中拓高效燃氣內燃機發電技術在鐵合金礦熱爐煤氣上的應用

　　Application of Zhongtuo High Efficiency Gas Internal Combustion Engine Power Generation Technology in Ferroalloy Mineral Heat Furnace Gas

　　實現碳達峰和碳中和的“雙碳”目標是國家的重大戰略。工業尾氣排放是溫室氣體的主要來源，控制工業尾氣碳排放是碳減排工作的關鍵，利用工業尾氣發電是實現工業尾氣碳減排的重要途徑。尾氣發電機組屬于資源綜合利用的關鍵裝備，在國家和地方政策上得到大力支持，在“雙碳”經濟背景下迎來新的發展機遇。01什么是礦熱爐煤氣

　　Realizing the "dual carbon" goals of peaking carbon emissions and achieving carbon neutrality is a major national strategy. Industrial exhaust emissions are the main source of greenhouse gases, and controlling industrial exhaust carbon emissions is the key to carbon reduction. Utilizing industrial exhaust for power generation is an important way to achieve industrial exhaust carbon reduction. Exhaust gas generator units are key equipment for comprehensive resource utilization and have received strong support from national and local policies, ushering in new development opportunities in the context of the "dual carbon" economy. 01 What is mineral furnace gas

　　礦熱爐又稱電弧電爐或電阻電爐，是一種陸續加料、連續作業的工業電爐，主要用于還原冶煉礦石、碳質還原劑及溶劑等原料，是鐵合金冶煉的主要設備。鐵合金尾氣工藝流程圖

　　Submerged arc furnace, also known as electric arc furnace or resistance electric furnace, is an industrial electric furnace that gradually feeds materials and operates continuously. It is mainly used for reducing and smelting raw materials such as ores, carbonaceous reducing agents, and solvents, and is the main equipment for ferroalloy smelting. Process Flow Diagram of Ferroalloy Tail Gas

　　在鐵合金的生產過程中，礦熱爐中的焦炭與礦石發生反應，會產生大量的尾氣，俗稱“礦熱爐煤氣”。礦熱爐煤氣是一種有毒有害的溫室氣體，其主要組分為CO、H2、CH4、CO2等氣體，因此，礦熱爐煤氣中又蘊含著豐富的化學能和熱能。目前，除少部分作為燃料使用外，絕大部分礦熱爐煤氣被燃燒后直接排至大氣，這樣既造成了嚴重的環境污染，又浪費了資源。如果采用高效的燃氣內燃機發電，實現能源充分利用并降低尾氣中有害物質的排放，可帶來經濟、環境和運營上的效益。02燃氣內燃機如何利用礦熱爐煤氣

　　In the production process of ferroalloys, the coke in the submerged arc furnace reacts with the ore, producing a large amount of exhaust gas, commonly known as "submerged arc furnace gas". Mineral furnace gas is a toxic and harmful greenhouse gas, mainly composed of gases such as CO, H2, CH4, CO2, etc. Therefore, mineral furnace gas contains abundant chemical and thermal energy. At present, except for a small portion used as fuel, the vast majority of mine blast furnace gas is directly discharged into the atmosphere after combustion, which not only causes serious environmental pollution but also wastes resources. If efficient gas internal combustion engines are used for power generation, achieving full energy utilization and reducing the emission of harmful substances in exhaust, it can bring economic, environmental, and operational benefits. How to utilize the coal gas from the ore blast furnace for 02 gas internal combustion engines

　　礦熱爐煤氣的主要成分為：CO、CO2、H2、CH4、N2、O2、H2O。其中CO 含量50%~85%，H2含量2%~14%，CH4含量0~6.5%，尾氣的燃燒低熱值約為7～11.5?MJ/Nm3，其具體成分及比例受生產原料、工況的變動影響大。可見，礦熱爐煤氣成分復雜，各氣體組分及含量變動較大。礦熱爐煤氣中的可燃氣體主要有CO、H2和CH4，其燃燒特性如表所示。其中CO和CH4的燃燒特性相近，而與CO和CH4相比，H2的燃燒速度非常快，引燃所需能量特別低，與空氣混合燃燒濃度范圍很寬，燃燒放熱速率極高，這些特性很容易導致內燃機在運行期間出現進氣回火、缸內早燃與爆燃等異常現象，造成效率下降與零部件損壞。同時，由于氫氣在大氣中的擴散系數大，使得氫氣與空氣混合均勻所需的時間非常短。而且，氫氣分子極小、滲透性強，對防泄漏提出更高要求，容易造成氫脆、滲透等問題。綜上，利用礦熱爐煤氣必須首先解決以下技術問題：

