EP1475597B1 - Heating element for regenerative heat exchanger and process for manufacturing same - Google Patents

Heating element for regenerative heat exchanger and process for manufacturing same Download PDF

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Publication number
EP1475597B1
EP1475597B1 EP04010542A EP04010542A EP1475597B1 EP 1475597 B1 EP1475597 B1 EP 1475597B1 EP 04010542 A EP04010542 A EP 04010542A EP 04010542 A EP04010542 A EP 04010542A EP 1475597 B1 EP1475597 B1 EP 1475597B1
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EP
European Patent Office
Prior art keywords
heating element
base
enamel
stick
layer
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EP04010542A
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German (de)
French (fr)
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EP1475597A2 (en
EP1475597A3 (en
Inventor
Hermann MÜLLER-ODENWALD
Friedrich Dr. Weyland
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General Electric Technology GmbH
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Alstom Power Energy Recovery GmbH
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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D17/00—Regenerative heat-exchange apparatus in which a stationary intermediate heat-transfer medium or body is contacted successively by each heat-exchange medium, e.g. using granular particles
    • F28D17/02—Regenerative heat-exchange apparatus in which a stationary intermediate heat-transfer medium or body is contacted successively by each heat-exchange medium, e.g. using granular particles using rigid bodies, e.g. of porous material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D19/00—Regenerative heat-exchange apparatus in which the intermediate heat-transfer medium or body is moved successively into contact with each heat-exchange medium
    • F28D19/04—Regenerative heat-exchange apparatus in which the intermediate heat-transfer medium or body is moved successively into contact with each heat-exchange medium using rigid bodies, e.g. mounted on a movable carrier
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
    • F28F19/00—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers
    • F28F19/02—Preventing the formation of deposits or corrosion, e.g. by using filters or scrapers by using coatings, e.g. vitreous or enamel coatings

Definitions

  • the invention relates to a trained as a profiled sheet steel heating element for a regenerative heat exchanger.
  • heating elements are well known.
  • a plurality of heating elements form the storage mass of a regenerative heat exchanger.
  • the storage mass required for heat transfer or for heat exchange is subject to special operational requirements when used in corrosive and / or dust-containing gas streams. This applies, for example, to the storage mass of air preheaters on boiler systems (boilers) or gas preheaters on flue gas cleaning systems, where the temperature of the storage mass is at least locally and / or temporarily below the Rauchgastaulicas and in conjunction with flue dust and / or other flue gas ingredients (additives, means for flue gas cleaning) form deposits on the storage mass or the heating surfaces of the heating elements.
  • plastic storage masses are expensive and disadvantageous because they have a low heat capacity and heat conduction, can not be economically represented in optimal form for heat engineering and a relatively low mechanical strength, temperature and Have thermal shock resistance and erosion resistance. Therefore, the use of plastic storage masses is limited to applications in low-dust flue gases, preferably as a cold end, ie at the heat exchanger outflow side of the flue gas, in gas preheaters on desulfurization (REA Gavo).
  • coated with base and non-stick enamel heating elements can be a particularly economical way to produce or represent a heat storage material that is corrosion resistant, has an abrasion resistant, dirt-repellent surface and has no thermal engineering and structural disadvantages or restrictions on the operation. It can be used with respect to heat exchange, pressure loss and mechanical stability optimized and proven steel sheet profiles and the non-stick enamel layer affects the heat transfer performance only slightly, d. H. With the high heat capacity of enamel and the additional mass, it is practically increased.
  • the dirt-repellent property of the heating elements according to the invention reduces or even completely prevents the build-up of pressure loss-increasing soil layers on the heating element profiles. This brings operational advantages, since then the intervals for the necessary to reach the maximum allowable pressure loss cleaning the storage mass can be extended and consequently also lower amounts of cleaning wastewater incurred. Nevertheless, if they form deposits, they adhere less firmly to the non-stick enamel and can therefore be cleaned with less blowing or rinsing pressure or with smaller amounts of blowing medium and / or environmentally harmful rinsing water.
  • the non-stick enamel coating with a layer thickness of 5 to 40 ⁇ m, wherein in a particularly advantageous embodiment of the invention a layer thickness of 15 to 25 ⁇ m is applied.
  • This thin layer is sufficient to largely protect the base enamel layer applied as corrosion protection from caking and adhesions.
  • the heating element whose total layer thickness, ie the base enamel layer including the non-stick enamel coating, 80 to 300 microns. With this layer thickness, an optimum with regard to corrosion resistance, thermal conductivity and coating costs is achieved.
  • the heating element By forming the heating element with an acid-fast base enamel layer with a removal value or weight loss after 18 hours testing time of a maximum of 10 g / m 2 (measurement in accordance with DIN 2743 and pr EN 14483-2), the heating element is provided with an extremely corrosion-resistant coating, which gives the heating element a long service life.
  • An advantageous embodiment of the heating element has a low-pore base enamel layer, wherein in a particularly advantageous manner, the base enamel layer is formed with a maximum of 15 pores per m 2 . Due to the low pore number ensures that the metal body remains largely protected against corrosion.
