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Energy Reports 7 (2021) 915–925

www.elsevier.com/locate/egyr

2021 International Conference on Energy Engineering and Power Systems (EEPS2021), August
20–22, 2021, Hangzhou, China

Optimization study on high-temperature corrosion prevention of the

water wall of a 1000 MW dual circle tangential boiler during
operation
Lantian Caoa,b ,∗, Rong Penga , Zhongyi Denga
a China Datang Corporation Science and Technology General Research Institute Co., Ltd East China Electric Power Test &Research
Institute, Hefei, 230088, China
b North east Electric Power University, Jilin, 132000, China

Received 4 September 2021; accepted 29 September 2021

Abstract
High-temperature corrosion of boiler water wall is one of the major factors that affect safe and economic operation of large
thermal generator sets. For the high-temperature corrosion of right and left water walls of a domestic 1000 MW dual circle
tangential boiler during trial operation, this paper studies impact on high-temperature corrosion of water walls from burner
height–width ratio and secondary air nozzle swing angle respectively through Fluent numerical simulation. Simulation results
show that a burner combination mode with a small height–width ratio shall be used during actual operation of the boiler. In
addition, when the secondary air nozzle is swung upward by 15◦ , the CO concentration at the place close to the wall surface
in the combustion zone is less than 3% with adequate oxygen content, which can reduce high-temperature corrosion risk of
water walls.
⃝c 2021 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the International Conference on Energy Engineering and Power Systems, EEPS, 2021.

Keywords: High-temperature corrosion; Numerical simulation; Dual circle tangential boiler; Burner height–width ratio; Secondary air nozzle
swing angle

1. Introduction
High-temperature corrosion of water walls is a common problem in combustion of pulverized coal boilers. In
recent years, scholars at home and abroad have made a large number of studies on high-temperature corrosion of
water walls. Such studies show that high-temperature corrosion can be controlled by changing the material of water
wall tubes [1–4], adding closing-to-wall air [5–7] and adjusting air distribution mode [8,9]. Hua, et al. [1] studied
the corrosion resistance of a composite ceramic coating. According to the test results, the metal test specimen (20G)
that is applied with new ceramic coating has SO2 corrosion, H2S corrosion and molten salt corrosion resistance.
∗ Corresponding author.

https://doi.org/10.1016/j.egyr.2021.09.181
2352-4847/⃝ c 2021 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (http:
//creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the scientific committee of the International Conference on Energy Engineering and Power Systems,
EEPS, 2021.
L. Cao, R. Peng and Z. Deng Energy Reports 7 (2021) 915–925

Liu, et al. [3] studied corrosion mechanisms of 3 common boiler steel materials, predicted categories and quantities
of main corrosive elements in flue gas based on a thermodynamic equilibrium model, and pointed out that austenitic
steel TP347H had high corrosion resistance. Meng, et al. [6] applied a different-distance closing-to-wall air nozzle
layout scheme based on jet oxygen supplementation characteristic of closing-to-wall air. The study shows that this
scheme is able to reduce the reducing atmosphere concentration in the near wall region of the side wall to a low
level with a closing-to-wall air consumption rate less than 4%. Chen, et al. [7] put forward a closing-to-wall air
combination scheme with combined front and rear wall openings and side wall slots. According to the study, this
scheme is able to save closing-to-wall air volume while realizing better high-temperature corrosion control effect.
For high-temperature corrosion of circle tangential boilers, Lv, et al. [8] performed numerical simulation of furnace
combustion with different air distribution modes. Results show that the highest CO content can be obtained and
high-temperature corrosion is easy to happen when inverted pyramid air distribution mode is used. Therefore, this
mode is not recommended in engineering practice. To eliminate high-temperature corrosion of water walls of a 600
MW supercritical opposite firing boiler, Sun, et al. [9] studied the impact on CO and H2 S volume fractions in the
near wall region from burner air volume with numerical simulation. Results show that bowl air distribution mode
is able to reduce the volume fraction of the reductive gas in the near wall region significantly.
However, almost all studies above need to change original boiler materials and structures at high cost, so they are
hard to be realized. This paper is to prevent high-temperature corrosion through combustion adjustment (choosing
appropriate burner height–width ratio and vertical secondary air swing angles) on the premise of not changing power
plant equipment and structures.
Wang, et al. [10] studied the impact on furnace combustion of a tangentially-fired boiler from burner height–width
ratio based on numerical simulation method, and learnt furnace combustion and corrosion states under different
burner height–width ratios. Theoretically, there are rules to follow for the impact on water wall high-temperature
corrosion of dual circle tangential boilers from burner height–width ratio, but there are no such studies yet. On the
other hand, some domestic scholars [11] studied the impact on combustion from horizontal swing of secondary air
nozzle. Vertical swing of secondary air nozzle has certain impact on water wall high-temperature corrosion of dual
circle tangential boilers in theory. But there are still no relevant studies yet.
Therefore, for high-temperature corrosion on the left wall and the right wall of a 1000 MW dual circle tangential
boiler of a power plant during boiler trial operation, this paper simulates furnace combustion under different burner
height–width ratios and secondary air nozzle swing angles respectively, and discusses the impact on water wall
high-temperature corrosion from burner height–width ratio and vertical secondary air nozzle swing angle through
analysis of component concentration field, temperature field and speed field.

