DESIGN AND THERMAL ANALYSIS OF A

SUPERCRITICAL CFB BOILER

ABSTRACT
A boiler is a closed vessel in which water or other fluid is heated. The fluid does not necessarily
boil. The heated or vaporized fluid exits the boiler for use in various processes or heating
applications, including central heating, boiler-based power generation, cooking, and sanitation.

Supercritical Circulating Fluidized Bed (CFB) boiler becomes an important development trend
for coal-fired power plant and thermal-hydraulic analysis is a key factor for the design and
operation of water wall.

In this thesis, a simple boiler and a CFB boiler are compared for the better heat transfer
performance. The 3D modeling of simple boiler and CFB boiler is done in Pro/Engineer and
Heat transfer analysis is done in Ansys.

The material used for boiler is steel. In this thesis, it is to be replaced with copper and brass.
Thermal analysis is done to verify the better heat transfer rate by comparing simple and CFB
boilers and better material.

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 1.1 INTRODUCTION TO BOILERS
A boiler is a closed vessel in which water or other fluid is heated. The fluid does not necessarily
boil. (In North America the term "furnace" is normally used if the purpose is not actually to boil
the fluid.) The heated or vaporized fluid exits the boiler for use in various processes or heating
applications, including central heating, boiler-based power generation, cooking, and sanitation.

MATERIALS
The pressure vessel of a boiler is usually made of steel (or alloy steel), or historically of wrought
iron. Stainless steel, especially of the austenitic types, is not used in wetted parts of boilers due to
corrosion and stress corrosion cracking. However, ferritic stainless steel is often used in
superheater sections that will not be exposed to boiling water, and electrically-heated stainless
steel shell boilers are allowed under the European "Pressure Equipment Directive" for production
of steam for sterilizers and disinfectors.

In live steam models, copper or brass is often used because it is more easily fabricated in smaller
size boilers. Historically, copper was often used for fireboxes (particularly for steam
locomotives), because of its better formability and higher thermal conductivity; however, in
more recent times, the high price of copper often makes this an uneconomic choice and cheaper
substitutes (such as steel) are used instead.

For much of the Victorian "age of steam", the only material used for boilermaking was the
highest grade of wrought iron, with assembly by rivetting. This iron was often obtained from
specialist ironworks, such as at Cleator Moor (UK), noted for the high quality of their rolled
plate and its suitability for high-reliability use in critical applications, such as high-pressure
boilers. In the 20th century, design practice instead moved towards the use of steel, which is
stronger and cheaper, with welded construction, which is quicker and requires less labour.

Cast iron may be used for the heating vessel of domestic water heaters. Although such heaters
are usually termed "boilers" in some countries, their purpose is usually to produce hot water, not
steam, and so they run at low pressure and try to avoid actual boiling. The brittleness of cast iron
makes it impractical for high pressure steam boilers.

FUEL
The source of heat for a boiler is combustion of any of several fuels, such as wood, coal, oil, or
natural gas. Electric steam boilers use resistance- or immersion-type heating elements. Nuclear
fission is also used as a heat source for generating steam, either directly (BWR) or, in most cases,
in specialized heat exchangers called "steam generators" (PWR). Heat recovery steam generators
(HRSGs) use the heat rejected from other processes such as gas turbines.

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CONFIGURATIONS

Boilers can be classified into the following configurations:

 "Pot boiler" or "Haycock boiler": a primitive "kettle" where a fire heats a partially
filled water container from below. 18th century Haycock boilers generally produced and
stored large volumes of very low-pressure steam, often hardly above that of the
atmosphere. These could burn wood or most often, coal. Efficiency was very low.

 Fire-tube boiler: Here, water partially fills a boiler barrel with a small volume left above
to accommodate the steam (steam space). This is the type of boiler used in nearly all
steam locomotives. The heat source is inside a furnace or firebox that has to be kept
permanently surrounded by the water in order to maintain the temperature of the heating
surface below the boiling point. The furnace can be situated at one end of a fire-tube
which lengthens the path of the hot gases, thus augmenting the heating surface which can
be further increased by making the gases reverse direction through a second parallel tube
or a bundle of multiple tubes (two-pass or return flue boiler); alternatively the gases may
be taken along the sides and then beneath the boiler through flues (3-pass boiler). In the
case of a locomotive-type boiler, a boiler barrel extends from the firebox and the hot
gases pass through a bundle of fire tubes inside the barrel which greatly increase the
heating surface compared to a single tube and further improve heat transfer. Fire-tube
boilers usually have a comparatively low rate of steam production, but high steam storage
capacity. Fire-tube boilers mostly burn solid fuels, but are readily adaptable to those of
the liquid or gas variety.

Diagram of a fire-tube boiler

 Water-tube boiler: In this type, tubes filled with water are arranged inside a furnace in a
number of possible configurations: often the water tubes connect large drums, the lower

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 ones containing water and the upper ones, steam and water; in other cases, such as a
monotube boiler, water is circulated by a pump through a succession of coils. This type
generally gives high steam production rates, but less storage capacity than the above.
Water tube boilers can be designed to exploit any heat source and are generally preferred
in high pressure applications since the high pressure water/steam is contained within
small diameter pipes which can withstand the pressure with a thinner wall.

Diagram of a water-tube boiler.

 Flash boiler: A specialized type of water-tube boiler.

1950s design steam locomotive boiler, from a Victorian Railways J class

 Fire-tube boiler with Water-tube firebox: Sometimes the two above types have been
combined in the following manner: the firebox contains an assembly of water tubes,
called thermic siphons. The gases then pass through a conventional firetube boiler. Water-
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 tube fireboxes were installed in many Hungarian locomotives, but have met with little
success in other countries.

 Sectional boiler: In a cast iron sectional boiler, sometimes called a "pork chop boiler"
the water is contained inside cast iron sections. These sections are assembled on site to
create the finished boiler.

SUPERHEATED STEAM BOILERS

A superheated boiler on a steam locomotive.

Most boilers produce steam to be used at saturation temperature; that is, saturated steam.
Superheated steam boilers vaporize the water and then further heat the steam in a superheater.
This provides steam at much higher temperature, but can decrease the overall thermal efficiency
of the steam generating plant because the higher steam temperature requires a higher flue gas
exhaust temperature. There are several ways to circumvent this problem, typically by providing
an economizer that heats the feed water, a combustion air heater in the hot flue gas exhaust path,
or both. There are advantages to superheated steam that may, and often will, increase overall
efficiency of both steam generation and its utilisation: gains in input temperature to a turbine
should outweigh any cost in additional boiler complication and expense. There may also be
practical limitations in using wet steam, as entrained condensation droplets will damage turbine
blades.

Superheated steam presents unique safety concerns because, if any system component fails and
allows steam to escape, the high pressure and temperature can cause serious, instantaneous harm
to anyone in its path. Since the escaping steam will initially be completely superheated vapor,
detection can be difficult, although the intense heat and sound from such a leak clearly indicates
its presence.

Superheater operation is similar to that of the coils on an air conditioning unit, although for a
different purpose. The steam piping is directed through the flue gas path in the boiler furnace.
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The temperature in this area is typically between 1,300–1,600 °C (2,372–2,912 °F). Some
superheaters are radiant type; that is, they absorb heat by radiation. Others are convection type,
absorbing heat from a fluid. Some are a combination of the two types. Through either method,
the extreme heat in the flue gas path will also heat the superheater steam piping and the steam
within. While the temperature of the steam in the superheater rises, the pressure of the steam
does not and the pressure remains the same as that of the boiler. Almost all steam superheater
system designs remove droplets entrained in the steam to prevent damage to the turbine blading
and associated piping.

