内外表面熔焊管强化凝结传热实验研究与机制分析
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摘要
蒸汽冷凝换热器是工程中的蒸汽动力装置以及汽动循环系统中必不可少的组成部分,其运行寿命和工作效率是整个热力系统安全经济运行的重要保障。多数蒸汽冷凝换热器内部主要的工作元件是各式各样的换热管,它们的传热系数直接决定了换热器的性能。因此研究蒸汽凝结换热管的强化传热技术具有十分重要的理论价值和现实意义。
水蒸气的冷凝换热作为传热学研究和应用的一个重要领域受到了越来越多的专家学者的重视,随着对冷凝过程机理的认识和了解,出现了大量对凝结模型的计算和研究,对凝结过程做出了定性和定量的描述。但是其中对于水蒸气凝结过程的强化换热研究的着眼点大多在管外凝结方面,对水蒸气的管内凝结换热特性的探索涉及较少；在强化传热措施方面,国内外多数研究采用的是管材的物理改造方法和一些外部扰流方法,其投入应用的难度较大,与工程实践的结合不够紧密。而对凝结表面采取改性处理(尤其是管内表面改性)的方法以达到强化换热的效果的系统的研究和报道并不多见。
鉴于此,本文采用基于炉内高温熔焊工艺的表面改性处理技术,对普通碳钢管的内外表面进行改性处理,构造了新型蒸汽凝结换热元件——表面熔焊管。本文从单管的管内外凝结实验,管束的外部凝结换热实验,数值计算及强化传热机理分析等几个方面入手,研究了熔焊表面对管材的凝结换热性能的提升效果。进行的主要工作及得出的相应结论如下：
(1)建立了表面熔焊管的管外凝结实验台,进行了表面熔焊管和普通钢管的管外凝结换热对比实验。分别以单管和管组的形式构建实验段,以管内循环水作为冷源,让水蒸气(以下简称蒸汽)分别在两种管材的外壁面发生凝结,通过对实验数据的计算得出表面熔焊管和普通钢管的总体换热系数及管外凝结换热系数并加以比较分析,得到了实验段总换热系数k与管内循环水流速(0.6-1.3m/s)变化的关系曲线,发现由表面熔焊管构成的实验段其换热系数比普通钢管的高出20%以上,且随着管内循环冷却水流量的增大,这一比值还有增大的趋势；通过计算发现实验中表面熔焊管的管外凝结换热系数ho约为普通钢管的3倍,说明其对凝结换热的强化作用十分显著；通过焊接热电偶测量壁温的方法,得到了管子沿周向和管长方向的壁温分布曲线,通过分析得出熔焊管的表面热流密度更高,且能够更均匀的承受热负荷。
(2)建立了管束凝结换热实验台,分别以四种不同换热管材(含表面熔焊管)构造管束进行真空状态下的管外凝结换热实验,得到了典型Re数下不同管束总体换热系数U和随真空度σ的变化曲线,发现了真空度越高,管束的换热性能越好,且相同工况下表面熔焊管束的换热性能要明显好于不锈钢管束,这一结论表明,作为换热元件,表面熔焊管有代替各种普通不锈钢管投入工程应用的潜力和价值。
(3)结合威尔逊图解法对管束实验的数据进行计算,得到了各管束的管外凝结换热系数α。随实验段真空度σ的变化规律,发现了高真空度能够强化换热的根源是真空的提升使得管束的凝结换热系数提高,这是因为真空度的提高使得蒸汽流动更为均匀,流速更快,汽流对冷凝液产生冲刷作用,令其更快脱离壁面,变相增大了凝结表面积；而且真空度越高,实验段内的不凝结气体含量越少,这样能够有效的降低界面的气膜热阻,增强凝结换热。
(4)采用套管式逆流换热机制建立了基于表面熔焊技术的管内凝结实验台。将高温熔焊工艺拓展至管内表面的改性处理,构造了内表面熔焊管,对蒸汽在其内部的凝结换热特性进行了实验研究,并与普通钢管的管内蒸汽凝结进行对比分析。分别得到了管内蒸汽为负压(0.064MPa)、常压(0.105MPa)和高于大气压(0.185MPa)时,套管环隙循环冷却水Re数对两种管材总体换热系数k的影响规律。实验发现,入口蒸汽为负压状态时,内表面熔焊管实验段的k值最多可高出普通钢管26%；当蒸汽入口压力接近大气压和高于大气压时,总体换热的强化幅度分别为30%和34%；实验还得到了内表面熔焊管和普通钢管的管内凝结换热系数hi的对比曲线,发现当入口蒸汽为负压(0.064MPa)状态时,内表面熔焊管的管内蒸汽凝结换热系数hi最高,随着蒸汽参数的升高,这一强化作用有所削弱,也就是说,当换热管内处于真空状态时,内表面熔焊管对管内蒸汽凝结换热效果的提升能力最为明显。结果表明,针对蒸汽在管内凝结的换热场合,将换热管材的内表面进行熔焊改性处理,也能够起到强化传热的作用。
