CN108153942B - Design method of flue gas turbine - Google Patents
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Abstract
The invention discloses a design method of a flue gas turbine, which is used for carrying out design calculation on the flue gas turbine. The method provides that the flue gas of a flue gas turbine is taken as a working medium, and the flue gas is considered to contain Ai2O3And SiO2The formed catalyst solid particles have the characteristic of gas-solid two-phase flow, and a flue gas flow coefficient and a relationship between the flow coefficient and the catalyst concentration are taken into design; the calculation is carried out by starting from a turbine outlet, carrying out reverse airflow calculation from back to front, and finally obtaining heat balance at a turbine inlet, wherein the flow passing through each section is consistent; and taking measures related to erosion resistance and the like on the aspects of pneumatics and structures. The design method is accurate, improves the efficiency of the calculated flue gas turbine, ensures that the flue gas turbine has enough strength reserve coefficient on the stress level of parts, and reduces the erosion of catalyst solid particles in pneumatic and structural design. The efficiency of the gas turbine can be higher on the premise of ensuring the safety, reliability and service life of the gas turbine.
Description
Technical Field
The invention relates to the field of devices applied to catalytic cracking waste heat energy recovery units in the petrochemical industry, in particular to a design method of a flue gas turbine.
Background
The flue gas turbine is a key device in a catalytic cracking waste heat energy recovery machine set in the petrochemical industry. The method uses the flue gas generated in the oil refining process flow as a working medium, converts the energy generated by the regeneration reaction of a catalyst in a catalytic cracking device into mechanical work, and drives a main fan and a motor.
Because the working conditions of the flue gas turbine are extremely severe (high temperature, high pressure and catalyst particles contained in the flue gas), the operation of the flue gas turbine is safe and reliable, whether the energy recovery complete set of unit can normally operate or not is directly influenced, and even whether the oil refining process can normally operate or not is influenced. Therefore, the design process of the flue gas turbine always puts the safety and the reliability at the first place.
The method for performing the pneumatic and performance calculation of the flue gas turbine by using the gas as the working medium and then performing the flow correction has the characteristics of mature calculation method, convenient and fast design and repeated iterative calculation. However, the working medium of the flue gas turbine is flue gas which has the obvious characteristic that the flue gas contains Ai2O3And SiO2The formed catalyst solid particles have the characteristic of gas-solid two-phase flow, which affects the performance and the flow capacity of the flue gas turbine and causes abrasion and erosion of blades and a shell. Therefore, the flow of the flue gas turbine calculated by adopting gas as a working medium has a large difference with the actual flow, the flow capacity of a channel of the flue gas turbine is seriously influenced, the circulation blockage is caused, the strength of a blade wheel disc is reduced, the efficiency of the flue gas turbine is reduced, the work capacity of the whole machine is reduced, and the safe, reliable and stable work of the flue gas turbine is directly influenced.
Disclosure of Invention
The invention aims to provide a design method of a flue gas turbine, which considers the characteristics of gas-solid two-phase flow, counts the flue gas flow coefficient and the relation between the flow coefficient and the catalyst concentration, and improves the efficiency as much as possible on the premise of ensuring the safety, the reliability and the service life so as to ensure the safe and reliable operation of the flue gas turbine in the service life and reduce the cost of the service life.
