CN118006370A - Method for replacing coal type in gasification adaptive operation in liquid slag-discharging gasification furnace - Google Patents
Method for replacing coal type in gasification adaptive operation in liquid slag-discharging gasification furnace Download PDFInfo
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- 238000007599 discharging Methods 0.000 title claims abstract description 13
- 230000003044 adaptive effect Effects 0.000 title claims abstract description 8
- 239000002802 bituminous coal Substances 0.000 claims abstract description 64
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 49
- 239000002994 raw material Substances 0.000 claims abstract description 42
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims abstract description 36
- 229910052717 sulfur Inorganic materials 0.000 claims abstract description 36
- 239000011593 sulfur Substances 0.000 claims abstract description 36
- 238000004519 manufacturing process Methods 0.000 claims abstract description 32
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- 238000006467 substitution reaction Methods 0.000 claims abstract description 23
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- 238000004364 calculation method Methods 0.000 claims description 51
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- 239000011575 calcium Substances 0.000 abstract description 2
- 229910052791 calcium Inorganic materials 0.000 abstract description 2
- 229910052742 iron Inorganic materials 0.000 abstract description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 22
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Classifications
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- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10J—PRODUCTION OF PRODUCER GAS, WATER-GAS, SYNTHESIS GAS FROM SOLID CARBONACEOUS MATERIAL, OR MIXTURES CONTAINING THESE GASES; CARBURETTING AIR OR OTHER GASES
- C10J3/00—Production of combustible gases containing carbon monoxide from solid carbonaceous fuels
- C10J3/72—Other features
- C10J3/723—Controlling or regulating the gasification process
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Abstract
The invention provides a method for replacing coal in a liquid slag-discharging gasification furnace for gasification adaptive operation, belonging to the technical field of coal gasification. The invention uses high activity, high heat value, low ash content and low sulfur coal, replaces petroleum coke with semi-coke and bituminous coal, breaks through the limitation of the original coal, and particularly in the technical development of the bituminous coal replacing petroleum coke, the invention finds an operation control mode and an economical coal blending mode which are suitable for new coal by carrying out intensive research on the applicability technology of the bituminous coal in the application of a shell gasifier, effectively improves the operation period of the coal gasification device and ensures the device to stably operate. The invention calculates the heat value, ash content, total sulfur, total water and volatile matters of the coal types required under different proportions under the condition that the heat value and indexes of the raw material coal are unchanged, ensures the heat value of the coal entering the furnace, widens the use channel of low-quality coals such as high iron, high calcium, high sulfur and the like, realizes the substitution of bituminous coal for petroleum coke, and reduces the production cost.
Description
Technical Field
The invention relates to the technical field of coal gasification, in particular to a method for replacing coal to perform gasification adaptive operation in a liquid slag-discharging gasification furnace.
Background
Along with the continuous development of the main stream technology of the large-scale and high-pressure coal gasification technology, under the background of the industrial policies of double carbon and double control, the technology integration of improving the overall efficiency of the liquid slag discharging gasification furnace, widening the adaptability of coal types, improving the capacity of the gasification furnace Shan Lusheng, reducing the reliability of a shutdown risk guaranteeing device, reducing the environmental influence degree of the gasification technology and strengthening the coal gasification and novel coal chemical industry is the development direction of the coal gasification technology.
The coal fed into the existing shell gasifier is a combination of petroleum coke and raw material coal, and the phenomena of slag blockage and pipeline corrosion of the gasifier are easy to occur due to high ash content and high sulfur content of the petroleum coke. Therefore, searching for a coal substitute of petroleum coke, providing an operation control mode and an economical coal blending mode which are suitable for new coal is an important research direction of coal gasification technology.
Disclosure of Invention
In view of the above, the present invention aims to provide a method for gasification adaptive operation in a liquid slag gasification furnace instead of coal. The method provided by the invention widens the coal utilization channel of the liquid slag discharging gasifier, realizes the substitution of bituminous coal for petroleum coke, and reduces the production cost while relieving the slag blockage and pipeline corrosion of the gasifier.
In order to achieve the above object, the present invention provides the following technical solutions:
the invention provides a method for replacing coal to gasify and adaptively operate in a liquid slag-discharging gasifier, which comprises the following steps:
The semi-coke or the bituminous coal is used as a substitute coal of petroleum coke, and the substitute coal is doped with raw material coal to be used as furnace coal; determining control indexes for replacing coal types according to known control indexes of coal fed into the furnace; the control indexes comprise heat value, ash content, total sulfur content, total water content and volatile content;
the method for determining the control index for replacing the coal type comprises the following steps:
setting the mass ratio of raw material coal to substitute coal as x to y;
the calorific value of the substitute coal is calculated according to formula 1:
In the formula 1, q Substitution of represents the calorific value of the coal instead of MJ/kg; q Into (I) represents the calorific value of the coal charged into the furnace, MJ/kg;
q Original source represents the calorific value of the raw coal, MJ/kg;
Ash was calculated according to equation 2 instead of coal:
In formula 2, a Substitution of represents ash content in place of coal species,%;
a Into (I) represents ash content of coal entering a furnace,%;
A Original source represents ash content of raw coal,%;
the total sulfur content of the replacement coal was calculated according to formula 3:
in the formula 3, S Substitution of represents total sulfur content of the coal instead of the coal; s Into (I) represents the total sulfur content of the coal entering the furnace,%;
s Original source represents the total sulfur content of the raw material coal,%;
the total water content of the replacement coal was calculated according to equation 4:
In formula 4, W Substitution of represents the total water content,%; w Into (I) represents the total water content of the coal entering the furnace,%;
w Original source represents the total water content of the raw material coal,%;
the volatile content of the substitute coal was calculated according to formula 5:
In formula 5, V Substitution of represents the volatile content of the substitute coal species,%;
V Into (I) represents the volatile content of the coal entering the furnace,%;
V Original source represents the volatile content of the raw coal,%.
