Development of Computer Program for Combustion Analysis in Pulverized Coal-fired Boilers 76

Development of Computer Program for Combustion

Analysis in Pulverized Coal-fired Boilers

Kenji Yamamoto OVERVIEW: The requirements in the design of a pulverized coal-fired boiler,
Takeru Fukuchi, D. Eng. (1) the complete combustion of the fuel, (2) the minimal release of
Masao Chaki, D. Eng. environmental pollutants, and (3) the uniformity of steam temperature at
the water wall outlet. To attain a design that can both satisfy these
Yoshio Shimogori
requirements over the range from partial load to full load and achieve
Jun’ichirô Matsuda economical operation, techniques for analyzing flow, combustion and heat
transfer inside the furnace are required. To meet that need, we have developed
a computer program for analyzing the combustion of pulverized coal,
radiation heat transfer, and changes in flow rate distribution and temperature
within the water wall tubes by simulation. Concerning the combustion of
pulverized coal, we formulated a devolatilization model, a char combustion
model, and an NOx and CO reaction model on the basis of fundamental
experiments on the combustion of coal particles. Concerning radiant heat
transfer between the flame and the water wall tubes, a radiative property
model of the gas-particle mixture is incorporated and the heat transport
rate is calculated by the discrete transfer (DT) method, which is highly
accurate but requires a small computational load. In addition, to analyze
the two-phase flow in the water wall tubes, we developed an algorithm that
can be applied to an arbitrary flow path network. Comparison of the results
calculated by this program with data on furnace operation under various
coal and load conditions confirmed that the furnace exit gas temperature
can be predicted to within ± 30°C. This technology can be used in the
redesigning of existing plants as well as in the design of new 1,000-MW
class boilers.

Fig. 1— Combustion
Analysis for a Pulverized-
Coal-fired Boiler.
A means of predicting the
state of combustion is
indispensable in the design
of a furnace, which is the
heart of the boiler. This
analysis program calculates
the combustion state from
the amount of fuel entering
from the burners and the
(a) Boiler side view (b) Example of calculated results
amount of air entering from
(gas temperature distribution )
the air ports.
 Hitachi Review Vol. 49 (2000), No. 2 77

INTRODUCTION equation in the same way as for the various gas

THERE is a need to improve the performance of components. The coal particles comprise water and
pulverized coal-fired boilers in terms of efficiency, volatile matter, char, and ash. The reaction rate
reliability, and effect on the environment. Specifically constants of these components are given as temperature
required are (1) reduction of unburned components in and oxygen concentration functions, and the changes
the ash, (2) reduction of NOx and CO in the exhaust in each component are calculated. The numerical
gases, and (3) uniformity in furnace exit steam calculations are performed by SIMPLE method (semi-
temperature, without extreme peaks in the heat flux implicit method for pressure-linked equations). In the
distribution to the walls. Because there is interaction vicinity of the burner, overlaid grids are employed,
among phenomena such as flow within the furnace, because it is capable of setting up a particularly detailed
combustion, and heat transfer within the water wall grid and so increases the accuracy of calculations for
tubes, to design a boiler that satisfies these areas in which there are sharp changes in state.
requirements in any operating state requires techniques This program incorporates models for predicting
for conducting an overall analysis of these phenomena combustion efficiency and the concentrations of gases
within the furnace. For that purpose, we developed a such as NOx and CO. Those respective models were
computer program that can conduct such an analysis developed on the basis of data from fundamental
on the basis of a physical model that is based on the experiments in which the type of coal, SR
results of fundamental experiments on the combustion (stoichiometric ratio) and temperature were varied.
of coal particles and burner performance experiments. This model made it possible to predict NO x
Here, we describe the feature of the model used concentration, which had previously been difficult to
by that program and present the results of experiments accomplish. Examples of the calculated results are
that were conducted with actual boiler. presented in Fig. 2.
In the two-stage combustion method, NOx is
PROGRAM FUNCTIONS AND STRUCTURE reduced to N2 in fuel rich zone. To predict the NOx
This program calculates the gas velocity,
temperature distribution, and gas composition
distribution within the furnace and the heat flux on
Low High
the water wall and the flow rate and temperature in
the water tubes, given formatted data on the boiler
dimensions, water wall tube geometry and arrange-
ment, connection state and boundary conditions such
as fuel and air flow rates, water flow rate, and pressure.
The program consists of a combustion calculation
module and a module for calculating flow distribution
in the water wall tubes. The combustion calculation
module analyzes the gas flow, coal-air reactions, and
radiation heat transfer phenomena. The heat flux
distribution of the water wall is determined by means
of the combustion analysis. The water wall tube flow
distribution calculation module accepts as input the
heat flux that is output by the combustion analysis and
analyzes the changes in flow rate and temperature for
each water tube.
SR distribution: NOx distribution: CO distribution:
In the two-stage Decrease in NOx Decrease CO at
COAL COMBUSTION MODEL combustion method, in low SR regions furnace exhit by
The flow rate and temperature distribution within low SR regions are (fuel rich zone) promotion of air
formed below the mixing
the furnace are obtained by solving the conservation air port.
equations for the mass, momentum, and energy of the Fig. 2— Examples of Combustion Analysis Within the Furnace.
air and combustion gases. The coal particles are In the two-stage combustion method, the SR near the burner is
assumed to be accompanied by the gas phase, and so precisely controlled so as to control the generation and release
their distribution is determined by solving the transport of gases that pollute the environment.
 Development of Computer Program for Combustion Analysis in Pulverized Coal-fired Boilers 78