(5)对管内凝结换热实验数据进行了回归分析,得到了热流密度q,范围(40-180kW/m2)下的普通钢管管内凝结换热系数实验关联式；得到了热流密度qi范围(40-230kW/m2)下的内表面熔焊管的管内凝结换热系数实验关联式,并进行了误差分析。
(6)通过管材表面的金相组织实验和能谱实验,分析了熔焊表面的微观结构和具体元素成分,结果表明,采用熔焊工艺可以在母管的钢表面植入含Ni、P、及少量Cr元素的合金固溶体化合层(厚度0.013-0.016mm),这一化合层致密,光洁,显微硬度高,这些特点正是表面熔焊管具有良好力学强度、抗腐蚀能力的根源。同时,熔焊表面的紧致和光洁使其可持久保存而不易脱落,保证了凝结水拥有较好的品质。
(7)通过对蒸汽凝结界面的能量平衡分析,得到了凝结液接触角θ与表面自由能的关系。进而结合金相和元素分析的结果,发现熔焊管表面的植入元素能够降低其表面自由能,增强凝结换热效果；将表面熔焊管的高光洁度和无序的表面非晶态结构等因素代入以临界液膜分裂厚度δc,表面不平整高度Hz和液膜平均厚度δl三者关系为过程判据的珠膜共存凝结模型,发现熔焊表面的上述特质使其更容易满足δ>δl+Hz的近珠状凝结判据,进一步解释了实验中能在熔焊改性处理的表面获得高凝结换热系数的原因。
(8)基于数值计算的相关理论方法,利用雷诺时均N-S方程描述套管管内水蒸气的流动,标准k-ε两方程湍流模型(Standard κ-ε Model)对水蒸气运动控制方程的雷诺应力项进行湍流封闭,采用标准壁面函数法进行近壁区处理,依据管内冷凝实验数据得到水蒸气在不同圆管管内的冷凝模型,建立了管内冷凝换热的数值计算模型。利用实验工况验证了所建数值计算模型的准确性,并对模拟结果进行了网格无关性考核。对于内表面熔焊管的速度温度及压力分布进行了分析,管内冷凝现象的传热及流动规律为：蒸汽侧参数沿着管中心线呈轴对称分布,横截面内的参数沿着流速方向越来越缓和；对比了相同时间段内普通钢管及内表面熔焊管的凝结量及压力梯度,说明了内表面熔焊管优越的冷凝能力；进一步研究了循环水雷诺数及蒸汽进口压力变化时的管内冷凝规律。
总体来讲,本文的研究揭示了表面熔焊技术强化管内外凝结换热的机理；通过对换热特性规律的研究,进一步完善了表面熔焊管的性能评价体系。为表面熔焊管全面投入工程应用提供了理论基础和现实指导。
Steam condensing heat exchanger is an indispensable part of the steam circulation system and the steam power plant, whose service life as well as the work efficiency is of great importance to the reliable and economic operation of the thermal system. Kinds of tubes for heat transfer assembled the main component of the steam condensing heat exchanger, its operating performance directly determined by heat transfer coefficient. It means that research on heat transfer enhancement of steam condensation tube has great theoretical value and practical significance.
