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JOB No. DOC. No. REV.

Structural Analysis & CFD Group
0-3952-20 ０
EN Technology Center, EN div.
DATE 28  Oct  08 SHEET 1 OF 14
PREP’D T H
CHK’D KK
APP’D KK

DQR PJ

Analysis of Water Sprayer in Flue Gas Bypass Line

(2nd Regenerator)

REV. DATE PAGE DESCRIPTION PREP’D CHK’D APP’D

28-Oct-08 ALL First Issue TH KK KK
1. Objective
CFD analysis of water sprayer in flue gas bypass line in case of emergency of heat recovery
equipment such as Economizer and Waste heat boiler has been conducted in order to predict
temperature decrease of flue gas at the inlet of other equipments. In addition, possibility of
water drip on the wall and coalescence due to collision between droplets from the counter
nozzles is studied.

2. Software

CFX-5 (Developer: ANSYS Inc., USA)

3. CFD Model and Conditions

3.1 CFD model
CFD analysis was carried out using spray dryer model. In this model,
droplets of water sprayed into flue gas line and each droplet passes
through each trajectory and evaporates influenced by surrounding fluid
flow and temperature. As a result of evaporation of droplets, the diameter
of droplets decrease and the temperature of flue gas decreased.

Diameter of droplet : 100 micro meter

Spray pattern : Cone
Spray angle : 90 degree
Initial droplet velocity: 80 m/s

3.2 Study cases

Study cases of Economizer bypass line are shown in Table-1. Study cases
of Waste Heat Recovery unit bypass line are shown in Table-2.

Table-1 Study Cases and conditions

(Economizer bypass line)
Condition Case-1 Case-2
(*1)
Design Case Turndown Case
Flue gas
Flow rate 609,700 kg/hr 312,840 kg/hr
Temperature 326 deg. C 318 deg. C
Spray water(SPR-1505)
Flow rate
Cooled flue gas
Temperature 242 deg. C 237 deg. C
(*1) 60 % operation of Batch Ho MG case ( 521,393 kg/hr)

Table-2 Study Cases and conditions

(Waste heat recovery unit bypass line)

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 Condition Case-3 Case-4
(*2)
Design Case Startup Case
Flue gas
Flow rate 152,640 kg/hr 19,011 kg/hr
Temperature 772 deg. C 400 deg. C
Spray water(SPR-1504)
Flow rate
Cooled flue gas
Temperature 350 deg. C 350 deg. C
(*2) Air only, Flow rate: 60% of 31685 kg/hr

3.3 Geometry model

Geometry model and position of water sprayer (SPR-1505) of 2 nd
regenerator flue gas bypass line for Economizer is shown Figure-1 and
Figure-2.
Geometry model and position of water sprayer (SPR-1504) of 2 nd
regenerator flue gas bypass line for Waste Heat Recovery Unit is shown
Figure-3 and Figure-4.

4. Results
4.1 Water sprayer (SPR-1505) of flue gas bypass line for Economizer
In case of case-1, design condition case for Economizer trip, trajectory and
diameter distribution of spray water particles in flue gas line are shown in
Figure-5 to Figure-9. Temperature profiles of flue gas are shown in Figure-
10 to Figure-15.
These results show that water particles evaporate completely near the inlet
of stack as shown in Figure-5 to Figure-7. Collision of particles to the wall is
not observed as shown in Figure-8 and Figure-9. Also, collision between
particles from counter nozzles is not observed as shown in Figure-5.
Temperature distribution in a cross-sectional area of pipe is shown in Figure-
10 and Figure-13 to Figure-15.,

In case of case-2, turndown condition case for Economizer trip, trajectory

and diameter distribution of spray water particles in flue gas line are shown
in Figure-16 to Figure-20. Temperature profiles of flue gas are shown in
Figure-21 to Figure-26.
These results show that water particles evaporate completely in the middle
of piping as shown in Figure-16 to Figure-17. Temperature distribution in a
cross-sectional area of pipe is shown in Figure-21 and Figure-24 to Figure-
26.

4.2 Water sprayer (SPR-1504 of 2 nd regenerator flue gas bypass line

for Waste Heat Recovery Unit

3
Later

4
 Stack (SK-
1501)

Figure-1　Geometry Model of Flue Gas Bypass Line for Economizer

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 24.9 m

4.56 m

Position of Water Sprayer

13.0 m (SPR-1505)

Nozzle position:
Upper side of
piping

Figure-2　　Position of Water Sprayer (Top View)

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Figure-3　　Geometry Model of Flue Gas Bypass Line for WHRU

16.0 12.4
m m

Nozzle position:
Lower side of
piping
(SPR-1504)

Figure-4　　　Position of Water Sprayer (Side View)

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 （Color: Diameter of water particle, micron）
Figure-5　　Trajectory and diameter of water particles(Case-1)

（Color: Diameter of water particle, micron）

Figure-6　　Trajectory and diameter of water particles (Case-1:Top View)

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 (Color: Diameter of water particle, micron）
Figure-7　　Trajectory and diameter of water particles (Case-1:Side View)

(View from SK-1501 stack)

Figure-8　　Trajectory and diameter of water particle (Case-1)

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 (View from SK-1501 stack)
Figure-9　　Trajectory and diameter of water particle (Case-1:Side view)

Figure-10　　Temperature profile of Flue Gas(Case-1)

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Figure-11 Temperature profile of Flue Gas (Case-1:Top view, Horizontal
plane）

Figure-12 Temperature profile of Flue Gas (Case-1:Side view, Vertical

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plane)

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 (5.2m length from center of T-junction)
Figure-13 Temperature profile of Flue Gas (Case-1: Vertical plan)

(10.5 m length from center of T-junction)

Figure-14 Temperature profile of Flue Gas (Case-1: Vertical plan)

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 (20.5 m length from center of T-junction)
Figure-15 Temperature profile of Flue Gas (Case-1: Vertical plan)

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 （Color: Diameter of water particle, micron）
Figure-16　　Trajectory and diameter of water particles(Case-2)

（Color: Diameter of water particle, micron）

Figure-17　　Trajectory and diameter of water particles (Case-2:Top View)

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 (Color: Diameter of water particle, micron）
Figure-18　　Trajectory and diameter of water particles (Case-2:Side
View)

(View from SK-1501 stack)

Figure-19　　Trajectory and diameter of water particle (Case-2)

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 (View from SK-1501 stack)
Figure-20　　Trajectory and diameter of water particle (Case-2:Side view)

Figure-21　　Temperature profile of Flue Gas(Case-2)

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Figure-22 Temperature profile of Flue Gas (Case-2: Top view, Horizontal
plane)

Figure-23 Temperature profile of Flue Gas (Case-2: Side view, Vertical

plane)

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 (5.2 m length from center of T-junction)
Figure-24 Temperature profile of Flue Gas (Case-2: Vertical plan)

(10.5 m length from center of T-junction)

Figure-25 Temperature profile of Flue Gas (Case-2: Vertical plan)

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 (20.5 m length from center of T-junction)
Figure-26 Temperature profile of Flue Gas (Case-2: Vertical plan)

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