中拓高效燃气内燃机发电技术在铁合金矿热炉煤气上的应用

　　Application of Zhongtuo High Efficiency Gas Internal Combustion Engine Power Generation Technology in Ferroalloy Mineral Heat Furnace Gas

　　实现碳达峰和碳中和的“双碳”目标是国家的重大战略。工业尾气排放是温室气体的主要来源，控制工业尾气碳排放是碳减排工作的关键，利用工业尾气发电是实现工业尾气碳减排的重要途径。尾气发电机组属于资源综合利用的关键装备，在国家和地方政策上得到大力支持，在“双碳”经济背景下迎来新的发展机遇。01什么是矿热炉煤气

　　Realizing the "dual carbon" goals of peaking carbon emissions and achieving carbon neutrality is a major national strategy. Industrial exhaust emissions are the main source of greenhouse gases, and controlling industrial exhaust carbon emissions is the key to carbon reduction. Utilizing industrial exhaust for power generation is an important way to achieve industrial exhaust carbon reduction. Exhaust gas generator units are key equipment for comprehensive resource utilization and have received strong support from national and local policies, ushering in new development opportunities in the context of the "dual carbon" economy. 01 What is mineral furnace gas

　　矿热炉又称电弧电炉或电阻电炉，是一种陆续加料、连续作业的工业电炉，主要用于还原冶炼矿石、碳质还原剂及溶剂等原料，是铁合金冶炼的主要设备。铁合金尾气工艺流程图

　　Submerged arc furnace, also known as electric arc furnace or resistance electric furnace, is an industrial electric furnace that gradually feeds materials and operates continuously. It is mainly used for reducing and smelting raw materials such as ores, carbonaceous reducing agents, and solvents, and is the main equipment for ferroalloy smelting. Process Flow Diagram of Ferroalloy Tail Gas

　　在铁合金的生产过程中，矿热炉中的焦炭与矿石发生反应，会产生大量的尾气，俗称“矿热炉煤气”。矿热炉煤气是一种有毒有害的温室气体，其主要组分为CO、H2、CH4、CO2等气体，因此，矿热炉煤气中又蕴含着丰富的化学能和热能。目前，除少部分作为燃料使用外，绝大部分矿热炉煤气被燃烧后直接排至大气，这样既造成了严重的环境污染，又浪费了资源。如果采用高效的燃气内燃机发电，实现能源充分利用并降低尾气中有害物质的排放，可带来经济、环境和运营上的效益。02燃气内燃机如何利用矿热炉煤气

　　In the production process of ferroalloys, the coke in the submerged arc furnace reacts with the ore, producing a large amount of exhaust gas, commonly known as "submerged arc furnace gas". Mineral furnace gas is a toxic and harmful greenhouse gas, mainly composed of gases such as CO, H2, CH4, CO2, etc. Therefore, mineral furnace gas contains abundant chemical and thermal energy. At present, except for a small portion used as fuel, the vast majority of mine blast furnace gas is directly discharged into the atmosphere after combustion, which not only causes serious environmental pollution but also wastes resources. If efficient gas internal combustion engines are used for power generation, achieving full energy utilization and reducing the emission of harmful substances in exhaust, it can bring economic, environmental, and operational benefits. How to utilize the coal gas from the ore blast furnace for 02 gas internal combustion engines

　　矿热炉煤气的主要成分为：CO、CO2、H2、CH4、N2、O2、H2O。其中CO 含量50%~85%，H2含量2%~14%，CH4含量0~6.5%，尾气的燃烧低热值约为7～11.5?MJ/Nm3，其具体成分及比例受生产原料、工况的变动影响大。可见，矿热炉煤气成分复杂，各气体组分及含量变动较大。矿热炉煤气中的可燃气体主要有CO、H2和CH4，其燃烧特性如表所示。其中CO和CH4的燃烧特性相近，而与CO和CH4相比，H2的燃烧速度非常快，引燃所需能量特别低，与空气混合燃烧浓度范围很宽，燃烧放热速率极高，这些特性很容易导致内燃机在运行期间出现进气回火、缸内早燃与爆燃等异常现象，造成效率下降与零部件损坏。同时，由于氢气在大气中的扩散系数大，使得氢气与空气混合均匀所需的时间非常短。而且，氢气分子极小、渗透性强，对防泄漏提出更高要求，容易造成氢脆、渗透等问题。综上，利用矿热炉煤气必须首先解决以下技术问题：