　　The main components of blast furnace gas are CO, CO2, H2, CH4, N2, O2, and H2O. The CO content is 50%~85%, the H2 content is 2%~14%, the CH4 content is 0~6.5%, and the low calorific value of the exhaust gas combustion is about 7~11.5? MJ/Nm3， Its specific composition and proportion are greatly affected by changes in production materials and working conditions. It can be seen that the composition of the coal gas in the blast furnace is complex, and the composition and content of each gas vary greatly. The combustible gases in the coal gas of the ore blast furnace mainly include CO, H2, and CH4, and their combustion characteristics are shown in the table. The combustion characteristics of CO and CH4 are similar, while compared with CO and CH4, H2 has a very fast combustion rate, requires particularly low energy for ignition, has a wide range of combustion concentration when mixed with air, and has a very high heat release rate. These characteristics can easily lead to abnormal phenomena such as intake backfire, early combustion and detonation in the cylinder during internal combustion engine operation, resulting in decreased efficiency and component damage. Meanwhile, due to the high diffusion coefficient of hydrogen in the atmosphere, the time required for hydrogen to mix evenly with air is very short. Moreover, hydrogen molecules are extremely small and highly permeable, placing higher demands on leak prevention, which can easily lead to issues such as hydrogen embrittlement and permeation. In summary, the following technical problems must be solved first when using the coal gas from a blast furnace:

　　1)遏制進氣回火，確保燃氣系統的供氣與混合安全可靠性；2)抑制缸內異常燃燒，協同組織缸內混合氣高效燃燒；3)克服燃氣組分變動影響，提高尾氣組分變動適應性。為此，中拓技術人員基于LY系列燃氣內燃機發電系統產品潛心研發了專利燃氣供給系統，并采用公司自主開發的稀薄低溫燃燒技術與分布式實時控制技術，經過了反復的試驗與應用驗證，有效地克服了上述技術障礙，取得較好的效果。03燃氣內燃機對氣體的組分及雜質含量要求

　　1) Control intake backfire and ensure the safety and reliability of gas supply and mixing in the gas system; 2) Inhibiting abnormal combustion in the cylinder and coordinating efficient combustion of the cylinder mixture; 3) Overcome the impact of changes in gas composition and improve the adaptability to changes in exhaust gas composition. To this end, Zhongtuo technicians have devoted themselves to developing a patented gas supply system based on the LY series gas internal combustion engine power generation system products, and have adopted the company's independently developed lean low-temperature combustion technology and distributed real-time control technology. After repeated experiments and application verification, the above technical obstacles have been effectively overcome and good results have been achieved. 03 Gas Internal Combustion Engine Requirements for Gas Composition and Impurity Content

　　為保證燃氣內燃機的穩定可靠運行，進入內燃機前的燃氣一般需要對礦熱爐排出的尾氣進行凈化處理，并滿足下表要求：04中拓工業煤氣內燃機組的優勢

　　To ensure the stable and reliable operation of gas internal combustion engines, the gas before entering the internal combustion engine generally needs to be purified from the exhaust gas discharged from the ore blast furnace, and meet the requirements in the following table: 04 Advantages of Zhongtuo Industrial Gas Internal Combustion Units

　　單機功率大，氣體適應性強中拓機組單機發電功率可達1500kW，是目前市場上礦熱爐煤氣發電應用產品中單機功率最大的內燃機發電機組，也是在此領域唯一單機功率超過1MW的產品。機組采用先進的氣體混合器和精確的控制系統，滿足適應多元化的工業尾氣氣體特點，一氧化碳含量20%以上即可運行。

　　The single unit power is high and the gas adaptability is strong. The single unit power generation of Zhongtuo unit can reach 1500kW, which is currently the largest single unit power internal combustion engine generator set in the market for mineral thermal furnace gas power generation applications. It is also the only product in this field with a single unit power exceeding 1MW. The unit adopts advanced gas mixers and precise control systems to meet the diverse characteristics of industrial exhaust gases, and can operate with a carbon monoxide content of over 20%.

　　發電效率高，盈利能力強機組優化了稀薄燃燒技術和預燃室式火花塞，使得燃料消耗更低，發電效率為40%左右，綜合利用效率可達到86%。相比國內同類產品25%左右的發電效率，中拓發電機組提高了燃氣利用率15%，高電效率可帶來高盈利。

　　High power generation efficiency and strong profitability. The unit has optimized lean combustion technology and pre chamber spark plugs, resulting in lower fuel consumption. The power generation efficiency is around 40%, and the comprehensive utilization efficiency can reach 86%. Compared to similar domestic products with a power generation efficiency of around 25%, Zhongtuo generator sets have increased gas utilization by 15%, and high electrical efficiency can bring high profits.