2. Boiler overview
The study object in this paper is a 1000 MW boiler that will be put into production in China in the near
future. It is a vertical water wall ultra-supercritical variable-pressure once-through boiler featured by Type Π layout,
single furnace, on-time intermediate reheating, low NOX main burner, high-position over-fire air staged combustion
technology and reverse dual circle tangential combustion method. The pulverizing system consists of medium-speed
mill cold primary air fan, positive pressure direct blowing pulverizing system, negative pressure furnace and balanced
ventilation pulverizing combustion system. One furnace is equipped with 6 medium-speed mills, which are arranged
on one side of the boiler. Among them, 5 are for operation and 1 is for standby (under BMCR condition). Pulverized
coal fineness of design coal type is R90 = 17%, and uniformity index is n = 1.05. Eight groups of tilting burners
featured by octagonal dual fireball tangential combustion are used. Each group is provided with 6 layers of primary
air nozzles and 16 layers of secondary air chambers. In addition, 3 layers of LSOFA over-fire air nozzles and 3
layers of HSOFA over-fire air nozzles are arranged 6.475 m and 10.485 m above the centerline of the upper layer
of pulverized coal nozzles respectively. For each layer of burners, two imaginary tangent circles with the same size
and opposite directions are formed by nozzle jet flows from No. 1, 2, 7, and 8 angles and that from No. 3, 4, 5,
and 6 angles of burners. Furnace height, width and depth are 57.5 m, 34.2 m and 16 m respectively. See Fig. 1
for layout of boilers and each group of burners, and see Fig. 2 for layout of each layer of burners and imaginary
tangent circles. Bituminous coal with 35.03% volatile is taken as the design coal type. According to scholars’
studies regarding impact on high-temperature corrosion from coal types [12–14], bituminous coal has little impact
on high-temperature corrosion, so this paper will not discuss the impact on high-temperature corrosion from coal
types. See Table 1 for coal quality analysis. Certain corrosion was found out on the left wall and the right wall of
the furnace during furnace shutdown after trial operation.
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Fig. 1. Layout of boiler and each group of burners.

Fig. 2. Layout of each layer of burners and schematic diagram of imaginary tangent circles.

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Table 1. Coal quality analysis.

Element analysis/% Proximate analysis/% Q gr.ar
Car Har Oar Nar Sar Aar Mad Vdaf Mt (MJ/kg)
51.93 2.65 9.59 0.56 0.98 21.89 10.37 35.03 12.4 19.63

3. Mathematical model and calculation

3.1. Mathematical model

In consideration of flow characteristics of fluids such as pulverized coal, air and flue gas in furnace, Eulerian–
Lagrangian method is applied to the mathematical model in this paper. Eulerian method is applied to continuous
phase (gas): κ-ε equation is applied to the turbulence model; non-premixed combustion model is applied to the
component model; P1 model is applied to radiation; and gaseous combustion is simulated with probability density
function (PDF) model. Lagrangian method is applied to dispersed phase (solid): Motion of pulverized coal particles
is described with discrete phase model; precipitation of coal volatile is simulated with single-rate model; combustion
of fixed carbon is simulated with dynamic diffusion reaction model; and particle tracing is performed with random
orbit method.