  • the heating element in each case has at least one single-layer base enamel layer and non-stick enamel coating.
  • Such a trained heating element is simple and inexpensive to manufacture.
  • the base enamel layer is applied after degreasing of the steel sheet directly and without primer on the steel sheet and / or applied the non-stick enamel coating directly on the base enamel layer without pretreatment.
  • the two enamel layers can be applied very economically without additional steps.
  • One advantageous method is to grind a frit or frit mixture of the non-stick enamel into a water-based slurry, to apply the slurry to the enamelled heating element by dipping or spraying, and then to place it in a kiln dry and melt.
  • This measure can be moved very economically in a conventional manner.
  • the drying and firing of the base enamel layer and / or the non-stick enamel layer takes place in a continuous furnace.
  • This process is characterized by high efficiency and energy efficiency.
  • non-stick enamel can be applied with the usual for enamelling of heating plates (base enamel) facilities and therefore no additional apparatus and facilities are necessary for the production.
  • a heating element according to the invention for a regenerative heat exchanger and a method for producing such a heating element will be described.
  • a heating element consists of a steel sheet, which is prepared by its profiling produced by profiling advantageously by degreasing or pickling, but without applying a primer for enamelling. Subsequently, an acid-resistant base enamel layer is applied to the steel sheet, which serves as corrosion protection.
  • the base enamel layer which is preferably formed pore poor and more preferably with a maximum of 15 pores per m 2 , it is a specially developed for the corrosion protection of heating elements enamel, which has proven itself for years in use in regenerative heat exchangers.
  • a slip of the non-stick enamel for example by spraying or dipping applied and then dried and fired.
  • the layer thickness of the non-stick enamel on the base enamel is advantageously formed with 5 to 40 microns, in a particularly advantageous manner with 15 to 25 microns.
  • the base enamel and the non-stick enamel can be applied in one or more layers, wherein a total layer thickness of 80 to 300 microns has been found to be particularly advantageous.
  • fluoroplastic coatings have non-stick enamel layers significantly higher abrasion resistance and also sticks the non-stick enamel better on the enamel than fluoroplastic on enamel.
  • non-stick enamels are relatively expensive, can be in the specified design, ie with relatively thin layer thickness, thus in a particularly economical, cost-effective manner heating elements with corrosion and erosion resistant and dirt-repellent coating produce, since little expensive material is needed.
  • Optical surface defects such. B. running marks, color and gloss defects play no role in the technical product heating element.
  • the non-stick enamel layer can, without having to pay attention to optics and beauty of the surface, advantageously be applied with little effort, with the already existing for the base enamelling production facilities, such as furnaces.
  • the composition of the two is Enamel coatings, for example, no food-grade purity required or necessary, ie that the lead and cadmium content of the enamel layers is less or not critical and therefore does not have to be limited, which simplifies the selection of raw materials and production of enamel frit and makes the coating comparatively much cheaper.
  • the non-stick enamel layer affects the heat transfer performance of the heating element only insignificantly, it is still increased by the high heat capacity of enamel and by the additional mass in a positive way.
  • Heating elements for regenerative heat exchangers which are exposed to acid-containing flue gas, must be provided with a very resistant, acid-resistant base enamel layer.
  • the base enamel layer must have a very specific acid resistance, which is determined in accordance with DIN 2743 + CEN Resolution in highly corrosive 30% sulfuric acid in a boiling test lasting several hours. The measured removal should be less than 10 g / m 2 after 18 hours cooking time.
  • Regenerative heat exchangers consist of a multiplicity of heating elements or heat accumulators which are heated by a hot gas, for example flue gas, and which subsequently release the stored heat to a colder fluid, for example air or gas.
  • a hot gas for example flue gas
  • a colder fluid for example air or gas.
  • Such regenerative heat exchangers can be used, for example, as air preheaters or gas preheaters in boiler systems, flue gas purification systems, etc.
  • the pollution temperature is called the Temperature at which, as a result of dew point undershooting and inclusion of flue dust (ash) in the flue gas condensate (sulfuric acid) formation of deposits can no longer be controlled with economically justifiable effort.
  • Heating elements which have anti-adhesive properties could not be used satisfactorily because of the erosive conditions in air preheaters.
  • plastics a relatively low permissible continuous operating temperature is disadvantageously added, which further restricts their use and represents a safety risk in the event of a malfunction.
  • a deposit formation is either prevented even at extreme dew point below or it is at least much easier to control, which ultimately allows a lowering of the flue gas temperature below the usual level.
  • a lower flue gas temperature means a higher boiler efficiency and thus a lower specific CO 2 emission (emitted amount of CO 2 per unit of electrical energy produced) and the downstream of the air preheater plants (electrostatic precipitator, flue gas cleaning system) can be built smaller (lower investment, lower operating costs).
  • a further advantage is that the dew point undershooting (sulfuric acid expulsion) leads to a reduction of the SO 3 / H 2 SO 4 concentration in the flue gas and thus reduces the risk of corrosion in downstream systems and the risk of aerosol formation.
  • heating elements according to the invention can also be used in less erosive and corrosive applications.

