Feb. 13, 2004 Feb. 13, 2004 CFD Modeling of Utility Boiler Components at ALSTOM Power Inc. Galen Richards
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Feb. 13, 2004Feb. 13, 2004
CFD Modeling of Utility Boiler Components at
ALSTOM Power Inc.Galen Richards
2-2-2004 Power Plant Laboratories
CFD at ALSTOM Power Inc.
Power Plant Laboratories (Windsor, CT)– 6 Engineers - full time CFD– 4 Engineers - part time CFD– Mainly use FLUENT– Also use CFX, Aiolos– Product development / problem solving for the Utility
Boiler business– Chemical process industry
2-2-2004 Power Plant Laboratories
PPL CFD Examples - Burners
Wall-Fired Coal Burner
LNCFS - P2™ Coal Nozzle
2-2-2004 Power Plant Laboratories
PPL CFD Examples - Boilers
HRSGStokerPC Boiler
2-2-2004 Power Plant Laboratories
PPL CFD Examples -Gas Turbine Combustors
2-2-2004 Power Plant Laboratories
Steam Drum Internals
2-2-2004 Power Plant Laboratories
PPL CFD Examples -Steam Drum Internals
Velocity Water m/s
4 Vanes 12 Vanes
2-2-2004 Power Plant Laboratories
Pulverizers
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Pulverizer - Classifier Design
Static Classifiers Dynamic Classifiers
2-2-2004 Power Plant Laboratories
Pulverizer - Exhauster Design
Geometry Particle Concentration
2-2-2004 Power Plant Laboratories
Pulverizer - Exhauster Design
Predicted Errosion Patterns
2-2-2004 Power Plant Laboratories
Oil-Fired Utility Boiler
2-2-2004 Power Plant Laboratories
Oil Burner - Impact of Tilt
Windbox
Aux Air Nozzles20o Up Tilt
Fuel Air Nozzle 20o Up Tilt
2-2-2004 Power Plant Laboratories
Oil-Fired Boiler
Particle Trajectories Gas Temperature
2-2-2004 Power Plant Laboratories
Natural Gas-Fired Utility Boiler
2-2-2004 Power Plant Laboratories
Gas-Fired Boiler: Description
MCR 700 MWNatural gas fuelTangential firing system5 burner elevations30% flue gas recirculation (FGR)FGR with combustion air 12% separated overfire air (SOFA)50 ppm NOx
2-2-2004 Power Plant Laboratories
Gas Fired Boiler
Objective: Low cost solution for NOx of 15 ppm
NOx reduction strategies– Increased FGR– Steam or water injection– SOFA quantity and location– Burners out of service– Decreased load
2-2-2004 Power Plant Laboratories
Gas-Fired Boiler: Geometry
Windbox
SOFA
DivisionPanels
Economizer
Reheater
SH PendantSH Platen
Outlet
2-2-2004 Power Plant Laboratories
Gas-Fired Boiler: Geometry
Gas Inlet
Oil Air Inlet
Gas InletCombustionAir Inlet
Gas Inlet
Oil Air Inlet
Gas Inlet
2-2-2004 Power Plant Laboratories
Gas-Fired Boiler: Baseline
Temperature Oxygen NOx
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Gas-Fired Boiler: NOx vs FGR
0
10
20
30
40
50
60
25 30 35 40 45 50% FGR
NO
x [p
pm-d
ry, c
or.]
NOx-Predicted
NOx-Measured
2-2-2004 Power Plant Laboratories
Gas-Fired Boiler: Conclusions
NOx emissions of 15 ppmachievable – Increase FGR to 45%– Inject 60,000 lb/hr of steam or
water through oil guns– or reduction to 950 ºF SH – Add independent yaw control
on SOFA tips to tune for CO
100 micron water droplets
2-2-2004 Power Plant Laboratories
SCR Design Issues– Flow Distribution– Temperature Distribution– System Pressure Drop– Particle Collection
2-2-2004 Power Plant Laboratories
SCR Design
TurningVanes
Mixer
AIG EconomizerOutlet
Catalyst
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SCR - Velocity Distribution
Velocity ft/s
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SCR - Measured NOx Profile
NOx, ppm
A - Side
B - Side
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SCR - Ammonia Injection Grid
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SCR - Ammonia Injection GridNormalizedmole fractionratio: NH3/NO
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SCR - Vane Design
Suggested Vane Installation
Max velocityat corner ~ 130 fps
Velocity at cornerreduced to ~ 80 fps
No Vanes in SCR Outlet
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SCR - Particle Collection
50 microns 250 microns
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SCR - Particle Collection
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0 50 100 150 200 250 300 350 400 450 500
Low Load - Flyash
High Load- Flyash
Col
lect
ed in
Hop
pers
(%)
Flyash Diameter - microns
2-2-2004 Power Plant Laboratories
SCR - Duct Metal Temperature
Diverging Section(includes spreader vanes)
Skin
Tem
pera
ture
(oR
)
SCR Inlet Duct
AIG Lances
Economizer Bypasses
2-2-2004 Power Plant Laboratories
Conclusions
CFD is a valuable design tool for a wide range of power generation applications
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