The invention adopts the following technical scheme:
a design method of a flue gas turbine comprises the following steps:
1) according to the design conditions of the catalytic cracking waste heat energy recovery unit, a preliminary structure scheme of the flue gas turbine is formulated, and input parameters of the design of the flue gas turbine are determined, wherein the input parameters comprise the flow, the pressure ratio and the working rotating speed of the flue gas turbine, and the components, specific heat, the flow speed, the flue gas flow coefficient, the catalyst concentration and the granularity of the flue gas;
2) performing initial performance estimation on the flue gas turbine through input parameters designed by the flue gas turbine, and selecting a proper number of stages for the flue gas turbine according to the initial performance estimation result of the flue gas turbine;
3) then carrying out detailed performance design calculation on the flue gas turbine, wherein the detailed performance design calculation adopts a calculation method of carrying out inverse airflow from the turbine outlet to the front;
during calculation, firstly setting the gas outlet angle of the stator blade and the gas outlet angle of the working blade, then gradually and respectively calculating the pneumatic parameters of the inlet section of the stator blade, the outlet section of the stator blade and the outlet section of the working blade through an iterative algorithm, enabling the flow rates of the inlet section of the stator blade, the outlet section of the stator blade and the outlet section of the working blade to be consistent when calculating the pneumatic parameters of all the sections, enabling the difference between the calculated gas outlet angle and a given value to be within an allowable working range, and finally calculating the heat balance at the turbine inlet; if the difference between the calculated gas outlet angle and the given value is larger than the allowable working range, performing detailed performance design calculation on the flue gas turbine again until the difference between the finally calculated gas outlet angle and the given value is within the allowable working range, and then performing the step 4);
4) after the detailed performance design and calculation of the flue gas turbine are completed, a blade erosion resisting measure is designed on the pneumatic and structural aspects of the flue gas turbine.
In the step 1), the design conditions of the catalytic cracking waste heat energy recovery unit comprise working condition parameters, medium components, use environment and safety indexes of a flue gas turbine;
the initial structure scheme for the flue gas turbine comprises the steps of gas inlet and exhaust scheme selection, hoisting mode selection, inlet and outlet flange design and rotor rotation direction selection of the flue gas turbine.
The flow velocity of the flue gas at the turbine outlet is not more than mach 0.3.
In the step 2), the flue gas turbine is selected to be single-stage or two-stage, and when the single-stage is adopted, the counter force of the flue gas turbine is selected to be 0.25-0.5; when two levels are adopted, the first level of counterforce is less than the second level of counterforce.
In the step 3), the air outlet angle of the stator blade is given to be 60 degrees, and the air outlet angle of the working blade is-50 degrees.
In the step 3), when the detailed performance design calculation of the flue gas turbine is carried out, the detailed performance design calculation of the flue gas turbine is carried out according to the initial structure scheme of the flue gas turbine, the input parameters, the channels and the stages, the power distribution ratio and the reaction force of the design of the flue gas turbine.
When the detailed performance design calculation of the flue gas turbine is carried out, the channel design of the flue gas turbine adopts a form of equal inner diameter, the outer expansion angle is within the range of 6-13 degrees, and the Mach number limit value of a turbine outlet is below 0.3.
The smoke turbine adopts a distribution rule of less front and more rear in the power distribution.
Compared with the prior art, the invention has the following beneficial effects:
the existing method for performing the pneumatic and performance calculation of the flue gas turbine by using gas as a working medium and then performing the flow correction needs repeated iterative calculation, so that the time consumption is huge, the working medium does not completely reflect the actual situation, and the method does not consider the situation that the gas turbine contains Ai2O3And SiO2The formed catalyst solid particles influence the performance and the flow capacity of the flue gas turbine, cause abrasion and erosion of blades and a shell, and directly influence the safe, reliable and stable operation of the flue gas turbine;
the design method of the flue gas turbine takes the flue gas of the flue gas turbine as a working medium, and considers that the flue gas contains Ai2O3And SiO2The formed catalyst solid particles not only influence the performance and the flow capacity of the flue gas turbine, but also cause abrasion erosion of blades and a shell, have the characteristic of gas-solid two-phase flow, and the flue gas flow coefficient and the relation between the flow coefficient and the catalyst concentration are calculated in the design, so that the calculated efficiency of the flue gas turbine is improved, the sufficient strength storage coefficient is ensured to be reserved on the stress level of parts of the flue gas turbine, and the erosion of the catalyst solid particles is reduced in the pneumatic and structural design. On the premise of ensuring the safety, reliability and service life of the flue gas turbine, the method has higher efficiency. The design method of the flue gas turbine is applied to TP series flue gas turbines, and the design method has the advantages of stable and reliable performance, long service life, high reliability and the like, and meets the design requirements.