SUPERCRITICAL STEAM GENERATOR

Boiler for a power plant.

Supercritical steam generators are frequently used for the production of electric power. They
operate at supercritical pressure. In contrast to a "subcritical boiler", a supercritical steam
generator operates at such a high pressure (over 3,200 psi or 22 MPa) that the physical
turbulence that characterizes boiling ceases to occur; the fluid is neither liquid nor gas but a
super-critical fluid. There is no generation of steam bubbles within the water, because the
pressure is above the critical pressure point at which steam bubbles can form. As the fluid
expands through the turbine stages, its thermodynamic state drops below the critical point as it
does work turning the turbine which turns electrical generator from which power is ultimately
extracted. The fluid at that point may be a mix of steam and liquid droplets as it passes into the
condenser. This results in slightly less fuel use and therefore less greenhouse gas production. The
term "boiler" should not be used for a supercritical pressure steam generator, as no "boiling"
actually occurs in this device.

1.2 INTRODUCTION TO CFB BOILERS

The Kyoto Protocol, regardless whether it is fully ratified or not, has been the catalyst for a
number of changes in the energy generation industry. Debate on future energy management for
power stations and what types of energy should be used continues to be quite intensive, and has
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resulted in a lot of new research and development work. One focus of this debate has been on
carbon dioxide (CO2) emissions and how to reduce them. As a result, coal remains somewhat
unpopular, due to the perception that coal - fired plants pollute the atmosphere and generate
higher emissions of CO2 than gas - fired technology.

Flue gas cleaning technologies have made major improvements here. The capture and
sequestration of CO2 is not yet an economic technology when burning coal. The industry
nevertheless needs to use coal as one of its fuel sources; and the only feasible method of
reducing CO2 in the near and medium term when utilizing coal is to emit as little CO 2 as
possible, by increasing plant efficiency.

Modern power plants are designed for high efficiency, not only for economical reasons but also
for environmental reasons, such as reducing fuel usage, the quantity of ash generated, and cutting
the level of pollutants emitted. Increasing efficiency also means lower emissions of CO2.

Supercritical steam parameters have been applied as a first step to achieving these goals. Most of
the large European thermal power plants fired on fossil fuels, such as coal and brown coal, that
have been commissioned over the last decade have incorporated supercritical steam parameters
In order to achieve even higher efficiencies, steam temperatures and pressures are being
continuously increased as much as the metals used in boiler tubes and turbine blades allow.

The larger plants built recently have been based on pulverized coal (PC) technology and much
development of this technology has taken place. However, circulating fluidized bed (CFB)
technology has emerged as a growing challenger. CFB boiler technology based on natural
circulation has reached utility scale over the last decade. The largest units in operation at the
moment are two 300 MW boilers operated by Jacksonville Electric Authority (JEA) in
Jacksonville, Florida, capable of burning either 100% coal or 100% petroleum coke or any
combination of the two. For CFB technology to be considered a viable technology
for meeting the power generation guidelines established by the United States Department of
Energy Road Map , it has to be designed with supercritical steam parameters. This step has now
been reached by Foster Wheeler, following the award of a contract by the Polish utility,
Poludniowy Koncern Energetyczny S. A. (PKE), in February 2003 to build the world’s first CFB
boiler operating at supercritical steam conditions, a 460 MWe unit to be built at their Lagisza
station.

Prior to winning the contract, Foster Wheeler had carried out extensive development work on the
mechanical design issues involved and understanding the process conditions affecting heat
transfer, flow dynamics, carbon burnout, gaseous emission suppression, hydraulic flow
s, etc.. Various methods and equipment, such as bench - scale test rigs, pilot plants, field testing
at operating units, model development, design correlations for conventional boiler design, and
simulation employing semi-empirical models or more theoretical models have been used for
developing and successfully implementing design criteria for larger units.

The Foster Wheeler supercritical once - through boiler (OTU) employs a licensed application of
Siemens’ low mass-flux BENSON vertical once-through technology. It also employs the results
of work performed under an EU-funded program aimed at further developing OTU CFB
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technology; that program known as High Performance Boiler (HIPE), began in 2002 under the
Community’s 5th Framework, and involves Foster Wheeler Energia Oy from Finland, Siemens
AG from Germany, the Technical Research Center of Finland, and Energoprojekt Katowice from
Poland. The BENSON system, together with some test results from the HIPE program, along
with a design description of Foster Wheeler’s 460 MW unit, are discussed below. The advantages
of using low mass - flux OTU technology for a CFB boiler are described in general.

SIEMENS BENSON LOW MASS - FLUX VERTICAL ONCE - THROUGH (OT)

TECHNOLOGY

With a total of more than 1,000 units delivered over many years to the power generation industry,
the BENSON boiler is the most commonly used type of once - through boiler. It operates at
power levels up to 1,300 MW, steam pressures up to 350 bar, and steam temperatures up to well
over 600°C. More than a quarter of units operate at supercritical pressure.

BENSON technology is centered on an evaporator design and has been licensed by Siemens
since 1933. It is a once - through design suitable for sub - and supercritical pressure and variable
pressure operation. Steam generators using the BENSON design incorporate features that are
critical to economic success on today’s competitive power markets. These features include:

 a highly efficient water/steam cycle, as a result of supercritical pressures and high steam
temperatures
 insensitivity of steam output and steam temperature to fluctuating fuel properties
 the capability for rapid load changes, due to variable-pressure operation and short start-up
times, thanks to thermo elastic design.

The extensive worldwide use of the BENSON boiler is the result of ongoing efforts to develop
the technology. The expanded knowledge base obtained through detailed studies, particularly of
the heat transfer mechanisms within furnace tubes, has made an important contribution to this
effort. New evaporator designs will continue to improve operating behavior and make boiler
manufacturing more cost - effective.

The BENSON Low Mass Flux design is unique. Earlier furnaces were designed with spiral
-wound tubes, and operating experience has been built up with several hundred boilers extending
over more than 30 years. A new development started in the 1980s in the form of vertical
evaporator tubing with low mass flux, based on the use of rifled tubes, as shown in Figure 1.

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Heat transfer in a rifled tube is very good, especially during evaporation, since centrifugal forces
transport the water fraction of the wet steam to the tube wall. The resulting wall wetting results
in excellent heat transfer from the wall to the fluid. This has the following advantages over
smooth tubes:

 No deterioration of heat transfer, even in the range of high steam quality

 Very good heat transfer, even at low mass flux
 Only a slight increase in wall temperature in the case of film boiling near critical pressure
 Potential for increased heat transfer by optimizing rifling geometry.

The Siemens high - pressure test rig – the largest in the world, with an electrical heater capacity
of about 2,000 kW – was used to generate more than 200,000 data points in an investigation of
standard commercial rifled tubes and tubes with modified rifling geometry. Changes to the rifling
geometry permit significant improvements in heat transfer to be achieved, as can be seen in
Figure 2.

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A vertical tube arrangement on the one hand, and rifling on the other, allow a design with very
low mass flux. This low mass flux changes the flow characteristics of a once-through system.

Increased heat input to an individual tube leads to increased throughput for the tube concerned,
instead of reduced throughput, as might be expected. This flow behavior – typical of drum
boilers – is known as a natural circulation or positive flow characteristic.

