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BOILER FURNACE
Abstract: Radiative heat transfer in the freeboard of large pulverized fuel utility
boilers was analyzed by applying one of the most accurate radiation models, the zone
method of analysis, to the prediction of incident radiative heat fluxes on the furnace
walls. Modeling the cooling water tubes in the freeboard was quite challenging and
using this method for unstructured mesh was leading to computationally demanding
calculations. By using this model, the behavior of temperature and heat flux within
the furnace and on the heat surfaces has been investigated. The velocity field of the
combusted fuel from burner has been modeled by using the existing formula for the
velocity field of turbulent jet exit from the burner orifice. The accuracy of the
method was tested by comparing its predictions with experimental measured
radiative fluxes on the walls. The final aim of the study was to find the needed
changes in boiler’s burners and load in order to change fuel quality from Mazut to
Methane without any damages in heat surfaces. By comparing the results of our
simulation for methane-state with experimental results for Mazut state, we found that
for preventing any damage in heat surfaces due to aforementioned fuel changes, the
load of the boilers should be decreased by 12%. By this fuel changing, the efficiency
of the boiler will increase and the boiler will work with a cleaner fuel.
∑a
i j
εg = g ,i (1 − exp(ki PL ) (8)
In these equations, rij is the size of the vector that
i =0
connects center of two elements to each Where k , P and L represents the emissivity, partial
other, θ i and θ j are the angle between the normal
pressure and effective path length of the gray gases,
vector of surface elements and aforementioned respectively. Term i = 0 is related to limpid gas. By
vector, and k is emissivity coefficient of gas. The using the method that described in (Viskanta and
order of these integrals is so high that analytical Mengae 1987) and by considering the water vapor
solutions for them are not possible except of some and CO2 and a limpid gas as the main products of
simple states, so for calculating them we employed combustion the coefficients of ag ,i has been
some mathematical technique we decrease the order
of integrals in a way that they can be calculated by calculated for several states of partial pressures.
numerical method. For example for surface-surface These coefficients employed for calculating directed
zones and for parallel zones, if we assume the (0, 0, flux area from total exchange area by the following
0) and (a, b, c) as the coordinates of two point of expression, for surface-surface zones:
these zones, we can change the equation 4 to the → N
Si S j = ∑ a s,n (Ti ) SiS j
expression: k = k
n =1 n
c2 (9)
∑
( si s j ) 1 1
B2
=
π ∫ ∫ 0
dx dy × (1 − x)(1 − y )
0
f ( ± x, ± y )
← N
Si S j = ∑ a s,n (Tj ) SiS j
− k g B rij (7) k = k
12 n =1
and rij = ( x + a ) + ( y + b)2 + c 2
e 2 n
where f ( x, y ) = ,
rij4 For surface-Volume zones:
and ∑ f ( ± x, ± y ) = f ( x, y ) + f ( − x, y ) + f ( x, − y ) + f ( − x, − y ) → N
Gi S j = ∑ a g,n (Tg,i ) G iS j
k=k
In this equation B represents characteristic length of n =1 n
(10)
gray gas. Therefore by using this technique, the order ← N
Gi S j = ∑ a s,n (T j ) G iS j
of integral will decrease and the numerical k=k
n =1 n
calculations will be much easier and more accurate.
This technique has also been used for other state of For volume-volume zones:
→ N
GiG j = ∑ a g,n (Tg,i ) G iG j
surface-surface zones and surface-volume and (11)
volume-volume zones. During calculation of directed k = k
n =1 n
exchange area for some elements we will be exposed
to singularity points for solving this kind of problem 3 VELOCITY FIELD WITHIN THE
we separate the integrals into two separate parts, the FURNACE
first part consist of singular points which has been
solved by analytical techniques and second one was For calculating the convective heat transfer term in
an integral without singular points which was solved energy balances in surface zone we need to have
by numerical method. Between several formulations velocity field within the furnace. In this order, we
of Simpson method for calculating integrals calculated velocity field within the furnace by some
numerically, the Simpson 1/3 has been chosen experimental formula. Almost all industrial flames
because of its simplicity and generality. For verifying are in the form of turbulent jet that exit from burner’s
validity of directed exchange area values, we used orifice. By defining an equivalence diameter for non-
the analytically calculated value that was reported for isothermal condition, velocity distribution and inlet
a simple case (Hotel and Sarofim, 1967). By using mass from around to jet can be calculated from
the aforementioned methods and techniques the following equations (Beer, 1972):
values of directed exchange area has been calculated
numerically for different possible states (singularity), d e = do (Ts To )1 2
(13)
the calculated values showed very good conformity U 6.4
= exp( −82( y x ) 2 )
with aforementioned reference values. U o ( x de )
After calculating directed exchange area, the total (14)
exchange area can be calculated from these values by m& e m& o = 0.32 ( x d e )
(15)
using the method that Hotel and Cohen reported in Where d e is equivalence diameter , x, y is position of
1935. We know that that the main products of
calculated point related to center of orifice , do is
combustion ( H 2O, CO2 )are not gray gases and by
orifice diameter Ts is temperature of calculated
using gray gas assumption for them the large amount
of error will enter to our calculation, but the exponent point, To is inlet temperature, U is axial velocity in
form of gray gas emission behavior can be good form calculated point, U o is axial velocity in orifice, m& o is
for modeling real gas(combustion product). inlet mass and m& e is the mass that enter to jet region
Therefore, a famous method for modeling the from neighbor regions.
