一、鎳基釬焊熱管技術的工作原理

　　1、 Working principle of nickel based brazed heat pipe technology

　　鎳基釬焊管，即將鎳鉻合金滲入鍋爐管或ND鋼（耐低溫露點腐蝕鋼）表面，形成致密光滑涂層，使管片和母管的焊著率為100%，有效地擴展了換熱面積，提高了換熱系數，同時具有很好的耐高溫和耐腐蝕性能。熱管是一種具有很高熱傳輸性能的元件，它集沸騰與凝結于一身，由管殼、管芯和傳導液組成。它的工作原理是：當蒸發段遇到高溫介質時，管內傳導液吸收蒸發潛熱后蒸發，傳導液蒸汽從管中心絕熱段通道流向凝結段，并放出潛熱，重新凝結成傳導液，凝結后的傳導液借助管芯的毛細力作用重新返回蒸發段再進行蒸發，這樣形成了一個閉合的循環系統。通過這種途徑，熱量從加熱區到了散熱區，對被加熱介質進行加熱，得到所需溫度的介質。鎳基釬焊熱管式余熱回收裝置利用高溫煙氣和被加熱介質傳熱系數的不同（煙氣傳熱系數小，被加熱介質傳熱系數的高），因而在傳熱系數小的煙氣側擴展換熱面積，將熱端—鎳基釬焊翅片吸收的熱量，與冷端—光管傳熱系數高的被加熱介質所吸收的熱量相同，使之產生有效的換熱平衡。

　　Nickel based brazed pipe, which involves the infiltration of nickel chromium alloy into the surface of boiler tubes or ND steel (low temperature dew point corrosion resistant steel) to form a dense and smooth coating, resulting in a 100% welding rate between the pipe segments and the main pipe. This effectively expands the heat transfer area, improves the heat transfer coefficient, and has good high temperature and corrosion resistance. A heat pipe is a component with high heat transfer performance, which combines boiling and condensation, and is composed of a shell, core, and conductive fluid. Its working principle is that when the evaporation section encounters a high-temperature medium, the conductive liquid inside the tube absorbs the latent heat of evaporation and evaporates. The conductive liquid vapor flows from the adiabatic section channel at the center of the tube to the condensation section, releasing latent heat and re condensing into conductive liquid. The condensed conductive liquid returns to the evaporation section for further evaporation by the capillary force of the tube core, thus forming a closed loop system. Through this pathway, heat is transferred from the heating zone to the heat dissipation zone, heating the heated medium to obtain the desired temperature of the medium. The nickel based brazed heat pipe type waste heat recovery device utilizes the difference in heat transfer coefficients between high-temperature flue gas and the heated medium (the flue gas has a lower heat transfer coefficient and the heated medium has a higher heat transfer coefficient), thus expanding the heat transfer area on the flue gas side with a lower heat transfer coefficient. The heat absorbed by the hot end nickel based brazed fins is equal to the heat absorbed by the heated medium with a higher heat transfer coefficient between the cold end and the light pipe, creating an effective heat transfer balance.

　　二、鎳基釬焊熱管式余熱回收裝置的結構特點

　　2、 Structural characteristics of nickel based brazed heat pipe type waste heat recovery device

　　1、結構緊湊單位長度的釬焊熱管換熱面積是普通光管的七倍左右，同時釬焊熱管之間用小半徑推制彎頭連接。因而相同換熱面積的釬焊熱管余熱回收裝置普通光管的設備相比，其體積和占地面積成數倍的減小，并且其重量也有不同幅度的降低。因而，在設備布置安裝和吊裝等方面為用戶提供了很大的空間。

　　1. The heat transfer area of a compact unit length brazed heat pipe is about seven times that of a regular bare pipe, and the brazed heat pipes are connected by small radius push bends. Therefore, compared to ordinary bare tube equipment, the volume and footprint of brazed heat pipe waste heat recovery devices with the same heat exchange area are reduced several times, and their weight is also reduced to varying degrees. Therefore, it provides users with a lot of space in terms of equipment layout, installation, and lifting.

