微孔陶瓷过滤法控制燃煤窑炉黑烟污染的理论研究
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摘要
我国大气颗粒物污染比较严重,其中形成可吸入颗粒物主要为工业烟尘与工业粉尘。燃煤电站、燃煤工业锅炉、燃煤炉窑等是烟尘的主要排放源。随着工业燃煤的消耗量不断增加,烟气中不容易沉降的超细粉尘与炭黑颗粒对大气环境污染越来越严重。因此,本文针对工业窑炉黑烟通过微孔陶瓷过滤器除尘过程的影响因素和过滤特性进行研究和模拟,这对工业高温烟气净化处理及环境保护具有重大理论和现实意义。
本课题主要研究内容及研究结果包括：
(1)对陶瓷过滤器和炭黑的物理化学性质进行研究分析,确定微观结构,调查陶粒滤料的孔隙特征和炭黑颗粒的微观表征,计算得出陶粒颗粒粒径公式以及孔径与粒径的关系式。对炭黑颗粒进行表征测试,分析炭黑的主要化学组成,确定炭黑颗粒粒径分布。
(2)对陶瓷过滤器进行数值和实验研究。通过建立过滤器模型,进行网格独立性验证,并进行CFD仿真研究。分别模拟计算了在多孔介质五种不同孔隙率条件下的入口气速与设备进出口压降的关系。由实验数据与CFD仿真曲线的对比可知,实验数据在仿真曲线两侧呈聚类变化趋势,即RNG k-ε仿真结果基本与实际变化规律相符合。利用CFD模型计算陶瓷过滤器除尘效率,将仿真结果与实验数据比较,结果显示模型计算与实验测试相吻合,这说明CFD模型能够很好地预测洁净陶瓷管的过滤。
(3)对陶瓷过滤时粉饼坍塌对压降的影响进行研究,提出了一个粉饼坍塌模型,综合考虑聚团间松驰因子、聚团的分形维数、聚团大小(包括聚团的粒径分布及累积筛下质量平均中位径)以及聚团配位数对孔隙率的联合影响,进而得出这些参数对过滤压降的联合影响。通过设计新颖的反演方法,模型的配位数与松驰因子可以通过实验和反演的方法得到,分形维数通过场发射电镜图的二值图由计盒数方法计算得到,聚团直径通过统计电镜照片由Rosin-Rammler拟合计算得出,从而计算出粉饼的聚团间孔隙率、聚团内孔隙率、粉饼总孔隙率以及压降随浮动参数变化的规律,将压降梯度的计算结果与实验值相比较,结果表明该坍塌粉饼过滤模型要远比没有坍塌的粉饼过滤模型更加接近真实值,从而证实了本模型的有效性。因此,考虑了配位数的粉饼坍塌模型由于高精度以及计算简单,在预测粉饼的压降时具有很好应用潜力。
(4)建立了一个预测过滤效率与压降损失的非稳态过滤的数值建模,并通过实验进行统计分析,由此预测粉尘沉降与脱落对压降的影响。并且设计一种新颖的悬挂装置来通过实验测定比截留量随时间的变化,从而可以得出压降随比截量的变化规律,进而得出压降随时间的瞬态变化规律,将所得结果与模型预测数据进行比较,结果显示陶瓷过滤元件的各种基本参数(包括陶瓷过滤滤管的初始孔隙率、陶瓷材料自然颗粒粒径、管壁厚度)和不同的操作条件(包括过滤操作风量、过滤入口含尘浓度)都对过滤过程中粉尘的沉积量有很大的影响,从而对过滤压降也有很大的影响。为进一步研究在反吹清灰的作用下连续过滤过程中粉尘沉降与脱落的动态过程,在多次清灰循环过程中测试了陶瓷过滤元件上的比截留量与压降的变化情况。最后,通过对动态过程的研究,分析了采用不同规格的陶瓷元件的过滤系统的清灰效率,以此来评价在初始阶段与稳定阶段的清灰特征。
(5)采用表面过滤理论对陶瓷过滤器的除尘性能进行研究,通过模拟分析粉尘在陶瓷管壁累积过程中过滤效率的时间特性以及在不同的浓度与风量条件下各种陶瓷管的初始除尘效率与稳定除尘效率,对陶瓷过滤器的除尘性能进行研究。
(6)通过建立脉冲反吹清灰过滤模型,对压降进行面积分率加权处理,通过Matlab编程对陶瓷过滤器的脉冲清灰过滤进行计算,分析粉饼覆盖面积分率与过滤清灰循环的关系。结果表明,随着吹脱循环次数的增加,陶瓷管粉尘附着容量越来越小,使得每进入下一轮循环后过滤粉尘沉积的增量变少,从而使得清灰操作后粉饼面积分率的增量也就相应地变小。对不同的粉饼覆盖面积分率时瞬态渗滤速度的时间变化规律进行分析,结果表明单位面积粉饼质量越小,渗滤速度随时间减小得越剧烈,相反,单位面积粉饼质量越大,渗滤速度随时间减小得越平缓。
Air pollution is quite serious in China today due to high total particle pollution exhaust emission level. Actually, the inhalable particulates are mainly composed of industrial smoke and fly dust. General speaking, the principal particle pollution emission sources mainly come from coal-fired power plants, industrial coal-fired boilers, and coal-fired furnaces. As the coal consumption is growing rapidly, the ultrafine dust and carbonblack particles hard to deposit are increasingly polluting the atmosphere. In the present work, several numerical models on the purification of industrial black smoke with porous ceramic filter were conducted to investigate the effect of dust deposit on filtration process, which is of great importance for smoke purification in high-temperature condition.