3.2. Grid division

In this paper, the entire furnace is taken as the study object, and grid of the furnace is divided as per four areas,
i.e. horizontal flue, furnace arch, burner and dry bottom hopper areas. Considering the main study object in this
paper is the flow field in the burner area, the grid in the burner area is densified, and O-type grid is used to prevent
false diffusion. Finally, multiple groups of individual tests are performed to determine grid number. The grid number
determined in the end is 2.05 million.

3.3. Boundary conditions and numerical solution

Boundary conditions are set up as follows before Fluent numerical simulation: Eight groups of burner nozzles are
set as velocity inlets, primary air temperature is set as 348 K, secondary air temperature is set as 598 K, pulverized
coal particle temperature is set as 348 K, Rosin–Rammler distribution with the minimum particle size of 10 µm,
the maximum particle size of 150 µm and the average particle size of 32 µm is applied to pulverized coal particle
with primary air and secondary air rate of 20% as well as secondary air and over-fire air rate of 80%. Pyramid
air distribution mode (15) is applied: The opening of the secondary air dampers in the lowest layer is set as 80%;
the opening of the secondary air dampers between the lowest layer of burners and the uppermost layer of burners
is set as 40%; the opening of the secondary air dampers above the uppermost layer of burners is reduced by 5%
successively till 10%; the opening of the primary and the secondary air nozzles and the over-fire air nozzle is set as
not less than 10% to prevent nozzle corrosion; the furnace wall surface is set as a wall for convective heat transfer
with the ash layer thermal conductivity hext of 450 w/m2 k, the working medium temperature Text of 350 ◦ C and
the ash layer surface blackness of 0.6. Furthermore, the furnace outlet is set as the pressure outlet with the pressure
of −80Pa. For numerical calculation, finite difference method is used to discretize the differential equation, and
SIMPLEC algorithm in second-order upwind difference scheme is used to solve the governing equation.

4. Simulation result and analysis

4.1. Model verification

Fig. 3 is CO distribution on the central plane of burners of Layer E when 5 coal mills (full load) are input. It
can be learnt from Fig. 2 that CO contents at most positions near left and right walls of the furnace are greater
than 6%, and that of partial areas is even higher than 10%. However, when CO content exceeds 3%, there is high
H2 S gas concentration, and the probability of occurrence of sulfide high-temperature corrosion will be improved
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Fig. 3. CO concentration on the central plane of Layer E when coal mills A, B, C, D and E are input.

significantly [15,16], i.e. water walls of left and right walls of the furnace are easy to have corrosion. Therefore,
corrosion of water walls of left and right walls during trial operation is consistent with the simulation result, which
proves simulation correctness. In addition, front and back walls have a low CO content, so there is almost no
high-temperature corrosion, which is also consistent with the actual situation.
When only burners of Layer A of the boiler are input, measured flue gas temperature and simulated flue gas
temperature of each measuring point in the furnace are shown in Table 2. According to Table 2, the error between
actual flue gas temperature and simulated flue gas temperature is within 5%, which further proves correctness of
the simulation in this paper.

