Numerical Study of the Effect of Primary Air Velocity of Pulverizer...
Transcript of Numerical Study of the Effect of Primary Air Velocity of Pulverizer...
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:20 No:01 70
202101-5353-IJMME-IJENS © February 2020 IJENS I J E N S
Abstract— The challenges faced by the electricity industry
in Indonesia at present with a considerable generating
capacity. One of them is the problem of variations in coal
calories and fuel prices. Besides that, it also relates to the
amount of generating capacity which has an impact on the
amount of NOx gas release which has the potential to disturb
the environment. By understanding the mechanism of
optimization and setting of the pulverizer in this case the primary air velocity settings that coming out of each pulverizer
output line can improve the performance of the generator itself
and reduce NOx gas. By setting the primary air velocity at the
outlet the process of forming fireball is more perfect which
influences a better combustion process. Thus, the purpose of
this research is to obtain the condition of setting the primary
air velocity so that it causes the combustion process to produce
exhaust gas with NOx content that meets the applicable
criteria. In this study the Computational Fluid Dynamics (CFD)
method is used. The boiler geometries are made using Gambit
software and for numerical simulations using ANSYS Fluent
software 19.2. For validation, the initial simulation results for the current boiler conditions are compared with actual
measurement data. Furthermore, it will be simulated by
varying the primary air velocity. The simulation results show that the effect of increasing in
velocity outlet of pulverizer on the combustion temperature in
the furnace (without changing secondary water) is inversely
proportional. The greater the velocity outlet pulverizer, the
lower the combustion temperature in the furnace. So that the
recommended model design is a variation of the velocity outlet
of pulverizer with a speed of 28 m/s because it has a
superheater inlet temperature slightly above the existing
model, so that the use of superheater and reheat spray only
slightly adds to the existing model while for NOx mass fraction
boiler output is around 65% of the existing model.
Index Term— Primary air velocity, fireball, computational
Fluid Dynamic, Power Plant.
I. INTRODUCTION
In boilers, air and exhaust gases play an important role in
the combustion process. The air system in general is a
system that functions as a medium for transporting coal to
the boiler, adding oxygen to the combustion process and
making turbulence (secondary air). In this case, there needs
to be optimal air control so that the combustion process is
perfect and efficient. While, the exhaust gas system is the output of the combustion process which is used to transfer
the hot gas from the remaining combustion process to water
and steam pipes and air heating elements. At the time of
stoichiometric combustion, it is a process of mixing
chemical elements between air and fuel which produce
products H, SOx, NOx, CO2, etc. Therefore, it is necessary
to pay attention to how much chemical elements are
produced in the combustion process. In addition, to pay
attention to the balance of fuel and air, it is also necessary to
study the effects of flow imbalance from each angle of the
burner on the combustion product. Air flow regulation can improve the combustion balance
in the boiler. Oxygen, exhaust gas flow rate, temperature
and NOx imbalance at the boiler outlet can be significantly
reduced [1]. Flow velocity distribution at the burner in high
speed of NOx formation occurs in the center of the fire ball
and small when the flow velocity in the burner decreases
until it does not reach the center of fireball and forms NOx it
widens [2].
Good tangential circulation of gas causes an increase in
flame distribution [3]. When primary air from the burner is
injected into the furnace, in the center of the furnace will form a fireball in a clockwise direction. The secondary air
concentric firing is biased relative to the direction of the
primary air jet. Near the water wall, it will result a stronger
oxidizing atmosphere. This is to reduce the risk of slagging
and longer residence time for pulverized coal in the furnace,
to diminish the carbon content in the fly ash. However, a
larger tangential circle diameter is formed, which leads to a
dense residual rotation flow at the furnace exit and this will
produce in an increase in the temperature deviation of the
gas at the crossover pass [4].
