一、鎳基釬焊熱管技術(shù)的工作原理

　　1、 Working principle of nickel based brazed heat pipe technology

　　鎳基釬焊管，即將鎳鉻合金滲入鍋爐管或ND鋼（耐低溫露點腐蝕鋼）表面，形成致密光滑涂層，使管片和母管的焊著率為100%，有效地擴(kuò)展了換熱面積，提高了換熱系數(shù)，同時具有很好的耐高溫和耐腐蝕性能。

　　Nickel based brazed pipe, which involves the infiltration of nickel chromium alloy into the surface of boiler tubes or ND steel (low temperature dew point corrosion resistant steel) to form a dense and smooth coating, resulting in a 100% welding rate between the pipe segments and the main pipe. This effectively expands the heat transfer area, improves the heat transfer coefficient, and has good high temperature and corrosion resistance.

　　熱管是一種具有很高熱傳輸性能的元件，它集沸騰與凝結(jié)于一身，由管殼、管芯和傳導(dǎo)液組成。它的工作原理是：當(dāng)蒸發(fā)段遇到高溫介質(zhì)時，管內(nèi)傳導(dǎo)液吸收蒸發(fā)潛熱后蒸發(fā)，傳導(dǎo)液蒸汽從管中心絕熱段通道流向凝結(jié)段，并放出潛熱，重新凝結(jié)成傳導(dǎo)液，凝結(jié)后的傳導(dǎo)液借助管芯的毛細(xì)力作用重新返回蒸發(fā)段再進(jìn)行蒸發(fā)，這樣形成了一個閉合的循環(huán)系統(tǒng)。通過這種途徑，熱量從加熱區(qū)到了散熱區(qū)，對被加熱介質(zhì)進(jìn)行加熱，得到所需溫度的介質(zhì)。

　　A heat pipe is a component with high heat transfer performance, which combines boiling and condensation, and is composed of a shell, core, and conductive fluid. Its working principle is that when the evaporation section encounters a high-temperature medium, the conductive liquid inside the tube absorbs the latent heat of evaporation and evaporates. The conductive liquid vapor flows from the adiabatic section channel at the center of the tube to the condensation section, releasing latent heat and re condensing into conductive liquid. The condensed conductive liquid returns to the evaporation section for further evaporation by the capillary force of the tube core, thus forming a closed loop system. Through this pathway, heat is transferred from the heating zone to the heat dissipation zone, heating the heated medium to obtain the desired temperature of the medium.

　　鎳基釬焊熱管式余熱回收裝置利用高溫?zé)煔夂捅患訜峤橘|(zhì)傳熱系數(shù)的不同（煙氣傳熱系數(shù)小，被加熱介質(zhì)傳熱系數(shù)的高），因而在傳熱系數(shù)小的煙氣側(cè)擴(kuò)展換熱面積，將熱端—鎳基釬焊翅片吸收的熱量，與冷端—光管傳熱系數(shù)高的被加熱介質(zhì)所吸收的熱量相同，使之產(chǎn)生有效的換熱平衡。

　　The nickel based brazed heat pipe type waste heat recovery device utilizes the difference in heat transfer coefficients between high-temperature flue gas and the heated medium (the flue gas has a lower heat transfer coefficient and the heated medium has a higher heat transfer coefficient), thus expanding the heat transfer area on the flue gas side with a lower heat transfer coefficient. The heat absorbed by the hot end nickel based brazed fins is equal to the heat absorbed by the heated medium with a higher heat transfer coefficient between the cold end and the light pipe, creating an effective heat transfer balance.

