隨著我國(guó)經(jīng)濟(jì)的快速發(fā)展，人口的增長(zhǎng)和城市化進(jìn)程的加快，城市生活垃圾產(chǎn)量也在急劇增加；同時(shí)，生活垃圾的無(wú)害化處理也得到了相應(yīng)的發(fā)展，形成了以焚燒發(fā)電為主的處理方式。隨著技術(shù)的不斷發(fā)展和行業(yè)變化，我國(guó)生活垃圾焚燒處理裝備向著大型化、高參數(shù)的方向邁進(jìn)，同時(shí)，對(duì)焚燒系統(tǒng)的高效、低碳、穩(wěn)定運(yùn)行提出了更高的要求。
我國(guó)自1987年開(kāi)始從國(guó)外引進(jìn)垃圾發(fā)電技術(shù)，深圳市首s次新建的垃圾發(fā)電廠開(kāi)始營(yíng)業(yè)，自此，國(guó)內(nèi)的垃圾焚燒發(fā)電技術(shù)后來(lái)居上，邁上了快車道。特別是近年來(lái)，隨著我國(guó)“碳達(dá)峰-碳中和”戰(zhàn)略目標(biāo)的提出，垃圾焚燒發(fā)電技術(shù)發(fā)展迅猛。垃圾焚燒發(fā)電裝機(jī)容量由2016年的549萬(wàn)千瓦增至2021年的1729萬(wàn)千瓦，目前垃圾電站的裝機(jī)容量和垃圾年處理量均列世界第d一。包括水冷壁、過(guò)熱器、再熱器、省煤器在內(nèi)的鍋爐四管是鍋爐組件中重要的熱量交換部件。由于城市生活垃圾中的氯、硫、堿金屬等是不可能消除的成分，因此在垃圾焚燒過(guò)程中，鍋爐四管金屬受熱面受到嚴(yán)重的高溫腐蝕難以避免。隨著垃圾焚燒爐中蒸汽參數(shù)逐漸提高，對(duì)于鍋爐受熱面防腐的要求也愈加嚴(yán)格。
當(dāng)管壁金屬或涂層由于腐蝕脫落或使管壁減薄到一定程度時(shí)，管內(nèi)的高壓水汽會(huì)沖出即出現(xiàn)高壓泄漏甚至爆管，迫使鍋爐非計(jì)劃停機(jī)維護(hù)，不僅會(huì)造成嚴(yán)重的安全隱患，也會(huì)對(duì)發(fā)電效率以及垃圾發(fā)電經(jīng)濟(jì)性都會(huì)造成極大影響。因此，一直以來(lái)垃圾鍋爐的高溫腐蝕防護(hù)問(wèn)題，成為阻礙垃圾發(fā)電行業(yè)發(fā)展的瓶頸，嚴(yán)重制約了我國(guó)垃圾處理環(huán)保產(chǎn)業(yè)的快速發(fā)展，也是擺在我國(guó)垃圾焚燒發(fā)電領(lǐng)域科技人員面前亟待解決的問(wèn)題。多年來(lái)，我國(guó)該領(lǐng)域的科技人員為此做出了艱苦的努力，取得了不少研究成果。本書是在吸收了近年來(lái)國(guó)內(nèi)外垃圾發(fā)電高溫防腐領(lǐng)域研究的基礎(chǔ)上，重點(diǎn)對(duì)作者多年來(lái)的研究成果進(jìn)行了闡述，旨在為相關(guān)科技人員開(kāi)發(fā)鍋爐高溫防腐新技術(shù)提供基礎(chǔ)。
本書共分七章，內(nèi)容主要包括垃圾電站鍋爐高溫腐蝕現(xiàn)狀與理論、垃圾電站鍋爐防腐技術(shù)與發(fā)展、垃圾電站鍋爐合金涂層的材料體系及特性、垃圾電站鍋爐合金涂層的高溫腐蝕特性、垃圾電站鍋爐重熔涂層技術(shù)、垃圾焚燒鍋爐的防腐優(yōu)化設(shè)計(jì)及應(yīng)用等。
龍吉生，男，1966年生于江西省吉安市吉水縣，1988年政府公派日本留學(xué)并于1994年獲工學(xué)博士學(xué)位。在日本技術(shù)開(kāi)發(fā)株式會(huì)社工作15年后，于2008年底回國(guó)創(chuàng)業(yè)，創(chuàng)立了上�？岛悱h(huán)境股份有限公司。現(xiàn)任上�？岛悱h(huán)境股份有限公司董事長(zhǎng)兼首席科學(xué)家，日本福岡大學(xué)客座教授，國(guó)務(wù)院政府特殊津貼獲得者，國(guó)家重點(diǎn)研發(fā)計(jì)劃首席科學(xué)家。是上海市領(lǐng)軍人才，住建部科技委城市環(huán)境衛(wèi)生專委會(huì)委員，國(guó)家發(fā)展改革委PPP專家，住建部可持續(xù)發(fā)展與資環(huán)專委會(huì)委員，住建部可持續(xù)發(fā)展與資源環(huán)境專家委員會(huì)委員。從事固廢處理技術(shù)研發(fā)和應(yīng)用近30年，在日期間主持了日本巖手、新瀉、宮崎等多個(gè)垃圾焚燒項(xiàng)目，回國(guó)后主持開(kāi)發(fā)了新一代爐排爐焚燒技術(shù)，該技術(shù)與裝備在國(guó)內(nèi)占據(jù)超過(guò)1/3的市場(chǎng)份額。帶領(lǐng)康恒環(huán)境在全國(guó)已投資建設(shè)約70余座垃圾焚燒發(fā)電項(xiàng)目，處理垃圾規(guī)模約10萬(wàn)噸/日。曾獲國(guó)家科學(xué)技術(shù)進(jìn)步二等獎(jiǎng)（公司）1項(xiàng)（2013）、教j育y部科學(xué)技術(shù)進(jìn)步獎(jiǎng)一等獎(jiǎng)1項(xiàng)（2012）、華夏建設(shè)科學(xué)技術(shù)獎(jiǎng)一、二等獎(jiǎng)各1項(xiàng)（2011、2020），曾獲日中科學(xué)技術(shù)交流協(xié)會(huì)“天田科學(xué)技術(shù)研究獎(jiǎng)”（1991）和日本廢棄物技術(shù)咨詢顧問(wèn)協(xié)會(huì)“有功獎(jiǎng)”（2001）等。已發(fā)表學(xué)術(shù)論文40余篇，參編著作4部，授權(quán)專利96項(xiàng)，其中發(fā)明專利15項(xiàng)。參編《生活垃圾焚燒污染控制標(biāo)準(zhǔn)》（GB18485-2014）等標(biāo)準(zhǔn)規(guī)范6項(xiàng)。
序
前言
1 概述 ······························································································· 1
1.1 我國(guó)生活垃圾產(chǎn)生及處理現(xiàn)狀 ································································· 1
