12

10
APPLICATION OF CFD & FEA FOR EFFICIENCY
IMPROVEMENT IN ENERGY SECTOR
8

Column 1
6
Column 2
Column 3

“We thrive to succeed as the most trusted

0
organization
Row 1 in
Row 2providing Row
and3 managing
Row 4 the

technologies worldwide...”
AGENDA
1 General Introduction
Vision & Mission

Core values

2 Computational Fluid Dynamics

Introduction

Applications

3 CFD In Energy Sector

Application of CFD For APH

Application of CFD For Boiler

Application of CFD For ESP

CFD & Digital Twinning

4 Finite Element Analysis

Introduction

Application Of FEA For APH

Application Of FEA For ESP

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 2/55

General Introduction

VISION
To be widely recognized as the
premier, global provider of Enterprise
Solutions

MISSION
To add value by improving business
processes through better use of
modern technology. We accomplish
this mission with a team of motivated
and experienced professionals with
excellent technical capabilities

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 3/55

Core Values

Teamwork Core component for our success performance

Innovation Drives our organizational growth

Commitment Committed to prompt and professional service

Confidentiality Stringent data security policies make our customers feel secu

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 4/55

Computational Fluid
Dynamics
Introduction

Computational Fluid
Dynamics (CFD)


Computer based numerical
modeling technique


Solves flow physics &
associated phenomenon


Cost effective design
optimization


Improve efficiency & reliability


Reduce lead time & cost

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 5/55

CFD – Work Flow
1 Geometry Preparation

2 Simulation / Run

3 Post – Processing / Results

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 6/55

Applications
AEROSPACE HVAC
WING BLADE ANALYSIS THERMAL COMFORT
EXT. AERODYNAMICS NATURAL AND
AERO-THERMODYNAMICS FORCED CONVECTION
LIFT, DRAG & MOMENT CLEAN ROOM
CABIN VENTILATION BUILDING SERVICES

ELECTRONICS
TURBOMACHINERY
CONJUGATE HEAT TRANSFER
POWER SECTOR FAN PERFORMANCE
PROCESS / CHEMICAL ELECTRONIC PACKAGING
DUCT OPTIMIZATION FAN CURVE OPERATING REGION
PARTICLE MIXING U/L, IEEE, NEMA STANDARDS
BURNER FLAME VISUALIZATION BLADE PROFILE DESIGN
FILTERS AND SEPARATOR FORCED CONVECTION
BOILER SIMULATION FLUID SOLID INTERACTION
DISCRETE ELEMENT MODELING BATTERY SIMULATION
EROSION / CORROSION
MULTIPHASE
MULTIPHASE / DEM

AUTOMOBILE
URBAN PLANNING
EXTERNAL AERODYNAMICS
WIND RESOURCE PLANNING
DRAG REDUCTION
NATURAL VENTILATION
IC ENGINE COMBUSTION
WIND FARMING
CATALYTIC REDUCTION
NATURAL HEATING
ACOUSTICS

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 7/55

Energy Sector
CFD in power plant industry

Cost effective design

optimization of


Ducts Clean Gas


Combustion systems BOILER EMS
Screen

Boilers & Accessories LTSH
ECO. Windbo
ESP

Air Pre-Heater (APH) Duct ESP-Inlet
Duct
x


ElectroStatic Precipitator (ESP) Deflector
Hone plate
Ash
ID Fan y

HVAC systems & components Hoppers
comb Coal
Mill
F.D Fan P.A. Fan

Fans

Coal Conveyor

Pulverizers

Mixers & Separators

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 8/55

Energy Sector

Applications of
CFD in Air PreHeater Design

SURFACE HEAT
FLOW
REACTION TRANSFER
Thermal
Pressure Drop
Phenomenon

Particle Settling Deposit

Formation
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 9/55
Air Pre-Heater
Duct optimization
Secondary Air Flue Gas
Duct Duct


Better flow distribution


Pressure drop reduction
Flue Gas
Duct

Reduce auxiliary power
consumption


Improve equipments/process Tempering
thermal characteristics Air Duct

Primary Air
Secondary Air Inlet Duct

Optimize insulation thickness Inlet Duct

Primary Air
Duct Mill Ducts

Ducting system of typical 500 MW coal fired power pla

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 10/55

Air Pre-Heater
Duct optimization
Tempering air
mixes with the
main hot air &

Detailed study of- flow to the coal
mills.