　　二、鎳基釬焊熱管式余熱回收裝置的結(jié)構(gòu)特點

　　2、 Structural characteristics of nickel based brazed heat pipe type waste heat recovery device

　　1、結(jié)構(gòu)緊湊

　　1. Compact structure

　　單位長度的釬焊熱管換熱面積是普通光管的七倍左右，同時釬焊熱管之間用小半徑推制彎頭連接。因而相同換熱面積的釬焊熱管余熱回收裝置普通光管的設(shè)備相比，其體積和占地面積成數(shù)倍的減小，并且其重量也有不同幅度的降低。因而，在設(shè)備布置安裝和吊裝等方面為用戶提供了很大的空間。

　　The heat transfer area of brazed heat pipes per unit length is about seven times that of ordinary bare pipes, and brazed heat pipes are connected by small radius push bends. Therefore, compared to ordinary bare tube equipment, the volume and footprint of brazed heat pipe waste heat recovery devices with the same heat exchange area are reduced several times, and their weight is also reduced to varying degrees. Therefore, it provides users with a lot of space in terms of equipment layout, installation, and lifting.

　　2、維修方便

　　2. Easy maintenance

　　釬焊熱管是采用整根無縫鋼管制造完成的，使其具有很高的耐壓性能，一般情況很少出現(xiàn)質(zhì)量方面的問題。如果偶然發(fā)現(xiàn)某一根釬焊熱管出現(xiàn)泄漏，也可以方便地進(jìn)行更換，即使不更換也不影響運行。

　　Brazed heat pipes are made of seamless steel pipes, which have high pressure resistance and rarely have quality issues. If a leakage is accidentally discovered in a brazed heat pipe, it can be easily replaced without affecting operation.

　　3、受壓元件無熱應(yīng)力

　　3. Pressure bearing components have no thermal stress

　　每一根釬焊熱管組裝時，無任何強(qiáng)制組裝現(xiàn)象，因而不會產(chǎn)生組裝應(yīng)力。同時每一端呈自由狀態(tài)。這樣設(shè)備在運行過程中，無熱應(yīng)力產(chǎn)生。

　　When assembling each brazed heat pipe, there is no forced assembly phenomenon, so there will be no assembly stress. At the same time, each end is in a free state. In this way, there is no thermal stress generated during the operation of the device.

　　4、標(biāo)準(zhǔn)化設(shè)計和靈活的尺寸變化

　　4. Standardized design and flexible size changes

　　迄今為止，我們已開發(fā)設(shè)計了多系列的標(biāo)準(zhǔn)產(chǎn)品。廣泛應(yīng)用于大中小型柴油機(jī)和天然氣發(fā)電機(jī)組，以及鍋爐的高溫?zé)煔獾挠酂峄厥绽?，另外，我們可在短時間內(nèi)按照用戶要求，根據(jù)用戶提供的設(shè)計參數(shù)，對各種余熱回收裝置進(jìn)行靈活設(shè)計。

　　So far, we have developed and designed multiple series of standard products. Widely used in large, medium, and small diesel engines, natural gas generator sets, as well as high-temperature flue gas recovery and utilization in boilers. In addition, we can flexibly design various waste heat recovery devices according to user requirements and design parameters provided by users in a short period of time.

　　5、可高效連續(xù)的運行

　　5. Can operate efficiently and continuously

　　根據(jù)其傳熱機(jī)理和結(jié)構(gòu)特點，我們不難得知，釬焊熱管技術(shù)具有較強(qiáng)的防垢、防灰和自除垢、除灰能力。因而其設(shè)備可以長時間的保持高效運行，這是普通光管換熱設(shè)備所不能比擬的。

　　Based on its heat transfer mechanism and structural characteristics, it is not difficult to know that brazed heat pipe technology has strong anti scaling, anti ash, and self descaling and ash removal capabilities. Therefore, its equipment can maintain efficient operation for a long time, which is incomparable to ordinary light tube heat exchange equipment.

