锅炉受热面的冲蚀磨损与防护综述

doi:10.11902/1005.4537.2022.282

中国腐蚀与防护学报

2023, Vol. 43

Issue (5): 957-970 CSTR: 32134.14.1005.4537.2022.282 DOI: 10.11902/1005.4537.2022.282

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锅炉受热面的冲蚀磨损与防护综述

李海燕¹, 刘欢¹(

), 王阁义¹, 张秀菊¹, 陈同舟², 俞云¹, 姚洪¹

^1.华中科技大学能源与动力工程学院武汉 430074
^2.武汉材料保护研究所有限公司武汉 430030

Review on Erosion-wear and Protection of Heat Exchange Surface in Power Station Boilers

LI Haiyan¹, LIU Huan¹(

), WANG Geyi¹, ZHANG Xiuju¹, CHEN Tongzhou², YU Yun¹, YAO Hong¹

^1.School of Energy and Power Engineering, Huazhong University of Science and Technology, Wuhan 430074, China
^2.Wuhan Research Institute of Materials Protection, Wuhan 430030, China

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摘要:

电站锅炉是火力发电的关键设备，燃料燃烧过程中，烟气与飞灰的气固两相流冲击极易导致锅炉受热面发生冲蚀磨损破坏，威胁电厂的安全稳定运行。本文综述了锅炉受热面冲蚀磨损的原因、破坏机理和预测模型。基于此针对锅炉受热面的特异性环境，总结了飞灰特性、受热面材质、服役环境等因素对冲蚀磨损破坏的影响。进一步地，从缓解冲蚀磨损的角度，综述了换热面加装防磨构件和涂覆耐磨材料的研究现状，并提出通过流场模拟优化受热面结构、采用金属陶瓷涂层进行防护是主要的发展方向，为锅炉受热面的冲蚀磨损研究和防护措施的开发应用提供参考和指导。

关键词 ：冲蚀磨损, 磨损机理, 磨损影响因素, 耐磨涂层, 电站锅炉, 受热面

Abstract：

Power plant boilers are the key equipment for thermal power generation. During the combustion process, under the impact of the gas-solid two-phase flow of flue gas and fly ash, the heat exchange tubes of the boiler are prone to erosion-wear damage. The deterioration or even explosion of tubes seriously threatens the safe and stable operation of the power plant. In this paper, the causes of erosion, failure mechanism of heat exchange surfaces and prediction models of erosion rate were reviewed, including the cutting wear/deformation wear caused by fly ash in the furnace and the calculation model of the corrosion rate by considering various erosion parameters. Based on this, according to the specific environment of heat exchange surfaces in boilers, the influence of fly ash characteristics (shape, particle size and hardness), tube materials (carbon steel/alloy steel), and the service environment of heat exchange surfaces (the flow rate of flue gas in furnace, erosion speed/angle of fly ash, tube surface temperature) on the erosion-wear damage was summarized in detail. It is believed that erosion speed and tube surface temperature are the most important factors affecting erosion damage. Furthermore, from the perspective of alleviating erosion-wear, the research status of adding anti-erosion components and erosion-resistant coating materials on heat exchange surfaces was also reviewed. It was proposed that the main development directions of anti-erosion measures were to optimize the structure of heat exchange surfaces through flow field simulation and to apply WC-Co/Cr₂C₃-NiCr cermet coatings. At the same time, it was also pointed out that to clearly understand the relationship between the cost and protection effect of coatings, and further to optimize the coating preparation process, so that to reduce costs could provide an important economic guidance for the utilization of coatings. This review can provide a reference for the research on erosion-wear of heat exchange surfaces in boilers, as well as the development and application of protective measures.

Key words： erosion abrasion mechanism factors affecting erosion anti-erosion coatings boiler heat exchange surface

收稿日期: 2022-09-21 32134.14.1005.4537.2022.282

ZTFLH:

TG174.4

基金资助:国家重点研发计划(2018YFC1901302)

通讯作者: 刘欢，E-mail：huanliu@hust.edu.cn，研究方向为固废高效热转化技术

Corresponding author: LIU Huan, E-mail: huanliu@hust.edu.cn

作者简介: 李海燕，女，1997年生，博士生

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引用本文:

李海燕, 刘欢, 王阁义, 张秀菊, 陈同舟, 俞云, 姚洪. 锅炉受热面的冲蚀磨损与防护综述[J]. 中国腐蚀与防护学报, 2023, 43(5): 957-970.
LI Haiyan, LIU Huan, WANG Geyi, ZHANG Xiuju, CHEN Tongzhou, YU Yun, YAO Hong. Review on Erosion-wear and Protection of Heat Exchange Surface in Power Station Boilers. Journal of Chinese Society for Corrosion and protection, 2023, 43(5): 957-970.

链接本文:

https://www.jcscp.org/CN/10.11902/1005.4537.2022.282 或 https://www.jcscp.org/CN/Y2023/V43/I5/957

图1 冲蚀磨损机理示意图[45]

Number

Calculation formula

Meaning of symbols

References

E = K x 4.95 ρ m ρ p 1 / 2 V 3 s i n 3 β H v 3 / 2

K: erosion constant; x: mass fraction of Si in the ash;ρ_m : density of mild steel; ρ_p : average density of ash particles; V: ash particle velocity; β: impingement angle;H_v : Vickers hardness number.

[52]

E = ∑ j = 1 2 K j C p j f β j U i n j g (D p) h T h ω j

j

=1, 2, represent polygon-shaped and spherical particles, respectively; K: erosion constant;C_p : particulate concentration; β: impact angle, U_i: impact velocity; D_p : particle size; T_h : homologous temperature ratio; ω: chemical composition of fly-ash particles

[53]

$E α = s i n α n 1 (1 + H v 1 - s i n α) n 2 E 90$

$E 90 = K (a H v) k 1 b (v v') k 2 (D D') k 3$

α: impact angle; H_v : Vickers hardness number; n₁、n₂、K、k₁、k₂、k₃ : indices and constants determined by the target material hardness, particle characteristics and erosion conditions.

[54, 55]

表1 冲蚀磨损预测模型

图2 飞灰颗粒的几何形貌

表2 燃煤飞灰与垃圾焚烧飞灰的成分 (mass fraction / %)

图3 在30°和90°冲蚀条件下冲蚀率随流速的变化关系[79]

图4 受热面腐蚀速度与温度的关系[103]

图5 不同h0-hs-S (mm)下防磨横梁附近粒子速度矢量分布[20]

图6 换热管冲蚀磨损破坏的壁面及FMI-3涂层(FeAlCrB)运行13 a后的上表面形貌[118]

图7 防磨涂层的材料与制备技术占比分布[4, 11, 24, 121~143]

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