ROLE OF CFD IN PRODUCT DEVELOPMENT

Transcription

1 Oilon - The Warm Way ROLE OF CFD IN PRODUCT DEVELOPMENT MSc. Joonas Kattelus CFD-day Espoo

2 Content of the presentation Company introduction Products Research & development at Oilon CFD and product developement Case 1 Ultrax - China Case 2 New series MW burner

3 Company introduction 1/3 OILON BRIEFLY

4 Company introduction 2/3 OILON DISTRIBUTORS

5 Company introduction 3/3 LAHTI, FINLAND HOLLOLA, FINLAND WUXI, CHINA KOKKOLA, FINLAND

6 Products 1/1 OILON BURNER Heat FAMILY Pump Family JUNIOR BURNER 6 26 BURNERS BURNERS kw kw kw BURNERS kw BURNERS MONOX 1000 M, 1200 M kw kw 400 ME 2500 ME kw POWERPLANT AND PROCESS BURNERS 2 80 MW OILON HYBRID HEATING SOLUTIONS OILON HEAT PUMP FAMILY

7 Research & Development 1/2 FACILITIES AND RESOUCES R&D centre in Lahti next to the company headquarters. Laboratory facilities for testing up to 12 MW gas/liquid fuel burners (fulfills standard EN requirements). Energon Clean Energy Center for Renewable Energy (bio-oils, gasification gases etc.). Sub contractors to execute e. g. CFD-calculations when own resoures aren t enough.

8 Research & Development 2/21/2 AIMS AND GOALS OF OUR R&D Promoting efficiency and energy savings (modern burner control systems, efficient heat pumps, etc.). Further development of burner reliability and versatility. Emission reduction (NO X, CO, particulates). Research in the field of renewable and difficult-to-burn fuels (bio-oil and gas, viscous liquids, process waste streams, co-combustion of gas & liquid). Elegant design and ease of maintenance.

9 CFD and product developement AT OILON CFD IS USED TO: Burner development Emissions Even flow distribution in burner head No temperature peaks in combustion chamber Air/fuel staging Low pressure drop Experimenting new technologies and methods (e. g. premixed combustion, FGR) => fewer prototypes. Find optimal burner-boiler combinations. Find optimal burner positioning and burning efficiency. Find out refractory wall and burner head parts heat stress. Guarantee successful projects.

10 Case 1 Ultrax - China CASE INFORMATION AND MESH Two Ultrax low-nox burners in a D- type boiler positioned vertically into the boiler front wall. Used fuel is Chinese natural gas (approximated as pure methane). Nominal capacity of the boiler is 74 MW. Thermal power of the feedfuel is 81 MW. Geographic altitude of the system is 900 m above sea level. Less dense, cold and moist combustion air. Geometry is highly complex, thus proper meshing demands carefull optimization between the solution accuracy and available resouces.

11 Case 1 Ultrax - China RESULTS AND VALIDATION Many important answers with a single model: Is the air distribution in flow channel even between burners? Is the air distributed as designed inside the burner (air staging)? How hot is the flame? What are the flame dimensions (will it fit to the combuston chamber)? What is the amount of thermal load in critical parts of the burner head?

12 Case 1 Ultrax - China 4/4 RESULTS AND VALIDATION The disperpersion between measurements occurs because there were ten identical boilers with different measurement data. Model underestimates the NOx-production by some % compared to measured minimum values. The trend of NOx reduction with decreasing thermal power is nevertheless well captured. Complete validation of the model would require much more cases.

13 Case 2 New series-4 5,5 MW burner 1/4 CASE INFORMATION AND MESH Complitely new series MW monoblock burner with integrated feed air fan. Unit is so called multifuel burner (burns gaseous & liquid fuels), but in this case the phenomenon of interest was related to examination of the air distribution in the burner head. No combustion. Objective of the study was to create circumstances for optimal air distribution in burner head thus minimizing emission levels. Flow geometry consists of a separate inlet air flow channel, a fan impeller and a burner part together with the burner head.

14 Case 2 New series-4 5,5 MW burner 3/4 RESULTS AND VALIDATION measured modelled Compared to measurement data, the velocities in burner head seems to be captured with reasonable accuracy (max Relative velocities [%] 4 5 deviation ± 4.5 %) measured modelled Relative velocities [%]

15 Case 2 New series-4 5,5 MW burner 4/4 FOLLOW-UP MEASURES With the newly developed and validated model an optimally shaped perforated plate was generated and inserted to the burner to eaven up the air stream. As a result the flow does not focus too much on the north-east side of the burner. Future work involves full scale combustion modelling with one of our test boilers along with the trial runs/separate measurements to ensure functionality of the product and proper validation of the model.

16 Thank you for your attention! Käyntiosoite/Visiting address Puhelin/Phone Fax Metsä-Pietilänkatu 1 Nat. (03) Nat. (03) FI LAHTI FINLAND Int Int Y-tunnus/Business Identity Code Kotipaikka/Registered Domicile Lahti