　　三、設(shè)計目的

　　3、 Design purpose

　　本設(shè)計利用10臺500kW瓦斯發(fā)電機(jī)組高溫?zé)煔庥酂岙a(chǎn)生5kgf/cm2飽和蒸汽用于生產(chǎn)。該電站10臺500kW瓦斯發(fā)電機(jī)組，測試結(jié)果表明，所燃?xì)怏w至多36%的熱量用來發(fā)電，約有38%的熱量通過高溫?zé)煔馀趴?。為充分利用余熱，設(shè)計一套余熱利用系統(tǒng)，充分利用高溫?zé)煔鉄崃?，使所燃?xì)怏w總熱量70%得到應(yīng)用。

　　This design utilizes 10 500kW gas generator units to generate 5kgf/cm2 saturated steam from high-temperature flue gas waste heat for production. The power station has 10 500kW gas generator units, and the test results show that up to 36% of the heat generated by the burned gas is used for power generation, and about 38% of the heat is discharged through high-temperature flue gas. To fully utilize waste heat, a waste heat utilization system is designed to fully utilize the heat of high-temperature flue gas, so that 70% of the total heat of the burned gas is applied.

　　四、系統(tǒng)組成及原理

　　4、 System composition and principle

　　鎳基釬焊熱管式余熱回收裝置是以鎳基釬焊熱管作為換熱元件，將煙氣的熱量通過擴(kuò)大受熱面積的熱管段傳遞給壓力汽包中的介質(zhì)。在其中加熱介質(zhì),采用自然循環(huán)的形式，把水變?yōu)轱柡驼羝?。通過水位控制器控制蒸汽空間，提高飽和蒸汽的質(zhì)量，當(dāng)水位達(dá)到低水位時，控制柜將信號給給水泵，水泵開啟送水直到水位達(dá)到高水位止，如此反復(fù)循環(huán)。系統(tǒng)主要由煙氣——水熱交換器（熱管蒸發(fā)器）、給水泵、閥門儀表、輸水輸汽管線、輸氣管線等組成。

　　The nickel based brazed heat pipe type waste heat recovery device uses nickel based brazed heat pipes as heat exchange elements to transfer the heat of flue gas to the medium in the pressure steam drum through the heat pipe section that expands the heating area. In it, the heating medium adopts a natural circulation form to turn water into saturated steam. By controlling the steam space through a water level controller, the quality of saturated steam is improved. When the water level reaches a low level, the control cabinet sends a signal to the feed pump, which starts to supply water until the water level reaches a high level. This cycle is repeated. The system mainly consists of a flue gas water heat exchanger (heat pipe evaporator), a feedwater pump, valves and instruments, water and steam pipelines, and gas pipelines.

　　系統(tǒng)的設(shè)計壓力為1.2Mpa，蒸汽介質(zhì)工作溫度在152℃，蒸汽量為4246kg/h，熱交換量為2675400kcal/h。

　　The design pressure of the system is 1.2Mpa, the working temperature of the steam medium is 152 ℃, the steam volume is 4246kg/h, and the heat exchange capacity is 2675400kcal/h.

　　五、熱工計算

　　5、 Thermal calculation

　　瓦斯在空氣中完全燃燒公式：

　　Formula for complete combustion of gas in air:

　　圖片

　　image

　　瓦斯在空氣中不完全燃燒公式：

　　Formula for incomplete combustion of gas in air:

　　圖片

　　image

　　瓦斯發(fā)電機(jī)組正常運轉(zhuǎn)時，發(fā)電功率為450kW、排煙溫度為550℃左右，當(dāng)鎳基釬焊熱管熱交換器出水溫度為152℃左右時，它排出的煙氣溫度為150℃，瓦斯完全燃燒時和空氣的體積比為1:10，為使燃料充分燃燒，一般燃?xì)馀c空氣的混合比例為1:13，（按1m3純瓦斯發(fā)3度電計算）

　　When the gas generator set operates normally, the power generation is 450kW and the exhaust temperature is around 550 ℃. When the outlet temperature of the nickel based brazed heat pipe heat exchanger is around 152 ℃, the exhaust temperature is 150 ℃. When the gas is completely burned, the volume ratio of gas to air is 1:10. In order to fully burn the fuel, the mixing ratio of gas to air is generally 1:13 (calculated based on 1m3 of pure gas generating 3 kWh of electricity)

　　500kW機(jī)組的耗氣總量為：450/3×（1＋13）＝2100m3/h。

　　The total gas consumption of a 500kW unit is 450/3 × (1+13)=2100m3/h.

