Design Analysis of Furnace Of A Steam

Generator

P M V Subbarao
Professor
Mechanical Engineering Department

Perfection of Primary Cause for All that

Continues…..
 Basic Anatomy of A SG

Convection Pass
Transfer only

Furnace

Creation, Generation & Transfer of

Thermal Energy
 Details of Basic Processes

• Flow of Air and Prepared Fuel

– Fluid Dynamics.
• Generation of Thermal Energy – Using Natural Resources.
– Combustion Sciences.
• Transfer of Thermal Energy to working fluid.
– Science of Heat Transfer.
 Aerodynamics Dynamics of Stationary Flame
• Along local Normal to Flame Surface:
• Burning Velocity > Flow Velocity : Flash Back Limit
• Burning Velocity < flow Velocity : Blow Off Limit
• Burning Velocity = Flow Velocity : Stable Flame.

i ng
u rn city
B lo
Ve
Air

Fuel Flow velocity

 Stability & Flammability Limits

Rich Mixture
Fuel Flow rate

Flash Back Stable Flame Blow off

Lean Mixture

Air Flow rate

 Burning Velocity & Residence Time
• Quality of Fuel & Fuel Chemistry.
• Air-fuel ratio
• Turbulence level

• Time to be spent by fuel particle in the furnace before it burns

completely.
• Residence time is inversely proportional to burning velocity.
• Fuel particle is continuously moving.
• The distance traveled by the fuel particle should be much larger than
furnace height.
• Swirl motion will ensure the required residence time.
• Internally generated swirl : Swirl Burners.
• Externally generated swirl: Direct Burners.
 Basics of Coal Combustion: Burning Time

Coal is a complex organic polymer consisting of large polycyclic

aromatic clusters of several fused rings strung together by assorted
hydrocarbon chains of varying lengths and other hetroatom (O, N,
S) linkages.
Phases of Coal Particle Combustion
 Phases of Combustion
• The first phase is associated with moisture evolution and
occurs at very low temperatures at about 373 K.
• The second phase at a heating rate of 1273 K/sec begins at
about 723 K.
• This is associated with a large initial evolution of carbon
dioxide and a small amount of tar.
• The third phase involves evolution of water chemically
formed in the range 773-973K and carbon dioxide as the
other significant product.
• The fourth phase involves a final rapid evolution of
carbon-containing species such as carbon oxides, tar,
hydrogen, and hydrocarbon gases in the temperature range
973-1173 K.
• The fifth phase is the high temperature formation of
carbon oxides.
Second Phase of Coal Combustion
Final Phase of Coal COmbustion
Modelling of Coal Cloud Combustion
 Typical Flame Speed of PC.

30%VM & 5 % Ash

Flame speed m/s

30%VM & 15 % Ash

30%VM & 30 % Ash

30%VM & 40 % Ash

A/F ratio
 Typical Flame Speed of PC.

30%VM & 5 % Ash

Flame speed m/s

20%VM & 5 % Ash

15%VM & 5 % Ash

A/F ratio
 Heat available for Radiation

 
     
Q fu  m c LHV  Q CO  Q C  Q slag  Q ai  A fl eff T fl4  Twa4


• Q CO Incomplete combustion loss

• QC Unburned Carbon loss


• Q slag Loss due to slag

• Q ai Energy brought in by preheated air & fuel.
 Combustion Limits on Furnace Design

• The lower limit of the furnace volume is

• dominated by the space required for burning the fuel completely, or
• to an extent less than the allowable unburned fuel loss.
• To complete the fuel combustion within the furnace space, the fuel
injected into the furnace has to reside there for a certain time longer
than some critical time t*r.
• The fuel residence time can be estimated by the residence time of the
combustion gas produced in the furnace.
• An average residence time tr can be proposed.

Fuel energy entering the furnace

tr 
Volume of the furnace  Max. Allowable rate of heat generation per unit volume

mc LHV
tr 
Vqv
 Intensity of Heat Release
Combustion Factor Macro Micro Particles
Particles
A volumetric combustion intensity, Iv (kW/m3) 250 – 750 1500 – 2500
Area Combustion Intensity, IA (kW/m2) 300 – 1800 Up to 7500
Coal Firing Density Jf,V ( kg/m3.hr) 30 – 100 1500 – 3000
Area Firing Density, Jf,A (kg/m2.hr) 40 – 250 Up to 1000
Air Velocity (m/sec) Up to 0.5 Up to 20
Exhaust Gas Velocity (m/sec) Up to 3 Up to 20
Combustion time (sec) Up to 5000 ~1
Particle Heating Rate (0C/sec) <1 10000
Heat Transfer Coefficients (W/m2 K) ~10 50 – 500
Heat Fluxes to Heat exchange (kW/m2) ~ 10 50 – 500
 mass of gas generated
V
density of gas.

mc LHV
tr 
 mg 
  qv
 
 g 

 g LHV
tr 
 mg 

m 
 qv
 c 
 g LHV
tr 
  A 
     1 qv
 F 
• Fuel combustion time is mainly dominated by the combustion reaction
velocity and the rate at which oxygen is supplied into the reaction
zone.
• The combustion reaction velocity depends on chemical characteristics
of the fuel.
• Main technical factors that affect the combustion time are:
• Combustion characteristics of the fuel.
• Mixing characteristics.
• Fluid flow characteristics of the furnace.
• The combustion time of an oil fuel droplet is generally less than 0.1
msec.
• In the case of coal combustion time is much longer.
 Design Constrains:Heat Release Rate

• Heat Release Rate per Unit Volume, qv, kW/m3

• Heat Release Rate per Unit Cross Sectional Area,qa,
kW/m2
• Heat Release Rate per Unit Wall Area of the Burner
Region, qb, kW/m2
• The maximum allowable heat flux of the water wall is
restricted by its water-side burnout (dryout) heat flux.
 Heat available to the furnace
     
Q fu  m c LHV  Q CO  Q C  Q slag  Q ai


• Q CO Incomplete combustion loss

• QC Unburned Carbon loss

• Q slag Loss due to slag

• Q ai Energy brought in by preheated air & fuel.

• A part of this total heat should be absorbed in furnace.

• The designer should provide an environment for the same.