Abstract

The device is made of profiled steel sheet provided with an acid-resistant basic enamel coating and whose surface is provided with an anti-adhesion enamel coating. The anti-adhesion enamel coating is applied with a coating thickness of 5 to 40 microns or 15 to 25 microns. The thickness of the basic enamel coating including the anti-adhesion coating is 80 to 300 microns. An independent claim is also included for the following: (a) a method of manufacturing an inventive device.

Description

Die Erfindung betrifft ein als profiliertes Stahlblech ausgebildetes Heizelement für einen Regenerativ-Wärmetauscher.The invention relates to a trained as a profiled sheet steel heating element for a regenerative heat exchanger.

Derartige Heizelemente sind allgemein bekannt. Eine Vielzahl von Heizelementen bilden die Speichermasse eines Regenerativ-Wärmetauschers. Die zur Wärmeübertragung bzw. zum Wärmetausch benötigte Speichermasse ist beim Einsatz in korrosiven und/oder staubhaltigen Gasströmen besonderen betrieblichen Beanspruchungen unterworfen. Dies trifft zum Beispiel für die Speichermasse von Luftvorwärmern an Kesselanlagen (Boiler) oder Gasvorwärmern an Rauchgasreinigungsanlagen zu, wo die Temperatur der Speichermasse zumindest lokal und/oder zeitweise unterhalb des Rauchgastaupunktes liegt und sich in Verbindung mit Flugstaub und/oder sonstigen Rauchgasinhaltsstoffen (Additive, Mittel zur Rauchgasreinigung) Beläge auf der Speichermasse bzw. den Heizflächen der Heizelemente bilden. Letztere erhöhen den Druckverlust für die Durchströmung der Speichermasse und führen im schlimmsten Fall zur vollständigen Versperrung/Verstopfung des Regenerativ-Wärmetauschers. Ein weiteres Problem besteht darin, dass Rauchgaskondensate in der Regel stark sauer sind. Die Speichermasse muss deshalb, besonders bei niedrigen Betriebstemperaturen, hinreichend korrosionsfest sein und die Beläge sollen möglichst leicht durch Blasen oder Spülen abzureinigen sein. Für solche Anwendungen sind Speichermassen aus emaillierten Stahlblechprofilen oder Speichermaterialien aus Kunststoff bekannt geworden ( DE 32 07 213 C3 ).Such heating elements are well known. A plurality of heating elements form the storage mass of a regenerative heat exchanger. The storage mass required for heat transfer or for heat exchange is subject to special operational requirements when used in corrosive and / or dust-containing gas streams. This applies, for example, to the storage mass of air preheaters on boiler systems (boilers) or gas preheaters on flue gas cleaning systems, where the temperature of the storage mass is at least locally and / or temporarily below the Rauchgastaupunktes and in conjunction with flue dust and / or other flue gas ingredients (additives, means for flue gas cleaning) form deposits on the storage mass or the heating surfaces of the heating elements. The latter increase the pressure loss for the flow through the storage mass and lead in the worst case to complete obstruction / blockage of the regenerative heat exchanger. Another problem is that flue gas condensates are usually very acidic. The storage mass must therefore be sufficiently resistant to corrosion, especially at low operating temperatures, and the deposits should be as easy to clean off as possible by blowing or rinsing. For such applications, storage masses of enamelled sheet steel profiles or plastic storage materials have become known ( DE 32 07 213 C3 ).

Emaillierte Stahlbleche sind zwar relativ gut korrosionsbeständig, haben aber den Nachteil einer relativ hohen Benetzbarkeit, was sind darin äußert, dass Beläge auf emaillierten Heizelementen mehr oder weniger fest haften. Speichermassen aus Kunststoff sind teuer und insofern nachteilig, weil diese eine geringe Wärmekapazität und Wärmeleitung aufweisen, nicht wirtschaftlich in für die Wärmetechnik optimaler Form dargestellt werden können und eine relativ geringe mechanische Festigkeit, Temperatur- und Temperaturwechselbeständigkeit sowie Erosionsfestigkeit besitzen. Deshalb beschränkt sich der Einsatz von Speichermassen aus Kunststoff auf Anwendungen in staubarmen Rauchgasen, vorzugsweise als Kaltendlage, d.h. an der Wärmetauscher-Ausströmseite des Rauchgases, in Gasvorwärmern an Entschwefelungsanlagen (REA Gavo).Although enameled steel sheets are relatively resistant to corrosion, but have the disadvantage of a relatively high wettability, which are expressed in that deposits on enameled heating more or less firmly adhere. Plastic storage masses are expensive and disadvantageous because they have a low heat capacity and heat conduction, can not be economically represented in optimal form for heat engineering and a relatively low mechanical strength, temperature and Have thermal shock resistance and erosion resistance. Therefore, the use of plastic storage masses is limited to applications in low-dust flue gases, preferably as a cold end, ie at the heat exchanger outflow side of the flue gas, in gas preheaters on desulfurization (REA Gavo).

Zur Verbesserung der schmutzabweisenden Eigenschaften und Erhöhung der Korrosionsbeständigkeit wurde vorgeschlagen, die Oberfläche emaillierter Heizelemente mit einer Beschichtung aus Fluorkunststoff zu versehen ( DE 199 40 627 Al). Die Antihafteigenschaften von Fluorkunststoffen, wie z. B. PTFE, sind bekannt, nachteilig ist aber die relativ geringe Erosionsfestigkeit solcher Beschichtungen. Wegen der beschränkten Erosionsfestigkeit können Heizelemente mit Fluorkunststoffbeschichtung nicht mit befriedigender Standzeit in mit partikelhaltigem Rauchgas beaufschlagten Regenerativ-Wärmetauschern, beispielsweise Luftvorwärmern an kohlegefeuerten Dampferzeugern, eingesetzt werden. Der Flugstaubgehalt im Rauchgas kann hier bei einer Strömungsgeschwindigkeit von über 10 m/s mehr als 20 g Staub/Nm3 betragen. Für einen wirtschaftlichen Kraftwerksbetrieb mit hohem Wirkungsgrad und niedrigen Emissionen soll die Abgastemperatur im Luftvorwärmer möglichst weit abgesenkt werden, was nur mit Hilfe von korrosionsbeständigen und schmutzabweisenden Heizflächen möglich ist.In order to improve the dirt-repellent properties and increase the corrosion resistance, it has been proposed to provide the surface of enamelled heating elements with a coating of fluoroplastic ( DE 199 40 627 Al). The non-stick properties of fluoroplastics, such. As PTFE, are known, but the disadvantage is the relatively low erosion resistance of such coatings. Because of the limited erosion resistance heating elements with fluoroplastic coating can not be used with satisfactory service life in charged with particulate flue gas regenerative heat exchangers, such as air preheaters on coal-fired steam generators. The flue gas content in the flue gas can be more than 20 g of dust / Nm 3 at a flow velocity of more than 10 m / s. For an economical power plant operation with high efficiency and low emissions, the exhaust gas temperature in the air preheater should be lowered as far as possible, which is only possible with the help of corrosion-resistant and dirt-repellent heating surfaces.

Es ist somit die Aufgabe dieser Erfindung, ein Heizelement der eingangs genannten Art anzugeben, das schmutzabweisende Eigenschaften besitzt, korrosions- und erosionsbeständig ist und trotzdem eine gute Wärmespeicherkapazität und Wärmeleitfähigkeit aufweist, hinreichend temperatur- und temperaturwechselbeständig ist und außerdem zu wirtschaftlich vertretbaren Kosten hergestellt werden kann. Es ist ferner Aufgabe der Erfindung Heizelemente zu schaffen, durch deren Einsatz es in kohlegefeuerten Dampferzeugern ermöglicht wird, die Abgastemperatur im Vergleich zum Stand der Technik noch weiter abzusenken. Es ist des weiteren Aufgabe der Erfindung, ein Verfahren zur Herstellung eines derartigen Heizelementes aufzuzeigen.It is therefore the object of this invention to provide a heating element of the type mentioned, which has dirt-repellent properties, corrosion and erosion resistant and still has a good heat storage capacity and thermal conductivity, is sufficiently temperature and temperature change resistant and can also be produced at an economically acceptable cost , It is a further object of the invention to provide heating elements, by the use of which it is possible in coal-fired steam generators to reduce the exhaust gas temperature even further compared to the prior art. It is a further object of the invention to provide a method for producing such a heating element.