Preferably, after the coal is fed into the furnace, the method further comprises the step of assisting in monitoring the furnace temperature of the gasifier by monitoring the saturated steam flow of the water-cooled wall of the gasifier, wherein the theoretical value of the saturated steam flow of the water-cooled wall of the gasifier is calculated according to the formula 6:
in the formula 6, F represents the saturated steam flow of the water-cooled wall of the gasification furnace, and kg/s;
f 1 represents the outlet mass flow rate of a water circulating pump of the medium-pressure boiler, and kg/s;
ρ 1 represents the density of saturated steam in the steam mixture at the outlet of the water wall of the hearth of the gasification furnace, kg/m 3;
ρ 2 represents the density of saturated water in the water vapor mixture at the outlet of the water wall of the hearth of the gasification furnace, kg/m 3;
ρ represents the density of the water vapor mixture at the outlet of the water-cooled wall of the hearth of the gasification furnace, kg/m 3;
k represents a correction coefficient;
If the measured value of the saturated steam flow of the water-cooled wall of the gasification furnace deviates from the theoretical value, the saturated steam density and the saturated water density are used for correction.
Preferably, after the coal is charged into the furnace, the method further comprises:
Adopting an APC controller of the gasification furnace, and realizing soft measurement of the furnace temperature of the gasification furnace according to the furnace temperature prediction model of the gasification furnace and the actual operation data of the device; on the basis of realizing soft measurement of the furnace temperature of the gasifier, the method overcomes the interference caused by coal quality change and downstream load demand change on the gasifier through a furnace temperature prediction model of the gasifier, and realizes automatic adjustment of the load of the gasifier and stable and optimal control of technological parameters;
The gasifier furnace temperature prediction model comprises a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler;
the furnace temperature measuring module based on wall heat transfer comprises a physical property parameter module, an input data module, a calculating module and a storage display module;
the physical property parameter module is used for storing physical property parameters of slag, synthetic gas and coal;
The input data module is used for acquiring industrial DCS data;
The calculation module comprises a calculation module I, a calculation module II, a calculation module III and a calculation module IV, wherein the calculation module I is used for calculating slag deposition amount, heat flux and SiC temperature; the calculation module II is used for calculating slag thickness related information; the calculation module III is used for calculating the surface temperature of the slag; the calculating module IV is used for calculating the temperature of the gasification furnace.
The furnace temperature measurement based on syngas chilling and convection waste boiler comprises:
And calculating the furnace temperature of the gasification furnace by mass accounting and heat accounting according to the chilling gas flow and temperature, the waste boiler inlet temperature, the waste boiler outlet temperature and the waste boiler steam yield and combining the outlet synthetic gas flow and components.
Preferably, the gasifier furnace temperature prediction model further comprises slag notch state monitoring, the slag notch state monitoring calculates slag notch slag thickness and channel area in real time through slag notch slag flow, phase change and heat transfer according to the slag notch water-cooled wall heat flux, and the rationality and reliability of the gasifier furnace temperature prediction model are verified by combining a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler.
Preferably, after the coal is charged into the furnace, the method further comprises:
Adopting a feedforward and feedback RTO system to cope with the influence of the fluctuation of the coal quality of the coal into the furnace on the production, and adjusting the oxygen-coal ratio and the steam-coal ratio according to the fluctuation of the coal quality of the coal into the furnace; the feedforward is based on parameters including coal quality detection data of the coal, quality, pressure, flow, steam and oxygen corresponding data of the coal, and initial production process parameters are formulated and references are provided for subsequent parameter adjustment; the feedback is to evaluate the current production condition and the coal quality change condition by utilizing the production feedback data of the gasifier, including the data of the product gas components, the flow, the pressure, the gasifier state data, the oxygen-coal ratio and the slag hole differential pressure, and refer to the feedforward variable, and to guide the adjustment of the next production parameters.
Preferably, the mass ratio of the raw material coal to the substitute coal is 0-5:1-5.
Preferably, the control indexes of the coal entering the furnace comprise:
preferably, the control indexes of the coal entering the furnace further comprise:
Preferably, the saturated steam flow rate of the water-cooled wall of the gasification furnace is controlled to be 4.2-4.4 kg/s.
The invention provides an APC control system of a liquid slag-discharging gasifier, which comprises a gasifier APC controller, a gasifier furnace temperature prediction model, an effective gas yield prediction model and a product gas composition prediction model;
The gasifier furnace temperature prediction model comprises a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler;
the furnace temperature measuring module based on wall heat transfer comprises a physical property parameter module, an input data module, a calculating module and a storage display module;
the physical property parameter module is used for storing physical property parameters of slag, synthetic gas and coal;
The input data module is used for acquiring industrial DCS data;
The calculation module comprises a calculation module I, a calculation module II, a calculation module III and a calculation module IV, wherein the calculation module I is used for calculating slag deposition amount, heat flux and SiC temperature; the calculation module II is used for calculating slag thickness related information; the calculation module III is used for calculating the surface temperature of the slag; the calculating module IV is used for calculating the temperature of the gasification furnace.
