A project under the guidance

of

Dr. M.R.Ravi & Mr. V.K. Prabodh


By
Pravat Ranjan Jena
2005JPG3145

3-D CFD Modeling Of Temperature imbalance and
NOx emission in a tangentially fired, tower type
500MWe boiler
Problem Description
TALCHER SUPER THERMAL POWER PROJECT
Once Through,
Tower Type,
Tangentially
Fired Boiler
Problem Description
Velocity at Mid x-section and at
mid y-section(500 MW)
Salient features of the flow:
Strongly swirling flow in
the furnace.
Recirculating flow into the
core section.

Source-M.Tech dissertation
of Prabodh(2002
ITSH SECTION
Problem Description
Temperature contour at Mid x-section
and at mid y-section(500 MW)
Low temperature
at the centre due
to recirculation of
cold gases into the
core at ITSH exit.

Source-M.Tech dissertation
of Prabodh(2002
Problem Description
Heat Transfer in ITSH
Bundles

Low heat
transfer in the
central banks
due to low gas
temperature.
High heat flux in
banks towards
the right and left
wall leading to
overheating.
Source-M.Tech dissertation
of Prabodh(2002
3D modelling of the
steam generator
using Gambit and
analysis with
Fluent to find
Optimum mass fraction of
SOFA
Optimum Yaw Angle
Optimum Location of SOFA
Gas velocity and Temperature
field
To predict
Objective

Proposed
Location
for
SOFA
ECO-1
ECO-2
LTRH
HTSH
HTRH
ITSH
Furnace Diagonal
Adjustable
Yaw
Existing
Over Fire Air
Proposed
Location
for
SOFA
Use the Geometric Model Developed by
Prabodh (2002) on Fluent 5.1
Reproduce the result on Fluent 6.2
Parametric study: Defining Base line
Yaw Angle variation : -15
0
,0
0
and +15
0

Mass Fraction variation : 5 to 10% of
stoichiometric air.
Velocity variation : 1 to 1.75 times
secondary air.
Location of SOFA : 42, 45 and 50 meter
Analysis of Result
Recommendations
Scope of Work
Work Plan
Case Details
Case
No
Location Mass Fraction Velocity
in
m/sec
YAW
Angle
Area of
Opening
of SOFA

bz

ofa

sofa


1-18
42
45
50
1
0.925
0.11
0.16


0.05
0.075
17
25.5
-15
0
0
0

+15
0


0.549
Case
No
Location Mass Fraction Velocity
in
m/sec
YAW
Angle
Area of
Opening
of SOFA

bz

ofa

sofa


19-36
42
45
50
1
0.925
0.90
0.11
0.16
0.16

0.05
0.075
0.10
20
30
0
0
0.466
0.698
0.933
0.311
0.620
Click to Case Details
Mathematical Modeling

Flow Modeling
Realizable k- model
Combustion Modeling
Non-Premixed, Non Adiabatic PDF model
Radiation Heat Transfer Modeling
P-1 Radiation Model
Discrete Phase Modeling
NO
x
Modeling
Post Processing of Thermal NO
x
and Fuel NO
x


Results and Discussion
Velocity Vector for base case and Case-9 at burner zone.
Flow Field
Velocity Vector for base case and Case-9 at ITSH inlet (50m).

Results and Discussion
Flow Field
Velocity Vector for base case and Case-9 at ITSH outlet (60m).

Results and Discussion
Flow Field
Results and Discussion
Temperature contour for base case and Case-9 at 50m plane.

Temperature Field
Results and Discussion
Temperature contour for base case and Case-9 at 60m plane.


Temperature Field
Results and Discussion
Temperature contour for base case at mid-x and mid-y plane.
Results and Discussion
Temperature contour at mid-x and mid-y plane for case-9
Results and Discussion
Flue Gas Temperature profile at mid-y axis for base case and case-9 at ITSH entry.
-Case-9
-Base Case
Click here
Results and Discussion
Flue Gas Temperature profile at mid-y axis for base case and case-9 at ITSH exit.
-Case-9
-Base Case
Click here
Results and Discussion
Click
Heating
Surface
Case No. 9
(500MW)

Base Case (500 MW)
Simulation Simulation Design Actual
Water Walls
6576.58
(44.87%)
6716.00
(45.91%)
6737.32
(46.05%)
5684.10
(38.85%)
ITSH
1466.84
(10.01%)
1393.15
(9.52%)
1139.05
(7.79%)
1766.15
(12.07%)
HRTH
895.76
(6.11%)
1178.91
(8.06%)
908.31
(6.21%)
908.72
(6.21%)
HTSH
2054.28
(14.01%)
1959.30
(13.39%)
1572.10
(10.75%)
1720.00
(11.76%)
LTRH
1036.75
(7.07%)
976.87
(6.68%)
1167.89
(7.98%)
1268.72
(8.67%)
Economizer
1351.69
(9.22%)
1303.24
(8.91%)
1336.35
(9.13%)
1323.08
(9.04%)
Total Heat
Transfer
13381.9
(91.32%)
13527.47
(92.46%)
12861.02
(87.91%)
12670.77
(86.61%)
Efficiency 0.9132 0.9246 0.8791 0.8661
Results and Discussion
HEAT TRANSFER TO THE ITSH COILS
0
2
4
6
8
10
12
1 2 3 4 5 6 7 8 9 10 11 12 13 14
ITSH COIL NUMBER
Q