Nowadays, the study on heat transfer of water vapor condensation as an important field of research and application of the heat transfer has got more and more attention of the experts and scholars. With deeper knowledge and understanding of the mechanism for condensation process, plenty of calculation and research on condensation model which made a qualitative and quantitative description of the process of condensation have been brought out. However, most study on enhancing heat transfer in condensation process of steam is confined in the tube outside condensation, while research on in-tube heat transfer characteristics is much less. In terms of heat transfer enhancement measure, most of the researches at home and abroad apply methods of physical modification or external disturbing of the tube, which are difficult in application of engineering practice and thus have few examples for engineering. Until today, systematic study and report on modifying condensation surface (especially the nner surface of the tube) to enhance heat transfer has not much conducted。
In view of this, surface modified technique based on the technology of high temperature fusion welding inside furnace is adopted in this article to modify the inner and outer surface of ordinary carbon steel tube and a new type of steam condensation heat transfer element, surface fusion welding tube, is constructed. In this article, the promotion of tube condensation heat transfer performance by fusion welding surface is researched in terms of condensation experiment of inner and outer surface of signal tube and tube bundle, numerical calculation and mechanism analysis of heat transfer enhancement. The main work and the corresponding conclusions are as follows:
(1) The outer surface condensation experimental platform of surface fusion welding tube was set up, and the outer surface condensation heat transfer contrast experiment between the surface fusion welding tube and ordinary steel tube was conducted. In the experiment, experimental section of signal tube and tube bundle were built respectively, with the circulating water in the tube as cold source, the water vapor (hereinafter referred to as steam) condensed on the outer surface of two kinds of tubes respectively. Through the calculation of experimental data, the overall heat transfer coefficient and outer surface condensation heat transfer coefficient of surface fusion welding tube and ordinary steel tube is got, and the relation curve of overall heat transfer coefficient k and flow rate of circulating water (0.6-1.3m/s) in tube is obtained, which shows that the overall heat transfer coefficient of surface fusion welding tube is over20%higher than that of ordinary steel tube, the value having a tendency to increase with the increase of flow rate of circulating water. The calculation results also shows that the outer surface condensation heat transfer coefficient h0of surface fusion welding tube is3times of ordinary steel tube, showing the surface fusion welding tube has a significant enhanced effect to the performance of condensation heat transfer. The wall temperature distribution curve of circumferential and length direction of tube is obtained through the method of measuring the wall temperature by welding the thermocouple. The analysis of the curve shows that the surface fusion welding tube has a higher surface heat flux density and is able to withstand the heat load more evenly.
(2) The condensation heat transfer experimental platform of tube bundles was set up, the tube bundles was constructed for establishing the condensation heat transfer experiment outside the tube under the vacuum level in four kinds of tube respectively (including the surface fusion welding tube), and the curves of the overall heat transfer coefficient U with the vacuum level in typical Re of different kinds of tubes are established. It is discovered that the heat transfer characteristic of the tube becomes better as the vacuum level gets higher, and the surface fusion welding tube's heat transfer characteristic is much better than that of the stainless steel tube. The conclusion indicates that it is very potential and worthwhile for the surface fusion welding tube to supersede the various ordinary stainless tube in engineering practice.
(3) By combing the experimental data with calculation in the way of Wilson plot technique the change law of the condensation heat transfer coefficient outside the tube with the vacuum level is obtained of the experimental section, finding that the high vacuum level can enhance the heat transfer is the condensation heat transfer coefficient will be improved as the vacuum level improves. This is because the high vacuum level can make the steam gain a faster velocity and flow more homogeneously. Detachment from the tube wall of the condensate is more frequently as it is sourced by the steam, making the condensation surface area become larger. Besides that, the higher vacuum level it is, the less content of the incondensable gas there will be in the experimental section, which can reduce the film resistance of the surface efficiently and enhance the condensation heat transfer.