　　平均重量按1.25kg/m3計算，總重：2100×1.25＝2625kg

　　The average weight is calculated at 1.25kg/m3, and the total weight is 2100 × 1.25=2625kg

　　排煙的比熱容按煙道氣體計算（煙道氣體的成分CO:13%，H2O:11%，N2:76%，在100℃—600℃的平均定壓比熱容為0.26kcal/kg·℃）。

　　The specific heat capacity of smoke exhaust is calculated based on the composition of flue gas (CO: 13%, H2O: 11%, N2: 76%, with an average constant pressure specific heat capacity of 0.26kcal/kg ·℃ at 100 ℃ -600 ℃).

　　圖片

　　image

　　10臺發(fā)電機(jī)組可利用排煙余熱產(chǎn)生5kgf/cm2蒸汽為：

　　10 generator sets can generate 5kgf/cm2 steam by utilizing exhaust waste heat

　?。?50－150）×0.26×2625×0.98×10＝2675400kcal/h

　?。?50－150）×0.26×2625×0.98×10＝2675400kcal/h

　　按進(jìn)水溫度20℃計算，蒸汽溫度152℃，蒸汽的熱含650kcal/kg則每小時可產(chǎn)生總蒸

　　Calculated based on an inlet water temperature of 20 ℃, a steam temperature of 152 ℃, and a steam heat content of 650kcal/kg, the total steam generated per hour can be calculated

　　汽量為：

　　The steam volume is:

　　2675400÷（650－20）＝4246kg

　　2675400÷（650－20）＝4246kg

　　方案1：用于夏季制冷

　　Option 1: Used for summer cooling

　　根據(jù)國內(nèi)制冷設(shè)備廠提供樣本參數(shù)來看，4246kg的蒸汽能夠帶動3957kw的溴化鋰機(jī)組。根據(jù)以往經(jīng)驗值來看按每平方米制冷量100瓦計算，則可供制冷面積為；

　　According to the sample parameters provided by domestic refrigeration equipment manufacturers, 4246kg of steam can drive 3957kw lithium bromide units. Based on past experience, if calculated at a cooling capacity of 100 watts per square meter, the available cooling area is;

　　3957kw×1000w÷100w/m2＝39570m2

　　3957kw×1000w÷100w/m2＝39570m2

　　方案2用于冬季供暖：

　　Option 2 for winter heating:

　　按進(jìn)水溫度20℃計算，加熱成95℃熱水計算，每小時可產(chǎn)生熱水量為：

　　Calculated based on an inlet water temperature of 20 ℃ and heated to 95 ℃ hot water, the amount of hot water produced per hour is:

　　2675400kcal/h÷（95℃－20℃）＝35672kg/h；

　　2675400kcal/h÷（95℃－20℃）＝35672kg/h；

　　按每平方米取暖熱量80瓦計算，則可供暖面積為（自熱工手冊中查得：每千瓦熱量合860千卡：2675400kcal/h÷860Kcal/kw=3110kw）:

　　Calculated based on a heating capacity of 80 watts per square meter, the available heating area is (according to the thermal manual: 860 kilocalories per kilowatt of heat: 2675400kcal/h ÷ 860Kcal/kw=3110kw):

　　3110kw×1000w/kw÷80w/m2＝38886m2

　　3110kw×1000w/kw÷80w/m2＝38886m2

　　注：瓦斯實際在缸內(nèi)燃燒不完全，產(chǎn)生一定量的一氧化碳，并在排氣管中繼續(xù)燃燒；實

　　Note: Gas actually burns incompletely in the cylinder, producing a certain amount of carbon monoxide, which continues to burn in the exhaust pipe; real

　　際煙氣排出的熱能比計算值要多。

　　The heat energy emitted from the flue gas is greater than the calculated value.

