Optimization of a Dual-Fuel Low-NOx Combustion System for a Tangentially-Fired Utility Boiler Operating at a High Elevation.

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1 Optimization of a Dual-Fuel Low-NOx Combustion System for a Tangentially-Fired Utility Boiler Operating at a High Elevation. by F. McKenty, N. Brais, M. Mifuji, L. Gravel, and Y. Sirois STAR Global Energy Forum Houston, Tx June, 2009 Brais Malouin & Associates Inc. 144 Barr Street, St-Laurent, Qc. Canada, H4T 1Y4 Tel: (514)

2 Images courtesy of Cerrey S.A. de C.V. Av. Republicana Mexicana 300 San Nicolas de Los Garza, N.L. Mexico C.P Industrial Boiler Manufacturer

3 Overview Motivation Objectives Problem Description CFD Modeling Results & Analysis Summary Conclusion 3

4 Introduction Motivation Stricter pollutant emission regulations are presenting new challenges to boiler and burner manufacturers in order to meet the new emission specifications. Develop new Boiler/Burner designs Retro-fit existing boilers with new combustion systems capable of meeting the emission specifications. Physical constraints limit the positioning of the new combustion system. Re-use existing components (fans, ducts etc..) as much possible to limit costs. Maintain the existing boiler s operational characteristics: Wall heat transfer Heat transferred to Superheaters, Reheaters and Convection Banks Gas temperature at key locations 4

5 Introduction Objective Replace the existing 32 burner (16 Natural Gas and 16 Heavy Oil #6) Tangentially Fired combustion system with a new Low NOx combustion system having 16 Dual-Fuel burners and 8 Over Fire Air (OFA ) ports. Use CFD to optimize the combustion system s firing angles in order to maintain the existing boiler s operational characteristics 5

6 Problem description Tangentially fired boilers Operating principal: Four or more burners located in the corners or on the boiler walls are fired tangentially to a target circle located at the center of the boiler. Objective: Create a rotating flow pattern in the center of the furnace. Use the furnace as a mixing vessel. Create a fireball in the middle of the furnace instead of several individual flames. This type of boiler design was originally developed for coal firing in order to minimize the space required for large utility boilers. 6

7 Problem description Tangentially fired boilers The size (diameter and height) of the fireball is highly dependant on the diameter of the target circle. If the target circle diameter is too large; the diameter of the fireball could increase until it reaches the furnace walls. If the target circle diameter is too small; the jets could impinge with one another and the rotating motion of the flow is lost. The size of the fireball is dependant on burner jet penetration into the furnace. Jet penetration is a function of jet momentum. Increased jet momentum means increased penetration and higher jet velocities at the location of the target circle and vice versa. 7

8 Problem description Tangentially fired boilers Increasing or decreasing the momentum of the burner jets will change the furnace aerodynamics. A target circle that was adequate for a given burner (jet momentum) may yield an inappropriate shape of the fireball if the burners are replaced with burners having jets with more or less momentum than the original burners. Jet momentum is defined as: G = mv = ρ V A V = (N ) Density decreases with altitude. m V = ρ A Velocity increases with altitude for a given flow rate. An increase in velocity will increase jet momentum. Consequence: A target circle diameter that is optimal at sea level may no longer be adequate when the boiler is located at high altitude (2000 ft and more). 8

9 Problem description Tangentially fired boilers Example: Comparison of a natural gas flame with standard target circle diameter for a single burner level T-fired boiler at sea level and at 5200ft altitude. Fireball at sea level Fireball at 5200 ft 9

10 Problem description Tangentially fired boilers Example: Comparison of a natural gas flame with the target circle diameter optimized for operation at sea level for a single level T-fired boiler with the same design operating at 5200ft altitude. Fireball at sea level Fireball at 5200 ft 10

