0
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.

FIGURES IN THIS ARTICLE
<>
Copyright © 2015 by ASME
Your Session has timed out. Please sign back in to continue.

References

Xuchang, X., Zhigang, W., Yuqun, Z., and Changhao, Z., 2007, “False Diffusion in Numerical Simulation of Combustion Processes in Tangential-Fired Furnace,” J. Mech. Sci. Technol., 21(11), pp. 1828–1846. [CrossRef]
Habib, M. A., Ben-Mansour, R., and Abualhamayel, H. I., 2010, “Thermal and Emission Characteristics in a Tangentially Fired Boiler Model Furnace,” Int. J. Energy Res., 34(13), pp. 1164–1182. [CrossRef]
Yuegui, Z., Tongm, X., Shien, H., and Mingchuan, Z., 2009, “Experimental and Numerical Study on the Flow Fields in Upper Furnace for Large Scale Tangentially Fired Boilers,” Appl. Therm. Eng., 29(4), pp. 732–739. [CrossRef]
Yuegui, Z., Mingchuan, Z., Tongmo, X., and Shien, H., 2009, “Effect of Opposing Tangential Primary Air Jets on the Flue Gas Velocity Deviation for Large-Scale Tangentially Fired Boilers,” Energy Fuels, 23(11), pp. 5375–5382. [CrossRef]
Boshu, H., Meiqian, C., Shumin, L., Lijuan, F., Jinyuan, X., and Wei-Ping, P., 2005, “Measured Vorticity Distributions in a Model of Tangentially Fired Furnace,” Exp. Therm. Fluid Sci., 29(5), pp. 537–554. [CrossRef]
Shyan-Shu, S., Yi-Hsin, C., Shi-Shang, J., Ming-Da, M., and Ta-Sung, H., 2010, “Statistical Key Variable Analysis and Model-Based Control for the Improvement of Thermal Efficiency of a Multi-Fuel Boiler,” Fuel, 89(5), pp. 1141–1149. [CrossRef]
Srdjan, B., Miroslav, S., Simeon, O., and Dragan, T., 2006, “Three-Dimensional Modeling of Utility Boiler Pulverized Coal Tangentially Fired Furnace,” Int. J. Heat Mass Transfer, 49(19–20), pp. 3371–3378. [CrossRef]
Vuthaluru, R., and Vuthaluru, H. B., 2006, “Modelling of a Wall Fired Furnace for Different Operating Conditions Using fluent,” Fuel Process. Technol., 87(7), pp. 633–639. [CrossRef]
Srdjan, B., Miroslav, S., Nenad, C., and Branislav, S., 2009, “Numerical Prediction of Pulverized Coal Flame in Utility Boiler Furnaces,” Energy Fuel, 23(11), pp. 5401–5412. [CrossRef]
Chungen, Y., Lasse, R., and Thomas, J., 2003, “Further Study of the Gas Temperature Deviation in Large-Scale Tangentially Coal-Fired Boilers,” Fuel, 82(9), pp. 1127–1137. [CrossRef]
Chungen, Y., Sebastien, C., Jean-Luc, H., Bernard, B., and Everest, P., 2002, “Investigation of the Flow, Combustion, Heat-Transfer and Emissions From a 609 MW Utility Tangentially Fired Pulverized-Coal Boiler,” Fuel, 81(8), pp. 997–1006. [CrossRef]
Hari, B. V., and Rupa, V., 2010, “Control of Ash Related Problems in a Large Scale Tangentially Fired Boiler Using CFD Modeling,” Appl. Energy, 87(4), pp. 1418–1426. [CrossRef]
Hou, S. S., Chen, C. H., Chang, C. Y., Wu, C. W., Ou, J. J., and Lin, T. H., 2011, “Firing Blast Furnace Gas Without Support Fuel in Steel Mill Boilers,” Energy Convers. Manage., 52(7), pp. 2758–2767. [CrossRef]
Ma, H. K., and Wu, F. S., 1992, “Effect of BFG on Unburned Carbon Formation in a Coal-Fired Boiler,” Int. Commun. Heat Mass Transfer, 19(3), pp. 409–421. [CrossRef]
Milorad, B., and Panos, M., 2000, “Energy Saving Does Not Yield CO2 Emissions Reductions: The Case of Waster Fuel Use in a Steel Mill,” Appl. Therm. Eng., 20(11), pp. 963–975. [CrossRef]