Drawings
FIG. 1 is a schematic flow chart of the design method of the present invention.
Detailed Description
The invention is further described below with reference to the figures and examples.
As shown in FIG. 1, the design method of the flue gas turbine of the invention is carried out by the following steps:
(1) formulating a structure scheme of the flue gas turbine:
according to the design conditions of the catalytic cracking waste heat energy recovery unit, preliminarily formulating a structure scheme of the flue gas turbine, wherein the design conditions comprise working condition parameters, medium components, a use environment and safety indexes, and the preliminary structure scheme of the flue gas turbine comprises an air inlet and exhaust scheme, a hoisting mode selection, an inlet and outlet flange design, design life requirements and rotor rotation direction selection;
(2) calculating basic data of the flue gas turbine:
according to the provided design conditions of working condition parameters, medium components, use environment and safety indexes of the catalytic cracking waste heat energy recovery unit, basic data of the flue gas turbine are calculated, wherein the basic data of the flue gas turbine comprise the flow, pressure ratio and working rotating speed of the flue gas turbine, and the components, specific heat, flow rate, flue gas flow coefficient, catalyst concentration and particle size of the flue gas, so that requirements are provided for the calculation of a subsequent flue gas turbine;
(3) performing initial performance estimation on the flue gas turbine:
estimating the initial performance of the flue gas turbine through the basic data of the flue gas turbine;
(4) selecting the number of stages of the flue gas turbine:
the loss condition fluctuation of the catalyst in the catalytic cracking waste heat energy recovery unit is large, and the loss condition fluctuation is large if the loss condition fluctuation is large and small if the loss condition fluctuation is small; under the condition of higher smoke concentration, to improve the wear resistance of flow elements, particularly movable and static blades, and to ensure high operating efficiency and safe reliability of a flue gas turbine, the flue gas turbine is designed according to low flue gas velocity, the flue gas velocity is taken as one of the design criteria of the flue gas turbine, and the flow velocity of flue gas at the outlet of the turbine is not more than Mach 0.3;
(5) selecting a channel flow of the flue gas turbine:
according to the design rule of impeller machinery, the channel form generally has three forms of equal outer diameter, equal inner diameter and equal intermediate diameter, and for the flue gas turbine, the channel form of the flue gas turbine is generally equal inner diameter, and the external expansion angle is within the range of 6-13 degrees. When the average diameter is determined, the size, the strength, the whole machine starting, the speed ratio U/Co and the outlet Mach number of the flue gas turbine wheel disc are mainly considered, wherein U is the peripheral speed of the flue gas turbine wheel disc, and Co is the equivalent speed of the flue gas turbine. The selection of the speed ratio U/Co directly influences the efficiency of the flue gas turbine, represents the level of the flue gas turbine to a certain extent, and has the highest relative efficiency when the speed ratio U/Co is 0.65; turbine exit mach number is also a consideration, and is typically limited to values no greater than 0.3 to reduce stall losses;
(6) calculating the power distribution ratio and the reaction force of the flue gas turbine:
in the aspect of work distribution, because a channel form with the same inner diameter is adopted, the circumferential speed of the first-stage blade tip is low, and the distribution rule with less front and more rear is more suitable. The first stage axial velocity is typically selected to be small to avoid over-length of the blades. In order to increase the anti-erosion capacity and prolong the service life of the flue gas turbine, the two-stage blades are uniformly worn as much as possible, and the speeds of the two-stage blades are close to each other. For the selection of the reaction force, the reaction force is too large, the airflow speed in the movable blade is increased, the reaction force is too small, the airflow speed in the guide blade is increased, and for two stages, the situation that no blade grid is arranged behind the second stage is considered, and the reaction force of the first stage is generally slightly smaller than that of the second stage;
(7) detailed performance calculation of the flue gas turbine:
and calculating the pneumatic performance according to the initial structure scheme of the flue gas turbine, the input parameters, the channel and the stage number, the power distribution ratio and the reaction force of the design of the flue gas turbine. The calculation method adopts the steps of starting from the turbine outlet, and calculating the reverse airflow from back to front. The flow rate of each section is consistent, and finally the heat balance is obtained at the inlet of the turbine. The calculation method is more accurate, because the stator blade is generally close to the blockage at the design point, when the reduced flow of the stator blade has small error, the influence on the expansion ratio is larger, the conditions of the outlet of the working blade and the outlet of the stator blade are different, the outlet of the working blade is uniformly increased and changed, and when the reduced flow has error, the obvious expansion ratio error cannot be caused;
(8) and (3) erosion resistance calculation of the blade of the flue gas turbine:
the flue gas in the catalytic cracking waste heat energy recovery unit in the petrochemical industry contains a certain amount of catalyst particles, and the erosion of blades is inevitable. The factors influencing abrasion erosion of the blade are many, such as the concentration and the particle size distribution of catalyst particles, the speed of flue gas, the attack angle of air flow, the abrasion index and the brittleness of the catalyst particles, the base material of the blade and the surface abrasion-resistant coating performance of the blade. Therefore, the gas turbine adopts anti-erosion measures in pneumatic and structural aspects, and the service life and the reliability of the blades of the gas turbine can be ensured.