Diese Aufgabe wird hinsichtlich des Heizelementes durch die kennzeichnenden Merkmale des Anspruches 1 gelöst und hinsichtlich des Verfahrens zur Herstellung eines Heizelementes durch die kennzeichnenden Merkmale des Anspruches 9 gelöst.This object is achieved with respect to the heating element by the characterizing features of claim 1 and solved with respect to the method for producing a heating element by the characterizing features of claim 9.

Vorteilhafte Ausgestaltungen der Erfindung sind den Unteransprüchen zu entnehmen.Advantageous embodiments of the invention can be found in the dependent claims.

Mit den mit Grund- und Antihaft-Email beschichteten Heizelementen lässt sich auf besonders wirtschaftliche Weise eine Wärme-Speichermasse herstellen bzw. darstellen, die korrosionsfest ist, eine abriebfeste, schmutzabweisende Oberfläche hat und keine wärmetechnischen und konstruktiven Nachteile oder Einschränkungen hinsichtlich der Betriebsweise aufweist. Es können die bezüglich Wärmetausch, Druckverlust und mechanischer Stabilität optimierten und bewährten Stahlblechprofile eingesetzt werden und die Antihaft-Emailschicht beeinflusst die Wärmeübertragungsleistung nur unwesentlich, d. h. bei der hohen Wärmekapazität von Email und durch die zusätzliche Masse wird sie praktisch sogar erhöht.With the coated with base and non-stick enamel heating elements can be a particularly economical way to produce or represent a heat storage material that is corrosion resistant, has an abrasion resistant, dirt-repellent surface and has no thermal engineering and structural disadvantages or restrictions on the operation. It can be used with respect to heat exchange, pressure loss and mechanical stability optimized and proven steel sheet profiles and the non-stick enamel layer affects the heat transfer performance only slightly, d. H. With the high heat capacity of enamel and the additional mass, it is practically increased.

Die schmutzabweisende Eigenschaft der erfindungsgemäßen Heizelemente vermindert oder verhindert sogar ganz den Aufbau von druckverlusterhöhenden Verschmutzungsschichten auf den Heizelementprofilen. Das bringt betriebliche Vorteile, da dann die Intervalle für die bei Erreichen des maximal zulässigen Druckverlustes notwendigen Reinigungen der Speichermasse verlängert werden können und infolgedessen auch geringere Mengen an Reinigungs-Abwasser anfallen. Bilden sich trotzdem Beläge, so haften diese auf dem Antihaft-Email weniger fest an und lassen sich deswegen mit geringerem Blas- oder Spüldruck bzw. mit geringeren Mengen an Blasmedium und/oder umweltbelastendem Spülwasser reinigen.The dirt-repellent property of the heating elements according to the invention reduces or even completely prevents the build-up of pressure loss-increasing soil layers on the heating element profiles. This brings operational advantages, since then the intervals for the necessary to reach the maximum allowable pressure loss cleaning the storage mass can be extended and consequently also lower amounts of cleaning wastewater incurred. Nevertheless, if they form deposits, they adhere less firmly to the non-stick enamel and can therefore be cleaned with less blowing or rinsing pressure or with smaller amounts of blowing medium and / or environmentally harmful rinsing water.

Als vorteilhaft hat sich gezeigt, die Antihaft-Email-Beschichtung mit einer Schichtstärke von 5 bis 40 µm aufzubringen, wobei in besonders vorteilhafter Ausbildung der Erfindung eine Schichtstärke von 15 bis 25 µm aufgebracht wird. Diese dünne Schicht reicht aus, um die als Korrosionsschutz aufgebrachte Grundemailschicht vor Anbackungen und Anhaftungen weitgehend zu schützen. In einer vorteilhaften Ausgestaltung des Heizelementes ist dessen Gesamtschichtdicke, d.h. der Grundemailschicht einschließlich der Antihaft-Email-Beschichtung, 80 bis 300 µm. Bei dieser Schichtdicke wird ein Optimum hinsichtlich der Korrosionsstandfestigkeit, Wärmeleitfähigkeit und Beschichtungskosten erzielt.It has proven to be advantageous to apply the non-stick enamel coating with a layer thickness of 5 to 40 μm, wherein in a particularly advantageous embodiment of the invention a layer thickness of 15 to 25 μm is applied. This thin layer is sufficient to largely protect the base enamel layer applied as corrosion protection from caking and adhesions. In an advantageous embodiment of the heating element whose total layer thickness, ie the base enamel layer including the non-stick enamel coating, 80 to 300 microns. With this layer thickness, an optimum with regard to corrosion resistance, thermal conductivity and coating costs is achieved.

Durch die Ausbildung des Heizelementes mit einer säurefesten Grundemailschicht mit einem Abtragswert bzw. Gewichtsverlust nach 18 Stunden Prüfzeit von maximal 10 g/m2 (Messung in Anlehnung an DIN 2743 und pr EN 14483-2) wird das Heizelement mit einer extrem korrosionsfesten Beschichtung ausgestattet, die dem Heizelement eine lange Standzeit verleiht.By forming the heating element with an acid-fast base enamel layer with a removal value or weight loss after 18 hours testing time of a maximum of 10 g / m 2 (measurement in accordance with DIN 2743 and pr EN 14483-2), the heating element is provided with an extremely corrosion-resistant coating, which gives the heating element a long service life.

