摘要
1 作为我国现代煤化工产业的核心示范区，榆林集聚了陕煤榆林化学1500万吨/年煤炭分质转化、神渭727公里输煤管道等一批重点项目，其粉煤加压输送系统的工况极特殊，如含尘量高的煤浆(颗粒浓度≥350kg/m3),输送距离长且需要加压输送，运行多个不同的工艺工况条件等。以锁斗阀、流量调节阀、三通换向阀为代表的阀门产品使用寿命只有6个月左右，极易发生阀体磨损失效、阀芯卡涩停机和维护费用高等问题。本文通过对包括神木化工、榆林能化在内的工厂失效阀门的拆解分析，利用CFD-DEM数值模拟和现场试验数据等手段，揭开了榆林地区特有的“煤浆高浓度冲蚀-温差应力耦合-颗粒粘附研磨”三重磨损机理。在此基础上提出了“材料梯度强化-抗粘附结构设计-本地化适配优化”的阀门改进方案，研制出适用于榆林煤质的氧化锆-碳化硅复合密封副、防结垢流线型阀内件和温差补偿结构，并经过陕煤榆林化学二期项目的工业试验验证，阀门无故障运行时间从传统金属阀门的4-6个月延长至4.8年，流量控制精度由原来的不超过±7%降至≤±7%,单套装置年维护成本减少上700余万元。本课题的研究成果可以有效保障榆林地区乃至类似工况下的粉煤加压输送系统稳定运行。
关键词：粉煤加压输送；关键阀门；磨损机理；结构改进；榆林煤化工；本地化适配
Abstract:
As the focal point of China’s coal chemical industry development efforts, Yulin houses various major coal chemical projects, among which the top three are: the ShaanxiCoal Yulin Chemical 15 Mt/a Coal Quality Divided Converting project, the 727km long Shenwei Coal Pipeline, and the pulverized coal pressurized conveying system in use. Because of the extremely harsh working environment (high-dust coal slurry (>350kg/m3), long-distance pressurized transmission, multi-processing-connection) in this region, local plants have encountered problems like wearing down of machines, jamming-caused machine shutdowns, high maintenance cost of vital machines, and regular failures of lock hopper valves, flow control valves and three-way reversing valves during their working process in approximately six month time.
Based on the disassembly analysis of defective valves from factories such as Shenmu Chemical and Yulin Energy&Chemical, combined with CFD-DEM numerical simulation and field measurement data, this paper reveals the particular "triple wear mechanism" specific to the Yulin region: "high-concentration slurry erosion—thermal stress coupling—particle adhesion and abrasion".
To deal with above problems, the research puts forward a solution "material gradient strengthening-anti-adhesion structural design-localized adaptation optimization", and focuses on the research on key technologies such as "zirconia-silicon carbide composite sealing pair matching Yulin coal qualities, anti-fouling streamline valve trims, and thermal compensation structure."
The industrial verification carried out in the Phase II project of Shaanxi Coal Yulin Chemical Project yielded highly satisfactory results, as shown by data collected in that stage. The valve operation period is now nearly 50 times longer, being more than 4. 8 years now. The Flow Control Variance is now within 7% which compares favourably to typical industry standards of around ±10%. The O&M savings for one 6F unit approach CNY 7 million per year alone. The research offers localized improvement solutions to assure the stability of the pulsed coal conveyance under pressurization conditions similar to Yulin’s and with good commercial promotion potential.
Keywords:Pressurized conveying of pulverized coal; key valves; wear mechanism; structural modification; localized fitting of Yulin coal chemical industry.
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