1415 1515 CFD Fea For Efficiency Improvement in Energy Sector by Saravanakumar K

12
APPLICATION OF CFD & FEA FOR EFFICIENCY

10
8 IMPROVMENT IN ENERGY SECTOR

Column 1
6
Column 2
Column 3
“0 We thrive
Row 1
to succeed as
Row 2
the most trusted
Row 3
organizationRowin
4
providing
and managing 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 & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR 2/49
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
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 secure
Computational Fluid Dynamics
Introduction
Computational Fluid Dynamics (CFD)

Computer based numerical modeling technique

Solves flow physics & associated phenomenon

1D (System level), 2D & 3D-Component Level

Cost effective design optimization

Improve efficiency & reliability

Reduce lead time & cost
CFD – Work Flow
1 Geometry Preparation
2 Simulation / Run
3 Post – Processing / Results
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
CONJUGATE HEAT TRANSFER TURBOMACHINERY
ELECTRONIC PACKAGING FAN PERFORMANCE
PROCESS / CHEMICAL POWER SECTOR FAN CURVE OPERATING REGION
PARTICLE MIXING U/L, IEEE, NEMA STANDARDS
DUCT OPTIMIZATION BLADE PROFILE DESIGN
FILTERS AND SEPARATOR FORCED CONVECTION
BURNER FLAME VISUALIZATION FLUID SOLID INTERACTION
DISCRETE ELEMENT MODELING BATTERY SIMULATION
BOILER SIMULATION
MULTIPHASE EROSION / CORROSION
MULTIPHASE / DEM
AUTOMOBILE
EXTERNAL AERODYNAMICS URBAN PLANNING
DRAG REDUCTION WIND RESOURCE PLANNING
IC ENGINE COMBUSTION NATURAL VENTILATION
CATALYTIC REDUCTION WIND FARMING
ACOUSTICS NATURAL HEATING
Energy Sector
CFD in power plant industry
Cost effective design optimization of


Ducts
Combustion systems
Clean Gas

Boilers & Accessories

BOILER EMS Screen

LTSH
ECO. Windbox
Air Pre-Heater (APH)
ESP
 Duct ESP-Inlet
Duct

ElectroStatic Precipitator (ESP) ID Fan
Ash
Hoppers
Honey Deflector
comb
plate
Coal Mill

HVAC systems & components F.D Fan P.A. Fan

Fans

Coal Conveyor & Pulverizers

Mixers & Separators
Air Preheater
Application of
CFD in Air PreHeater Design
SURFACE HEAT
FLOW
REACTION Thermal TRANSFER
Pressure Drop Phenomenon
Particle Settling Deposit
Formation
Air Preheater
Duct optimization Secondary Air Duct Flue Gas Duct

Better flow distribution
Flue Gas

Pressure drop reduction Duct

Reduce auxiliary power consumption
Tempering Air
Duct

Improve equipments/process thermal Secondary Air Primary Air Inlet
Inlet Duct
characteristics
Duct
Primary Air
Duct Mill Ducts

Optimize insulation thickness Ducting system of typical 500 MW coal fired power plant
Air Preheater
Duct optimization
Tempering air mixes
with the main hot air
& flow to the coal
mills.

Detailed study of-

Air/fuel & flue gas temperature

Better thermal distribution

Increase thermal efficiency

Optimize insulation thickness
Primary air duct – Temperature profile
Air Preheater
Duct optimization – Gas Side Benefits
Air Preheater
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
Reduction in High
FLUE GAS FLUE GAS
Thermal
Velocity zone at Base Design
Distribution of
outer periphery
Hot PA System
with Tempering
Air
PA SA SA PA
APH B APH A
FLUE GAS FLUE GAS
Optimized Design
Air Preheater
Eco Outlet
Duct Optimization Benefits

Effective Utilization of APH HEs

Reduce erosion-Outboard HEs
SA E
SI
PA E
SA E
PA E
SI
SI
SI
D
D
D
D

Improved heat transfer characteristics

Enhanced performance & efficiency
RAPH-B Inlet RAPH-A Inlet

Pressure Drop savings Uniform velocity distribution
at RAPH inlet sections
Velocity (m/s)
Air Preheater
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. DU VAR1 PROFILE

Effective waste heat recovery

Increase combustion efficiency Time FNC PROFILE Time FNC PROFILE
Step:0.2 Step:20
s s

Increase boiler efficiency
Boiler
Application of
CFD in Boiler
HEAT
FLOW COMBUSTION TRANSFER
Pressure Drop Thermal
Phenomenon
Gas Distribution Reaction &
Chemical Kinetics
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,.)
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
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
Boiler-Auxiliary
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
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
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
Boiler
Radiative Heat Transfer Analysis of Boiler First Pass
Temperature
Vel_0.5 Vel_10
Vel_5
Temperature (K)
Boiler-Auxiliary
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
Boiler-Auxiliary
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
Boiler-Auxiliary
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

Design modifications & Performance
enhancement
Boiler-Auxiliary
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
Electrostatic Precipitator
Application of
CFD in ESP
ELECTRO HEAT
FLOW HYDRO TRANSFER
Pressure Drop DYNAMICS Thermal
Phenomenon
Gas Distribution Charged Particle
Motion
ESP- Flow analysis

Field flow uniformity

Field pressure distribution

Increase collecting efficiency

Optimized designs to,

Improve performance
Reduce pollution
Higher velocities
 Higher turbulence to the flow arise after the screen
due to the obstruction created due to the reduction
by the screen
in flow area

