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Power Technology and Engineering Vol. 44, No.

3, 2010

METHODS FOR UTILIZATION OF THE HEAT IN SMOKESTACK


VENTILATOR AIR AT THERMAL POWER PLANTS

S. K. Ziganshina1 and A. A. Kudinov1

Translated from Élektricheskie Stantsii, No. 4, April 2010, pp. 22 – 27.

Methods are proposed for utilization of the heat of heated air emerging from the air channel of smokestacks.
Numerical calculations for a 240-m-high smokestack at the Samara thermal power plant are used to determine
the economic effect of recirculating the air heated in the air heater.
Keywords: smokestack, air channel, combustion products, air heater, heated air, recirculation, pressure loss,
boiler, furnace, fuel, combustion, heat utilization, economic effect.

In order to increase their operational reliability, some de- of the stack body wall is 200 mm and the channel width is
signs for reinforced concrete smokestacks have an annular 60 mm. At a height of 236.5 m there are 12 ventilation ports
air ventilation channel rather than thermal insulation be- with windbreak boxes. Viewing ports of size 640 × 350 mm
tween the reinforced concrete body of the smokestack and in the body and 400 × 250 mm in the lining have been made
the refractory lining, In order to avoid cracking of the lining, at heights of 56 and 176 m.
the air introduced into the air channel is heated in an air In order to protect the reinforced concrete body from cor-
heater to temperatures such that the temperature drop across
rosion, the static pressure in the air channel should be greater
the lining structure is acceptable [1, 2].
than the pressure in the gas outlet channel over the entire
The Samara thermal power plant of the firm JSC “Volzh-
height of the stack. The difference in these pressures is re-
skaya TGK,” which is mainly fired with natural gas, has 5
type BKZ-420-140 power generation boilers (units No. 1 – ferred to as the counterpressure. The counterpressure is cre-
– 5), 8 type PTVM-100 (units No. 1 – 3) and KVGM-180- ated by the entry of heated air into the air channel by natural
150-2 (units No. 4 – 8) water heating boilers. The combus- draft or force ventilation. Two heating ventilator systems are
tion products from the power generation boilers in units 4 provided, each of which consists of an air intake chamber, a
and 5 and the water heater boilers in units 4 – 8 are dis- heater and a ventilator fan unit. The latter includes a type
charged to the atmosphere through the 240-m-high smoke- Ts4-76-10 blower with a capacity of 27,000 m3/h. However,
stack at unit No. 2. The flue gas temperature is 130°C. The despite the presence of the fan units, the smokestack for unit
smokestack at unit No. 2 consists of a supporting reinforced No. 2 at the Samara thermal power plant operates with natu-
concrete body and an inner acid resistant refractory lining, ral ventilation of heated air and this regime is permitted
separated by an annular air ventilation channel of varying when it provides the counterpressure between the air and gas
width. The lining is made of type 200 acid-resistant straight outlet channels along the stack height. The feasibility of
and radial bricks. At the base of the stack (elevation 0 m) operating the stack with natural convection is established on
the outer diameter of the stack body is 24.1 m and its walls the basis of measurements. According to the instructions for
are 600 mm thick. The inner diameter at the top of the stack the operation of the smokestack at unit No. 2, the static pres-
is 8.4 m and at its base, 20.8 m. At elevation 5 m, the rein-
sure in the air channel must be 5 kgf/cm2 (50 Pa) higher than
forced concrete body has two windows of size 16,700 ×
the pressure in the gas outlet channel. The pressure drop is
× 8,800 mm for gas ducts. Beginning at a height of 5 m, the
measured using two instruments in the smokestack control
reinforced concrete body has an air channel whose width at
5 m height is 380 mm and at 25 m, 490 mm. Then, with in- unit with sensors positioned in the smokestack at heights of
creasing height the width of the channel gradually decreases; 41 and 236 m.
up to H = 150 m it exceeds the thickness of the supporting During an accident, breakdown of the ventilator unit
body of the smokestack. At a height of 220 m, the thickness (if the stack is operating with forced feed of heated air) or
failure of the lining seal, and when the instruments indicate a
1 Samara State Technical University, Samara, Russia; zero pressure drop between the air and gas outlet channels,
e-mail: tes@samgtu.ru then the ventilator windows in the reinforced concrete body

