一、镍基钎焊热管技术的工作原理

　　1、 Working principle of nickel based brazed heat pipe technology

　　镍基钎焊管，即将镍铬合金渗入锅炉管或ND钢（耐低温露点腐蚀钢）表面，形成致密光滑涂层，使管片和母管的焊着率为100%，有效地扩展了换热面积，提高了换热系数，同时具有很好的耐高温和耐腐蚀性能。

　　Nickel based brazed pipe, which involves the infiltration of nickel chromium alloy into the surface of boiler tubes or ND steel (low temperature dew point corrosion resistant steel) to form a dense and smooth coating, resulting in a 100% welding rate between the pipe segments and the main pipe. This effectively expands the heat transfer area, improves the heat transfer coefficient, and has good high temperature and corrosion resistance.

　　热管是一种具有很高热传输性能的元件，它集沸腾与凝结于一身，由管壳、管芯和传导液组成。它的工作原理是：当蒸发段遇到高温介质时，管内传导液吸收蒸发潜热后蒸发，传导液蒸汽从管中心绝热段通道流向凝结段，并放出潜热，重新凝结成传导液，凝结后的传导液借助管芯的毛细力作用重新返回蒸发段再进行蒸发，这样形成了一个闭合的循环系统。通过这种途径，热量从加热区到了散热区，对被加热介质进行加热，得到所需温度的介质。

　　A heat pipe is a component with high heat transfer performance, which combines boiling and condensation, and is composed of a shell, core, and conductive fluid. Its working principle is that when the evaporation section encounters a high-temperature medium, the conductive liquid inside the tube absorbs the latent heat of evaporation and evaporates. The conductive liquid vapor flows from the adiabatic section channel at the center of the tube to the condensation section, releasing latent heat and re condensing into conductive liquid. The condensed conductive liquid returns to the evaporation section for further evaporation by the capillary force of the tube core, thus forming a closed loop system. Through this pathway, heat is transferred from the heating zone to the heat dissipation zone, heating the heated medium to obtain the desired temperature of the medium.

　　镍基钎焊热管式余热回收装置利用高温烟气和被加热介质传热系数的不同（烟气传热系数小，被加热介质传热系数的高），因而在传热系数小的烟气侧扩展换热面积，将热端—镍基钎焊翅片吸收的热量，与冷端—光管传热系数高的被加热介质所吸收的热量相同，使之产生有效的换热平衡。

　　The nickel based brazed heat pipe type waste heat recovery device utilizes the difference in heat transfer coefficients between high-temperature flue gas and the heated medium (the flue gas has a lower heat transfer coefficient and the heated medium has a higher heat transfer coefficient), thus expanding the heat transfer area on the flue gas side with a lower heat transfer coefficient. The heat absorbed by the hot end nickel based brazed fins is equal to the heat absorbed by the heated medium with a higher heat transfer coefficient between the cold end and the light pipe, creating an effective heat transfer balance.

　　二、镍基钎焊热管式余热回收装置的结构特点

　　2、 Structural characteristics of nickel based brazed heat pipe type waste heat recovery device

　　1、结构紧凑

　　1. Compact structure

　　单位长度的钎焊热管换热面积是普通光管的七倍左右，同时钎焊热管之间用小半径推制弯头连接。因而相同换热面积的钎焊热管余热回收装置普通光管的设备相比，其体积和占地面积成数倍的减小，并且其重量也有不同幅度的降低。因而，在设备布置安装和吊装等方面为用户提供了很大的空间。

　　The heat transfer area of brazed heat pipes per unit length is about seven times that of ordinary bare pipes, and brazed heat pipes are connected by small radius push bends. Therefore, compared to ordinary bare tube equipment, the volume and footprint of brazed heat pipe waste heat recovery devices with the same heat exchange area are reduced several times, and their weight is also reduced to varying degrees. Therefore, it provides users with a lot of space in terms of equipment layout, installation, and lifting.

