Simulation and Validation of a Mass Burn WTE Boiler Using CFD Modeling

2004 ◽  
Author(s):  
Greg Epelbaum
Keyword(s):  
Flue Gas ◽  
Cfd Modeling ◽  
Design Parameters ◽  
Air Distribution ◽  
Gas Temperature ◽  
Corrosion Rates ◽  
Velocity Surface ◽  
Boiler Tubes ◽  
Chloride Salts ◽  
Simulation And Validation

American Ref-Fuel Company (ARC) spends millions of dollars each year on corrosion related costs in the boilers. The corrosion is caused by chloride salts in the slag that deposit on the boiler tubes, coupled with the high temperatures of flue gas going through the boiler. Corrosion rates are known to be very sensitive to the flue gas temperature and velocity, surface temperature and heat flux through the slag, oxygen in flue gas distribution, etc. These parameters are primarily determined by the firing rate of the boiler, and they are also affected by combustion control and air distribution in the boiler. Some design parameters, such as surface area of refractory, tile, and inconel overlay, also affect the flue gas temperature throughout the boiler, and thereby impact corrosion.

The Energy-Saving Optimization of the Organic Heat Transfer Material Heater

2012 ◽  
Vol 455-456 ◽  
pp. 284-288
Author(s):  
Wei Li Gu ◽  
Jian Xiang Liu
Keyword(s):  
Heat Transfer ◽  
Energy Saving ◽  
Flue Gas ◽  
Theoretical Basis ◽  
Operation Management ◽  
Exergy Loss ◽  
Irreversible Processes ◽  
Design Parameters ◽  
Gas Temperature

this paper studies the typical irreversible processes such as combustion and heat transfer with temperature difference based on the theory of thermodynamics, analyzes the influencing factors on exergy loss in irreversible processes, on the basis of this analysis, proposes the energy-saving optimization measures on design and operation management of the organic heat transfer material heater, and specially points out that in the design process, objective function can be constructed with the exergy loss as evaluation index to determine the outlet flue gas temperature of furnace and the flue gas temperature, and provides theoretical basis for the determination of design parameters.

Concepts and Experiences for Higher Plant Efficiency With Modern Advanced Boiler and Incineration Technology

2010 ◽  
Author(s):  
Armin Main ◽  
Thomas Maghon
Keyword(s):  
Flue Gas ◽  
Power Plants ◽  
Fossil Fuels ◽  
Live Steam ◽  
Gas Temperature ◽  
Higher Plant ◽  
Advantages And Disadvantages ◽  
Boiler Tubes ◽  
Steam Parameters ◽  
Plant Efficiency

The efforts for reducing CO2 Emissions into atmosphere and increasing costs for fossil fuels concepts are the drivers for Energy from Waste (EfW) facilities with higher plant efficiency. In the past steam parameters for EfW were requested mainly at 40 bars and 400 °C (580 psi and 752 F). In case of coal fired power plants at the same location as the EfW facilities higher steam parameters at 90 bar, 520 °C (1305 psi, 968 F) have been used for the design of stoker and boiler. This long-term experience with higher steam parameters is the platform for the todays and future demand in higher plant efficiency. Increase in EfW plant efficiency is achievable by increasing temperature and pressure of live steam going along with optimized combustion conditions when using well proven grate technology for waste incineration. On the other hand higher steam parameters result in higher corrosion rates on the boiler tubes and the optimization of the combustion conditions are limited by the burn out quality requirements of slag and flue gas. Advantages and disadvantages have therefore to be balanced carefully. This paper will present different measures for optimized boiler and combustion conditions compared to an EfW plant with live steam at 40 bars and 400 °C (580 psi and 752 F) and 60% excess of combustion air. Plants operated at these conditions have very low maintenance costs created by corrosion of boiler tubes and show performance with very high availability. The following parameters and experiences will be evaluated: - reduction of excess air; - flue gas temperature at boiler outlet; - higher steam parameters (pressure and temperature); - heating surfaces for steam superheating in the radiation boiler section; - steam reheating; - external superheaters using auxiliary fuels. The comparison of the different methods for increasing the efficiency together with resulting technology challenges incorporates the experiences from modern EfW reference facilities built in Naples/Italy, Ruedersdorf (Berlin)/Germany and Heringen/Germany.