radiation behavior of real gas is weight summation of
4 ENERGY BALANCE EQUATIONS IN Q& g ,net + Q& a + Q& g + Q& conv . + Q& rad . = 0 (19)
SURFACE AND VOLUME ZONES
The first term on the left hand side is net heat
For every surface zone (s), energy conservation generated from combustion can be calculated from
equation can be written as: Q& g ,net = V& × C (20)
g v , net
As + C s + Qs = Fs (16)
Where V&g the volume rate of inlet fuel to this volume
Where
As : The amount of energy that is absorbed by zone and Cv , net is net heat of combustion for fuel.
surface zone (s) from the energy which is emitted
from all zones (even itself). Q& a in eq.18 is the energy of combustion air at inlet
Cs : The convective energy that is transferred from/to temperature and Q& g is the rate of decrease in sensible
surface zone (s) to/from neighbor volume zones.
enthalpy of gas flowing through the zone. These two
Qs : The amount of energy that exits from furnace to
parameters can be calculated from:
load by this surface zone (s).
ρ a H a (Ta )
X
Fs : The amount of energy emitted from surface Q& a = V&G Rs 1 + (21)
zone(s). 100
By using the theory that was explained in section 1,
X
this energy balance can be rewrite in better shape: Q& g = V&G Rs + Rs ρ g H g (T g ) (22)
m ← L → 100
∑ S S σ T + ∑G S σ T
j =1
i j
4
j
j =1
j i
4
g, j − Aiε iσ Ti4 + Ai qi,conv. = Q& i In these equations, we have:
Rs : Volume rate of air to fuel in stoichiometric
(17)
Where m and L represents number of surface zones condition
and number of volume zones, respectively. The first ρ a : Density of inlet air
term on the left hand side of this equation is
ρ g : Density of combustion product
summation of all radiation that reached to this
surface zone from all surface zones in enclosure. The H a : Enthalpy of the air
second term on the left hand side represents
summation of all radiation that reached to this H g : Enthalpy of the fuel
surface zone from all volume zones in the enclosure. x : Additional air (%)
The third term represents the radiation emits from For radiative energy term in volume zone balance,
this surface zone. The fourth term is the amount of we can write:
convective energy from neighbor volume zone. The l ← m ← N
Q& rad = ∑ Gi G j σ Tg , j + ∑ Gi S j σ T j − 4 ∑ an k g ,nVi σ Tg ,i
4 4
right hand side represents the amount of heat transfer
j =1 j =1 n =1
to load (water walls) from this surface zone. This
value can be approximated by having the condition (23)
of water in entering and exiting the boiler and By substituting equations (20-23) into eq.19, we will
dividing the whole enthalpy changes between surface have:
l ← m ← N
zones, expect the burner’s surface zones, equally. For
a furnace with m surface zones, we will have m ∑ Gi G jσ Tg , j + ∑ Gi S j σ T j4 − 4∑ an k g ,nViσ Tg4,i −
j =1 j =1 n =1
energy balance in this shape.
For volume zones, we should also write energy ( Q& conv. ) + ( Q& g ,net )i + ( Q& a )i + ( Q& g )i =0 (24)
balance:
Where Q& conv. represents the convective heat transfer to
Av + Bv + Cv + Dv − Ev = Fv (18)
Av : The total radiative energy that is absorbed in
all surface zone that are in neighbor of this volume
zone.
volume v from all the energy that emitted from all Same as surface zone we can write one energy
zones in the system. balance for every volume zones. By solving these
Bv : The heat energy of the gas that is entered to this nonlinear equations together, we will reach to final
volume zone. solution for temperature in all surface and volume
Cv : The amount of energy that is transferred to/from zones.
neighbor surface zone by convection mechanism. 5 INTRODUCING THE MODEL
Dv : The energy generated in this volume zone by the
combustion mechanism. The boiler that is modeled in this research is made by
Ev : The heat energy of the gas that is exited from
CE Company. This kind of boiler has natural
circulation for water and the furnace dimensions are
this volume zone.
Fv : The total energy that is emitted from volume 22.4 ft × 33.6 ft × 67.2 ft .The side walls of the furnace is
made of the stainless steel tubes with 2.5in diameter.
zone v.
These tubes connect to each other by the plates with
This equation can be explained in other shape:
0.5in thickness and the center to center distance of
the tube is 3in . All the walls are made by this kind of amount of mass transfer between the volume zones
tubes and just there are no any tubes in the part of which is necessary for completing the energy balance
boiler that gas exits. This complex shape of walls has in surface and volume zones (Eq.17 and Eq.24), is
been replaced by an equivalent surface with calculated. According to the pattern in Fig. 2, the
emissivity of 0.85 . The method was explained by portion of convective term in whole heat transfer
Hottel and Cohen in 1935 is used for calculating the process is maximum in the chimney of the furnace
amount of the equivalent surfaces. This boiler has 16 relative to other parts.
burners that are placed in two stages with different
height in the front (8 burners) and rear (8 burners)
walls of the boiler. Figure 1 shows a simplified
model of this furnace that we used for our simulation.
As illustrated in figure 1, by using asymmetric
property of this furnace, we should just simulate a
half of surfaces and volume.