The invention provides a method for replacing coal types to carry out gasification adaptability operation in a liquid slag-discharging gasification furnace, which uses high-activity, high-heat value, low ash content and low sulfur coal, uses semi-coke and bituminous coal to replace petroleum coke, breaks through the limitation of the original coal types, and particularly in the technical development of replacing petroleum coke by bituminous coal, the invention gradually finds an operation control mode and an economic coal blending mode which are suitable for new coal types through deep research on the applicability technology of the bituminous coal in the application of a shell gasification furnace, effectively improves the operation period of a coal gasification device, and ensures that the device runs stably. The invention calculates the heat value, ash content, total sulfur, total water and volatile matters of the coal types required under different proportions under the condition that the heat value and indexes of the raw material coal are unchanged, ensures the heat value of the coal entering the furnace, realizes that the blending combustion proportion of the bituminous coal is improved from 10% to more than 60%, widens the use channel of low-quality raw material coal such as high iron, high calcium, high sulfur and the like, realizes the substitution of the bituminous coal for petroleum coke, and reduces the production cost. The invention controls the calorific value of the coal fed into the furnace to be 25-28 MJ/kg, controls ash content to be about 16-20%, ash melting point to be 1250-1350 ℃ and sulfur content to be about 1.5-2%, and reduces ash content and sulfur content to have a slow effect on abrasion and corrosion rate of gasification furnaces, venturi scrubbers, synthetic gas pipelines and post-system equipment.
Furthermore, the invention is used for assisting in monitoring the temperature of the gasification furnace by monitoring the saturated steam flow of the water-cooled wall of the gasification furnace, thereby effectively solving the problem of controlling and checking the instant temperature of the gasification furnace when the thermal load (J) and the small chamber steam yield (F) are not uniform due to the drift of the measuring instrument.
According to the invention, the gasifier APC controller is used for performing gasifier multivariable control operation, so that automatic adjustment of the gasifier load and stable and optimal control of each key process parameter can be realized; the RTO system adopting feedforward and feedback is used for coping with the influence of coal fluctuation of the coal into the furnace on production, and the setting of the oxygen-coal ratio and the steam-coal ratio can be adjusted according to the fluctuation of the coal. The gasification adaptive operation provided by the invention can maximize the gas production rate of effective gas, is constrained by excellent deslagging capability of the gasifier, meets the safety production boundary and the like, and has key optimization variables of oxygen-coal ratio, steam-coal ratio or methane content of product gas. By solving the optimization problem, optimal technological parameters can be recommended in real time, and the aims of maximizing the gas production rate and stabilizing the production are fulfilled.
Drawings
FIG. 1 is an overall scheme of a gasifier RTO;
FIG. 2 is a gasifier RTO refinement;
FIG. 3 is a graph of the results of an economic comparison of 26MJ bituminous coal with 28MJ bituminous coal.
Detailed Description
The invention provides a method for replacing coal to gasify and adaptively operate in a liquid slag-discharging gasifier, which comprises the following steps:
The semi-coke or the bituminous coal is used as a substitute coal of petroleum coke, and the substitute coal is doped with raw material coal to be used as furnace coal; determining control indexes for replacing coal types according to known control indexes of coal fed into the furnace; the control indexes comprise heat value, ash content, total sulfur content, total water content and volatile content;
the method for determining the control index for replacing the coal type comprises the following steps:
setting the mass ratio of raw material coal to substitute coal as x to y;
the calorific value of the substitute coal is calculated according to formula 1:
In the formula 1, q Substitution of represents the calorific value of the coal instead of MJ/kg; q Into (I) represents the calorific value of the coal charged into the furnace, MJ/kg;
q Original source represents the calorific value of the raw coal, MJ/kg;
Ash was calculated according to equation 2 instead of coal:
In formula 2, a Substitution of represents ash content in place of coal species,%;
a Into (I) represents ash content of coal entering a furnace,%;
A Original source represents ash content of raw coal,%;
the total sulfur content of the replacement coal was calculated according to formula 3:
in the formula 3, S Substitution of represents total sulfur content of the coal instead of the coal; s Into (I) represents the total sulfur content of the coal entering the furnace,%;
s Original source represents the total sulfur content of the raw material coal,%;
the total water content of the replacement coal was calculated according to equation 4:
In formula 4, W Substitution of represents the total water content,%; w Into (I) represents the total water content of the coal entering the furnace,%;
w Original source represents the total water content of the raw material coal,%;
the volatile content of the substitute coal was calculated according to formula 5:
In formula 5, V Substitution of represents the volatile content of the substitute coal species,%;
V Into (I) represents the volatile content of the coal entering the furnace,%;
V Original source represents the volatile content,%;
in the present invention, the liquid slag-discharging gasification furnace is preferably a shell gasification furnace.
In the invention, the mass ratio of the raw material coal to the substitute coal is preferably 0 to 5:1 to 5, more preferably 0:1, 1:5, 1:3, 1:2, 1:1, 2:1, 3:1 or 5:1 when the substitute coal and the raw material coal are doped.
According to the operation condition of the gasification furnace and the operation condition of equipment, the control index of the coal entering the furnace is formulated as shown in table 1. The lower heating value is used below to represent the heating value.
TABLE 1 coal-to-furnace control index
Based on the heat value of the coal which is fed into the furnace, the heat value, ash content, total sulfur, total water and volatile of the coal which are required under different proportions are calculated under the condition that the heat value and indexes of the raw material coal are unchanged, and the rest indexes are calculated according to the conventional indexes without calculation.
As an example of the present invention, the raw coal input analysis values are shown in Table 2.
TABLE 2 analytical values of raw coal in plant
The index ranges of the coal types replaced at different blending ratios were calculated according to formulas 1 to 5, based on the raw material coal having a calorific value of 23.5MJ/kg, ash content of 24%, sulfur content of 3%, moisture content of 9% and volatile content of 10%, as shown in table 3.