　　六、施工說明

　　6、 Construction Instructions

　　1、系統(tǒng)中的管線分別采用以下具體規(guī)格DN80（給水主管線）、DN100（蒸汽主管線）。

　　1. The pipelines in the system adopt the following specific specifications: DN80 (water supply main pipeline) and DN100 (steam main pipeline).

　　2、鎳基釬焊熱管式熱交換器：安裝在現(xiàn)有發(fā)電機(jī)組的上部外端，盡量靠近發(fā)動機(jī)排氣口，將消聲器改裝在換熱器的尾部上。

　　2. Nickel based brazed heat pipe heat exchanger: installed at the upper outer end of the existing generator set, as close as possible to the engine exhaust port, with the muffler modified at the rear of the heat exchanger.

　　3、排氣口到換熱器、消聲器管線采取保溫措施，保溫材料選用厚100mm硅酸鋁，用鋼絲捆扎，外包鍍鋅鐵皮，用鉚釘固緊。

　　3. Insulation measures shall be taken for the pipeline from the exhaust port to the heat exchanger and muffler. The insulation material shall be 100mm thick aluminum silicate, tied with steel wire, wrapped with galvanized iron sheet, and fastened with rivets.

　　4、給水和蒸汽輸送管線采用架空鋪設(shè)或埋地鋪設(shè)，首先在管線表面涂刷防銹漆兩道，然后采用60mm巖棉管包扎保溫，用鋼絲捆扎，外包油氈玻璃絲布防雨層，最外層刷綠色面漆，并用紅箭頭標(biāo)示水流方向。

　　4. The water supply and steam transmission pipelines are laid overhead or underground. First, two layers of anti rust paint are applied to the surface of the pipeline. Then, 60mm rock wool pipes are wrapped for insulation, tied with steel wire, and covered with oil felt glass wool cloth for rain protection. The outermost layer is painted with green topcoat and marked with red arrows indicating the direction of water flow.

　　5、系統(tǒng)安裝完畢后，進(jìn)行管線沖洗和水壓試驗，試驗壓力1.5MPa，沖洗試壓后方可開泵試運行。

　　5. After the system installation is completed, pipeline flushing and water pressure testing shall be carried out with a test pressure of 1.5MPa. The pump can only be started for trial operation after flushing and pressure testing.

　　七、經(jīng)濟(jì)效益綜合分析及報價

　　7、 Comprehensive analysis and quotation of economic benefits

　　鎳基釬焊熱管式余熱回收裝置

　　Nickel based brazed heat pipe type waste heat recovery device

　　蒸汽型——汽水分離器和設(shè)備合為一體

　　Steam type - steam water separator and equipment integrated

　　每套報價：——萬元.，10套合計價格為：——萬元

　　Price per set: -10000 yuan The total price for 10 sets is: -10000 yuan

　　1、設(shè)備型號及參數(shù)

　　1. Equipment model and parameters

　　型號：——

　　Model:——

　　設(shè)計壓力：1.0MPa;

　　Design pressure: 1.0MPa;

　　換熱面積：當(dāng)量面積——m2；實際換熱面積——m2；

　　Heat exchange area: equivalent area - m2; actual heat exchange area - m2;

　　適合發(fā)電機(jī)實際輸出功率：500kw機(jī)組；

　　Suitable for actual output power of generators: 500kW units;

　　2、供貨范圍

　　2. Scope of Supply

　　設(shè)備主體包括保溫，主要受壓元件采用鍋爐管制造；配套閥門儀表：安全閥、蒸汽出口閥、排污閥、放空閥、壓力表、壓力表彎、針形閥、給水閥、水位控制器、雙色水位計；配對法蘭：余熱回收裝置與煙道連接的DN250法蘭2片；耐高溫三通閥：耐溫1000℃，耐熱不銹鋼內(nèi)膽，型號DN250帶配對法蘭；全自動控制柜；換熱器給水泵；