231
1570-145X/10/4403-0231 © 2010 Springer Science + Business Media, Inc.
232 S. K. Ziganshina and A. A. Kudinov

Flue gases at its outlet remains constant, at 65 – 68°C. The economic ef-
ficiency was calculated for the case in which the average
8
A–A temperature of the air in the stack channel is 66.2°C.
1
1 In monetary terms, the average daily heat loss from
A A
2 heated air carried out of the air channel of the smokestack is
2 5
given by Eq. (1) as
3 3
4
4 24 ´ 10 – 6
( T day ) avg = 780.5 ´ 54,000 ´
Cold air 4187

10 11 9 6 7 ´1146
. ´ 1( 66.2 - 38
. ) = 17276
. thousand rubles/day.
Fig. 1. Smokestack with an air channel in which the air heated in
a heater is recirculated: 1, reinforced concrete body; 2, lining; 3, gas where 3.8°C is the yearly average outside air temperature for
outlet channel; 4, air channel; 5, vertical barriers; 6, heater; the city of Samara; 66.2°C is the temperature of the heated
7, blower; 8, annular intake collector; 9, air intake to heater; air fed into the air channel of the smokestack corresponding
10, duct; 11, regulator device. to 3.8°C; 54,000 m3/h is the flow rate of heated air fed into
the stack air channel.
The annual cost of heating the air supplied to the stack
of the stack must be closed and the defects in the lining or air channel of unit No. 2 at the Samara plant averages
ventilator unit must be eliminated as soon as possible. 17.276 × 365 = 6305.75 thousand rubles.
According to the instructions for operation of the smoke- Therefore, boiler units in which the flue gases are ejected
stack of unit No. 2, the temperature of the air fed into the air into the upper layers of the atmosphere through a smokestack
channel depends on the outside air temperature. Sensors for with an air channel have the disadvantage of emitting the
determining the temperature drop in the lining are installed at heated air from the air channel into the atmosphere, i.e., they
smokestack heights of 41 and 236 m. For a temperature drop lose the heat in this air. In order to eliminate this shortcom-
of 90°C at a height of 41 m and 100°C at 236 m, steps must ing, we propose directing the heated air emerging from the
be taken to raise the temperature of the air fed into the stack air channel of smokestacks into the air intake chamber of the
air channel. heater [3]. So as to reduce the cooling of the heated air which
The amount of thermal energy, in monetary terms, may take place during this transfer, it is proposed that two
expended in heating the air fed into the stack air channel per vertical barriers be installed in the stack air channel to sepa-
day, Tday (thousands of rubles per day) is given by rate it into two equal parts, along with an annular air intake
collector joining the two parts of the stack air channel.
24 ×10 -6 The proposed method for utilizing the heat of the hot air
T day = S T L A rc( t out – t in ), (1) emerging from the air channel of a smokestack is carried out
4187
in the following way (Fig. 1).
where ST is the cost of thermal energy, rubles/Gcal (ST = The initially cold air collected from the atmosphere is
= 780.5 rubles/Gcal according to data from JSC “Samara- fed to the inlet 9 through a duct 10, and is then directed to
énergo” for 2008); LA is the volume flow rate of air, m3/h; tin the heater 6, where it is heated to the required temperature
and tout are the temperatures of the air at the inlet to the and fed into the air channel 4 of the smokestack by a blower
heater (outside air) and at its outlet (heated), respectively,°C; fan 7.
ñ is the density of the air, kg/m3 at tavg = 0.5(tout + tin); c is The air heated by the heater initially moves upward
the specific heat capacity of the air, equal roughly to along one part of the air channel, then emerges from it
1 kJ/(kg · K) for temperatures of –20 to 100°C. through the ventilator windows in the reinforced concrete
The values of tout as a function of tin for smokestacks body 1 of the smokestack, and enters an annular intake 8.
with a flue gas temperature of 130°C are listed here [2]: The air is fed via the annular inlet into the other part of the
air channel, along which it moves downward, leaves the
tin, °C tout, °C channel through the ventilator windows in the stack body 1,
–20 85 and arrives at the inlet 9.
–10 80 In both parts of the air channel the blower 7 maintains a
0 70 static pressure greater than the pressure in the gas outlet
+10 60 channel 3 over its entire length. This prevents the diffusion
+20 50
of corrosive species in the flue gases toward the reinforced
An analysis of the calculated temperature fields showed concrete body 1 of the stack, which is thereby protected from
that during the summer the air is heated from 30 to 85°C as it corrosion. It is true that, because of this, some of the heated
moves up the smokestack channel, while during the winter air will enter the gas outlet channel 3 through leaks in the lin-
the temperature of the air at the inlet to the stack channel and ing 2. In addition, some of the heated air will be lost through
Methods for Utilization of the Heat in Smokestack Ventilator Air at Thermal Power Plants 233