Air/fuel & flue gas
temperature


Better thermal distribution


Increase thermal efficiency


Optimize insulation thickness

Primary air duct – Temperature profile

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 11/55

Air Pre-Heater
Duct optimization - For Gas Side
FROM ECONOMIZER O/L To APH I/L

TO AIR PRE-HEATERS

ASH HOPPERS
FLUE GAS INLET
DUCT

CENTER
SECTION

TRANSITION
PIECE

Reduction in High Velocity zones at outer periphery.
AIR PRE-HEATER 
Improved flow distribution across APH Inlet section
Base Design Optimized Design

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 12/55

Air Pre-Heater
Duct optimization – Gas Side Benefits

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 13/55

Air Pre-Heater
Duct optimization - For Air Side
PRIMARY AIR SIDE SECONDARY AIR SIDE

Pressure Distribution in
Cold & Hot PA System
with Tempering Air

PA SA SA PA

APH B APH A

Thermal Distribution of Hot PA

System with Tempering Air FLUE GAS FLUE GAS

Reduction in Base Design

High Velocity
zone at outer
periphery
PA SA SA PA

APH B APH A

FLUE GAS FLUE GAS

Optimized Design

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 14/55

Air Pre-Heater
Duct Optimization Benefits


Effective Utilization of APH
HE’s


Reduce erosion-Outborad HE’s


Pressure Drop savings


Improved heat transfer
characteristics


Enhanced performance &
efficiency

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 15/55

Air Pre-Heater
APH-Heating Element Analysis-Flow + Heat Transfer
DU VAR1 PROFILE FNC PROFILE


Gas flow pattern through heating elements


Optimization of heating elements


Better heat transfer characteristics
Unsteady Heat Transfer Study of APH Heating Elements.
DU VAR1 PROFILE
Temperature Plot.
Effective waste heat recovery
DU VAR1 PROFILE



Increase combustion efficiency


Increase boiler efficiency Time
Step:0.2
FNC PROFILE
Time
Step:20 s
FNC PROFILE

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 16/55

Air Pre-Heater
APH-Heating Element
Analysis
Ash Particle Deposition Soot Blowing

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 17/55

Energy Sector

Applications of
CFD in Boiler

HEAT
FLOW COMBUSTION TRANSFER
Thermal
Pressure Drop
Phenomenon

Gas Distribution Reaction &

Chemical Kinetics
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 18/55
Boiler
Cold Air Velocity Test using
CFD


Optimize gas & pressure part heat
transfer


Locate erosion prone zones


Detailed study of -

Flow pattern

Velocity pattern


Reduce erosion
-(superheater & economiser tubes etc,.)

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 19/55

 Boiler
Base Optimized
FURNACE

FURNACE
CHIMNEY

CHIMNEY
High velocity zones Reduction in high velocity
observed in the rear zones observed at the
arch panel RHS side rear arch panel RHS side

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 20/55

Boiler
0° Tilt -25° Tilt +25° Tilt

FURNACE FURNACE FURNACE

High velocity at the rear

arch panel observed at
+25° burner tilt

CHIMNEY CHIMNEY CHIMNEY

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 21/55

 Boiler
Base Optimized

FURNACE FURNACE
RHS

RHS
LHS

LHS
CHIMNEY CHIMNEY

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 22/55

Boiler
CFBC Boiler- Fluidization

Bubbling
bed
phenomen
on and
resulting
particle
motion
tracking
Recovery Boiler- Flow

Flow modeling of
air port systems
w.r.t to different
port
configuration

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 23/55

Boiler
Windbox analysis using CFD


Optimize primary & secondary
air requirements


Detailed study of-

Velocity distribution

Flow rate

Pressure


Optimize windbox design


Increase combustion efficiency


Reduce pollution
Velocity Streamlines through Velocity Vectors through
Primary air duct Secondary air duct