The major focuses and research findings of this paper are as follows:
(1) The physicochemical properties of ceramic material and carbonblack dust were investigated and their microstructures were characterized correspondingly. The particle size ceramic material was expressed by the deduced formulas and the size distribution of carbonblack particles was fitted to acquire the equivalent mean diameter. Simultaneously, the chemical compositions of those materials were tested by the X-ray diffractometer.
(2) The CFD simulation and experimental investigation were performed for the ceramic filter in high temperature. The Pro/Engineering software was employed to establish the3-dimensional model of ceramic filter, and the corresponding model mesh was created by the Gambit software. In order to validate the model mesh, the grid independent validation was conducted by Richardson interpolation method. Finally,5specifications of porosities were applied to calculate the relationship between inlet flow velocity and filtration pressure drop. The results show that the simulated curves are in agreement with the experimental data, indicating that the CFD simulation can well predict the filtration process with clean ceramic filter.
(3) A cake collapse model was proposed to investigate the effect of fractal compression on cake porosity by taking the combined effect of relaxation ratio, fractal dimension, aggregate size, and coordination number into account. Subsequently, the effect of those variables on cake pressure drop was derived using the porosity function. Furthermore, a novel inversion method was designed to acquire the real coordination number and the corresponding relaxation ratios for the model. Through the analysis of binary images of field emission scanning electron micrographics (FE-SEMs), the fractal dimension was calculated with the fitting logarithmic pixel values by a box-counting dimension method. The aggregate size was obtained by Rosin-Rammler fitting of the statistical aggregate size in the FE-SEMs. Hence, the independence of inter-and intra-aggregate porosity, cake porosity and cake pressure drop on the fractal dimension and relaxation ratio for the reverse-calculated coordination number. By comparison, it is found that the model predictions with consideration of cake collapse are more close to the experimental data than the model without considering the cake collapse. Due to high-accuracy and simple computation, this model displays a great application potential in the prediction of cake pressure drop.
(4) An unsteady model on dust deposit was established to predict the change of pressure drop with the specific deposit. Thus, the effect of dust deposit and detachment on the pressure drop was predicted. By calculation, it is evident that the basic parameters (such as primary porosity, diameter of ceramic granular, and vessel thickness), and operation conditions (operation flow rate and ambient concentration) have great influence in the dust deposit, resulting in the effect on pressure drop. To further study the dynamic process during filtration with cleaning, the changes of specific deposit and pressure drop in many cleaning-filtration cycles were researched, and the corresponding cleaning efficiencies of ceramic filters with different specifications of ceramic vessels were analyzed for assessing the cleaning profiles in the early and steady stages.
(5) To study the collection performance of ceramic filter, a filtration model with application of cake surface theory was established. By analyzing the dust accumulation process, the time-independent collection efficiency, and the primary and steady collection efficiency under different ambient concentration and filtration filow rate were investigated.