TABLE 3 index ranges for coal replacement at different blending ratios
In the invention, after the coal is fed into the furnace, the invention also preferably comprises the step of assisting in monitoring the temperature of the gasification furnace by monitoring the saturated steam flow of the water-cooled wall of the gasification furnace, wherein the theoretical value of the saturated steam flow of the water-cooled wall of the gasification furnace is calculated according to the formula 6:
in the formula 6, F represents the saturated steam flow of the water-cooled wall of the gasification furnace, and kg/s;
f 1 represents the outlet mass flow rate of a water circulating pump of the medium-pressure boiler, and kg/s;
ρ 1 represents the density of saturated steam in the steam mixture at the outlet of the water wall of the hearth of the gasification furnace, kg/m 3;
ρ 2 represents the density of saturated water in the water vapor mixture at the outlet of the water wall of the hearth of the gasification furnace, kg/m 3;
ρ represents the density of the water vapor mixture at the outlet of the water-cooled wall of the hearth of the gasification furnace, kg/m 3;
k represents a correction coefficient;
If the measured value of the saturated steam flow of the water-cooled wall of the gasification furnace deviates from the theoretical value, the saturated steam density and the saturated water density are used for correction.
In the invention, under the determined temperature, pressure and gasifier operation conditions, a determined function system exists between the saturated steam flow F of the gasifier water wall and the density ρ of the water vapor mixture at the outlet of the water wall, as shown in the formula 6. The saturated steam flow F of the water-cooled wall of the gasification furnace and the density rho of the water-vapor mixture at the outlet of the water-cooled wall are determined, and the other one can be determined according to a functional relation.
In the invention, the saturated steam flow of the water-cooled wall of the gasification furnace is preferably controlled to be 4.2-4.4 kg/s.
In the invention, after the coal is charged into the furnace, the method further comprises the following steps:
Adopting an APC controller of the gasification furnace, and realizing soft measurement of the furnace temperature of the gasification furnace according to the furnace temperature prediction model of the gasification furnace and the actual operation data of the device; on the basis of realizing soft measurement of the furnace temperature of the gasification furnace, the method overcomes the interference caused by coal quality change and downstream load demand change on the gasification furnace by using a furnace temperature prediction model of the gasification furnace, and realizes automatic adjustment of the load of the gasification furnace and stable and optimal control of technological parameters.
In the invention, the gasifier furnace temperature prediction model comprises a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler.
In the present invention, the actual operating data includes one or more of gasifier steam production, carbon dioxide and methane content in the syngas.
In the invention, the furnace temperature measuring module based on wall heat transfer comprises a physical property parameter module, an input data module, a calculating module and a storage display module.
In the invention, the physical property parameter module is used for storing physical property parameters of slag, synthesis gas and coal. In the present invention, the physical property parameters preferably include one or more of a viscosity-temperature characteristic curve, a critical temperature, an ash melting point, a slag heat conductivity coefficient, a slag density, a slag heat capacity, a synthesis gas composition, a gas heat conductivity coefficient, a turbulent heat transfer coefficient, a coal elemental analysis, and a coal industry analysis. In the present invention, these physical properties are substantially constant when the coal quality is constant.
In the invention, the input data module is used for collecting industrial DCS data. In the present invention, the industrial DCS data preferably includes one or more of steam yield, steam temperature, boiler water make-up flow, boiler water make-up temperature, drum blowdown flow, drum blowdown temperature, and in-furnace coal flow. In the invention, the industrial DCS data are key data of a model and software, and dynamically change in real time in the temperature prediction process of the gasifier, so that an interface is specially arranged to read the data from a DCS server or a cache server.
In the invention, the furnace temperature measuring module based on wall heat transfer also preferably comprises a gasification furnace structural module. In the invention, the gasifier structure module is an optional module. In the invention, the gasifier structure module is mainly used for storing structural parameters of the gasifier, including one or more of water wall height, inner diameter, lower cone angle and diameter, and detailed information of the inner diameter of the gasifier and slag flowing direction can be obtained through the module.
In the invention, the calculation module comprises a calculation module I, a calculation module II, a calculation module III and a calculation module IV, wherein the calculation module I is used for calculating slag deposition amount, heat flux and SiC temperature; the calculation module II is used for calculating slag thickness related information; the calculation module III is used for calculating the surface temperature of the slag; the calculating module IV is used for calculating the temperature of the gasification furnace.
In the present invention, the parameters of the inputs of the resulting computing modules I, II, III and IV preferably include one or more of 14TIRCA-0006、14PDI-0020、14LI-0001A～C、13TIRA-0038A～D、13TIRA-0036A～D、13TIRA-0037A～D、14TI-0001A1～C1、14TISZA-0007/08、14TI-0003、14FISZA-0002、14FISA-0001.
In the invention, the storage display module mainly realizes the storage and real-time display of the temperature prediction data.
In the present invention, the furnace temperature measurement based on syngas chilling and convection waste boiler comprises:
And calculating the furnace temperature of the gasification furnace by mass accounting and heat accounting according to the chilling gas flow and temperature, the waste boiler inlet temperature, the waste boiler outlet temperature and the waste boiler steam yield and combining the outlet synthetic gas flow and components.
In the invention, the gasifier furnace temperature prediction model also preferably comprises a slag notch state monitor, wherein the slag notch state monitor calculates the thickness and the passage area of slag notch slag in real time according to the heat flux density of a slag notch water-cooled wall through slag notch slag flow, phase change and heat transfer, and verifies the rationality and the reliability of the gasifier furnace temperature prediction model by combining a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler.
In the invention, the gasifier APC controller has the functions of:
① According to the downstream hydrogen demand, controlling the load of the gasification furnace to be stabilized at a target value, wherein the main regulating means is the total amount of oxygen;
② Controlling the soft measurement temperature of the gasifier to be stabilized at a target value, wherein the main regulation means is the oxygen-coal ratio of the gasifier;
③ The steam oxygen ratio of the gasification furnace is controlled to be stabilized at a target value, and the main regulation means is the steam adding amount of the gasification furnace.
In the present invention, the gasifier APC controller variable table is shown in table 4.
