gas flow – how to improve it to enhance esp, boiler, fgd...
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Airflow Sciences Corporation
Gas Flow – How to Improve ItGas Flow – How to Improve Itto Enhance ESP, Boiler, FGD, SCR, to Enhance ESP, Boiler, FGD, SCR,
SNCR Performance SNCR Performance
WPCA Seminar – Duke EnergyWPCA Seminar – Duke EnergySeptember 3, 2008September 3, 2008
Robert Mudry, P.E.Robert Mudry, P.E.Vice President – EngineeringVice President – EngineeringAirflow Sciences CorporationAirflow Sciences [email protected]@airflowsciences.com
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Airflow Sciences Corporation
OutlineOutline
IntroductionIntroduction
Flow Distribution Analysis TechniquesFlow Distribution Analysis Techniques
Application to BoilersApplication to Boilers
Application to Air Pollution Control EquipmentApplication to Air Pollution Control Equipment
Other ApplicationsOther Applications
ConclusionsConclusions
QuestionsQuestions
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Airflow Sciences Corporation
IntroductionIntroduction
Why is Flow Distribution Important?Why is Flow Distribution Important?
EnvironmentalEnvironmentalParticulate CaptureParticulate CaptureNOxNOxSOx SOx HgHgSOSO33CEMsCEMs
PerformancePerformanceHeat RateHeat RateCapacity Capacity Pressure LossPressure LossCombustionCombustionInstrumentationInstrumentation
MaintenanceMaintenanceFoulingFoulingPluggagePluggageErosionErosionCorrosionCorrosionVibrationVibration
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Airflow Sciences Corporation
OutlineOutline
IntroductionIntroduction
Flow Distribution Analysis TechniquesFlow Distribution Analysis Techniques• Field TestingField Testing• Computational Fluid Dynamics (CFD)Computational Fluid Dynamics (CFD)• Physical Flow ModelingPhysical Flow Modeling
Application to BoilersApplication to Boilers
Application to APC EquipmentApplication to APC Equipment
Other ApplicationsOther Applications
ConclusionsConclusions
QuestionsQuestions
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Airflow Sciences Corporation
Field Testing Field Testing VelocityVelocity
TemperatureTemperature
PressurePressure
ParticulateParticulate
Chemical speciesChemical species
ESP Field Testing
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Airflow Sciences Corporation
Computational Fluid Dynamics (CFD) Computational Fluid Dynamics (CFD)
Numerical simulation of flowNumerical simulation of flow Utilize high speed computers and sophisticated Utilize high speed computers and sophisticated
softwaresoftware Calculate flow propertiesCalculate flow properties
• VelocityVelocity
• PressurePressure
• TemperatureTemperature
• AmmoniaAmmonia
• Particle streamlinesParticle streamlines
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Airflow Sciences Corporation
Control Volume ApproachControl Volume Approach• Divide the flow domain into distinct control volumesDivide the flow domain into distinct control volumes
• Solve the Navier-Stokes equations (Conservation of Mass, Solve the Navier-Stokes equations (Conservation of Mass, Momentum, Energy) in each control volumeMomentum, Energy) in each control volume
Computational Fluid Dynamics (CFD) Computational Fluid Dynamics (CFD)
Inflow Outflow
Control Volume or “Cell”
ESP model with 3,550,000 cells
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Airflow Sciences Corporation
Physical Flow ModelingPhysical Flow Modeling
Lab representation of geometryLab representation of geometry
Typical scale 1:8 to 1:16Typical scale 1:8 to 1:16
““Cold flow” modelingCold flow” modeling
Visualize flow with smokeVisualize flow with smoke
Simulate ash depositionSimulate ash deposition
Measure flow propertiesMeasure flow properties
• VelocityVelocity
• PressurePressure
• Tracer gasTracer gas
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Airflow Sciences Corporation
Typical 1/12 scale physical model
• Turning vanes
• AIG w/static mixers
• Economizer bypass
• Economizer outlet
• LPA screen
• Vanes• Rectifier
•Catalyst layers
• Air heater
• Dampers
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1010Airflow Sciences Corporation
OutlineOutline
IntroductionIntroduction
Flow Distribution Analysis TechniquesFlow Distribution Analysis Techniques
Application to BoilersApplication to Boilers• Primary / Secondary Air SystemsPrimary / Secondary Air Systems• FurnaceFurnace• SNCRSNCR
Application to APC EquipmentApplication to APC Equipment