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 24/55

Boiler
Combustion analysis using
CFD


Air/fuel mixing phenomenon


Optimize air/fuel requirements


Increase combustion efficiency


Temperature distribution
pattern


Fire ball location


Emission prediction & control


Optimize burners & nozzles

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 25/55

Boiler
Pulverised coal combustion
for boilers


Assess physical, chemical &
thermal processes


Detailed study of-

Coal combustion

Furnace-wall heat transfer


Optimize burner geometry &
position


Improve combustion efficiency


Predict & Reduce pollution

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 26/55

Boiler
LIQUID & GASEOUS FUEL COMBUSTION
Temperature Products
Mass Fraction
StaticFraction
Mass Temprature From
of CO2 Burner
From Tip Tipof CO
Burner
2500
0.14
MassTemperature
Static Fraction Of CO2 (High_Fuel_Velocity)
(in °C)_High_Fuel_Velocity
Static
MassTemperature
Fraction Of CO2
(in °C)_Low_Fuel_Velocity
(Low_Fuel_Velocity)
0.12
Oil Burner 2000

C)CO2
0.1

Mass Fraction(ºof
Temperature
1500
0.08

Mass Fraction of O 2
0.06
1000

0.04

500
0.02

00
5.5
5.5 55 4.5
4.5 44 3.5
3.5 3 2.5 2 1.5 1 0.5
0.5 00
Position
Position from
from Burner
BurnerTip
Tip (m)
(m)

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 27/55

Boiler
Radiative Heat Transfer Analysis of Boiler First Pass
Temperature

_a
ne

_b
zo

ne
zo

_c
ne
zo

_d
ne

_e
zo

ne
zo
Vel_0. Vel_10
5

Vel_
5

Temperature (K)

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 28/55

Boiler
Heat Exchanger Analysis


Better heat transfer
characteristics


Detailed performance
assessment


Design optimization of heat
transfer elements


Effective heat transfer process


Flow visualization


Increase component life cycle

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 29/55

Boiler
Fan Analysis


Detailed flow pattern analysis.


Design optimization


Desired pressure and flow rate


Effective flow distribution &
heat transfer


Reduce auxiliary power
consumption


Increase plant efficiency

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 30/55

Boiler
Fan Analysis
Flow Induced Vibration Impeller Resizing

FD Fan Outlet To APH Inlet Duct Size reduction of ID Fan Impeller-

Vibration Centrifugal Fan with Aerofoil Type Blade

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 31/55

Boiler
Pulverizers-Bowl Mill Flow
Analysis


Coal particle distribution and
flow pattern assessment


Optimization of components-
vane wheel, classifiers and
etc,.


Detailed study on the Impact of
air flow on coal particles


Enhance flow distribution &
coal feed to furnace


Design modifications &
Performance enhancement
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 32/55
Coal Conveyor
Conveyor Dust Control
Analysis


Identify flow induced causes
for coal dust formation


Optimization of chutes and
coal dust arresters


Erosion prevention in coal
conveying systems


Minimize coal loss through dust
formation


Reduce air pollution


Increase coal utilization factor
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 33/55
Energy Sector

Applications of
CFD in ESP

ELECTRO HEAT
FLOW HYDRO TRANSFER
DYNAMICS Thermal
Pressure Drop
Phenomenon

Gas Distribution Charged Particle

Motion
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 34/55
ElectroStatic
Precipitator
ESP- Flow analysis


Field flow uniformity


Field pressure distribution


Increase collecting efficiency


Optimized designs to,

Improve performance

Reduce pollution

Lesser downtime
Higher
Higher turbulence to velocities
the flow due to the arise after the
obstruction created screen due to
by the screen the reduction
in flow area
Scree
n Scree
n

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 35/55

ElectroStatic
Precipitator
ESP- Flow analysis


Field flow uniformity


Field pressure distribution


Increase collecting efficiency


Optimized designs to,

Improve performance

Reduce pollution

Lesser downtime

GD Screen and Plate Arrangement

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 36/55
ElectroStatic
Precipitator
Duct Flow Optimization For ESP
Inlet Ducts
Major Problems

Uneven Flow Distribution in Connecting Ducts

Higher Pressure Drop

Erosion

Ash Deposition

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 37/55

ElectroStatic
Precipitator
Duct Flow Optimization For
ESP-Benefits


Enhanced flow distribution


Detailed analysis of flow pattern
VELOCITY (m/s)

Detailed study of-

Velocity Coefficient of Variance – Comparison
25

Density EXISTING DESIGN OPTIMIZED DESIGN

20
Temperature
Coefficient of Variance (CoV)

16.68 17.22
14.21

Viscosity 15 13.58

10

Reduce erosion & Ash Deposition
5

Pressure Drop Savings
0
ESP-A PASS ESP-B PASS

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 38/55

Other Applications
Pumps

Valves
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 39/55
APPLICATIONS OF FEA IN
POWER PLANTS

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

Air PreHeater
APH-Thermo Mechanical Stress of Diaphragm
Plate Thermal Boundary Conditions
APH - CAD Model
The average metal temperature is applied on
each diaphragm plate, located at the
corresponding Flue gas, PA & SA Side.