According to the authors [5], there are three mecahnism
must be taken account in the modeling of NOx formation, such as: formation of thermal NOx, formation of prompt
NOx, and formation of fuel NOx. Temperature in the burner
zone and the resulting NOx emissions are closely related to
the type of fuel used. The air that is inserted into the boiler
can cool the exhaust gas so that the temperature and
concentration of the species drops as the ratio of excess air
[6]. Higher mixing rates from air and fuel tend to reduce
unburned combustibles at the expense of higher NOx
emissions [7]. The increase in the Primary air ratio has a
large influence on combustion performance. Overall, the
combustion process decreases with increasing Primary air ratio. However, in the main burner region and the area
above separated-over fire air (SOFA), the combustion characteristics show the trend of parabolic with the Primary
water ratio increasing [8]. The increase of the air flow rate
Numerical Study of the Effect of Primary Air
Velocity of Pulverizer Output on NOx
Formation in the Boiler of Labuan Steam Power
Plant, Indonesia Taufik Hidayat1, Triyogi Yuwono1, 2, *)
1Graduate Student in the Department of Mechanical Engineering, Institut Teknologi Sepuluh Nopember, 2Department of Mechanical Engineering, Institut Teknologi Sepuluh Nopember,
Jl. Arif Rahman Hakim, Kampus ITS-Sukolilo, Surabaya-60111, East Java, Indonesia *) Corresponding Author: [email protected]
International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:20 No:01 71
202101-5353-IJMME-IJENS © February 2020 IJENS I J E N S
leads as expected is a decrease of the furnace outlet temperature and an increase in NOx emissions [9]. When the difference in primary and secondary air flow velocity is large it can increase the combustion temperature but an increase in NOx emissions [10].
The suggested formula for NOx concentration was based
on three factors, i.e. moisture, fixed carbon, and fuel ratio
correlations. Having compared the calculated amount of
NOx generation from the actual power plant using four
system indicator factors (coefficients) while considering the
design and operating conditions of each boiler [11].
In accordance with the authors [12], the concentration of
NO augments fast in the furnace lowers part. In this zone,
volatile N reacts with O2 to form CNO that is in due course
oxidized to NO. Simultaneously, at the bottom of the
furnace, the combustion of charcoal particles forms NO. Compared with the observations of physical model, the
predictions through CFD model were generally better. The
CFD could precisely simulate the mixing and flow fields of
the boiler for a varied range of the inlet flow rate, however
some difference were also found for some flow conditions.
Primary air ratio has high impacts on the temperature and
atmosphere of combustion inside the furnace. Because, the
characteristics of NOx formation are mainly dependent on
the temperature of combustion and the oxidation/reduction
atmosphere inside the furnace [14].
II. RESEARCH METHODOLOGY
a. Simulation
This research includes 3 steps; the first step is taking
operational data as a basis for reference, including
operational data taken through Distribute Control System
(DCS), and laboratory data. The next step is to create a 3D
Boiler model base on real geometry of boiler with Gambit
Software, and the last is to validate the simulating model
and running several operating patterns with Computational
fluid dynamics (CFD) to get optimum results.
In this simulation data is taken from Labuan’s Power
Plant with 300 MW capacities of sub-critical specifications,
natural circulation, single furnace, tangential firing and, single reheat and balance draft [15].
This 3D Boiler model has 757724 nodes with shape of
the mesh are hexahedral and tetrahedral as shown in Fig. 1.
There are 5 coal burner elevation layers, 7 secondary air
dampers and 1 layer separated-over fire air (SOFA).
Operating data is obtained from the parameters in the
Distribute Control System (DCS), manual book and
laboratory data for coal properties. In this simulation we use
2 types of coal that is Low rank coal (LRC) for burner A and
burner B while burner C and E using medium rank coal
(MRC). Table 1 shows the properties of the coal, it is consist of ultimate and proximate analysis that needed for
input in simulation. While the other input data are:
a) Primary air Flow (kg/s).
b) Secondary Air Flow (kg/s).
c) Coal Flow (kg/s).
d) Boiler Outlet Pressure (Pa).
e) Heat exchanger (W/m3).
Fig. 1. Meshing boiler geometry models.
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Table I.