concentration, it is necessary to estimate the diameter, wavelength of the electromagnetic wave, and
combustion rate and the gas composition in fuel rich an optical property of the particle material (complex
zone. The coal reacts with CO2 and H2O to produce refractive index). Also, although geometrical optics
CO and H 2 . This is called the gasification. theory and Rayleigh scattering theory are also used,
Conventionally, in a pulverized coal-fired boiler, the they are respectively approximations of Mie scattering
oxidation reaction between char and O2 is dominant at the upper and lower limits of particle size to reduce
and so the gasification reaction calculation is often the computation time.
omitted. Omitting that calculation creates an error of For the modeling of radiative transfer, the DT
about 10% in the combustion rate in fuel rich zone. In method (a kind of ray-tracing method) is employed.2)
this program, the accuracy of predicting the With that method, it is possible to obtain a solution
combustion rate in fuel rich zone and the gas that is quite consistent with the strict solution with a
composition were improved by new models for the practically small computational load. As an example
oxidation and gasification 1). of that, the results of calculations of radiative transfer
Moreover, in the prediction of NO x, it is necessary in a one-dimensional system (a radiative gas between
to estimate the CH and OH radical concentrations, two flat plates of different temperature) are shown in
which are very small components, as well as CO2, H2O, Fig. 3. The solution obtained by the DT method is the
CO, H2 and other high concentration gas components. same as the strict solution at various optical thicknesses
This program incorporates a model that allows highly (degrees of gas opaqueness).
accurate calculation of radical concentrations, and so
improves the accuracy of NOx estimations. In the low FLOW CALCULATION MODEL IN WATER
SR regions that are formed within the furnace, NOx WALL TUBES
concentration is decreased by reduction reaction with A detailed estimate of the temperature distribution
CH radicals (Fig. 2). in the water wall is important in optimizing the
structure and improving the soundness in the design
RADIATION HEAT TRANSFER MODEL of the water wall of a pulverized coal-fired boiler
For large boilers, the heat transfer from the furnace.
combustion gases in the furnace to the surrounding In the past, the accuracy of temperature estimations
water wall is mostly radiation heat transfer. The heat has been limited because a coarse mesh is
flux distribution on the water wall affects the steam conventionally used when evaluating the temperature
temperature distribution within the water wall tubes,
and the heat transfer rate at the water wall determines
the furnace exit gas temperature. For that reason, 1.0

modeling of the radiation heat transfer is important in Optical thickness τ0 = 10.0 (–)
the furnace analysis.
Dimensionless gas temperature