　　2、維修方便釬焊熱管是采用整根無縫鋼管制造完成的，使其具有很高的耐壓性能，一般情況很少出現質量方面的問題。如果偶然發現某一根釬焊熱管出現泄漏，也可以方便地進行更換，即使不更換也不影響運行。

　　2. Easy to maintain, brazed heat pipes are made of seamless steel pipes, which provide high pressure resistance and rarely cause quality issues. If a leakage is accidentally discovered in a brazed heat pipe, it can be easily replaced without affecting operation.

　　3、受壓元件無熱應力每一根釬焊熱管組裝時，無任何強制組裝現象，因而不會產生組裝應力。同時每一端呈自由狀態。這樣設備在運行過程中，無熱應力產生。

　　3. There is no thermal stress on the pressure bearing components. When assembling each brazed heat pipe, there is no forced assembly phenomenon, so there will be no assembly stress. At the same time, each end is in a free state. In this way, there is no thermal stress generated during the operation of the device.

　　4、標準化設計和靈活的尺寸變化迄今為止，我們已開發設計了多系列的標準產品。廣泛應用于大中小型柴油機和天然氣發電機組，以及鍋爐的高溫煙氣的余熱回收利用，另外，我們可在短時間內按照用戶要求，根據用戶提供的設計參數，對各種余熱回收裝置進行靈活設計。5、可高效連續的運行根據其傳熱機理和結構特點，我們不難得知，釬焊熱管技術具有較強的防垢、防灰和自除垢、除灰能力。因而其設備可以長時間的保持高效運行，這是普通光管換熱設備所不能比擬的。三、設計目的本設計利用10臺500kW瓦斯發電機組高溫煙氣余熱產生5kgf/cm2飽和蒸汽用于生產。該電站10臺500kW瓦斯發電機組，測試結果表明，所燃氣體至多36%的熱量用來發電，約有38%的熱量通過高溫煙氣排空。為充分利用余熱，設計一套余熱利用系統，充分利用高溫煙氣熱量，使所燃氣體總熱量70%得到應用。

　　4. So far, we have developed and designed multiple series of standard products with standardized design and flexible size changes. Widely used in large, medium and small diesel engines and natural gas generator sets, as well as in the recovery and utilization of waste heat from high-temperature flue gas in boilers. In addition, we can flexibly design various waste heat recovery devices according to user requirements and design parameters provided by users in a short period of time. 5. According to its heat transfer mechanism and structural characteristics, it is not difficult to know that brazed heat pipe technology has strong anti scaling, anti ash, and self-cleaning and ash removal capabilities. Therefore, its equipment can maintain efficient operation for a long time, which is incomparable to ordinary light tube heat exchange equipment. 3、 Design purpose: This design utilizes 10 500kW gas generator units to generate 5kgf/cm2 saturated steam from high-temperature flue gas waste heat for production. The power station has 10 500kW gas generator units, and the test results show that up to 36% of the heat generated by the burned gas is used for power generation, and about 38% of the heat is discharged through high-temperature flue gas. To fully utilize waste heat, a waste heat utilization system is designed to fully utilize the heat of high-temperature flue gas, so that 70% of the total heat of the burned gas is applied.