Eine vorteilhafte Ausbildung des Heizelementes weist eine porenarme Grundemailschicht auf, wobei in besonders vorteilhafter Weise die Grundemailschicht mit maximal 15 Poren je m2 ausgebildet ist. Durch die geringe Porenzahl wird erreicht, dass der Metallgrundkörper weitestgehend vor Korrosion geschützt bleibt.An advantageous embodiment of the heating element has a low-pore base enamel layer, wherein in a particularly advantageous manner, the base enamel layer is formed with a maximum of 15 pores per m 2 . Due to the low pore number ensures that the metal body remains largely protected against corrosion.

In vorteilhafter Ausgestaltung weist das Heizelement jeweils mindestens eine einlagige Grundemailschicht und Antihaft-Email-Beschichtung auf. Ein derartig ausgebildetes Heizelement ist einfach und kostengünstig herzustellen.In an advantageous embodiment, the heating element in each case has at least one single-layer base enamel layer and non-stick enamel coating. Such a trained heating element is simple and inexpensive to manufacture.

Ein Verfahren zur Herstellung eines Heizelementes nach Anspruch 1 zeichnet sich durch folgende Schritte aus:

  • Stahlbänder werden mit Hilfe von Profilwalzen profiliert und daraus entsprechend der geforderten Maße Heizelemente zugeschnitten,
  • auf die zugeschnittenen Stahlbleche wird die säurefeste Grundemailschicht aufgebracht und in einem weiteren Arbeitsschritt
  • die Antihaft-Email-Beschichtung auf die säurefeste Grundemailschicht aufgetragen.
A method for producing a heating element according to claim 1 is characterized by the following steps:
  • Steel strips are profiled with the aid of profile rollers and from these, heating elements are cut to size according to the required dimensions.
  • On the cut steel sheets, the acid-resistant base enamel layer is applied and in a further step
  • apply the non-stick enamel coating to the acid-resistant base enamel layer.

In vorteilhafter Ausbildung des erfindungsgemäßen Verfahrens wird die Grundemailschicht nach der Entfettung des Stahlbleches direkt und ohne Haftgrund auf das Stahlblech aufgebracht und/oder die Antihaft-Email-Beschichtung ohne Vorbehandlung direkt auf die Grundemailschicht aufgebracht. Dadurch können die beiden Emailschichten sehr wirtschaftlich ohne zusätzliche Arbeitsschritte aufgebracht werden.In an advantageous embodiment of the method according to the invention, the base enamel layer is applied after degreasing of the steel sheet directly and without primer on the steel sheet and / or applied the non-stick enamel coating directly on the base enamel layer without pretreatment. As a result, the two enamel layers can be applied very economically without additional steps.

Ein vorteilhaftes Verfahren sieht vor, eine Fritte oder Frittenmischung des Antihaft-Emails zu einem wasserbasigen Schlicker zu vermahlen, den Schlicker durch Tauchen oder Spritzen auf das grundemaillierte Heizelement aufzubringen und dann in einem Brennofen zu trocknen und aufzuschmelzen. Durch diese Maßnahme kann in konventioneller Weise sehr wirtschaftlich verfahren werden.One advantageous method is to grind a frit or frit mixture of the non-stick enamel into a water-based slurry, to apply the slurry to the enamelled heating element by dipping or spraying, and then to place it in a kiln dry and melt. By this measure can be moved very economically in a conventional manner.

Vorteilhafterweise erfolgt das Trocknen und Brennen der Grundemailschicht und/oder der Antihaft-Email-Schicht in einem Durchlaufofen. Dieses Verfahren zeichnet sich durch hohe Effektivität und Energieeffizienz aus.Advantageously, the drying and firing of the base enamel layer and / or the non-stick enamel layer takes place in a continuous furnace. This process is characterized by high efficiency and energy efficiency.

Ein weiterer Vorteil des erfinderischen Verfahrens ist, dass das Antihaft-Email mit den zum Emaillieren von Heizblechen (Grundemail) üblichen Einrichtungen aufgebracht werden kann und somit für die Herstellung keine zusätzlichen Apparate und Einrichtungen notwendig sind.Another advantage of the inventive method is that the non-stick enamel can be applied with the usual for enamelling of heating plates (base enamel) facilities and therefore no additional apparatus and facilities are necessary for the production.

Anhand eines Ausführungsbeispiels wird ein erfindungsgemäßes Heizelement für einen Regenerativ-Wärmetauscher und ein Verfahren zur Herstellung eines solchen Heizelementes beschrieben.Based on an embodiment, a heating element according to the invention for a regenerative heat exchanger and a method for producing such a heating element will be described.

Ein Heizelement besteht aus einem Stahlblech, das nach seiner mittels Profilierwalzen hergestellten Profilierung in vorteilhafter Weise durch Entfetten oder Beizen, jedoch ohne Aufbringen eines Haftgrundes für die Emaillierung vorbereitet wird. Anschließend wird eine säurebeständige Grundemailschicht auf das Stahlblech aufgebracht, die als Korrosionsschutz dient. Bei der Grundemailschicht, die vorzugsweise porenarm und besonders bevorzugt mit maximal 15 Poren je m2 ausgebildet ist, handelt es sich um ein speziell für den Korrosionsschutz von Heizelementen entwickeltes Email, das sich über Jahre beim Einsatz in Regenerativ-Wärmetauschern bewährt hat.A heating element consists of a steel sheet, which is prepared by its profiling produced by profiling advantageously by degreasing or pickling, but without applying a primer for enamelling. Subsequently, an acid-resistant base enamel layer is applied to the steel sheet, which serves as corrosion protection. In the base enamel layer, which is preferably formed pore poor and more preferably with a maximum of 15 pores per m 2 , it is a specially developed for the corrosion protection of heating elements enamel, which has proven itself for years in use in regenerative heat exchangers.