TABLE 4 variable table for APC controller of gasifier
In the present invention, after the coal being charged into the furnace, the method further preferably includes:
Adopting a feedforward and feedback RTO system to cope with the influence of the fluctuation of the coal quality of the coal into the furnace on the production, and adjusting the oxygen-coal ratio and the steam-coal ratio according to the fluctuation of the coal quality of the coal into the furnace; the feedforward is based on parameters including coal quality detection data of the coal, quality, pressure, flow, steam and oxygen corresponding data of the coal, and initial production process parameters are formulated and references are provided for subsequent parameter adjustment; the feedback is to evaluate the current production condition and the coal quality change condition by utilizing the production feedback data of the gasifier, including the data of the product gas components, the flow, the pressure, the gasifier state data, the oxygen-coal ratio and the slag hole differential pressure, and refer to the feedforward variable, and to guide the adjustment of the next production parameters.
In the invention, the whole scheme of the RTO of the gasifier is shown in FIG. 1; the gasifier RTO refinement is shown in fig. 2.
In the present invention, the table of variables required for RTO of the gasifier is shown in table 5.
TABLE 5 variable table for RTO of gasifier
The invention provides an APC control system of a liquid slag-discharging gasifier, which comprises a gasifier APC controller, a gasifier furnace temperature prediction model, an effective gas yield prediction model and a product gas composition prediction model;
The gasifier furnace temperature prediction model comprises a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler;
the furnace temperature measuring module based on wall heat transfer comprises a physical property parameter module, an input data module, a calculating module and a storage display module;
the physical property parameter module is used for storing physical property parameters of slag, synthetic gas and coal;
The input data module is used for acquiring industrial DCS data;
The calculation module comprises a calculation module I, a calculation module II, a calculation module III and a calculation module IV, wherein the calculation module I is used for calculating slag deposition amount, heat flux and SiC temperature; the calculation module II is used for calculating slag thickness related information; the calculation module III is used for calculating the surface temperature of the slag; the calculating module IV is used for calculating the temperature of the gasification furnace.
The invention relies on multi-mode data fusion, mechanism AI fusion technology and strong feature extraction and modeling capability of a large model to construct the following production process key index prediction and evaluation model: 1) A gasifier temperature soft measurement model; 2) An effective gas yield prediction model; 3) And a product gas composition prediction model. The gasifier temperature soft measurement model carries out real-time soft measurement on the temperature in the gasifier according to the current production process data so as to help an optimal control system and process personnel judge the current running state of the gasifier; the effective gas yield prediction model and the product gas composition prediction model give the prediction results of the yield of the effective gas and the ratio of each gas composition according to the current raw material feeding performance parameters (including coal dust, oxygen, medium pressure superheated steam, VHP nitrogen, HP nitrogen and LP nitrogen), key process parameter setting conditions and real-time operation parameters of the gasifier device.
The following examples are provided to illustrate the method of the present invention for the gasification adaptive operation of coal in a liquid slag gasifier in place of coal, but they should not be construed as limiting the scope of the present invention.
Example 1
According to the current operation condition of the gasification furnace and the operation condition of equipment, the control index of the coal to be charged is formulated as shown in table 1, and the analysis value of the raw coal to be charged into the plant is formulated as shown in table 2. The mass ratio of the raw material coal to the substitute coal is set to be x:y, and the raw material coal is calculated according to the raw material coal to substitute coal = 0:1, the raw material coal to substitute coal = 1:5, the raw material coal to substitute coal = 1:3, the raw material coal to substitute coal = 1:2, the raw material coal to substitute coal = 1:1, the raw material coal to substitute coal = 2:1, the raw material coal to substitute coal = 3:1x and the raw material coal to substitute coal = 5:1. For example, according to the ratio of 1:1, the control index for replacing the coal type is calculated as follows:
Heating value: the calorific value of the coal fed into the furnace is calculated according to 25MJ/kg and the calorific value of the raw material coal is 23.5MJ/kg, and q Substitution of = [ 25- (23.5/2) ] is 2=26.5 MJ/kg.
Ash content: the ash content of the coal into the furnace is 16%, the ash content of the raw material coal is 24%, and A Substitution of = [ 16- (24/2) ] is 2=8%.
Total sulfur: the sulfur content of the coal entering the furnace is 2%, and the sulfur content of the raw material coal is 3%, wherein S Substitution of = [ 2- (3/2) ] is 2=1%.
Full water: the water content of the coal entering the furnace is 9%, and the water content of the raw material coal is 9%, wherein W Substitution of = [ 9- (9/2) ] is 2=9%.
Volatile components: the ash content of the coal entering the furnace is calculated according to 20%, and V Substitution of = [ 20- (10/2) ] is 2=20%.
The index ranges of the coal types under different coal blending were calculated by the above calculation methods, as shown in table 3.
Example 2
In the early stage preparation of 2019, the gasification furnace has the condition of mixing and burning bituminous coal, the mixing and burning proportion is gradually increased from 10% to 35%, the bituminous coal is used in different areas such as Qinghai, gansu, shaanxi and the like, the bituminous coal with different heating values and different ash contents of 26-28 MJ is prepared, the matched raw coal comprises different raw coal with high sulfur coal, 23.5MJ, 24.5MJ and the like, the mixed coal of different bituminous coal and different raw coal proportions is subjected to the trial burning from 2019 to 10 months, the 25% device for the mixing and burning proportion is completed for 72 hours in the period of 12-14 months, the performance test of the device for about 50% is realized in the period of stable operation of the device in more than two years, the production cost is greatly reduced, and the applicability of the bituminous coal in the application of the shell gasification furnace is continuously explored, so that a new operation control mode and an economical mode suitable for the new coal are gradually found.