Examples
The embodiment specifically takes the design of a flue gas turbine of a catalytic cracking waste heat energy recovery unit in a certain petrochemical industry as an example:
(1) formulating a structure scheme of the flue gas turbine:
according to the design conditions of the catalytic cracking waste heat energy recovery unit, the structural scheme of the flue gas turbine is preliminarily formulated, wherein the design conditions comprise working condition parameters, medium components, use environment and safety indexes. The preliminary scheme for determining the structure of the flue gas turbine is that air is axially fed horizontally, air is exhausted vertically upwards, a rotor moves forwards horizontally for hoisting, the pressure grades of inlet and outlet flanges are PN4.0 and 2.5, the design life is 10 ten thousand hours, and the rotation direction of the rotor is anticlockwise.
(2) Calculating basic data of the flue gas turbine:
according to the design conditions of the catalytic cracking waste heat energy recovery unit, such as working condition parameters, medium components, use environment and safety indexes, the primary calculation of the basic data of the flue gas turbine is carried out, wherein the basic data of the flue gas turbine comprises the flow, pressure ratio and working rotating speed of the flue gas turbine, and the components, specific heat, flow rate, flue gas flow coefficient, catalyst concentration and particle size of the flue gas, and the detailed table 1 shows the basic data. And determining input parameters and states of the design of the flue gas turbine, and making requirements for the calculation of the subsequent flue gas turbine.
TABLE 1
| Serial number | Name (R) | Numerical value | Unit of |
| 1 | Inlet pressure | 2.4 | Kilogram/centimeter2 |
| 2 | Outlet pressure | 1.09 | Kilogram/centimeter2 |
| 3 | Inlet flow rate | 2000 | Standard rice3Minute/min |
| 4 | Inlet temperature | 650 | ℃ |
| 5 | Average specific heat at constant pressure | 0.2994 | Great calorie/kilogram degree |
| 6 | Molecular weight of flue gas | 28.62 | / |
(3) Performing initial performance estimation on the flue gas turbine:
and estimating the initial performance of the flue gas turbine according to the basic data of the flue gas turbine. The calculation results are detailed in table 2.
TABLE 2
(4) Selecting the number of stages of the flue gas turbine:
the loss condition fluctuation of the catalyst in the catalytic cracking waste heat energy recovery unit is large, and the loss condition fluctuation is large if the loss condition fluctuation is large and small if the loss condition fluctuation is small; in the catalyst, the particles with the particle size of more than 10 mu m account for 2.5-3.5%, the maximum particles reach 30 mu, and under the smoke concentration, the smoke turbine is designed according to the low smoke flow speed, wherein the flow speed of the smoke at the outlet of the turbine is not more than Mach 0.3, and the smoke flow speed is taken as one of the design criteria of the smoke turbine, so as to improve the wear resistance of the flow elements, particularly the movable and static blades, and ensure the high operation efficiency and the safe reliability of the smoke turbine.
