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CFD modeling of Erosion of Flue gas ducting in a power plant

Conference Paper · January 2009

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Proceedings of the 2 National Conference on CFD applications in power and industry sectors
January 28-29, 2009, BHEL-Corp R&D, Hyderabad, India
CFD modeling of Erosion of Flue gas ducting in a power plant
Ramesh Avvari A
ABSTRACT
Flue gas ducting in a typical power plant encounters erosion at
guide-vanes, duct walls very frequently due to impact of high
velocity abrasive ash particles over a prolonged period of
operation. This could lead to puncturing of duct walls and /or
guide vanes often necessitating replacement or maintenance,
which is usually done during annual shut downs. Procedure for
erosion prediction through CFD modeling is developed for duct
walls. This enables the designer to take corrective actions for
modifying the shape of duct to make the flow streamlined and
reduce the chances of erosion. Better-streamlined flow in a duct
will reduce pressure drop, power consumption by fan and
maintenance costs due to erosion.
INTRODUCTION
Erosion of power plant equipment like tubular pressure
parts, air heater, ducts etc frequently result in extensive damage
to the equipment leading to repair / replacement of the worn out
parts. Erosion of tubular pressure parts is a common problem
arising in power plant operation leading to shut down of power
production due to rupture and breakdown of tubes and leakage
of steam. Indian coals having large amount of ash, are more
severe in causing erosion of power plant equipment. Erosion is
more aggressive in case of economiser zone, and comparatively
less aggressive in Low Temperature Super heater (LTSH), final
SH, Reheater (RH) and platen SH zones. In economiser and
LTSH zones erosion is more due to the pitch to tube diameter
ratio is less and tubes are closely spaced. Also the flue gas and
ash particles are further accelerating due to gravity and a higher
momentum from ash particles is induced in the metallic surfaces
of Economiser and LTSH zones. RH and platen SH zones are
affected especially in the bottom portions due to flow taking a
change due to gas direction.
The water wall tubes surrounding the burner panels also face
problem of erosion due to high velocity gradients near burner
zone and impingement of high velocity ash particles. Erosion is
a function of many different parameters like particle (ash)
velocity, angle of impingement, ash and metal temperature,
material composition of ash and target material (steel tubes),
duration of operation, metal’s mechanical properties, geometry,
pitch spacing, and arrangement of tubes inline or staggered etc.
A Primary Author - Senior Development Engineer, R&D, BHEL-Trichy.
B Co-author - Deputy General Manager, R&D, BHEL-Trichy.
S. Gowrisankar B
Though not as serious as in pressure parts, erosion of duct walls
or guide vanes is also a matter of concern in power plants,
especially in the duct zones between Economizer outlet to ESP
inlet, where ash particles flow along with flue gases. Though
seldom resulting in any emergency warranting immediate repair,
the slow erosion of duct plates and guide vanes, especially in
bends, will affect the flow streamlining effect of guide vanes,
leading to increase in pressure drop during plant operation.
These have to be repaired or replaced during plant shut down;
sometimes the replacement could lead to almost replacement of
the entire duct in some power plants using high ash coals.
Erosion occurs due to presence of very high velocity pockets
near bends, where change of flow direction takes place abruptly
leading to loss of streamline flow behavior.
Erosion is a process in which material is removed from the
surface layers of an object by the abrasive particle stream. It is a
localized phenomenon causing removal of small quantity of
target material from the following mechanisms. 1) Removal of
material due to cutting wear 2) Removal of material due to
repeated plastic deformation 3) Effect of temperature on the
tensile / ductility properties of the material leading to brittle and
ductile fracture at the point of impact. Though the first two
mechanisms are significant at ambient to lower temperature
regimes, prediction of relevant contribution individually is
difficult. The third mechanism is of significant importance to
high temperature applications as in a boiler furnace. A
mechanistic model is developed jointly with IIT Madras,
considering different steel grades, ash composition, size
distribution analysis, surface roughness, quantity and duration
of impingement of ash on small cut out samples of tubes.
EROSION MODELS
There are many different mathematical models2-4 developed
involving different parameters by various authors, which are
applicable at ambient as well as elevated temperatures. Some of
the literature models are given by Finnie.I , J.G.Mbabzi,
S.K.Das et al.etc. IIT Madras-BHEL (Model 1) have
developed1 a mechanistic mathematical model on conducting
experiments varying ash samples, target material samples,
quantity and time of impact, angle of impact etc at ambient
conditions and is given by
 0.5075 In CFD modeling based prediction, the above model is
 Qp 
VP0.8828 D P0..3128   (Ra )1.2431 (Cr )0.0693 implemented using UDF as ε = E’ x K’ where E’ = V3 sin3 β
V
 F  (both V and β are CFD-predicted, from the modeled flow
E = 7.08 × 10 − 6
(Sinα )0.1787 M 0.3265 (Ti )0.4105 domain.
where E is erosion loss (g), Vp is fly ash particle velocity (m/s), K’ = Ke Ie(x) ρmρp1/2 /σy3/2 (this is taken as constant, being a
Dp is the particle size (microns), Qpis the particle flow rate function of ash and steel properties). The erosion prediction
(kg/min), VF is the volumetric flow rate of the gas (m3/min) using the above two models are compared in this paper.
[Area of Nozzle * Velocity], α is the impact angle (rad), Ra is
the surface roughness (micro.m), M is the percentage of
moisture present in the fly ash, Ti is percentage of titania EROSION MODELING CAPABILITY BUILDING
present in the fly ash and Cr is the percentage of chromium
present in the low alloy steel. The erosion modeling methodology is developed for
In CFD modelling based prediction, the above model is plugged application to any ducting or pressure parts system. The erodent
in as a UDF and is represented as E=K E* where is taken as ash, and eroded part is modeled as wall. First the
flow field in domain is solved using flue gas as single phase
VP0.8828
E* = and flow and later ash (second phase) is injected into the domain
( Sinα )
0.1787
filled with flue gas and tracked using Lagrangian-Eulerian
0.5075 approach. Based on the number of ash particle impacts on the
 Qp 
( Ra ) (Cr )
1.2431 0.0693
0..3128
D   walls, the rate of erosion is arrived at. The dependence of
P