11 Problem description Tangentially fired boilers Additional problems are encountered when trying to optimize the firing configuration for both Natural Gas and Heavy Oil firing: The optimal target circle diameter for natural gas firing is most often too small for Oil firing because of the difference in the distribution of momentum in the flames. The core of the central vortex for oil flames can become unstable. 1 st burner level - NG 1 st burner level Oil #6 11

12 Problem description Tangentially fired boilers Combustion of the fuel increases the gas temperature in the burner jet and causes the expansion of hot combustion gases. Dual-Fuel (54% Oil 46% NG) Firing Temperature (K) 12

13 Problem description Tangentially fired boilers The expansion of the gases causes local acceleration in the jet in the ratio of about 5/1. Dual-Fuel (54% Oil 46% NG) Firing Velocity Magnitude (m/s) 13

14 Problem description Tangentially fired boilers The local acceleration is more pronounced and localized for heavy oil burners because all the fuel is concentrated in front of the oil gun. Dual-Fuel (54% Oil 46% NG) Firing Velocity Magnitude (m/s) 14

15 Problem description Tangentially fired boilers The jets from Oil flames usually have much higher momentum and penetration than Natural Gas flames. It is obvious that the optimal target circle diameter will be different depending on the fuel. The problem is compounded when operating at high altitudes because the effect on gas firing does not vary proportionally to the effect on oil firing. 15

16 Problem description Tangentially fired boilers The firing angles should be determined according to the burner design, fuels to be fired and the altitude at which the unit will operate. The target circle for dual fuel burners must be a compromise between the optimal firing angles for Natural Gas and the optimal firing angles for Heavy Oil. Natural Gas Firing Oil #6 Firing Burner Level 1 - Velocity Magnitude (m/s) 16

17 Problem description Tangentially fired boilers Even when the optimal firing angles for Natural Gas have been modified to accommodate oil firing, the final firing angles for Natural Gas yield a much smaller vortex diameter in the center of the furnace. Reducing the vortex diameter helps keep the reacting regions away from the furnace walls. NG-Firing Original sea level firing angles NG-Firing Optimized firing angles Burner Level 1 - Velocity Magnitude (m/s) 17

18 Problem description Tangentially Fired 300MW Utility Boiler Boiler Characteristics: 300 MW Utility Boiler Gross Heat Input : 800MW (2725 MMBTU/hr) Steam Generation : 907,000 kg/hr (2,000,000 lbs/hr) Altitude : 1722 m (5649 ft) Project: Replace the existing combustion system (32 burners : 16 NG, 16 Oil) with a new 16 Dual-Fuel tilt-burner Low NOx firing system. New Combustion System characteristics: 16 tilting burners 8 OFA ports The firing system must be able to operate with: Natural Gas Heavy Oil #6 Dual Fuel Firing (NG and Oil) 25% FGR 12% Excess Air 18

19 Problem description Tangentially Fired 300MW Utility Boiler: New Combustion System : Most of the NOx produced in this furnace are the result of thermal NOx formation. Thermal NOx formation requires: High temperatures (T>1800K). The presence of sufficient quantities of oxygen and nitrogen. Limiting Thermal NOx formation in this furnace is achieved by: Fuel Staging at the burner level Fuel and air are injected in such a way as to minimize the presence of high temperature zones and high concentrations of oxygen at the same place. Furnace Staging The overall Fuel/Air mixture at the burner level is maintained fuel-rich in order to minimize NOx formation by denying the reaction the necessary oxygen. The remainder of the combustion air is injected at the OFA level once the temperature of the combustion products has decreased. Secondary combustion, in excess air, at the OFA level of the CO remaining in the combustion products therefore takes place at a lower temperature and produce less thermal NOx. 19

