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高管式加热炉热效率、实现节能减排，而且能够实现经济效益与社会效益的共赢。 本设计的管式加热炉应用于常减压工艺，综合给定的加热炉设计条件、设计要求、加热炉可能出现的运行情况及经济效益等因素的限制，对所要设计的管式加热炉的类型及设计方案进行优化筛选，最终选用两台辐射-对流型圆筒加热炉联合运行方案。本设计方案的核心部分是管式加热炉的工艺计算，即：加热炉总热负荷计算、燃料燃烧的计算、燃料用量和烟气流量计算、辐射段及对流段的热力计算及校核计算、辐射室与对流室的结构尺寸计算、炉内压力计算、烟气阻力计算、烟囱理论最低高度计算等。查阅管式加热炉节能方面的文献，该设计采用了半预混式瓦斯喷嘴、声波吹灰器、陶质纤维炉墙结构，并选择螺杆膨胀机作为烟气余热再利用设备，这不仅提高了辐射-对流型圆筒加热炉的综合热效率，还能够很好的做到节能减排。
关键词：常减压工艺；辐射—对流型加热炉；工艺计算；余热再利用
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Abstract
Tube heating furnace is the main heating equipment in the refinery and one of the major energy-consuming equipment. Tube heating furnace is almost involved in various types of process of oil processing, and is the major equipment to achieve cleavage and conversion reaction, and determines the product quality and energy consumption of the entire refinery or device. In today's extremely tight energy supply-demand relationship, through rational design, and optimization of the structure of the tube heating furnace system, it can not only improve thermal efficiency of the tube heating furnace, achieve energy conservation, but also achieve win-win economic and social benefits. The tube heating furnace in this design is applied to the atmospheric-vacuum technology. In this paper, the given design conditions, design requirements and the possible operations that may arise and economic benefits and limiting factors are integrated to optimize and screen the type of the tube heating furnace to be designed and design proposals. The combined operation scheme of two sets of radiation-convection cylindrical heating furnaces is finally chosen. The core part of this design is the process calculation of the tube furnace, that is the calculation of the total heat load of heating furnace, fuel combustion, fuel consumption and flue gas flow, the thermodynamic calculation of the radiation section and convection section and check calculation, the calculation of the structural dimensions of the radiation chamber and convection room, the calculation of furnace pressure, the flue gas resistance, and of the theoretically minimum height of chimney and other calculations. After consulting the literature concerning the energy saving of tube furnaces, this design adopts the semi-pre-mixed gas nozzle, the
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sonic soot blower, the ceramic fiber furnace wall structure and selects the screw expander as the waste heat recycling equipment of flue gas, which not only improves the overall thermal efficiency of the radiation-convection cylindrical heating furnace, but also achieves energy conservation and emission reduction.
Key words : Atmospheric-vacuum process；Radiation-convection type heating furnace；Process calculation；Recyling of waste heat
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目 录
1 引 言 ................................................................................................................................................. 1
1.1 选题的依据及意义 ............................................................................................................. 1
1.2 国内外炼化工艺加热炉节能技术应用现状及发展趋势 ......................................... 1
1.2.1 国外炼化工艺加热炉节能技术应用现状 ....................................................... 1
1.2.2 国内炼化工艺加热炉节能技术应用现状 ....................................................... 2
1.2.3 炼化工艺加热炉节能技术发展趋势................................................................. 2
1.3 设计的创新点 ...................................................................................................................... 3
1.4 设计方案 ............................................................................................................................... 3
2管式加热炉工艺计算 ...................................................................................................................... 4
2.1 计算设计热负荷及加热炉选型 ...................................................................................... 4
2.1.1 计算设计热负荷 ..................................................................................................... 4
2.1.2 炉型选择................................................................................................................... 6
2.2 燃烧过程计算 ...................................................................................................................... 6
2.2.1计算燃料的热值 ...................................................................................................... 7
2.2.2 计算理论空气量 ..................................................................................................... 8
2.2.3 选取过剩空气系数及加热炉排烟温度 ............................................................ 8
2.2.4 计算加热炉热设计效率 ....................................................................................... 9
2.2.5 燃料气用量 ........................................................................................................... 10
2.2.6 计算烟气流量 ...................................................................................................... 10
2.3 辐射室热力计算 .............................................................................................................. 11
2.3.1 估算辐射段热负荷 ............................................................................................. 11
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2.3.2 选取辐射室炉管表面热强度 ........................................................................... 12
2.3.3 估算辐射室炉管管壁温度 ................................................................................ 13
2.3.4 计算辐射室炉管加热表面积 ........................................................................... 14
2.3.5 确定辐射室炉管管程数、管径及管心距 .................................................... 14
2.4 辐射室炉体尺寸 .............................................................................................................. 15
2.4.1 辐射炉管的节圆直径、有效长度 .................................................................. 15
2.4.2 辐射炉管根数 ...................................................................................................... 16
2.4.3 辐射段炉膛直径 .................................................................................................. 16
2.4.4 辐射段炉膛高度 .................................................................................................. 17
2.5对流室炉体尺寸................................................................................................................ 17
2.5.1 对流室炉管管径、管心距 ................................................................................ 18
2.5.2 对流室炉管管长及对流室宽度 ....................................................................... 18
2.6 辐射段传热核算 .............................................................................................................. 21
2.6.1 当量冷平面 ........................................................................................................... 21
2.6.2 总辐射交换因数 .................................................................................................. 22
2.6.3 辐射段热平衡 ...................................................................................................... 23
