浙江中控太(tai)陽能(neng)技(ji)術(shu)有(you)限公司基于(yu)其德令哈10MW以及(ji)(ji)50MW塔式電站的(de)運行(xing)經驗,對熔鹽(yan)塔式太(tai)陽能(neng)熱(re)發電站中相關儀表選型及(ji)(ji)注意(yi)事(shi)項等進行(xing)了分析。
壓力表用于測(ce)(ce)量(liang)和指示(shi)工業(ye)系統(tong)環境壓力的儀(yi)表,應用非常普遍(bian)。在太陽能光熱電站(zhan)熔(rong)鹽(yan)(yan)(yan)(yan)系統(tong)中,壓力表同樣是不可或缺的重要測(ce)(ce)量(liang)設備之一,其主要功能為檢測(ce)(ce)熔(rong)鹽(yan)(yan)(yan)(yan)管路、部(bu)分熔(rong)鹽(yan)(yan)(yan)(yan)儲罐壓力。與流(liu)量(liang)計相同,熔(rong)鹽(yan)(yan)(yan)(yan)的高(gao)溫(wen)和凝固特(te)性(xing)導致常規性(xing)儀(yi)表不能夠滿足熔(rong)鹽(yan)(yan)(yan)(yan)工況對儀(yi)表的特(te)殊(shu)(shu)需(xu)求。熔(rong)鹽(yan)(yan)(yan)(yan)壓力表選(xuan)型和結構設計也(ye)需(xu)特(te)殊(shu)(shu)考慮。
隔(ge)(ge)(ge)膜式(shi)壓力表(biao)通過壓力表(biao)隔(ge)(ge)(ge)膜將工作介(jie)質(zhi)(zhi)和(he)導(dao)壓介(jie)質(zhi)(zhi)隔(ge)(ge)(ge)離,其原(yuan)理上較適用(yong)(yong)于(yu)工況(kuang)較為(wei)苛刻的(de)腐(fu)蝕性介(jie)質(zhi)(zhi)中(zhong),該類壓力表(biao)可(ke)以考(kao)慮用(yong)(yong)于(yu)高(gao)溫(wen)(wen)熔鹽(yan)系統中(zhong),隔(ge)(ge)(ge)膜材料可(ke)選用(yong)(yong)鉭等耐(nai)高(gao)溫(wen)(wen)耐(nai)腐(fu)蝕金屬材料。中(zhong)間導(dao)壓介(jie)質(zhi)(zhi)通常使用(yong)(yong)硅(gui)油(you),但高(gao)溫(wen)(wen)工況(kuang)下即便是專門耐(nai)熱(re)的(de)高(gao)溫(wen)(wen)硅(gui)油(you)也難以承(cheng)受565℃的(de)高(gao)溫(wen)(wen)(國內高(gao)溫(wen)(wen)硅(gui)油(you)最(zui)高(gao)耐(nai)受溫(wen)(wen)度在(zai)350℃左(zuo)右(you),國外高(gao)溫(wen)(wen)硅(gui)油(you)最(zui)高(gao)耐(nai)受溫(wen)(wen)度在(zai)400℃左(zuo)右(you))。從這(zhe)點可(ke)以看出,隔(ge)(ge)(ge)膜式(shi)壓力表(biao)導(dao)壓介(jie)質(zhi)(zhi)的(de)耐(nai)溫(wen)(wen)能力是該種儀表(biao)能否使用(yong)(yong)的(de)最(zui)為(wei)關鍵因素。
1、鈉鉀合金介質
鈉鉀(jia)(jia)(jia)合(he)(he)金(jin)(jin)是(shi)鈉(Na)和(he)鉀(jia)(jia)(jia)(K)的合(he)(he)金(jin)(jin),其(qi)常(chang)溫(wen)狀態下(xia)為液體,不同配比情況下(xia)其(qi)熔點和(he)沸點均不相(xiang)同。熔點最(zui)低的鈉鉀(jia)(jia)(jia)合(he)(he)金(jin)(jin)鉀(jia)(jia)(jia)含(han)量為78%,鈉含(han)量為22%,該(gai)鈉鉀(jia)(jia)(jia)合(he)(he)金(jin)(jin)熔點為-12.6℃,沸點為785℃,過(guo)去其(qi)主要(yao)作用(yong)是(shi)冷卻劑、催化劑和(he)干(gan)燥(zao)劑。
鈉鉀合金-12.6~785℃的(de)液態溫(wen)度范圍作為熔(rong)(rong)鹽工(gong)(gong)況下(xia)新型隔膜式壓力表的(de)導壓介質是非常合適(shi)的(de),其溫(wen)度區間完全(quan)囊括了熔(rong)(rong)鹽工(gong)(gong)藝(yi)溫(wen)度范圍。-12.6℃的(de)熔(rong)(rong)點溫(wen)度不僅適(shi)用于(yu)正常廠房的(de)環境溫(wen)度,即(ji)便是在(zai)環境溫(wen)度極低(最低溫(wen)度可(ke)達(da)到-30℃以下(xia))的(de)高海拔區域,也可(ke)以通過安(an)裝在(zai)管路和設(she)備上(shang)的(de)電加(jia)熱設(she)備進(jin)行加(jia)熱升溫(wen),短時間內(nei)融化并達(da)到正常工(gong)(gong)作狀態。