Nach dem Aufbringen der Grundemailschicht wird vorteilhafterweise ohne Vorbehandlung der emaillierten Oberfläche ein Schlicker des Antihaft-Emails, zum Beispiel durch Aufsprühen oder Tauchen, aufgebracht und anschließend getrocknet und gebrannt. Die Schichtdicke des Antihaft-Email auf dem Grundemail ist vorteilhaft mit 5 bis 40 µm, in besonders vorteilhafter Weise mit 15 bis 25 µm ausgebildet. Das Grundemail sowie das Antihaft-Email kann je nach Anwendungsfall ein- oder mehrlagig aufgebracht werden, wobei eine Gesamtschichtdicke von 80 bis 300 µm sich als besonders vorteilhaft gezeigt hat.After application of the base enamel layer advantageously without pretreatment of the enamelled surface, a slip of the non-stick enamel, for example by spraying or dipping applied and then dried and fired. The layer thickness of the non-stick enamel on the base enamel is advantageously formed with 5 to 40 microns, in a particularly advantageous manner with 15 to 25 microns. Depending on the application, the base enamel and the non-stick enamel can be applied in one or more layers, wherein a total layer thickness of 80 to 300 microns has been found to be particularly advantageous.

Es hat sich ferner gezeigt, dass eine dünne Antihaft-Emailschicht entsprechend den obigen Angaben ohne besondere Vorbehandlung der Grundemailoberfläche auf diese fest haftend aufgebracht werden kann und diese relativ dünne Antihaft-Emailschicht die Benetzbarkeit der Heizelementoberfläche soweit herabsetzt, dass mit Fluorkunststoffen vergleichbare antiadhäsive Eigenschaften erreicht werden. Da schon allein die säurefeste, porenarme Grundemailschicht das Stahlprofil hinreichend vor Korrosion schützt, muss die Antihaft-Emaildeckschicht keinen Beitrag als Korrosionsschutzschicht bringen und kann somit sehr dünn ausfallen und bei der Applikation muss nicht auf Poren und sonstige Beschichtungsfehler geachtet werden. Durch die niedrige Benetzbarkeit oder mit anderen Worten, hohe schmutzabweisende Eigenschaft der Antihaft-Email-Beschichtung wird der Aufbau von druckverlusterhöhenden Verschmutzungsschichten auf den Heizelementen verhindert bzw. wesentlich vermindert. Dadurch können Reinigungsintervalle verlängert werden bzw. geringere Mengen an Reinigungsmedien eingesetzt werden.It has also been found that a thin non-stick enamel layer according to the above information without special pre-treatment of Grundemailoberfläche can be applied to this firmly adhering and this relatively thin non-stick enamel layer, the wettability of the Heizelementoberfläche far enough so that fluororesins comparable anti-adhesive properties are achieved , Since the acid-resistant, low-pore base enamel layer alone sufficiently protects the steel profile against corrosion, the non-stick enamel topcoat does not have to contribute as a corrosion protection layer and can therefore be very thin and care must be taken during the application to pores and other coating defects. Due to the low wettability or in other words, high dirt-repellent property of the non-stick enamel coating, the build-up of pressure loss increasing soil layers on the heating elements is prevented or substantially reduced. As a result, cleaning intervals can be extended or smaller amounts of cleaning media can be used.

Gegenüber Beschichtungen gemäß dem Stand der Technik, beispielsweise Fluorkunststoffbeschichtungen haben Antihaft-Emailschichten eine deutlich höhere Abriebfestigkeit und außerdem haftet das Antihaft-Email besser auf dem Grundemail als Fluorkunststoff auf Email.Compared with coatings according to the prior art, for example fluoroplastic coatings have non-stick enamel layers significantly higher abrasion resistance and also sticks the non-stick enamel better on the enamel than fluoroplastic on enamel.

Da Antihaft-Emails relativ teuer sind, lassen sich in der angegebenen Ausführung, also mit relativ dünner Schichtstärke, somit in besonders wirtschaftlicher, kostengünstiger Weise Heizelemente mit korrosions- und erosionsbeständiger sowie schmutzabweisender Beschichtung herstellen, da wenig teures Material gebraucht wird. Optische Oberflächenfehler wie z. B. Laufspuren, Farb- und Glanzfehler spielen bei dem technischen Produkt Heizelement keine Rolle. Die Antihaft-Emailschicht kann, ohne Optik und Schönheit der Oberfläche beachten zu müssen, vorteilhaft mit geringem Aufwand appliziert werden, und zwar mit den für die Grundemaillierung ohnehin vorhandenen Fertigungseinrichtungen, z.B. Durchlauföfen. Da es sich bei der oben vorgeschlagenen Lösung um eine technische Anwendung handelt, ist bei der Zusammensetzung der beiden Emailschichten beispielsweise auch keine lebensmittelechte Reinheit gefordert bzw. notwendig, d.h. dass der Blei- und Cadmiumgehalt der Emailschichten weniger bzw. nicht kritisch ist und deswegen nicht limitiert werden muss, was die Rohstoffauswahl und Herstellung der Emailfritte vereinfacht und die Beschichtung vergleichsweise deutlich kostengünstiger macht. Die Antihaft-Emailschicht beeinflusst die Wärmeübertragungsleistung des Heizelementes nur unwesentlich, sie wird durch die hohe Wärmekapazität von Email und durch die zusätzliche Masse in positiver Weise noch erhöht.Since non-stick enamels are relatively expensive, can be in the specified design, ie with relatively thin layer thickness, thus in a particularly economical, cost-effective manner heating elements with corrosion and erosion resistant and dirt-repellent coating produce, since little expensive material is needed. Optical surface defects such. B. running marks, color and gloss defects play no role in the technical product heating element. The non-stick enamel layer can, without having to pay attention to optics and beauty of the surface, advantageously be applied with little effort, with the already existing for the base enamelling production facilities, such as furnaces. Since the solution proposed above is a technical application, the composition of the two is Enamel coatings, for example, no food-grade purity required or necessary, ie that the lead and cadmium content of the enamel layers is less or not critical and therefore does not have to be limited, which simplifies the selection of raw materials and production of enamel frit and makes the coating comparatively much cheaper. The non-stick enamel layer affects the heat transfer performance of the heating element only insignificantly, it is still increased by the high heat capacity of enamel and by the additional mass in a positive way.