Table 2. Comparison of actual flue gas temperature and simulated flue gas temperature of each measuring point.
Measuring point Actual flue gas temperature (K) Simulated flue gas temperature (K)
Near wall of burners of Layer A 1097 1114
Near wall of burners of Layer B 1068 1085
Near wall of burners of Layer C 1011 1037
Near wall of burners of Layer D 963 995
Near wall of burners of Layer E 924 948
Near wall of burners of Layer F 895 922
Position of the short soot blower in Layer D 867 884
Between over-fire air of layer II 838 851
Furnace outlet 731 753

4.2. Impact on High-temperature Corrosion from Burner height–width Ratio

Meaning of burner height–width ratio is as follows: when primary and secondary air nozzles that are input
for each group of burners are taken as an integral whole, the ratio of height and width of the integral whole is
burner height–width ratio. This paper simulates furnace combustion under five conditions. See Table 3 for loads
and height–width ratios under different conditions (since burners under condition 5 are discontinuous, there is no
uniform height–width ratio).
Fig. 4 shows the O2 concentration distribution on the center line Lx of Z-0 section that is 0.7 m from the water
wall of the side wall under different burner height–width ratios. The area with O2 concentration less than 2% (i.e. the
area on the left of f = 2%) is anoxic and easy to have high-temperature corrosion. It can be easily learnt from the
figure that corrosion area from right to left and from condition 1 to condition 5 is increasing gradually.
All oxygen concentration curve under condition 1 is on the right side of f = 2% with adequate oxygen content,
so there will not be high-temperature corrosion. This is because only burners of Layer A are started under condition
1, the boiler is running under low load, air volume is distributed as per the minimum air volume of the boiler rather
than the air–coal ratio of the coal mill, so that adequate oxygen is introduced to the furnace. Furthermore, when
only one burner is started, the tangent circle generated in the boiler is small (as shown in Fig. 5), the wall surface
temperature will not be too high, so there will not be high-temperature corrosion. However, flames in the furnace
are too concentrated, and ambient temperature is relatively low under this condition, which is not beneficial to stable
combustion of pulverized coal.
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Table 3. Burner height–width ratios under different conditions.

Condition Load (MW) Input nozzle Height–width ratio
1 200 AAL/A/AAU 2.566
2 400 AAL/A/AAU/AB/BBL/B/BBU 5.942
3 600 AAL/A/AAU/AB/BBL/B/BBU/CCL/C/CCU 8.687
4 600 DDL/D/DDU/DE/EEL/E/EEU/EF/FFL/F/FFU1/FFU2 9.466
5 1000 AAL∼EF –

Based on comparison of curves under conditions 1, 2 and 3, areas that are affected by high-temperature corrosion
will be increased along with increase of burners used. Namely, when burner height–width ratio is increased, high-
temperature corrosion will be aggravated. Two tangent circles of the same size and in opposite directions will be
formed in the furnace under effect of burner bottom air. When they pass by burners of the first layer, injected
pulverized coal particle will be coerced to form an “air surrounding fuel” environment. Moreover, the primary air
will entrain flue gas along the way to the burners of the next layer in the rising process till burners of the last
layer that are started. Tangent circles will be enlarged constantly along with introduction of large amount of flue
gas along the way. This is why when burner height–width ratio is increased, high-temperature corrosion will be
aggravated. On the other hand, load under condition 2 and condition 3 is greater than 300 MW, and air is distributed
as per air–coal ratio of coal mill. Therefore, excess oxygen content of burners of Layer 1 will become less than
less along with increase of burner number, i.e. the greater the height–width ratio, the less the oxygen content in
the furnace, the easier high-temperature corrosion is. Particularly, the corrosion area under condition 2 is relatively
small. According to Fig. 6, two tangent circles formed in the furnace are of moderate size, the temperature field in
the furnace is relatively uniform, pulverized coal is burning stably, so it is an ideal condition.
Based on comparison of curves under conditions 4 and 3, the high-temperature corrosion area under condition 4
is larger than that under condition 3. This is because the number of secondary nozzles under condition 4 is greater
than that under condition 3 under the same load and burner number, and the continuous increasing tangent circle
distance is greater than that under condition 3, so corrosion is more serious than that under condition 3. It is also in
accordance with the rule of “the greater the burner height–width ratio, the more serious high-temperature corrosion
is”. Therefore, when choosing from combination of burners A, B and C and combination of burners D, E and F for
the power plant, better effect can be obtained when combination of burners A, B and C having smaller height–width
ratio is chosen.
Condition 5 (full load) has the most serious high-temperature corrosion and the largest corrosion area. If the
burner combination under condition 5 is continuous, the height–width ratio will reach 15.473, which is much
greater than that under condition 4. Therefore, dividing burners with the same angle into two vertical groups in
power plant design is able to reduce high-temperature corrosion to certain extent. It can be learnt from Fig. 4 that
O2 concentration in the central areas of burners of Layer C and Layer D increases obviously. This is because when
airflow and flue gas pass by this area, almost no flue gas will take part in this airflow, and the tangent circle formed
in the upper part is small, negative pressure is concentrated in the central area of the upper part. On this background,
tangent circle airflow rises from downward will be reduced in this area, and O2 concentration near the wall surface
will be increased to some extent. This is why O2 concentration in 12–14 m area under conditions 1–3 increases
obviously. However, despite high-temperature corrosion is reduced to some extent when burners are divided into two
groups, high-temperature corrosion still exists, and it is the most serious under this condition (full load). Therefore,
how to eliminate high-temperature corrosion under full load becomes the next study direction of this paper.