　　2、维修方便

　　2. Easy maintenance

　　钎焊热管是采用整根无缝钢管制造完成的，使其具有很高的耐压性能，一般情况很少出现质量方面的问题。如果偶然发现某一根钎焊热管出现泄漏，也可以方便地进行更换，即使不更换也不影响运行。

　　Brazed heat pipes are made of seamless steel pipes, which have high pressure resistance and rarely have quality issues. If a leakage is accidentally discovered in a brazed heat pipe, it can be easily replaced without affecting operation.

　　3、受压元件无热应力

　　3. Pressure bearing components have no thermal stress

　　每一根钎焊热管组装时，无任何强制组装现象，因而不会产生组装应力。同时每一端呈自由状态。这样设备在运行过程中，无热应力产生。

　　When assembling each brazed heat pipe, there is no forced assembly phenomenon, so there will be no assembly stress. At the same time, each end is in a free state. In this way, there is no thermal stress generated during the operation of the device.

　　4、标准化设计和灵活的尺寸变化

　　4. Standardized design and flexible size changes

　　迄今为止，我们已开发设计了多系列的标准产品。广泛应用于大中小型柴油机和天然气发电机组，以及锅炉的高温烟气的余热回收利用，另外，我们可在短时间内按照用户要求，根据用户提供的设计参数，对各种余热回收装置进行灵活设计。

　　So far, we have developed and designed multiple series of standard products. Widely used in large, medium, and small diesel engines, natural gas generator sets, as well as high-temperature flue gas recovery and utilization in boilers. In addition, we can flexibly design various waste heat recovery devices according to user requirements and design parameters provided by users in a short period of time.

　　5、可高效连续的运行

　　5. Can operate efficiently and continuously

　　根据其传热机理和结构特点，我们不难得知，钎焊热管技术具有较强的防垢、防灰和自除垢、除灰能力。因而其设备可以长时间的保持高效运行，这是普通光管换热设备所不能比拟的。

　　Based on its heat transfer mechanism and structural characteristics, it is not difficult to know that brazed heat pipe technology has strong anti scaling, anti ash, and self descaling and ash removal capabilities. Therefore, its equipment can maintain efficient operation for a long time, which is incomparable to ordinary light tube heat exchange equipment.

　　三、设计目的

　　3、 Design purpose

　　本设计利用10台500kW瓦斯发电机组高温烟气余热产生5kgf/cm2饱和蒸汽用于生产。该电站10台500kW瓦斯发电机组，测试结果表明，所燃气体至多36%的热量用来发电，约有38%的热量通过高温烟气排空。为充分利用余热，设计一套余热利用系统，充分利用高温烟气热量，使所燃气体总热量70%得到应用。

　　This design utilizes 10 500kW gas generator units to generate 5kgf/cm2 saturated steam from high-temperature flue gas waste heat for production. The power station has 10 500kW gas generator units, and the test results show that up to 36% of the heat generated by the burned gas is used for power generation, and about 38% of the heat is discharged through high-temperature flue gas. To fully utilize waste heat, a waste heat utilization system is designed to fully utilize the heat of high-temperature flue gas, so that 70% of the total heat of the burned gas is applied.

　　四、系统组成及原理

　　4、 System composition and principle

　　镍基钎焊热管式余热回收装置是以镍基钎焊热管作为换热元件，将烟气的热量通过扩大受热面积的热管段传递给压力汽包中的介质。在其中加热介质,采用自然循环的形式，把水变为饱和蒸汽。通过水位控制器控制蒸汽空间，提高饱和蒸汽的质量，当水位达到低水位时，控制柜将信号给给水泵，水泵开启送水直到水位达到高水位止，如此反复循环。系统主要由烟气——水热交换器（热管蒸发器）、给水泵、阀门仪表、输水输汽管线、输气管线等组成。

　　The nickel based brazed heat pipe type waste heat recovery device uses nickel based brazed heat pipes as heat exchange elements to transfer the heat of flue gas to the medium in the pressure steam drum through the heat pipe section that expands the heating area. In it, the heating medium adopts a natural circulation form to turn water into saturated steam. By controlling the steam space through a water level controller, the quality of saturated steam is improved. When the water level reaches a low level, the control cabinet sends a signal to the feed pump, which starts to supply water until the water level reaches a high level. This cycle is repeated. The system mainly consists of a flue gas water heat exchanger (heat pipe evaporator), a feedwater pump, valves and instruments, water and steam pipelines, and gas pipelines.

