www.psl.bc.

ca
Recovery Boiler
Modeling
Process Simulation Ltd.
www.psl.bc.ca
Develop modeling tools to
improve existing designs
and operating procedures,
and to lower carry over
and environmental impact
Analyse performance of
different air systems and
liquor firing strategies
Objectives
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Introduction
Process and equipment design
was, until recently, based on
experience
Advances in numerical methods
and computer speed and
memory
increased possibility of using
more scientific methods,
called mathematical
modeling, for process design
and optimization
Computing Hardware Trends
0.1
1
10
100
1000
10000
1980 1985 1990 1995 2000
Memory
(MB)
0.1
1
10
100
1000
Speed
(MIPS)
Memory
Speed
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Mathematical Modeling Applications
in Other Industries
Computer
Jet engines
Weather
Automotive
Harrier jet
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Equipment Modeling Capabilities:
Mature Developing Preliminary
Time
Bark Boiler
BFB Bark Boiler
Hydrocyclone
Head box
Digester
Lime kiln
Gasifier
Recovery Boiler
We have active projects on this equipment
>30 6 4 1 1
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Client List
Weyerhaeuser USA
Weyerhaeuser Canada
Canfor
Kvaerner
Scott Paper
Anthony Ross
Weldwood
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Why Use Modeling?
Recovery Boiler environment is too severe for
measurement
The model provides comprehensive information
throughout the entire boiler at relatively low cost
Can evaluate what if scenarios to improve
operation/design
Supplements steam chief and operator knowledge
of recovery boiler operations
Assists mill managers in making informed decisions
regarding boiler refits/replacements
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Details of the Recovery Boiler Model
Liquor Combustion Model
Advanced and verified solution algorithm
Black liquor combustion model
Drying
Pyrolysis CO, CO
2
, CH
4
, H
2
, H
2
O
Char gasification
Gas phase combustion model
Advanced radiation model
Convective section model
Char bed model
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Issues Addressed by the Model
High excess air
CO, CO
2
, and other emissions
Mechanical carryover & plugging
Bed blackouts
Superheater and waterwall tube thermal
stress failures
Boiler stability and capacity


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Input Data Required
Boiler geometry
Bed shape
Convective section layout
Air temperature and flow rate at each port
Liquor characteristics
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Model Predictions
Gas species (e.g. H
2
,O
2
,N
2
,CO,CO
2
,H
2
O,CH
4
)
distributions
Gas flow velocity fields
Temperature distributions and heat transfer
to wall surfaces
Liquor spray combustion and droplet
trajectories.
Carryover characteristics
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Model Validation
Water Model Measurements
Full Scale Measurements
Isothermal flow validation
Hot flow validation
Temperature measurements at bullnose
Carryover prediction trends
CO emission trends
Velocity measurements
CE Boiler Model
B&W Boiler Model
Different aspects of model results
have been validated against data
from operating boilers
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Recovery Boiler Refit Example
High plugging rates
High gas temperature
at superheater
Bed growth control
The Issue:
The Objective:
To recommend modifications to
air system
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Tertiary Air Ports (20%)
Secondary Air Ports (30%)
Primary Air Ports (50%)
Base Case Modified Air System
Test Case Geometries
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Secondary Air System Problem and Solution
Jets collide
Carryover
Core forms
Secondary
jets
Liquor guns
Jets Interlace
Uniform flow
Secondary
jets
Base Case
Modified Air System
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Primary
V = 30 m/s
50% Air
T = 423 K
M = 46 kg/s
z = 1.2 m
Liquor Guns
HV=15000 kJ/kg
T = 400 K
M = 18 kg/s
z = 7 m
Base
Case
Secondary
V = 85 m/s
30% Air
T = 423 K
M = 27.6 kg/s
z = 3 m
Tertiary
20% Air
V = 50 m/s
T = 423 K
M = 18.4 kg/s
z = 10 m
Modified
Air
System
Tertiary
20% Air
V = 50 m/s
T = 423 K
M = 18.4 kg/s
z = 10 m
Secondary
V = 85 m/s
30% Air
T = 423 K
M = 27.6 kg/s
z = 3 m
Common
Air/Liquor
System
Data in
Plan View
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1600
1500
1400
1300
1200
1100
1000
900
800
700
600
T[K]
Base Case
1600
1500
1400
1300
1200
1100
1000
900
800
700
600
T[K]
Modified Air System
Temperature Profiles
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Velocity Profiles
16
14
12
10
8
6
4
2
0
-2
-4
20m/s
Upward
velocity
W [m/s]
Base Case
16
14
12
10
8
6
4
2
0
-2
-4
20m/s
Upward
velocity
W [m/s]
Modified Air System
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X
Y
Z
X
Y
Z
---- drying
---- pyrolysis
---- char
---- smelt
Fuel Particle Trajectories
Base Case
Modified Air System
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Y
Z
X
200
160
140
120
100
80
60
40
20
5
0
Modified Air System
Total Carryover
at Superheater
0.03%
Carryover
mass flux
[g/s/m
2
]
Y
Z
X
200
160
140
120
100
80
60
40
20
5
0
Carryover
mass flux
[g/s/m
2
]
Base Case
Total Carryover
at Superheater
4.06%
Carryover Mass Flux
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0
2
4
6
8
10
12
14
16
18
20
Base Case
Modified Air System
Water Smelt Pyro. Char
Wall
0
5
10
15
20
25
30
Water Smelt Pyro. Char
InFlight
0
1
2
3
4
5
Water Smelt Pyro. Char
Carryover
0
3
6
9
12
15
Water Smelt Pyro. Char
Bed
Black Liquor Particulate Distribution
(% of total liquor input)
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X
Y
Z
O2
0.16
0.14
0.12
0.1
0.08
0.07
0.06
0.05
0.04
0.02
X
Y
Z
O2
0.16
0.14
0.12
0.1
0.08
0.07
0.06
0.05
0.04
0.02
Oxygen Concentration Distribution
Base Case
Modified Air System
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X
Y
Z
CO
0.1
0.05
0.01
0.005
0.003
0.001
0.0005
0.0001
5E-05
X
Y
Z
CO
0.1
0.05
0.01
0.005
0.003
0.001
0.0005
0.0001
5E-05
Carbon Monoxide Concentration Distribution
Base Case
Modified Air System
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Conclusions
The modified air system:
Larger air ports provides better jet penetration.
Increases gas mixing
Breaks up the vertical air core
Significantly reduces plugging rates.
Reduces gas temperatures at superheater
In general, modeling:
Provides detailed data to facilitate efficient
operation of Recovery Boilers.
Helps mill managers make informed decisions
regarding boiler refits/replacements