application of cfd techniques in energy sector€¦ · 1 geometry preparation 2 3 cfd – work...

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APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 2/30

1 General Introduction

Energy Sector

Vision & Mission

3

AGENDA

Duct Flow OptimizationCombustionWindbox

Core values

CAVTElectroStatic Precipitator (ESP)Air Pre-HeaterHeat Exchangers

Computational Fluid Dynamics2IntroductionApplications

FansCoal ConveyorPulverizers


VISIONTo be widely recognized as the premier, global provider of Enterprise Solutions

MISSIONTo add value by improving business processes through better use of modern technology. We accomplish this mission with a team of motivated and experienced professionals with excellent technical capabilities

General Introduction


Teamwork

Innovation

Commitment

Confidentiality

Core component for our success performance

Drives our organizational growth

Committed to prompt and professional service

Stringent data security policies make our customers feel secure

Core Values


Introduction

Computational Fluid Dynamics (CFD) Computer based numerical modeling

technique Solves flow physics & associated

phenomenon Cost effective design optimization Improve efficiency & reliability Reduce lead time & cost

Computational Fluid Dynamics


Simulation / Run

Post – Processing / Results

Geometry Preparation1

2

3

CFD – Work Flow


AEROSPACEWING BLADE ANALYSISEXT. AERODYNAMICS

AERO-THERMODYNAMICSLIFT, DRAG & MOMENT

CABIN VENTILATION

HVACTHERMAL COMFORT

NATURAL AND FORCED CONVECTION

CLEAN ROOMBUILDING SERVICES

PROCESS / CHEMICALPARTICLE MIXING

FILTERS AND SEPARATORDISCRETE ELEMENT MODELING

MULTIPHASE

POWER SECTORDUCT OPTIMIZATION

BURNER FLAME VISUALIZATIONBOILER SIMULATION

EROSION / CORROSIONMULTIPHASE / DEM

ELECTRONICSCONJUGATE HEAT TRANSFER

ELECTRONIC PACKAGINGU/L, IEEE, NEMA STANDARDS

FORCED CONVECTIONBATTERY SIMULATION

URBAN PLANNINGWIND RESOURCE PLANNING

NATURAL VENTILATIONWIND FARMING

NATURAL HEATING

TURBOMACHINERYFAN PERFORMANCE

FAN CURVE OPERATING REGIONBLADE PROFILE DESIGN

FLUID SOLID INTERACTION

AUTOMOBILEEXTERNAL AERODYNAMICS

DRAG REDUCTIONIC ENGINE COMBUSTIONCATALYTIC REDUCTION

ACOUSTICS

Applications


BOILER EMS Screen

LTSHECO.

Deflector plate

ESP-Inlet Duct

ESP

Honey combAsh

HoppersID Fan

Duct

Clean Gas

F.D Fan P.A. FanCoal Mill

Windbox

CFD in power plant industry

Cost effective design optimization of Ducts Combustion systems Boilers & Accessories Air Pre-Heater (APH) ElectroStatic Precipitator (ESP) HVAC systems & components Fans Coal Conveyor Pulverizers Mixers & Separators

Energy Sector


Duct Flow OptimizationDuct optimization usign CFD

Better flow distribution Pressure drop reduction Reduce auxiliary power consumption Improve equipments/process thermal

characteristics Optimize insulation thickness

Flue Gas Duct

Flue Gas DuctSecondary Air Duct

Primary Air Duct Mill Ducts

Tempering Air Duct

Secondary Air Inlet Duct

Primary Air Inlet Duct

Ducting system of typical 500 MW coal fired power plant


Duct Flow OptimizationFlow

Better flow distribution Detailed analysis of flow pattern Detailed study of-

Velocity Density Temperature Viscosity

Reduce erosion

ESP-A PASS ESP-B PASS0

5

10

15

20

25

16.68 17.22

13.58 14.21

EXISTING DESIGN OPTIMIZED DESIGN

Coeffi

cient

of Va

rianc

e (Co

V)

Coefficient of Variance – Comparison


Duct Flow OptimizationTemperature

Detailed study of- Air/fuel & flue gas temperature

Better thermal distribution Increase thermal efficiency Optimize insulation thickness

Tempering air mixes with the main hot air & flow to the

coal mills.