(6) A pulse-jet cleaning and filtration model was proposed by using the weighted area fraction assumption. With the utilization of Matlab software, the pulse-jet cleaning and filtration procedure was calculated by a program to acquire the relationship between area fractions and cleaning-filtration cycle. The results show that as the cycle number increases, the capture capability of filtration media increasingly becomes weaker and the increment of dust deposit in the next cycle become smaller, resulting in the decrease of the increment of area fraction. For different dust area fractions, the analysis of instantaneous weighted filtration velocity with time was conducted. It is found that the smaller mass per unit area caused the sharp decrease of filtration, and vice versa.
本课题主要研究内容及研究结果包括：
(1)对陶瓷过滤器和炭黑的物理化学性质进行研究分析,确定微观结构,调查陶粒滤料的孔隙特征和炭黑颗粒的微观表征,计算得出陶粒颗粒粒径公式以及孔径与粒径的关系式。对炭黑颗粒进行表征测试,分析炭黑的主要化学组成,确定炭黑颗粒粒径分布。
(2)对陶瓷过滤器进行数值和实验研究。通过建立过滤器模型,进行网格独立性验证,并进行CFD仿真研究。分别模拟计算了在多孔介质五种不同孔隙率条件下的入口气速与设备进出口压降的关系。由实验数据与CFD仿真曲线的对比可知,实验数据在仿真曲线两侧呈聚类变化趋势,即RNG k-ε仿真结果基本与实际变化规律相符合。利用CFD模型计算陶瓷过滤器除尘效率,将仿真结果与实验数据比较,结果显示模型计算与实验测试相吻合,这说明CFD模型能够很好地预测洁净陶瓷管的过滤。
(3)对陶瓷过滤时粉饼坍塌对压降的影响进行研究,提出了一个粉饼坍塌模型,综合考虑聚团间松驰因子、聚团的分形维数、聚团大小(包括聚团的粒径分布及累积筛下质量平均中位径)以及聚团配位数对孔隙率的联合影响,进而得出这些参数对过滤压降的联合影响。通过设计新颖的反演方法,模型的配位数与松驰因子可以通过实验和反演的方法得到,分形维数通过场发射电镜图的二值图由计盒数方法计算得到,聚团直径通过统计电镜照片由Rosin-Rammler拟合计算得出,从而计算出粉饼的聚团间孔隙率、聚团内孔隙率、粉饼总孔隙率以及压降随浮动参数变化的规律,将压降梯度的计算结果与实验值相比较,结果表明该坍塌粉饼过滤模型要远比没有坍塌的粉饼过滤模型更加接近真实值,从而证实了本模型的有效性。因此,考虑了配位数的粉饼坍塌模型由于高精度以及计算简单,在预测粉饼的压降时具有很好应用潜力。
(4)建立了一个预测过滤效率与压降损失的非稳态过滤的数值建模,并通过实验进行统计分析,由此预测粉尘沉降与脱落对压降的影响。并且设计一种新颖的悬挂装置来通过实验测定比截留量随时间的变化,从而可以得出压降随比截量的变化规律,进而得出压降随时间的瞬态变化规律,将所得结果与模型预测数据进行比较,结果显示陶瓷过滤元件的各种基本参数(包括陶瓷过滤滤管的初始孔隙率、陶瓷材料自然颗粒粒径、管壁厚度)和不同的操作条件(包括过滤操作风量、过滤入口含尘浓度)都对过滤过程中粉尘的沉积量有很大的影响,从而对过滤压降也有很大的影响。为进一步研究在反吹清灰的作用下连续过滤过程中粉尘沉降与脱落的动态过程,在多次清灰循环过程中测试了陶瓷过滤元件上的比截留量与压降的变化情况。最后,通过对动态过程的研究,分析了采用不同规格的陶瓷元件的过滤系统的清灰效率,以此来评价在初始阶段与稳定阶段的清灰特征。
(5)采用表面过滤理论对陶瓷过滤器的除尘性能进行研究,通过模拟分析粉尘在陶瓷管壁累积过程中过滤效率的时间特性以及在不同的浓度与风量条件下各种陶瓷管的初始除尘效率与稳定除尘效率,对陶瓷过滤器的除尘性能进行研究。
(6)通过建立脉冲反吹清灰过滤模型,对压降进行面积分率加权处理,通过Matlab编程对陶瓷过滤器的脉冲清灰过滤进行计算,分析粉饼覆盖面积分率与过滤清灰循环的关系。结果表明,随着吹脱循环次数的增加,陶瓷管粉尘附着容量越来越小,使得每进入下一轮循环后过滤粉尘沉积的增量变少,从而使得清灰操作后粉饼面积分率的增量也就相应地变小。对不同的粉饼覆盖面积分率时瞬态渗滤速度的时间变化规律进行分析,结果表明单位面积粉饼质量越小,渗滤速度随时间减小得越剧烈,相反,单位面积粉饼质量越大,渗滤速度随时间减小得越平缓。
Air pollution is quite serious in China today due to high total particle pollution exhaust emission level. Actually, the inhalable particulates are mainly composed of industrial smoke and fly dust. General speaking, the principal particle pollution emission sources mainly come from coal-fired power plants, industrial coal-fired boilers, and coal-fired furnaces. As the coal consumption is growing rapidly, the ultrafine dust and carbonblack particles hard to deposit are increasingly polluting the atmosphere. In the present work, several numerical models on the purification of industrial black smoke with porous ceramic filter were conducted to investigate the effect of dust deposit on filtration process, which is of great importance for smoke purification in high-temperature condition.
