Advanced industrial ceramic heat pipe recuperators

This paper summarizes the results of an investigation involving the use of ceramic heat pipe recuperators for high-temperature heat recovery from industrial furnaces. The function of the recuperator is to preheat combustion air with furnace exhaust gas. To maximize fuel savings, a very high air preheat temperature is desirable; this necessitates the use of ceramic elements in the recuperator.The heat pipe recuperator comprises a bundle of individual ceramic heat pipes acting in concert, with a partition separating the air and exhaust gas flow streams. The heat pipe fluid is a liquid metal. The ceramic heat pipe recuperator concept offers several advantages as compared to tubular type ceramic recuperators. Because each heat pipe is essentially an independent heat exchanger, the failure of a single tube does not compromise recuperator integrity and has only a minimal effect on overall heat exchanger performance. This independent element characteristic also enables easier replacement of individual heat pipes in the recuperator. In addition, the heat pipe acts as an essentially isothermal heat transfer device, leading to a high thermodynamic efficiency.Cost estimates developed for heat pipe recuperator systems indicate favorable payback periods. Laboratory studies have demonstrated the feasibility of fabricating the required ceramic tubes, coating the inside of the tubes with CVD tungsten (which functions as both a protective layer and a heat pipe fluid wick), and sealing the heat pipe with an electron-beam-welded or vacuum-brazed end cap.     

An open cycle absorption heat pump

The absorption cycle can be also of the open type. This concept has been utilized in developing solar cooling absorption systems. Another possibility not yet investigated is an open cycle absorption heat pump. The system rests upon the utilization of a packed tower operating with liquid desiccants. The tower dehumidifies both the exhausted air of heating plant and the exhaust of a natural gas boiler. A conventional heater heats up the regenerator of the sorbent and the inlet air. Simulations give a PER of the system (the open cycle heat pump) higher than 1.3 with respect to the Gross Calorific Value of natural gas. This value is difficult to obtain with the more complex closed cycle absorption or vapour compression cycle motor driven heat pump.     

Thermal performance of waste-heat recuperator with heat pipes for thermal power station

Analytical studies were conducted to investigate the thermal performance of a heat pipe heat exchanger to recover thermal energy from exhaust hot gas from a boiler, in order to replace a conventional heat recovery system (Ljungstrom) in the steam power plant.     

The effect of the operating parameters of heat recovery steam generators on combined cycle/sea-water desalination plant performance

Combined gas/steam turbine cycle plants have been proposed for cogeneration of electricity and process steam. Examples are combined-cycle power plants coupled with sea-water desalination, district heating plants, chemical industries, etc. In combined heat and power plants, the gas turbine exhaust heat is utilized through the use of heat recovery steam generators (HRSG's). As a result, these waste heat generators (boilers), whether fired or unfired, control the performance of the combined plant lower side (bottoming cycle). Moreover, any changes made in the HRSG operating parameters (i.e. the pinch point, approach temperature, first and second stage pressures, and mass ratios) can greatly affect the HRSG performance and will eventually affect the overall combined plant performance. This paper presents a method to predict the performance of the heat recovery steam generators (HRSG)/steam bottoming cycle combined with sea-water desalination plant at various steam and exhaust gas conditions.     

The influence of the exhaust system unsteady gas flow and insulation on the performance of a turbocharged diesel engine

A comprehensive digital computer program is used to simulate the unsteady gas flow in the exhaust and inlet systems of a multi-cylinder, turbocharged, medium-high speed, four-stroke diesel engine installed at the authors' laboratory. The simulation assumes one-dimensional, time-varying gas flow in the engine pipes and incorporates numerous realistic fluid dynamic, thermodynamic and heat-transfer features. The characteristic mathematical transformation solution of the gas-flow dynamics partial differential equations is interfaced with First-Law analysis models of the cylinders main chambers and prechambers. The simulation results are compared most favourably against the engine's experimental performance results, which include mean air consumption rate, pressure histories at various locations on the exhaust system, and energy-mean temperature values at the exit of the exhaust system. The simulation results are also utilized for the determination of the various cylinders' exhaust waves intensity, as they are imposed by the design characteristics of the exhaust manifold. The plotting of relevant charts, showing the contour variation of gas pressure, temperature and Mach index against engine crank angle and pipe length, aids the correct interpretation of the observed behaviour. The detailed simulation of the fluid dynamic and heat-transfer fields in the engine exhaust system, permits an interesting parametric study of the influence of the degree of insulation of the exhaust system on the energy and exergy (availability) content of the exhaust gases before the turbocharger turbine, by coupling the above First-Law with Second-Law analysis concepts.     