　　The main components of blast furnace gas are CO, CO2, H2, CH4, N2, O2, and H2O. The CO content is 50%~85%, the H2 content is 2%~14%, the CH4 content is 0~6.5%, and the low calorific value of the exhaust gas combustion is about 7~11.5? MJ/Nm3， Its specific composition and proportion are greatly affected by changes in production materials and working conditions. It can be seen that the composition of the coal gas in the blast furnace is complex, and the composition and content of each gas vary greatly. The combustible gases in the coal gas of the ore blast furnace mainly include CO, H2, and CH4, and their combustion characteristics are shown in the table. The combustion characteristics of CO and CH4 are similar, while compared with CO and CH4, H2 has a very fast combustion rate, requires particularly low energy for ignition, has a wide range of combustion concentration when mixed with air, and has a very high heat release rate. These characteristics can easily lead to abnormal phenomena such as intake backfire, early combustion and detonation in the cylinder during internal combustion engine operation, resulting in decreased efficiency and component damage. Meanwhile, due to the high diffusion coefficient of hydrogen in the atmosphere, the time required for hydrogen to mix evenly with air is very short. Moreover, hydrogen molecules are extremely small and highly permeable, placing higher demands on leak prevention, which can easily lead to issues such as hydrogen embrittlement and permeation. In summary, the following technical problems must be solved first when using the coal gas from a blast furnace:

　　1)遏制进气回火，确保燃气系统的供气与混合安全可靠性；2)抑制缸内异常燃烧，协同组织缸内混合气高效燃烧；3)克服燃气组分变动影响，提高尾气组分变动适应性。为此，中拓技术人员基于LY系列燃气内燃机发电系统产品潜心研发了专利燃气供给系统，并采用公司自主开发的稀薄低温燃烧技术与分布式实时控制技术，经过了反复的试验与应用验证，有效地克服了上述技术障碍，取得较好的效果。03燃气内燃机对气体的组分及杂质含量要求

　　1) Control intake backfire and ensure the safety and reliability of gas supply and mixing in the gas system; 2) Inhibiting abnormal combustion in the cylinder and coordinating efficient combustion of the cylinder mixture; 3) Overcome the impact of changes in gas composition and improve the adaptability to changes in exhaust gas composition. To this end, Zhongtuo technicians have devoted themselves to developing a patented gas supply system based on the LY series gas internal combustion engine power generation system products, and have adopted the company's independently developed lean low-temperature combustion technology and distributed real-time control technology. After repeated experiments and application verification, the above technical obstacles have been effectively overcome and good results have been achieved. 03 Gas Internal Combustion Engine Requirements for Gas Composition and Impurity Content

　　为保证燃气内燃机的稳定可靠运行，进入内燃机前的燃气一般需要对矿热炉排出的尾气进行净化处理，并满足下表要求：04中拓工业煤气内燃机组的优势

　　To ensure the stable and reliable operation of gas internal combustion engines, the gas before entering the internal combustion engine generally needs to be purified from the exhaust gas discharged from the ore blast furnace, and meet the requirements in the following table: 04 Advantages of Zhongtuo Industrial Gas Internal Combustion Units

　　单机功率大，气体适应性强中拓机组单机发电功率可达1500kW，是目前市场上矿热炉煤气发电应用产品中单机功率最大的内燃机发电机组，也是在此领域唯一单机功率超过1MW的产品。机组采用先进的气体混合器和精确的控制系统，满足适应多元化的工业尾气气体特点，一氧化碳含量20%以上即可运行。

　　The single unit power is high and the gas adaptability is strong. The single unit power generation of Zhongtuo unit can reach 1500kW, which is currently the largest single unit power internal combustion engine generator set in the market for mineral thermal furnace gas power generation applications. It is also the only product in this field with a single unit power exceeding 1MW. The unit adopts advanced gas mixers and precise control systems to meet the diverse characteristics of industrial exhaust gases, and can operate with a carbon monoxide content of over 20%.

　　发电效率高，盈利能力强机组优化了稀薄燃烧技术和预燃室式火花塞，使得燃料消耗更低，发电效率为40%左右，综合利用效率可达到86%。相比国内同类产品25%左右的发电效率，中拓发电机组提高了燃气利用率15%，高电效率可带来高盈利。

　　High power generation efficiency and strong profitability. The unit has optimized lean combustion technology and pre chamber spark plugs, resulting in lower fuel consumption. The power generation efficiency is around 40%, and the comprehensive utilization efficiency can reach 86%. Compared to similar domestic products with a power generation efficiency of around 25%, Zhongtuo generator sets have increased gas utilization by 15%, and high electrical efficiency can bring high profits.