In radiation heat transfer, the heat of high- 2.0

temperature gas and particles (radiative media) is

propagated in the furnace as electromagnetic waves. 0.5 0.1
That electromagnetic wave is absorbed by the water 0.5
wall at the boundary of the furnace, which results in
the heat transfer. 1.0
For the analysis, modeling of the radiative media
and that of radiative transfer are required.
A radiative medium is a substance that emits and DT method
Strict solution
absorbs electromagnetic waves. In pulverized coal
combustion, radiation characteristics of the gas 0
0 0.5 1.0
molecules (H2O, CO2) and particles (raw coal, char, Dimensionless position between two flat plates
fly ash, soot) are modeled. For the gas molecules, the
Fig. 3— Comparison of Strict Radiative Transport Solutions and
“Weighted Sum of Gray Gases,” which is a kind of Results of the DT Method.
optical database, is employed. The properties of the The DT solutions are nearly the same as the strict solutions for
solid particles, on the other hand, are given by the Mie a three dimensional system of complex shape as well as for the
scattering theory. The theory involves the particle basic one-dimensional system shown here.
 Hitachi Review Vol. 49 (2000), No. 2 79

distribution. Moreover, it was not possible to deal with in the water wall tubes with the earlier described coal
the changes in the combustion and heat flux combustion model and radiative heat transfer model,
distribution that accompany changes in the burner it is possible to understand in detail the thermal-
pattern and type of coal, so extra design margins were hydraulic characteristics for each individual water tube.
required.
The water wall of a 1,000-MW class boiler furnace, COMPARISON WITH VALUES MEASURED IN
usually has approximately 2,000 water tubes and AN ACTUAL PLANT
approximately 60 headers (flow collectors that feed As described above, this program was constructed
flow into and out of the water tubes). These water tubes by combining the physical models that represent the
and tube collectors form a complex network of flow phenomena of each elemental process. To verify the
paths. Accordingly, to estimate the local temperature overall computational accuracy, the results of an
distribution, it is necessary to divide this entire flow analysis produced by this program were compared with
path network into a mesh to find a solution. We were data measured at an actual plant. The items that were
able to analyze this complex flow path network by compared were various and included the heat flux
applying a heat flow model that is used in the field of distribution, the unburned component in the ash, and
nuclear engineering and developing a new algorithm the NOx concentration in the gas. In particular, the
that is suitable for boilers. In this technique, the mass, values for the furnace exit gas temperature, which
momentum, and energy conservation equations are indicates the thermal balance in the gas, were shown
solved for an analysis mesh of all of the water tubes to be consistent in the range from –23°C to +28°C.
and tube collectors. The flow distribution of the water These values were calculated for different load
tubes is determined from the pressure loss in each conditions and types of coal of multiple plants and
water tube and the conservation of mass in the tube compared with the measured value.
collectors. The water in the flow path network A feature of this program is that it is possible to
undergoes various phase changes, depending on the calculate the steam-side model continuously from the
operating conditions, and may be a single-phase liquid, combustion model. Here, we describe the results of
two-phase flow, superheated steam, compressed water, comparing the furnace heat absorption which
super-critical water, and so on. This analytical model represents the steam-side heat balance, and the furnace
can deal with all of these conditions, and steady-state exit steam temperature.
or transient analysis is possible under a broad range The computations were performed for furnace heat
of furnace operating conditions. absorption rate and furnace outlet steam temperature
By integrating this newly developed model of flow under rising load in a large-capacity, coal-fired, once-

Furnace outlet steam 400

temperature (°C)
Measured Calculated
300
1,000
800
Load and furnace heat 600 Load
absorption rate (MW) 400 Furnace heat Measured Calculated
200 absorption
0
0 5 10 15 20 25 Time (min)