Heated air from


stack air channel

¢ , tout
LA
Heater

Heated air into


Fig. 2. Scheme for determining the temperature of the Cold air
stack air channel
Lcold, tin LA, tca LA, tout
cooled air entering the heater.

possible leaks in other parts of the air loop. Thus, cold air is Values of tca, Tday, and Tyear for the yearly average outside
fed through a duct 10 into the inlet 9 to make up for the loss temperature of 3.8°C in Samara are given as functions of ä in
of hot air; the cold air flow rate is varied by a regulator Table 1.
device 11. The temperature tca of the cooled air entering the heater
The resulting flow of cooled air is directed through the for different values of ä was calculated in the following way:
inlet 9 to the heater 6, where its temperature is raised to the the specific heat of the air, as before, was taken to be
init
required level and then it moves on into the air channel of the 1 kJ/(kg · K). For an initially chosen value t ca the corre-
smokestack. Here the flow rate of the heat transfer agent sponding value of ñca was calculated and Eq. (3) was used to
used for heating the air is reduced because the temperature of calculate the temperature of the cooled air flow entering the
the cooled air arriving at the heater exceeds that of the cold, heater:
ambient (drawn from the atmosphere) air that was initially
fed into the heater. d ´ 1276
. ´ 38
. + (1 - d ) ´ 1041
. ´ 66.2
calc
t ca = =
Thus, when the heated air is recirculated, efficient use is r ca
made of the heat contained in it, since then the flow rate of
the heat transfer agent used in the heater is reduced; i.e., it d ´ 4.8488 + (1 - d ) ´ 68.9142
costs less to run the smokestack reliably. In addition, because = .
the air channel of the smokestack is divided into two, a r ca
smaller amount of heated air is fed into it; this also reduces
the flow rate of the heat transfer agent into the heater to heat
init
If | t ca - t ca
calc
| < 0.5°C, i.e., if the difference between the
the air fed into the air channel of the smokestack. assumed initial and calculated temperatures of the cooled air
The temperature of the cooled air flow entering the flow was less than 0.5°C, then the calculated temperature of
heater can be determined using the equation (Fig. 2) the cooled air was taken to be equal to its actual value.
The daily average cost of heating the air fed into the air
channel of the smokestack of unit No. 2 at the Samara ther-
L A c ca r ca t ca = L cold c in rin t in + L¢ Ac out rout t out , (2) mal power plant, Tday (in thousands of rubles per day), was
determined using the following formula under the assump-
where cca, ñca, cin, ñin, and cout, ñout are the specific heat of the tion that the smokestack with vertical barriers in the air chan-
air [kJ/(kg · K)] and density of the air at the temperatures tca, nel to separate it into two equal parts operates with forced
tin, and tout, respectively. feed of the heated air, i.e., the heated air is fed into the stack
Given that Lcold = äLA and L A = (1 – ä)LA, we obtain the air channel by a blower with capacity of 27,000 m3/h:
following formula for Lca:
24 ´ 10 -6
T day = 780.5 ´ 27,000 ´
dc in r in t in + (1 - d ) c out r out t out 4187
t ca = , (3)
c ca r ca
´1146
. ´ 1( 66.2 - t ca ) = 013843
. ( 66.2 - t ca ).

where ä is the fraction of the heated air lost through leaks in For determining the pressure loss owing to friction as the
the air line out of the total air flow entering the heater. heated air moves along one part of the stack air channel, the