　　升功率高，强化系数大采用高增压比深度中冷与米勒循环稀薄燃烧技术和自主创新研发的前馈空燃比实时精确控制技术，提高了矿热炉煤气发动机的强化系数，升功率达到16.95kW/L，居全国之首。

　　The high power consumption and high enhancement coefficient are achieved through the use of high boost ratio deep intercooling and Miller cycle lean combustion technology, as well as the independently developed feedforward air-fuel ratio real-time precise control technology, which improves the enhancement coefficient of the mineral heat furnace gas engine. The power consumption reaches 16.95kW/L, ranking first in the country.

　　氮氧化物排放低，减轻环保压力通过精准地控制缸内燃烧温度，从而有效减低了氮氧化物（NOX）的排放量，实测排放485 mg/Nm?，大大减少脱硝成本和环保压力。

　　Low nitrogen oxide emissions reduce environmental pressure by precisely controlling the combustion temperature in the cylinder, effectively reducing the emission of nitrogen oxides (NOX). The measured emission is 485 mg/Nm? Greatly reduce the cost of denitrification and environmental pressure.

　　机油消耗低，降低运营成本本公司通过消化国外先进的机油消耗设计技术，对机油在润滑与密封过程中所产生的蒸发与燃烧消耗进行了细化分解，并对相关关键系统零部件（如活塞-缸套、曲轴箱通风系统等）进行了设计优化，机组运行润滑油消耗低至0.3g/kWh，逼近国际先进水平，较国内同类产品水平领先优势明显。

　　Low oil consumption reduces operating costs. Our company has refined and decomposed the evaporation and combustion consumption of oil during lubrication and sealing processes by digesting advanced oil consumption design technologies from abroad. We have also optimized the design of key system components such as piston cylinder liners and crankcase ventilation systems. The lubricating oil consumption during unit operation is as low as 0.3g/kWh, approaching the international advanced level and having a significant advantage over similar domestic products.

　　可用性高，运行时间长更清洁的燃烧和核心进口运动件使物理损耗降到极致，机组的维护间隔更长，大修周期48000h以上，年运行时长8000h以上。

　　High availability, longer running time, cleaner combustion, and core imported moving parts minimize physical wear and tear. The maintenance interval of the unit is longer, with a major overhaul cycle of over 48000 hours and an annual operating time of over 8000 hours.

　　结构紧凑，安全性高机组体积小，重量轻，降低了对安装场地的要求；采用多级阻火防爆设计和先进的爆震控制技术，能有效避免非正常工况对机组的损害。

　　Compact structure, high safety, small size and light weight of the unit, reducing the requirements for installation site; The use of multi-stage flame retardant and explosion-proof design and advanced detonation control technology can effectively avoid damage to the unit caused by abnormal operating conditions.

　　备件充足，维护便捷中拓拥有内蒙、山西、湖南、广东四大零件中心，完备的服务体系、专业的维护人员可满足全国各地的售后需求。05中拓矿热炉煤气发电示范案例

　　Adequate spare parts and convenient maintenance. Zhongtuo has four major parts centers in Inner Mongolia, Shanxi, Hunan, and Guangdong, with a complete service system and professional maintenance personnel to meet after-sales needs across the country. 05 Zhongtuo Mining Thermal Furnace Gas Power Generation Demonstration Case

　　·?内蒙古丰镇市丰宇26.4MW工业尾气发电项目2022年5月，该项目一期11*1.2MW并网成功、投入运行。此项目总规划装机容量为26.4MW，一期配置11台中拓自主品牌LY1600GH-M1.2MW工业煤气发电机组，采用并网不上网的模式。项目投产后预计年发电量约1.05亿度，节约标准煤3.46万吨/年，减排二氧化碳12.4万吨/年。

　　·In May 2022, the Fengyu 26.4MW industrial tail gas power generation project in Fengzhen City, Inner Mongolia, successfully connected the first phase of the project with a capacity of 11 * 1.2MW and put it into operation. The total planned installed capacity of this project is 26.4MW, and the first phase will be equipped with 11 independent brand LY1600GH-M1.2MW industrial gas generator units from Zhongtuo, using a grid connected mode without grid connection. After the project is put into operation, it is expected to generate approximately 105 million kilowatt hours of electricity annually, save 34600 tons of standard coal per year, and reduce carbon dioxide emissions by 124000 tons per year.