一般(ban)來說(shuo),隔膜(mo)(mo)式壓(ya)(ya)力表是(shi)以法蘭形(xing)式安裝于管道上的(de),這種凹陷結(jie)構(gou)不但可能成為熔鹽(yan)系統(tong)泄漏隱(yin)患,還有可能使膈膜(mo)(mo)和介質(zhi)接觸的(de)地方(fang)發生熔鹽(yan)掛壁堵(du)塞,導致(zhi)儀表失效。為了避(bi)免(mian)發生這種情況,需對壓(ya)(ya)力表專門設(she)計帶可插入擴散膜(mo)(mo)片(pian)的(de)法蘭式膈膜(mo)(mo)密封(feng)方(fang)式。具(ju)體構(gou)造如圖1所示,其中,1—壓(ya)(ya)力表本體,2—散熱(re)結(jie)構(gou),3—法蘭結(jie)構(gou),4—管道,5—擴散膜(mo)(mo)片(pian)結(jie)構(gou)膜(mo)(mo)盒,6—NaK合金介質(zhi)。
圖1:可插入擴散(san)膜(mo)片的法(fa)蘭式NaK隔膜(mo)式壓力表
這種開放(fang)式突出的(de)膜片(pian)可以保證即便是有熔鹽(yan)(yan)能凝結在膜片(pian)上,也能及(ji)時在熔鹽(yan)(yan)沖(chong)刷(shua)下短時間內(nei)融化附著在表面的(de)熔鹽(yan)(yan)。
然而,鈉(na)鉀(jia)合金(jin)還有很強的(de)(de)還原性,介質一旦遇(yu)到(dao)空(kong)氣和水會迅(xun)速發(fa)生(sheng)燃燒甚(shen)至爆炸(zha)。在工業系統中,任何(he)存在安全隱患的(de)(de)設備都需要進行嚴(yan)格(ge)的(de)(de)安全認證和日常檢查的(de)(de)。鈉(na)鉀(jia)合金(jin)本身就存在燃燒甚(shen)至爆炸(zha)的(de)(de)可能,一旦儀(yi)表內部發(fa)生(sheng)泄漏就會發(fa)生(sheng)嚴(yan)重事故(gu),何(he)況熔鹽高溫下本身就有強氧化性。
2、低溫熔鹽
低(di)(di)溫熔(rong)鹽(yan)介(jie)質(zhi)作為導壓介(jie)質(zhi)的(de)方案也理論上(shang)存在(zai)于高(gao)溫壓力表的(de)研(yan)(yan)究中。其低(di)(di)熔(rong)點和(he)高(gao)沸點特性(xing)的(de)優越性(xing)僅(jin)次于NaK合金(jin)介(jie)質(zhi),并且(qie)暴露(lu)于外界(jie)不會發(fa)生化(hua)學反應,安(an)全性(xing)遠高(gao)于NaK合金(jin)介(jie)質(zhi)。現今業(ye)界(jie)當中,北(bei)京工(gong)業(ye)大學所(suo)研(yan)(yan)發(fa)的(de)低(di)(di)熔(rong)點混合熔(rong)鹽(yan)介(jie)質(zhi)熔(rong)點為83.7℃,沸點可達到(dao)592.9℃。
低溫熔(rong)(rong)(rong)鹽(yan)(yan)(yan)導壓介(jie)質(zhi)壓力(li)(li)表與鈉(na)鉀合金介(jie)質(zhi)隔膜式(shi)壓力(li)(li)表總體(ti)上結構設(she)計基(ji)本相同,從(cong)功能(neng)上來說可以做到正常運行(xing),但在實際工況中(zhong)使用(yong)還是稍顯不足(zu)。熔(rong)(rong)(rong)鹽(yan)(yan)(yan)由(you)于(yu)(yu)膨脹量較(jiao)大,當系(xi)統長(chang)期停運時(shi),膜盒中(zhong)填充(chong)(chong)的(de)(de)低溫熔(rong)(rong)(rong)鹽(yan)(yan)(yan)介(jie)質(zhi)會自然凍(dong)結,膜盒填充(chong)(chong)液密封區域(yu)耐(nai)膨脹能(neng)力(li)(li)不足(zu),膨脹的(de)(de)熔(rong)(rong)(rong)鹽(yan)(yan)(yan)極可能(neng)毀壞膜盒。另外,系(xi)統系(xi)統啟(qi)動(dong)時(shi)將對膜盒內凝固的(de)(de)熔(rong)(rong)(rong)鹽(yan)(yan)(yan)進行(xing)融化,熔(rong)(rong)(rong)點83.7℃的(de)(de)熔(rong)(rong)(rong)鹽(yan)(yan)(yan)也需要長(chang)時(shi)間(jian)熔(rong)(rong)(rong)化過程(cheng)。由(you)于(yu)(yu)熔(rong)(rong)(rong)鹽(yan)(yan)(yan)介(jie)質(zhi)的(de)(de)特殊性,現該種壓力(li)(li)表實驗(yan)項(xiang)目中(zhong)使用(yong)較(jiao)少,產(chan)品尚(shang)欠成熟開發。