　　系统的设计压力为1.2Mpa，蒸汽介质工作温度在152℃，蒸汽量为4246kg/h，热交换量为2675400kcal/h。

　　The design pressure of the system is 1.2Mpa, the working temperature of the steam medium is 152 ℃, the steam volume is 4246kg/h, and the heat exchange capacity is 2675400kcal/h.

　　五、热工计算

　　5、 Thermal calculation

　　瓦斯在空气中完全燃烧公式：

　　Formula for complete combustion of gas in air:

　　图片

　　image

　　瓦斯在空气中不完全燃烧公式：

　　Formula for incomplete combustion of gas in air:

　　图片

　　image

　　瓦斯发电机组正常运转时，发电功率为450kW、排烟温度为550℃左右，当镍基钎焊热管热交换器出水温度为152℃左右时，它排出的烟气温度为150℃，瓦斯完全燃烧时和空气的体积比为1:10，为使燃料充分燃烧，一般燃气与空气的混合比例为1:13，（按1m3纯瓦斯发3度电计算）

　　When the gas generator set operates normally, the power generation is 450kW and the exhaust temperature is around 550 ℃. When the outlet temperature of the nickel based brazed heat pipe heat exchanger is around 152 ℃, the exhaust temperature is 150 ℃. When the gas is completely burned, the volume ratio of gas to air is 1:10. In order to fully burn the fuel, the mixing ratio of gas to air is generally 1:13 (calculated based on 1m3 of pure gas generating 3 kWh of electricity)

　　500kW机组的耗气总量为：450/3×（1＋13）＝2100m3/h。

　　The total gas consumption of a 500kW unit is 450/3 × (1+13)=2100m3/h.

　　平均重量按1.25kg/m3计算，总重：2100×1.25＝2625kg

　　The average weight is calculated at 1.25kg/m3, and the total weight is 2100 × 1.25=2625kg

　　排烟的比热容按烟道气体计算（烟道气体的成分CO:13%，H2O:11%，N2:76%，在100℃—600℃的平均定压比热容为0.26kcal/kg·℃）。

　　The specific heat capacity of smoke exhaust is calculated based on the composition of flue gas (CO: 13%, H2O: 11%, N2: 76%, with an average constant pressure specific heat capacity of 0.26kcal/kg ·℃ at 100 ℃ -600 ℃).

　　图片

　　image

　　10台发电机组可利用排烟余热产生5kgf/cm2蒸汽为：

　　10 generator sets can generate 5kgf/cm2 steam by utilizing exhaust waste heat

　　（550－150）×0.26×2625×0.98×10＝2675400kcal/h

　　（550－150）×0.26×2625×0.98×10＝2675400kcal/h

　　按进水温度20℃计算，蒸汽温度152℃，蒸汽的热含650kcal/kg则每小时可产生总蒸

　　Calculated based on an inlet water temperature of 20 ℃, a steam temperature of 152 ℃, and a steam heat content of 650kcal/kg, the total steam generated per hour can be calculated

　　汽量为：

　　The steam volume is:

　　2675400÷（650－20）＝4246kg

　　2675400÷（650－20）＝4246kg

　　方案1：用于夏季制冷

　　Option 1: Used for summer cooling

　　根据国内制冷设备厂提供样本参数来看，4246kg的蒸汽能够带动3957kw的溴化锂机组。根据以往经验值来看按每平方米制冷量100瓦计算，则可供制冷面积为；

　　According to the sample parameters provided by domestic refrigeration equipment manufacturers, 4246kg of steam can drive 3957kw lithium bromide units. Based on past experience, if calculated at a cooling capacity of 100 watts per square meter, the available cooling area is;

　　3957kw×1000w÷100w/m2＝39570m2

　　3957kw×1000w÷100w/m2＝39570m2

　　方案2用于冬季供暖：

　　Option 2 for winter heating:

　　按进水温度20℃计算，加热成95℃热水计算，每小时可产生热水量为：

　　Calculated based on an inlet water temperature of 20 ℃ and heated to 95 ℃ hot water, the amount of hot water produced per hour is:

　　2675400kcal/h÷（95℃－20℃）＝35672kg/h；

　　2675400kcal/h÷（95℃－20℃）＝35672kg/h；

　　按每平方米取暖热量80瓦计算，则可供暖面积为（自热工手册中查得：每千瓦热量合860千卡：2675400kcal/h÷860Kcal/kw=3110kw）:

　　Calculated based on a heating capacity of 80 watts per square meter, the available heating area is (according to the thermal manual: 860 kilocalories per kilowatt of heat: 2675400kcal/h ÷ 860Kcal/kw=3110kw):

　　3110kw×1000w/kw÷80w/m2＝38886m2

　　3110kw×1000w/kw÷80w/m2＝38886m2

　　注：瓦斯实际在缸内燃烧不完全，产生一定量的一氧化碳，并在排气管中继续燃烧；实

　　Note: Gas actually burns incompletely in the cylinder, producing a certain amount of carbon monoxide, which continues to burn in the exhaust pipe; real

　　际烟气排出的热能比计算值要多。

　　The heat energy emitted from the flue gas is greater than the calculated value.

　　六、施工说明

　　6、 Construction Instructions

　　1、系统中的管线分别采用以下具体规格DN80（给水主管线）、DN100（蒸汽主管线）。

　　1. The pipelines in the system adopt the following specific specifications: DN80 (water supply main pipeline) and DN100 (steam main pipeline).

　　2、镍基钎焊热管式热交换器：安装在现有发电机组的上部外端，尽量靠近发动机排气口，将消声器改装在换热器的尾部上。

　　2. Nickel based brazed heat pipe heat exchanger: installed at the upper outer end of the existing generator set, as close as possible to the engine exhaust port, with the muffler modified at the rear of the heat exchanger.

　　3、排气口到换热器、消声器管线采取保温措施，保温材料选用厚100mm硅酸铝，用钢丝捆扎，外包镀锌铁皮，用铆钉固紧。

　　3. Insulation measures shall be taken for the pipeline from the exhaust port to the heat exchanger and muffler. The insulation material shall be 100mm thick aluminum silicate, tied with steel wire, wrapped with galvanized iron sheet, and fastened with rivets.

　　4、给水和蒸汽输送管线采用架空铺设或埋地铺设，首先在管线表面涂刷防锈漆两道，然后采用60mm岩棉管包扎保温，用钢丝捆扎，外包油毡玻璃丝布防雨层，最外层刷绿色面漆，并用红箭头标示水流方向。

　　4. The water supply and steam transmission pipelines are laid overhead or underground. First, two layers of anti rust paint are applied to the surface of the pipeline. Then, 60mm rock wool pipes are wrapped for insulation, tied with steel wire, and covered with oil felt glass wool cloth for rain protection. The outermost layer is painted with green topcoat and marked with red arrows indicating the direction of water flow.

　　5、系统安装完毕后，进行管线冲洗和水压试验，试验压力1.5MPa，冲洗试压后方可开泵试运行。

　　5. After the system installation is completed, pipeline flushing and water pressure testing shall be carried out with a test pressure of 1.5MPa. The pump can only be started for trial operation after flushing and pressure testing.

　　七、经济效益综合分析及报价

　　7、 Comprehensive analysis and quotation of economic benefits

　　镍基钎焊热管式余热回收装置

　　Nickel based brazed heat pipe type waste heat recovery device

　　蒸汽型——汽水分离器和设备合为一体

　　Steam type - steam water separator and equipment integrated

　　每套报价：——万元.，10套合计价格为：——万元

　　Price per set: -10000 yuan The total price for 10 sets is: -10000 yuan

　　1、设备型号及参数

　　1. Equipment model and parameters

　　型号：——

　　Model:——

　　设计压力：1.0MPa;

　　Design pressure: 1.0MPa;

　　换热面积：当量面积——m2；实际换热面积——m2；

　　Heat exchange area: equivalent area - m2; actual heat exchange area - m2;

