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造纸机废液余能回收双击式水轮机设计及能量转换特性研究

Research on the design and energy conversion characteristics of crossflow turbine for residual energy recovery from the waste liquid of the papermaking machine

  • 摘要: 新月型造纸机因其高效、节能而得到广泛应用,但造纸完成后的纸浆废液会以高速喷向吸水箱护板,对护板产生巨大的机械冲击和损坏,同时造成纸浆废液中携带的动能的浪费。因此本文以某造纸机为研究对象,提出采用双击式水轮机对纸浆废液中携带的余压能量回收。通过对两种不同转轮方案的双击式水轮机进行多个转速的数值研究,以揭示导流板形式及转轮转速对双击式水轮机内部流动及能量转换的影响规律。分析结果表明:方案Ⅰ(导流板1集中并引导水流冲击转轮左侧,导流板2避免流出转轮的水流飞溅到成型辊影响纸质)时,导流板对纸浆废液的约束作用较小,使得导流板与成型辊之间区域以及转轮第一次做功区域均产生较大的湍动能,引起能量耗散并产生较大的水力损失,同时沿圆周方向水流做功分布分散,两次做功时环量消耗能力相当,且沿圆周方向出现了多个区域的环量突变。方案Ⅱ(通过双导流板型式约束水流的流动方向,水流冲击转轮右侧)能够很好的引导水流流向转轮,高湍动能区域明显减小,因此转轮的水力损失较小,有助于双击式水轮机能量特性的提高,且转轮做功区域相对集中,约85%环量在330°~30°的第一次冲击做功区域实现了转化。随着转轮转速的增大,双击式水轮机二次做功区域逐渐向一次做功区域靠近,尤其是大转速情况下两次做功的水流相互掺杂干扰,引起较大水力损失。不同方案的双击式水轮机效率均能随着转速的增加而出现极大值,方案Ⅰ转轮在250 r/min时效率最高为39.2%。方案Ⅱ转轮在300 r/min时效率最高为56.4%。因此,采用方案Ⅱ设计的方案水力效率更优。本文所得研究结果对造纸工业的绿色发展以及高效利用具有重要的参考意义。

     

    Abstract: A crescent-shaped papermaking machine has been widely applied in recent years, due to its high efficiency and energy conservation. However, the pulp waste liquid can be sprayed towards the guard plate of the water absorption box at high speed after paper production. Huge mechanical impact and damage to the guard plate can also result in the waste of the kinetic energy carried by the pulp waste liquid. Therefore, this article aims to recover and utilize the residual pressure energy carried by the pulp waste liquid through a crossflow turbine. Numerical studies were also performed on two schemes of crossflow turbines at multiple rotational speeds(Scheme I featured a single deflector guiding flow to impact the left side of the runner (inducing counter-clockwise rotation), with an additional deflector near the forming roller to prevent water splash affecting study quality. Scheme II was utilized as a dual-deflector system to direct flow onto the right side of the runner (clockwise rotation), steering effluent away from the forming roller. A systematic investigation was made to explore the influence of the deflector form and the rotational speed of the runner on the internal flow and energy conversion of the double-impulse turbine. The results indicate that in Scheme I: The deflector exhibited the weak constraint effect on the pulp waste liquid, while both the area between the deflector and forming roller and the first work phase zone of the runner generated the high turbulent kinetic energy, leading to the energy dissipation and significant hydraulic losses. There was a dispersion of the water flow along the circumferential direction, particularly with the comparable circulation consumption capacity in the two work phases. Multiple circulation abrupt peaks occurred circumferentially, due to the uneven energy transfer. The scheme II with the double deflectors well guided the water flow to the runner, significantly reducing the high turbulent kinetic energy area, and the Hydraulic loss of the runner. The energy of the crossflow turbine was improved to relatively concentrate the working area of the runner, where about 85% of the circulation was transformed in the first impact working area from 330° to 30°. The second working area of the crossflow turbine gradually approached the first working area with the increase of the runner rotational speed. Especially in the case of high rotational speed, the water flow of the two working times was mixed and interfered with each other, leading to large hydraulic losses. The maximum efficiency of the crossflow turbines was reached under the different schemes with the increase of the rotational speed. In Scheme I, there was the highest efficiency of 39.2% at 250 r/min. In Scheme II, the highest efficiency of 56.4% was found at 300r/min. As such, Scheme II's dual-deflector guided the flow to impact the runner's right side for the clockwise rotation. An optimal speed of 300 r/min was represented as a highly effective solution to recover the residual energy from the paper machine. Therefore, Scheme II demonstrated the superior hydraulic efficiency. The finding can also provide a strong reference to optimize the energy recovery turbine for papermaking machines.

     

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