According to the relation between the inlet temperature and the expansion ratio of the catalytic cracking gas and the stage number, when the inlet temperature is 648 ℃, the optimal expansion ratio of a single stage is 2.4, the inlet temperature of the single stage is 650 ℃, the expansion ratio is 2.148, and a single-stage turbine is suitable in terms of comprehensive consideration of structure, strength, service life and the like.
(5) Flue gas turbine channel flow selection
According to the design rule of impeller machinery, the channel form generally has three forms of equal outer diameter, equal inner diameter and equal intermediate diameter, and for the flue gas turbine, the channel form of the flue gas turbine is generally equal inner diameter, and the external expansion angle is within the range of 6-13 degrees. When the average diameter is determined, the size, the strength, the whole machine starting, the speed ratio U/Co and the outlet Mach number of the flue gas turbine wheel disc are mainly considered, wherein U is the peripheral speed of the flue gas turbine wheel disc, and Co is the equivalent speed of the flue gas turbine. The selection of the speed ratio U/Co directly influences the efficiency of the flue gas turbine, represents the level of the flue gas turbine to a certain extent, and is the highest relative efficiency when the speed ratio U/Co is 0.65. Turbine exit mach number is also a consideration and is typically limited to values no greater than 0.3 to reduce the stall loss.
And the external expansion angle of the rotor blade of the cold-state channel of the machine is determined to be 7 degrees and 50 degrees by considering the aerodynamic parameters of the machine and comprehensively considering the factors of the outlet Mach number, the diameter of the wheel disc, the strength, the service life and the like.
(6) Power distribution ratio and reaction calculation of flue gas turbine
In the aspect of work distribution, because a channel form with the same inner diameter is adopted, the circumferential speed of the first-stage blade tip is low, and the distribution rule with less front and more rear is more suitable. The first stage axial velocity is typically selected to be small to avoid over-length of the blades. In order to increase the anti-erosion capacity and prolong the service life of the flue gas turbine, the two-stage blades are uniformly worn as much as possible, and the speeds of the two-stage blades are close to each other. For the selection of the counterforce, the counterforce is too large, the airflow speed in the movable blade is increased, the counterforce is too small, the airflow speed in the guide blade is increased, and for two stages, the situation that no blade grid is arranged behind the second stage is considered, and the counterforce of the first stage is generally slightly smaller than that of the second stage. The machine is a single-stage turbine, and the counter force is 0.42.
(7) Detailed performance calculation of the flue gas turbine:
and calculating the pneumatic performance according to the initial structure scheme of the flue gas turbine, the input parameters, the channel and the stage number, the power distribution ratio and the counter force of the design of the flue gas turbine. The calculation method adopts the steps of starting from the turbine outlet, and calculating the reverse airflow from back to front. The flow rate of each section is consistent, and finally the heat balance is obtained at the inlet of the turbine. The calculation method is accurate, because the stator blade is generally close to the blockage at the design point, when the reduced flow of the stator blade has small error, the influence on the expansion ratio is larger, and when the outlet of the working blade is different from the outlet of the stator blade, the outlet of the working blade is uniformly increased and changed, and when the reduced flow has error, the obvious expansion ratio error cannot be caused. The calculation results are detailed in table 3.
TABLE 3
(8) And (3) erosion resistance calculation of the blade of the flue gas turbine:
the flue gas in the catalytic cracking waste heat energy recovery unit in the petrochemical industry contains a certain amount of catalyst particles, and the erosion of blades is inevitable. The factors influencing abrasion erosion of the blade are many, such as the concentration and the particle size distribution of catalyst particles, the speed of flue gas, the attack angle of air flow, the abrasion index and the brittleness of the catalyst particles, the base material of the blade and the surface abrasion-resistant coating performance of the blade. Therefore, the gas turbine adopts anti-erosion measures in pneumatic and structural aspects, and the service life and the reliability of the blades of the gas turbine can be ensured.