Lesser downtime Screen Screen
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
Duct Flow Optimization For ESP Inlet Ducts
Major Problems
●
Uneven Flow Distribution in Connecting Ducts
●
Higher Pressure Drop
●
Erosion
●
Ash Deposition
Duct Flow Optimization For ESP-Benefits

Enhanced flow distribution

Detailed analysis of flow pattern

Detailed study of-
Velocity
VELOCITY (m/s)


Density Coefficient of Variance – Comparison
25
EXISTING DESIGN OPTIMIZED DESIGN
Temperature
Coefficient of Variance (CoV)


20
16.68 17.22

Viscosity 15 13.58 14.21
10

Reduce erosion & Ash Deposition 5

Pressure Drop Savings 0
ESP-A PASS ESP-B PASS
CFD & Digital Twinning
Artificial Intelligence in power industry

Simulation + Data Processing + AI

Data driven decision making

Reliable control systems

Efficient palnt operation

Reduce Men & Machine-Interaction

Effective Plant Utilization

Reduce energy & resource wastage
Finite Element Analysis
Finite Element Analysis - A computational program based on numerical methods
Predicts components response when subjected to thermal and structural loads
Verifies design integrity and identifies critical location on a component
2 3
Geometry FEA
Discretization Solver
FEA
3D CAD Process Cycle Optimized
Geometry Design
1 4
APPLICATION OF FEA FOR
APH & ESP
APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

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

Air Preheater
APH - FEA Results
Temperature Distribution on Diaphragm Plates & Rotor Post
Displacement Result for one

Sector
Diaphragm Plate Rotor Post
Temperature Distribution (K)
Displacement in X-Axis (mm)

Air Preheater
APH – Bearing Housing FEA
APH Bearing Housing and Its Loadings 1420 mm
1280 mm
1792 mm
Axial Load = 400 Tons

1420 mm
1280 mm
CAD Model
1790 mm
Radial Load = 40 Tons
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)

Housing Seating area displacement is Stress Induced 56.4 MPa
with in the limit
Yield Strength 240 MPa
Air Preheater
APH – Center Section FEA
Hot End Center Section
LOADS APPLIED
1. Gravity
2. Clamping
3. Flue Gas & Air Pressure
4. Flue Gas & Air Temperature

General Arrangement of Center Section
Air Preheater
Center Section - FEA Results
Displacement in Y-Axis (mm) Von-mises Stress (MPa)

Air Preheater
APH –Radial Seals FEA TALCON SEAL®
Patent Filed
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

Air Preheater
Existing Radial seals Leakage Area Predicted by FEA
8
TALCON SEAL®
7 Patent Filed RUBBING
NO-CONTACT
6
Turn Down (mm)
2
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

Air Preheater
Existing Radial Seals Vs New Radial Seals
TALCON SEAL® 8
Patent Filed 7 TALCON SEAL®

6 Patent Filed
Turn Down (mm) 5
2 New Seal Deflection Sector Plate
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 Gap Outboard Gap Leakage Area Radial Other Leakage Total Leakage
(mm) (mm) (mm2) Leakage (%) (%) (%)
2.0 % 6.0 % 8.0 %

Existing Seal 0.5 0 1200
New Seal 0.5 0.5 600 1.0% 6.0 % 7.0 %

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

Support Insulator - FEA Results
Von-mises
Displacement Stress (MPa)
in Z-Axis
(mm)

ESP – Support Insulator FEA
Support Insulator CAD Model
CONICAL SUPPORT CYLINDRICAL

INSULATOR SUPPORT INSULATOR
Compressive Force = 4500 N

Support Insulator - FEA Results
12
10
Von-Mises Stress (MPa)
8
6
4
CYLINDER
2 CONE
0
0 5 10 15 20 25 30 35
Insulator Thickness (mm)
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

THANK YOU

1415 1515 CFD Fea For Efficiency Improvement in Energy Sector by Saravanakumar K

Uploaded by

Copyright:

Available Formats

1415 1515 CFD Fea For Efficiency Improvement in Energy Sector by Saravanakumar K

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

1415 1515 CFD Fea For Efficiency Improvement in Energy Sector by Saravanakumar K

Uploaded by

Copyright:

Available Formats

12

APPLICATION OF CFD & FEA FOR EFFICIENCY

8 IMPROVMENT IN ENERGY SECTOR

2 Computational Fluid Dynamics

3 CFD In Energy Sector

4 Finite Element Analysis

Innovation Drives our organizational growth

Commitment Committed to prompt and professional service

3 Post – Processing / Results

Cost effective design optimization of

Boilers & Accessories

FLUE GAS FLUE GAS

FURNACE FURNACE FURNACE

CHIMNEY CHIMNEY CHIMNEY

Coefficient of Variance (CoV)

APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

Flue Gas Side Primary Air Side

Secondary Air Side

Displacement Result for one

Diaphragm Plate Rotor Post

Temperature Distribution (K)

Displacement in X-Axis (mm)

APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

Axial Load = 400 Tons

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

Hot End Center Section

3. Flue Gas & Air Pressure

4. Flue Gas & Air Temperature

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

APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

Side Support Guide Angle

Isometric View - Front

Middle Flat Bars

Isometric View - Back

APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

Patent Filed 7 TALCON SEAL®

2 New Seal Deflection Sector Plate

Sector Plate Position Saved Leakage Area

2.0 % 6.0 % 8.0 %

New Seal 0.5 0.5 600 1.0% 6.0 % 7.0 %

APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

CONICAL SUPPORT CYLINDRICAL

Compressive Force = 4500 N

Von-Mises Stress Comparison between Conical & Cylindrical Sections

APPLICATION OF CFD & FEA FOR EFFICIENCY IMPROVMENT IN ENERGY SECTOR

You might also like