The advantages of a vertically tube furnace can be summarized as follows:

 Mass flux reduction from 2,000 to 1,000 kg/m²s, with a similar flow characteristic to that
of drum boilers
 Cost - effective fabrication and assembly
 Low minimum load and simple start-up
 Reduced slagging and erosion on furnace wall due to parallel gas flow
 Reduced evaporator pressure drop.

The BENSON low mass flux design was first tested in the Farge 420 MW supercritical power
plant, using a few small test sections. The first coal - fired boiler with an evaporator based on the
Siemens low mass flux design was built in Yaomeng, China, and has now been in successful
operation since mid - 2002. The boiler – a repowering project at a 30 MW power plant –
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incorporates the special challenge of a center water wall with heat input from both sides and
configured parallel to the water walls. Despite the large variations in heat input between the outer
water walls and the center water wall, the temperature variations at the outlet of the water wall
heat exchange surfaces are negligible.

CFB plants incorporating once - through boilers rated up to 100 MW have been in operation for
many years. The state of the art when these plants were constructed featured a relatively
elaborate riser – downcomer system for the water walls. The largest CFB plants to date, rated in
the 300 MW range, are designed with drum boilers. However, once - through operation and
elevated steam conditions up to approximately 600°C and 300 bar are required to make CFB
technology a real competitor to pulverized coal firing for large plants.

Table 1 shows the references for CFB BENSON boilers with vertical riser - downcomer systems
and PC BENSON Boilers with low mass flux installations.

As part of the EU HIPE research program, an evaporator concept for a 460 MW e CFB plant was
elaborated, based on the Siemens low mass flux design. Fluid mechanics analysis have been
performed, as well as heat transfer measurements in the BENSON test rig using rifled tube, such
as that used in the intermediate water walls (wing walls) of a combustor subject to heat input
from both sides.

Due to the differing geometries and heat inputs involved, the evaporator had to be subdivided
into a number of systems, configured in parallel. The individual mass flows and the
corresponding outlet temperatures from the water wall sections were then determined.

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The effects of variations in heat input and the loss of a fuel feeder on the temperatures were also
investigated.

The selection of a relatively low design mass flux between 400 kg/m²s and 700 kg/m²s
depending on the type of tube – yields a good positive flow characteristic for all tubes, for the
smooth tubes in the front, rear, and side walls, as well as for the rifled tubes in the intermediate
walls (wings walls).

This means that even large variations in heat input are evened out by the adjustment of individual
mass flows, which takes place automatically as a result of the self - regulating characteristic. At
full load, the differences between the highest and lowest individual tube temperatures at the
evaporator outlet are only 35 K, even in the event of the loss of a fuel feeder, as shown in Figure
3.

Further investigations performed for partial load conditions (75% and 40%) yielded even lower
temperature differences.

Thanks to the low mass fluxes, the evaporator pressure drop between the point of distribution to
the individual systems and the separator inlet only amounts to 2.7 bar at full load. This makes a
major contribution to reducing the auxiliary power requirement.
CFB technology imposes stringent requirements on water wall tubing. The high ash loading in
the combustor requires the use of tubing running parallel to the flue gas/ash flow. Wound tubing,

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such as that usually implemented in the furnaces of pulverized coal - fired boilers, is not feasible
for the combustor. In addition, some variations in heat input must be assumed. The combustor
walls feature zones of greatly differing heat input, especially in the upper section. As a result,
several sections in the ash discharge area are provided with lining. Higher output plants require
intermediate water walls, with heat input to both sides, where necessary.

In the CFBs constructed to date as once through boilers, the combustor has been implemented
using a system of risers and down comers, each featuring a complex redistribution of the
water/steam mixture after each pass. Thanks to the BENSON low mass flux design, an
evaporator concept is now available that fulfills the above requirements and is cost effective,
thanks to its inherent simplicity. Medium flows take place in parallel through all tubes in one
pass, and no distribution of water/steam mixture is required. There are only negligible variations
in temperature between the tubes at the outlet from the combustor, as variations in heat input are
evened out by the positive flow characteristic. The relatively low heat flux in the combustor
compared to that in the furnace of pulverized coal - fired boilers all ows smooth tubes to be used
for the water walls subject to single - sided heat input. In addition, the suitability of the
evaporator system for variable pressure operation meets all power plant requirements with regard
to operating flexibility.

ADVANTAGES OF A SUPERCRITICAL OTU CFB BOILER

One general feature of Siemens’ low mass-flux BENSON OTU technology is that it results in a
lower water/steam side pressure drop. This reduces feed water pump power consumption,
thereby reducing the plant net heat rate.

Other advantages of an OTU CFB include the fact that a low and uniform heat flux makes
boiler tubes insensitive to overheating, as earlier discussed. As the combustion temperature is
relatively low in a CFB, i.e. 850 - 880 ºC (1562-1616 ºF), there is no slagging or fouling of the
furnace water walls and, hence, no deterioration of heat transfer.

In addition, the following general advantages should be mentioned:

 fuel flexibility
 multi-fuel capability
 low emissions without the need for secondary clean up

One inherent feature of a CFB boiler is its insensitivity to variations in fuel composition. In
many cases, coal or brown coal from the same mine varies widely in terms of heat value, ash
content, and moisture. Such variations do not materially affect the combustion temperature, due
to the thermal wheel that the circulating solids create, i.e. the solids act as a buffer against any
variations in fuel characteristics and the amount of fuel present in the unit is only a few percent
of the total amount of bed material.
The relatively uniform combustion temperature provided by the CFB results in a uniform
heat flux and even temperatures in the boiler tubes.
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Multi-fuel operation is another inherent feature of a CFB unit. When firing several different
fuels, heat fluxes will also be low and uniform , due to the buffer characteristics of the
circulating solids. These are clear advantages for a plant owner, as fuel property variations and
fuel availability will not become an issue, giving owners a larger degree of freedom to use the
most economical fuel source. This is increasingly important, as many plant owners rely on
imported coal or coal from various mines.

A CFB boiler generates low levels of gaseous emissions without the use of additional flue gas
cleaning equipment. The cost of flue gas desulfurization (FGD) and selective catalytic reduction
(SCR) systems can be very significant. In addition, an SCR system requires ammonia injection,
and the catalyst must be replaced on a regular basis. A CFB produces more ash, since in furnace
sulfur reduction is not as efficient as an FGD. On the other hand, limestone can be used directly
and lime is not required. The cost of lime is typically several times higher than the cost of
limestone. The end product of a CFB is always dry and there are no wet discharge streams.

Even though the CFB operates at a much lower temperature than a pulverized coal fired unit, the
high particle residence time and turbulent mixing provided by the hot circulating solids to
enhance carbon burnout and in, practice, the two units operate with similar combustion
efficiencies.

The CFB, however, can operate with a lower flue gas exit temperature which enhances boiler
efficiency. The reason for this lower flue gas temperature is the economizer, which can be used
more effectively in a CFB. The water temperature can be raised in the economizer while still
maintaining the appropriate steam/water ratio by weight in the furnace tubes, as the heat fluxes
are lower than in a pulverized coal-fired unit. The SO2 content in CFB flue gas is also
significantly lower than in a PC, since sulfur capture takes place in the furnace. This results in a
lower acid dew point and flue gas can be colder without cold end corrosion.

While more auxiliary power is needed for fluidization, no mills are required and there is no
additional flue gas pressure drop due to FGD and SCR units, and no water consumption, as in a
FGD. The power demand of these components is more or less equal to the power needed for
fluidization.

Overall, CFB boiler technology offers so many advantages that it can be expected to be utilized
more and more in future large scale power generation based on coal or brown coal.