TABLE 1. Values of tca, Tday, and Tyear for the Yearly Average Outside Temperature as Functions of ä
ä
Characteristic
0.05 0.10 0.15 0.20 0.25 0.30
tca,°C 62.5 58.8 55.1 51.6 48.1 44.7
Tday, thousand rubles/day 0.5122 1.0244 1.5366 3.0211 2.5056 2.9762
Tyear, thousand rubles/year 186.95 373.91 560.86 737.70 914.54 1086.31
234 S. K. Ziganshina and A. A. Kudinov

latter was divided into 12 computational segments along its The equivalent diameter of the computational segment of
height. the stack air channel is taken to be twice the channel width
The frictional pressure loss Äpfr (in Pa) in a computa- [7], i.e.
tional segment of the stack air channel is given by
D avg - d avg
d e = 2d avg = 2 = D avg – d avg , (6)
l rV 2 2
Dp fr =l , (4)
de 2 where äavg = (Davg – davg)/2 is the average width of the com-
putational segment of the stack air channel.
where ë is the hydraulic friction coefficient, de is the equiva- The average area F (m2) of the transverse cross section
lent diameter of the computational section (m), l is the length of the computational segment of the stack air channel is
of the computational section (m), V is the flow velocity of given by
the air (m/sec), and ñ is the density of air (kg/m3) for tout =
= 66.2°C and ñ = 1.041 kg/m3. p 2
F= ( D avg - d avg
2
) = 0.3925( D avg
2
- d avg
2
). (7)
The coefficient of hydraulic friction for a Reynolds 8
number Re = Vde > 4000 is given by the Altschul formula [4]
Knowing F, we can determine the average flow velocity
0. 25 0. 25
V of the heated air over the computational segment of the
æk 68 ö æk 68 n ö stack air channel using the formula
l = 011
. çç e + ÷÷ = 011
. çç e + ÷÷ , (5)
è d e Re ø è d e Vd e ø
V = LA/F, (8)
where ke is the equivalent roughness of the walls of the air where LA is the volume flow rate of air (m3/sec)
outlet channel (m) (according to [5], ke = 0.005 m) and í is
the kinematic viscosity of the air (m2/sec) (for tout = 66.2°C, LA = 27,000/3,600 = 7.5 m3/sec.
í = 1.962 × 10–5 m2/sec).
Since the smokestack has a conical shape, the average in- The calculated pressure losses owing to friction as the
ner and outer diameters davg and Davg of the computational heated air moves over the segments of the stack air channel
segment of the stack air channel can be found using the fol- at unit No. 2 of the Samara thermal power plant are listed in
lowing formulas [6]: Table 2.
It was found that the frictional pressure drop as the
2 d 1t d 1b 2 d 2t d 2b heated air moves through an annular inlet with a rectangular
d avg = ; D avg = , transverse cross section and surrounding the outside of the
d 1t + d 1b d 2t + d 2b
reinforced concrete body of the smokestack at the height of
the ventilation ports is 55.16 Pa (V = 15 m/sec, a = b =
where the subscripts 1 and 2 denote inner and outer, respec- = 0.5 m, de = 0.5 m, l = 15.7 m, ke = 0.0001 m for sheet steel
tively, while t and b denote the top and bottom diameters of [8]) and the pressure drop owing to friction as heated air
the computational segment of the stack air channel. moves through the remaining part of the air loop (from the

TABLE 2. Calculated Pressure Drops Owing to Friction as Heated Air Moves Through Sections of the Air Channel of the Smokestack at Unit
No. 2 of the Samara Thermal Power Plant
Segment Äpfr, Pa
d1b, m d2b, m d1t, m d2t, m l, m davg, m Davg, m de, m F, m2 V, m/sec ë Re
No.
1 21.54 22.30 19.12 20.10 20.0 20.258 21.143 0.885 14.380 0.522 0.033 23,524.08 0.107
2 19.12 20.10 17.16 18.10 20.0 18.087 19.048 0.961 14.000 0.536 0.033 26,226.64 0.102
3 17.16 18.10 15.72 16.64 15.0 16.408 17.339 0.931 12.330 0.608 0.033 28,858.73 0.101
4 15.72 16.64 14.62 15.50 15.0 15.150 16.050 0.900 11.018 0.681 0.033 31,215.49 0.131
5 14.62 15.50 12.80 13.60 25.0 13.650 14.488 0.838 9.259 0.810 0.033 34,612.74 0.334
6 12.80 13.60 11.68 12.40 20.0 12.214 12.972 0.758 7.493 1.001 0.033 38,667.99 0.458
7 11.68 12.40 10.64 11.24 20.0 11.136 11.792 0.656 5.901 1.271 0.034 42,478.53 0.874
8 10.64 11.24 9.60 10.08 20.0 10.093 10.628 0.535 4.353 1.723 0.035 46,999.88 2.048
9 9.60 10.08 9.01 9.37 20.0 9.296 9.712 0.416 3.107 2.414 0.037 51,238.13 5.447
10 9.01 9.37 8.72 8.96 20.0 8.863 9.160 0.298 2.107 3.560 0.040 54,037.40 17.866
11 8.72 8.96 8.88 9.00 20.0 8.799 8.980 0.181 1.261 5.948 0.045 54,778.44 92.467
12 8.88 9.00 8.88 9.00 16.5 8.880 9.000 0.120 0.842 8.906 0.05 54,469.71 284.194
Total — — — — — — — — — — — — 404.129
Methods for Utilization of the Heat in Smokestack Ventilator Air at Thermal Power Plants 235

