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Abstract
Studies into the effects of operating conditions in a wall fired furnace using commercial code FLUENT is presented in this paper. The
mathematical model is based on a Eulerian description for the continuum phase and a stochastic Lagrangian description for the coal particles. A
3-D combustor model is used to determine the temperature and heat flux profiles and other thermal characteristics for a typical 500 MW utility boiler
firing medium volatile coal. Temperature profiles for a 100% boiler load as well as reduced boiler loads are predicted using the 3-D model. Particle
trajectories are analyzed to identify the causes of operational problems such as fouling on burners, regions of high-unburnt carbon and temperatures
achieved in various parts of the boiler during the combustion process. The effect of excess air on the furnace temperature pattern is also studied.
Model calculations showed good agreement with experimental measurements in both full and pilot scale systems as well as limited literature data.
Using the experience obtained by these CFD model studies can potentially improve the operation of a boiler, regarding stability and local material
temperature of the walls, which lay a foundation for the boiler operating expert system.
2006 Elsevier B.V. All rights reserved.
Keywords: Wall fired furnace; Grid generation; CFD; Turbulent flow; Multiphase flow; Particle trajectories
1. Introduction
The interest on performance optimisation of large utility
boilers has become very relevant in recent years. All the
optimisation strategies are directed at extending their lifetime,
increasing the thermal efficiency and reducing the pollutant
emissions. Moreover, efficient use of pulverised coal is crucial
to the utility industry. To achieve higher combustion efficiency,
the major influencing factors such as the particle size
distribution, gas and particle temperatures, local heat release,
local oxygen concentration, kinetic parameters for coal devolatilization and char oxidation, char properties should be
understood thoroughly [1,2]. In engineering practice, it is very
difficult to investigate the combustion processes of various
kinds of combustibles directly in the boiler. Rather than
constructing real boilers and trying to check and improve
Corresponding author. Tel.: +61 8 9266 4685; fax: +61 8 9266 2681.
E-mail address: h.vuthaluru@exchange.curtin.edu.au (H.B. Vuthaluru).
0378-3820/$ - see front matter 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.fuproc.2006.01.004
634
radiation distribution within the furnace. This paper concentrates on the prediction of furnace performance for different
boiler operating conditions. The boiler geometry and operating
conditions along with the mathematical model used are detailed
in the following section. Results simulated are based on real
cases (different operating conditions used in the industry), but
the data sources have necessarily been disguised to the extent
that industry proprietary concerns are not infringed. It must be
mentioned that the verification of the computational simulations
are expensive to obtain, but even if the user has experimental
data available, the comparison between these data and
predictions leaves the user uncertain about both the errors in
the model and experimental data. Nevertheless, using the
experience obtained by a CFD model can significantly improve
the operation of a boiler, regarding stability and local material
temperature of the walls.
2. Furnace geometry and operating conditions
The three-dimensional geometry was created using GAMBIT a FLUENT pre-processor [15]. An isotropic view of the
geometry and grid system is shown in Fig. 1. The meshedgeometry contained 192,950 nodes with hexahedral cells in one
zone and the remaining zones with quadrilateral cells.
In order to make accurate quantitative predictions about
combustion behavior, it is important that an appropriate
geometry is created with suitable meshing techniques. About
Table 1
Specifications of the furnace geometry
Parameter
Value (m)
30
2.29 & 1.98
4.57
2.48
2.14
Proximate analysis
(% db)
Ultimate analysis
(% daf)
Moisture
Ash content
Volatile matter
Fixed carbon
Total sulfur
17
4
37
43
0.83
Carbon
Hydrogen
Nitrogen
Sulfur
Oxygen
74.42
4.9
1.5
1.0
18.13
Base case
32 firing
22
firing
21
firing
32 firing
with excess
air
19.95 &
343
89.57 &
573 K
37
68.1
15.96 &
343
71.66 &
573 K
37
54.4
11.97 &
343
53.74 &
573 K
37
40.8
635
Fig. 3. Scaled residuals for total combustion process including the discrete phase.
636
1.80e+03
1.73e+03
1.66e+03
1.59e+03
1.52e+03
1.45e+03
1.38e+03
1.31e+03
1.24e+03
1.17e+03
1.10e+03
1.03e+03
9.60e+02
8.90e+02
8.20e+02
7.50e+02
6.80e+02
6.10e+02
Y
5.40e+02
4.70e+02
4.00e+02 Z
Fig. 4. Temperature fields in a coal fired furnace at three different operating conditions. Plane z = 10.65 m crossing first burner in each row.
furnace walls in three tiers, only five of the burner sets are in
operation at any particular time and one set is used as a standby.
Hence, only five sets are considered as full load (hereafter
referred to as base case) for modelling the operation.
The calculated primary and secondary air velocities are 20
and 30 m/s, respectively, which have been determined from the
mass flow of combustion air and temperature of preheated air.
Another boundary condition is the outflow that is expressed as
outlet with the external radiation temperature. This temperature
is equal to the wall temperature and approximately corresponds
with vaporization of water in evaporator. In this case, the
temperature of the walls is equal to 600 K with an emissivity of
1. The summary of boundary conditions (inlets and outlets
conditions) is given in Table 3.
4.1. Solution approach to base model
It is generally recommended to start and obtain a nonreacting flow solution for coal combustion [57]. Despite the
2.10e+03
2.02e+03
1.93e+03
1.85e+03
1.76e+03
1.68e+03
1.59e+03
1.51e+03
1.42e+03
1.34e+03
1.25e+03
1.17e+03
1.08e+03
9.95e+02
9.10e+02
8.25e+02
7.40e+02
6.55e+02
5.70e+02
4.85e+02
4.00e+02
Table 4
Comparison of predicted temperatures with measurements in full- and pilotscale furnaces and (literature) reported data
Y
Z
Case
Base case
32 firing
22
firing
21
firing
Base case 32
firing with
excess air
Current model
Full scale boiler
Pilot scale furnace
Literature datab
1332
12901350
1331a
1287
1304
1260
1168
1067
1495
a
A firing rate of 218 kWth with excess air adjusted to give 2.6% (v/v, dry)
oxygen in flue gas.
b
Reported values correspond to base-case (all 20 burners), 14 rows (16
burners) and partial load 34 rows (8 burners) in service, respectively.
Base case
32 firing
22
firing
21
firing
Base case 32
firing with
excess air
Current model
Full scale
Pilot scale
Literature data a
5.4 105
3.0 105
4.98 105
3.18 105
3.91 105
2.94 105
8.16 105
3.3 105
3.2 105
1.65 105
637
Rear
Wall
Fig. 6. Radiation heat flux (w/m2) to walls for the case of excess air.
Right
Wall
638
Fig. 7. Particle traces coloured by particle residence time for selected burner
ports. a) Base case; b) Base case with excess air.
639