2.6.4 辐射段烟气出口温度 ......................................................................................... 24
2.6.5 核算辐射段热负荷 ............................................................................................. 25
2.6.6 核算辐射段表面热强度 .................................................................................... 26
2.6.7 核算辐射段油料入口温度及辐射段炉管壁温 ........................................... 26
2.7 对流段的传热计算 .......................................................................................................... 27
2.7.1 对流段热负荷 ...................................................................................................... 27
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2.7.2 对流段内的传热平均温差 ................................................................................ 27
2.7.3 对流室炉管内膜传热系数 ................................................................................ 28
2.7.4 对流室炉管外膜传热系数 ................................................................................ 29
2.7.5 对流管的总传热系数 ......................................................................................... 32
2.7.6 对流室内炉管表面积及管排数 ....................................................................... 32
2.7.7 对流炉管的表面传热强度 ................................................................................ 33
2.8 过热蒸汽段计算 .............................................................................................................. 33
2.8.1 过热蒸汽段烟气平均温度 ................................................................................ 33
2.8.2 过热蒸汽段两种介质换热的平均温差 ......................................................... 34
2.8.3 管内介质的质量流速 ......................................................................................... 34
2.8.4 过热蒸汽管的对流传热系数 ........................................................................... 35
2.8.5 过热蒸汽段炉管表面积及管排数 .................................................................. 37
2.9 炉管压降计算（有相变化） ........................................................................................ 38
2.9.1 汽化段压力降 ...................................................................................................... 38
2.9.2 加热段压力降 ...................................................................................................... 44
2.9.3 加热炉炉管总压力降 ......................................................................................... 46
2.9.4 加热炉炉管入口压力 ......................................................................................... 46
2.10 烟囱计算 .......................................................................................................................... 46
2.10.1 烟气通过对流段的阻力 .................................................................................. 46
2.10.2 烟气由辐射段到对流段的阻力 .................................................................... 48
2.10.3 烟气由过热蒸汽段到烟囱的阻力 ................................................................ 49
2.10.4 烟气在烟囱挡板处的阻力 ............................................................................. 49
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2.10.5 烟气在烟囱内的摩擦损失 ............................................................................. 50
2.10.6 烟气在烟囱内的动能损失 ............................................................................. 51
2.10.7 烟囱高度 ............................................................................................................. 51
3 辐射—对流型圆筒加热炉炉管系统的选用......................................................................... 56
3.1 炉管材料的选择 .............................................................................................................. 56
3.2 钉头管 ................................................................................................................................ 56
3.3 炉管吊钩 ............................................................................................................................ 57
3.4 炉管拉钩 ............................................................................................................................ 57
3.5 看火门 ................................................................................................................................ 58
3.6人孔门 ................................................................................................................................. 58
3.7 防爆门 ................................................................................................................................ 60
3.8 清扫门 ................................................................................................................................ 61
4 辐射—对流型圆筒加热炉结构的选用 .................................................................................. 62
4.1 加热炉主体结构 .............................................................................................................. 62
4.1.1 辐射室结构 ........................................................................................................... 62
4.1.2 对流室结构 ........................................................................................................... 62
4.1.3 炉底结构................................................................................................................ 63
4.1.4 炉墙结构................................................................................................................ 63
4.2 加热炉附件结构 .............................................................................................................. 64
4.2.1 喷嘴 ......................................................................................................................... 64
4.2.2 平台、梯子 ........................................................................................................... 64
4.2.3 吹灰器 .................................................................................................................... 65
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5 优化烟气余热再利用方案 ........................................................................................................ 67
5.1 烟气酸露点温度 .............................................................................................................. 67
5.2 余热再利用方案 .............................................................................................................. 67
5.2.1 国内外烟气余热再利用方案 ........................................................................... 67
5.2.2 设计采用的烟气余热再利用方案 .................................................................. 69
结 论 ................................................................................................................................................... 71
谢 辞 ................................................................................................................................................. 72
参考文献 ............................................................................................................................................ 73
附 录 ................................................................................................................................................. 76
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发表于 2013-2-1 08:50:13