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1.3 INTRODUCTION TO CAD
Throughout the history of our industrial society, many inventions have been patented and
whole new technologies have evolved. Perhaps the single development that has impacted
manufacturing more quickly and significantly than any previous technology is the digital
computer.
Computers are being used increasingly for both design and detailing of engineering components
in the drawing office.Computer-aided design(CAD) is defined as the application of computers
and graphics software to aid or enhance the product design from conceptualization to
documentation. CAD is most commonly associated with the use of an interactive computer
graphics system, referred to as a CAD system. Computer-aided design systems are powerful
tools and in the mechanical design and geometric modeling of products and components.
There are several good reasons for using a CAD system to support the engineering design
function:

 To increase the productivity

 To improve the quality of the design
 To uniform design standards
 To create a manufacturing data base
 To eliminate inaccuracies caused by hand-copying of drawings and inconsistency
between
 Drawings

CAD/CAM SOFTWARE

Software allows the human user to turn a hardware configuration into a powerful design and
manufacturing system. CAD/CAM software falls into two broad categories,2-D and 3-D,
based on the number of dimensions are called 2-D representations of 3-D objects is inherently
confusing. Equally problem has been the inability of manufacturing personnel to properly read
and interpret complicated 2-D representations of objects. 3-D software permits the parts to be
viewed with the 3-D planes-height,width, and depth-visible. The trend in CAD/CAM is toward
3-D representation of graphic images. Such representation approximate the actual shape and
appearance of the object to be produced; therefore, they are easier to read and understand.

APPLICATIONS OF CAD/CAM

The emergence of CAD/CAM has had a major impact on manufacturing, by standardizing

product development and by reducing design effort, tryout, and prototype work; it has made
possible significantly reduced costs and improved productivity.

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15 INTRODUCTION TO PRO/ENGINEER
Pro/ENGINEER, PTC's parametric, integrated 3D CAD/CAM/CAE solution, is used by
discrete manufacturers for mechanical engineering, design and manufacturing.

Created by Dr. Samuel P. Geisberg in the mid-1980s, Pro/ENGINEER was the industry's first
successful parametric, 3D CAD modeling system. The parametric modeling approach uses
parameters, dimensions, features, and relationships to capture intended product behavior and
create a recipe which enables design automation and the optimization of design and product
development processes.

Companies use Pro/ENGINEER to create a complete 3D digital model of their products. The
models consist of 2D and 3D solid model data which can also be used downstream in finite
element analysis, rapid prototyping, tooling design, and CNC manufacturing. All data is
associative and interchangeable between the CAD, CAE and CAM modules without conversion.
A product and its entire bill of materials(BOM) can be modeled accurately with fully associative
engineering drawings, and revision control information. The associativity in Pro/ENGINEER
enables users to make changes in the design at any time during the product development process
and automatically update downstream deliverables. This capability enables concurrent
engineering — design, analysis and manufacturing engineers working in parallel — and
streamlines product development processes.

Pro/ENGINEER is an integral part of a broader product development system developed by PTC.

It seamlessly connects to PTC’s other solutions including Windchill, ProductView, Mathcad and
Arbortext.

1.6 INTRODUCTION TO FEA

Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who utilized the Ritz
method of numerical analysis and minimization of variational calculus to obtain approximate
solutions to vibration systems. Shortly thereafter, a paper published in 1956 by M. J. Turner, R.
W. Clough, H. C. Martin, and L. J. Topp established a broader definition of numerical analysis.
The paper centered on the "stiffness and deflection of complex structures".

FEA consists of a computer model of a material or design that is stressed and analyzed for
specific results. It is used in new product design, and existing product refinement. A company is
able to verify a proposed design will be able to perform to the client's specifications prior to
16
manufacturing or construction. Modifying an existing product or structure is utilized to qualify
the product or structure for a new service condition. In case of structural failure, FEA may be
used to help determine the design modifications to meet the new condition.

There are generally two types of analysis that are used in industry: 2-D modeling, and 3-D
modeling. While 2-D modeling conserves simplicity and allows the analysis to be run on a
relatively normal computer, it tends to yield less accurate results. 3-D modeling, however,
produces more accurate results while sacrificing the ability to run on all but the fastest computers
effectively. Within each of these modeling schemes, the programmer can insert numerous
algorithms (functions) which may make the system behave linearly or non-linearly. Linear
systems are far less complex and generally do not take into account plastic deformation. Non-
linear systems do account for plastic deformation, and many also are capable of testing a material
all the way to fracture.

FEA uses a complex system of points called nodes which make a grid called a mesh. This mesh
is programmed to contain the material and structural properties which define how the structure
will react to certain loading conditions. Nodes are assigned at a certain density throughout the
material depending on the anticipated stress levels of a particular area. Regions which will
receive large amounts of stress usually have a higher node density than those which experience
little or no stress. Points of interest may consist of: fracture point of previously tested material,
fillets, corners, complex detail, and high stress areas.

A wide range of objective functions (variables within the system) are available for minimization
or maximization:

 Mass, volume, temperature

 Strain energy, stress strain
 Force, displacement, velocity, acceleration
 Synthetic (User defined)

There are multiple loading conditions which may be applied to a system. Some examples are
shown:

 Point, pressure, thermal, gravity, and centrifugal static loads

 Thermal loads from solution of heat transfer analysis
 Enforced displacements
 Heat flux and convection
 Point, pressure and gravity dynamic loads

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Each FEA program may come with an element library, or one is constructed over time. Some
sample elements are:

 Rod elements
 Beam elements
 Plate/Shell/Composite elements
 Shear panel
 Solid elements
 Spring elements
 Mass elements
 Rigid elements
 Viscous damping elements

Types of Engineering Analysis

Structural analysis consists of linear and non-linear models. Linear models use simple
parameters and assume that the material is not plastically deformed. Non-linear models consist of
stressing the material past its elastic capabilities. The stresses in the material then vary with the
amount of deformation as in.

Vibrational analysis is used to test a material against random vibrations, shock, and impact.
Each of these incidences may act on the natural vibrational frequency of the material which, in
turn, may cause resonance and subsequent failure.

Fatigue analysis helps designers to predict the life of a material or structure by showing the
effects of cyclic loading on the specimen. Such analysis can show the areas where crack
propagation is most likely to occur. Failure due to fatigue may also show the damage tolerance of
the material.

Heat Transfer analysis models the conductivity or thermal fluid dynamics of the material or
structure. This may consist of a steady-state or transient transfer. Steady-state transfer refers to
constant thermo properties in the material that yield linear heat diffusion.

Results of Finite Element Analysis

FEA has become a solution to the task of predicting failure due to unknown stresses by showing
problem areas in a material and allowing designers to see all of the theoretical stresses within.
This method of product design and testing is far superior to the manufacturing costs which would
18
accrue if each sample was actually built and tested.
In practice, a finite element analysis usually consists of three principal steps:

1. Preprocessing: The user constructs a model of the part to be analyzed in which the
geometry is divided into a number of discrete sub regions, or elements," connected at
discrete points called nodes." Certain of these nodes will have fixed displacements, and
others will have prescribed loads. These models can be extremely time consuming to
prepare, and commercial codes vie with one another to have the most user-friendly
graphical “preprocessor" to assist in this rather tedious chore. Some of these
preprocessors can overlay a mesh on a preexisting CAD file, so that finite element
analysis can be done conveniently as part of the computerized drafting-and-design
process.
2. Analysis: The dataset prepared by the preprocessor is used as input to the finite element
code itself, which constructs and solves a system of linear or nonlinear algebraic
equations

Kijuj = fi

where u and f are the displacements and externally applied forces at the nodal points. The
formation of the K matrix is dependent on the type of problem being attacked, and this
module will outline the approach for truss and linear elastic stress analyses. Commercial
codes may have very large element libraries, with elements appropriate to a wide range of
problem types. One of FEA's principal advantages is that many problem types can be
addressed with the same code, merely by specifying the appropriate element types from
the library.

