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球团回转窑煤粉-富氢燃气复合燃烧及污染物生成数值模拟

Numerical simulation of co-combustion of pulverized coal and hydrogen-rich gas and pollutant formation in oxidized pellet rotary kiln

  • 摘要: 为响应钢铁行业节能降碳与超低排放要求,本研究以ϕ6.858 m×45.72 m的球团回转窑为对象,基于计算流体力学(computational fluid dynamics,CFD)方法和有限速率/涡耗散(finite-rate/eddy-dissipation,FR/ED)机制建立煤粉与天然气/氢气复合燃烧模型,对纯煤粉燃烧以及不同替代比例下天然气、氢气部分替代煤粉时窑内流场、温度场和污染物生成特性进行了系统分析。结果表明,掺入富氢燃气后在喷嘴附近形成了典型的回流区,有利于燃料的充分燃烧;天然气和氢气掺混后,火焰由纯煤粉工况下的“细长圆柱状”逐渐演变为高比例天然气工况下的“紧凑纺锤状”,从而有效改善煤粉燃烧滞后并使温度场分布更均匀。相比之下,掺氢工况对前端燃烧的强化作用较天然气更为明显。但当替代比例较高时,窑头附近会出现新的局部高温区,尤其在掺氢工况下更易造成燃烧器喷枪及前端耐火材料热负荷增加。燃料替代能够显著抑制氮氧化物(NOx)生成,在60%替代比例下,出口NOx质量分数由纯煤工况的0.034 2%分别降低至0.013 5%(天然气)和0.013 2%(氢气),降幅超60%。天然气与氢气在二氧化碳(CO2)减排机制上存在显著差异。在60%替代比例下,掺加天然气工况下CO2峰值质量分数仅从纯煤的0.17降低至0.13左右,而掺氢工况下的CO2峰值降低至0.08以下,降幅超过50%,实现深度脱碳。综合权衡回转窑的热工稳定性、设备安全性及减排需求,建议天然气或氢气替代煤粉的热值比例为40%。本研究为回转窑燃料结构优化及低碳清洁燃烧技术提供了重要理论参考与工程指导。

     

    Abstract: To meet the requirements of energy conservation, carbon reduction, and ultra-low emissions in the iron and steel industry, ϕ6.858 m×45.72 m pellet rotary kiln was investigated. A co-combustion model of pulverized coal and natural gas/hydrogen was established based on computational fluid dynamics (CFD) and the finite-rate/eddy-dissipation (FR/ED) mechanism. Flow field, temperature field, and pollutant formation characteristics in the kiln were systematically investigated under pure pulverized coal combustion and under different substitution ratios of natural gas and hydrogen.Results show that, after hydrogen-rich gaseous fuel is introduced, typical recirculation zone is formed near the burner nozzle, which is favorable for more complete fuel combustion. With the addition of natural gas or hydrogen, the flame gradually changes from the slender cylindrical shape under the pure pulverized coal condition to compact spindle-like shape at high natural gas substitution ratios, effectively alleviating the ignition delay of pulverized coal and making the temperature distribution more uniform. In particular, the front-end combustion enhancement effect is more pronounced under hydrogen-blending conditions than under natural gas-blending conditions. However, at high substitution ratios, a new local high-temperature zone appears near the kiln head, especially under hydrogen-blending conditions, which is more likely to increase the thermal load on the burner nozzle and the front-end refractory materials. Fuel substitution can significantly suppress NOx formation. At a substitution ratio of 60%, the outlet NOx mass fraction decreases from 0.034 2% under the pure coal condition to 0.013 5% for natural gas and 0.013 2% for hydrogen, respectively, corresponding to reductions of more than 60%. Natural gas and hydrogen exhibit significant differences in the mechanism of CO2 reduction. At a substitution ratio of 60%, the peak CO2 mass fraction only decreases from 0.17 to about 0.13 under natural gas substitution, whereas it drops to below 0.08 under hydrogen substitution, with a reduction of more than 50%, indicating a much stronger decarbonization effect. Considering the thermal stability of the rotary kiln, equipment safety, and emission reduction requirements, 40% is recommended as the optimal substitution ratio for both natural gas and hydrogen. This study provides an important theoretical basis and engineering guidance for fuel structure optimization and low-carbon clean combustion in rotary kilns.

     

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