Flow Distribution Influences on Flow Distribution Influences on Air Pollution Control Equipment Air Pollution Control Equipment Performance Performance Robert Mudry, P.E. Vice President – Engineering Airflow Sciences Corporation [email protected]WPCA Seminar – Ameren May 31 – June 1, 2006 Robert Mudry, P.E. Robert Mudry, P.E. Vice President Vice President – – Engineering Engineering Airflow Sciences Corporation Airflow Sciences Corporation rmudry rmudry @ @ airflowsciences airflowsciences .com .com WPCA Seminar WPCA Seminar – – Ameren Ameren May 31 May 31 – – June 1, 2006 June 1, 2006 1 1 Airflow Sciences Corporation
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Flow Distribution Influences onFlow Distribution Influences onAir Pollution Control Equipment Air Pollution Control Equipment
PerformancePerformanceRobert Mudry, P.E.Vice President – EngineeringAirflow Sciences [email protected]
WPCA Seminar – AmerenMay 31 – June 1, 2006
Robert Mudry, P.E.Robert Mudry, P.E.Vice President Vice President –– EngineeringEngineeringAirflow Sciences CorporationAirflow Sciences Corporationrmudryrmudry@@airflowsciencesairflowsciences.com.com
WPCA Seminar WPCA Seminar –– AmerenAmerenMay 31 May 31 –– June 1, 2006June 1, 2006
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OutlineOutline
IntroductionFlow Distribution Analysis TechniquesApplication to Air Pollution Control Equipment• ESP• FF• SCR• FGD
Other ApplicationsConclusionsQuestions
IntroductionIntroductionFlow Distribution Analysis TechniquesFlow Distribution Analysis TechniquesApplication to Air Pollution Control EquipmentApplication to Air Pollution Control Equipment•• ESPESP•• FFFF•• SCRSCR•• FGDFGD
Other ApplicationsOther ApplicationsConclusionsConclusionsQuestionsQuestions
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IntroductionIntroduction
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Why is Flow Distribution Important to APC Equipment?• Performance
Flow uniformityChemical species injectionAsh capture / build-up
• Operating costsPressure dropErosionCorrosion
Applications• Design of new equipment• Retrofit of existing equipment• Solving operational or maintenance issues
Why is Flow Distribution Important to APC Equipment?Why is Flow Distribution Important to APC Equipment?•• Performance Performance
Flow uniformityFlow uniformityChemical species injectionChemical species injectionAsh capture / buildAsh capture / build--upup
ApplicationsApplications•• Design of new equipmentDesign of new equipment•• Retrofit of existing equipmentRetrofit of existing equipment•• Solving operational or maintenance issuesSolving operational or maintenance issues
OutlineOutline
Introduction
Flow Distribution Analysis Techniques• Field Testing• Computational Fluid Dynamics (CFD)• Physical Flow Modeling
Application to APC Equipment
Other Applications
Conclusions
Questions
IntroductionIntroduction
Flow Distribution Analysis TechniquesFlow Distribution Analysis Techniques•• Field TestingField Testing•• Computational Fluid Dynamics (CFD)Computational Fluid Dynamics (CFD)•• Physical Flow ModelingPhysical Flow Modeling
Application to APC EquipmentApplication to APC Equipment
Other ApplicationsOther Applications
ConclusionsConclusions
QuestionsQuestions
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ESP Field Testing
Field Testing Field Testing Velocity
Temperature
Pressure
Particulate
Chemical species
VelocityVelocity
TemperatureTemperature
PressurePressure
ParticulateParticulate
Chemical speciesChemical species
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Physical Flow Physical Flow ModelingModeling
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Pros• Easy flow visualization• Ash buildup analysis• Touch & feel benefit• Gas injection possible
Cons• “Cold” flow• Geometric simplification• Scaled (incl perforated plate)• Longer schedule & more $$ than CFD model• Harder to make design changes (serial)
ConsCons•• ““ColdCold”” flowflow•• Geometric simplificationGeometric simplification•• Scaled (Scaled (inclincl perforated plate)perforated plate)•• Longer schedule & more $$ than CFD modelLonger schedule & more $$ than CFD model•• Harder to make design changes (serial)Harder to make design changes (serial)
Pros• Thermal effects considered• Full scale• Lower $$ and time than physical model• Liquid & gas injection possible• Easy to make changes• Design runs done in parallel
Cons• Geometry is “virtual”• Bulk effects of small geometry modeled• Ash dropout & reentrainment prediction issues• Require high-end computers