3. Postprocessing: In the earlier days of finite element analysis, the user would pore
through reams of numbers generated by the code, listing displacements and stresses at
discrete positions within the model. It is easy to miss important trends and hot spots this
way, and modern codes use graphical displays to assist in visualizing the results. A typical
postprocessor display overlays colored contours representing stress levels on the model,
showing a full field picture similar to that of photo elastic or moiré experimental results.

19
1.7 INTRODUCTION TO ANSYS
ANSYS is general-purpose finite element analysis (FEA) software package. Finite Element
Analysis is a numerical method of deconstructing a complex system into very small pieces (of
user-designated size) called elements. The software implements equations that govern the
behaviour of these elements and solves them all; creating a comprehensive explanation of how
the system acts as a whole. These results then can be presented in tabulated, or graphical forms.
This type of analysis is typically used for the design and optimization of a system far too
complex to analyze by hand. Systems that may fit into this category are too complex due to their
geometry, scale, or governing equations.

ANSYS is the standard FEA teaching tool within the Mechanical Engineering Department at
many colleges. ANSYS is also used in Civil and Electrical Engineering, as well as the Physics
and Chemistry departments.

ANSYS provides a cost-effective way to explore the performance of products or processes in a

virtual environment. This type of product development is termed virtual prototyping.

With virtual prototyping techniques, users can iterate various scenarios to optimize the product
long before the manufacturing is started. This enables a reduction in the level of risk, and in the
cost of ineffective designs. The multifaceted nature of ANSYS also provides a means to ensure
that users are able to see the effect of a design on the whole behavior of the product, be it
electromagnetic, thermal, mechanical etc.

Generic Steps to Solving any Problem in ANSYS

Like solving any problem analytically, you need to define (1) your solution domain, (2) the
physical model, (3) boundary conditions and (4) the physical properties. You then solve the
problem and present the results. In numerical methods, the main difference is an extra step called
mesh generation. This is the step that divides the complex model into small elements that
become solvable in an otherwise too complex situation. Below describes the processes in
terminology slightly more attune to the software.

Build Geometry

Construct a two or three dimensional representation of the object to be modeled

and tested using the work plane coordinate system within ANSYS.

Define Material Properties

20
 Now that the part exists, define a library of the necessary materials that compose
the object (or project) being modeled. This includes thermal and mechanical
properties.

Generate Mesh

At this point ANSYS understands the makeup of the part. Now define how the
modeled system should be broken down into finite pieces.

Apply Loads

Once the system is fully designed, the last task is to burden the system with
constraints, such as physical loadings or boundary conditions.

Obtain Solution

This is actually a step, because ANSYS needs to understand within what state
(steady state, transient… etc.) the problem must be solved.

Present the Results

After the solution has been obtained, there are many ways to present ANSYS’
results, choose from many options such as tables, graphs, and contour plots.

SPECIFIC CAPABILITIES OF ANSYS

Structural

Structural analysis is probably the most common application of the finite element method as it
implies bridges and buildings, naval, aeronautical, and mechanical structures such as ship hulls,
aircraft bodies, and machine housings, as well as mechanical components such as pistons,
machine parts, and tools.

· Static Analysis - Used to determine displacements, stresses, etc. under static loading
conditions. ANSYS can compute both linear and nonlinear static analyses. Nonlinearities
can include plasticity, stress stiffening, large deflection, large strain, hyper elasticity,
contact surfaces, and creep.

· Transient Dynamic Analysis - Used to determine the response of a structure to

arbitrarily time-varying loads. All nonlinearities mentioned under Static Analysis above
are allowed.

· Buckling Analysis - Used to calculate the buckling loads and determine the buckling
mode shape. Both linear (eigenvalue) buckling and nonlinear buckling analyses are
possible.
21
In addition to the above analysis types, several special-purpose features are available such as
Fracture mechanics, Composite material analysis, Fatigue, and both p-Method and Beam
analyses.

Modal Analysis - A modal analysis is typically used to determine the vibration characteristics
(natural frequencies and mode shapes) of a structure or a machine component while it is being
designed. It can also serve as a starting point for another, more detailed, dynamic analysis, such
as a harmonic response or full transient dynamic analysis.

Modal analyses, while being one of the most basic dynamic analysis types available in ANSYS,
can also be more computationally time consuming than a typical static analysis. A reduced
solver, utilizing automatically or manually selected master degrees of freedom is used to
drastically reduce the problem size and solution time.

Harmonic Analysis - Used extensively by companies who produce rotating machinery, ANSYS
Harmonic analysis is used to predict the sustained dynamic behavior of structures to consistent
cyclic loading. Examples of rotating machines which produced or are subjected to harmonic
loading are:

 Turbines
o Gas Turbines for Aircraft and Power Generation

o Steam Turbines

o Wind Turbine

o Water Turbines

o Turbopumps

 Internal Combustion engines

 Electric motors and generators

 Gas and fluid pumps

 Disc drives

A harmonic analysis can be used to verify whether or not a machine design will successfully
overcome resonance, fatigue, and other harmful effects of forced vibrations.

22
 Chapter - 2
LITERATURE SURVEY
PAPER 1 - 460 MWe SUPERCRITICAL CFB BOILER DESIGN FOR
ŁAGISZA POWER PLANT BY Ilkka Venäläinen, Rafał Psik
Circulating fluidized bed (CFB) boiler technology has been growing in size and number over the
past two decades and it has established its position as utility scale boiler technology. Plant sizes
up to 300 MWe are in operation today and designs for larger boilers are being developed. The
next natural step for CFB technology is to go for supercritical steam parameters and larger boiler
sizes. A Polish utility company Południowy Koncern Energetyczny SA (PKE) placed an order to
Foster Wheeler Energia Oy for a 460 MWe supercritical CFB boiler for their Łagisza power
plant. Contract was signed at the end of year 2002 and the engineering work is now ongoing.
This will be the first supercritical once through CFB boiler in the world. A modern power plant is
designed for high efficiency not only for economical reasons but also for enhanced
environmental performance in terms of reduced emissions and quantity of ash generated due to
lower fuel consumption. Cutting CO2 emissions is one of the main drivers. To achieve these
goals, supercritical steam parameters have been applied. Now this technology is available also
for CFB technology. This combines a high plant efficiency with the other well known benefits of
CFB technology, such as: fuel flexibility, low emissions and high availability.

The boiler design for 460 MWe Łagisza power plant utilizes low mass flux BENSON Vertical
once-through technology developed and licensed by Siemens AG, Germany. CFB boiler with
low and uniform furnace heat flux is extremely well suited for the Benson technology providing
a stable operation of the boiler also during load changes and abnormal operation conditions.

The paper describes the 460 MWe supercritical CFB boiler concept and presents the technical
solutions of the boiler design with auxiliary equipment. The findings of the dynamic simulations
of boiler operation are presented and discussed.

NOTE – In this paper, the dynamic simulations of CFB boiler operations are discussed.