(4) The in-tube condensation experimental platform based on the surface of fusion welding technology was set up by using the mechanism of double tube type counter flow heat exchange. Through modifying inner-surface of tube by high temperature fusion welding craft to construct inner-surface fusion welding tube, the experimental study is carried out on inner condensation heat transfer characteristic of the steam, and comparing with that of the inner condensation steam in ordinary steel tubes, the regularity is obtained that how the Re of circulating cooling water in casing ring gap influences the overall heat transfer coefficient k of two kind of tubes under different inner steam pressure:at negative pressure (0.064MPa), at atmospheric pressure(0.105MPa) and at higher atmospheric pressure (0.185MPa). It is found that the k of the inner-surface fusion welding tube is26percent higher than that of ordinary tube when the inlet steam is of negative pressure, and the strengthening amplitude of overall heat exchange are30and34percent respectively when the pressure of inlet steam closes to and higher than the atmospheric pressure. At the same time, the contrast curve of inner condensation heat transfer coefficient.hi of an inner-surface fusion welding tube and that in an ordinary tube is obtained, showing that the inner condensation heat transfer coefficient hi of an inner-surface fusion welding tube is highest under negative pressure (0.064MPa), and also showing that the enhancing impact is weaken in some degree along with the increase of steam parameters. That is to say, when the heat exchange tube is in vacuum state, the inner-surface fusion welding tube is the best one in promoting the effect of in-tube steam condensation and heat transfer. The result indicates that in the heat transfer situation of in-tube steam condensation, modifying the inner-surface of the heat exchange tube by fusion welding craft can take effect in enhancing heat transfer.
(5) Experimental correlative of condensation heat transfer coefficient in ordinary steel tube under the heat flux density qi range of160-430kW/m2and that of condensation heat transfer coefficient in inner-surface fusion welding tube under the heat flux density qi range of180-540kW/m2are derived from regression analysis based on experimental data of in-tube condensation heat transfer experiment, and Simultaneously error analysis was conducted.
(6) Microstructure and specific elemental composition of fusion welding surface were studied by metallographic structure experiment and EDS experiment of tube surface. The results indicate that alloy solid solution combination layer (thickness between0.013mm and0.016mm) containing Ni, P, and few Cr element can be implanted to steel surface of main pipe by fusion welding technology. This combination layer is tight, smooth, and its micro hardness is high. These features make the surface fusion welding tube possess good mechanical strength and resistance to corrosion. In addition, because of the compact and smooth cheek of fusion welding surface, the combination layer can be persisted and not easily fall off, by which the high quality of condensate can be guaranteed.
(7) The relation between the contact angle9and surface free energy was obtained through energy balance analysis of the steam condensation interface. And then, by combining the results of metallurgical and elemental analysis, it was found that implanted elements of fusion welding surface can reduce the free energy to enhance condensation heat transfer effect. Owing to the high degree of finish and disordered amorphous surface structure of fusion welding tube, the δc>δi,+Hz approximate dropwise condensation criterion of film-dropwise coexisting model which determined by critical film split thickness δc, surface uneven height H2, and average film thickness δi, is satisfied. As a result, further explantation is obtained for the reason why the fusion welding surface has better performance on condensation heat transfer in the experiment.
(8) Numerical calculation model of inner surface condensation heat transfer was built based on relevant theoretical methods of numerical computation, whose accuracy is verified with the experiment conditions.. Reynolds averaged Navier-Stokes equation (RNS) is used to describe the flow of steam in the double tube, standard k-ε model to enclose the Reynolds stress term of the governing equation of steam motion, and standard wall functions to handle the near wall. Condensation model of steam in different tube was got based on the experiment data, meanwhile, the grid independence of the simulated results has been checked. The distribution of velocity, temperature and pressure of inner-surface fusion welding tube were analyzed. The heat transfer law and flow regularity of inner-surface condensation shows that:the parameters of steam is axially symmetrical distribution through the centerline of the tube, and that of the cross section become relaxer along the flow direction; the condensation quantity and pressure gradient of ordinary steel tube and inner-surface fusion welding tube are contrasted at the same time, which shows the superior condensation capacity of inner-surface fusion welding tube; the inner-surface condensation law is further researched with the changes of Re of circulating water and inlet pressure of steam.
