Fuel Processing Technology 138 (2015) 616628

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Fuel Processing Technology

journal homepage: www.elsevier.com/locate/fuproc

Inuence of vertical burner tilt angle on the gas temperature deviation in

a 700 MW low NOx tangentially red pulverised-coal boiler
Dengfeng Tian a, Lijin Zhong b, Peng Tan a, Lun Ma a, Qingyan Fang a,, Cheng Zhang a,
Dianping Zhang b, Gang Chen a,
a
b

State Key Laboratory of Coal Combustion, Huazhong University of Science and Technology, Wuhan 430074, PR China
Zhuhai Power Plant, Zhuhai 519000, PR China

a r t i c l e

i n f o

Article history:
Received 19 April 2015
Received in revised form 26 June 2015
Accepted 4 July 2015
Available online 14 July 2015
Keywords:
Tangentially red boiler
Reheat steam temperature deviation
Gas temperature deviation
Tilt angle

a b s t r a c t
In the present paper, computational uid dynamic modelings were established to research a newly presented reheat steam temperature deviation solution on the basis of FLUENT 6.3.26 considering a 700 MWe tangentially
red pulverised-coal boiler, which confronted with severe ue gas and re-heat steam temperature deviation.
The model was solidly validated by grid independence test and comparison with the experimental data obtained
from a series of on-site measurements. Upon reliable validation, the model was further used to investigate the
forming mechanism of re-heat steam temperature deviation as well as the inuence of burner tilt angle on it.
The conclusions mainly include (1) Residual swirling ow in the upper furnace caused the ue gas velocity
and temperature deviations in crossover pass. For a typical anticlockwise tangential ring system, the ue gas
velocity and temperature were lower in left part of crossover pass. The deviation of ue gas further generated
the convective heat transfer imbalance of nal re-heater, therefore, the temperature deviation of re-heat steam
was severe. (2) Tilting the burner upward can effectively reduce the intensity of residual ow as well as the
ue gas deviation degree. The +11 tilt angle of burner was relatively optimum considering the ue gas deviation
and nal re-heater overheating potential. Specically, the intensity of residual swirl ow dropped 44% with
burner tilting upward for +11. Practical operation of boiler demonstrated that the reheat steam temperature
deviation was reduced from 22 C to 10 C in this case. (3) When the tilt angle of additional air (AA) was bias
set, the ow eld of upper furnace was changed. Consequently, the residual swirl ow intensity and the ue
gas deviation were reduced considerably. On-site measurements indicated that the combination of tilting burner
upward for +11 and setting the bias of AA tilt angle for 10 can further reduce the re-heat steam temperature
deviation to 4 C.
2015 Elsevier B.V. All rights reserved.

1. Introduction
Tangentially red boilers are most widely used in power generation
industry. To a tangentially red boiler in which the burners were
installed at the four corners separately, the air jet ow and fuel inlets
from each corner interact with each other and form a concentric
swirling re ball in the middle of the furnace. This combustion method
ensures sufcient residence time of the coal particles, high combustion
efciency, good ame stability and fullness, and good adaptability to
loads and various coal types. However, the main disadvantage of this
method is the residual swirling of ue gas at entrance of the platen
zone, which was widely believed to be the primary cause of ue gas
temperature and velocity deviation in crossover pass [16]. Zhang [7]

Corresponding authors.
E-mail addresses: qyfang@hust.edu.cn (Q. Fang), gangchen@hust.edu.cn (G. Chen).

http://dx.doi.org/10.1016/j.fuproc.2015.07.002
0378-3820/ 2015 Elsevier B.V. All rights reserved.

investigated the temperature deviation from the perspective of nonlinear ow characteristics and concluded that the ue gas temperature deviation was inevitable due to nonlinear ow in the furnace. The ue gas
deviations further cause steam temperature deviation and increase the
failure potential of heat exchanger pipes. Therefore, the economic performance and safety of the boiler operation are seriously inuenced
[811]. As an inherent feature of a tangentially red boiler, the ue
gas temperature deviation was also found to increase considerably
with increasing boiler capacity [12]. Ghen and Zheng [13] found a positive correlation between the voluminal heat load of upper furnace qv.
up and the deviation of the ue gas temperature by analyzing a large
amount of reliable operational data. The higher voluminal heat load of
the upper furnace signies that the more fuel was burned and more
ue gas was produced in the upper furnace per unit time and unit
volume. It partially explained the substantially increase of ue gas
temperature and velocity deviations along with the raised voluminal
heat load of the upper furnace.

D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

Nomenclature

n
P

ni
nj
xi
yj
x
y
h
Vxi
Vyj
q
l
t
h
A
S
Q

standard deviation
grid number of P7
swirling momentum moment of ue gas, N m
ue gas density, kg/m3
grid number of x axis
grid number of y axis
distance between the ith grid of x axis and the center of
furnace, m
distance between the jth grid of y axis and the center of
furnace, m
grid space of x axis, m
grid space of y axis, m
unit of furnace height, m
tangential velocity of ith grid of x axis, m/s
tangential velocity of jth grid of y axis, m/s
heat transfer quantity of ue gas per unit mass through
ue which is l meters in length, J
length of ue gas pass, m
equivalent heat transfer temperature difference, K
coefcient of convective heat transfer, W/(m2 K)
equivalent area of heat transfer, m2
equivalent sectional area of ue gas pass, m2
equivalent total amount of heat transfer of ue gas
pass, J