The Effects of Varied Hydrogen Chloride Gas Concentrations on Corrosion Rates of Commercial Tube Alloys Under Simulated Environment of WTE Facilities

2008 ◽  
Author(s):  
Shang-Hsiu Lee ◽  
Marco J. Castaldi
Keyword(s):  
Flue Gas ◽  
Metal Temperature ◽  
Waste To Energy ◽  
Composition Analysis ◽  
Gas Composition ◽  
Gas Temperature ◽  
Elementary Composition ◽  
Corrosion Rates ◽  
Simulated Environment ◽  
Hcl Concentration

In order to clarify the effects of HCl concentrations on corrosion rates of commercial tubing in Waste-to-Energy (WTE) boilers, a corrosion test was made by altering the HCl concentration from 0 to 1000ppm, together with simulated flue gas composition. Three commercial tubing SA178A, SA213 T11 and NSSER-4 samples were investigated under a well controlled thermal gradient where the gas temperature was at 700°C and metal temperatures ranged from 480 to 580°C. The duration of each test was 100 hours. The posttest analyses included observations of surface morphology and elementary composition analysis of corrosion products by scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS). The corrosion rates were acquired by measuring the mass loss of samples after the test. The results showed that the addition of HCl to the flue gas increased the corrosion rates of test samples, but the relation between the HCl concentration and corrosion rate was not linear. The HCl effects on corrosion rates were more prominent when its concentration changed from 0 to 500ppm. In addition, the HCl effects were promoted by the increase of metal temperature in particular when metal temperature was over 560°C.

Lab-Scale Study on Fireside Superheaters Corrosion in MSWI Plants

2009 ◽  
Author(s):  
Jean-Michel Brossard ◽  
Florimonde Lebel ◽  
Christophe Rapin ◽  
Jean-Franc¸ois Mareˆche´ ◽  
Xavier Chaucherie ◽  
...  
Keyword(s):  
Flow Pattern ◽  
Flue Gas ◽  
Gas Flow ◽  
Operating Conditions ◽  
Gas Temperature ◽  
Steam Temperature ◽  
Corrosion Tests ◽  
Corrosion Rates ◽  
First Results

Combustion of the municipal waste generates highly corrosive gases (HCl, SO2, NaCl, KCl and heavy metals chlorides) and ashes containing alkaline chlorides and sulphates. Currently, corrosion phenomena are particularly observed on superheater’s tubes. Corrosion rates depend mainly on installation design, operating conditions i.e. gas and steam temperature and velocity of the flue gas containing ashes. This paper presents the results obtained using an innovative laboratory-scale corrosion pilot, which simulates MSWI boilers conditions characterized by a temperature gradient at metal tube on the presence of corrosive gases and ashes. The presented corrosion tests were realized on carbon steel at fixed metal temperature (400°C). The influence of the flue gas temperature, synthetic ashes composition and flue gas flow pattern were investigated. After corrosion test, cross section of tube samples were characterised to evaluate thickness loss and estimate corrosion rate while the elements present in corrosion layers were analysed. Corrosion tests were carried out twice in order to validate the accuracy and reproducibility of results. First results highlight the key role of molten phase related to the ash composition and flue gas temperature as well as the deposit morphology, related to the flue gas flow pattern, on the mechanisms and corrosion rates.

scholarly journals Low-Cost Organic Adsorbents for Elemental Mercury Removal from Lignite Flue Gas

Energies ◽  
2021 ◽  
Vol 14 (8) ◽  
pp. 2174
Author(s):  
Marta Marczak-Grzesik ◽  
Stanisław Budzyń ◽  
Barbara Tora ◽  
Szymon Szufa ◽  
Krzysztof Kogut ◽  
...  
Keyword(s):  
Flue Gas ◽  
Low Cost ◽  
Elemental Mercury ◽  
Mercury Content ◽  
Flue Gases ◽  
Mercury Removal ◽  
Gas Purification ◽  
Gas Temperature ◽  
Corn Straw ◽  
Flue Gas Purification