Effect of control modes and turbine cooling on the part load performance in the gas turbine cogeneration system

This work aims to analyse the part load performance in a cogeneration system which consists of a single shaft gas turbine and a heat recovery steam generator. Two distinct part load control modes are considered: the constant air flow and the variable air flow. Meanwhile, the effect of variation in the coolant fraction is evaluated, whose purpose is to maintain the blade temperature as high as possible and thus minimise the coolant consumption. The design point parameters of the heat recovery steam generator are determined by the limiting factors on the part load operation, which are represented by the pinch point temperature difference and the approach temperature difference. It turns out that for both air flow control modes, the variable control of coolant fraction leads to improvement of the gas turbine efficiency, while it reduces the heat recovery potential. On the whole, the variable control of coolant fraction has a favourable effect on the overall fuel economy in the cogeneration system.     

Energy conservation in the refinery by utilizing reformed fuel gas and furnace flue gases

Decrease of fuel supplies and cost increases make it vital for industries, especially energy intensive ones, to consider conserving available sources and convert losses into sources of energy.In this paper, a gas turbine-based cogeneration system is suggested to utilize a refinery's reformer gas in the gas turbine, and furnaces flue gases together with the engine exhaust gases in a heat recovery steam generator, HRSG. This is proposed as an alternative to the currently used system where the gas turbine and the steam generator are used separately. Operating variables comprising compressor pressure ratio and turbine inlet temperature are varied widely to evaluate performance; namely power, SFC, overall efficiency and annual fuel savings at design and off-design loading conditions using a dedicated computer program.Results show that the proposed system offers 100% higher overall efficiency and $5.25 million annual fuel saving for a 12 MW_e gas turbine.     

Gas turbine waste heat recovery distillation system

This article presents a method for improving the gas turbine's performance through an efficient utilization of the waste heat in a distillation system with a special arrangement. This consists of two trains of VTE/MEB connected to increase the fresh water produced. Exhaust gases from the gas turbine are used in a multi-temperature level heat recovery system with five feed heaters, and gases are released to ambient at 130°C. Distillation top train has nine effects and evaporation range from 130 to 82°C while the bottom train has six effects with evaporation range from 76 to 46°C and is supplied with the steam leaves the last effect in the top train.Thermal analysis using a 32.67 MW gas turbine showed that the present arrangement can produce 3.2 million gallons per day (mgd) of fresh water with more than 4 g/kWh at a performance ratio (PR) of 8.8. This is 34% more than that produced in an existing gas-turbine distillation combination and 14% more than that expected from a reverse osmosis plant driven by a bottoming Rankine power cycle.     

Enhancing gas turbine performance by intake air cooling using an absorption chiller

The performance of gas turbines, operated either as a simple cycle or a combined cycle, is critically constrained by the prevailing ambient temperature, particularly in arid and tropical climates. This paper investigates the option of cooling the intake air to the compressor of the gas-turbine system using an absorption chiller in order to increase the gas turbine capacity. High-temperature waste heat from the exhaust gas may be utilized to produce steam in a recovery boiler. Part of the steam produced could then be used to drive a lithium-bromide double-effect absorption chiller which in turn could cool the incoming air. An analysis carried out by taking the weather data of Bangkok (Thailand) indicates that reducing the temperature from ambient condition to 15°C could help to increase the instantaneous power output between 8 and 13%. As an outcome, as much as 11% additional electricity could be generated from the same gas turbine power plant.A simple economic assessment indicates that the proposed scheme will require a minimal investment as compared to the commissioning cost of a new gas turbine unit to meet the corresponding capacity increment. The latter will need nearly four times higher initial cost than the amount estimated for the proposed scheme. Thus, implementation of such a system would significantly abate the negative impact of the ambient temperature, while providing an economically and environmentally attractive option for energy producers in most developing nations of the world which are located in arid and tropical zones.     

