Gas-side fouling, erosion and corrosion
of heat exchanger for middle and low temperature flue gas waste heat
recovery

YaLing HE; SongZhen TANG; FeiLong WANG; QinXin ZHAO; WenQuan TAO

doi:10.1360/N972016-00248

Chinese Science Bulletin

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Chinese Science Bulletin, Volume 61, Issue 17: 1858-1876(2016) https://doi.org/10.1360/N972016-00248

Gas-side fouling, erosion and corrosion of heat exchanger for middle and low temperature flue gas waste heat recovery

YaLing HE, SongZhen TANG, FeiLong WANG, QinXin ZHAO, WenQuan TAO

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ReceivedFeb 22, 2016
AcceptedMar 11, 2016
PublishedMay 10, 2016

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Abstract

With the ongoing emphasis on the efficient use of energy, much effort is put on the development and application of various heat recovery technologies. Heat exchangers play an important role in energy transfer and utilization and are widely used to recover waste energy from different kinds of heat sources in many fields such as energy and power engineering, petroleum and chemical engineering, air conditioning and refrigeration, aviation and aerospace, etc. In the heat exchangers for waste heat recovery, the gas-side fluid mediums usually are unclean and corrosive. The problems of fouling, erosion and corrosion of heat exchangers in the middle and low temperature flue gas-side caused by the high ash content, viscous and corrosive components are inevitable, and how to effectively solve the problems has been the subject of much research in recent years. In this paper, the researches of fouling, erosion and corrosion characteristics in middle and low temperature flue gas heat exchangers are reviewed. The causes and influence factors are discussed. Firstly, the fouling mechanisms of heat exchangers are introduced and the existing theoretical models, empirical models, and numerical methods of particle transport, impact and deposition are reviewed. The ash fouling characteristics of 6-row tube heat exchangers are presented and the effects of flue gas velocity, particle diameter, spanwise tube pitch, longitudinal tube pitch, tube shape and geometry conditions on fouling rate are discussed. Both decrease of the longitudinal tube spacing and increase of spanwise spacing can effectively reduce the deposition of particles. The geometry of elliptical tubes can fulfill this requirement for fouling reduction with smaller longitudinal spacing and larger spanswise pitch. The feasibility of using oval tube is explored for the fouling reduction. Compared with the circular tube arrangement, the deposition rate of the elliptical tube was decreased by 68.8%. Secondly, the existing erosion mechanisms, theories and methods are introduced. Different erosion models, including the model advantages and disadvantages are also summarized. The dynamics behaviour of the entrained solid particles in the flow and the deformation of the tube surface due to erosion are presented. The effects of particle diameter, particle mass flow rate and fluid Reynolds number are discussed. Among the three parameters, fluid Reynolds number has the most important effect on the erosion of tube surface. Erosion mainly occurs at the first part of the single tube surface. Thirdly, the existing mechanisms, theories and methods of corrosion characteristics of heat exchangers are introduced. Then a coupling numerical model, developed in author’s previous research, is discussed to predict the condensation characteristics of sulfuric acid vapor on heat exchanger surfaces. The corrosion risk can be reduced by decreasing the water vapor concentration and increasing the flue gas temperature. The effects of operating parameters and geometry conditions on the sulfuric acid condensation and corrosion characteristics are also discussed. A correlation of Sh number of sulfuric acid versus fin geometries for a 10-row tube bundle is provided. In order to reveal the anti-corrosion characteristics of different materials and the coupling mechanisms between the fouling and dewpoint corrosion, the online water-cooled test system and laboratory static sample test system on the corrosion characteristics of heat exchangers are introduced. Some dewpoint corrosion resistant steels are presented. The mechanism of dewpoint corrosion is revealed, the relationship between the thickness of corrosion layer and wall temperature is discussed and the coupling mechanisms between the fouling and dewpoint corrosion are also discussed. The corrosion products are composed of the ash and acid reaction products in the outer layer, iron sulfate in the middle layer, and iron oxide in the inner layer. The innermost layer is the main corrosion layer. Finally, the research needs and prospect of fouling, erosion and corrosion research are discussed. Hope to solve the problems of designing the anti-fouling, anti-erosion and anti-corrosion heat exchangers, and promote the development of efficient utilization technologies in middle and low temperature flue gas heat exchangers.