The research presented by the authors in this paper focused on understanding the behavior of mercury during coal combustion and flue gas purification operations. The goal was to determine the flue gas temperature on the mercury emissions limits for the combustion of lignites in the energy sector. The authors examined the process of sorption of mercury from flue gases using fine-grained organic materials. The main objectives of this study were to recommend a low-cost organic adsorbent such as coke dust (CD), corn straw char (CS-400), brominated corn straw char (CS-400-Br), rubber char (RC-600) or granulated rubber char (GRC-600) to efficiently substitute expensive dust-sized activated carbon. The study covered combustion of lignite from a Polish field. The experiment was conducted at temperatures reflecting conditions inside a flue gas purification installation. One of the tested sorbents—tire-derived rubber char that was obtained by pyrolysis—exhibited good potential for Hg0 into Hg2+ oxidation, resulting in enhanced mercury removal from the flue. The char characterization increased elevated bromine content (mercury oxidizing agent) in comparison to the other selected adsorbents. This paper presents the results of laboratory tests of mercury sorption from the flue gases at temperatures of 95, 125, 155 and 185 °C. The average mercury content in Polish lignite was 465 μg·kg−1. The concentration of mercury in flue gases emitted into the atmosphere was 17.8 µg·m−3. The study analyzed five low-cost sorbents with the average achieved efficiency of mercury removal from 18.3% to 96.1% for lignite combustion depending on the flue gas temperature.

Numerical simulation and field test study of desulfurization wastewater evaporation treatment through flue gas

2014 ◽  
Vol 70 (7) ◽  
pp. 1285-1291 ◽  
Author(s):  
Jia-jia Deng ◽  
Liang-ming Pan ◽  
De-qi Chen ◽  
Yu-quan Dong ◽  
Cheng-mu Wang ◽  
...  
Keyword(s):  
Field Test ◽  
Flue Gas ◽  
Cfd Simulation ◽  
Electrostatic Precipitator ◽  
Negative Impact ◽  
Positive Impact ◽  
Field Tests ◽  
Gas Temperature ◽  
Simulation Results ◽  
Desulfurization Wastewater

Aimed at cost saving and pollution reduction, a novel desulfurization wastewater evaporation treatment system (DWETS) for handling wet flue gas desulfurization (WFGD) wastewater of a coal-fired power plant was studied. The system's advantages include simple process, and less investment and space. The feasibility of this system has been proven and the appropriate position and number of nozzles, the spray droplet size and flue gas temperature limitation have been obtained by computational fluid dynamics (CFD) simulation. The simulation results show that a longer duct, smaller diameter and higher flue gas temperature could help to increase the evaporation rate. The optimal DWETS design of Shangdu plant is 100 μm droplet sprayed by two nozzles located at the long duct when the flue gas temperature is 130 °C. Field tests were carried out based on the simulation results. The effects of running DWETS on the downstream devices have been studied. The results show that DWETS has a positive impact on ash removal efficiency and does not have any negative impact on the electrostatic precipitator (ESP), flue gas heat exchanger and WFGD. The pH values of the slurry of WFGD slightly increase when the DWETS is running. The simulation and field test of the DWETS show that it is a feasible future technology for desulfurization wastewater treatment.

NOx process inhibition and energy efficiency improvement in new swirl modification device for steel slag based on coal combustion

2018 ◽  
Vol 16 (7) ◽  
Author(s):  
Junxiang Guo ◽  
Lingling Zhang ◽  
Daqiang Cang ◽  
Liying Qi ◽  
Wenbin Dai ◽  
...  
Keyword(s):  
Energy Efficiency ◽  
Flue Gas ◽  
Coal Combustion ◽  
Steel Slag ◽  
Coal Ash ◽  
Combustion Efficiency ◽  
Gas Temperature ◽  
Staged Combustion ◽  
Energy Efficiency Improvement ◽  
Swirl Combustion

Abstract In this study, a novel swirl combustion modified device for steel slag was designed and enhanced with the objective of achieving highly efficient and clean coal combustion and also for achieving the whole elements utilization of coal. Coal ash and steel slag were melted in the combustion chamber and subsequently entered the slag chamber. The detrimental substances solidified and formed crystals, which allowed for the comprehensive utilization of the ash and slag. Our experiments mainly aimed to mitigate the formation of NOx, while using the heat and slag simultaneously during the coal combustion without a combustion efficiency penalty. The increase in the device’s energy efficiency and reduction in the NOx emissions are important requirements for industrialization. The experiments were carried out in an optimized swirling combustion device, which had a different structure and various coal feeding conditions in comparison to previously reported devices. The fuel-staged and non-staged combustion experiments were compared under different coal ratios (bitumite:anthracite). For the fuel-staged combustion experiments, the NOx concentration in the flue gas was observed to decrease significantly when the coal ratio of 1:1, an excess air coefficient of 1.2, and a fuel-staged ratio of 15:85 were used. Under these conditions, the flue gas temperature was as high as 1,620°C, while the NOx concentration was as low as 320 mg/m3 at 6 % O2. The air-surrounding-fuel structure that formed in the furnace was very beneficial in reducing the formation of NOx. In comparison to other types of coal burners, the experimental combustion device designed in this study achieved a significant reduction of NOx emissions (approximately 80 %).