20 Problem description Tangentially Fired 300MW Utility Boiler: New Combustion System : CFD investigation of the new combustion system: Determine the optimal tangential burner firing angles to: Ensure stable fireball aerodynamics for all fuels fired at the given altitude. Ensure adequate mixing of Combustion Products and OFA for complete combustion. Avoid flame impingement on the superheaters and the furnace walls. Ensure that the furnace heat transfer characteristics are similar to those of Cerrey s performance run predictions (idealized design cases) for each type of fuel firing by comparing theoretical and CFD predictions of Furnace Outlet Plane (FOP) gas temperatures. 20

21 CFD Modeling Numerical Models Code: STAR-CD Fluid Flow Steady-State (SIMPLE) Oil Droplets Lagrangian Particle Tracking Model - Coupled Turbulence High-Reynolds k-ε Model Radiation Discrete Ordinate Model Participating Media Radiation Model Superheaters, Re-Heaters and Economizer Volumetric heat-sink corresponding to empirical measurements => sorent.f Source term for dp according to empirical measurements => sormom.f 21

22 CFD Modeling Numerical Models Combustion In-house 5 fluid stream combustion model implemented with STAR-CD User Subroutines sorsca.f and scalfn.f The 5 fluid streams represent: Heavy Oil #6 Natural Gas FGR Gases Dry Combustion Air Water Vapor NOTE: - Because of the varying levels of humidity (0% in Natural Gas to 100% in the oil atomizing steam) streams 1-4 are considered dry. - The humidity content of the different streams is modeled using the 5 th scalar for water vapor. 22

23 CFD Modeling Numerical Models Combustion Primary Reaction Model Each fuel stream is considered to react independently of the others. Combustion air within a given cell is distributed proportionally between the different fuel streams present. Chemical Equilibrium solution (Gibbs Free Energy Minimization) for the reaction of each fuel stream with its portion of the combustion air. Transport equation for CO CO concentrations obtained from the chemical equilibrium model in the Reacting zones are used as the source of CO production for the kinetically controlled transport equation Transport equation for NOx Reaction rate for thermal NOx production based on the Zeldovich mechanism Final combustion product concentrations are obtained by recombining the products from each of the streams and transport equations. 23

24 CFD Modeling Discretization: Detailed Burner 24

25 CFD Modeling Discretization: Detailed Burner - 4 million cells 25

26 CFD Modeling Inlet Boundary Conditions for the Boiler Simulations are obtained from the Detailed Burner Simulations 26

27 CFD Modeling Discretization: Boiler & Burners - 8 million cells 27

28 Results and Analysis Optimization of the Firing System 25 different burner angles and OFA placement configurations were tested with CFD. The final firing system design allows for both Natural Gas and Oil #6 fireball flames to develop properly and be contained inside the furnace area. The final Firing System / OFA design allows for all combustion products to be properly mixed within the furnace area. The final firing system design was also verified to operate properly at 50% turndown. 28