Heizelemente für Regenerativ-Wärmetauscher, die mit Säure enthaltendem Rauchgas beaufschlagt werden, müssen mit einer sehr widerstandsfähigen, säurebeständigen Grundemailschicht versehen sein. Um diesen Anforderungen zu genügen, muss die Grundemailschicht eine ganz bestimmte Säurefestigkeit aufweisen, die in Anlehnung an die DIN 2743+CEN Resolution in hochkorrosiver 30%iger siedender Schwefelsäure in einem mehrstündigen Kochversuch bestimmt wird. Der dabei gemessene Abtrag sollte weniger als 10 g/m2 nach 18 Stunden Kochzeit betragen.Heating elements for regenerative heat exchangers, which are exposed to acid-containing flue gas, must be provided with a very resistant, acid-resistant base enamel layer. To meet these requirements, the base enamel layer must have a very specific acid resistance, which is determined in accordance with DIN 2743 + CEN Resolution in highly corrosive 30% sulfuric acid in a boiling test lasting several hours. The measured removal should be less than 10 g / m 2 after 18 hours cooking time.

Regenerativ-Wärmetauscher bestehen aus einer Vielzahl von Heizelementen bzw. Wärmespeichern, die durch ein heißes Gas, beispielsweise Rauchgas aufgeheizt werden und die anschließend die gespeicherte Wärme an ein kälteres Fluid, beispielsweise Luft oder Gas abgeben. Derartige Regenerativ-Wärmetauscher können beispielsweise als Luftvorwärmer oder Gasvorwärmer in Kesselanlagen, Rauchgasreinigungsanlagen usw. eingesetzt werden.Regenerative heat exchangers consist of a multiplicity of heating elements or heat accumulators which are heated by a hot gas, for example flue gas, and which subsequently release the stored heat to a colder fluid, for example air or gas. Such regenerative heat exchangers can be used, for example, as air preheaters or gas preheaters in boiler systems, flue gas purification systems, etc.

Aus Gründen der besseren Wirtschaftlichkeit (höherer Wirkungsgrad) einer Kesselanlage wird bei Luftvorwärmern eine möglichst tiefe Rauchgasaustrittstemperatur (Temperatur des Rauchgases nach Durchströmen des Regenerativ-Wärmetauschers) und damit auch eine möglichst tiefe Kaltendtemperatur des Regenerativ-Wärmetauschers angestrebt. Bei SO3 und staubhaltigen Rauchgasen (Rohgas Kohlefeuerung: bis über 20 g Staub / Nm3 Rauchgas) waren bisher wegen zu schneller Belagsbildung und schlechter Abreinigbarkeit für die Tiefe der Kaltendtemperatur Grenzen gesetzt. Luftvorwärmer werden nach dem Stand der Technik so ausgelegt, dass die Kaltendtemperatur oberhalb der sogenannten Verschmutzungstemperatur liegt. Als Verschmutzungstemperatur bezeichnet man die Temperatur, ab der in Folge von Taupunktsunterschreitung und Einbindung von Flugstaub (Asche) in das Rauchgaskondensat (Schwefelsäure) Belagsbildungen nicht mehr mit wirtschaftlich vertretbarem Aufwand beherrschbar sind. Heizelemente, die beispielsweise mit Hilfe von Fluorkunststoffbeschichtungen antiadhäsive Eigenschaften besitzen oder Speichermasse aus Kunststoff, konnten wegen der erosiven Bedingungen in Luftvorwärmern nicht mit befriedigender Standzeit eingesetzt werden. Bei Kunststoffen kommt noch nachteilig eine relativ niedrige zulässige Dauerbetriebstemperatur hinzu, was deren Einsatz weiter einschränkt und im Störfall ein Sicherheitsrisiko darstellt. Mit einem Regenerativ-Wärmetauscher, der mit erfindungsgemäßen Heizelementen ausgebildet ist, wird eine Belagsbildung selbst bei extremer Taupunktsunterschreitung entweder verhindert oder sie ist zumindest wesentlich besser beherrschbar, was letztlich eine Absenkung der Rauchgastemperatur unter das bisher übliche Niveau zulässt. Eine tiefere Rauchgastemperatur bedeutet einen höheren Kesselwirkungsgrad und damit eine geringere spezifische CO2 -Emission (emittierte Menge CO2 pro Einheit produzierte elektrische Energie) und die dem Luftvorwärmer nachgeschalteten Anlagen (Elektrofilter, Rauchgasreinigungsanlage) können kleiner gebaut werden (geringere Investitionen, niedrigere Betriebskosten). Ein weiterer Vorteil ist, dass durch die Taupunktsunterschreitung (Austauen von Schwefelsäure) eine Reduzierung der SO3/H2SO4-Konzentration im Rauchgas einher geht und damit die Korrosionsgefahr in nachgeschalteten Anlagen und die Gefahr der Aerosolbildung gemindert wird.For reasons of better economy (higher efficiency) of a boiler system is aimed at air preheaters as deep as possible flue gas outlet temperature (temperature of the flue gas after flowing through the regenerative heat exchanger) and thus the lowest possible cold end of the regenerative heat exchanger. In the case of SO 3 and dusty flue gases (raw gas coal firing: up to more than 20 g of dust / Nm 3 flue gas), limits were previously set for the depth of the cold end temperature because of too rapid formation of deposits and poor cleanability. Air preheaters are designed according to the prior art so that the cold end temperature is above the so-called pollution temperature. As the pollution temperature is called the Temperature at which, as a result of dew point undershooting and inclusion of flue dust (ash) in the flue gas condensate (sulfuric acid) formation of deposits can no longer be controlled with economically justifiable effort. Heating elements which have anti-adhesive properties, for example with the aid of fluoroplastic coatings or plastic storage material, could not be used satisfactorily because of the erosive conditions in air preheaters. In the case of plastics, a relatively low permissible continuous operating temperature is disadvantageously added, which further restricts their use and represents a safety risk in the event of a malfunction. With a regenerative heat exchanger, which is formed with heating elements according to the invention, a deposit formation is either prevented even at extreme dew point below or it is at least much easier to control, which ultimately allows a lowering of the flue gas temperature below the usual level. A lower flue gas temperature means a higher boiler efficiency and thus a lower specific CO 2 emission (emitted amount of CO 2 per unit of electrical energy produced) and the downstream of the air preheater plants (electrostatic precipitator, flue gas cleaning system) can be built smaller (lower investment, lower operating costs). A further advantage is that the dew point undershooting (sulfuric acid expulsion) leads to a reduction of the SO 3 / H 2 SO 4 concentration in the flue gas and thus reduces the risk of corrosion in downstream systems and the risk of aerosol formation.