Overall, this dissertation revealed the condensation heat transfer enhancing mechanism of surface fusion welding technology by tube externally and internally research. Performance evaluation system of surface fusion welding tube is further consummated by study of heat transfer characteristic, and all the work have provided theoretical basis and practical guidance for comprehensive engineering application of surface fusion welding tube.
水蒸气的冷凝换热作为传热学研究和应用的一个重要领域受到了越来越多的专家学者的重视,随着对冷凝过程机理的认识和了解,出现了大量对凝结模型的计算和研究,对凝结过程做出了定性和定量的描述。但是其中对于水蒸气凝结过程的强化换热研究的着眼点大多在管外凝结方面,对水蒸气的管内凝结换热特性的探索涉及较少；在强化传热措施方面,国内外多数研究采用的是管材的物理改造方法和一些外部扰流方法,其投入应用的难度较大,与工程实践的结合不够紧密。而对凝结表面采取改性处理(尤其是管内表面改性)的方法以达到强化换热的效果的系统的研究和报道并不多见。
鉴于此,本文采用基于炉内高温熔焊工艺的表面改性处理技术,对普通碳钢管的内外表面进行改性处理,构造了新型蒸汽凝结换热元件——表面熔焊管。本文从单管的管内外凝结实验,管束的外部凝结换热实验,数值计算及强化传热机理分析等几个方面入手,研究了熔焊表面对管材的凝结换热性能的提升效果。进行的主要工作及得出的相应结论如下：
(1)建立了表面熔焊管的管外凝结实验台,进行了表面熔焊管和普通钢管的管外凝结换热对比实验。分别以单管和管组的形式构建实验段,以管内循环水作为冷源,让水蒸气(以下简称蒸汽)分别在两种管材的外壁面发生凝结,通过对实验数据的计算得出表面熔焊管和普通钢管的总体换热系数及管外凝结换热系数并加以比较分析,得到了实验段总换热系数k与管内循环水流速(0.6-1.3m/s)变化的关系曲线,发现由表面熔焊管构成的实验段其换热系数比普通钢管的高出20%以上,且随着管内循环冷却水流量的增大,这一比值还有增大的趋势；通过计算发现实验中表面熔焊管的管外凝结换热系数ho约为普通钢管的3倍,说明其对凝结换热的强化作用十分显著；通过焊接热电偶测量壁温的方法,得到了管子沿周向和管长方向的壁温分布曲线,通过分析得出熔焊管的表面热流密度更高,且能够更均匀的承受热负荷。
(2)建立了管束凝结换热实验台,分别以四种不同换热管材(含表面熔焊管)构造管束进行真空状态下的管外凝结换热实验,得到了典型Re数下不同管束总体换热系数U和随真空度σ的变化曲线,发现了真空度越高,管束的换热性能越好,且相同工况下表面熔焊管束的换热性能要明显好于不锈钢管束,这一结论表明,作为换热元件,表面熔焊管有代替各种普通不锈钢管投入工程应用的潜力和价值。
(3)结合威尔逊图解法对管束实验的数据进行计算,得到了各管束的管外凝结换热系数α。随实验段真空度σ的变化规律,发现了高真空度能够强化换热的根源是真空的提升使得管束的凝结换热系数提高,这是因为真空度的提高使得蒸汽流动更为均匀,流速更快,汽流对冷凝液产生冲刷作用,令其更快脱离壁面,变相增大了凝结表面积；而且真空度越高,实验段内的不凝结气体含量越少,这样能够有效的降低界面的气膜热阻,增强凝结换热。