The major focuses and research findings of this paper are as follows:
(1) The physicochemical properties of ceramic material and carbonblack dust were investigated and their microstructures were characterized correspondingly. The particle size ceramic material was expressed by the deduced formulas and the size distribution of carbonblack particles was fitted to acquire the equivalent mean diameter. Simultaneously, the chemical compositions of those materials were tested by the X-ray diffractometer.
(2) The CFD simulation and experimental investigation were performed for the ceramic filter in high temperature. The Pro/Engineering software was employed to establish the3-dimensional model of ceramic filter, and the corresponding model mesh was created by the Gambit software. In order to validate the model mesh, the grid independent validation was conducted by Richardson interpolation method. Finally,5specifications of porosities were applied to calculate the relationship between inlet flow velocity and filtration pressure drop. The results show that the simulated curves are in agreement with the experimental data, indicating that the CFD simulation can well predict the filtration process with clean ceramic filter.
(3) A cake collapse model was proposed to investigate the effect of fractal compression on cake porosity by taking the combined effect of relaxation ratio, fractal dimension, aggregate size, and coordination number into account. Subsequently, the effect of those variables on cake pressure drop was derived using the porosity function. Furthermore, a novel inversion method was designed to acquire the real coordination number and the corresponding relaxation ratios for the model. Through the analysis of binary images of field emission scanning electron micrographics (FE-SEMs), the fractal dimension was calculated with the fitting logarithmic pixel values by a box-counting dimension method. The aggregate size was obtained by Rosin-Rammler fitting of the statistical aggregate size in the FE-SEMs. Hence, the independence of inter-and intra-aggregate porosity, cake porosity and cake pressure drop on the fractal dimension and relaxation ratio for the reverse-calculated coordination number. By comparison, it is found that the model predictions with consideration of cake collapse are more close to the experimental data than the model without considering the cake collapse. Due to high-accuracy and simple computation, this model displays a great application potential in the prediction of cake pressure drop.
(4) An unsteady model on dust deposit was established to predict the change of pressure drop with the specific deposit. Thus, the effect of dust deposit and detachment on the pressure drop was predicted. By calculation, it is evident that the basic parameters (such as primary porosity, diameter of ceramic granular, and vessel thickness), and operation conditions (operation flow rate and ambient concentration) have great influence in the dust deposit, resulting in the effect on pressure drop. To further study the dynamic process during filtration with cleaning, the changes of specific deposit and pressure drop in many cleaning-filtration cycles were researched, and the corresponding cleaning efficiencies of ceramic filters with different specifications of ceramic vessels were analyzed for assessing the cleaning profiles in the early and steady stages.
(5) To study the collection performance of ceramic filter, a filtration model with application of cake surface theory was established. By analyzing the dust accumulation process, the time-independent collection efficiency, and the primary and steady collection efficiency under different ambient concentration and filtration filow rate were investigated.
(6) A pulse-jet cleaning and filtration model was proposed by using the weighted area fraction assumption. With the utilization of Matlab software, the pulse-jet cleaning and filtration procedure was calculated by a program to acquire the relationship between area fractions and cleaning-filtration cycle. The results show that as the cycle number increases, the capture capability of filtration media increasingly becomes weaker and the increment of dust deposit in the next cycle become smaller, resulting in the decrease of the increment of area fraction. For different dust area fractions, the analysis of instantaneous weighted filtration velocity with time was conducted. It is found that the smaller mass per unit area caused the sharp decrease of filtration, and vice versa.
引文
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