Your Success is Our Goal FURNACE TROUBLESHOOTING WITH PHOENICS IX International PHOENICS Users Conference Moscow,

Your Success is Our Goalwww.siemens.com/itps1 www.chemtech.com.br

FURNACE TROUBLESHOOTING WITH PHOENICS

IX International PHOENICS Users ConferenceIX International PHOENICS Users Conference

Moscow, 25Moscow, 25thth September 2002 September 2002

Your Success is Our Goal

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Furnace Troubleshooting

IX International PHOENICS Users Conference

Chemtech - A Siemens Company, Rio de Janeiro / RJ – BrazilChemtech - A Siemens Company, Rio de Janeiro / RJ – Brazil

Petrobras / CENPES, Rio de Janeiro / RJ – BrazilPetrobras / CENPES, Rio de Janeiro / RJ – Brazil

AUTHORS

Flávio Martins de Queiroz GuimarãesFlávio Martins de Queiroz Guimarães

Bruno de Almeida BarbabelaBruno de Almeida Barbabela

Luiz Eduardo Ganem Rubião Luiz Eduardo Ganem Rubião

Ricardo SerfatyRicardo Serfaty


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INTRODUCTION – THE SYSTEM

Distribution-chamber

Plenum

Combustion-chamber

Underground-duct


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INTRODUCTION – THE PROBLEM

The increase in the pre-heated air mass-flow lead The increase in the pre-heated air mass-flow lead to several problems during the furnace operation:to several problems during the furnace operation:

Problem 1Problem 1: Hot air has a high swirl flow inside : Hot air has a high swirl flow inside the underground duct;the underground duct;

Problem 2Problem 2: The mass flux distribution between : The mass flux distribution between the two plenum is not uniform;the two plenum is not uniform;

Problem 3Problem 3: The mass flux distribution between : The mass flux distribution between the burners within the plenum is not uniform;the burners within the plenum is not uniform;

Problem 4Problem 4: The flames in the two combustion : The flames in the two combustion chambers are leading.chambers are leading.


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PROBLEM 1 – UNDERGROUND DUCTDescription


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PROBLEM 1 – UNDERGROUND DUCTSGeometry


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PROBLEM 1 – UNDERGROUND DUCTGeneral Settings

All simulations were run on PHOENICS v3.3. The All simulations were run on PHOENICS v3.3. The follow configuration was setting:follow configuration was setting:

Grid: Grid: cartesiancartesian PARSOL:PARSOL: no no Energy Equation: Energy Equation: nono noCombustion: noCombustion: Turbulence Model: Turbulence Model: standard k-standard k-, Chen-Kim k-, Chen-Kim k-

and RNG k-and RNG k- Transient: Transient: nono


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PROBLEM 1 – UNDERGROUND DUCTOriginal Case Simulation


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PROBLEM 1 – UNDERGROUND DUCTProblem Identification

1 2


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PROBLEM 1 – UNDERGROUND DUCTProblem Solution

1

2


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PROBLEM 1 – UNDERGROUND DUCTProblem Solution Results

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PROBLEM 2 – UNDERGROUND DUCTDescription


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PROBLEM 2 – UNDERGROUND DUCTSGeometry


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PROBLEM 2 – UNDERGROUND DUCTGeneral Settings


Grid: Grid: cartesiancartesian PARSOL:PARSOL: no no Energy Equation: Energy Equation: nono Combustion: noCombustion: no Turbulence Model: Turbulence Model: standard k-standard k-, Chen-Kim k-, Chen-Kim k-



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PROBLEM 2 – UNDERGROUND DUCTOriginal Case Simulation


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PROBLEM 2 – UNDERGROUND DUCTProblem Identification

Mass Flow35% Greater


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PROBLEM 2 – UNDERGROUND DUCTProblem Solution

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PROBLEMS 3 & 4 – PLENUMDescription


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PROBLEM 3 & 4 – PLENUMGeometry


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PROBLEM 3 & 4 – PLENUMGeneral Settings

All simulations were run on PHOENICS v3.3 and All simulations were run on PHOENICS v3.3 and v.3.4. The follow configuration was setting:v.3.4. The follow configuration was setting:

Grid: Grid: cartesiancartesian PARSOL:PARSOL: active (on some cases) active (on some cases) Energy Equation: Energy Equation: nono Combustion: noCombustion: no Turbulence Model: Turbulence Model: standard k-standard k-, Chen-Kim k-, Chen-Kim k-



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PROBLEM 3 & 4 – PLENUM Problem Identification

Burners Mass Flow Profile

0.6000.6500.7000.7500.8000.8500.9000.9501.000

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

Burners

Mas

s F

low

(kg

/s)


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1

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PROBLEM 3 & 4 – PLENUM Problem Solution

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PROBLEM 3 & 4 – PLENUM Problem Solution Results

Burners Mass Flow Profile

0.6000.6500.7000.7500.8000.8500.9000.9501.000

Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8

Burners

Mas

s F

low

(kg

/s)


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PROBLEM 3 & 4 – PLENUM Problem Solution Results

1

2

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PROBLEM 4 – COMBUSTION CHAMBERDescription


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PROBLEM 4 – COMBUSTION CHAMBER Geometry


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PROBLEM 4 – COMBUSTION CHAMBER General Settings


Grid: Grid: cartesiancartesian PARSOL: activePARSOL: active Energy Equation: Energy Equation: activeactive Combustion: active (SCRS)Combustion: active (SCRS) Turbulence Model: Turbulence Model: Chen-Kim k-Chen-Kim k- Transient: Transient: nono


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PROBLEM 4 – COMBUSTION CHAMBER Original Case Simulation


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PROBLEM 4 – COMBUSTION CHAMBER Problem Solution Results


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CONCLUSIONS

The results showed good qualitative agreement with observed The results showed good qualitative agreement with observed behavior during furnace operation. behavior during furnace operation.

Although the Chen-Kim and RNG k-Although the Chen-Kim and RNG k- models converged to the models converged to the same solution behavior, the standard k-same solution behavior, the standard k- one seems to under- one seems to under-predict the recirculation zones and the flames inclination.predict the recirculation zones and the flames inclination.

That result indicates that the leaning flames are not only caused That result indicates that the leaning flames are not only caused by bad distribution of air but may also be caused by the number by bad distribution of air but may also be caused by the number of firing ports in each burner. Decreasing the number of ports of firing ports in each burner. Decreasing the number of ports might lead to a higher momentum jet from the residing ports, might lead to a higher momentum jet from the residing ports, which might in turn mix the fuel better with the preheated air which might in turn mix the fuel better with the preheated air stream and create shorter flames. This would result in a smaller, stream and create shorter flames. This would result in a smaller, more compact flame envelope, which would have less tendency more compact flame envelope, which would have less tendency of leaning to either side of the furnaceof leaning to either side of the furnace

Documents

Your Success is Our Goal FURNACE TROUBLESHOOTING WITH PHOENICS IX International PHOENICS Users Conference Moscow,