(4)采用套管式逆流换热机制建立了基于表面熔焊技术的管内凝结实验台。将高温熔焊工艺拓展至管内表面的改性处理,构造了内表面熔焊管,对蒸汽在其内部的凝结换热特性进行了实验研究,并与普通钢管的管内蒸汽凝结进行对比分析。分别得到了管内蒸汽为负压(0.064MPa)、常压(0.105MPa)和高于大气压(0.185MPa)时,套管环隙循环冷却水Re数对两种管材总体换热系数k的影响规律。实验发现,入口蒸汽为负压状态时,内表面熔焊管实验段的k值最多可高出普通钢管26%；当蒸汽入口压力接近大气压和高于大气压时,总体换热的强化幅度分别为30%和34%；实验还得到了内表面熔焊管和普通钢管的管内凝结换热系数hi的对比曲线,发现当入口蒸汽为负压(0.064MPa)状态时,内表面熔焊管的管内蒸汽凝结换热系数hi最高,随着蒸汽参数的升高,这一强化作用有所削弱,也就是说,当换热管内处于真空状态时,内表面熔焊管对管内蒸汽凝结换热效果的提升能力最为明显。结果表明,针对蒸汽在管内凝结的换热场合,将换热管材的内表面进行熔焊改性处理,也能够起到强化传热的作用。
(5)对管内凝结换热实验数据进行了回归分析,得到了热流密度q,范围(40-180kW/m2)下的普通钢管管内凝结换热系数实验关联式；得到了热流密度qi范围(40-230kW/m2)下的内表面熔焊管的管内凝结换热系数实验关联式,并进行了误差分析。
(6)通过管材表面的金相组织实验和能谱实验,分析了熔焊表面的微观结构和具体元素成分,结果表明,采用熔焊工艺可以在母管的钢表面植入含Ni、P、及少量Cr元素的合金固溶体化合层(厚度0.013-0.016mm),这一化合层致密,光洁,显微硬度高,这些特点正是表面熔焊管具有良好力学强度、抗腐蚀能力的根源。同时,熔焊表面的紧致和光洁使其可持久保存而不易脱落,保证了凝结水拥有较好的品质。
(7)通过对蒸汽凝结界面的能量平衡分析,得到了凝结液接触角θ与表面自由能的关系。进而结合金相和元素分析的结果,发现熔焊管表面的植入元素能够降低其表面自由能,增强凝结换热效果；将表面熔焊管的高光洁度和无序的表面非晶态结构等因素代入以临界液膜分裂厚度δc,表面不平整高度Hz和液膜平均厚度δl三者关系为过程判据的珠膜共存凝结模型,发现熔焊表面的上述特质使其更容易满足δ>δl+Hz的近珠状凝结判据,进一步解释了实验中能在熔焊改性处理的表面获得高凝结换热系数的原因。
(8)基于数值计算的相关理论方法,利用雷诺时均N-S方程描述套管管内水蒸气的流动,标准k-ε两方程湍流模型(Standard κ-ε Model)对水蒸气运动控制方程的雷诺应力项进行湍流封闭,采用标准壁面函数法进行近壁区处理,依据管内冷凝实验数据得到水蒸气在不同圆管管内的冷凝模型,建立了管内冷凝换热的数值计算模型。利用实验工况验证了所建数值计算模型的准确性,并对模拟结果进行了网格无关性考核。对于内表面熔焊管的速度温度及压力分布进行了分析,管内冷凝现象的传热及流动规律为：蒸汽侧参数沿着管中心线呈轴对称分布,横截面内的参数沿着流速方向越来越缓和；对比了相同时间段内普通钢管及内表面熔焊管的凝结量及压力梯度,说明了内表面熔焊管优越的冷凝能力；进一步研究了循环水雷诺数及蒸汽进口压力变化时的管内冷凝规律。
总体来讲,本文的研究揭示了表面熔焊技术强化管内外凝结换热的机理；通过对换热特性规律的研究,进一步完善了表面熔焊管的性能评价体系。为表面熔焊管全面投入工程应用提供了理论基础和现实指导。
Steam condensing heat exchanger is an indispensable part of the steam circulation system and the steam power plant, whose service life as well as the work efficiency is of great importance to the reliable and economic operation of the thermal system. Kinds of tubes for heat transfer assembled the main component of the steam condensing heat exchanger, its operating performance directly determined by heat transfer coefficient. It means that research on heat transfer enhancement of steam condensation tube has great theoretical value and practical significance.