PAPER 2 - A MAJOR STEP FORWARD---THE SUPERCRITICAL CFB

BOILER by Ragnar Lundqvist, Andre Schrief, Pertti Kinnunen, Kari
Myöhänen, Mani Seshamani

23
Since the start-up of a coal-fired, 30 MW e bubbling fluidized bed boiler in the US at Rivesville,
West Virginia in 1977, fluidized bed boilers have grown steadily in size, matured into a
circulating fluidized bed (CFB) configuration, and now offer utilities enhanced performance,
high reliability, and the ability to burn a wide variety of fuels.

Having built the Rivesville demonstration unit and the world’s largest CFB boilers, Foster
Wheeler has been a pioneer in this effort. The largest units now in operation, with a nominal 300
MWe capacity, are located at Jacksonville Electric Authority’s Northside Generating Station
These began operation in 2002 and can fire coal or petroleum coke in varying proportions.

Although CFB technology was previously viewed by some as being limited to relatively small
sizes and serving only a niche ‘hard-to-burn’ fuel market, it is obvious that CFBs have grown to
meet the power industry’s need for large-scale power generation, minimum stack gas emissions,
and fuel flexibility.

The next step in the evolution of CFB technology has been the move to advanced steam cycle
conditions to maximize plant efficiencies. In February 2003, the Polish utility Poludniowy
Koncern Energetyczny S.A. awarded Foster Wheeler a contract to build the world’s first CFB
boiler operating at supercritical steam conditions---a 460 MWe unit to be built at their Lagisza
station. In addition to operating at supercritical pressure (27.50MPa/3989psig main steam throttle
pressure) with superheat and reheat steam temperatures of 560°C and 580°C (1040°F and
1076°F) respectively, the CFB will incorporate BENSON Vertical Low Mass Flux Once-
Through Technology developed by Siemens Power Generation of Erlangen, Germany. This
technology allows the boiler to operate with reduced pressure drop, thus minimizing auxiliary
power demand and increasing plant efficiency. In addition, tube flow characteristics are typical
of drum-type units, where an increase in heat flux translates automatically into an increase in
tube side flow rate. The latter is very important, as it protects tubes against over-temperature
under the worst upset conditions, without having to resort to mechanically complex, high
pressure drop designs.

This paper describes the 460 MWe supercritical CFB boiler, Siemens Low Mass Flux Once
Through Technology and its advantages for a CFB design, and presents the results of design
analyses investigating the effects of varying furnace conditions, both steady-state and loss of fuel
feed, on tube water/steam flow distributions and evaporator outlet temperatures.

NOTE – In this paper, the advantage of using of BENSON Low Mass Flux technology in
supercritical CFB boiler is presented.

PAPER 3 - SUPERCRITICAL BOILER OPTIONS FOR FIRING LOW

VOLATILE CHINESE COALS by Stephen J. Goidich and David E. Wagner
China’s tremendous growth in power generation capacity can be characterized as trending from
300 MWe and 600 MWe class subcritical boilers, to supercritical boilers ranging from 600 MWe

24
to 1,000 MWe. The use of high cycle efficiency supercritical boilers is a key part of any strategy
to lower the total acid rain and greenhouse gas forming emissions.

In China, there are abundant reserves of low volatile coal. The use of low volatile fuels has been
successfully demonstrated and implemented in 300 and 600 MWe class subcritical Arch-Fired
Pulverized Coal units, and in 300 MWe class subcritical Circulating Fluidized Bed units.

This paper presents the application of supercritical technology and boiler design to the proven
combustion methods of Arch Fired Pulverized Coal and Circulating Fluid Bed for boiler sizes
exceeding 600 MWe. The ability to successfully burn these low volatile fuels in an efficient
manner, and within emission control standards is of critical importance to the future growth of
the Chinese power generation industry.

NOTE – In this paper, the design, fabrication and construction of a 460 MWe CFB OTU boiler
for the Lagisza project located in Bedzin, Poland, for successful firing of low volatile coals in
while producing steam for high efficiency, supercritical steam cycles is discussed.

PAPER 4 – DESIGN THEORY OF CIRCULATING FLUIDIZED BED

BOILERS By Guangxi YUE, Junfu LU, Hai ZHANG, Hairui YANG,
Jiansheng ZHANG, Qing LIU, Zheng LI, Eric JOOS, Philippe JAUD

Studies on circulating fluidized bed (CFB) boilers have being conducted at the Tsinghua
University (TH) for about two decades and much of works are done to link the fundamentals
with practical application. A full set of design theory was developed and some key elements of
this theory are presented in this paper.

First, a classification of state of the solid-gas two-phase flow in CFB boiler is given. TH’s studies
validated that a CFB boiler can be generally described as the superposition of a fast bed in the
upper part with a bubbling bed or turbulent bed in the bottom part. A concept model of material
balance for the open system of CFB boiler was developed and later improved as a more
comprehensive 1-D model taking ash formation, particle attrition and segregation in bed into
account. Some results of the models are discussed.

Then the concept of State Specification of a CFB boiler is defined and discussed. The State
Specification is regarded as the first step to design a CFB and a base to classify different style of
CFB boiler technologies for various CFB boiler manufacturers. The State Specification adopted
by major CFB boiler makers is summarized and associated importance issues are addressed. The
heat transfer model originally developed by Leckner and his coworkers is adopted and improved.
It is further calibrated with experimental data obtained on the commercial CFB boiler
measurements. The principle, improvements and application of the model are introduced. Some
special tools developed for heat transfer field test are also given.

Also, combustion behaviors of char and volatile content are studied, and the combustion
difference between a CFB boiler and a bubbling bed is analyzed. The influence of volatile

25
content and size distribution is discussed. The concept of vertical distribution of combustion and
heat in CFB boiler furnace is introduced and discussed as well. In the last, the suggested design
theory of CFB boiler is summarized.

NOTE – In this paper, A set of design theory for CFB boiler has been developed by the
researchers at Tsinghua University, based on twenty-year research and development experience
on CFB boiler. The theory couples the fundamental studies in the laboratory with the
experiments on the commercial CFB boilers, and has been applied in designing more than 100
commercial CFB boilers.

PAPER 5 - The Performance of a Loop Seal in a CFB Boiler by Andreas

Johansson, Filip Johnsson and Bengt-Åke Andersson
High in-bed heat transfer and low corrosive environment imply that the loop seal of a circulating
fluidized bed (CFB) boiler is an advantageous location for superheaters. In order to increase the
knowledge on the flow pattern and the heat transfer distribution to the tubes within a loop seal,
measurements were performed in the loop seal of a 30MW CFB boiler as well as in a 1/3 scaled-
down seal operated according to simplified scaling laws. The scale model measurements show
that the solids recirculation flux can be maintained with a substantial decrease of the fluidization
flow in the seal compared to that currently used at full load conditions. It was also possible to
significantly decrease the fraction of the bottom of the seal that was fluidized without affecting
the solids flux through the seal. A gradient in the solids flow were detected in the vertical
direction.

NOTE – In this paper, the advantages of using loop seal in a 30MW circulating fluidized bed
(CFB) boiler is high in heat transfer and low corrosive environmental effects.

PAPER 6 - Latest Development of CFB Boilers in China by G. X. Yue, H. R.

Yang, J. F. Lu, H. Zhang
The circulating fluidized bed (CFB) coal-fired boiler has being rapidly developed in China since
1980s and becomes a key clean coal technology used in thermal and power generation. In this
paper, the development history and development status of the CFB boiler in China are
introduced. The development history of the CFB boiler in China is divided into four periods and
the important features of each period are given. Some latest research activities and important
results on CFB boilers, and the typical achievements and newest development of the CFB boiler
in China are also introduced. In addition, a few challenges and development directions including
the capacity scaling up, SO2 removal and energy saving are discussed.