617

employed computational uid dynamic code FLUENT to investigate

the usage of brown coal and beneciated semicoke in a 600 MW
ultra-critical tangentially red boiler. They numerically analyzed the
blending coal combustion characteristics by changing variables including coal injection location, brown coal blending ratio, air staging ratio
and blending ratio of beneciated semicoke.
To date, electricity power generation industry has been the major
source of greenhouse gas emissions, and it is necessary to take
effective measures to reduce the greenhouse gas emission through
the application of carbon capturing technology. Available carbon
capturing technology includes the pre-combustion capture, postcombustion capture and oxy-fuel combustion. Since the oxy-fuel
combustion was widely considered most viable technology applicable in coal-red power plant, scholars have done intense research
on this subject by means of computational uid dynamic code recently [2226].
As far as the authors are aware, no numerical research has been conducted about the relationship between the ue gas temperature deviation of tangentially red boiler and the burner tilt angle. The major
objective of this paper is to propose a new method that tilt the main
burners upward and set the tilt angle of additional air (AA) bias in
each corner to alleviate the ue gas and reheat steam temperature deviation. Validated computational uid dynamic modeling considering a
700 MW low-NOx tangentially red pulverised-coal boiler was
established and the model was further used to intensively analyze the
mechanism of this newly presented method with particularly attention
on the ow pattern within the furnace.
2. Computational methodology

The temperature and velocity deviation of ue gas and its inuence

on the steam temperature has been a signicant research topic for
decades, massive amount of experience accumulated. The existing
solutions to ue gas temperature deviation can be divided into two
categories. One category of solution involves reduction of the heat
transfer deviation from the side of the steam by optimizing the structure
and re-arranging the platen heat exchanger [4]. The other involves
weakening the residual swirling intensity, usually by opposing the tangential swirling direction of the air jet ow from the over re air (OFA)
or the separated over re air (SOFA) [1416]. In addition, the application of a dual-tangential-circle ring system within a single chamber
is also helpful to decrease the residual swirling intensity via two
counteracting tangential ue gas ow systems in opposite directions
[17,18]. Although partially opposing the tangential circle direction of
OFA or SOFA has been proven to be effective solution to decrease the
gas temperature deviation, it is not applicable for boilers installed
with burners that cannot change their yaw angle horizontally. The
present paper describes a suitable method, i.e., tilting the main burners
upward and setting the bias of the tilt angle of the additional air (AA) in
each corner, to alleviate the ue gas and reheat steam temperature
deviation.
As an effective research approach, computational uid dynamic
(CFD) has been widely used in acquiring and analyze the combustion,
owing and heat transfer characteristics in tangentially red boiler. In
recent study, researchers mainly focus on application of brown coal,
blended multifuel combustion and the numerical prediction of oxyfuel combustion. Audai et al. [19] developed a computational uid
dynamic modeling for the combustion characteristic of brown coal in
a 550 WMe tangentially red boiler under different operation scenarios
on the basis of AVL Fire CFD code. Their work revealed the combustion
characteristics of brown coal within 550 MWe boiler and the solution
to optimize the operation. Dodds et al. [20] numerically analyzed the
wear distribution due to coal particle and sand within the mill duct system of a brown coal fueled power plant by means of computational uid
dynamic code. The authors found the greater erosion on the upper leg
swirl vanes compared with the lower leg due to the orientation of secondary ows attributed to the mill-duct geometry. Jian et al. [21]

2.1. The utility boiler

This study has been conducted considering a 700 MW tangentially
red pulverised-coal utility boiler at the Zhuhai Power Station, Guangdong Province, China. The boiler was manufactured by Mitsubishi
Heavy based on Mitsubishi Advanced Combustion Technology
(MACT), which combined a Multiple Pollution Minimum (MPM) primary air burner and deep air staging combustion. The schematic diagram of
the boiler is shown in Fig. 1 The boiler is equipped with the following
nozzles: six primary air (PA) nozzles, six secondary air (SA) nozzles,
three OFA nozzles and three AA nozzles located at each corner. Approximately 30% of the total combustion air was supplied into the furnace
through AA nozzles acting as deep air staging combustion nozzles to
achieve low NOx combustion. The tilt angle of the PA, SA, and OFA
nozzles can be changed from 25 to +25 continuously in the vertical
direction, and the tilt angles of the AA nozzles can be changed from
30 to +30 vertically. However, the yaw angle of the AA nozzles cannot be regulated horizontally.
As shown in Fig. 1, the horizontal planes P1 (52 m) and P2 (48 m) are
located at the middle and bottom of the platen zone, respectively. P3
(43 m) is located at the entrance cross-section of platen zone. P4
(38 m) is located exactly above the upper most AA burner. The vertical
planes P5 and P6 were the longitudinal cross-sections of the left and
right sides of the furnace, respectively, and the vertical plane P7 is the
entrance cross-section of the nal re-heater. All these planes are crucial
for the following analysis.
The practical operating parameters of this boiler indicate that the
reheat steam temperature of the right side was 20 C higher than that
of the left side and that the reheat steam overheating on the right side
occurred frequently for the nal re-heater, resulting in desuperheating
water spraying system being frequently acting and the local right-side
tube over overheating during boiler operation. It has negative inuence
on the security and economic performance of the boiler operation.
Generally, the reheat steam temperature will rise with increasing of
burner tilt angle, while the reheat steam and metal temperatures may
exceed their design values with an excessive tilt angle. Therefore, the

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D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

AA 3
AA 2
AA 1

OFA 3
OFA 2
OFA 1
F
EF
E
DE
D
CD
C
BC
B
AB
A
AA

(a)

(b)

(c)

Fig. 1. Schematic diagram of boiler (a), arrangement of burners (b) and grid of the horizontal cross-section in the burner zone (c). (x, y and z axes stand for the directions of depth, width,
and height, respectively).

burner tilt angle for practical operation should be properly set, considering the reheat steam temperature, metal temperature, and boiler
efciency.