3、結構改造
改造結(jie)(jie)構通(tong)過儀(yi)表(biao)(biao)(biao)(biao)結(jie)(jie)構上進行(xing)優化,保(bao)(bao)(bao)證儀(yi)表(biao)(biao)(biao)(biao)正(zheng)常工(gong)作(zuo)。該(gai)結(jie)(jie)構采用延(yan)(yan)(yan)(yan)長管(guan)(guan)降(jiang)溫(wen)(wen)的(de)(de)辦法,熔(rong)(rong)(rong)(rong)鹽介(jie)質(zhi)從流動管(guan)(guan)道中(zhong)進入(ru)延(yan)(yan)(yan)(yan)長管(guan)(guan)并(bing)通(tong)過延(yan)(yan)(yan)(yan)長管(guan)(guan)散熱(re),在到(dao)達儀(yi)表(biao)(biao)(biao)(biao)膈(ge)膜(mo)前使熔(rong)(rong)(rong)(rong)鹽溫(wen)(wen)度(du)降(jiang)到(dao)壓(ya)力(li)表(biao)(biao)(biao)(biao)高溫(wen)(wen)硅(gui)油安全(quan)工(gong)作(zuo)溫(wen)(wen)度(du)以下。然而(er),壓(ya)力(li)表(biao)(biao)(biao)(biao)僅考慮延(yan)(yan)(yan)(yan)長管(guan)(guan)降(jiang)溫(wen)(wen)是不夠的(de)(de),復雜的(de)(de)工(gong)況和外部(bu)環境很可能導致降(jiang)溫(wen)(wen)過快,溫(wen)(wen)度(du)低的(de)(de)熔(rong)(rong)(rong)(rong)鹽易凝固在延(yan)(yan)(yan)(yan)長管(guan)(guan)中(zhong)。針對可能的(de)(de)熔(rong)(rong)(rong)(rong)鹽凝固問(wen)題,對延(yan)(yan)(yan)(yan)長裝置(zhi)(zhi)配置(zhi)(zhi)了保(bao)(bao)(bao)溫(wen)(wen)層、熱(re)電偶以及電伴熱(re)設備(bei)(bei),實現對壓(ya)力(li)表(biao)(biao)(biao)(biao)溫(wen)(wen)度(du)進行(xing)準確控制(zhi)(zhi),保(bao)(bao)(bao)證壓(ya)力(li)表(biao)(biao)(biao)(biao)法蘭(lan)膈(ge)膜(mo)處介(jie)質(zhi)溫(wen)(wen)度(du)控制(zhi)(zhi)在導壓(ya)介(jie)質(zhi)高溫(wen)(wen)硅(gui)油耐受溫(wen)(wen)度(du)范圍內,且不產生(sheng)熔(rong)(rong)(rong)(rong)鹽凝固問(wen)題。設備(bei)(bei)結(jie)(jie)構如圖2所示,其中(zhong),1—壓(ya)力(li)表(biao)(biao)(biao)(biao)本體,2—散熱(re)結(jie)(jie)構,3—法蘭(lan)結(jie)(jie)構,4—保(bao)(bao)(bao)溫(wen)(wen)層,5—保(bao)(bao)(bao)溫(wen)(wen)套(tao)管(guan)(guan)(電伴熱(re)),6—延(yan)(yan)(yan)(yan)長管(guan)(guan),7—管(guan)(guan)道:
圖2:帶延(yan)長管結構的(de)隔(ge)膜式壓(ya)力表(biao)
改造(zao)儀表(biao)通過(guo)延長(chang)(chang)管進(jin)行介質降溫(wen),通過(guo)加熱裝置(zhi)以及(ji)控溫(wen)裝置(zhi)進(jin)行嚴格溫(wen)度控制,原理簡單(dan)、易于操作且成本相對較低。現今這種配置(zhi)延長(chang)(chang)結(jie)構壓力表(biao)已運用到多數實際(ji)光熱電(dian)站項目當中。
綜(zong)合研究(jiu)結果表(biao)(biao)明,現(xian)階段熔(rong)鹽壓力表(biao)(biao)最為成熟的(de)選型和(he)結構設計形式如下:可(ke)以采用配置延長結構和(he)溫(wen)控功能(neng)的(de)壓力表(biao)(biao),既保(bao)證使用中壓力表(biao)(biao)導壓介質(zhi)不(bu)會超溫(wen)揮(hui)發,也確保(bao)與(yu)膈膜接觸處的(de)熔(rong)鹽不(bu)會低溫(wen)凍結。NaK介質(zhi)或其(qi)他導壓介質(zhi)壓力表(biao)(biao)雖然原理上(shang)可(ke)行,但實際可(ke)靠性尚待驗(yan)證。