ProsPros•• Thermal effects consideredThermal effects considered•• Full scaleFull scale•• Lower $$ and time than physical modelLower $$ and time than physical model•• Liquid & gas injection possibleLiquid & gas injection possible•• Easy to make changesEasy to make changes•• Design runs done in parallelDesign runs done in parallel
ConsCons•• Geometry is Geometry is ““virtualvirtual””•• Bulk effects of small geometry Bulk effects of small geometry modeledmodeled•• Ash dropout & Ash dropout & reentrainmentreentrainment prediction issuesprediction issues•• Require highRequire high--end computersend computers
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OutlineOutline
IntroductionFlow Distribution Analysis TechniquesApplication to APC Equipment• ESP• FF• SCR• FGD
Other ApplicationsConclusionsQuestions
IntroductionIntroductionFlow Distribution Analysis TechniquesFlow Distribution Analysis TechniquesApplication to APC EquipmentApplication to APC Equipment•• ESPESP•• FFFF•• SCRSCR•• FGDFGD
Other ApplicationsOther ApplicationsConclusionsConclusionsQuestionsQuestions
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ESP Flow ModelingESP Flow Modeling
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Flow distribution
Flow balance between cells
Pressure loss
Thermal mixing
Gas conditioning
Ash deposition
Flow distributionFlow distribution
Flow balance Flow balance between cellsbetween cells
Pressure lossPressure loss
Thermal mixingThermal mixing
Gas conditioningGas conditioning
Ash depositionAsh deposition
ESP Velocity DistributionESP Velocity DistributionUniform velocity within collection region
Industry standards• ICAC• % RMS
deviation
Uniform velocity within collection regionUniform velocity within collection region
Industry standardsIndustry standards•• ICACICAC•• % RMS % RMS
deviationdeviation
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Gas Flow BalanceGas Flow Balance
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Industry standard +/- 10% deviationIndustry standard +/Industry standard +/-- 10% deviation10% deviation
CFD modeling to predict:CFD modeling to predict:•• Gas velocity patternsGas velocity patterns•• LPA particle pathsLPA particle paths•• Hopper capture efficiencyHopper capture efficiency•• Pressure lossPressure loss•• Erosion potentialErosion potential
FGD Flow ModelingFGD Flow Modeling
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Flow distributionWater droplet behaviorPressure loss Ash deposition
Flow distributionFlow distributionWater droplet behaviorWater droplet behaviorPressure loss Pressure loss Ash depositionAsh deposition
OutlineOutline
Introduction
Flow Modeling Methods
Application to APC Equipment
Other Applications
Conclusions
Questions
IntroductionIntroduction
Flow Modeling MethodsFlow Modeling Methods
Application to APC EquipmentApplication to APC Equipment
Other ApplicationsOther Applications
ConclusionsConclusions
QuestionsQuestions
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Power IndustryPower IndustryVirtually every component of a power plant can be modeled that involves flow (air, gas, liquid, steam, particulate), heat transfer, combustion, or chemical reaction
Virtually every component of a power plant can be modeled Virtually every component of a power plant can be modeled that involves flow (air, gas, liquid, steam, particulate), heat that involves flow (air, gas, liquid, steam, particulate), heat transfer, combustion, or chemical reactiontransfer, combustion, or chemical reaction
Gas flow patterns have significant impact on the performance of air pollution control equipment
Analysis and design tools include field testing and flow modeling
CFD and physical modeling are applied to a wide range of equipment “from the fan to the stack”
Gas flow patterns have significant impact on Gas flow patterns have significant impact on the performance of air pollution control the performance of air pollution control equipmentequipment
Analysis and design tools include field testing Analysis and design tools include field testing and flow modelingand flow modeling
CFD and physical modeling are applied to a CFD and physical modeling are applied to a wide range of equipment wide range of equipment ““from the fan to the from the fan to the stackstack””
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Questions?Questions?
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If you would like an electronic copy of this presentation, please contact Rob Mudry as follows:[email protected]. 734-525-0300