Other ApplicationsOther Applications
ConclusionsConclusions
QuestionsQuestions
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1111Airflow Sciences Corporation
Primary Air / Coal Flow BalancingPrimary Air / Coal Flow Balancing Optimize combustionOptimize combustion
• Balance PA flowsBalance PA flows
• Equal coal flow per burnerEqual coal flow per burner
• Adequate finenessAdequate fineness
Modeling and testingModeling and testing
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1212Airflow Sciences Corporation
Windbox Flow BalancingWindbox Flow Balancing Optimize combustionOptimize combustion
• Balance secondary airBalance secondary air
• Control flow entering Control flow entering burner (ram air effect)burner (ram air effect)
Modeling and testingModeling and testing
Burner SA flow balance
BaselineMax deviation 29.4%
DesignMax deviation 9.2%
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1313Airflow Sciences Corporation
Furnace Combustion OptimizationFurnace Combustion Optimization Typical goalsTypical goals
• Reduce NOxReduce NOx
• Minimize LOIMinimize LOI
• Improve heat transferImprove heat transfer
• Avoid corrosionAvoid corrosion
• Decrease slaggingDecrease slagging
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1414Airflow Sciences Corporation
SNCRSNCR Performance is influenced byPerformance is influenced by
• Temperature distributionTemperature distribution
• Velocity patternsVelocity patterns
Testing and modeling used to Testing and modeling used to optimize performanceoptimize performance
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1515Airflow Sciences Corporation
OutlineOutline
IntroductionIntroduction
Flow Distribution Analysis TechniquesFlow Distribution Analysis Techniques
Application to BoilersApplication to Boilers
Application to APC EquipmentApplication to APC Equipment• ESPESP• FFFF• Mercury / SO3Mercury / SO3• SCRSCR• FGDFGD
Other ApplicationsOther Applications
ConclusionsConclusions
QuestionsQuestions
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1616Airflow Sciences Corporation
ESP Flow OptimizationESP Flow Optimization
Flow distributionFlow distribution
Flow balance Flow balance between cellsbetween cells
Pressure lossPressure loss
Thermal mixingThermal mixing
Gas conditioningGas conditioning
Ash depositionAsh deposition
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1717Airflow Sciences Corporation
ESP Velocity DistributionESP Velocity Distribution Uniform velocity within collection regionUniform velocity within collection region
Industry standardsIndustry standards• ICACICAC
• % RMS % RMS deviationdeviation
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1818Airflow Sciences Corporation
Gas Flow BalanceGas Flow Balance Industry standard +/- 10% deviationIndustry standard +/- 10% deviation
21 %
35 %
26 %18 %
Percent of total mass flow through each chamber
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1919Airflow Sciences Corporation
Pressure DropPressure Drop General goal: General goal:
• Minimize DPMinimize DP
MethodsMethods• VanesVanes
• Duct contouringDuct contouring
• Area managementArea management
Flow
Ductwork redesign saves 2.1 inches H2O over baseline
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2020Airflow Sciences Corporation
ESP Gas ConditioningESP Gas Conditioning
Modify ash resistivityModify ash resistivity• SOSO33, ammonia, others, ammonia, others
Alter gas density, viscosityAlter gas density, viscosity• HumidificationHumidification
Low SO3
Concentration
High SO3
Concentration
SO3 Concentration
Temperature
Res
isti
vity
5 ppm SO3
Humidification gone awry
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2121Airflow Sciences Corporation
Ash DepositionAsh Deposition
Drop outDrop out
Re-entrainmentRe-entrainment
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2222Airflow Sciences Corporation
Fabric Filter Flow ModelingFabric Filter Flow Modeling
Uniform velocity distribution and equal balance Uniform velocity distribution and equal balance between compartmentsbetween compartments
Pressure lossPressure loss Avoid bag erosionAvoid bag erosion Ash depositionAsh deposition
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2323Airflow Sciences Corporation
Mercury / SO3 ReductionMercury / SO3 Reduction
Injection upstream of baghouse or ESPInjection upstream of baghouse or ESP• Activated carbonActivated carbon
• Lime, Trona, SBS, etc.Lime, Trona, SBS, etc.
