Case Study for Design of a Duct to Reduce Pressure drop and

Erosion on Duct Wall

1. Name of Station and Capacity

Mahagenco. Nashik Unit#3, Capacity of 210 MW Thermal Power Plant.

2. Problematic area with specific problem

High Erosion of Duct Wall and high Pressure Drop in Flue Gas duct connecting AH Outlet to
ESP. inlet which was affecting to run plant on 100% Capacity.

3. Line of action for solution
To reduce the erosion rate in duct and reduce high turbulence area, the Existing duct was replaced
totally by Redesigning the Duct Layout using CFD and Designing the Guide Vanes for Streamline
flow at Bend.

4. Theory
Design of the duct using CFD, in which the Numerical model of Duct was developed using
CFX-10 Software. Flue Gas flow through the duct was solved by using finite volume method with
fine Hexa unstructured mesh.
The turbulence flow field was solved using k- turbulence model. The Governing
Equations of mass, momentum and Energy for steady state incompressible flow are defined using
RANS Equation.
The flow through the duct is modeled by boundary condition at inlet mass flow rate at 147
Kg/sec at 147 C and outlet as Static Pressure o 180 MM of WG and solved by iterative method.

5. Results & Discussion


Fig.1: Existing Duct with Wall Velocity

Fig.2: After Modification Duct with Wall Velocity




Fig.3: Existing Duct B-pass velocity pattern in duct


Fig.4: Modified duct B-pass velocity pattern in duct



Fig.5: Erected New Duct
6. Performance data

ID fan current (Amp.)
Load
A Pass B Pass

Before
Modification

180 MW

140

140

After modification

215 MW

112

122

Payback Period: 20 Amps. Saving in ID fan current, so Payback period is 15 Months.


7. Conclusion / Benefits
The reduction in pressure drop across the duct system, from Air-heater outlet to ESP inlet
By 10 mm of WC.
The velocities on duct walls are reduced below 18 m/sec, which results in reduced erosion
rates.
Uniform mass flow rates through each duct have been achieved
Low velocity has been achieved at the ESP inlet to improve ESP.Performence.
Low ID fan load so saving in Power.