The numerical simulation was performed on the basis of CFD code

known as Fluent 6.3.26. Pulverised coal combustion processes within
the boiler furnace contain several closely coupled sub-processes, including turbulent ow, solid particle transport and combustion, gas phase
combustion and multiform of heat transfer. In the present study, the
turbulent ow was calculated using the standard k- model [30,31].
Solid particle transport was simulated by Stochastic Particle Trajectory
(SPT) model, which considered the inuence of the turbulent uctuation of the continuous phase on the particle trajectories. Particle radiation interaction was also considered. Radiation heat transfer within
furnace was calculated by P-1 model, which considered the radiation
scattering effect and was suitable for combustion equipment with
large optical thickness and complex geometry. The emissivity of ue
gas was calculated by weighted-sum-of-gray-gases model (WSGGM)
[32] which has been widely used in computational uid dynamics and
reached good balance between calculating efciency and accuracy [33,
34]. WSGGM assumed that the emissivity of ue gas was decided by
local temperature and partial pressure of gas species. Specically, the
emissivity of ue gas (T,i) can be expressed as a sun of the emissivity
of several hypothetical gray gas weighted by temperature-depended
factors:
I1
X



i T 1eai pBTcs

K v1

K v2

Coals 1 Volatileg 1 1 chars

2.2. Mathematical models

T; i

model [35], i.e., one reaction controls at low temperature and the
other reaction at high temperature:

i1

where i(T) is the weighting factor of ith gray gas, s is the path length, ai
is the absorption coefcient of gas mixture, and p is the sum of partial
pressure of gas species e.g. H2O and CO2 [26]. Coal particle heterogeneous combustion consisted of devolatilization and char combustion
processes. Devolatilization was modeled by two-competing-reaction

Coals 2 Volatileg 1 2 chars:

Char combustion was controlled by both oxygen diffusion and the

surface chemical reaction rate [36,37]. The recommended kinetic data
of devolatilization and char combustion were available in Table 1.
Non-premixed combustion model was adopted to simulate the gas
phase turbulent combustion, the transport equations of mixturefraction were solved instead of a series of reactions for individual
species. The concentration of species was then derived from calculated
mixture-fraction on the basis of chemical equilibrium assumption. Inuence of turbulence uctuation on chemistry was taken into consideration by probability density function (PDF) [40,41].
In this study, the formation of thermal NOx and fuel NOx was considered, while prompt NOx was ignored [2529]. The thermal NOx was
formed by oxidating of N2 in combustion air and simulated by a set of
strongly temperature-dependent chemical reactions [26,43] from extended Zeldovich mechanism. Fuel NOx was simulated by De Soete
model [44], assuming that the fuel-bound nitrogen was distributed
within char and volatile. The nitrogen from volatile was rstly released
as intermediates HCN and NH3, then the intermediates were oxidated to
NO or reduced to N2, while nitrogen from char converted to NO directly.

Table 1
Reaction kinetic parameters [38,39].
Reaction

Char combustion
Devolatilization 1(1 = 0.3)
Devolatilization 2 (2 = 1)

K A ; exp RT

0.0043 kg/m2 s Pa
3.75 105 s1
1.46 1013 s1

8.37 107 J/kmol

7.366 104 J/mol
2.511 105 s1 J/mol

D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

The partial equilibrium approach was adopted to calculate the concentration of [O] and [OH] [2628]. Since the concentration of NO was far
lower than main species in coal combustion processes, the NOx formation was usually decoupled from coal combustion processes and the
transport equations for NO, HCN, and NH3 were calculated on the
basis of given convergent ow-eld solution [21,2628]. Audai [26]
simulated the NOx formation together with the coal combustion processes by solving the transport equations simultaneously with the coal
combustion reaction. They found that whether the NOx formation was
decoupled from coal combustion processes or not has little impact on
NOx simulation results. The inuence of turbulent ow temperature
and species concentration uctuation on NO formation was taken into
consideration by the adopting of probability density function (
PDF) [42].