　　升功率高，強化系數大采用高增壓比深度中冷與米勒循環稀薄燃燒技術和自主創新研發的前饋空燃比實時精確控制技術，提高了礦熱爐煤氣發動機的強化系數，升功率達到16.95kW/L，居全國之首。

　　The high power consumption and high enhancement coefficient are achieved through the use of high boost ratio deep intercooling and Miller cycle lean combustion technology, as well as the independently developed feedforward air-fuel ratio real-time precise control technology, which improves the enhancement coefficient of the mineral heat furnace gas engine. The power consumption reaches 16.95kW/L, ranking first in the country.

　　氮氧化物排放低，減輕環保壓力通過精準地控制缸內燃燒溫度，從而有效減低了氮氧化物（NOX）的排放量，實測排放485 mg/Nm?，大大減少脫硝成本和環保壓力。

　　Low nitrogen oxide emissions reduce environmental pressure by precisely controlling the combustion temperature in the cylinder, effectively reducing the emission of nitrogen oxides (NOX). The measured emission is 485 mg/Nm? Greatly reduce the cost of denitrification and environmental pressure.

　　機油消耗低，降低運營成本本公司通過消化國外先進的機油消耗設計技術，對機油在潤滑與密封過程中所產生的蒸發與燃燒消耗進行了細化分解，并對相關關鍵系統零部件（如活塞-缸套、曲軸箱通風系統等）進行了設計優化，機組運行潤滑油消耗低至0.3g/kWh，逼近國際先進水平，較國內同類產品水平領先優勢明顯。

　　Low oil consumption reduces operating costs. Our company has refined and decomposed the evaporation and combustion consumption of oil during lubrication and sealing processes by digesting advanced oil consumption design technologies from abroad. We have also optimized the design of key system components such as piston cylinder liners and crankcase ventilation systems. The lubricating oil consumption during unit operation is as low as 0.3g/kWh, approaching the international advanced level and having a significant advantage over similar domestic products.

　　可用性高，運行時間長更清潔的燃燒和核心進口運動件使物理損耗降到極致，機組的維護間隔更長，大修周期48000h以上，年運行時長8000h以上。

　　High availability, longer running time, cleaner combustion, and core imported moving parts minimize physical wear and tear. The maintenance interval of the unit is longer, with a major overhaul cycle of over 48000 hours and an annual operating time of over 8000 hours.

　　結構緊湊，安全性高機組體積小，重量輕，降低了對安裝場地的要求；采用多級阻火防爆設計和先進的爆震控制技術，能有效避免非正常工況對機組的損害。

　　Compact structure, high safety, small size and light weight of the unit, reducing the requirements for installation site; The use of multi-stage flame retardant and explosion-proof design and advanced detonation control technology can effectively avoid damage to the unit caused by abnormal operating conditions.

　　備件充足，維護便捷中拓擁有內蒙、山西、湖南、廣東四大零件中心，完備的服務體系、專業的維護人員可滿足全國各地的售后需求。05中拓礦熱爐煤氣發電示范案例

　　Adequate spare parts and convenient maintenance. Zhongtuo has four major parts centers in Inner Mongolia, Shanxi, Hunan, and Guangdong, with a complete service system and professional maintenance personnel to meet after-sales needs across the country. 05 Zhongtuo Mining Thermal Furnace Gas Power Generation Demonstration Case

　　·?內蒙古豐鎮市豐宇26.4MW工業尾氣發電項目2022年5月，該項目一期11*1.2MW并網成功、投入運行。此項目總規劃裝機容量為26.4MW，一期配置11臺中拓自主品牌LY1600GH-M1.2MW工業煤氣發電機組，采用并網不上網的模式。項目投產后預計年發電量約1.05億度，節約標準煤3.46萬噸/年，減排二氧化碳12.4萬噸/年。

　　·In May 2022, the Fengyu 26.4MW industrial tail gas power generation project in Fengzhen City, Inner Mongolia, successfully connected the first phase of the project with a capacity of 11 * 1.2MW and put it into operation. The total planned installed capacity of this project is 26.4MW, and the first phase will be equipped with 11 independent brand LY1600GH-M1.2MW industrial gas generator units from Zhongtuo, using a grid connected mode without grid connection. After the project is put into operation, it is expected to generate approximately 105 million kilowatt hours of electricity annually, save 34600 tons of standard coal per year, and reduce carbon dioxide emissions by 124000 tons per year.