1. Test-burning bituminous coal 72h performance test
After a large amount of research and preparation in the early stage in 2 months and 27 days in 2019, the gasification furnace is provided with a bituminous coal blending condition after carrying out a plurality of safety evaluations on a gasification coal grinding unit and a coal powder conveying unit, and the bituminous coal is subjected to trial combustion, the blending proportion is gradually increased from 10% to about 35%, the bituminous coal is used in different areas such as Qinghai, gansu, shaanxi and the like, the bituminous coal with different heat values and different ash contents is 26-28 MJ, the performance test of a 25% device with the blending proportion is completed in 12-14 days of 3 months, the device is stably operated for about 10 months, the applicability of the bituminous coal in the application of the shell gasification furnace is deeply explored, and an operation control mode and an economic coal blending mode which are suitable for new coal types are gradually found. Each index achieves the expected effect.
2. Safety guarantee measure
The bituminous coal has high volatile components, has the risks of smoldering and naturalness, and ensures the proper safety measures. The raw material stacking place is good in safety fire-fighting facilities, normal operation is realized, the monitoring of the stacking place is enhanced, and measures should be taken in time when the temperature of the coal pile is raised, smoke is generated and the like. And (3) pouring the crushed coal bin into a low-pressure nitrogen blind plate of the crushed coal bin, properly supplementing nitrogen into the crushed coal bin, then, keeping the standby line for a long time, bridging the crushed coal bin when starting the coal grinding line (because the nitrogen compacts the coal), and then, closing the nitrogen supplementing of the crushed coal bin. And the oxygen content of the system is strictly controlled to be less than 8% and the CO content of the system is strictly controlled to be less than 5000ppm in the running process of the coal grinding system. After the coal grinding system is stopped, the back blowing operation is kept, nitrogen is properly fed into the system, the CO content and the temperature change of the system are monitored, and the CO is detected twice for each shift at the emptying port (13 th floor) of the coal grinding line when the coal grinding system is stopped, and records are made. And if the coal grinding system needs to be shut down for maintenance, the back blowing operation of the cloth bag filter is kept for at least one day under the stop state of the circulating fan. And in the running process, monitoring the temperature change of the V1201 and the V1205, keeping the nitrogen of each device smooth, and ensuring that the S1201 is back-blown normally. And a temporary accident nitrogen joint is arranged on site, and when the device is suddenly stopped, the 1200 unit keeps inert environment accident nitrogen.
3. Working condition parameter variation after mixing and burning bituminous coal
(1) The actual operation coal blending analysis data after the bituminous coal blending (the blending ratio of bituminous coal is 25%) are shown in table 6.
Table 6 after bituminous coal blending, actual running blending analysis data
The change in the particle size of the pulverized coal before and after burning the bituminous coal is shown in Table 7.
TABLE 7 variation of pulverized coal particle size before and after burning bituminous coal
(2) Operating parameters of gasifier, ash, slag, carbon content of filter cloth and weight change condition
The process parameters after the bituminous coal was co-fired are shown in table 8.
TABLE 8 Process parameter variation after blending and firing bituminous coal
The sulfur content of the coal charged and the H 2 S content in the synthesis gas are shown in Table 9.
TABLE 9 sulfur content of coal charged to furnace and H 2 S content in syngas
It can be seen that after the bituminous coal is blended and burned, the coal feeding amount is increased, the effective gas rises, the ammonia yield rises, and the SGC outlet temperature rises.
(3) Carbon content in slag, filter cake and ash
The ash, slag, filter cake carbon content analysis is shown in table 10.
TABLE 10 analysis of ash, slag and cake carbon content
The ash, slag, cake amount statistics are shown in table 11.
TABLE 11 statistics of ash, slag, cake quantity
It can be seen that the carbon content in ash tends to decrease after the bituminous coal is blended and burned, and the carbon content in filter cake decreases obviously; the amount of the coal slime is reduced, and the amount of the slag is increased.
4. Type of trial-combustion bituminous coal
Different bituminous coals are used for statistics by Yunnan Tian chemical industry Co Ltd (hereinafter referred to as Tianan) in 2019 for 3-10 months, as shown in Table 12, in more than half a year, bituminous coals with different heating values and different ash component contents in different areas such as Qinghai, gansu and Shaanxi, 26-28MJ and the like are used for Tianan, and matched raw material coals are selected from different raw material coals such as high sulfur coals, 23.5MJ and 24.5MJ, and the economical efficiency and operability of the mixture ratio of the different bituminous coals and the different raw material coals are comprehensively analyzed and researched to find out corresponding mixing proportion and operation parameters.
Table 12 2019 coal total analysis data trial firing bituminous coal statistics
Summary of technical effects
① The carbon conversion rate is improved. Through the performance test of the mixed burning of the bituminous coal for 72 hours, the load of the gasification furnace is 19.4kg/s, the proportion of the bituminous coal to be burned is 25%, and through examination and calculation, the carbon conversion rate is 96.18%, compared with the performance test of 2018 (petroleum coke 15%, the load of the gasification furnace is 19.6 kg/s), the conversion rate is improved by 2.18% under the condition that the oxygen load is 0.2kg/s lower. From the annual analysis, the carbon conversion of the gasification furnace reaches about 98 percent.
② And improving production operation data of soot blending combustion. And (3) coal blending analysis: the heat value of the bituminous coal is lower than that of the petroleum coke, the ash content is higher than that of the petroleum coke, the heat value of the blended coal is lower than that of the petroleum coke by 1.11MJ/kg, the ash content is higher by 3%, and the ash melting point is lower by 41 ℃.
And (5) coal feeding analysis: the heat value of the bituminous coal is 0.6MJ/Kg lower than that of the petroleum coke blending coal, ash content is unchanged, and ash melting point is 2 ℃ lower than that of the petroleum coke blending coal.
The volatile matter of the bituminous coal is high, the activity is high, under the same load, more 81 tons of coal are fed each day, the effective gas rises by 5.2kNm 3/h, and more 81 tons of liquid ammonia are produced each day.
The sulfur content of the bituminous coal is low, and the H2S content in the synthetic gas of the bituminous coal is reduced by 2787ppm under the same load. The corrosion to equipment is greatly reduced.