619

Table 3
Coal property.
Proximate analysis, (wt.%), as received (ar)
Volatile matter
Moisture
Ash
Fixed carbon
Low heating value, (kJ/kg)

27.0
16.30
8.77
47.93
23,035.0

Ultimate analysis, (wt.%), as received (ar)

Carbon
Hydrogen
Oxygen
Nitrogen
Sulfur

61.30
3.65
8.90
0.78
0.30

2.3. Cases studied set up

In actual operation of the boiler, the burner was usually tilted upward for specic angle in order to increase the steam temperature,
while the reheat steam temperature and metal temperatures may exceed their design values with an excessive tilt angle. Therefore, the
burner tilt angle should be properly established. The numerical simulations were conducted for 8 cases presented in Table 2, which were
established on the basis of practical operating parameters. Cases 14
were conducted to study the inuence of the burner tiling up angle on
the ue gas deviation. Cases 3, 5, and 6 were conducted to study the inuence of the bias setting of the AA tilt angle. Cases 3, 7, and 8 with 100%
load, 75% load and 50% load, respectively, were performed to validate
the condence of the numerical simulation. The coal properties are presented in Table 3.
2.4. Boundary condition
The boundary condition of the burner inlets, the mass ow rate and
the temperature of the air inlets were properly established according to
practical operating parameters. Operating parameters are presented in
Table 4. The wall function method was used to consider the near-wall
effect, and the temperature boundary condition was used for the heat
transfer boundary condition of the wall. In this study, 24 surface type
of injections were set up in each of the primary air inlets. The pulverised
coal particle diameter distribution obeys Rosin-Rammler algorithm
with an average diameter of 65 m and a spread parameter of 1.5
achieved form the pulverised-coal sampling. Total number of tracked
particles was 25,920. The SIMPLE algorithm of pressure correction was
used to consider the coupling of the velocity and pressure elds [45].
The governing equations were calculated with appropriate underrelaxation and TDMA line-by-line iterations. A rst-order nite difference scheme was used and the calculation didn't end until the solution
satises the pre-specied tolerances, which were set to 1 106 for interactions of energy, radiation heat transfer, NO, and 1 104 for other
equations.

Main burner tilt angle ()

1
2
3
4
5
6
7
8

Special attention was paid to the grid system to improve the accuracy of the numerical calculation. The structured grids were used because
this approach can ensure the high quality of grid system. Grid independence test was conducted for case 1 in order to reach the balance between computational accuracy and computing cost. Three grid
systems with 1,270,946, 2,501,812 and 3,466,378 cells were considered
respectively. The latter two grid systems were achieved by rening the
meshes in burner region and upper furnace that represent regions of
high variables and ow gradients. All the grid systems were assessed
by comparing the gas velocity component Vy, gas temperature along
the line 1 (x = 018.60 m, y = 10.73 m, z = 18.16 m in the B layer
PA cross-section) and line 2 (x = 018.60 m, y = 10.73 m, z =
21.70 m in the D layer PA cross-section). It is evident from Fig. 2 that
the computational results of grid system with 2,501,812 cells and
3,466,378 cells are almost identical. Therefore, the grid system with
2,501,812 cells was adopted in present study considering computational accuracy and computing cost. Besides, the grids of the horizontal
cross-section were properly designed, i.e., the grid lines were set approximately along the ow direction to decrease the pseudo-diffusion
error [46] as shown in Fig. 1.

2.6. Full-scale experimental tests

The experimental measurements of combustion were conducted
under different loads. Some performance parameters, such as the
carbon content in the y ash, the oxygen concentration in the ue gas,
and NOx emissions, were measured. A MSI EURO-type ue gas analyzer
was used to measure the components of the ue gas. Flue gas and y ash
samplings were conducted at the entrance of the air pre-heater. Coal
sampling was performed at the coal hopper exits. Pulverised coal sampling was conducted using the sampling equipment installed on the

Table 4
Operating parameters.

Table 2
Simulation cases.

Case
Case
Case
Case
Case
Case
Case
Case

2.5. Grid independence test

AA tilt angle ()

#1

#2

#3

#4

#1

#2

#3

#4

0
+4
+11
+22
+11
+11
+11
+11

0
+4
+11
+22
+11
+11
+11
+11

0
+4
+11
+22
+11
+11
+11
+11

0
+4
+11
+22
+11
+11
+11
+11

0
+4
+11
+22
+12
+6
+11
+11

0
+4
+11
+22
+16
+16
+11
+11

0
+4
+11
+22
+16
+16
+11
+11

0
+4
+11
+22
+12
+6
+11
+11

(+ stands for tilting up the burners).

Mass ow rate (kg/s)

Total air ow rate
Primary air
Secondary air
OFA
AA
Pulverised coal feed rate
Inlet temperature (K)
Primary air and coal mixture
Secondary air, OFA and AA

Case 1 (100%
load)

Case 7 (75%
load)

Case 8 (50%
load)

681
172
175
108
226
76

538
142
141
89
162
58

380
95
108
51
126
40

338
578

338
578

338
578

620

D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

Fig. 2. Grid independence test: (a) gas velocity component Vy and (c) gas temperature along line 1 (x = 018.60 m, y = 10.73 m, z = 18.16 m in the B layer PA cross-section) and (b) gas
velocity component Vy and (d) gas temperature along line 2 (x = 018.60 m, y = 10.73 m, z = 21.70 m in the D layer PA cross-section).

pipes of the primary air and the pulverised coal mixture. The bottom ash
was also sampled.
The ue gas temperature measurement was conducted using a
suction thermocouple through four observation ports along the furnace height. The measurement points were 1.0 m away from the
front wall and 2.6 meter away from the right side wall. In addition,
the ue gas temperatures were also measured through seven observation ports along the furnace width at the platen zone. These measuring points were 1.0 m away from the front wall and 1.0 m above
the furnace nose.