1.1.1 生活垃圾的產(chǎn)生及性質(zhì) ··································································· 1
1.1.2 生活垃圾的處理現(xiàn)狀 ······································································ 5
1.2 生活垃圾焚燒技術(shù)發(fā)展及難點(diǎn) ································································· 9
1.2.1 垃圾焚燒大型化及蒸汽高參數(shù)化發(fā)展 ················································· 9
1.2.2 鍋爐長(zhǎng)周期安全穩(wěn)定運(yùn)行的需求凸顯 ················································ 15
參考文獻(xiàn) ································································································· 19
2 垃圾焚燒鍋爐高溫腐蝕現(xiàn)狀與理論 ······················································· 21
2.1 背景及意義 ························································································ 21
2.1.1 垃圾焚燒鍋爐受熱面爆管現(xiàn)狀 ························································· 21
2.1.2 垃圾焚燒鍋爐的高溫腐蝕問(wèn)題 ························································· 24
2.1.3 垃圾焚燒鍋爐高溫防腐的迫切性 ······················································ 25
2.2 垃圾焚燒鍋爐高溫腐蝕類型 ·································································· 26
2.2.1 含氯氣體引起的腐蝕 ····································································· 26
2.2.2 固態(tài)堿金屬氯化物引起的腐蝕 ························································· 26
2.2.3 熔融態(tài)堿金屬氯化物引起的腐蝕 ······················································ 27
2.3 垃圾焚燒鍋爐高溫腐蝕產(chǎn)物 ·································································· 28
2.3.1 垃圾焚燒鍋爐管壁的腐蝕產(chǎn)物 ························································· 28
2.3.2 氯化腐蝕的基本過(guò)程 ····································································· 30
2.4 垃圾焚燒鍋爐高溫腐蝕機(jī)理 ·································································· 31 2.4.1 高溫腐蝕的規(guī)律 ···········································································31
2.4.2 高溫氯腐蝕微觀過(guò)程 ·····································································32
2.4.3 高溫腐蝕的影響因素 ·····································································33
2.5 高溫腐蝕速度規(guī)律 ··············································································· 36
2.5.1 腐蝕速度與管壁溫度間的關(guān)系 ·························································36
2.5.2 腐蝕速度的主要影響因素 ·······························································40
2.5.3 高溫腐蝕速率小結(jié) ········································································46
參考文獻(xiàn) ·································································································· 48
3 垃圾焚燒鍋爐防腐涂層技術(shù)與發(fā)展 ······················································ 50
3.1 垃圾焚燒鍋爐管基材 ············································································ 51
3.2 基于制備工藝的防腐涂層體系 ································································ 54
3.2.1 熱噴涂技術(shù) ·················································································55