K = 7.08 × 10 −6  VF  temperature on erosion is studied, and it is possible to vary the

M 0.3265 (Ti ) ash properties, metal properties, temperature, flow rate etc and
0.4105

the erosion equations developed are capable of including these

The effect of instantaneous particle velocity and impingement
angle is represented by E* term for all ash particles tracked,
whereas effect of ash and steel properties are covered by
constant K. The above equation doesn’t take care of
temperature term and is best applicable for lower temperature
(say T<500°C) conditions.
For high temperature flows, the model given by S.K.Das2 et al
(Model 2) taken for study is given by
Where ε is the erosion rate, Ke is a constant, x is the silica
content, Ie(x) is the erosion index of ash (function of silica
content), ρm and ρp are the densities of material and particle, V
is the velocity, β is the impact angle and σy is the yield stress.
Yield stress expressed as a function of temperature and reported
by SK Das2 et.al. for different materials are as under.
parameters. The effect of flow related parameters dependent on
velocity of ash particles, angle of impingement, velocity of flue
gas and geometrical features such as pitch to diameter ratios in
case of pressure parts, flow upstream effects in case of ducting /
furnace that affect erosion rate can be captured using the
developed procedure.
APPLICATION TO FLUE GAS DUCTING EROSION
PREDICTION
A typical 210MW boiler site is selected (for data collection &
subsequent validation) in which severe erosion of ducting is
taking place in between Air heater (AH) to inlet of Electrostatic
precipitator (ESP) region. The ducting is initially designed with
severe layout constraints, and multiple 900 bends are
accommodated successively with in very short lengths. It is
known that any 900 bend causes flow to be disturbed severely
alongside causing pressure drop; and flow develops only after
about 60 to 80 times hydraulic diameter distance along the duct.
But in practical situations it is not possible to provide such long
development lengths and hence a compromise is made. The
present erosion prediction analysis is applied for this problem to
predict the zones of severe erosion and a ‘what-if’ analysis is
done to suitably modify the duct such that flow is streamlined
and erosion is reduced. However, it is to be noted that
modifications arrived at of such ‘what-if’ analyses is not generic
but is very specific to the concerned site geometry, flow
conditions and particular erosiveness of the coal-ash in
question.

,
where T is in K.