4.3. Impact on high-temperature corrosion from secondary air nozzle swing angles

4.3.1. Simulation result and analysis

According to the analysis above, the most serious high-temperature corrosion occurs under full load. To deal
with this problem, this paper takes condition 5 as the original condition, and changes the vertical swing angle of the
secondary nozzle under the same air distribution mode and air supply volume to study impact on high-temperature
corrosion from vertical swing angle of secondary nozzle. Ly is the intersecting line between Z-0 section and the
center section of primary air nozzle of Layer E. Fig. 7 shows changes in CO concentration on Ly when secondary
air nozzle swing angle changes upward or downward.
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Fig. 4. O2 concentration distribution on Lx under different conditions.

Fig. 5. Temperature field of the center section of burners of Layer A under condition 1.

Fig. 6. Temperature field of the center section of burners of Layer B under condition 2.

According to Fig. 7, CO concentration distribution under different swing angles shows the same law: CO
concentration on Ly rises before decreases from front wall to rear wall, and the peak point occurs at the position
slightly close to front wall. This is because jet flow of angle 1 inclines seriously towards right wall of the furnace
under jet flow of angle 2, while jet flow of angle 4 inclines seriously towards left wall of the furnace under jet flow
of angle 3, leading to intense combustion in the area that is slightly close to front wall. It is anoxic in this area,
so pulverized coal cannot be burnt completely, and that is why the highest CO concentration occurs (as shown in
Fig. 8). Different peak point positions under different swing angles are caused by different tangent circle shapes of
Layer E under different swing angles.
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Fig. 7. CO concentration on Ly under different swing angles.

Fig. 8. Velocity field on the central plane of Layer E when the coal mill is under full load.