　　The main body of the equipment includes insulation, and the main pressure components are made of boiler tubes; Supporting valve instruments: safety valve, steam outlet valve, drain valve, vent valve, pressure gauge, pressure gauge bend, needle valve, water supply valve, water level controller, dual color water level gauge; Paired flange: Two DN250 flanges connecting the waste heat recovery device to the flue; High temperature resistant three-way valve: resistant to 1000 ℃, heat-resistant stainless steel inner liner, model DN250 with matching flange; Fully automatic control cabinet; Heat exchanger feedwater pump;

　　3、經(jīng)濟(jì)效益

　　3. Economic benefits

　　按每臺發(fā)電機(jī)每年正常運行300天，每噸蒸汽的價值為60元計算，10臺發(fā)電機(jī)每年余熱回收所產(chǎn)生的價值為：

　　Based on the normal operation of each generator for 300 days per year and a value of 60 yuan per ton of steam, the value of waste heat recovery generated by 10 generators per year is:

　　60×24×300×4.246≈183.4萬元

　　60 × 24 × 300 × 4.246 ≈ 1.834 million yuan

　　4、投資回收期：

　　4. Investment payback period:

　　設(shè)備投資：——萬元；

　　Equipment investment: -10000 yuan;

　　X÷183.4×12≈Y（個月）

　　X ÷ 183.4 × 12 ≈ Y (months)

　　綜合上述可知，10臺發(fā)電機(jī)機(jī)組余熱回收系統(tǒng)成本可在Y個月內(nèi)收回，本系統(tǒng)運行期按5年計算，可節(jié)約資金——萬元。

　　Based on the above, it can be concluded that the cost of the waste heat recovery system for 10 generator units can be recovered within Y months. If the operating period of this system is calculated as 5 years, it can save tens of thousands of yuan in funds.

　　八、熱管式余熱回收裝置與針管式余熱回收裝置性能比較

　　8、 Performance comparison between heat pipe waste heat recovery device and needle tube waste heat recovery device

　　具有以下優(yōu)點：

　　It has the following advantages:

　　1、設(shè)備投資省

　　1. Equipment Investment Province

　　因為針管式不能采用氣包和換熱器連為一體的結(jié)構(gòu)，需要單獨的汽水分離器，同時需要熱水循環(huán)泵兩臺，設(shè)備造價相比較要高出10%左右；

　　Because the needle tube type cannot adopt a structure that integrates an air bag and a heat exchanger, a separate steam water separator is required, and two hot water circulation pumps are needed, resulting in an equipment cost that is about 10% higher compared to others;

　　2、運行費用低

　　2. Low operating costs

　　因為針管式余熱回收裝置要產(chǎn)蒸汽需采用強(qiáng)制循環(huán)，這樣僅熱水循環(huán)泵的運行費用一項，按循環(huán)泵揚程50米，流量50立方米，電機(jī)功率20千瓦計算，每年耗電量為15萬千瓦時，折合人民幣7.5萬元。

　　Because the needle type waste heat recovery device requires forced circulation to produce steam, only the operating cost of the hot water circulation pump is included. Calculated based on the pump head of 50 meters, flow rate of 50 cubic meters, and motor power of 20 kilowatts, the annual power consumption is 150000 kilowatt hours, equivalent to 75000 yuan.

　　3、換熱效果好

　　3. Good heat exchange effect

　　同樣面積的兩種換熱器，熱管的換熱效果明顯優(yōu)于針管，吸收熱量相對要多一些，如同樣60平方米的換熱器，同樣產(chǎn)0.6MPa飽和蒸汽，熱管換熱器煙氣出口溫度比針管的低15℃。

　　Two types of heat exchangers with the same area, the heat transfer effect of the heat pipe is significantly better than that of the needle pipe, absorbing relatively more heat. For example, a 60 square meter heat exchanger produces 0.6MPa saturated steam, and the exhaust gas outlet temperature of the heat pipe heat exchanger is 15 ℃ lower than that of the needle pipe.

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