Primary Air Side

Flue Gas Side

Secondary Air Side

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

Air PreHeater
APH - FEA Results
Temperature Distribution on Diaphragm Plates & Rotor Post

Displacement Result for one

Sector

Diaphragm Rotor Post

Plate

Temperature Distribution (K)

Displacement in X-Axis (mm)

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

Air PreHeater
APH – Bearing Housing FEA
1420 mm
APH Bearing Housing and Its Loadings 1280 mm

1792 mm

Axial Load = 400 Tons

1420 mm
1280 mm

CAD Model

1790 mm

Radial Load = 40 Tons

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

Air PreHeater
Bearing Housing - FEA Results
Displacement Plot Stress Plot

Induced Stress is
maximum at bolt
holes

Displacement in Y-Axis (mm) Von-mises Stress (MPa)

Stress Induced 56.4 MPa

Housing Seating area displacement is Yield Strength 240 MPa

with in the limit
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR
Air PreHeater
APH – Center Section FEA

Hot End Center Section

General Arrangement of Center Section

LOADS APPLIED
1. Gravity
2. Clamping
3. Flue Gas & Air Pressure
4. Flue Gas & Air Temperature
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR
Air PreHeater
Center Section - FEA Results

Displacement Plot Stress Plot

Displacement in Y-Axis (mm) Von-mises Stress (MPa)

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

Air PreHeater
APH –Radial Seals FEA
Development of New Radial Seal Arrangement using FEA

Side Support Guide Angle

Seals
Seal Stiffener
In-board Diaphragm Plate Out-board

Isometric View - Front

Middle Flat Bars

Out-board In-board

Isometric View - Back

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR
Air PreHeater
Existing Radial seals Leakage Area Predicted by FEA
8

7
RUBBING
NO-CONTACT

6
Turn Down (mm)

Old Seal Deflection Sector Plate

1
Sector Plate Position Leakage Area

0
0 500 1000 1500 2000 2500 3000 3500
Length of Diaphragm Plate (mm)

Inboard Gap Outboard Gap Leakage Area

(mm) (mm) (mm2)

0.5 0 1200

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

Air PreHeater
8
Existing Radial Seals Vs New Radial Seals

6
Turn Down (mm)

New Seal Deflection Sector Plate

2
Sector Plate Position Saved Leakage Area
1
Diaphragm Plate Position

0
0 500 1000 1500 2000 2500 3000 3500
Length of Diaphragm Plate (mm)

Inboard Outboard Leakage Radial Other Total

Gap Gap Area Leakage Leakage Leakage
(mm) (mm) (mm2) (%) (%) (%)

Existing Seal 0.5 0 1200 2.0 % 6.0 % 8.0 %

New Seal 0.5 0.5 600 1.0% 6.0 % 7.0 %
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR
ElectroStatic
Precipitator
ESP – Structural FEA

Electrostatic Precipitator CAD Model

LOADS APPLIED
1. Gravity
2. Monorail Weight
3. Collecting Electrode Weight
4. Emitting Electrode Weight
5. ESP Pressure
6. Ash Load
7. Wind Load
8. Seismic Load

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

ElectroStatic
Precipitator
Support Insulator - FEA Results
Displacement Plot Stress Plot

Von-mises
Displacement Stress (MPa)
in Z-Axis
(mm)

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

ElectroStatic
Precipitator
ESP – Support Insulator FEA
Support Insulator CAD Model

CONICAL SUPPORT CYLINDRICAL

INSULATOR SUPPORT INSULATOR

Compressive Force = 4500 N

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

ElectroStatic
Precipitator
Support Insulator - FEA Results
12

10
Von-Mises Stress (MPa)

0
0 5 10 15 20 25 30 35

Von-Mises Stress Comparison between Conical & Cylindrical Sections

The stress values (Von-Mises) predicted using FEA is almost similar for both conical and
cylindrical shaped support insulator.
Thus we can use cylindrical shaped support insulator instead of conical shaped
support insulator

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR

Customers

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 54/55

 THANK YOU

APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 55/55