Properties of coal
Heating Value Unit
AR
LRC MRC
Higher Heating Value (AR) kcal/kg-f 3,999 4,582
Higher Heating Value (AR) kJ/kg-f 16,744 19,183
Ultimate Analysis
Carbon Content (AR) wt % 43 58
Hydrogen Content (AR) wt % 3 6
Oxygen Content (AR) wt % 13 27
Sulfur Content (AR) wt % 0 1
Nitrogen Content (AR) wt % 1 1
Ash Content (AR) wt % 9 7
Moisture Content (AR) wt % 30 -
Total wt % 100 100
ProximateAnalysis
Total Moisture Content (AR) wt % 30 -
Fixed Carbon Content (AR) wt % 29 39
Volatile Matter (AR) wt % 32 38
Ash Content (AR) wt % 9 7
Total wt % 100 84
Carbon Content in Fly Ash wt % 2 2
Carbon Content in Bottom Ash wt % 2 2
Fly Ash Split wt % 1 1
Bottom Ash Split wt % 0 0
Mass of Residue wt % 0 0
Carbon in Ash wt % 2 2
Unburn Carbon in Fuel wt % 0 0
Carbon Burned Content wt % 43 58
Fig. 2. Boundary conditions and sensor location.
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Fig. 3. Comparison between results of measurement and simulation – for validation.
Table II
Comparison data between results of measurement and simulation
Sensor Positions 1 2 3 4 5 6
Measured Results (0C) 971 889 800 660 654 401
Simulation Results (0C) 950 859 853 676 636 438
Error 2.20% 3.40% 6.60% 2.40% 2.80% 9.20%
Boundary conditions in this simulation, it can be classified
into 4 types, which are wall, mass flow inlet, pressure outlet
and interior. Fig. 2 describe inlet is primary air, coal flow
and secondary air is used boundary condition mass-flow-
inlet, while the boiler outlet uses a pressure outlet. Primary
air enters the furnace through burners A, B, C, D and E, but
in this simulation the D burner is standby so that the D
burner can be defined as a wall. Secondary air enters the
furnace through burners AA, AB, BC, CC, DD, DE, EF, and
EFF whereas the water wall tube becomes a boundary condition of the wall type by entering the temperature value
which is assumed to be the temperature of the water flowing
in the tube. Heat exchanger described as porous media with
its own heat absorption.
b. Validation
Before proceeding with the simulation at the various case
stages it is necessary to validate the simulation data. In this
study validation of the flue gas temperature between the
actual data is compared with the simulation data.
Fig. 3 indicates the comparison of the actual operating data
of the point of the flue gas temperature. Retrieval of data for
validation by making iso-points, in accordance with the
points, where the sensor is placed in the boiler sensor. Table
2 shows the measurement and simulation results. The results
showed that the simulation accuracy was assessed from the
error value between the actual (measured) data and the
simulation data less than 10%, with an average error value
of 4.43%. So, the simulation method used in this study can
be considered an accurate simulation and can be used to simulate the problem studied.
c. Simulation with alternative design
In this variation of simulation all parameters are made the
same as validation data except velocity Primary air outlet
data. Variations in velocity Primary air outlet affect the Primary air mass flow needed. The Table 3 mass flow data
obtained from several velocity Primary air outlets.
0
200
400
600
800
1000
1200
1 2 3 4 5 6
Tem
peratu
re (
oC
)
Sensor position
Measured results
Simulation results
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Table III
Variation of simulation model
Velocity (m/s) PA per layer (T/h) Total PA (T/h) SA Flow (T/h) Total Air Flow (T/h) Coal Flow (T/h)
23 27.5 109.9 643.4 753.3 165.4
24 35.4 141.7 643.4 785.1 165.4
26 51.4 205.4 643.4 848.8 165.4
28 67.3 269.1 643.4 912.5 165.4
30 83.2 332.8 643.4 976.2 165.4
32 99.1 396.5 643.4 1,039.9 165.4
III. RESULTS AND DISCUSSION
To analyze the effect of variations in primary air flow
velocity on boiler that affects combustion process, so it is
necessary to analyze the contours of the magnitude of flow velocity on the boiler. Simulation results of the velocity
magnitude in the boiler as shown in Fig. 4.
Inside the boiler, the combustion process of particles of
coal and air produces flue gas with high temperature having
the direction of flue gas flowing from the furnace to the boiler outlet.
Fig. 4. Velocity Magnitude.