29 Results and Analysis Natural Gas Firing 29

30 Results and Analysis Natural Gas Firing Burner Level 1 - Velocity Magnitude (m/s) 30

31 Results and Analysis Natural Gas Firing Burner Level 2 - Velocity Magnitude (m/s) 31

32 Results and Analysis Natural Gas Firing Burner Level 3- Velocity Magnitude (m/s) 32

33 Results and Analysis Natural Gas Firing Burner Level 4 - Velocity Magnitude (m/s) 33

34 Results and Analysis Natural Gas Firing OFA Level - Velocity Magnitude (m/s) 34

35 Results and Analysis Natural Gas Firing Temperature (K) 35

36 Results and Analysis Natural Gas Firing Furnace Centerline - Temperature (K) 36

37 Results and Analysis Natural Gas Firing Platen SH3 - Gas Temperature (K) 37

38 Results and Analysis Natural Gas Firing Right view Left view Furnace Wall Heat Flux (W/m 2 ) 38

39 Results and Analysis Heavy Oil #6 Firing 39

40 CFD Analysis - Salamanca Unit 3 Oil #6 Firing Droplets diameter (m) 40

41 CFD Analysis - Salamanca Unit 3 Oil #6 Firing Velocity Magnitude (m/s) 41

42 Results and Analysis Oil #6 Firing Burner Level 1 - Velocity Magnitude (m/s) 42

43 Results and Analysis Oil #6 Firing Burner Level 2 - Velocity Magnitude (m/s) 43

44 Results and Analysis Oil #6 Firing Burner Level 3- Velocity Magnitude (m/s) 44

45 Results and Analysis Oil #6 Firing Burner Level 4 - Velocity Magnitude (m/s) 45

46 Results and Analysis Oil #6 Firing OFA Level - Velocity Magnitude (m/s) 46

47 Results and Analysis Oil #6 Firing Temperature (K) 47

48 Results and Analysis Oil #6 Firing Furnace Centerline - Temperature (K) 48

49 Results and Analysis Oil #6 Firing Platen SH3 - Gas Temperature (K) 49

50 Results and Analysis Oil #6 Firing Right view Left view Furnace Wall Heat Flux (W/m 2 ) 50

51 Results and Analysis Dual-Fuel (54% Oil 46% NG) Firing 51

52 Results and Analysis Dual-Fuel (54% Oil 46% NG) Firing Velocity Magnitude (m/s) 52

53 Results and Analysis Dual-Fuel (54% Oil 46% NG) Firing Temperature (K) 53

54 Results and Analysis Dual-Fuel (54% Oil 46% NG) Firing Furnace Centerline - Temperature (K) 54

55 Results and Analysis Dual-Fuel (54% Oil 46% NG) Firing Platen SH3 - Gas Temperature (K) 55

56 Results and Analysis Dual-Fuel (54% Oil 46% NG) Firing Right view Left view Furnace Wall Heat Flux (W/m 2 ) 56

57 Results and Analysis Comparisons of Natural Gas, Oil#6 and Dual Fuel Firing 57

58 Results and Analysis Temperature Contours VS Type of Fuel Fired Gas Oil #6 Dual Fuel Furnace Centerline - Temperature (K) 58

59 Results and Analysis Luminous Flame Contour VS Type of Fuel Fired Gas Oil #6 Dual Fuel 59

60 Results and Analysis OPTIMIZED FIRING SYSTEM RESULTS Case CFD T(K) FOP Cerrey T(K) FOP relative difference of FOP Temperatures Natural Gas % Oil # % Dual Fuel (54% Oil 46% NG) % 60

61 Summary The STAR-CD simulations have enabled us to design a combustion system with the following characteristics: The optimized burner firing angles enable complete mixing of combustion products and Over Fire Air before leaving the furnace for all three firing modes. The temperature of the combustion products at the FOP (Furnace Outlet Plane) closely match with Cerrey s design predictions. The temperatures at the FOP correspond to the inlet temperatures of Platen SH3, and these temperatures closely match design values so the Platen SH3 should not be subject to excessive heating. The gas temperature contours in the furnace area are similar for all three firing modes; the oil flames being slightly hotter. 61

62 Summary The STAR-CD simulations have enabled us to design a combustion system with the following characteristics. The Luminous Flame Contours are similar for all three fuels. The Furnace Wall Heat Fluxes are within normal values for natural gas and heavy oil flames. Wall Heat Fluxes are normally higher for Oil than NG because of the increased radiation from the Oil flame. The wall heat flux corresponding to the dual-fuel fireball is between the two extremes as expected. The steady-state simulation results show that emissions and temperatures will be within technical specifications. 62

63 Conclusions The aerodynamics of the flow and the mass transfer inside the furnace are extremely complex. Altitude creates an additional constraint which must be taken into account. The combustion system design must be adjusted to accommodate the size and altitude of the boiler to be retro-fitted. CFD is an integral and critical part of BMA s engineering process when dealing with the interaction of so many complex physical phenomena. With so many operational requirements, CFD analyses are necessary in order to gain enough information about boiler operation under different conditions in order to ensure that the design meets all of the project s requirements. 63

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