柴油机排气过程流动的多维瞬态数值模拟研究

柴油机排气过程气体的流动直接影响到排气管换热、发动机噪音、废气再循环系统设计等,对柴油机整体性能起着重要作用.因此,本文利用大型通用CFD软件STAR-CD及ES-ICE,在进气压缩、喷雾燃烧过程多维瞬态数值模拟基础上,对柴油机排气过程流动进行多维瞬态数值模拟研究,通过计算给出排气过程中气体的流场分布,为柴油机排气系统的优化设计提供重要的理论指导.     

基于显热回收的分离式热管传热特性的实验研究

针对新风空调机组,采用倾角为15°的分离式热管用于显热回收.研究充液率,迎面风速及空气进口温度对显热效率的影响,分析了其影响规律.研究表明,采用热管空调机组设计风速范围内,充液率介于66％～75％时,其换热效率最高.迎面风速较低时,空气进口温度介于34℃～36℃,其显热效率较高.因此,采用分离式热管机组适合用于高热地区...     

新型焦电联产系统集成与特性分析

本文针对传统焦炭生产工艺的不足、并应用联产系统整合思路,研究提出新型焦炭动力联产系统.新系统取消了传统炼焦工艺中直接燃用焦炉煤气为炭化室提供炼焦热量的方式,采用外置煤炭燃烧室提供热量,从而实现用低品质煤炭替代高品质焦炉煤气;节省下来的富氢、高热值的焦炉煤气作为燃料提供给联合循环,实现高效洁净发电;改进炼焦过程烟气废热回收方式,使得排烟损失大大降低.分析结果表明,新系统具有优良的热力性能,相对节能率高达15%左右.对系统关键过程的图像(火用)分析分析表明,燃烧过程和换热过程等变革与改进是系统性能提升的关键所在.本文研究将为冶金生产的可持续发展提供新思路与新系统方案.     

燃气轮机采用不同冷却技术对IGCC系统性能影响

本文分析了用于燃气轮机系统的冷却技术,对采用空气冷却技术的GE-9FA,GE-9G型燃气轮机以及采用蒸汽冷却技术的GE-9H型燃气轮机进行了设计工况点的校核,通过定量计算重点研究了采用两种不同冷却技术的燃气轮机整合到IGCC系统中对系统热力性能、系统参数优化规律及环保性能的影响,从而为研究高效、环保的IGCC系统提供有价值的参考。     

低温空气制冷系统中板翅换热器性能实验研究

对低温空气制冷系统中的散热器、回热器性能进行实验研究,测量不同工况条件下两个锯齿形板翅式换热器的换热效率及系统性能,分析了换热器低压侧和高压侧的空气流量对换热器及系统性能的影响。结果表明:(1)散热器低压侧空气流量是影响其效率的主要因素;(2)回热器效率随其低压侧空气流量的增大而增大,随其高压空气流量的增大而减小;(3)高压空气流量是影响制冷量的主要因素;在其它工况参数不变的条件下,高压空气流量增大7.9%,制冷量最大增加14.5%。     

极端高温环境下空气源热泵冷热水机组制冷实验研究

针对现有空气源热泵冷热水机组高温环境运行效果差、效率低、排气温度过高导致停机等问题,设计一套基于准双级压缩循环理论,以R410A为制冷剂的中压补气型空气源热泵冷热水机组。在50℃极端环境温度下,采用中压补气技术,对系统的制冷性能进行实验研究。结果表明:(1)系统出水温度由10℃增至15℃时,制冷量增加77.28%,EER提高59.02%,系统的制冷量、功率和EER均随出水温度的升高而增加;(2)相较不补气模式,系统排气温度由111.9℃降至106.23℃,制冷量由14.14 kW增至16.05 kW,可有效降低排气温度,提升制冷量,能更好提高系统超高温制冷时的稳定性。     