NOTE – In this paper, the latest research activities and important results on CFB boilers, and the
typical achievements and newest development of the CFB boiler in China are discussed.

26
 Chapter- 3

DESIHNING MODELS OF SIMPLE & CFB BOILERS

SIMPLE BOILER
2D SKETCH

Revolve about center axis at 3600

27
Model after revolve

Creating a tangent datum plane to the cylindrical surface

Take extrude command to remove the material

28
Extrude Command to create pipe

29
Final model

30
2D DRAWING

31
CFB BOILER
2D SKETCH

Revolve Command

32
Revolved model

Extrude command used for cylindrical shaft

33
Removing Material from inner part of the cylindrical shaft

34
Applied round command in between cylindrical shaft and boiler

Final model of CFB boiler

35
2D DRAWING

36
 Chapter - 4
THERMAL ANALYSIS OF BOILER
SIMPLE BOILER

MATERIAL - STEEL
Open >Ansys14.5 >Mechanical APDL 14.5

File > Change Directory

File > Change Job name

File>import>open file

Import model that is converted to .iges format in Pro/Engineer

Imported Model

37
Preferences>Thermal>ok

Preprocessor>Element type>add/edit/delete>add>solid>20node279>ok

Material properties>Material model

STEEL PROPERTIES

Density = 0.0000077Kg/mm3

Thermal conductivity = 0.05W/mm-K

Specific heat = 460 J /(Kg-K)

Meshing > Mesh Tool > Select Smart Size > Select Mesh

Meshed Model

38
LOADS

Loads>define loads>apply>thermal>temperature>on areas>select temperature area>ok

Temperature=1123K

Convection>on areas>select convection areas>ok

Film coefficient =0.39 W/mm2-K

Bulk temperature = 303K

Solution>solve>current Ls>ok

General post processor>plot results>contour plot>nodal solution>Nodal temperature> >ok

39
NODAL TEMPERATURE

General post processor>plot results>contour plot>nodal solution>thermal gradient> >ok

THERMAL GRADIENT

General post processor>plot results>contour plot>nodal solution>heat flux> >ok

40
THERMAL FLUX

MATERIAL - COPPER
DENSITY = 0.0000089Kg/mm3

THERMAL CONDUCTIVITY = 0.39W/mm-K

SPECIFIC HEAT = 390 J/Kg-K

FILM COEFFICIENT =0.39 W/mm2-K

TEMPERATURE=1123K

BULK TEMPERATURE = 303K

41
NODAL TEMPERATURE

42
THERMAL GRADIENT

THERMAL FLUX

43
MATERIAL - BRASS
DENSITY = 0.0000085Kg/mm3

THERMAL CONDUCTIVITY = 0.11W/mm-K

SPECIFIC HEAT = 390 J(Kg-K)

FILM COEFFICIENT =0.39 W/mm2-K

TEMPERATURE=1123K

BULK TEMPERATURE = 303K

NODAL TEMPERATURE

44
THERMAL GRADIENT

45
THERMAL FLUX

CFB BOILER

46
MATERIAL - STEEL
File>import>open file

Imported model

Preferences>thermal>ok

Preprocessor>element type>add/edit/delete>add>solid>20node90>ok

Material properties>material models

STEEL PROPERTIES

DENSITY = 0.0000077Kg/mm3
47
THERMAL CONDUCTIVITY = 0.05W/mm-K

SPECIFIC HEAT = 460 J/(Kg-K)

Meshed model

Loads>define loads>apply>thermal>temperature>on areas>select temperature area>ok

Convection>on areas>select convection areas>ok

Film coefficient =0.39 W/mm2-K

Temperature=1573K

Bulk temperature = 303K

48
Solution>solve>current Ls>ok

General post processor>plot results>contour plot>nodal solution>Nodal temperature> >ok

NODAL TEMPERATURE

General post processor>plot results>contour plot>nodal solution>thermal gradient> >ok

49
THERMAL GRADIENT

General post processor>plot results>contour plot>nodal solution>heat flux> >ok

THERMAL FLUX
50
MATERIAL - COPPER
NODAL TEMPERATURE
51
THERMAL GRADIENT

52
THERMAL FLUX

53
MATERIAL - BRASS

54
NODAL TEMPERATURE

THERMAL GRADIENT

55
THERMAL FLUX

COMPUTATIONAL FLUID DYNAMICS

56
Computational Fluid Dynamics (CFD) is one of the branches of fluid mechanics that
uses numerical methods and algorithms to solve and analyze problems that involve fluid
flows. Computers are used to perform the millions of calculations required to simulate the
interaction of fluids and gases with the complex surfaces used in engineering. However, even
with simplified equations and high speed supercomputers, only approximate solutions can be
achieved in man y cases. More accurate codes that can accurately and quickly simulate
even complex scenarios such as supersonic or turbulent flows are an ongoing area of research.

CFD provides a qualitative (and sometimes even quantitative) prediction of fluid flows
by means of:

a) mathematical modeling (partial differential equations)

b) numerical methods (discretization and solution techniques)

c) software tools (solvers, pre- and post processing utilities)

CFD ANALYSIS PROCESS

1. Selection of analysis type Floatran CFD
2. Mathematical model Creating Key points with Co-ordinate values
3. Mesh generation nodes/cells division
4. CFD software implementation, debugging
8. Simulation run parameters, stopping criteria
9. Post processing visualization, analysis of data
10. Verification model validation / adjustment

ADVANTAGES OF CFD

1. It provides the flexibility to change design parameters without the expense of Hardware
changes. It therefore costs less than laboratory or field experiments, allowing Engineers to try
more alternative designs than would be feasible otherwise.

2. It has a faster turnaround time than experiments.

3. It guides the engineer to the root of problems, and is therefore well suited for Troubleshooting.

4. It provides comprehensive information about a flow field, especially in regions where

Measurements are either difficult or impossible to obtain.

Chapter – 5
57
5.1 CFD ANALYSIS OF SIMPLE BOILER
INLET VELOCITY – 4m/s
→→Ansys → Workbench→ Select analysis system → Fluid Flow (Fluent) → double click

→→Select geometry → right click → import geometry → select browse →open part → ok

Imported Model

→→ select mesh on work bench → right click →edit

Select mesh on left side part tree → right click → generate mesh →

58
Meshed model

Inlet

59
Outlet

60
SPECIFYING BOUNDARIES FOR INLET AND OUTLET

Select edge → right click → create named section → enter name → inlet

Select edge → right click → create named section → enter name → outlet

File →export → fluent →input file(mesh) → enter required name → save.

→→ ansys → fluid dynamics → fluent → select 2D or 3D → select working directory → ok

→→file → read → mesh → select file → ok.

