Research Papers

Simulation of an Industrial Tangentially Fired Boiler Firing Metallurgical Gases

[+] Author and Article Information
Guangwu Tang

Center for Innovation Through Visualization
and Simulation,
Purdue University Calumet,
2200 169th Street
Hammond, IN 46323
e-mail: tang@purduecal.edu

Bin Wu

Center for Innovation Through Visualization
and Simulation,
Purdue University Calumet,
2200 169th Street,
Hammond, IN 46323
e-mail: bin.wu@purduecal.edu

Kurt Johnson

ArcelorMittal, Global Research
and Development,
3001 E. Columbus Drive,
East Chicago, IN 46312
e-mail: Kurt.Johnson@arcelormittal.com

Albert Kirk

ArcelorMittal-Burns Harbor,
250 U.S. 12,
Burns Harbor, IN 46312
e-mail: Albert.Kirk@arcelormittal.com

Chenn Q. Zhou

Center for Innovation Through Visualization
and Simulation,
Purdue University Calumet,
2200 169th Street,
Hammond, IN 46323
e-mail: czhou@purduecal.edu

1Corresponding author.

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF THERMAL SCIENCE AND ENGINEERING APPLICATIONS. Manuscript received December 11, 2013; final manuscript received July 8, 2014; published online September 24, 2014. Assoc. Editor: Ting Wang.

J. Thermal Sci. Eng. Appl 7(1), 011003 (Sep 24, 2014) (11 pages) Paper No: TSEA-13-1204; doi: 10.1115/1.4028344 History: Received December 11, 2013; Revised July 08, 2014

In industrial environments, boiler units are widely used to supply heat and electrical power. At an integrated steel mill, industrial boilers combust a variable mixture of metallurgical gases combined with additional fuels to generate high-pressure superheated steam. Most tangentially fired boilers have experienced water wall tube failures in the combustion zone, which are thought to be caused by some deficiency in the combustion process. The challenge faced in this present process is that there are very limited means to observe the boiler operation. In this study, a three-dimensional computational fluid dynamics (CFD) modeling and simulation of an industrial tangentially fired boiler firing metallurgical gases was conducted. Eddy dissipation combustion model was applied on this multiple fuel combustion process. Simulation results obtained from the developed CFD model were validated by industrial experiments. A quick comparison of the flame shape from the simulation to the actual flame in the boiler showed a good agreement. The flow field and temperature distribution inside the tangentially fired boiler were analyzed under the operation conditions, and a wall water tube overheating problem was observed and directly related to the flow characteristics.

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Fig. 2

Burner configuration

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Fig. 3

Flame profiles captured by camera

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Fig. 4

Temperature contours and streamlines

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Fig. 5

Species of CO mass fraction 0.01 isosurface

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Fig. 6

Contour of velocity magnitude and Y velocity vector at the center plane

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Fig. 7

Velocity vectors at the left and right side of the boiler

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Fig. 8

Velocity vectors at different levels along the vertical pass way

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Fig. 9

Temperature contours at different levels along boiler height

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Fig. 10

Average temperature along the boiler height

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Fig. 11

Contour of major species mass fraction at the center plane of the burners

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Fig. 12

Species mass fraction along the height of the vertical pass way

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Fig. 13

contour of temperature nonuniformity at the left and front wall

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Fig. 14

Flow streamlines colored by temperature and velocity




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