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““We thrive to succeed as the most trusted organization in providing We thrive to succeed as the most trusted organization in providing and managing the technologies worldwide...”and managing the technologies worldwide...”
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 2/30
1 General Introduction
Energy Sector
Vision & Mission
3
AGENDA
Duct Flow OptimizationCombustionWindbox
Core values
CAVTElectroStatic Precipitator (ESP)Air Pre-HeaterHeat Exchangers
Computational Fluid Dynamics2IntroductionApplications
FansCoal ConveyorPulverizers
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 3/30
VISIONTo be widely recognized as the premier, global provider of Enterprise Solutions
MISSIONTo 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
General Introduction
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 4/30
Teamwork
Innovation
Commitment
Confidentiality
Core component for our success performance
Drives our organizational growth
Committed to prompt and professional service
Stringent data security policies make our customers feel secure
Core Values
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 5/30
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
Computational Fluid Dynamics
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 6/30
Simulation / Run
Post – Processing / Results
Geometry Preparation1
2
3
CFD – Work Flow
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 7/30
AEROSPACEWING BLADE ANALYSISEXT. AERODYNAMICS
AERO-THERMODYNAMICSLIFT, DRAG & MOMENT
CABIN VENTILATION
HVACTHERMAL COMFORT
NATURAL AND FORCED CONVECTION
CLEAN ROOMBUILDING SERVICES
PROCESS / CHEMICALPARTICLE MIXING
FILTERS AND SEPARATORDISCRETE ELEMENT MODELING
MULTIPHASE
POWER SECTORDUCT OPTIMIZATION
BURNER FLAME VISUALIZATIONBOILER SIMULATION
EROSION / CORROSIONMULTIPHASE / DEM
ELECTRONICSCONJUGATE HEAT TRANSFER
ELECTRONIC PACKAGINGU/L, IEEE, NEMA STANDARDS
FORCED CONVECTIONBATTERY SIMULATION
URBAN PLANNINGWIND RESOURCE PLANNING
NATURAL VENTILATIONWIND FARMING
NATURAL HEATING
TURBOMACHINERYFAN PERFORMANCE
FAN CURVE OPERATING REGIONBLADE PROFILE DESIGN
FLUID SOLID INTERACTION
AUTOMOBILEEXTERNAL AERODYNAMICS
DRAG REDUCTIONIC ENGINE COMBUSTIONCATALYTIC REDUCTION
ACOUSTICS
Applications
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 8/30
BOILER EMS Screen
LTSHECO.
Deflector plate
ESP-Inlet Duct
ESP
Honey combAsh
HoppersID Fan
Duct
Clean Gas
F.D Fan P.A. FanCoal Mill
Windbox
CFD in power plant industry
Cost effective design optimization of Ducts Combustion systems Boilers & Accessories Air Pre-Heater (APH) ElectroStatic Precipitator (ESP) HVAC systems & components Fans Coal Conveyor Pulverizers Mixers & Separators
Energy Sector
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 9/30
Duct Flow OptimizationDuct optimization usign CFD
Better flow distribution Pressure drop reduction Reduce auxiliary power consumption Improve equipments/process thermal
characteristics Optimize insulation thickness
Flue Gas Duct
Flue Gas DuctSecondary Air Duct
Primary Air Duct Mill Ducts
Tempering Air Duct
Secondary Air Inlet Duct
Primary Air Inlet Duct
Ducting system of typical 500 MW coal fired power plant
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 10/30
Duct Flow OptimizationFlow
Better flow distribution Detailed analysis of flow pattern Detailed study of-
Velocity Density Temperature Viscosity
Reduce erosion
ESP-A PASS ESP-B PASS0
5
10
15
20
25
16.68 17.22
13.58 14.21
EXISTING DESIGN OPTIMIZED DESIGN
Coeffi
cient
of Va
rianc
e (Co
V)
Coefficient of Variance – Comparison
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 11/30
Duct Flow OptimizationTemperature
Detailed study of- Air/fuel & flue gas temperature
Better thermal distribution Increase thermal efficiency Optimize insulation thickness
Tempering air mixes with the main hot air & flow to the
coal mills.
Primary air duct – Temperature profile
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 12/30
Combustion 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 13/30
Combustion 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 14/30
WindboxWindbox 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 Primary air duct
Velocity Vectors through Secondary air duct
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 15/30
CAVTCold 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 16/30
CAVTBase Optimized
FU
RN
AC
E
CH
IMN
EY
FU
RN
AC
E
CH
IMN
EY
High velocity zones observed in the rear arch panel RHS side
Reduction in high velocity zones observed at the
rear arch panel RHS side
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 17/30
CAVTBase FURNACE
CHIMNEY
RH
S
LH
S
FURNACE
CHIMNEY
RH
S
LH
S
Optimized
High lane velocity observed at the front
and rear sides of LTSH Lower bank Reduction in high lane
velocity observed at the front and rear sides of
LTSH Lower bank
LTSH Lower Bank-Top
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 18/30
CAVT
FURNACE
CHIMNEY CHIMNEY
FURNACE FURNACE
CHIMNEY
0° Tilt -25° Tilt +25° Tilt
High velocity at the rear arch panel observed at
+25° burner tilt
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 19/30
CAVTBase Optimized
RH
S
LH
S
FURNACE
CHIMNEYR
HS
LH
S
FURNACE
CHIMNEY
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 20/30
ElectroStatic PrecipitatorESP- Flow analysis
Field flow uniformity Field pressure distribution Increase collecting efficiency Optimized designs to,
Improve performance Reduce pollution Lesser downtime
Higher turbulence to the flow due to the
obstruction created by the screen
Screen
Higher velocities arise after the
screen due to the reduction in flow
area
Screen
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 21/30
ElectroStatic PrecipitatorESP- Flow analysis
Field flow uniformity Field pressure distribution Increase collecting efficiency Optimized designs to,
Improve performance Reduce pollution Lesser downtime
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 22/30
Air Pre-HeaterAPH-Heating Element Analysis
Gas flow pattern through heating elements.
Optimization of heating elements Better heat transfer characteristics Effective waste heat recovery Increase combustion efficiency Increase boiler efficiency
DU VAR1 PROFILE FNC PROFILE
DU VAR1 PROFILE
FNC PROFILE
DU VAR1 PROFILE
FNC PROFILE
Unsteady Heat Transfer Study of APH Heating Elements. Temperature Plot.
Time Step:0.2 s
Time Step:20 s
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 23/30
Heat Exchangers 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 24/30
Fans 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 25/30
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 26/30
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 27/30
Other Applications Separators
Coal pipe erosion
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 28/30
Valves
Pumps
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 29/30
Customers
APPLICATION OF CFD TECHNIQUES IN ENERGY SECTOR 30/30
THANK YOU
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