outlet of the hot air out of the second part of the air channel The power drawn by the electric motor from the grid is
to its inlet into the first part of the stack air channel) is given by
81.745 Pa (V = 15 m/sec, ab = 625 × 800 mm, de = 0.702 m,
l = 35 m, ke = 0.0001 m), with the equivalent diameter of the Nc = krN/çe, (11)
rectangular air ducts given by [4]
where kr is the power reserve coefficient which accounts for
de = 4FA/PA = 2ab/(a + b ), (9) the factors not derived from the calculations (kr = 1.1 [8])
and çe is the efficiency of the electric motor (çe = 0.9 [9]).
where FA is the transverse cross sectional area of the air duct Substituting the numerical values yields
(m2), PA is the perimeter of the air duct (m), and a and b are
the lengths of the sides of the rectangular air duct (m). Nc = 1.1 × 11/0.9 = 13,4 kW.
Thus, the overall pressure loss owing to friction during
recirculation of the heated air will be The annual cost of the electrical energy required for
forced feed of heated air into the air channel of the smoke-
(Äpfr)tot = 404.129 + 55.16 + 404.129 + 81.745 = 945.2 Pa. stack at a rate of 1.0397 rubles per kW · h will be

The overall pressure drop including the pressure losses at 13,4 × 24 × 365 × 1,0397 × 10–3 =
local resistances (Äpfr)tot as the heated air moves along the
closed air loop is = 122,044 thousand rubles/year.

p = (Äpfr)tot + (ÄpL)tot = 1.2(Äpfr)tot = If we take ä = 0.3, then the annual amount of thermal en-
ergy in monetary terms required to heat the cooled air flow
= 1.2 × 945.2 = 1134 Pa. fed into the stack air channel will be 1086.31 thousand rubles
(see Table 1). Thus, the combined annual cost of ensuring re-
The density of the flowing air decreases because it is liable operation of the smokestack is 122.044 + 1086.31 =
heated and if the blower after the heater shuts down, the = 1208.35 thousand rubles/year.
characteristics of both the electrical grid and the blower will Therefore, the savings resulting from recirculation of the
change. When these characteristics change simultaneously heated air is
and in proportion, the operating point moves along a vertical,
so that the pressure varies, while the capacity of the blower 6305.74 – 1208.35 = 5097 thousand rubles/year =
remains unchanged [9].
Since the characteristic of the type Ts4-76-10 blower has = 5 mln 97 thousand rubles/year.
been constructed for standard conditions at T0 = 273 + 20 =
= 293 K, we have We have proposed [10] directing the heated air after the
stack air channel into the boiler unit for burning of the fuel.
T 273 + 66.2 The amount of heat Q (in kilowatts) expended in heating the
p0 = p = 1134 = 1313 Pa. air in the heater is given by
T0 293
Q = LAñavg(tout – tin)/3600.
On the blower characteristic at LA = 27,000 m3/h and
p0 = 1313 Pa, we find the operating point and find the effi- The blast air flow rate for a BKZ-420 power generation
ciency of the blower to be çA = 0.79 and its angular fre- boiler at its nominal steam capacity of 420 tons/h with gas
quency to be ù = 99 rad/sec (corresponding to a rotation fre- operation is 315,000 – 320,000 m3/h. Before it reaches
quency of n = 30ù/ð = 946 rpm). the boiler furnace, the blast air is fed into an air preheater
The shaft power of the electric motor (in kilowatts) is at a temperature of 30°C, i.e., after preheating in the heater.
given by Thus, the ratio of the amount of heat QA.chan (in kilowatts)
expended in heating the outside air before it is fed into the air
pL A channel of the smokestack to the amount of heat QB.A (in
N = , (10)
3600 ´ 1000hA ht kilowatts) expended in heating the blast (outside) air before
it is fed to the air preheater of the boiler is
where çt is the transmission efficiency, equal to 1 for direct
connection of the ventilator wheel to the shaft of the electric Q A.chan 54,000 ´ 1146
. ( 66.2 - 3,8 )
= = 0.38.
motor [8]. With this, we have Q B.A 315,000 ´ 1218
. ´ ( 30 - 38
. )