Funded by

国家重点基础研究发展计划(2013CB228304)

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图1
煤燃烧过程中积灰形成示意图^[5]
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图2
(网络版彩色)顺排布置圆管圆周的沉积率分布^[15]. u=5 m/s, d_p=5 mm
Click to view Download high-quality image

图3
(网络版彩色)不同参数对换热性能和沉积率的影响^[15]. (a), (b) 颗粒直径和流速对沉积率的影响; (c), (d) 纵向节距对换热阻力性能和沉积率的影响; (e), (f) 横向节距对换热阻力性能和沉积率的影响
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图4
(网络版彩色)顺排椭圆管圆周的沉积率分布^[15]. u=5 m/s, d_p=5 mm
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图5
(网络版彩色)不同管型和管排布置的涡量和颗粒场分布图^[15]. (a) 圆管顺排; (b) 圆管错排; (c) 椭圆管顺排; (d) 椭圆管错排. u=5 m/s, d_p=5 mm
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图6
(网络版彩色)管型及布置形式对沉积率的影响^[15]. u=5 m/s, d_p=5 mm
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图7
不同尺寸颗粒的碰撞轨迹^[37]. (a) d_p=0.01 mm; (b) d_p=0.03 mm; (c) d_p=0.05 mm; (d) d_p=0.08 mm; (e) d_p=0.1 mm
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图8
(网络版彩色)管壁磨损深度圆周分布^[37]. (a) 不同颗粒直径; (b) 不同颗粒流量; (c) 不同雷诺数
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图9
不同时刻管壁边界变化图^[37]. d_p=30 mm, Re=11174
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图10
雷诺数对最大磨损深度的影响^[37]. d_p=30 mm, q_m=0.004 kg/s
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图11
(网络版彩色)腐蚀速率随壁温变化的曲线^[1,46]
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图12
(网络版彩色)翅片表面温度、硫酸质量分数、酸分压及酸凝结率在翅片表面的分布图^[52]. (a) 翅片温度; (b) 硫酸质量分数; (c) 酸分压; (d) 凝结率
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图13
(网络版彩色)不同参数对酸凝结率和酸液质量分数的影响^[52].(a) 流速; (b), (c) 酸组分含量; (d), (e) 烟气温度; (f), (g) 水组分含量
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图14
(网络版彩色)10排H型翅片管换热器示意图^[56]
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图15
(网络版彩色)Re数和翅片厚度对酸沉积率和冷凝硫酸质量分数的影响^[56]. (a) Re数; (b) 翅片厚度
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图16
(网络版彩色)管型和布置方式的影响. (a) 酸凝结速率; (b) 冷凝的酸液浓度
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图17
(网络版彩色)实验室挂片实验装置示意图^[60]
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图18
(网络版彩色)真实烟气水冷低温腐蚀实验装置示意图^[61]
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图19
(网络版彩色)不同材料模拟气氛下腐蚀层厚度对比图^[60]
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图20
(网络版彩色)不同钢材真实烟气中腐蚀层厚度对比图^[62]
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图21
(网络版彩色)积灰与酸耦合机理示意图^[64]