Waste heat recovery of dura (Iraq) oil refinery and alternative cogeneration energy plant

The first part of this paper presents a waste heat recovery scheme for the Dura (Baghdad, Iraq) oil refinery energy plant. Both the wasted heat of the process return condensate and the flue gases are utilized for low temperature feedwater and fuel heating. The steam saved, both from the main steam line and turbine extraction system, was found to increase the steam and plant overall efficiency by 18%.An alternative cogeneration energy plant is presented in the second part of this study. The proposed plant utilizes the gas turbine exhaust, in conjunction with a heat recovery boiler, to produce the process steam requirement. With this alternative plant, the overall efficiency increases by 31.6%, while the steam efficiency increases by 19%. The outstanding features and advantages of the proposed plants are highlighted.     

引射系统排气装置的数值模拟

为削弱引射系统尾气对光传输的影响,依据将尾气排放到光传输区域以外的设计思路,运用数值模拟的方法,对引射系统排气管道内的流场特性及尾气射流影响区域开展了研究。通过对直管道以及弯管道内流场特性的数值分析和比较,给出了一种排气管道的结构设计方式。在给定系统出口速度的情况下,运用多组分输运模型,分别对无自然风和有侧向自然风状态下的尾气影响范围进行了分析,初步确定了尾气射流排出系统后的影响区域,并依据尾气影响区域,对管道长度及布置方式进行了研究。     

化学氧碘激光器尾气主动冷却技术试验

使用主动冷却技术降低化学氧碘激光器(COIL)尾气的温度,是提高引射式压力恢复系统引射效率的一项关键技术。采用理论计算和数值模拟的方法,得出了满足技术指标要求的冷却器系统设计参数,并研制了一套以管翅式热交换器、液氮循环汽化提供制冷量的COIL尾气主动冷却试验装置。与激光器的对接试验结果表明,在COIL出光60s试验中,热交换器可以使尾气温度从590K降低到160K,出口截面温度不均匀度小于21K,经过热交换器的气流总压损失小于100Pa。     

采用复合吸附剂多功效热管型吸附制冷机

设计制造了一台采用复合吸附剂(氯化钙和活性炭)-氨工作对的双床多功效热管型吸附制冷机,并进行了大量实验,获得了新型热管型吸附制冷系统的制冷特性。本系统分别采用丙酮或水为热管工作液,以加热器加热来模拟渔船余热加热。实验得出渔船制冰工况和船舶空调工况下的单位质量吸附剂的制冷功率SCP和制冷系统COP。结果显示水热管工质更适合于船舶余热应用。     

Gas turbine exhaust gas heat recovery at South Baghdad (Iraq) power plant

Gas turbine exhaust is usually relatively clean, especially the exhaust from natural gas turbines. The use of such gases to improve the overall thermal efficiency of a steam power plant has the advantage of reducing the cost of cleaning the equipment and reducing the maintenance costs of the heat recovery equipment used in the application.In this paper, two proposals for recovering the waste energy of the exhaust gases from a gas turbine unit, fuelled by natural gas at south Baghdad Power Plant (Iraq) are discussed. The proposals cover improvements to the thermal efficiency of a steam power plant installed near the gas turbine unit. The first proposal is to use the exhaust gases to preheat the feed water at four feed water heaters, in order to increase the power output. This arises because of the savings in the amount of steam extracted at a different level used for preheating the feed water line. The second proposal is to use the thermal energy in the exhaust gases to reheat the extracted stream, at five points at a high thermal potential, to increase the thermal gain at the preheating feed water line. This avoids the complexity associated with rejection of the extracted steam. The first roposal shows that a 1.22–14.9% saving in fuel consumption is achievable and the overall thermal efficiency of the steam power plant becomes 29–34% (at different gas turbine plant loads). The second proposal shows that a 2.3–7.35% saving in fuel consumption can be attained and the corresponding thermal efficiency will be 30.3–32%.