　　·?内蒙古丰镇市科翰14.4MW工业尾气发电项目2022年6月，该项目并网成功、投入运行。配置12台中拓自主品牌LY1600GH-M型工业煤气集装箱式发电机组，总装机容量为14.4MW。所发电量采用并网不上网的模式，全部供内蒙古科翰冶金公司使用。该电厂投产后预计年发电量约1.15亿度，可节约标准煤3.68万吨/年，减排二氧化碳13.52万吨/年。06应用展望

　　·The 14.4MW industrial tail gas power generation project in Kehan, Fengzhen City, Inner Mongolia was successfully connected to the grid and put into operation in June 2022. Configure 12 independent brand LY1600GH-M industrial gas container type generator sets from Taichung Tuo, with a total installed capacity of 14.4MW. The generated electricity will be connected to the grid without being connected to the grid, and all will be used by Inner Mongolia Kehan Metallurgical Company. After the power plant is put into operation, it is expected to generate approximately 115 million kilowatt hours of electricity annually, saving 36800 tons of standard coal per year and reducing carbon dioxide emissions by 135200 tons per year. 06 Application Outlook

　　当前，在 “双碳”战略的号召下，各大行业加大了碳排放跟踪力度，国家发改委等部委联合下发了《铁合金行业节能降碳改造升级实施指南》，大力推进高耗能行业节能降碳工作顺利开展。矿热炉煤气发电应用，可以提高能源利用率，减少环境污染，实现降本增效，是集资源循环利用、低碳环保和厂区安全生产优势为一体的利好之选。从经济性上考量，矿热炉煤气的自发电量既能供以自用，减少企业用电支出，又可以选择并入国家电网，产生直接经济效益。以单台1MW燃气发电机组测算，中拓机组年度发电量为800万度左右，以电价0.55元每度计算，可创造经济效益人民币440万元左右。中拓作为燃气内燃机发电领域中具备自主研发能力的民族品牌，在矿热炉煤气发电应用领域积累了丰富的项目实战经验。中拓以低热值矿热炉煤气为原料发电项目的高度适应和成熟运用，有效保障了客户获得持续可观的收益，引领铁合金企业实现节能、减排、降碳绿色高质量发展。预见未来，矿热炉煤气的发电应用大有可为。

　　Currently, under the call of the "dual carbon" strategy, major industries have increased their efforts to track carbon emissions. The National Development and Reform Commission and other departments have jointly issued the "Implementation Guidelines for Energy Conservation and Carbon Reduction Upgrades in the Ferroalloy Industry", vigorously promoting the smooth implementation of energy conservation and carbon reduction work in high energy consuming industries. The application of coal gas power generation in ore blast furnaces can improve energy utilization efficiency, reduce environmental pollution, and achieve cost reduction and efficiency improvement. It is a favorable choice that integrates the advantages of resource recycling, low-carbon environmental protection, and factory safety production. From an economic perspective, the self generated electricity from mining furnace gas can be used for self consumption, reducing the electricity expenditure of enterprises, and can also be integrated into the national power grid to generate direct economic benefits. Based on a single 1MW gas-fired generator unit, the annual power generation of Zhongtuo unit is about 8 million kWh. Calculated at an electricity price of 0.55 yuan per kWh, it can create an economic benefit of about 4.4 million RMB. As a national brand with independent research and development capabilities in the field of gas internal combustion engine power generation, Zhongtuo has accumulated rich project practical experience in the application of mine heat furnace gas power generation. The highly adaptable and mature application of Zhongtuo's low calorific value ore blast furnace gas as raw material for power generation projects effectively ensures that customers can obtain sustained and considerable profits, leading ferroalloy enterprises to achieve energy-saving, emission reduction, carbon reduction, green and high-quality development. Looking ahead to the future, there is great potential for the power generation application of coal gas from mining furnaces.

　　本文由 矿热炉煤气发电机组  友情奉献.更多有关的知识请点击  http://www.zhongtuopower.cn/   真诚的态度.为您提供为全面的服务.更多有关的知识我们将会陆续向大家奉献.敬请期待.

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