　　四、系統組成及原理

　　4、 System composition and principle

　　鎳基釬焊熱管式余熱回收裝置是以鎳基釬焊熱管作為換熱元件，將煙氣的熱量通過擴大受熱面積的熱管段傳遞給壓力汽包中的介質。在其中加熱介質,采用自然循環的形式，把水變為飽和蒸汽。通過水位控制器控制蒸汽空間，提高飽和蒸汽的質量，當水位達到低水位時，控制柜將信號給給水泵，水泵開啟送水直到水位達到高水位止，如此反復循環。系統主要由煙氣——水熱交換器（熱管蒸發器）、給水泵、閥門儀表、輸水輸汽管線、輸氣管線等組成。系統的設計壓力為1.2Mpa，蒸汽介質工作溫度在152℃，蒸汽量為4246kg/h，熱交換量為2675400kcal/h。五、熱工計算瓦斯在空氣中完全燃燒公式：瓦斯在空氣中不完全燃燒公式：瓦斯發電機組正常運轉時，發電功率為450kW、排煙溫度為550℃左右，當鎳基釬焊熱管熱交換器出水溫度為152℃左右時，它排出的煙氣溫度為150℃，瓦斯完全燃燒時和空氣的體積比為1:10，為使燃料充分燃燒，一般燃氣與空氣的混合比例為1:13，（按1m3純瓦斯發3度電計算）500kW機組的耗氣總量為：450/3×（1＋13）＝2100m3/h。平均重量按1.25kg/m3計算，總重：2100×1.25＝2625kg排煙的比熱容按煙道氣體計算（煙道氣體的成分CO:13%，H2O:11%，N2:76%，在100℃—600℃的平均定壓比熱容為0.26kcal/kg·℃）。10臺發電機組可利用排煙余熱產生5kgf/cm2蒸汽為：（550－150）×0.26×2625×0.98×10＝2675400kcal/h按進水溫度20℃計算，蒸汽溫度152℃，蒸汽的熱含650kcal/kg則每小時可產生總蒸汽量為：2675400÷（650－20）＝4246kg

　　The nickel based brazed heat pipe type waste heat recovery device uses nickel based brazed heat pipes as heat exchange elements to transfer the heat of flue gas to the medium in the pressure steam drum through the heat pipe section that expands the heating area. In it, the heating medium adopts a natural circulation form to turn water into saturated steam. By controlling the steam space through a water level controller, the quality of saturated steam is improved. When the water level reaches a low level, the control cabinet sends a signal to the feed pump, which starts to supply water until the water level reaches a high level. This cycle is repeated. The system mainly consists of a flue gas water heat exchanger (heat pipe evaporator), a feedwater pump, valves and instruments, water and steam pipelines, and gas pipelines. The design pressure of the system is 1.2Mpa, the working temperature of the steam medium is 152 ℃, the steam volume is 4246kg/h, and the heat exchange capacity is 2675400kcal/h. 5、 Thermal calculation formula for complete combustion of gas in air: formula for incomplete combustion of gas in air: When the gas generator unit is operating normally, the power generation is 450kW, and the exhaust temperature is around 550 ℃. When the outlet temperature of the nickel based brazed heat pipe heat exchanger is around 152 ℃, the exhaust temperature is 150 ℃. When the gas is completely burned, the volume ratio of gas to air is 1:10. In order to fully burn the fuel, the general mixing ratio of gas and air is 1:13. (Calculated based on 1m3 pure gas generating 3 kWh of electricity) The total gas consumption of a 500kW unit is: 450/3 × (1+13)=2100m3/h. The average weight is calculated at 1.25kg/m3, and the total weight is 2100 × 1.25=2625kg. The specific heat capacity of the exhaust gas is calculated based on the flue gas (the composition of the flue gas is CO: 13%, H2O: 11%, N2: 76%, and the average constant pressure specific heat capacity at 100 ℃ -600 ℃ is 0.26kcal/kg ·℃). 10 generator sets can generate 5kgf/cm2 steam using exhaust waste heat, which is: (550-150) × 0.26 × 2625 × 0.98 × 10=2675400kcal/h. Calculated based on the inlet water temperature of 20 ℃, the steam temperature is 152 ℃, and the heat content of the steam is 650kcal/kg. Therefore, the total steam production per hour is: 2675400 ÷ (650-20)=4246kg

　　方案1：用于夏季制冷根據國內制冷設備廠提供樣本參數來看，4246kg的蒸汽能夠帶動3957kw的溴化鋰機組。根據以往經驗值來看按每平方米制冷量100瓦計算，則可供制冷面積為；3957kw×1000w÷100w/m2＝39570m2方案2用于冬季供暖：按進水溫度20℃計算，加熱成95℃熱水計算，每小時可產生熱水量為：2675400kcal/h÷（95℃－20℃）＝35672kg/h；按每平方米取暖熱量80瓦計算，則可供暖面積為（自熱工手冊中查得：每千瓦熱量合860千卡：2675400kcal/h÷860Kcal/kw=3110kw）:3110kw×1000w/kw÷80w/m2＝38886m2注：瓦斯實際在缸內燃燒不完全，產生一定量的一氧化碳，并在排氣管中繼續燃燒；實際煙氣排出的熱能比計算值要多。六、施工說明1、系統中的管線分別采用以下具體規格DN80（給水主管線）、DN100（蒸汽主管線）。