The front edge of the blade root of the flue gas turbine is provided with a turning step, and abrasion-resistant alloy is welded on the step to reduce the segregation of catalyst particles caused by secondary flow at the blade root, so that the concentration of the catalyst particles is uniformly distributed along the blade height to reduce the erosion effect; the axial spacing between the movable blade and the fixed blade is increased, the scouring speed of catalyst particles is reduced, and the fatigue life of the blades is prolonged; the erosion of the air outlet edge of the blade is particularly serious, and the thickness of the air outlet edge of the blade is increased so as to prolong the service life of the blade.
Claims (7)
1. A design method of a flue gas turbine is characterized by comprising the following steps:
1) according to the design conditions of the catalytic cracking waste heat energy recovery unit, a preliminary structure scheme of the flue gas turbine is formulated, and input parameters of the design of the flue gas turbine are determined, wherein the input parameters comprise the flow, the pressure ratio and the working rotating speed of the flue gas turbine, and the components, specific heat, the flow speed, the flue gas flow coefficient, the catalyst concentration and the granularity of the flue gas;
2) performing initial performance estimation on the flue gas turbine through input parameters designed by the flue gas turbine, and selecting a proper number of stages for the flue gas turbine according to the initial performance estimation result of the flue gas turbine;
3) carrying out detailed performance design calculation on the flue gas turbine, wherein the detailed performance design calculation adopts a method of calculating reverse airflow from the rear to the front from the turbine outlet, during calculation, firstly setting the air outlet angle of the stator blade and the air outlet angle of the working blade, then calculating the pneumatic parameters of each section through an iterative algorithm, and during calculation of the pneumatic parameters of each section, enabling the flow passing through the inlet section of the stator blade, the outlet section of the stator blade and the outlet section of the working blade to be consistent, enabling the difference between the calculated air outlet angle and a given value to be within an allowable working range, and finally calculating the heat balance at the turbine inlet; if the difference between the calculated gas outlet angle and the given value is larger than the allowable working range, performing detailed performance design calculation on the flue gas turbine again until the difference between the finally calculated gas outlet angle and the given value is within the allowable working range, and then performing the step 4);
4) after the detailed performance design and calculation of the flue gas turbine are completed, designing a blade erosion resisting measure on the pneumatic and structural aspects of the flue gas turbine;
in the step 3), when the detailed performance design calculation of the flue gas turbine is carried out, the detailed performance design calculation of the flue gas turbine is carried out according to the initial structure scheme of the flue gas turbine, the input parameters, the channels and the stages, the power distribution ratio and the reaction force of the design of the flue gas turbine.
2. The design method of the flue gas turbine according to claim 1, wherein in the step 1), the design conditions of the catalytic cracking waste heat energy recovery unit comprise working condition parameters, medium components, use environment and safety indexes of the flue gas turbine;
the initial structure scheme for the flue gas turbine comprises the steps of gas inlet and exhaust scheme selection, hoisting mode selection, inlet and outlet flange design and rotor rotation direction selection of the flue gas turbine.
3. The method of claim 1, wherein the flue gas has a flow velocity at the turbine outlet of no greater than mach 0.3.
4. The design method of the flue gas turbine as claimed in claim 1, wherein in the step 2), the flue gas turbine is selected from a single stage or two stages, and when the single stage is adopted, the reaction force of the flue gas turbine is selected to be between 0.25 and 0.5; when two levels are adopted, the first level of counterforce is less than the second level of counterforce.
5. The design method of the flue gas turbine according to claim 1, wherein in the step 3), the outlet angle of the given stator blade is 60 degrees, and the outlet angle of the working blade is-50 degrees.
6. The design method of the flue gas turbine as claimed in claim 1, wherein when the detailed performance design calculation of the flue gas turbine is carried out, the channel design of the flue gas turbine is in a form of equal inner diameter, the outer expansion angle is in a range of 6-13 degrees, and the limit value of the Mach number of the outlet of the turbine is below 0.3.
7. The design method of the flue gas turbine according to claim 1, wherein the flue gas turbine adopts a less-forward and more-backward distribution rule in the work distribution.
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