In the furnace, the air flow and coal particles coming out of
the four corners of the boiler burner and secondary water will form a fireball, with the fireball the trajectory of coal
particles becoming longer, which causes the time span of
particles in the furnace area will be longer. Another thing the effect of pressure area at the center of the furnace occurs
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small due to in simulations 23 and 24 the low flue gas
velocity is in the lowest area of the boiler (bottom ash) due to
the lack of air flow, causing a portion of the coal particle on
burner A to go downward. In the middle part of the furnace a
low pressure is caused by the fireball effect. In simulations
23 and 24, taking vector velocity magnitude is done by
making a vertical cross section of the boiler. The velocity
magnitude vector results are shown in Fig. 4, the range of
velocity of coal varies between 0-23.5 m/s for all variations. In simulations 23 and 24 the low velocity primary air outlet
which indicates that the fireball that occurs at the center of
the furnace is only small and only reaches the super heater
inlet which is reduced due to constriction at the super heater
inlet. In the burner wall area, there is a low-pressure spot that
occurs in the burner area that is not standby.
Whereas, the low pressure outlets of the boiler are caused by
reduced flue gas velocity, after passing through the super
heater, reheat, and economizer panels. In simulation 26, the
pressure in the middle of the furnace which has a low
pressure widens due to the formation of an enlarged fireball
because the direction of coal flow in each corner affects each
other away from the midpoint of the furnace. The greater the
velocity primary air outlet the wider or larger approaching
the wall of the water wall. In simulation 28, 30 and 32, the
formation of fireball enlarges near the wall and is formed to
the bottom ash area to the super heater area.
The highest temperature occurs in the furnace area because
in this area the combustion process travels to the boiler outlet, the temperature decreases more and more due to
absorption in the water wall, super heater, reheat and
economizer. In Fig. 5, it is shown that the temperature
measurement range is between 0 oC to 1210 oC with a cross
section on the boiler, with the low velocity furnace
temperature produced higher when compared with higher
velocity.
Fig. 5. Static temperature cross section of the boiler.
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Fig. 6. Distribution of profile temperature along furnace height.
Fig. 7. The pattern of fireball formation in velocity variations.
Fig. 6 demonstrates the combustion temperature at the
related elevation; where 7 m-elevation is the elevation at the
bottom ash while at the 47-m elevation is the super heater
inlet elevation. At variations 23, 24, and 26 the outlet furnace
temperature is high because the ratio of air and fuel is very
lame, i.e.; 1: 4.6-5.3, so that makes burning very rich which
causes very high temperatures, whereas the ratio of primary
air and secondary air is 1: 5.8 - 3.2. As for variations of 28,
7
12
17
22
27
32
37
42
47
52
200 400 600 800 1000 1200 1400 1600
Ele
vati
on
(m
)
Static Temperature (°C)
23 m/s
24 m/s
26 m/s
28 m/s
30 m/s
32 m/s
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30 and 32, the ratio of air and fuel is 1: 5.5 - 6.3 which is
close to ideal combustion, but the ratio of primary air and
secondary air is 1: 2.3 - 1.6. This causes the combustion
temperature to decrease due to primary air temperature is
52.5 oC while secondary air is 324.4 oC. Theoretically, the
ratio between primary and secondary air for a 300 MW plant
is 1: 2.8 [7]. In addition to coal calories which greatly affect
the combustion results, it is also important to consider the
velocity outlet which serves to determine the location of the combustion process. The transverse contour area of each
burner and inlet super heater elevation in Fig. 7 can explain
the effect of fireball pattern formation on the velocity
primary air outlet.
It is noticed that the effect of the velocity of primary air
outlet on the combustion temperature is inversely
proportional to the temperature of combustion. For the effect
of fireball pattern formation on the velocity of the primary air
outlet, it is seen that the effect of the velocity primary air
outlet on the combustion temperature is inversely
proportional to the temperature of combustion. for the case of
variations of 24 m/s and 28 m/s in the bottom ash area, NO
concentrations can increase rapidly. Char particles are not
formed but volatile N reacts with the change of O2 to NO
which is then oxidized to NOx. So that the NOx mass
fraction in that area increases in that area [12]. In Fig. 8 can
be seen in burner A at a variation of 24 m/s high output
temperature so that thermal NOx can be created. Whereas in
the bottom ash, the largest NOx formation occurs due to organic nitrogen which is chemically bound in coal. The
reaction of NOx formation on the char surface is described in
the formula below:
C_Char+1/2 O_2↔〖CO〗_Char
N_Char+1/2 O_2↔NO+Char
NO+2〖CO〗_Char↔N_2+2〖CO〗_2+Char
Fig. 8. NOx Mass contour on cross section of boiler.