Impact of Operating Conditions and Design Parameters on Gas Turbine Hot Section Creep Life

2010 ◽  
Author(s):  
S. Eshati ◽  
M. F. Abdul Ghafir ◽  
P. Laskaridis ◽  
Y. G. Li
Keyword(s):  
Gas Turbines ◽  
Performance Model ◽  
Operating Conditions ◽  
Creep Model ◽  
Design Parameters ◽  
Gas Temperature ◽  
Creep Life ◽  
Cooling Effectiveness ◽  
Radial Temperature ◽  
The Impact

This paper investigates the relationship between design parameters and creep life consumption of stationary gas turbines using a physics based life model. A representative thermodynamic performance model is used to simulate engine performance. The output from the performance model is used as an input to the physics based model. The model consists of blade sizing model which sizes the HPT blade using the constant nozzle method, mechanical stress model which performs the stress analysis, thermal model which performs thermal analysis by considering the radial distribution of gas temperature, and creep model which using the Larson-miller parameter to calculate the lowest blade creep life. The effect of different parameters including radial temperature distortion factor (RTDF), material properties, cooling effectiveness and turbine entry temperatures (TET) is investigated. The results show that different design parameter combined with a change in operating conditions can significantly affect the creep life of the HPT blade and the location along the span of the blade where the failure could occur. Using lower RTDF the lowest creep life is located at the lower section of the span, whereas at higher RTDF the lowest creep life is located at the upper side of the span. It also shows that at different cooling effectiveness and TET for both materials the lowest blade creep life is located between the mid and the tip of the span. The physics based model was found to be simple and useful tool to investigate the impact of the above parameters on creep life.

Effect of Air Distribution on Solid Fuel Bed Combustion

1997 ◽  
Vol 119 (2) ◽  
pp. 120-128 ◽  
Author(s):  
J. T. Kuo ◽  
W.-S. Hsu ◽  
T.-C. Yo
Keyword(s):  
Combustion Efficiency ◽  
Pollutant Emissions ◽  
Air Distribution ◽  
Gas Temperature ◽  
One Dimensional ◽  
Supply And Distribution ◽  
Air Supply ◽  
Burning Rates ◽  
Side Walls ◽  
Detailed Chemical

One important aspect of refuse mass-burn combustion control is the manipulation of combustion air. Proper air manipulation is key to the achievement of good combustion efficiency and reduction of pollutant emissions. Experiments, using a small fix-grate laboratory furnace with cylindrical combustion chamber, were performed to investigate the influence of undergrate/sidewall air distribution on the combustion of beds of wood cubes. Wood cubes were used as a convenient laboratory surrogate of solid refuse. Specifically, for different bed configurations (e.g., bed height, bed voidage, bed fuel size, etc.), burning rates and combustion temperatures at different bed locations were measured under various air supply and distribution conditions. One of the significant results of the experimental investigation is that combustion, with air injected from side walls and no undergrate air, has the maximum combustion efficiency. On the other hand, combustion with undergrate air achieves higher combustion rates but with higher CO emissions. A simple one-dimensional model was constructed to derive correlation of combustion rate as a function of flue gas temperature and oxygen concentration. Despite the fact that the model is one-dimensional and many detailed chemical and physical processes of combustion are not considered, comparisons of the model predictions and the experimental results indicate that the model is appropriate for quantitative evaluation of bed-burning rates.

A Model for Calculating the Outlet Flue Gas Temperature of FGD Absorption Tower

2011 ◽  
Vol 130-134 ◽  
pp. 3812-3816
Author(s):  
Gang Xu ◽  
Yao Tian ◽  
Xing Yuan ◽  
Yong Ping Yang
Keyword(s):  
Theoretical Model ◽  
Energy Balance ◽  
Water Consumption ◽  
Flue Gas ◽  
Flue Gas Desulfurization ◽  
Gas Temperature ◽  
Significance Analysis

Theoretical model for calculating the outlet flue gas temperature of limestone-gypsum wet flue gas desulfurization (FGD) absorption tower is important for water consumption calculation. In this paper, the energy balance in the spray zone is analyzed and a model for calculating the outlet flue gas temperature of FGD absorption tower is proposed. An example computation of the outlet flue gas temperature of a typical 600MW class unit’s operation data is introduced, the result has verified the model. A further study of significance analysis has then been made to analyze and simplify the model.

Sign in / Sign up

Export Citation Format

Share Document