Es versteht sich von selbst, dass die erfindungsgemäßen Heizelemente auch bei weniger erosiven und korrosiven Anwendungen eingesetzt werden können.It goes without saying that the heating elements according to the invention can also be used in less erosive and corrosive applications.

Claims (14)

  1. A heating element for a regenerative heat exchanger, which is designed as profiled sheet steel, characterised in that the profiled sheet steel is provided with an acid-resistant base enamel coating, the surface of which has a non-stick enamel coating.
  2. The heating element according to claim 1, characterised in that the non-stick enamel coating is applied with a layer thickness of 5 to 40 µm.
  3. The heating element according to claim 1, characterised in that the non-stick enamel coating is applied with a layer thickness of 15 to 25 µm.
  4. The heating element according to one of the preceding claims, characterised in that the base enamel layer, including the non-stick enamel coating, is applied with a layer thickness of 80 to 300 µm.
  5. The heating element according to one of the preceding claims, characterised in that the acid-resistant base enamel layer has an abrasion value or weight loss after an 18-hour test time in 30 % boiling sulphuric acid of maximum 10 g/m2.
  6. The heating element according to one of the preceding claims, characterised in that the base enamel layer has low porosity.
  7. The heating element according to one of the preceding claims, characterised in that the base enamel layer is designed with an average of maximum 15 pores/m2.
  8. The heating element according to one of the preceding claims, characterised in that the base enamel layer and the non-stick enamel coating are each at least single-layered.
  9. A method of producing a heating element for a regenerative heat exchanger according to claim 1, characterised in that steel strips are profiled with the help of section rolls and the heating element is cut from these in line with the required dimensions, that the sheet steel is base-enamelled for acid resistance and that the non-stick enamel coating is applied to the base enamel layer.
  10. The method according to claim 9, characterised in that the base enamel layer is applied straight onto the sheet steel without an adhesive base once the sheet steel has been degreased.
  11. The method according to one of the claims 9 or 10, characterised in that the non-stick enamel coating is applied straight onto the base enamel layer without pre-treatment.
  12. The method according to one of the claims 9 to 11, characterised in that a frit or frit mixture of the non-stick enamel is ground into a water-based slip, the slick is applied by immersion or spraying onto the base-enamelled heating element and then dried and melted on in a furnace.
  13. The method according to one of the claims 9 to 12, characterised in that the drying and burning of the base enamel layer and/or the non-stick enamel layer takes place in a continuous furnace.
  14. The method according to one of the claims 9 to 13, characterised in that the non-stick enamel coating is applied using the facilities needed to apply the base enamel layer.
EP04010542A 2003-05-08 2004-05-04 Heating element for regenerative heat exchanger and process for manufacturing same Expired - Lifetime EP1475597B1 (en)

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DE10320462 2003-05-08
DE10320462A DE10320462B3 (en) 2003-05-08 2003-05-08 Heating element for a regenerative heat exchanger and method for producing a heating element

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EP1475597A3 EP1475597A3 (en) 2006-11-15
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DE102008030733A1 (en) 2008-06-27 2009-12-31 Munters Euroform Gmbh Plate packet for cold end coating of regenerative gas preheater, has plates alternatively arranged in packet such that retaining slots extend from upper longitudinal edge and lower longitudinal edge of plates
DE102009006855A1 (en) 2008-11-04 2010-05-06 Munters Euroform Gmbh Plate package for cold end layer
DE102012203278A1 (en) 2012-03-01 2013-09-05 Sgl Carbon Se Rotary heat exchanger with heat exchanger plates or heat exchanger tubes made of carbon and graphite materials
CN103063079B (en) * 2013-01-17 2014-09-10 南京圣诺热管有限公司 Metal enamel heat transmission element and processing method thereof

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4250215A (en) * 1979-02-26 1981-02-10 General Housewares Corp. Cooking utensil with non-stick cooking surface
DE3207213C3 (en) * 1982-02-27 1995-03-23 Kraftanlagen Ag Plastic storage block for heat transfer between gas flows in heat exchangers
DE3405768A1 (en) * 1984-02-17 1985-08-22 Asta Ullrich GmbH Annweiler am Trifels, 6747 Annweiler Enamelled metal sheet
DE3445319A1 (en) * 1984-12-07 1986-06-12 Gerhard 1000 Berlin Kutter Gas outflow device
DE4122949A1 (en) * 1991-07-11 1993-01-14 Rothemuehle Brandt Kritzler HEATING SHEET PACKAGE FOR REGENERATIVE HEAT EXCHANGER AND METHOD AND DEVICE FOR PRODUCING PROFILE SHEETS FOR SUCH HEATING SHEET PACKAGES
DE4309844C2 (en) * 1993-03-26 1998-11-05 Krc Umwelttechnik Gmbh Process for producing a tube bundle heat exchanger for flue gases
DE4415178C2 (en) * 1994-04-29 1997-03-20 Flucorrex Ag Flawil Corrosion-resistant composite pipe, process for its production and its use
DE19940627A1 (en) * 1999-08-27 2001-03-01 Abb Patent Gmbh Heating element for a regenerative heat exchanger and method for producing a heating element

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EP1475597A2 (en) 2004-11-10
ATE497598T1 (en) 2011-02-15
ES2361926T3 (en) 2011-06-24
DE10320462B3 (en) 2005-03-03
EP1475597A3 (en) 2006-11-15

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