3. Results and discussion

3.1. Validation of the numerical simulations
Validation of the numerical simulations after achieving convergent
solutions is mandatory. The calculated ue gas temperatures were compared with the measured values along the furnace height and at the
platen zone. Fig. 3 indicates that the calculated temperatures were consistent to the measured values, with maximum error less than 9%. The
comparison of the calculated and measured values of the carbon

Fig. 3. Comparison of the simulated and measured temperature proles of case 3: (a) prole along the furnace height, (b) prole along the furnace width.

D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

Table 5
Comparison between the calculated and experimental results.
Item
O2 (vol.%)
NOx (mg/m3, 6% O2)
Carbon content in y ash (%)
CO (ppm)

Calculated
Measured
Calculated
Measured
Calculated
Measured
Calculated
Measured

Case 3

Case 7

Case 8

2.74
2.60
132.8
147
1.46
1.17
495
653

3.62
3.80
146.7
153
1.27
1.41
439
395

3.91
3.84
138.7
148
1.12
0.88
84
75

content in the y ash and O2, the CO concentration, and the NO emissions in the ue gas is presented in Table 5. The calculated values of
the carbon content, O2 concentration and NOx emissions are in good

621

agreement with the measured values. The calculated results can properly reveal the variation characteristics of the carbon content and the NOx
emissions. These results indicated that the models adopted in the present study are suitable for correctly investigating the ow, combustion,
and heat transfer characteristics of the boiler.
3.2. Flue gas deviation characteristics of case 1
Fig. 4 shows the ue gas velocity and temperature distributions in
the boiler for case 1. The four horizontal planes are cross-sections of
PA, OFA, and AA and the entrance of the platen zone. As shown in
Fig. 4, the distribution of velocity and temperature are in good agreement, demonstrating the existence of a tangential re ball inside the
furnace. The penetration depth of the AA air ow was larger than
those of the PA and the OFA for its larger mass ow rate and

Fig. 4. Gas velocity and temperature distribution in the boiler: (a) velocity (m/s), (b) temperature (K).

Fig. 5. Velocity and temperature distributions of the inlet cross-section P7 of the nal re-heater: (a) velocity (m/s), (b) temperature (K).

622

D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

(a) P5(left)

(b) P6(right)

Fig. 6. Streamline distributions of the vertical cross-sections in the upper furnace (m/s): (a) P5 (left), (b) P6 (right).

momentum. The tangential ow in the furnace was intensied by AA air

inlets, and tangential ow at the entrance of the platen zone, i.e., the residual swirling momentum of the ue gas, was also observed.
Since P7 is inlet cross-section of nal re-heater, the ue gas ow and
temperature distribution characteristics of P7 have crucial impact on
heat transfer characters of nal re-heater and reheat steam temperature
deviations. Fig. 5 shows the simulated velocity and temperature
distributions of P7. This gure indicates the obvious deviations of ue
gas velocity and temperature. To perform quantitative analysis of the
ue gas deviations, P7 was divided into four parts by center lines
along the width and height directions. Flue gas velocity and temperature distributions were relatively more uniform in the upper part of
P7 and non-uniform in the lower part. The velocity and temperature
in the right zone of the bottom part were larger than that in the left
zone.
To conduct quantitatively evaluation of the ue gas deviation degree; the non-uniformity coefcient M and the deviation factor E are introduced. MT represents the non-uniformity degree of temperature
distribution of P7. Mv represents the non-uniformity degree of velocity
distribution of P7. MT and Mv are dened as follows:
MT

T ave 3 T
T ave

(a) P2

v
u
n
u 1 X
T t
T i T ave 2
n1 i1

Mv

V ave 3 v
Vave

v
u
n
u 1 X
V V ave 2
v t
n1 i1 i
where Ti is the temperature in the ith cell of P7, Vi is the velocity in the
ith cell of P7, and Tave and Vave are the average temperature and velocity
values of P7. ET and Ev represent the deviation degree between the right
part and left part of P7, respectively; these quantities are dened below.
ET

T ave:right
T ave:left

Ev

V ave:right
:
V ave:left

(b) P1

Fig. 7. Streamline distributions of the cross-sections P1 and P2 in the platen zone (m/s): (a) P2, (b) P1.

D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

623

introduced to conduct quantitative analysis of swirling intensity of

ue gas for different cases and different positions. P is dened as follows:
0
1
nj
ni
X
1 @X
2
2
P
V x xh
j V y j y j yhA
2 i1 i xi i
j1

Fig. 8. Tube metal temperature of the outlet header of the nal re-heater.

Based on the analysis above, the ue gas deviation was mainly found
in the lower part of P7, while the distribution was relatively more uniform in the upper part. For this case, the deviation factor of the upper
and bottom parts, Eup and Ebottom, respectively, is introduced. The denitions of Eup and Ebottom are of similar form, with the only difference that
Eup is dened as the ratio of the average value of corresponding variable
in upper-right to that in the upper-left and Ebottom was dened as the
ratio of that in the bottom-right to the bottom-left. The values of Eup
and Ebottom in case 1 were ET.up = 1.059, ET.bottom = 1.309, Ev.up =
1.434, Ev.bottom = 7.881, MT = 1.599, and Mv = 2.611. It is clear that
the values of E, Eup, Ebottom, and M exhibit high degree of consistency
with gas deviation distribution characteristics. Therefore, in this paper,
these coefcients and factors will be used synthetically to conduct
quantitative evaluation and comparison of ue gas velocity and temperature deviations for different cases.