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0
0.0002
0.0004
0.0006
0.0008
0.001
0.0012
1 2 3 4 5 623 m/s 24 m/s 26 m/s 28 m/s 30 m/s 32 m/s
Fig. 9. Mass fraction of NOx along furnace height.
Fig. 10. Mass fraction of NOx at outlet boiler.
The formula shows that the amount of NOx produced by nitrogen in coal increases with increasing residence time of
the burned particles. This relation can be observed as long as
the reaction occurs at temperatures above 800°C. The
increase in NOx due to nitrogen in the fuel can also occur
due to an increase in oxygen content in the flame which
results in a fuel poor condition [16], so that the mass fraction
of NOx is high in the bottom ash area.
At variations of 23 m/s, 24 m/s, 26 m/s and 28 m/s, thermal
NOx formation occurs with a high mass fraction because
around the burner area E temperature in the furnace section
reaches the requirement of thermal NOx formation of
1204oC. The asymmetry of NOx mass fraction formation in the area is due to the narrowing of the profile furnace when
entering the superheater inlet so that the fireball in the form
of fireball shifts to one side depending on the speed of the
primary air velocity. In variations of 30 m/s and 32 m/s in the
E burner area, NOx mass fraction formation also occurs but
this is small because the resulting temperature of combustion
is very low as in Fig. 8 above.
In case of variation 28 m/s, there is NOx formation in the
reheat area due to unburned coal in the furnace area and
oxidized area to form NOx.
0
0.0002
0.0004
0.0006
0.0008
0.001
0.0012
0.0014
0 10 20 30 40 50 60
Mass
Fracti
on
of
Poll
uta
n N
Ox
23 m/s 24 m/s
26 m/s 28 m/s
30 m/s 32 m/s
Velocity Variation
Elevation (m)
Mass
Fract
ion
of
NO
x
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For more details on the distribution of NOx mass fraction
can be seen in Fig. 9 which explains the magnitude of NOx
mass fraction to the height of the furnace. The data taken is
NOx data in the middle of the furnace from the bottom ash to
the superheater inlet.
Fig.10 illustrates the NOx mass fraction at the boiler outlet
before the highest preheater water, where for a variation of
26 m/s is 0,000976 and the lowest at a variation of 30 m/s is
0.00000402.
IV. CONCLUSION
The simulation results show that the effect of increasing
the velocity outlet of pulverizer on the combustion
temperature in the furnace (without changing secondary
water) is inversely proportional. The greater the velocity
outlet of pulverizer, the lower the combustion temperature in
the furnace. The combustion temperature at super heater inlet
temperature for existing model is 1218oC, meanwhile the
variation 23 m/s is 1433oC, the variation 24 m/s is 1438oC,
the variation 26 m/s is 1434oC, the variation 28 m/s is 1257oC, the variation 30 m/s s is 1106oC, and the variation of
32 m/s are 592oC.
The NOx mass fraction that occurs at the boiler outlet for
the existing model is 0.001991, while the variation 23 m/s is
0.000507, the variation 24 m/s is 0.00671, the variation 26
m/s is 0.00976, the variation 28 m/s is 0.00727, the variation
30 m/s is 0.00000402, and the variation of 32 m/s is
0.000163
From the analysis of numerical simulation results, the
recommended model design is a variation of the velocity
outlet of pulverizer with a speed of 28 m/s because it has a super heater inlet temperature slightly above the existing
model, so that the use of super heater and reheat spray only
slightly adds to the existing model while for NOx mass
fraction boiler output is about 35% of the existing model.
ACKNOWLEDGMENTS
This research did not receive any specific grant from
funding agencies in the public, commercial, or not-for-profit
sectors. Also, the authors have declared no conflict of
interest.
NOMENCLATURE Abbreviation
AR as received
CFD Computational Fluid Dynamic
DCS Distribute Control System
LRC Low Rank Calories
MRC Medium Rank calories
MSM Medium Speed Mill
OVA Separated Over fire Air
PA Primary air
SA Secondary air
wt % weight percent
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