General →Pressure based

Model → energy equation → on

Model → Viscous → Edit

Materials → new → create or edit → specify Fluid material →steam

Specific heat(Cp)=1220j/kgk

Thermal conductivity(K)=0.0454w/mk

Viscosity=1.72e-5kg/ms
61
Boundary conditions → Inlet → Edit

Pressure=1×105Pa

Temperature=1123k

Velocity magnitude → 4m/s

Solution → Solution Initialization→ Hybrid Initialization →done

Run calculations → No of iterations = 10 → calculate → calculation complete

→→ Results → graphics and animations → contours → setup

Velocity Magnitude

62
Static Pressure

63
64
Temperature

Mass flow rate

"Flux Report"

Mass Flow Rate (kg/s)

-------------------------------- --------------------
Contact_region-src 0.055101183
Contact_region-trg -0.055101183
Contact_region_2-src 69.560766
Contact_region_2-trg -69.560766
Inlet 69.766149
Interior-14 69.560766
Interior-5 0.055101183
Interior-____msbr -713.21841
Outlet 0.17223006
Wall-12 0
Wall-13 0
Wall-15 0
Wall-16 0
Wall-____msbr 0
---------------- --------------
Net 69.938379
65
INLET VELOCITY – 5m/s

Velocity Magnitude

66
Static Pressure

67
Temperature

Mass flow rate

"Flux Report"

Mass Flow Rate (kg/s)

-------------------------------- --------------------
Contact_region-src 0.057976114
Contact_region-trg -0.057976114
Contact_region_2-src 86.993662
Contact_region_2-trg -86.993662
Inlet 87.207687
Interior-14 86.993662
Interior-5 0.057976114
Interior-____msbr -927.42256
Outlet 0.67397801
Wall-12 0
Wall-13 0
Wall-15 0
Wall-16 0
Wall-____msbr 0
---------------- --------------------
Net 87.881665

68
INLET VELOCITY – 6m/s

Velocity Magnitude

69
Static Pressure

70
Temperature

Mass flow rate

"Flux Report"

Mass Flow Rate (kg/s)

-------------------------------- --------------------
Contact_region-src -0.051243801
Contact_region-trg 0.051243801
Contact_region_2-src 104.27867
Contact_region_2-trg -104.27867
Inlet 104.64922
Interior-14 104.27867
Interior-5 -0.051243801
Interior-____msbr -1102.6194
Outlet -0.39583613
Wall-12 0
Wall-13 0
Wall-15 0
Wall-16 0
Wall-____msbr 0
---------------- --------------------
Net 104.25339

71
5.2 CFD ANALYSIS OF CFB BOILER
INLET VELOCITY – 4m/s
→→Ansys → Workbench→ Select analysis system → Fluid Flow (Fluent) → double click

→→Select geometry → right click → import geometry → select browse →open part → ok

Imported Model

→→ select mesh on work bench → right click →edit

Select mesh on left side part tree → right click → generate mesh →

72
Meshed model

Inlet

73
Outlet

SPECIFYING BOUNDARIES FOR INLET AND OUTLET

74
 Select edge → right click → create named section → enter name → inlet

Select edge → right click → create named section → enter name → outlet

File →export → fluent →input file(mesh) → enter required name → save.

→→ ansys → fluid dynamics → fluent → select 2D or 3D → select working directory → ok

→→file → read → mesh → select file → ok.

General →Pressure based

Model → energy equation → on

Model → Viscous → Edit

Materials → new → create or edit → specify Fluid material →steam

Specific heat(cp)=1220j/kgk

Thermal conductivity(k)=0.0454w/mk

Viscosity=1.72e-5kg/ms

Boundary conditions → Inlet → Edit

75
Pressure=1×105Pa

Temperature=1573k

Velocity magnitude → 4m/s

Solution → Solution Initialization→ Hybrid Initialization →done

Run calculations → No of iterations = 10 → calculate → calculation complete

→→ Results → graphics and animations → contours → setup

Velocity Magnitude

Static Pressure

76
77
Temperature

Mass flow rate

"Flux Report"

Mass Flow Rate (kg/s)

-------------------------------- --------------------
Inlet 39.813224
Interior-____msbr 928.74986
Outlet -40.278172
Wall-____msbr 0
---------------- --------------------
Net -0.46494834

78
INLET VELOCITY – 5m/s

Velocity Magnitude

79
Static Pressure

80
Temperature

Mass flow rate

"Flux Report"

Mass Flow Rate (kg/s)

-------------------------------- --------------------
Inlet 49.76653
Interior-____msbr 1158.845
Outlet -50.18769
Wall-____msbr 0
---------------- --------------------
Net -0.42116011

81
INLET VELOCITY – 6m/s

Velocity Magnitude

82
Static Pressure

83
Temperature

Mass flow rate

"Flux Report"

Mass Flow Rate (kg/s)

-------------------------------- --------------------
Inlet 59.719836
Interior-____msbr 1404.2771
Outlet -60.209737
Wall-____msbr 0
---------------- --------------------
Net -0.48990058

Chapter – 6
84
6.1 RESULTS TABLE
SIMPLE BOILER

MATERIAL STEEL COPPER BRASS

NODAL
1123 1123 1123
TEMPERATURE(K)
THERMAL
22.0208 21.1724 21.8559
GRADIENT(K/mm)
HEAT FLUX
1.10104 8.25724 2.40415
(W/mm2)

CFB BOILER

MATERIAL STEEL COPPER BRASS

NODAL
1573 1573 1573
TEMPERATURE(K)

THERMAL 16.3554 15.9157 16.2347

GRADIENT(K/mm)
HEAT
1.47198 9.23111 3.57164
FLUX(W/mm2)

6.2 CFD RESULTS

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 Results
Inlet
Velocity Outlet Mass flow
(m/s) Pressure(Pa) Temperature(K)
Velocity(m/s) rate (Kg/s)

4m/s 2.067e+02 1.36e+07 1.12e+03 69.938379

Simple
5m/s 3.34e+02 2.12e+07 1.12e+03 87.881665
boiler

6m/s 4.01e+02 3.05e+07 1.12e+03 104.25339

0.46494834
4m/s 4.00e+00 1.06e+00 1.57e+03

CFB boiler 5m/s 5.00e+00 1.65e+00 1.57e+03 0.42116011

6m/s 6.00e+00 2.36e+00 1.57e+03 0.48990058

Chapter – 7

CONCLUSION

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In this thesis, a simple boiler and a CFB boiler are compared for the better heat transfer
performance. The 3D modeling of simple boiler and CFB boiler is done in Pro/Engineer and
Heat transfer analysis is done in Ansys.

The material used for boiler is steel. In this thesis, it is to be replaced with copper and brass.
Thermal analysis is done to verify the better heat transfer rate by comparing simple and CFB
boiler and better material.

By observing the thermal analysis results, by using CFB boiler, heat transfer rate is increased
since thermal flux is more than that of simple boiler.

By comparing the materials, using copper is better since thermal flux is more.

So it can be concluded that using CFB boilers yields better results than simple boilers.

REFERENCES

1. 460 MWe SUPERCRITICAL CFB BOILER DESIGN FOR ŁAGISZA POWER PLANT
BY Ilkka Venäläinen, Rafał Psik

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2. A MAJOR STEP FORWARD---THE SUPERCRITICAL CFB BOILER by Ragnar
Lundqvist, Andre Schrief, Pertti Kinnunen, Kari Myöhänen, Mani Seshamani

3. SUPERCRITICAL BOILER OPTIONS FOR FIRING LOW VOLATILE CHINESE

COALS by Stephen J. Goidich and David E. Wagner

4. DESIGN THEORY OF CIRCULATING FLUIDIZED BED BOILERS By Guangxi

YUE, Junfu LU, Hai ZHANG, Hairui YANG, Jiansheng ZHANG, Qing LIU, Zheng LI,
Eric JOOS, Philippe JAUD

5. The Performance of a Loop Seal in a CFB Boiler by Andreas Johansson, Filip Johnsson
and Bengt-Åke Andersson

6. PAPER 6 - Latest Development of CFB Boilers in China by G. X. Yue, H. R. Yang, J. F.

Lu, H. Zhang

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