3.3. Mechanism analysis of the ue gas temperature deviation

Fig. 4 shows the anti-clockwise residual swirling of ue gas before it
enters into the platen zone. The swirling momentum moment P [1] is

where is the gas density, Vxi and Vyj are the tangential velocity of ue
gas in x and y directions, respectively, xi and yj are the distances between
the a cell and the furnace center in x and y directions, respectively, x
and y are grid spacings in the x and y directions. h is the unit of furnace height. The ue gas swirling momentum moment P in P4 and P3
is 4.558 N m and 2.504 N m, respectively, indicating rapid decay of
ue gas swirling movement intensity in the furnace nose area. The vertical velocity component Vz increased with the furnace height, and the
horizontal components (Vxi and Vyj) reduced at the same time because
of the gradually reducing passage area of the furnace arch. Consequently, the calculated value of P decreases considerably.
Fig. 6 shows the simulated ow eld of the upper furnace. Planes P5
and P6 are vertical cross-sections of the left and right sides of the furnace respectively. As shown in Fig. 6, the ue gas in the right side (P6)
ows directly into the horizontal ue gas pass, while the ue gas in
the left side (P5) tends to ow towards the front wall. This difference
of ow pattern in the upper furnace is mainly caused by the residual
swirling of ue gas, which causes the horizontal velocity component
Vx of ue gas in the left side point towards the front wall, while in the
right side, Vx points towards the horizontal ue gas pass. This ow
eld difference of upper furnace inuences the distribution of the
horizontal component Vx as well as the ue gas ow rate distribution
along the width of the horizontal ue gas pass.
Fig. 7 shows the ow pattern of the platen zone by using streamlines
of the ue gas. The horizontal cross-sections P1 and P2 are located in the
upper and lower part of platen zone respectively. Fig. 7(a) indicates that
the ow pattern of the right and left sides of the horizontal ue gas pass
is remarkably different. In the left side, a part of ue gas ows towards
the front wall and further ows across the platen heat exchanger because of the residual swirling, forming some vortices between the
plates. Moreover, a fraction of ue gas in the left part ows through
the gaps between the front wall and division platen super-heater to
the right part of ue gas pass. However, the ue gas in the right part
ows along the arrangement of plates. It implies that the velocity and
net ow rate deviation of ue gas in the horizontal ue gas pass is

Fig. 9. Vertical velocity component Vz and Vx distributions along the width of the cross-section P4: (a) Vz, (b) Vx.

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D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

the ow deviation of ue gas is located mainly in lower half of the

horizontal ue gas pass.
3.4. Mechanism analysis of the re-heat steam temperature deviation
The residual swirling of the ue gas causes the deviation of the velocity and the net ow rate of the ue gas in the horizontal ue gas
pass along its width, as detailed above. These deviations result in the
heat transfer deviation for the re-heater and further cause the deviation
of the reheat steam temperature. Because the nal re-heater is a convective heat exchanger, only the convective heat transfer is considered
here. The equivalent heat transfer quantity of ue gas per unit mass
through ue pass, which is l meters in length, is q, and it is expressed
as follows:
q hAt

Fig. 10. Swirling momentum moment distributions along the furnace height.

mainly caused by the residual swirling of ue gas. As shown in Fig. 7(b),

the ow pattern of the upper part of the platen zone (P1) is relatively
more symmetrical than that of P2, which indicates that the swirling intensity of ue gas weakens rapidly due to the inuence of the plates and

l
Vx

where h is equivalent surface coefcient of the convective heat transfer

between ue gas and nal re-heater, A is the equivalent area of heat
transfer, and t is the equivalent heat transfer temperature difference.
The equivalent surface coefcient of the convective heat transfer can
be expressed as follows [47] (Re b 1.0 105):
0:65

h V x

10

Fig. 11. Evaluation indices of ue gas deviation of P7: (a) indices of temperature under different burner tilt angles, (b) indices of velocity under different burner tilt angles, (c) indices of
temperature with AA bias setting, (c) indices of velocity with AA bias setting.

D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

where coefcient is independent of V x. The formulas (7) and (8) show

the negative correlation between q and Vx. Therefore, with greater ue
gas velocity, the heat release per unit mass of ue gas becomes smaller,
i.e., the ue gas temperature becomes higher. In this case, the ue gas in
the right part of the horizontal ue pass (in which ue gas velocity and
the net ow rate are greater than those in the left part) has the higher
temperature. The total amount of equivalent heat transfer Q within
ue gas pass can be expressed as follows:
0:65

Q V x

At

l
0:65
SV x V x AlSt
Vx

11

where S is the equivalent sectional area of ue gas pass and SV x is the

equivalent ow rate of ue gas. This qualitative formula indicates that
the total amount of convective heat transfer in the right part of ue
pass is greater than that in the left because of the larger Vx. As a result,
the reheat steam temperature of the right part is higher than that in
the left part. Based on the analysis above, the gas temperature and reheat steam deviations are basically determined by the ow deviation
of the ue gas and the ow deviation is caused by the residual swirling
of the ue gas.
The tube metal temperatures of the nal re-heater were determined
from the distributed control system (DCS) under different loads. The
measuring points are located at the inlet tube of the outlet header of
the nal re-heater and are evenly distributed along the width of the furnace roof. Fig. 8 shows the tube metal temperature of the nal re-heater
outlet header. The temperature proles of tube metal basically coincided with the ue gas temperature distribution characteristics shown in
Fig. 5. As shown in Fig. 8, the temperature of the 13th point at the
right is found to be relatively higher than the temperature of the other
points and closest to the warning value of 610 C. This high temperature
is mainly caused by the heat transfer imbalance described previously.
Therefore, the reduction of the ue gas deviation can also be helpful to
reduce the excessive temperature of the tube metal of the nal reheater.