Nowadays, the study on heat transfer of water vapor condensation as an important field of research and application of the heat transfer has got more and more attention of the experts and scholars. With deeper knowledge and understanding of the mechanism for condensation process, plenty of calculation and research on condensation model which made a qualitative and quantitative description of the process of condensation have been brought out. However, most study on enhancing heat transfer in condensation process of steam is confined in the tube outside condensation, while research on in-tube heat transfer characteristics is much less. In terms of heat transfer enhancement measure, most of the researches at home and abroad apply methods of physical modification or external disturbing of the tube, which are difficult in application of engineering practice and thus have few examples for engineering. Until today, systematic study and report on modifying condensation surface (especially the nner surface of the tube) to enhance heat transfer has not much conducted。
In view of this, surface modified technique based on the technology of high temperature fusion welding inside furnace is adopted in this article to modify the inner and outer surface of ordinary carbon steel tube and a new type of steam condensation heat transfer element, surface fusion welding tube, is constructed. In this article, the promotion of tube condensation heat transfer performance by fusion welding surface is researched in terms of condensation experiment of inner and outer surface of signal tube and tube bundle, numerical calculation and mechanism analysis of heat transfer enhancement. The main work and the corresponding conclusions are as follows:
(1) The outer surface condensation experimental platform of surface fusion welding tube was set up, and the outer surface condensation heat transfer contrast experiment between the surface fusion welding tube and ordinary steel tube was conducted. In the experiment, experimental section of signal tube and tube bundle were built respectively, with the circulating water in the tube as cold source, the water vapor (hereinafter referred to as steam) condensed on the outer surface of two kinds of tubes respectively. Through the calculation of experimental data, the overall heat transfer coefficient and outer surface condensation heat transfer coefficient of surface fusion welding tube and ordinary steel tube is got, and the relation curve of overall heat transfer coefficient k and flow rate of circulating water (0.6-1.3m/s) in tube is obtained, which shows that the overall heat transfer coefficient of surface fusion welding tube is over20%higher than that of ordinary steel tube, the value having a tendency to increase with the increase of flow rate of circulating water. The calculation results also shows that the outer surface condensation heat transfer coefficient h0of surface fusion welding tube is3times of ordinary steel tube, showing the surface fusion welding tube has a significant enhanced effect to the performance of condensation heat transfer. The wall temperature distribution curve of circumferential and length direction of tube is obtained through the method of measuring the wall temperature by welding the thermocouple. The analysis of the curve shows that the surface fusion welding tube has a higher surface heat flux density and is able to withstand the heat load more evenly.
(2) The condensation heat transfer experimental platform of tube bundles was set up, the tube bundles was constructed for establishing the condensation heat transfer experiment outside the tube under the vacuum level in four kinds of tube respectively (including the surface fusion welding tube), and the curves of the overall heat transfer coefficient U with the vacuum level in typical Re of different kinds of tubes are established. It is discovered that the heat transfer characteristic of the tube becomes better as the vacuum level gets higher, and the surface fusion welding tube's heat transfer characteristic is much better than that of the stainless steel tube. The conclusion indicates that it is very potential and worthwhile for the surface fusion welding tube to supersede the various ordinary stainless tube in engineering practice.
(3) By combing the experimental data with calculation in the way of Wilson plot technique the change law of the condensation heat transfer coefficient outside the tube with the vacuum level is obtained of the experimental section, finding that the high vacuum level can enhance the heat transfer is the condensation heat transfer coefficient will be improved as the vacuum level improves. This is because the high vacuum level can make the steam gain a faster velocity and flow more homogeneously. Detachment from the tube wall of the condensate is more frequently as it is sourced by the steam, making the condensation surface area become larger. Besides that, the higher vacuum level it is, the less content of the incondensable gas there will be in the experimental section, which can reduce the film resistance of the surface efficiently and enhance the condensation heat transfer.