　　Scheme 1: Used for summer refrigeration. According to the sample parameters provided by domestic refrigeration equipment manufacturers, 4246kg of steam can drive 3957kW lithium bromide units. Based on past experience, if calculated at a cooling capacity of 100 watts per square meter, the available cooling area is; 3957kw × 1000w ÷ 100w/m2=39570m2 Scheme 2 for winter heating: Calculated based on an inlet water temperature of 20 ℃ and heated to 95 ℃ hot water, the hourly hot water production is 2675400kcal/h ÷ (95 ℃ -20 ℃)=35672kg/h; Calculated based on 80 watts of heating heat per square meter, the heating area is (according to the thermal manual: 860 kilocalories per kilowatt of heat: 2675400kcal/h ÷ 860Kcal/kw=3110kw × 1000w/kw ÷ 80w/m2=38886m2). Note: Gas is not completely burned in the cylinder, producing a certain amount of carbon monoxide, which continues to burn in the exhaust pipe; The actual heat energy emitted from flue gas is greater than the calculated value. 6、 Construction instructions: 1. The pipelines in the system adopt the following specific specifications: DN80 (water supply main pipeline) and DN100 (steam main pipeline).

　　2、鎳基釬焊熱管式熱交換器：安裝在現有發電機組的上部外端，盡量靠近發動機排氣口，將消聲器改裝在換熱器的尾部上。

　　2. Nickel based brazed heat pipe heat exchanger: installed at the upper outer end of the existing generator set, as close as possible to the engine exhaust port, with the muffler modified at the rear of the heat exchanger.

　　3、排氣口到換熱器、消聲器管線采取保溫措施，保溫材料選用厚100mm硅酸鋁，用鋼絲捆扎，外包鍍鋅鐵皮，用鉚釘固緊。

　　3. Insulation measures shall be taken for the pipeline from the exhaust port to the heat exchanger and muffler. The insulation material shall be 100mm thick aluminum silicate, tied with steel wire, wrapped with galvanized iron sheet, and fastened with rivets.

　　4、給水和蒸汽輸送管線采用架空鋪設或埋地鋪設，首先在管線表面涂刷防銹漆兩道，然后采用60mm巖棉管包扎保溫，用鋼絲捆扎，外包油氈玻璃絲布防雨層，最外層刷綠色面漆，并用紅箭頭標示水流方向。5、系統安裝完畢后，進行管線沖洗和水壓試驗，試驗壓力1.5MPa，沖洗試壓后方可開泵試運行。

　　4. The water supply and steam transmission pipelines are laid overhead or underground. First, two layers of anti rust paint are applied to the surface of the pipeline. Then, 60mm rock wool pipes are wrapped for insulation, tied with steel wire, and covered with oil felt glass wool cloth for rain protection. The outermost layer is painted with green topcoat and marked with red arrows indicating the direction of water flow. 5. After the system installation is completed, pipeline flushing and water pressure testing shall be carried out with a test pressure of 1.5MPa. The pump can only be started for trial operation after flushing and pressure testing.

　　七、經濟效益綜合分析及報價鎳基釬焊熱管式余熱回收裝置蒸汽型——汽水分離器和設備合為一體每套報價：——萬元.，10套合計價格為：——萬元

　　7、 Comprehensive analysis and quotation of economic benefits: Nickel based brazed heat pipe type waste heat recovery device, steam type - steam water separator and equipment integrated, with a quotation of 10000 yuan per set The total price for 10 sets is: -10000 yuan

　　1、設備型號及參數型號：——設計壓力：1.0MPa;換熱面積：當量面積——m2；實際換熱面積——m2；適合發電機實際輸出功率：500kw機組；

　　1. Equipment model and parameter model: - Design pressure: 1.0MPa; Heat exchange area: equivalent area - m2; actual heat exchange area - m2; suitable for generator actual output power: 500kW unit;