(
M
W
)
case-1
case-2
case-3
case-4
case-5
case-6
case-19
case-20
case-21
case-22
case-23
case-24
Base Case
Heat Transfer in ITSH Bundles for all cases at 42-meter elevation
Results and Discussion
HEAT TRANSFER TO THE ITSH COILS
0
2
4
6
8
10
12
1 2 3 4 5 6 7 8 9 10 11 12 13 14
ITSH COIL NUMBER
Q

(
M
W
)
case-7
case-8
case-9
case-10
case-11
case-12
case-25
case-26
case-27
case-28
case-29
case-30
base-case
Heat Transfer in ITSH Bundles for all cases at 45-meter elevation
Results and Discussion
HEAT TRANSFER TO THE ITSH COILS
0
2
4
6
8
10
12
1 2 3 4 5 6 7 8 9 10 11 12 13 14
ITSH COI L NUM BER
Q

(
M
W
)
case-13
case-14
case-15
case-16
case-17
case-18
case-31
case-32
case-33
case-34
case-35
case-36
Base Case
Heat Transfer in ITSH Bundles for all cases at 50-meter elevation .
Results and Discussion
HEAT TRANSFER TO THE ITSH COILS
0
2
4
6
8
10
12
1 2 3 4 5 6 7 8 9 10 11 12 13 14
ITSH COIL NUMBER
Q

(
M
W
)
Case-9
Base Case
Heat Transfer in ITSH Bundles for Base Case and Case-9
Results and Discussion
Temperature contour at burner zone (35m) for case-9 O2 contour at burner zone (35m) for case-9
NOx contour at burner zone (35m) for case-9
Click here to Total NOx Table
Click here to AvTe- 50m
Click here to AvTe-60m
Results and Discussion
Temperature contour at mid-x and mid-y plane for case-9 O2 contour at mid-x and mid-y for case-9
NOx contour at mid-x and mid-y for case-9
Results and Discussion
Effect of Yaw Angle of SOFA on NO
x
emission is insignificant.
NOx vs YAW ANGLE
0
100
200
300
400
500
600
700
Yaw Angle in Degree
N
O
x

i
n

p
p
m
42m (mass fraction-0.05)
42m(mass fraction-0.075)
45m(mass fraction-0.05)
45m(mass fraction-0.075)
50m(mass fraction-0.05)
50m(mass fraction-0.075)
0
0
+15
0
-15
0

Results and Discussion
0
100
200
300
400
500
600
700
17m/s 20m/s 30m/s
Velocity in m/sec
N
O
x

i

n


p
p
m
SOFA Elevation- 42m
SOFA Elevation-45m
SOFA Elevation-50m
0
100
200
300
400
500
600
700
20m/s 30m/s
Velocity in m/sec
N

O

x



i

n



p

p

m
SOFA Elevation-42m
SOFA Elevation-45m
SOFA Elevation502m
Effect of Velocity on NO
x
is
significant only at 45 m

SOFA
: 0.1;
OFA
: 0.16;
BZ
: 0.90

SOFA
: 0.05;
OFA
: 0.11;
BZ
: 1.0

0
100
200
300
400
500
600
700
20m/s 25.5m/s 30m/s
Velocity in m/sec
N
O
x


i

n


p
p
m
SOFA elevation-42m
SOFA Elevation-45m
SOFA Elevation-50m

SOFA
: 0.075;
OFA
: 0.16;
BZ
: 0.925

Results and Discussion
0
100
200
300
400
500
600
700
0.05 0.075 0.1
Mass Fraction
N
O
x

i
n

p
p
m
42m,vel-20m/s
42m,vel-30m/s
45m,vel-20m/s
45mvel-30m/s
50m,vel-20m/s
50m,vel-30m/s
As the mass fraction of SOFA is increased the
elevation of SOFA for minimum NO
x
increases
0
200
400
600
800
Case Number
N
O
x

i
n

p
p
m
42m all cases
45m all cases
50m all cases
1 2 3 4 5 6 19 20 21 22 23 24
7 8 9 10 11 12 25 26 27 28 29 30
13 14 15 16 17 18 31 32 33 34 35 36
Results and Discussion
As the Area of opening of SOFA is changed along with velocity and
mass fraction a sharp rise in NO
x
emission is observed at 45-m.
Concluding remarks
Introduction of SOFA successfully eliminates flow reversal
at ITSH and results in a more uniform gas temperature.
Effect of Yaw angle of SOFA on NO
x
emission is
insignificant.
Effect of velocity of SOFA on NO
x
emission is significant
only at 45-m.
As the mass fraction of SOFA is increased, the optimum
velocity (for minimum NO
x
) increases (for 45-m cases)
Minimum NO
x
of 285.83 ppm(w) was obtained for Case-10.
However, Case-9 was selected as the optimum solution
with NO
x
emission of 303.63 ppm (w) with a more uniform
temperature distribution compared to Case-10.
Scope For Future Work

Effects of other variables like angle of tilt,
different locations, velocity, mass fraction and
area of opening of SOFA can be studied.
Effect of SOFA on slagging in the furnace zone
needs to be studied.
Effect of SOFA on char burn out needs to
studied.
Thank You

0
200
400
600
800
1000
1200
1400
1600
1800
2000
15 23 31 39 41 43 45 47 49 51 75
Elevation in meter
P
l
a
n
e

A
v
e
r
a
g
e

N
O
x
,

O
2
,

T
e
m
p
e
r
a
t
u
r
e
Case_13_NOx(scale in 1e-06)
Case_1_NOx(scale in 1e-06)
Case_1_Temp
Case_7_Temp
Case_13_Temp
Case_1_O2(scale in 1e-04)
Case_7_O2(scale in 1e-04)
Case_13_O2(scale in 1e-04)
Case_7_NOx (scale in 1e-06)