(4) The in-tube condensation experimental platform based on the surface of fusion welding technology was set up by using the mechanism of double tube type counter flow heat exchange. Through modifying inner-surface of tube by high temperature fusion welding craft to construct inner-surface fusion welding tube, the experimental study is carried out on inner condensation heat transfer characteristic of the steam, and comparing with that of the inner condensation steam in ordinary steel tubes, the regularity is obtained that how the Re of circulating cooling water in casing ring gap influences the overall heat transfer coefficient k of two kind of tubes under different inner steam pressure:at negative pressure (0.064MPa), at atmospheric pressure(0.105MPa) and at higher atmospheric pressure (0.185MPa). It is found that the k of the inner-surface fusion welding tube is26percent higher than that of ordinary tube when the inlet steam is of negative pressure, and the strengthening amplitude of overall heat exchange are30and34percent respectively when the pressure of inlet steam closes to and higher than the atmospheric pressure. At the same time, the contrast curve of inner condensation heat transfer coefficient.hi of an inner-surface fusion welding tube and that in an ordinary tube is obtained, showing that the inner condensation heat transfer coefficient hi of an inner-surface fusion welding tube is highest under negative pressure (0.064MPa), and also showing that the enhancing impact is weaken in some degree along with the increase of steam parameters. That is to say, when the heat exchange tube is in vacuum state, the inner-surface fusion welding tube is the best one in promoting the effect of in-tube steam condensation and heat transfer. The result indicates that in the heat transfer situation of in-tube steam condensation, modifying the inner-surface of the heat exchange tube by fusion welding craft can take effect in enhancing heat transfer.
(5) Experimental correlative of condensation heat transfer coefficient in ordinary steel tube under the heat flux density qi range of160-430kW/m2and that of condensation heat transfer coefficient in inner-surface fusion welding tube under the heat flux density qi range of180-540kW/m2are derived from regression analysis based on experimental data of in-tube condensation heat transfer experiment, and Simultaneously error analysis was conducted.
(6) Microstructure and specific elemental composition of fusion welding surface were studied by metallographic structure experiment and EDS experiment of tube surface. The results indicate that alloy solid solution combination layer (thickness between0.013mm and0.016mm) containing Ni, P, and few Cr element can be implanted to steel surface of main pipe by fusion welding technology. This combination layer is tight, smooth, and its micro hardness is high. These features make the surface fusion welding tube possess good mechanical strength and resistance to corrosion. In addition, because of the compact and smooth cheek of fusion welding surface, the combination layer can be persisted and not easily fall off, by which the high quality of condensate can be guaranteed.
(7) The relation between the contact angle9and surface free energy was obtained through energy balance analysis of the steam condensation interface. And then, by combining the results of metallurgical and elemental analysis, it was found that implanted elements of fusion welding surface can reduce the free energy to enhance condensation heat transfer effect. Owing to the high degree of finish and disordered amorphous surface structure of fusion welding tube, the δc>δi,+Hz approximate dropwise condensation criterion of film-dropwise coexisting model which determined by critical film split thickness δc, surface uneven height H2, and average film thickness δi, is satisfied. As a result, further explantation is obtained for the reason why the fusion welding surface has better performance on condensation heat transfer in the experiment.
(8) Numerical calculation model of inner surface condensation heat transfer was built based on relevant theoretical methods of numerical computation, whose accuracy is verified with the experiment conditions.. Reynolds averaged Navier-Stokes equation (RNS) is used to describe the flow of steam in the double tube, standard k-ε model to enclose the Reynolds stress term of the governing equation of steam motion, and standard wall functions to handle the near wall. Condensation model of steam in different tube was got based on the experiment data, meanwhile, the grid independence of the simulated results has been checked. The distribution of velocity, temperature and pressure of inner-surface fusion welding tube were analyzed. The heat transfer law and flow regularity of inner-surface condensation shows that:the parameters of steam is axially symmetrical distribution through the centerline of the tube, and that of the cross section become relaxer along the flow direction; the condensation quantity and pressure gradient of ordinary steel tube and inner-surface fusion welding tube are contrasted at the same time, which shows the superior condensation capacity of inner-surface fusion welding tube; the inner-surface condensation law is further researched with the changes of Re of circulating water and inlet pressure of steam.
Overall, this dissertation revealed the condensation heat transfer enhancing mechanism of surface fusion welding technology by tube externally and internally research. Performance evaluation system of surface fusion welding tube is further consummated by study of heat transfer characteristic, and all the work have provided theoretical basis and practical guidance for comprehensive engineering application of surface fusion welding tube.
引文
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