625

for approximately 30% of the total air, was added into the furnace from
AA nozzles at approximately 32 m in height; as a result, the rapidly decreasing tendency of P is obviously reduced, and even a slight increase in
the swirling momentum moment P is observed. In the furnace nose and
the platen zone, the swirling momentum moment P decreases relatively
faster. Overall, the swirling momentum moment P curves decrease with
increasing in tilt angle. The swirling momentum moment P in entrance
cross section of platen zone (P3) is 2.52 N m in case 1, 1.94 N m in case 2,
1.71 N m in case 3, and 1.41 N m in case 4.
Fig. 11 shows the evaluation indices of the ue gas deviation under
different cases. It clearly demonstrates that the evaluation indices of
the ue gas deviation reduce with the increase of burner tilt angle.
The variation of ET.bottom and Ev.bottom with the increase of burner tilt
angle is particularly remarkable compared with the other corresponding items. Fig. 12 shows the temperature distributions of nal reheater inlet cross-section P7. The temperature distribution becomes
more evenly with the increasing of burner tilt angle. Based on analysis
of each evaluation index in Fig. 11 and temperature distribution of
nal re-heater inlet cross-section presented in Fig. 12, we can draw

(a) Case 1

(b) Case 2

(c) Case 3

(d) Case 4

(e)

(f)

3.5. Effect of the burner tilt angle on ue gas temperature deviation

Fig. 9 shows the proles of Vz and Vx along the width direction of
cross-section P4 under different burner tilt angles. As shown, the proles of Vz for different cases under different burner tilt angles are similar.
All of these proles have the M-shaped overall curve, and the proles
are basically symmetrical. The vertical velocity component Vz of the
ue gas considerably increases with the rising of burner tilt angle. This
increase occurs mainly because the air jet-ow momentum in z direction provided from the air inlets increase with the tiling up angles of
the burners, while those of the x- and y-directions decrease. Fig. 9
shows that the proles of Vx under different burner tilt angles are also
similar, with the same symmetrical double-peak curve. The horizontal
velocity component Vx decreases with an increasing tilt angle, whereas
the tangential circle of the swirling ue gas, which is dened as the
distance between the two peaks of the Vx prole, obviously decreases.
Fig. 10 shows the prole of ue gas swirling momentum moment P
along the furnace height. As shown in Fig. 10, the proles of P for the different cases have the similar form of a single peak curve. The swirling
momentum moment initially increased with the furnace height. On
the one hand, the momentum of the air jet-ow provided into the furnace from the burners is converted into the swirling momentum of
the ue gas within the tangential ring system. On the other hand, the
turbulent dissipation weakens the swirling intensity of tangential ue
gas, i.e., the swirling momentum moment of ue gas is weakened to
some degree. The maximum of P occurs in the center area of main burner zone at approximately 22 m in height due to the combined action of
the two abovementioned factors. Meanwhile, because no air jet ow is
added into the furnace between the upper-most OFA and the rst
layer of the AA, the moment P decreases rapidly. The AA, which accounts

Case 5

Case 6

Fig. 12. Temperature distributions of the inlet cross-section P7 of the nal re-heater
(K):(a) case 1, (b) case 2, (c) case 3, (d) case 4, (e) case 5, (f) case 6.

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D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

(a) Case 3

(b) Case 5

(c) Case 6

Fig. 13. Streamline distributions of the cross-section P3 (m/s): (a) case 3, (b) case 5, (c) case 6.

the conclusion that the velocity and temperature deviation of the ue

gas in the horizontal ue gas pass are reduced considerably by tilting
up the burners. During the practical operation of this boiler, the tilt

(a) Case 3

angle of all the burners was normally set to +11. In this circumstance,
the reheat steam temperature of right side can reach the designed value,
and the deviation of reheat steam temperature decreases from

(b) Case 5

(c) Case 6
Fig. 14. Streamline distributions of the cross-section P2 in the platen zone: (a) case 3, (b) case 5, (c) case 6.