2
The geometry (plan & elevation) of the regular and proposed
layouts are as in fig 1.
Fig1: Regular layout between Proposed layout between AH to
AH to ESP inlet ESP with modification
There are site constraints like coal mill lying just below the duct
where flow splitting is taking place and as well as service &
support floors located above and below the duct portions.
Erosion of duct walls and baffle vanes is reported frequently
from site, and regular maintenance or replacing of some
portions during annual periodic maintenance has been going on.
RESULTS & DISCUSSION
The velocity contours (m/s) predicted in regular and proposed
ducts are shown in fig 2. The regular ducting has maximum
velocity of 24.3m/s where as for proposed ducting the
maximum velocity is reduced to 19.2 m/s. Erosion is
proportional to velocity magnitude raised to power of 0.88 in
model 1 where as it is 3 in model 2. Hence for high temperature
flows, erosion is likely to be over-predicted. Normally flue gas
ducts are designed for 10-15m/s and air ducts for 15-20m/s of
average velocity.
Fig2: Regular layout – Velocity Proposed layout with
contours modification – Velocity contours
The velocity vectors (m/s) predicted for regular & proposed
ducts are shown in fig 3.
Fig3: Regular layout – Velocity Proposed layout with
vectors modification – Velocity vectors
There are high velocity zones (>18m/s) especially in 90°
portions in regular configuration leading to erosion of guide
vanes and nearby duct walls in that zone. This has been avoided
in proposed ducting. There are recirculation zones and zones of
low velocity in regular configuration as shown in fig 4, which
are significantly absent or subdued in the proposed
configuration.
Fig4: Regular layout – Velocity vectors showing
recirculation zones
The pressure contours (pascal) predicted in regular and
proposed ducts are shown in fig 5. The outlets are modeled with
constant pressure outlet boundary condition (-1980 pascal) in
both cases. The pressure drop predicted in regular
configuration is 44.22 mmwc where as it is 13.58 mmwc in
proposed configuration, reducing by 69%. The main source of
pressure drop was successive sharp 900 bends in regular
configuration.
Fig5: Regular layout – Pressure Proposed layout with modification –
contours Pressure contours
DP=44.33mmwc DP=13.58mmwc
The erosion contours predicted by Model 1 for regular and
proposed duct configurations is presented in fig 6. The value of
3
E* is predicted by CFD and the multiplication of constant K Proposed 132.63 62.24 -6.14 70.39 +6.14
which is a function of ash and metal properties is to be used layout
with site data. The surface integral of erosion of walls is taken
for the comparison between both models. The CFD predicted The comparison of static pressures in each of the legs of AH to
integral value is 0.014 kg/(m2-s)-m2 for regular and 0.0185 ESP system is shown in table 2. The pressure drop reduced
kg/(m2-s)-m2 for proposed configuration. from 44.22mmwc to 13.58 mmwc in between AH to ESP inlet,
a reduction by 70% due to optimization.
The erosion contours predicted by Model 2 (SK Das et al) for
regular and proposed duct configurations are presented in fig 7. Table 2 Static pressure (pascal) Pressure drop
The value of E’ is predicted by CFD and multiplication with (mmwc)
constant K’ which is function of ash and metal properties is to Description Inlet Out A Out B Leg A Leg B
be used with site data. Since the model takes care the effect of Regular -1546.24 -1980 -1980 44.22 44.22
temperature in its equation, the erosion contour is more layout
localised compounded with velocity effect. The surface integral Proposed -1846.8 -1980 -1980 13.58 13.58
of erosion of walls is taken for the comparison between both layout
models. The CFD predicted integral value is 3585 kg/(m2-s)-
m2 for regular and 523 kg/(m2-s)-m2 for proposed Some photographs taken during site visits of the AH to ESP
configuration, 85% reduction compared to base case. eroded portions are shown below (fig 8). A good one-to-one
Interpretation of contours by location is to be done qualitatively corroboration could be seen with CFD predictions (refer fig 6 &
only, as the values of parameters in constant K and K’ are not 7) thereby increasing the confidence level with which the
taken into consideration in this study. modeling procedure can be utilized to predict actual erosion of
ducting.
Fig6: Regular layout – Proposed layout with
Model 1 -Erosion contours modification – Model 1- CONCLUSIONS
Erosion contours
The erosion will be higher wherever there is high velocities at
localized spots, and ash deposition occurs where there is low
velocities, or in combination with recirculation zones. With the
new method of applying erosion modeling, we can see the
erosion contours of the zones predicted to be affected with high
erosion. Predominantly erosion is function of velocity of ash
Erosion integral 0.014(kg/m2-s)m2 Erosion integral 0.0185 (kg/m2-s)m2
Fig8: Photographs taken at site depicting erosion of ducting
Fig7: Regular layout –Model Proposed layout with
2 - Erosion contours modification – Model 2 -
Erosion contours

Erosion integral 3585 (kg/m2-s)m2 Erosion integral 523 (kg/m2-s)m2

The comparison of mass flow rates in each of the legs of AH to

ESP system is shown in table 1. The deviation in flow compared
to ideal flow rate of equal halves is reduced from 9% to 6%
after optimization.

Table 1 Mass flow rates (kg/s)

Description Inlet Out A % Out B %
Deviation Deviation
Regular 132.63 60.1 -9.37 72.53 +9.37
layout

4
particles and the angle of impingement. It is suggested that the
layout should be optimal, with more flow uniformity, and with
minimum zones of high or low velocity regions, for avoiding
erosion of ducting. In such cases the resultant erosion will be
more uniformly spread out, prolonging the usable life of
components before premature failure. The said prediction
model is used to predict zones of higher erosion or higher
erosion-vulnerability zones, which can be designed with
suitably higher thicker plates or additional fortification.

ACKNOWLEDGMENTS

The authors express their sincere thanks to BHEL

management for giving permission to publish paper and for
presenting it at 2nd National Conference on CFD applications in
power and industry sectors, BHEL Corp R&D, Hyderabad.

REFERENCES

1. R Nagarajan, Sreenivas Jayanti, “Development of

Predictive Model for Fly-Ash Erosion Phenomena in Coal-
Burning Boilers”, an RBIC project between IITM &
BHEL, 2007.
2. S K Das, K M Godiwalla, S P Mehrotra, K K M Sastry and
P K Dey, “Analytical model for erosion behavior of
impacted fly-ash Particles on coal-fired boiler
components”, S¯ adhan¯ a Vol. 31, Part 5, October 2006,
pp. 583–595.
3. Finnie. I, Erosion of surfaces by solid particles”, Wear
3(1960), pp 87-103.
4. J.G.Mbabazi, T.J.Sheer, “Computational prediction of
erosion of air heater elements by fly ash particles”, Wear
261 (2006), pp 1322-1336.

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