表1 磨损模型对比

文献	数学模型及主要参数	模型介绍	优缺点
Finnie^[27]	$\begin{matrix} V = K \frac{m v^{2}}{p} f (α) \\ f (α) = {\begin{matrix} \sin 2 α ? 3 \sin^{2} α, ? α \leq 18.5 ° \\ \cos^{2} α / 3, ????????????? α > 18.5 ° \end{matrix} \end{matrix}$	该模型是很早根据磨损的实验现象和各种结果描述磨损微切削机理的模型. 模型假设颗粒在切削金属的过程中不发生碎裂, 认为固体颗粒对韧性材料的磨损主要源自颗粒对材料的犁削作用	此磨损模型对于韧性材料在冲击角度是小角度( $α < 45 °$ )时, 与实验结果吻合较好, 但当冲击角度较大时, 该模型与实验偏差较大, 尤其 $α = 90 °$ 时, 该模型的磨损量为0
Hashish^[28]	$\begin{matrix} W = \frac{7}{π} \frac{m}{ρ_{p}} {(\frac{v}{C})}^{2.5} \sin (2 α) \sqrt{\sin α} \\ C = \sqrt{\frac{3 σ_{t} R_{f}^{3 / 5}}{ρ_{p}}} \end{matrix}$	该模型对Finnie模型进行了修改, 改进了其中的速度指数并加入了粒子形状的影响	该模型中不需要实验常数, 所以使用较方便. 然而该模型主要基于韧性材料, 因而主要适用于韧性材料低冲击角的磨损情况
Mbabazi等人^[29]	$E = \frac{0.47 z^{4.95} ρ_{m} ρ_{p}^{1 / 2} V 3 \sin^{3} β}{σ_{y}^{3 / 2}}$	该模型综合考虑了颗粒和金属表面的性质、颗粒的运动特性	该模型计算简便, 但主要适用于特定材料(低碳钢)
Tabakoff等人^[30]	$\begin{matrix} E = K_{1} {1 + C_{K} [K_{2} sin (\frac{90}{β_{0}} β_{1})]}^{2} \\ + V_{i}^{2} {cos}^{2} β_{1} (1 ? R_{1}^{2}) \\ + K_{3} (^{V_{i} sin β_{1}) 4} \end{matrix}$	该模型是通过对煤灰颗粒磨损金属材料进行了大量的实验研究, 回归总结出煤灰碰撞管壁磨损率的计算公式	此模型已被Schade等人^[40]用于预测燃煤电站锅炉磨损速率, 与实验结果十分吻合. 但含碳量不同时机械性能差别较大. 此模型反应不出碳钢含碳量不同时磨损量的差异
The Erosion/Corrosion Research Center (E/ CRC)^[31]	$\begin{matrix} E R = C (^{B H) ? 0.59} F_{s} V_{p}^{n} F (θ) \\ F (θ) = \sum_{i = 1}^{5} A_{i} θ^{i} \end{matrix}$	该模型源于实验数据, 主要针对碳钢和铝材料. 该模型引入了包含目标材料的机械特性的变量-布氏硬度	此模型是在高速撞击条件下获得的, 对于低速撞击的工况不具有普遍适用性. 且没有明确考虑颗粒大小的影响
Oka等人^[32,33]	$\begin{matrix} E (α) = g (α) E_{90} \\ g (α) = (^{\sin α) n 1} (^{1 + H v (1 ? \sin α)) n 2} \\ E_{90} = K (^{H v) k 1} {[\frac{v}{v^{'}}]}^{k 2} {[\frac{d}{d^{'}}]}^{k 3} \end{matrix}$	该模型以大量的磨损实验为基础, 综合考虑颗粒的碰撞速度、碰撞角度、目标材料的硬度、颗粒粒径和几种颗粒类型等主要影响因素	适用于任何材料, 任意撞击角度和撞击速度. 但没有明确考虑颗粒的形状
Lee等人^[34]	$E = \sum_{j = 1}^{2} K_{j} C_{p j} f (β_{j}) V^{n_{j}} g (d_{p}) h (T_{h}) ω_{j}$	该模型从撞击速度、粒子尺寸、粒子形状、粒子的力学特性、飞灰浓度、被撞击材料的温度和省煤器结构等方面进行考虑	该模型包含有重要的磨损参数, 但磨损常数的确定需要进行大量的试验获得

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Gas-side fouling, erosion and corrosion of heat exchanger for middle and low temperature flue gas waste heat recovery

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