D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

approximately 20 C to 10 C. The frequency of the right-side reheat

steam over-heating was also reduced. If burner tilt angle further increased, the right-side metal over-heating of nal re-heater may
occur. The tilting upward of burners is an effective measure to decrease
the ue gas deviation. However, when the tilt angle of the burners
reached approximately 11, the reheat steam temperature deviation
remained 10 C, and a further increasing in burner tilt angle to reduce
the ue gas deviation is not applicable considering the over-heating potential of the nal re-heater right-side pipes.
3.6. Effect of AA tilt angle bias setting on ue gas temperature deviation
As described above, titling the burners upward to further reduce the
ue gas deviations and reheat steam temperature deviation is not applicable for the over-heating potential of nal re-heater right-side pipes
when the tilt angle exceeds +11. In this work, a new measure to decrease the ue gas deviation is presented, which was achieved by setting the tilt angle of AA at each corner bias, as described in Table 2.
The AA tilt angles of the rst and fourth corners were less than those
of the second and third corners. Fig. 13 shows the streamline distributions in the horizontal cross-section P3 of cases 3, 5, and 6. Fig. 13 clearly
indicates that the center of the swirling ue gas is moved noticeably towards the bottom-right corner of P3 when the AA tilt angle was bias set.
This result mainly occurred because the horizontal component of air jet
momentum from the rst and fourth corner is larger than that from second corner and third corner, so the center of the swirling ue gas is
pushed towards the bottom-right corner. The moving of the center of
the swirling ue gas before the platen zone further inuenced the
ow eld of the platen zone. As mentioned previously, a part of the
ue gas owed across the platen heat ex-changer and formed some vortices between the plates because of ue gas residual swirling, which illustrated the ow eld deviation of ue gas pass. As shown in Fig. 14,
four typical vortices are observed in P2 of case 3, which are mainly distributed at the left part of the horizontal ue gas pass. In Fig. 14(b) and
(c), four typical vortices are still observed, but they have moved rightward at different levels. This observation indicates that the region of
platen zone in which the ow eld is inuenced by the ue gas residual
swirling spatially moved rightward, i.e., the ow deviation was reduced
to a certain extent.
Fig. 15 shows the proles of swirling momentum moment P of the
ue gas along the furnace height for cases 3, 5, and 6. The gure clearly
shows that the bias setting of the AA tilt angle has no signicant inuence on the prole of P below the position of AA, while the inuence
is observable after AA inputting position. The ue gas swirling momentum moments of case 5 and case 6 were less than that of case 3 after AA

627

is injected. The conversion of gas jet momentum to swirling momentum

requires good interaction of the air jet ow from each corner, i.e., the
formation of a tangential ring system requires a symmetrical arrangement of the air jet ow of the four corners. When the bias of the tilt
angle of AA was set, the air jet ow from each corner was no longer symmetrically organized, which partially inhibited the conversion of the gas
jet momentum to the swirling momentum. The swirling momentum
moment of the ue gas at the entrance cross section of the platen
zone (P3) was 1.71 N m in case 3, 1.42 N m in case 5, and 1.08 N m in
case 6, and the effectiveness of reducing the residual swirling momentum moment P by setting the bias of the AA tilt angle is of the same
order of magnitude as the effectiveness of tilting the main burners upward detailed in Fig. 10. Fig. 11(c) and (d) shows the evaluation indices
of ue gas deviations of cases 3, 5, and 6. Fig. 12 shows the temperature
distribution of nal re-heater inlet cross-section P7. Fig. 11 and Fig. 12
indicate that the bias setting of the tilt angle of AA can effectively reduce
the ue gas deviations in crossover pass. During practical operation,
the bias setting scheme of case 6 can reduce the reheat steam temperature deviation from approximately 10 C in case 3 to less than
4 C. At the same time, the super-heat steam temperature can
reach the designed value without pipes over-heating, the boiler efciency can reach approximately 94.72%, and the NOx emission is less
than 147 mg/m3((O2) = 6%). Therefore, the application of tilting
main burners at + 11 upward and setting the AA tilt angle bias at
10 can effectively reduce the reheat steam temperature deviation to
less than 4 C ensuring high boiler efciency and low NOx emission.

4. Conclusions
In this study, CFD modelings were developed to investigate a newly
presented solution of re-heat steam temperature deviation on the
basis of FLUENT 6.3.26 considering a 700 MWe tangentially red
pulverised-coal boiler. The residual swirling of the ue gas in the
upper furnace was found to cause ue gas deviation in the bottom
part of the nal re-heater inlet cross section. Flue gas velocity and
temperature in the right part were higher than those in the left
part for a typical anticlockwise tangential ring system. These ue gas
deviations accounted for steam temperature deviation and frequent
right-side steam overheating.
Tilting the burner upward can effectively reduce the intensity of residual ow as well as the ue gas deviation degree. The burner tilt angle
of +11 was relatively optimum considering the ue gas deviation and
potential of nal re-heater overheating. The intensity of residual swirl
ow dropped about 44% and boiler practical operation demonstrated
that the reheat steam temperature deviation was reduced from 22 C
to 10 C in this condition.
The newly presented methods involve tilting the burner upward and
setting the bias of the AA tilt angles. When the tilt angle of AA was bias
set, the ow eld of upper furnace was changed. Consequently, the
residual swirl ow intensity and the ue gas deviation were reduced
considerably. During practical operation, when the burner tilt angle
was set at +11 and the bias of the AA tilt angle was set at 10, the reheat temperature deviation was reduced to less than 4 C from the initial 20 C of case 1. Besides, the frequency of the right-side re-heat
steam overheating was also reduced while ensuring a high boiler
efciency and low NOx emission in this circumstance.

Acknowledgments

Fig. 15. Swirling momentum moment distributions along with the furnace height.

The authors gratefully acknowledge the Project on the Integration

of Industry, Education and Research of Guangdong Province (No.
2012B091100173), Youth Foundation of Huazhong University of Science and Technology (No. 2014QN185) and the National Natural Science Foundation of China for funding this research (No. 51390494).

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D. Tian et al. / Fuel Processing Technology 138 (2015) 616628

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