Gas temperature
distribution within High
the furnace

Air port

Fig. 4— Comparison of the Amount of Heat Absorbed Low

by the Furnace and Steam Temperature. Burner
There is good agreement between the calculated
values and measured values. This program can be
applied to both transient and steady state analyses.
 Development of Computer Program for Combustion Analysis in Pulverized Coal-fired Boilers 80

through boiler and the results were compared with the ABOUT THE AUTHORS
measured values. The furnace heat absorption and
furnace outlet steam temperature values for the process Kenji Yamamoto
Joined Hitachi, Ltd. in 1995, and now works at the
in which the load increased at 4%/min, the highest Power & Industrial Systems R&D Laboratory of the
rate of increase in actual operation, are shown in Fig. Power & Industrial Systems. He is currently engaged
4. The calculated values are largely in agreement with in research and development in combustion systems.
the measured values, so the changes in the amount of Mr. Yamamoto is a member of the Japan Society of
Mechanical Engineers, and can be reached by e-mail
heat absorbed by the furnace and the furnace outlet
at [email protected].
steam temperature can be predicted.
The above results confirm that this program is Takeru Fukuchi
capable of calculating both the combustion-gas side Joined Babcock-Hitachi K.K. in 1991 and, now works
at the Thermal Power Research Department of the
and steam-side temperatures with good accuracy. This
Kure Research Laboratory. He is currently engaged
is the result of using physical models that faithfully in research and development concerning heat transfer
represent the phenomena of each elemental process. in furnaces. Dr. Fukuchi is a member of the Japan
Society of Mechanical Engineers and the Heat
CONCLUSIONS Transfer Society of Japan, and can be reached by e-
mail at
We have briefly described a computer program for [email protected].
analyzing the characteristics of a pulverized coal-fired
boiler and validated its effectiveness by comparison Masao Chaki
with actual measured values. Joined Hitachi, Ltd. in 1993, and now works at the
Power & Industrial Systems R&D Laboratory of the
This program can handle not only the furnace exit
Power & Industrial Systems. He is currently engaged
gas temperature and the steam temperature in the water in research and development in nuclear and
wall tubes, which are heat transfer characteristics, but thermoelectric power systems. Dr. Chaki is a member
also the generation of small-quantity gas components of the Atomic Energy Society of Japan, and can be
such as NOx. Because the models used in this program reached by e-mail at [email protected].

are based on physical phenomena, the program can be

Yoshio Shimogori
used to predict the general characteristics of boilers, Joined Babcock-Hitachi K.K. in 1991, and now works
such as NOx concentration, unburned component, and at the Project Integration Section of the
steam temperature with changes in operating Thermoelectric Power Division at the Kure Office. He
conditions such as load or type of coal. is currently engaged in the planning, basic design,
and development of industrial boilers. Mr. Shimogori
This program is also used to design the latest plants
is a member of the Institute of Thermoelectric Power
by predicting plant performance. To further increase Technology, and can be reached by e-mail at
the reliability of the analysis program and to broaden [email protected].
its range of applications, we intend to continue with
comparisons to the operating conditions of actual plant Jun’ichirô Matsuda
Joined Babcock-Hitachi K.K. in 1984, and now
and with improvement in the program functions. works at the Thermoelectric Power Technology
Section of the Integrated Technologies Division. He is
REFERENCES currently engaged in the basic design and
development of industrial boilers. Mr. Matsuda is a
(1) K. Yamamoto, et al., “Char Surface Reaction Model for
member of the Institute of Thermoelectric Power
Pulverized Coal Combustion,” Transactions of the Japan
Technology, and can be reached by e-mail at
Society of Mechanical Engineers, Issue B 65-637, pp. 260 -
[email protected].
266 (1999).
(2) F.C. Lockwood, et al., “A new Radiation Solution Method for
Incorporation in General Combustion Prediction Procedures,”
18th Symposium (International) on Combustion, pp. 1405 -
1414 (1981).