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    世界首台700 MW超超临界CFB锅炉启动调试与运行优化

    Commissioning and operational optimization of the world’s first 700 MW ultra-supercritical CFB boiler

    • 摘要: 为应对锅炉容量与参数跃升后的燃烧稳定性、水动力安全及宽负荷调峰挑战,验证世界首台700 MW超超临界循环流化床锅炉技术方案的可行性,针对云南能投红河电厂700 MW超超临界CFB锅炉,对锅炉启动调试与运行优化全过程进行了系统阐述。该锅炉采用M形单炉膛、单布风板、无外置床设计,炉膛截面积575 m2,主蒸汽参数29.3 MPa/605 ℃、再热蒸汽温度623 ℃,燃用高水分褐煤。在布风板阻力与冷态流化特性试验基础上确定了最小流化风量,并优化点火方案使床温升至600 ℃时间缩短2 h。从燃烧、汽水、控制及辅助系统实施了优化调试:标定风量使一次风量偏差±3%;调整播煤风与二次风配风使床温偏差≤30 ℃;优化氧量场使高负荷下氧量偏差±0.3%;制定负荷–床压定值曲线,结合连续与间歇排渣控制床压波动±0.5 kPa;采用前馈+反馈复合控制,使水冷壁壁温偏差≤30 ℃、高温过热器出口壁温≤620 ℃、再热汽温波动±3 ℃;整定风机变频器参数使一次风机电流波动≤8 A、二次风机≤5 A;采用模型预测控制优化床温、床压调节,实现SCR/SNCR与燃烧系统协同控制,使NO排放质量浓度波动±5 mg/Nm3,负荷变化率3 %/min,关键参数自动投入率100%;优化吹灰策略与脱硫系统,使排烟温度稳定在132~136 ℃、脱硫效率不低于99.7%。结果表明:调试后锅炉热效率超93.5%,供电煤耗低于282 g/kWh,均优于设计指标,一次性完成168 h满负荷试运行,平均负荷率99.4%,SO2、NO及粉尘排放满足超低排放要求。验证了700 MW超超临界循环流化床锅炉在无外置床设计、大炉膛均匀流化、高海拔褐煤高效燃烧及超低排放方面的可行性与先进性,为后续超超临界CFB锅炉的设计建设提供了工程参考。

       

      Abstract: To address the challenges of combustion stability, hydrodynamic safety and wide-load peak-load regulation following the significant increase in boiler capacity and parameters, and to verify the feasibility of the technical solution for the world's first 700 MW ultra-supercritical circulating fluidised bed (CFB) boiler, a systematic account is provided of the entire process of start-up, commissioning and operational optimisation for the 700 MW ultra-supercritical CFB boiler at Yunnan Energy Investment’s Honghe Power Station. The boiler employs an M-shaped single furnace chamber design with a single air distribution plate and no external bed, featuring a furnace cross-sectional area of 575 m2. The main steam parameters are 29.3 MPa/605 ℃, with a reheat steam temperature of 623 ℃, and it burns high-moisture lignite. Based on tests of air distribution plate resistance and cold-state fluidisation characteristics, the minimum fluidisation air flow rate was determined, and the ignition procedure was optimised to reduce the time required to raise the bed temperature to 600 ℃ by 2 hours. Optimisation and commissioning were carried out across the combustion, steam-water, control and auxiliary systems: air flow rates were calibrated to ensure a primary air flow deviation of ±3%; the distribution of coal-feeding air and secondary air was adjusted to ensure a bed temperature deviation of ≤30 ℃; the oxygen concentration field was optimised to ensure an oxygen concentration deviation of ±0.3% at high loads; a load-bed pressure setpoint curve was established, and bed pressure fluctuations were maintained at ±0.5 kPa through a combination of continuous and intermittent ash discharge control; a feedforward-feedback composite control strategy was adopted to ensure a water-cooled wall temperature deviation of ≤30 ℃, a high-temperature superheater outlet wall temperature of ≤620 ℃, and a reheat steam temperature fluctuation of ±3 ℃; Adjust the parameters of the fan variable-frequency drives to ensure that current fluctuations in the primary fan are≤8 A and in the secondary fan ≤5 A; employ model predictive control to optimise bed temperature and bed pressure regulation, achieving coordinated control of the SCR/SNCR and combustion systems, resulting in NOx emission concentration fluctuations of ±5 mg/Nm3, a load change rate of 3 %/min, and a 100% automatic engagement rate for key parameters; optimise soot-blowing strategies and the desulphurisation system to stabilise flue gas temperature at 132−136 ℃ and ensure desulphurisation efficiency of no less than 99.7%. The results show that, following commissioning, the boiler’s thermal efficiency exceeded 93.5% and the coal consumption for power generation was below 282 g/kWh, both of which surpassed the design targets. A 168-hour full-load trial operation was successfully completed in a single attempt, with an average load factor of 99.4%, while SO2, NOx and dust emissions met ultra-low emission requirements. The feasibility and advanced nature of the 700 MW ultra-supercritical CFB boiler were thereby validated regarding its external-bed-free design, uniform fluidization in large furnaces, efficient high-altitude lignite combustion, and ultra-low emissions, providing a critical engineering reference for subsequent ultra-supercritical CFB boiler designs.

       

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