The conversion rate is improved, the filter cake amount is reduced by 33.89 tons per day compared with the petroleum coke, the slag amount is 29.55 tons more per day due to the increase of the coal feeding amount, and the ash amount is not changed greatly.
The carbon content in the slag and ash is not changed greatly, and the carbon content in the filter cake is reduced by 9.83 percent.
③ Process parameter optimization is optimized
Reducing steam production control. The ash content of the bituminous coal is low, the volatile matter is high, the reactivity is good, the steam yield is reduced from 4.4-4.6 kg/s to 4.2-4.4 kg/s, and after the furnace temperature is reduced, the slag blocking of a slag system and the like are effectively controlled and relieved.
Reducing the limestone addition proportion. The addition ratio of the limestone is adjusted to be 0.4 plus or minus 0.2 percent because the CaO is high and the ash melting point is low. Greatly saves the consumption of limestone.
According to the invention, through analyzing the process data and the running conditions of the mixed-burned bituminous coal, the running conditions of each coal gasification process are stable, and each process parameter is controlled in an index range.
5. Economic analysis
1) 72 Hour performance check economic analysis
Performance test is carried out on the bituminous coal blending burning condition in 2019, 3 months and 12-14 days, and economic comparison is carried out on the bituminous coal blending burning condition and the blended burning petroleum coke under the same load.
The combustion data pair is shown in table 13.
Table 13 comparison of burn data
It can be seen that the total coal feeding amount of the gasification furnace is increased by 247.8 tons during the mixed burning use period of the bituminous coal by comparing the production data of the two time periods and the three days, and the synthetic ammonia yield is increased by 335.3 tons compared with the mixed burning period of the petroleum coke.
The consumption comparison analysis is shown in table 14.
Table 14 consumption comparative analysis
The raw material coal price is taken as the raw material coal ex-warehouse cost price of 2 months, and the price reaches the field price 772.38 yuan/ton. The price of the bituminous coal reaches 1189 yuan/ton of the tax price of the reading bed, the tax rate is 16 percent, the cost of the reading bed reaches 20 yuan/ton of the factory part, and the tax rate is 6 percent; the tax rate of petroleum coke to the reading shop is 1099 yuan/ton, the tax rate is 16%, and the cost of the reading shop to the factory is 8.97 yuan/ton, and the tax rate is 6%. And (3) comparing the consumption data to the consumption of ammonia and coal in tons during the mixed burning of the bituminous coal, wherein the consumption is increased by 31.39 yuan/ton.
2) Economic comparative analysis
① The ratio of 28MJ bituminous coal to petroleum coke is shown in Table 15
Table 15 28MJ bituminous coal vs. Petroleum coke
Comparison analysis: the coal consumption cost per ton of ammonia is increased by 31.39 yuan per ton of ammonia; however, the yield of the synthetic ammonia is 335.31 tons higher than that of the mixed-fired petroleum coke, the total brix of the mixed-fired bituminous coal is 16.04 ten thousand yuan higher than that of the mixed-fired petroleum coke, the brix of the mixed-fired bituminous coal is 5.34 ten thousand yuan higher than that of the mixed-fired petroleum coke, and the production cost of ton ammonia is reduced by 31.04 yuan.
By economic analysis, the cost of burning bitumite per ton of ammonia is reduced by 31.04 yuan per ton.
② The results of the 26MJ bituminous coal economic comparison with the 28MJ bituminous coal are shown in fig. 3.
By economic analysis, the cost per ton of ammonia of the blended burning 26MJ bituminous coal is reduced by 42.92 yuan/ton compared with that of 28MJ bituminous coal.
Conclusion(s)
By analyzing feasibility and economy of the mixed-burned bituminous coal of the gasification furnace, the mixed-burned bituminous coal has economy, stability to device operation and long-period operation of the device. Particularly, the bituminous coal has low sulfur content, is favorable for slowing down sulfur corrosion to equipment, has good activity and complete reaction, and obviously increases the ammonia yield.
Example 3
The gasification furnace APC controller is used for carrying out the operation of the multivariable control of the gasification furnace, and the influence of the fluctuation of the coal quality of the coal entering the furnace on the production is dealt with by adopting a feedforward and feedback RTO system. After the project is implemented, the mobility of the gasification furnace slag is effectively controlled, and the endangered operation conditions of the gasification furnace, such as slag blocking of a slag hole of the gasification furnace, formation of large slag blocks and the like, in the original control mode are effectively eliminated.
The foregoing is merely a preferred embodiment of the present invention and it should be noted that modifications and adaptations to those skilled in the art may be made without departing from the principles of the present invention, which are intended to be comprehended within the scope of the present invention.
Claims (10)
1. A method for replacing coal in gasification adaptive operation in a liquid slag gasifier, comprising the steps of:
The semi-coke or the bituminous coal is used as a substitute coal of petroleum coke, and the substitute coal is doped with raw material coal to be used as furnace coal; determining control indexes for replacing coal types according to known control indexes of coal fed into the furnace; the control indexes comprise heat value, ash content, total sulfur content, total water content and volatile content;
the method for determining the control index for replacing the coal type comprises the following steps:
setting the mass ratio of raw material coal to substitute coal as x to y;
the calorific value of the substitute coal is calculated according to formula 1:
in the formula 1, q Substitution of represents the calorific value of the coal instead of MJ/kg;
q Into (I) represents the calorific value of the coal charged into the furnace, MJ/kg;
q Original source represents the calorific value of the raw coal, MJ/kg;
Ash was calculated according to equation 2 instead of coal:
In formula 2, a Substitution of represents ash content in place of coal species,%;
a Into (I) represents ash content of coal entering a furnace,%;
A Original source represents ash content of raw coal,%;
the total sulfur content of the replacement coal was calculated according to formula 3:
In the formula 3, S Substitution of represents total sulfur content of the coal instead of the coal;
s Into (I) represents the total sulfur content of the coal entering the furnace,%;
s Original source represents the total sulfur content of the raw material coal,%;
the total water content of the replacement coal was calculated according to equation 4:
in formula 4, W Substitution of represents the total water content,%;
W Into (I) represents the total water content of the coal entering the furnace,%;
w Original source represents the total water content of the raw material coal,%;
the volatile content of the substitute coal was calculated according to formula 5:
In formula 5, V Substitution of represents the volatile content of the substitute coal species,%;
V Into (I) represents the volatile content of the coal entering the furnace,%;
V Original source represents the volatile content of the raw coal,%.
