能：9.31×10⁷

碳气化^[34]

C + CO₂

\overset{}{̿}

2CO

指前因子：2224

温度指数β：0.0

活化能：2.199×10⁸

水煤气反应^[35]

C + H₂O

\overset{}{̿}

H₂ + CO

指前因子：63.3

温度指数β：0.0

活化能：1.168×10⁷

表4 熔渣气化炉燃烧模型涉及化学反应及速率

Table 4 Chemical reactions and kinetics of the MEKL combustion zone model

反应类型

化学反应方程

化学反应速率

碳燃烧^[33]

C + O₂

\overset{}{̿}

CO₂

指前因子：1.04×10⁵

温度指数β：1.0

活化能：9.31×10⁷

碳气化^[34]

C + CO₂

\overset{}{̿}

2CO

指前因子：2224

温度指数β：0.0

活化能：2.199×10⁸

水煤气反应^[35]

C + H₂O

\overset{}{̿}

H₂ + CO

指前因子：63.3

温度指数β：0.0

活化能：1.168×10⁷

表5 熔渣气化炉燃烧区数学模型算例设置

Table 5 Case settings of the MEKL combustion zone model

项目

参数

基准算例

气化剂质量流量：

氧气137180 kg/h;

水蒸气12621 kg/h

气化剂入口温度：513 K

气化剂流量的影响

基准算例气化剂流量的0.5, 1.0, 1.5, 2.0倍

图3 喷嘴燃烧区模型验证所需几何和网格

Fig.3 The geometry and mesh adopted in the model validation

表6 模型验证所用参数及设置

Table 6 Parameters and settings used in the model validation

模型参数设置	具体设置
模型基础框架	欧拉-欧拉多相流模型
模型主相	气相
模型次相	颗粒相
气相性质	密度：1.225 kg/m³, 黏度：1.789×10^-5 kg/(m·s)
曳力模型	Huilin-Gidspow
操作条件	压强：101325 Pa, 温度：298 K
算例1	气相入口速度：65 m/s 气相入口直径：0.001 m 颗粒填充高度：0.20 m
算例2	气相入口速度：85 m/s 气相入口直径：0.002 m 颗粒填充高度：0.30 m
算例3	气相入口速度：112 m/s 气相入口直径：0.003 m 颗粒填充高度：0.25 m

图4 模型结果与实验测量结果对比

Fig.4 Comparison of the experimental measurement with the simulation result

图5 模型预测的燃烧区深度与实验测量结果对比

Fig.5 Comparison of the calculated depth of the combustion zone with the experimental measurement

图6 模型所得煤气成分变化规律与文献[37]结果对比

Fig.6 Comparison of calculated gas composition with previous study[37]

图7 模型网格无关性验证

Fig.7 Mesh independent test of the model

图8 熔渣气化炉中喷嘴前端燃烧区形成过程

Fig.8 Formation process of the combustion zone at the front end of the nozzle in the slagging gasifier

图9 熔渣气化炉中喷嘴前端高温区形成过程

Fig.9 Formation process of high temperature zone at front end of nozzle in slagging gasifier

图10 熔渣气化炉中喷嘴前端氧气分布

Fig.10 Distribution of oxygen at front end of nozzle in slagging gasifier

图11 熔渣气化炉中喷嘴前端水蒸气分布

Fig.11 Distribution of water vapor at front end of nozzle in slagging gasifier

图12 熔渣气化炉中喷嘴前端一氧化碳分布

Fig.12 Distribution of carbon monoxide at front end of nozzle in slagging gasifier

图13 熔渣气化炉中喷嘴前端二氧化碳分布

Fig.13 Distribution of carbon dioxide at front end of nozzle in slagging gasifier

图14 熔渣气化炉中喷嘴前端氢气分布

Fig.14 Distribution of hydrogen at front end of nozzle in slagging gasifier

图15 气化剂流量对含碳颗粒运动的影响

Fig.15 Effects of the flowrate of gasification agent on the movement of carbon-containing particles

图16 气化剂流量对气体速度的影响

Fig.16 Effects of the flowrate of gasification agent on the gas velocity

图17 气化剂流量对气体温度的影响

Fig.17 Effects of the flowrate of gasification agent on the gas temperature

图18 气化剂流量对氧气分布的影响

Fig.18 Effects of the flowrate of gasification agent on the oxygen distribution

图19 气化剂流量对水蒸气分布的影响

Fig.19 Effects of the flowrate of gasification agent on the water vapor distribution

图20 气化剂流量对氢气分布的影响

Fig.20 Effects of the flowrate of gasification agent on the hydrogen distribution

图21 气化剂流量对一氧化碳分布的影响

Fig.21 Effects of the flowrate of gasification agent on the carbon monoxide distribution

图22 气化剂流量对二氧化碳分布的影响

Fig.22 Effects of the flowrate of gasification agent on the carbon dioxide distribution

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