Primary air duct – Temperature profile


Combustion Combustion analysis using CFD

Air/fuel mixing phenomenon Optimize air/fuel requirements Increase combustion efficiency Temperature distribution pattern Fire ball location Emission prediction & control Optimize burners & nozzles


Combustion Pulverised coal combustion for boilers

Assess physical, chemical & thermal processes

Detailed study of- Coal combustion Furnace-wall heat transfer

Optimize burner geometry & position Improve combustion efficiency Predict & Reduce pollution


WindboxWindbox analysis using CFD

Optimize primary & secondary air requirements

Detailed study of- Velocity distribution Flow rate Pressure

Optimize windbox design Increase combustion efficiency Reduce pollution

Velocity Streamlines through Primary air duct

Velocity Vectors through Secondary air duct


CAVTCold Air Velocity Test using CFD

Optimize gas & pressure part heat transfer

Locate erosion prone zones

Detailed study of - Flow pattern Velocity pattern

Reduce erosion

-(superheater & economiser tubes etc,.)


CAVTBase Optimized

FU

RN

AC

E

CH

IMN

EY

FU

RN

AC

E

CH

IMN

EY

High velocity zones observed in the rear arch panel RHS side

Reduction in high velocity zones observed at the

rear arch panel RHS side


CAVTBase FURNACE

CHIMNEY

RH

S

LH

S

FURNACE

CHIMNEY

RH

S

LH

S

Optimized

High lane velocity observed at the front

and rear sides of LTSH Lower bank Reduction in high lane

velocity observed at the front and rear sides of

LTSH Lower bank

LTSH Lower Bank-Top


CAVT

FURNACE

CHIMNEY CHIMNEY

FURNACE FURNACE

CHIMNEY

0° Tilt -25° Tilt +25° Tilt

High velocity at the rear arch panel observed at

+25° burner tilt


CAVTBase Optimized

RH

S

LH

S

FURNACE

CHIMNEYR

HS

LH

S

FURNACE

CHIMNEY


ElectroStatic PrecipitatorESP- Flow analysis

Field flow uniformity Field pressure distribution Increase collecting efficiency Optimized designs to,

Improve performance Reduce pollution Lesser downtime

Higher turbulence to the flow due to the

obstruction created by the screen

Screen

Higher velocities arise after the

screen due to the reduction in flow

area

Screen


ElectroStatic PrecipitatorESP- Flow analysis

Field flow uniformity Field pressure distribution Increase collecting efficiency Optimized designs to,

Improve performance Reduce pollution Lesser downtime


Air Pre-HeaterAPH-Heating Element Analysis

Gas flow pattern through heating elements.

Optimization of heating elements Better heat transfer characteristics Effective waste heat recovery Increase combustion efficiency Increase boiler efficiency

DU VAR1 PROFILE FNC PROFILE

DU VAR1 PROFILE

FNC PROFILE

DU VAR1 PROFILE

FNC PROFILE

Unsteady Heat Transfer Study of APH Heating Elements. Temperature Plot.

Time Step:0.2 s

Time Step:20 s


Heat Exchangers Heat Exchanger Analysis

Better heat transfer characteristics Detailed performance assessment Design optimization of heat transfer

elements Effective heat transfer process Flow visualization Increase component life cycle


Fans Fan Analysis

Detailed flow pattern analysis. Design optimization Desired pressure and flow rate Effective flow distribution & heat

transfer Reduce auxiliary power consumption Increase plant efficiency


Coal Conveyor Conveyor Dust Control Analysis

Identify flow induced causes for coal dust formation

Optimization of chutes and coal dust arresters

Erosion prevention in coal conveying systems

Minimize coal loss through dust formation

Reduce air pollution Increase coal utilization factor


Pulverizers Bowl Mill Flow Analysis

Coal particle distribution and flow pattern assessment

Optimization of components-vane wheel, classifiers and etc,.

Detailed study on the Impact of air flow on coal particles

Enhance flow distribution & coal feed to furnace

Design modifications & Performance enhancement


Other Applications Separators

Coal pipe erosion


Valves

Pumps


Customers


THANK YOU

application of cfd techniques in energy sector€¦ · 1 geometry preparation 2 3 cfd – work...

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