Fig. 7(a) shows CO concentration distribution on Ly when secondary air nozzle swings downward. It can be
learnt from the figure that when secondary air nozzle swings downward, size of the area with CO concentration
greater than 3% decreases before increases when the swing angle is increased from 0◦ to 15◦ , and then, to 30◦ .
Explanation is as follows: when the swing angle is within 0–15◦ , and when secondary air nozzle swing angle
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increases from 0◦ to 15◦ , velocity of secondary air in horizontal direction is decreasing, supplementary amount to
the mainstream flue gas is reducing, tangent circle size will be reduced to certain extent, and the degree of corrosion
will be reduced, too. However, since downward jet flow will hinder rising of the mainstream flue gas, the rising
velocity of the mainstream flue gas keeps decreasing along with increase of downward swing angle. Moreover,
rigidity of horizontal jet flow will decrease along with increase of swing angle, more flue gas will be introduced
during rising, and tangent circle size in the furnace will increase, leading to aggravation of the degree of corrosion.
For this reason, when swing angle is gradually increased to 30◦ from 15◦ , hindering on rising of mainstream flue gas
from jet flow will be increased further, and rigidity of horizontal jet flow will keep reducing. Effect on mainstream
flue gas from them is greater than that on mainstream flue gas from decrease of secondary air velocity in horizontal
direction, so the tangent circle size increases, and the corrosion area increases, too.
Fig. 7(b) shows CO concentration distribution on Ly when secondary air nozzle swings upward. Based on the
figure, when secondary air nozzle swings upward, CO concentration at the place close to the wall surface in the
combustion zone at 15◦ is less than 3%, so there is no high-temperature corrosion area [15–17], and the best high-
temperature corrosion prevention effect can be obtained. Explanation is as follows: when the swing angle is within
0–15◦ , and when secondary air nozzle swing angle increases from 0◦ to 15◦ upward, velocity of secondary air in
horizontal direction will decrease, and supplementary amount to flue gas will be reduced. In addition, upward jet
flow will not hinder rising of mainstream flue gas, so that tangent circle size decreases significantly. When swing
angle reaches 15◦ approximately, corrosion area is reduced to zero. High-temperature corrosion area has increased
to some extent when the swing angle increases from 15◦ to 30◦ . This is because continuous drop of rigidity of
secondary air in horizontal direction leads to the fact that jet flow is easy to be introduced to the mainstream
flue gas, and the effect on the mainstream flue gas is greater than that on the mainstream flue gas from decrease
of secondary air in horizontal direction. On this background, the tangent circle in the furnace increases, intense
combustion happens near the wall surface, CO concentration increases, so that the corrosion area increases.
Numerical simulations and field operation practices of other scholars show that the boiler can control the flame
center position and adjust the temperature of reheated steam and superheated steam by adjusting the swing angle
of the secondary air nozzle during operation. However, there has not been much research on the influence of the
reducing atmosphere near the water walls. Based on the analysis above, when it is necessary to lift flame center
position of the boiler, the secondary air nozzle shall be swung upward by 15◦ to prevent high-temperature corrosion.

4.3.2. Field tests and verification

There are 8 measuring points that are 0.7 m from four corners of the furnace on the cross section of burners of
Layer E. Refer to Fig. 9 for schematic diagram of measuring points. Comparison of CO concentration before and
after swing angle adjustment is obtained by sampling 8 measuring points under 0◦ swing angle and 15◦ upward
swing angle of secondary air nozzle under full load for flue gas composition analysis, and the result is shown in
Fig. 10.
According to Fig. 10, when the swing angle is swung upward by 15◦ , CO concentration drops obviously, and
concentration of all measuring points is lower than 3%, so that high-temperature corrosion will not happen in
theory [15–17], which proves simulation and analysis correctness. Afterwards, the power plant found out that
corrosion aggravation of left and right walls was not obvious during furnace shutdown inspection after two months’
trial operation. It proves correctness of simulation and analysis in this paper again.

5. Conclusions
For the high-temperature corrosion in partial areas of a 1000 MW dual circle tangential boiler during trial
operation, this paper studies impact on high-temperature corrosion of water walls from burner height–width ratio
and vertical swing angle of secondary air nozzle respectively with numerical simulation. Conclusions are as follows:
(1) The dual circle tangential boiler is easy to have high-temperature corrosion in water wall areas of left and
right walls.
(2) Increase of burner height–width ratio will aggravate high-temperature corrosion of water walls. So burner
combinations with low height–width ratio are recommended in actual operation on the premise of meeting
combustion requirements.
(3) When two layers of burners are input, combustion is stable with relatively slight high-temperature corrosion,
which is an ideal condition and recommended to be used frequently in engineering practice.
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Fig. 9. Position diagram of measuring points of burners of Layer E.

Fig. 10. Comparison of CO concentration before and after swing angle adjustment.

(4) When secondary air nozzle is swung upward by 15◦ , best high-temperature corrosion prevention effect
of water walls can be obtained. Therefore, when it is necessary to swing secondary nozzles upward in actual
operation of a power plant, it is recommended to swing them upward by 15◦ to reduce probability of occurrence
of high-temperature corrosion.

Declaration of competing interest

The authors declare that they have no known competing financial interests or personal relationships that could
have appeared to influence the work reported in this paper.

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