　　适合发电机实际输出功率：500kw机组；

　　Suitable for actual output power of generators: 500kW units;

　　2、供货范围

　　2. Scope of Supply

　　设备主体包括保温，主要受压元件采用锅炉管制造；配套阀门仪表：安全阀、蒸汽出口阀、排污阀、放空阀、压力表、压力表弯、针形阀、给水阀、水位控制器、双色水位计；配对法兰：余热回收装置与烟道连接的DN250法兰2片；耐高温三通阀：耐温1000℃，耐热不锈钢内胆，型号DN250带配对法兰；全自动控制柜；换热器给水泵；

　　The main body of the equipment includes insulation, and the main pressure components are made of boiler tubes; Supporting valve instruments: safety valve, steam outlet valve, drain valve, vent valve, pressure gauge, pressure gauge bend, needle valve, water supply valve, water level controller, dual color water level gauge; Paired flange: Two DN250 flanges connecting the waste heat recovery device to the flue; High temperature resistant three-way valve: resistant to 1000 ℃, heat-resistant stainless steel inner liner, model DN250 with matching flange; Fully automatic control cabinet; Heat exchanger feedwater pump;

　　3、经济效益

　　3. Economic benefits

　　按每台发电机每年正常运行300天，每吨蒸汽的价值为60元计算，10台发电机每年余热回收所产生的价值为：

　　Based on the normal operation of each generator for 300 days per year and a value of 60 yuan per ton of steam, the value of waste heat recovery generated by 10 generators per year is:

　　60×24×300×4.246≈183.4万元

　　60 × 24 × 300 × 4.246 ≈ 1.834 million yuan

　　4、投资回收期：

　　4. Investment payback period:

　　设备投资：——万元；

　　Equipment investment: -10000 yuan;

　　X÷183.4×12≈Y（个月）

　　X ÷ 183.4 × 12 ≈ Y (months)

　　综合上述可知，10台发电机机组余热回收系统成本可在Y个月内收回，本系统运行期按5年计算，可节约资金——万元。

　　Based on the above, it can be concluded that the cost of the waste heat recovery system for 10 generator units can be recovered within Y months. If the operating period of this system is calculated as 5 years, it can save tens of thousands of yuan in funds.

　　八、热管式余热回收装置与针管式余热回收装置性能比较

　　8、 Performance comparison between heat pipe waste heat recovery device and needle tube waste heat recovery device

　　具有以下优点：

　　It has the following advantages:

　　1、设备投资省

　　1. Equipment Investment Province

　　因为针管式不能采用气包和换热器连为一体的结构，需要单独的汽水分离器，同时需要热水循环泵两台，设备造价相比较要高出10%左右；

　　Because the needle tube type cannot adopt a structure that integrates an air bag and a heat exchanger, a separate steam water separator is required, and two hot water circulation pumps are needed, resulting in an equipment cost that is about 10% higher compared to others;

　　2、运行费用低

　　2. Low operating costs

　　因为针管式余热回收装置要产蒸汽需采用强制循环，这样仅热水循环泵的运行费用一项，按循环泵扬程50米，流量50立方米，电机功率20千瓦计算，每年耗电量为15万千瓦时，折合人民币7.5万元。

　　Because the needle type waste heat recovery device requires forced circulation to produce steam, only the operating cost of the hot water circulation pump is included. Calculated based on the pump head of 50 meters, flow rate of 50 cubic meters, and motor power of 20 kilowatts, the annual power consumption is 150000 kilowatt hours, equivalent to 75000 yuan.

　　3、换热效果好

　　3. Good heat exchange effect

　　同样面积的两种换热器，热管的换热效果明显优于针管，吸收热量相对要多一些，如同样60平方米的换热器，同样产0.6MPa饱和蒸汽，热管换热器烟气出口温度比针管的低15℃。

　　Two types of heat exchangers with the same area, the heat transfer effect of the heat pipe is significantly better than that of the needle pipe, absorbing relatively more heat. For example, a 60 square meter heat exchanger produces 0.6MPa saturated steam, and the exhaust gas outlet temperature of the heat pipe heat exchanger is 15 ℃ lower than that of the needle pipe.

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