Uniform injectionUniform injection
Maximize residence timeMaximize residence time
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2424Airflow Sciences Corporation
SCR Flow OptimizationSCR Flow Optimization
Velocity distributionVelocity distribution
Thermal mixingThermal mixing
NOx profile / mixingNOx profile / mixing
Ammonia injectionAmmonia injection
Pressure lossPressure loss
Large particle ash (LPA) Large particle ash (LPA) or “popcorn ash” captureor “popcorn ash” capture
Ash depositionAsh deposition
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2525Airflow Sciences Corporation
SCR Velocity DistributionSCR Velocity Distribution
Uniform velocity profileUniform velocity profile• At ammonia injection gridAt ammonia injection grid
• At catalyst inletAt catalyst inlet
• At air heater inletAt air heater inlet
Minimal angularityMinimal angularity• At catalyst inletAt catalyst inlet
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2626Airflow Sciences Corporation
SCR Thermal MixingSCR Thermal Mixing
SCR low load SCR low load operation with operation with economizer bypasseconomizer bypass
CFD model to design CFD model to design mixer using full scale mixer using full scale operating conditionsoperating conditions
Physical model tracer Physical model tracer gas tests to confirm gas tests to confirm designdesign
Without mixer, ΔT = ±83 °F
With mixer, ΔT = ±15 °F
553 ° F
825 ° F
630 ° F
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2727Airflow Sciences Corporation
SCR Ammonia InjectionSCR Ammonia Injection Desire uniform NH3-to-NOx Desire uniform NH3-to-NOx
ratio at catalystratio at catalyst Tracer gas used to represent Tracer gas used to represent
flows in physical modelflows in physical model Track gas species in CFDTrack gas species in CFD
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2828Airflow Sciences Corporation
SCR Large Particle Ash CaptureSCR Large Particle Ash Capture
Catalyst openings for coal-fired Catalyst openings for coal-fired plants are smaller than LPA particlesplants are smaller than LPA particles
Once LPA becomes “wedged” into a Once LPA becomes “wedged” into a cell, fine ash builds up as wellcell, fine ash builds up as well• Hard to cleanHard to clean
• Get dunes of ash on top Get dunes of ash on top layer catalystlayer catalyst
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2929Airflow Sciences Corporation
LPA System Design – Key PointsLPA System Design – Key Points Capture LPA in hoppers of adequate sizeCapture LPA in hoppers of adequate size
LPA screens have become standard practice LPA screens have become standard practice
Ash deflection baffles also usefulAsh deflection baffles also useful
Screen erosion and pluggage remain issuesScreen erosion and pluggage remain issues
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3030Airflow Sciences Corporation
Ash DepositionAsh Deposition
Duct floorsDuct floors
Turning vanesTurning vanes
CatalystCatalyst
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3131Airflow Sciences Corporation
Ash Deposition – Model TestingAsh Deposition – Model Testing
Drop outDrop out
Re-entrainmentRe-entrainment
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3232Airflow Sciences Corporation
FGD Flow ModelingFGD Flow Modeling Flow distributionFlow distribution Water droplet behaviorWater droplet behavior Pressure loss Pressure loss Ash depositionAsh deposition
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3333Airflow Sciences Corporation
FGD Flow ModelingFGD Flow Modeling
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3434Airflow Sciences Corporation
OutlineOutline
IntroductionIntroduction
Flow Modeling MethodsFlow Modeling Methods
Application to BoilersApplication to Boilers
Application to APC EquipmentApplication to APC Equipment
Other ApplicationsOther Applications
ConclusionsConclusions
QuestionsQuestions
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3535Airflow Sciences Corporation
Power IndustryPower Industry FansFans
DuctsDucts
PulverizersPulverizers
WindboxesWindboxes
FurnacesFurnaces
Air HeatersAir Heaters
StacksStacks
TurbinesTurbines
CondensersCondensers
HRSGsHRSGs
……
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3636Airflow Sciences Corporation
ConclusionsConclusions
Gas flow patterns have significant impact on Gas flow patterns have significant impact on the performance of power plant equipmentthe performance of power plant equipment
Analysis and design tools include field testing Analysis and design tools include field testing and flow modelingand flow modeling
CFD and physical modeling are applied to a CFD and physical modeling are applied to a wide range of equipment “from the fan to the wide range of equipment “from the fan to the stack”stack”