　　2、供貨范圍設備主體包括保溫，主要受壓元件采用鍋爐管制造；配套閥門儀表：安全閥、蒸汽出口閥、排污閥、放空閥、壓力表、壓力表彎、針形閥、給水閥、水位控制器、雙色水位計；配對法蘭：余熱回收裝置與煙道連接的DN250法蘭2片；耐高溫三通閥：耐溫1000℃，耐熱不銹鋼內膽，型號DN250帶配對法蘭；全自動控制柜；換熱器給水泵；3、經濟效益按每臺發電機每年正常運行300天，每噸蒸汽的價值為60元計算，10臺發電機每年余熱回收所產生的價值為：60×24×300×4.246≈183.4萬元4、投資回收期：設備投資：——萬元；X÷183.4×12≈Y（個月）綜合上述可知，10臺發電機機組余熱回收系統成本可在Y個月內收回，本系統運行期按5年計算，可節約資金——萬元。

　　2. The supply scope of the equipment includes insulation, and the main pressure components are manufactured using boiler tubes; Supporting valve instruments: safety valve, steam outlet valve, drain valve, vent valve, pressure gauge, pressure gauge bend, needle valve, water supply valve, water level controller, dual color water level gauge; Paired flange: Two DN250 flanges connecting the waste heat recovery device to the flue; High temperature resistant three-way valve: resistant to 1000 ℃, heat-resistant stainless steel inner liner, model DN250 with matching flange; Fully automatic control cabinet; Heat exchanger feedwater pump; 3. The economic benefits are calculated based on the normal operation of each generator for 300 days per year, with a value of 60 yuan per ton of steam. The value generated by the waste heat recovery of 10 generators per year is approximately 1.834 million yuan. 4. Investment payback period: Equipment investment: -10000 yuan; X ÷ 183.4 × 12 ≈ Y (months) Based on the above, it can be concluded that the cost of the waste heat recovery system for 10 generator units can be recovered within Y months. The operating period of this system is calculated as 5 years, which can save funds of -10000 yuan.

　　八、熱管式余熱回收裝置與針管式余熱回收裝置性能比較具有以下優點：1、設備投資省因為針管式不能采用氣包和換熱器連為一體的結構，需要單獨的汽水分離器，同時需要熱水循環泵兩臺，設備造價相比較要高出10%左右；2、運行費用低因為針管式余熱回收裝置要產蒸汽需采用強制循環，這樣僅熱水循環泵的運行費用一項，按循環泵揚程50米，流量50立方米，電機功率20千瓦計算，每年耗電量為15萬千瓦時，折合人民幣7.5萬元。3、換熱效果好同樣面積的兩種換熱器，熱管的換熱效果明顯優于針管，吸收熱量相對要多一些，如同樣60平方米的換熱器，同樣產0.6MPa飽和蒸汽，熱管換熱器煙氣出口溫度比針管的低15℃。

　　8、 The performance comparison between the heat pipe type waste heat recovery device and the needle tube type waste heat recovery device has the following advantages: 1. Low equipment investment. Because the needle tube type cannot adopt a structure that combines an air bag and a heat exchanger, a separate steam water separator is required, and two hot water circulation pumps are needed. The equipment cost is about 10% higher compared to others; 2. The operating cost is low because the needle tube waste heat recovery device requires forced circulation to produce steam, which only includes the operating cost of the hot water circulation pump. Calculated based on the pump head of 50 meters, flow rate of 50 cubic meters, and motor power of 20 kilowatts, the annual power consumption is 150000 kilowatt hours, equivalent to 75000 yuan. 3. Two types of heat exchangers with the same area have better heat transfer effects. The heat transfer effect of the heat pipe is significantly better than that of the needle pipe, and it absorbs relatively more heat. For example, a 60 square meter heat exchanger produces 0.6MPa saturated steam, and the exhaust gas outlet temperature of the heat pipe heat exchanger is 15 ℃ lower than that of the needle pipe.

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