Gicquel, O., Vervisch, L., Joncquet, G., Labegorre, B., and Darabiha, N., 2003, “Combustion of Residual Steel Gases: Laminar Flame Analysis and Turbulent Flamelet Modeling,” Fuel, 82(8), pp. 983–991. [CrossRef]
Habib, M. A., Ben-Mansour, R., Badr, H. M., Ahmed, S. F., and Ghoniem, A. F., 2012, “Computational Fluid Dynamic Simulation of Oxyfuel Combustion in Gas-Fired Water Tube Boilers,” Comput. Fluids, 56, pp. 152–165. [CrossRef]
Qingyan, F., Amir, A. B. M., Yan, W., Zixue, L., and Huaichun, Z., 2012, “Numerical Simulation of Multifuel Combustion in a 200 MW Tangentially Fired Unity Boiler,” Energy Fuels, 26(1), pp. 313–323. [CrossRef]
Chun-Lang, Y., 2012, “Numerical Investigation of the Heat Transfer and Fluid Flow in a Carbon Monoxide Boiler,” Int. J. Heat Mass Transfer, 55(13–14), pp. 3601–3617. [CrossRef]
Shih, T. H., Liou, W. W., Shabbir, A., and Zhu, J., 1995, “A New k-ε Eddy-Viscosity Model for High Reynolds Number Turbulent Flows-Model Development and Validation,” Comput. Fluids, 14(3), pp. 227–238. [CrossRef]
FLUENT 13.0, Theory Guide, FLUENT, Inc.
Habib, M. A., Ben-Mansour, R., and Antar, M. A., 2005, “Flow Field and Thermal Characteristics in a Model of a Tangentially Fired Furnace Under Different Conditions of Burner Tripping,” Heat Mass Transfer, 41(10), pp. 909–920. [CrossRef]
Daniel, J. O., Ferreira, M. C., and Song, W. P., 2012, “The Impact of Radiation on Gas Combustion Modeling for a Kraft Recovery Boiler,” 11th International Symposium on Process Systems Engineering, Singapore, July 15–19.
Qinggang, X., Song-Chang, K., and Alberto, P., 2013, “Development of a Generalized Numerical Frame Work for Simulating Biomass Fast Pyrolysis in Fluidized-Bed Reactors,” Chem. Eng. Sci., 99, pp. 305–313. [CrossRef]
Qinggang, X., Lijuan, D., Wei, W., and Wei, G., 2011, “SPH Method for Two-Fluid Modeling of Particle-Fluid Fluidization,” Chem. Eng. Sci., 66(9), pp. 1859–1865. [CrossRef]
Versteeg, H. K., and Malalasekera, W., 2007, An Introduction to Computational Fluid Dynamics, the Finite Volume Method, Prentice-Hall, Essex, UK.
Joseph, K. L. L., Shek, C. H., and Wong, K. W., 2001, “A Novel Technique to Detect Hot Spots in High Temperature Boiler,” Sens. Actuators A, 95(1), pp. 51–54. [CrossRef]

Figures

Grahic Jump Location
Fig. 2

Burner configuration

Grahic Jump Location
Fig. 11

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

Grahic Jump Location
Fig. 12

Species mass fraction along the height of the vertical pass way

Grahic Jump Location
Fig. 3

Flame profiles captured by camera

Grahic Jump Location
Fig. 4

Temperature contours and streamlines

Grahic Jump Location
Fig. 5

Species of CO mass fraction 0.01 isosurface

Grahic Jump Location
Fig. 6

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

Grahic Jump Location
Fig. 7

Velocity vectors at the left and right side of the boiler

Grahic Jump Location
Fig. 8

Velocity vectors at different levels along the vertical pass way

Grahic Jump Location
Fig. 9

Temperature contours at different levels along boiler height

Grahic Jump Location
Fig. 10

Average temperature along the boiler height

Grahic Jump Location
Fig. 13

contour of temperature nonuniformity at the left and front wall

Grahic Jump Location
Fig. 14

Flow streamlines colored by temperature and velocity

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In