1134 × 27,000 We have also proposed directing the air heated in the
N = 11 kW.
3600 ´ 1000 ´ 0.79 ´ 1 heater following a stack air channel that has been divided
236 S. K. Ziganshina and A. A. Kudinov

B feed line to the heater, i.e., recirculating it, or into the boiler
B–B
Flue gases Flue gases unit for burning of the fuel.
2. It has been found that at present the cost of heating
8
the air fed to the air channel of the 240-m-high smokestack at
4 unit No. 2 of the Samara thermal power plant averages
1
À À
2 6.305 million rubles/year. With recirculation of the heated
1 3 air, the costs of providing reliable operation of this smoke-
2 5 stack would average 1.208 million rubles/year, for a savings
3 To boiler of 5.970 million rubles/year.
unit for
Air fuel
burning
REFERENCES
6 7
B 1. L. A. Rikhter, Thermal Power Plants and the Protection of the
Atmosphere [in Russian], Énergiya, Moscow (1975).
Fig. 3. Design of a smokestack with an air channel: 1, reinforced
2. V. Ya. Ryzhkin, Thermal Power Plants [in Russian], Énergiya,
concrete body; 2, lining; 3, gas outlet channel; 4, air channel; 5, ver-
Moscow (1976).
tical barriers; 6, heater; 7, blower; 8, openings in vertical barriers; 3. Patent No. 2254428 (RF), A. A. Kudinov and S. K. Ziganshina,
for cross section A – A see Fig. 1. “A method for operating smokestacks,” Byull. Izobret., No. 17
(2005).
4. A. A. Kudinov, Engineering Hydromechanics [in Russian],
into two parts by two vertical barriers into the boiler system Mashinostroenie, Moscow (2008)
for burning of the fuel [11]. Here, making openings (Fig. 3) 5. É. P. Volkov, E. I. Gavrilov, and F. P. Duzhikh, Gas-Exhaust
Pipes in Thermal Power Plants and Nuclear Power Plants [in
in the vertical barriers installed in the stack air channel Russian], Énergoatomizdat, Moscow (1987).
makes it possible to avoid installing an annular intake for re- 6. . M. Shchegolev, Fuel, Furnaces, and Boiler Units [in Russian],
moval of the heated air from one part of the stack air channel Gosstroiizdat, Moscow (1953).
to the other. 7. I. A. Shishkov, V. G. Lebedev, and D. S. Belyaev, Smokestacks
for Power Plants [in Russian], Énergiya, Moscow (1976).
8. G. V. Ruslanov, M. Ya. Rozkin, and É. L. Yampol’skii, Heating
and Ventilation of Residential and Public Buildings. A Hand-
CONCLUSIONS
book [in Russian], Budivel’nik, Kiev (1983).
9. M. P. Kalinushkin, Ventilator Systems [in Russian], Vysshaya
1. Methods have been developed for utilization of the Shkola, Moscow (1979).
10. Patent No. 2303198 (RF), A. A. Kudinov and S. K. Ziganshina,
heat in the ventilation air of smokestacks at thermal power
“Boiler unit,” Byull. Izobret., No. 20 (2007).
plants which involve directing the heated air emerging from 11. Patent No. 2299377 (RF), A. A. Kudinov and S. K. Ziganshina,
the air channel of the smokestack either into the intake of a Boiler unit,” Byull. Izobret., No. 14 (2007).

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