3.2.2 堆焊技術(shù) ····················································································64
3.2.3 感應(yīng)熔焊技術(shù) ··············································································67
3.2.4 滲鋁涂層技術(shù) ··············································································70
3.2.5 納米陶瓷涂層技術(shù) ········································································72
3.2.6 激光熔覆涂層技術(shù) ········································································74
3.3 涂層材料體系設(shè)計(jì)及其協(xié)同發(fā)展 ····························································· 76
3.3.1 合金材料體系 ··············································································77
3.3.2 金屬陶瓷材料體系 ········································································77
3.3.3 涂層工藝與材料的協(xié)同發(fā)展 ····························································77
參考文獻(xiàn) ·································································································· 79
4 垃圾焚燒鍋爐防腐涂層的材料體系及特性 ············································· 85
4.1 高溫防腐合金 ····················································································· 85
4.1.1 鎳基高溫耐蝕合金 ········································································85
4.1.2 Ni
?
Cr 型耐蝕合金 ········································································88
4.1.3 Ni
?
Mo 型耐蝕合金 ······································································88
4.1.4 Ni
?
Cr
?
Mo 系耐蝕合金 ·································································89
4.2 Ni
?
Crx
?
Mo 系高溫耐蝕合金涂層 ·························································· 89
4.2.1 Ni
?
Crx
?
Mo 系高溫耐蝕合金涂層制備 ·············································89
4.2.2 Ni
?
Crx
?
Mo 系耐蝕合金涂層顯微硬度分析 ·······································91
4.2.3 Ni
?
Crx
?
Mo 系耐蝕合金涂層顯微組織分析 ·······································91
4.2.4 Ni
?
Crx
?
Mo 系高溫耐蝕合金涂層電化學(xué)測(cè)試分析 ······························98 4.3 Ni
?
Cr
?
Mox 系高溫耐蝕合金涂層 ·························································101
4.3.1 Ni
?
Cr
?
Mox 系高溫耐蝕合金涂層制備 ··········································· 101
4.3.2 Ni
?
Cr
?
Mox 系高溫耐蝕合金涂層組織 ··········································· 102
4.3.3 Ni
?
Cr
?
Mox 系高溫耐蝕合金浸泡腐蝕性能 ····································· 104
參考文獻(xiàn) ································································································ 114
5 垃圾焚燒鍋爐防腐涂層的高溫腐蝕特性 ··············································· 117
5.1 Ni
?
Cr
?
Mo 系合金涂層的高溫氯腐蝕特性 ·············································· 117
5.1.1 Ni
?
Cr
?
Mo 系合金涂層高溫腐蝕試驗(yàn)設(shè)計(jì) ······································· 117
5.1.2 高溫堿金屬氯化物熔鹽腐蝕實(shí)驗(yàn) ···················································· 118
5.1.3 TP347H 不銹鋼的高溫氯腐蝕 ······················································· 121
5.1.4 Ni
?