　　·?內蒙古豐鎮市科翰14.4MW工業尾氣發電項目2022年6月，該項目并網成功、投入運行。配置12臺中拓自主品牌LY1600GH-M型工業煤氣集裝箱式發電機組，總裝機容量為14.4MW。所發電量采用并網不上網的模式，全部供內蒙古科翰冶金公司使用。該電廠投產后預計年發電量約1.15億度，可節約標準煤3.68萬噸/年，減排二氧化碳13.52萬噸/年。06應用展望

　　·The 14.4MW industrial tail gas power generation project in Kehan, Fengzhen City, Inner Mongolia was successfully connected to the grid and put into operation in June 2022. Configure 12 independent brand LY1600GH-M industrial gas container type generator sets from Taichung Tuo, with a total installed capacity of 14.4MW. The generated electricity will be connected to the grid without being connected to the grid, and all will be used by Inner Mongolia Kehan Metallurgical Company. After the power plant is put into operation, it is expected to generate approximately 115 million kilowatt hours of electricity annually, saving 36800 tons of standard coal per year and reducing carbon dioxide emissions by 135200 tons per year. 06 Application Outlook

　　當前，在 “雙碳”戰略的號召下，各大行業加大了碳排放跟蹤力度，國家發改委等部委聯合下發了《鐵合金行業節能降碳改造升級實施指南》，大力推進高耗能行業節能降碳工作順利開展。礦熱爐煤氣發電應用，可以提高能源利用率，減少環境污染，實現降本增效，是集資源循環利用、低碳環保和廠區安全生產優勢為一體的利好之選。從經濟性上考量，礦熱爐煤氣的自發電量既能供以自用，減少企業用電支出，又可以選擇并入國家電網，產生直接經濟效益。以單臺1MW燃氣發電機組測算，中拓機組年度發電量為800萬度左右，以電價0.55元每度計算，可創造經濟效益人民幣440萬元左右。中拓作為燃氣內燃機發電領域中具備自主研發能力的民族品牌，在礦熱爐煤氣發電應用領域積累了豐富的項目實戰經驗。中拓以低熱值礦熱爐煤氣為原料發電項目的高度適應和成熟運用，有效保障了客戶獲得持續可觀的收益，引領鐵合金企業實現節能、減排、降碳綠色高質量發展。預見未來，礦熱爐煤氣的發電應用大有可為。

　　Currently, under the call of the "dual carbon" strategy, major industries have increased their efforts to track carbon emissions. The National Development and Reform Commission and other departments have jointly issued the "Implementation Guidelines for Energy Conservation and Carbon Reduction Upgrades in the Ferroalloy Industry", vigorously promoting the smooth implementation of energy conservation and carbon reduction work in high energy consuming industries. The application of coal gas power generation in ore blast furnaces can improve energy utilization efficiency, reduce environmental pollution, and achieve cost reduction and efficiency improvement. It is a favorable choice that integrates the advantages of resource recycling, low-carbon environmental protection, and factory safety production. From an economic perspective, the self generated electricity from mining furnace gas can be used for self consumption, reducing the electricity expenditure of enterprises, and can also be integrated into the national power grid to generate direct economic benefits. Based on a single 1MW gas-fired generator unit, the annual power generation of Zhongtuo unit is about 8 million kWh. Calculated at an electricity price of 0.55 yuan per kWh, it can create an economic benefit of about 4.4 million RMB. As a national brand with independent research and development capabilities in the field of gas internal combustion engine power generation, Zhongtuo has accumulated rich project practical experience in the application of mine heat furnace gas power generation. The highly adaptable and mature application of Zhongtuo's low calorific value ore blast furnace gas as raw material for power generation projects effectively ensures that customers can obtain sustained and considerable profits, leading ferroalloy enterprises to achieve energy-saving, emission reduction, carbon reduction, green and high-quality development. Looking ahead to the future, there is great potential for the power generation application of coal gas from mining furnaces.

　　本文由 礦熱爐煤氣發電機組  友情奉獻.更多有關的知識請點擊  http://www.xzwdy.cn/   真誠的態度.為您提供為全面的服務.更多有關的知識我們將會陸續向大家奉獻.敬請期待.

　　This article is a friendly contribution from the coal gas generator set of the mine heating furnace For more related knowledge, please click http://www.xzwdy.cn/ Sincere attitude To provide you with comprehensive services We will gradually contribute more relevant knowledge to everyone Coming soon.