It is shown that the standard method of design of boiler furnaces is not suitable for nonstandard operating conditions. A physicomathematical model of the furnace process is suggested for design studies of promising furnace devices and of conditions of flame extinction. An example of engineering design of a furnace with controlled process is presented.
Keywords: standard method, furnace design, operating conditions, model, furnace process, study, extinction.
The theory and design of heat exchange in furnaces presented in [1, 2] have been developed for the most part by
professors A. M. Gurvich and V. V. Mitor. For many years
these norms have played a determining role in the creation
and maintenance of boiler units in Russia. In 1998 the furnace part of the standard method was amended in the third
edition [3].
Under conditions of unsteady supply of fuel to power
generating units, of the need for changing (or, on the contrary, for preservation of) their operating parameters and for
raising the flexibility of operation, and of increasingly stringent economical and ecological requirements, it has became
necessary to control the processes of combustion and heat
exchange in the furnace chambers of boilers. It is obvious
that the zero-dimensional standard methods of furnace design developed for traditional furnace and burner devices
have limited possibilities as applied to novel technologies of
firing, especially for solid fuel. This circumstance makes it
necessary to develop a zonal engineering method of furnace
design, which will consider simultaneously the processes of
mixing, combustion, and heat exchange in the furnace.
Unfortunately, the procedure for computation of radiant
heat exchange recommended in [3] does not involve the concepts of the degree of flame blackness afl and of the reduced
degree of furnace blackness af widely used in scientific literature. This has led to discrepancies in methodological recommendations on design of furnace devices issued jointly by
the Central Boiler and Turbine Institute (TsKTI) and the
All-Russia Thermal Engineering Institute (VTI) [4].
Considering the computation of heat exchange in furnaces we should not neglect the discussion in [5] concerning
the reliability of the values of the coefficient of thermal efficiency of waterwalls recommended in [2, 3], which is determined as the ratio of the radiant heat flows taken up by a
1
(1)
Since the value of the heat flow qt is measured quite reliably, for the specified the temperature Teff it is fully determined by the product y a f . This gives some leeway for
choosing the factors and af individually. Numerous experimental data show that the gas temperature at the outlet from
boiler furnaces computed by the method of [2] is usually
lower than the actual temperature [5]. This means that the
computed values of the degree of blackness af (or of the coefficient ) have been overestimated. This drawback is absent in [3]. This could have been done in [2] if the assumption that the areas of the surfaces of the waterwall Fw and of
the flame Ffl in the equation relating af, afl, and are the
same were not used; this relation should have the form [6]
af =
a fl
,
a fl + ( F - a fl )y
(2)
179
1570-145X/06/4003-0179 2006 Springer Science + Business Media, Inc.
180
A. A. Shatil
u
w
w3
w2
w1
In recent years TsKTI specialists developed an approximate zero-one-dimensional zonal model and TORKA software for computing the firing process in boilers [7, 8], which
was later generalized to furnace devices with different aerodynamic circuits and methods of fuel firing [9]. This physicomathematical model of the process (stationary combustion, extinction, inflammation, heat exchange) employs the
ideas presented in [10]. Specifically, L. A. Vulis suggests ...
to give up observation of the behavior of individual particles
of fuel or combustible mixture and concentrate on the phenomena occurring in the central part of the furnace volume.
He also notes that the introduction of volume-averaged values of temperature and concentration better meets the actual
conditions of the occurrence of the process in those parts of
the furnace chamber where the fresh mixture intensely mixes
with the combustion products.
Organization of the firing process is based on mixing of
three flows, i.e., of the oxidizer (air), of the fuel, and of the
combustion products. The applied science of firing considers
two mechanisms of diffusion (mixing), i.e., molecular and
turbulent ones. However, it is obvious that these two mechanisms are accompanied by convective mixing caused by the
aerodynamic structure of the flow, i.e., the structure of the
burning device or of the furnace chamber itself.
In actual furnace devices all the three mixing mechanisms (molecular, turbulent, and convective) act in parallel
and every subsequent mechanism cannot occur without the
preceding ones. In other words division of flows into small
volumes due to the turbulence increases their total surface
for the occurrence of molecular mixing. In its turn, convective mass transfer not only ensures mixing of distant gas volumes but also creates velocity gradients that intensify manyfold the turbulent mass transfer in them. Therefore, it can be
assumed that the latter mechanism plays a determining role
in the three mechanisms of mixing in a furnace. This allows
us to estimate the quality of mixing in actual furnaces by
studying their models.
181
X2 = 1.0
= 1.15
20.3
X2 = 0.66 = 1.15
580
16.8
X2 = 0.33
= 1.15
13.3
X1 = 1.0 = 1.15
X1 = 0.67
a = 0.70
8.5
a
X1 = 0.22
a = 0.55
0.50V
B = 0.9
6.3
Fig. 2. Model of a furnace with top and undergrate blast (a) and distribution of the vertical velocities of flow in it (b).
0.45V
4.3
0.20V
B = 0.9
X2
J, C
, %
q 4, %
q3, %
CO, %
CNO x , mg/m3
q, Mcal/(m2 h)
0.22
0.67
1.0
0.33
0.66
1.0
0.9
1.0
1.0
0.55
0.70
1.15
1.15
1.15
1.15
1376
1433
1364
1328
1259
1197
33.49
62.14
83.59
95.84
97.62
98.31
1.08
1.86
11.23
3.44
2.13
1.60
55.53
36.00
5.18
0.72
0.25
0.09
25.34
13.04
1.25
0.17
0.06
0.02
88
245
502
554
562
565
163
181
159
145
115
93
182
A. A. Shatil
Ex
2
4
0.5
3
0.05
Fig. 4. Diagram of the thermal regime of combustion: 1, heat liberation curve; 2, heat removal curves; 3, initial point of the process
( = 0, = 0), C, point of stationary regime; Ex, point of extinction;
In, point of inflammation; 4, point of crisis-free regime.
(3)
(4)
(5)
or
(6)
183
Tex, K
Tex, K
a
b ex =
1106 - 8.3V g
1660 - 8.3V g
1500
(7)
(8)
1000
500
0
4
12 3 11 10
2 1
6
11 4
12
3
10 2
6 1
1500
5
13 7
50
5
7
8
V g, %
1000
500
0
13
50
V g, %
184
CONCLUSIONS
1. Development of new technologies of firing organic
fuel and improvement of the operating furnace devices requires creation of a method for their computational study.
2. The computational model of the firing process developed by TsKTI has been tested on a great number of furnaces
of operating boilers firing a wide spectrum of fuel in all firing stages from pilot firing to extinction and on various furnace devices. This allows us to recommend the model and
the TORKA software for computational studies not only of
traditional boiler furnaces but also of furnaces employing
novel firing technologies.
3. It is expedient to have at least two modifications of
the software for practical purposes. One of them can be used
for design studies of furnaces and the other (simpler) modification can be used for an operating furnace (or a boiler as a
whole) for estimating the consequences of various possible
working situations.
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A. A. Shatil
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