2. The method of claim 1, further comprising assisting in monitoring gasifier furnace temperature by monitoring gasifier water-wall saturated steam flow after the entering coal, wherein the theoretical value of gasifier water-wall saturated steam flow is calculated according to equation 6:
in the formula 6, F represents the saturated steam flow of the water-cooled wall of the gasification furnace, and kg/s;
f 1 represents the outlet mass flow rate of a water circulating pump of the medium-pressure boiler, and kg/s;
ρ 1 represents the density of saturated steam in the steam mixture at the outlet of the water wall of the hearth of the gasification furnace, kg/m 3;
ρ 2 represents the density of saturated water in the water vapor mixture at the outlet of the water wall of the hearth of the gasification furnace, kg/m 3;
ρ represents the density of the water vapor mixture at the outlet of the water-cooled wall of the hearth of the gasification furnace, kg/m 3;
k represents a correction coefficient;
If the measured value of the saturated steam flow of the water-cooled wall of the gasification furnace deviates from the theoretical value, the saturated steam density and the saturated water density are used for correction.
3. The method of claim 1, further comprising, after charging the coal into the furnace:
Adopting an APC controller of the gasification furnace, and realizing soft measurement of the furnace temperature of the gasification furnace according to the furnace temperature prediction model of the gasification furnace and the actual operation data of the device; on the basis of realizing soft measurement of the furnace temperature of the gasifier, the method overcomes the interference caused by coal quality change and downstream load demand change on the gasifier through a furnace temperature prediction model of the gasifier, and realizes automatic adjustment of the load of the gasifier and stable and optimal control of technological parameters;
The gasifier furnace temperature prediction model comprises a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler;
the furnace temperature measuring module based on wall heat transfer comprises a physical property parameter module, an input data module, a calculating module and a storage display module;
the physical property parameter module is used for storing physical property parameters of slag, synthetic gas and coal;
The input data module is used for acquiring industrial DCS data;
The calculation module comprises a calculation module I, a calculation module II, a calculation module III and a calculation module IV, wherein the calculation module I is used for calculating slag deposition amount, heat flux and SiC temperature; the calculation module II is used for calculating slag thickness related information; the calculation module III is used for calculating the surface temperature of the slag; the calculating module IV is used for calculating the temperature of the gasification furnace.
The furnace temperature measurement based on syngas chilling and convection waste boiler comprises:
And calculating the furnace temperature of the gasification furnace by mass accounting and heat accounting according to the chilling gas flow and temperature, the waste boiler inlet temperature, the waste boiler outlet temperature and the waste boiler steam yield and combining the outlet synthetic gas flow and components.
4. The method according to claim 3, wherein the gasifier furnace temperature prediction model further comprises slag notch state monitoring, the slag notch state monitoring calculates slag notch slag thickness and channel area in real time according to slag notch flow, phase change and heat transfer, and the rationality and reliability of the gasifier furnace temperature prediction model are verified by combining a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler.
5. The method of claim 1, further comprising, after charging the coal into the furnace:
Adopting a feedforward and feedback RTO system to cope with the influence of the fluctuation of the coal quality of the coal into the furnace on the production, and adjusting the oxygen-coal ratio and the steam-coal ratio according to the fluctuation of the coal quality of the coal into the furnace; the feedforward is based on parameters including coal quality detection data of the coal, quality, pressure, flow, steam and oxygen corresponding data of the coal, and initial production process parameters are formulated and references are provided for subsequent parameter adjustment; the feedback is to evaluate the current production condition and the coal quality change condition by utilizing the production feedback data of the gasifier, including the data of the product gas components, the flow, the pressure, the gasifier state data, the oxygen-coal ratio and the slag hole differential pressure, and refer to the feedforward variable, and to guide the adjustment of the next production parameters.
6. The method according to claim 1, wherein the mass ratio of raw coal to substitute coal is 0-5:1-5.
7. The method of claim 1, wherein the control indicators of the coal being charged comprise:
8. The method of claim 5, wherein the control indicators of the coal being charged further comprise:
9. The method according to claim 1, wherein the saturated steam flow rate of the water-cooled wall of the gasification furnace is controlled to be 4.2-4.4 kg/s.
10. An APC control system of a liquid slag discharging gasifier comprises a gasifier APC controller, a gasifier furnace temperature prediction model, an effective gas yield prediction model and a product gas composition prediction model;
The gasifier furnace temperature prediction model comprises a furnace temperature measurement module based on wall heat transfer and a furnace temperature measurement module based on synthesis gas chilling and convection waste boiler;
the furnace temperature measuring module based on wall heat transfer comprises a physical property parameter module, an input data module, a calculating module and a storage display module;
the physical property parameter module is used for storing physical property parameters of slag, synthetic gas and coal;
The input data module is used for acquiring industrial DCS data;
The calculation module comprises a calculation module I, a calculation module II, a calculation module III and a calculation module IV, wherein the calculation module I is used for calculating slag deposition amount, heat flux and SiC temperature; the calculation module II is used for calculating slag thickness related information; the calculation module III is used for calculating the surface temperature of the slag; the calculating module IV is used for calculating the temperature of the gasification furnace.
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