Cr
?
Mo 系鎳基合金的高溫氯腐蝕 ············································· 127
5.1.5 Ni
?
Cr
?
Mo 系鎳基合金涂層的高溫氯腐蝕 ······································· 132
5.1.6 Ni
?
Cr
?
Mo 系鎳基合金涂層的高溫腐蝕機(jī)理 ···································· 137
5.1.7 Ni
?
Cr
?
Mo 系合金涂層的高溫氯腐蝕特性總結(jié) ································· 140
5.2 高 Mo/W 系 Ni
?
Cr
?
Mo 合金涂層的高溫氯/硫腐蝕特性 ·····························141
5.2.1 高 Mo/W 系 Ni
?
Cr
?
Mo 合金涂層的制備 ········································ 141
5.2.2 高溫氯硫?qū)嶒?yàn)過(guò)程 ······································································ 142
5.2.3 TP347H 不銹鋼的高溫氯硫腐蝕 ····················································· 144
5.2.4 NiCr17Mo 合金涂層的高溫氯硫腐蝕特性 ········································· 150
5.2.5 NiCrMo10W 系合金涂層的高溫氯硫腐蝕特性 ··································· 156
5.2.6 高 Mo/W 系 Ni
?
Cr
?
Mo 合金涂層的高溫氯硫腐蝕機(jī)理 ······················· 162
5.2.7 高 Mo/W 系 Ni
?
Cr
?
Mo 合金涂層的高溫氯硫腐蝕特性總結(jié) ················· 166
參考文獻(xiàn) ································································································167
6 垃圾焚燒余熱鍋爐受熱面重熔涂層技術(shù)研究 ········································· 172
6.1 二次重熔技術(shù) ····················································································172
6.1.1 應(yīng)用背景 ···················································································· 172
6.1.2 國(guó)內(nèi)外研究現(xiàn)狀 ··········································································· 173
6.2 耐垃圾焚燒煙氣重熔涂層的制備工藝 ·····················································175
6.2.1 實(shí)驗(yàn)材料 ···················································································· 176
6.2.2 熱噴涂層的制備 ··········································································· 176
6.2.3 涂層的二次重熔 ··········································································· 177
6.3 重熔涂層的實(shí)驗(yàn)方法 ···········································································180
6.3.1 測(cè)試方法 ···················································································· 180 6.3.2 物相分析 ··················································································· 182
6.4 重熔涂層的顯微組織與元素分布 ··························································· 185
6.4.1 火焰噴涂 ··················································································· 185
6.4.2 火焰重熔 ··················································································· 187
6.4.3 激光重熔 ··················································································· 194
6.4.4 感應(yīng)重熔 ··················································································· 197
6.4.5 小結(jié) ························································································· 201
6.5 重熔涂層的顯微硬度 ·········································································· 202
6.5.1 火焰重熔層的顯微硬度 ································································· 202
6.5.2 激光重熔層的顯微硬度 ································································· 203
6.5.3 感應(yīng)重熔層的顯微硬度 ································································· 203
6.6 重熔涂層的高溫腐蝕特性 ···································································· 204
6.7 二次重熔工藝對(duì)比 ············································································· 210
6.8 感應(yīng)重熔涂層的工程應(yīng)用 ···································································· 212
參考文獻(xiàn) ································································································ 216
7 垃圾焚燒鍋爐的防腐優(yōu)化設(shè)計(jì)及應(yīng)用 ·················································· 219
7.1 高參數(shù)余熱鍋爐防腐設(shè)計(jì)現(xiàn)狀及趨勢(shì) ····················································· 219
7.1.1 主蒸汽參數(shù)對(duì)防腐設(shè)計(jì)的影響 ························································ 219
7.1.2 綜合經(jīng)濟(jì)效益分析 ······································································· 226
7.2 典型垃圾焚燒鍋爐防腐工程應(yīng)用案例及分析 ············································ 228
7.2.1 我國(guó)南部某垃圾焚燒發(fā)電項(xiàng)目 ························································ 228
7.2.2 我國(guó)北部某垃圾焚燒發(fā)電項(xiàng)目 ························································ 257
參考文獻(xiàn) ································································································ 273
后記 ································································································· 276
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