COMPUTATIONAL ANALYSIS OF AIR-PRE HEATER

USING CFD
Presented by,
R.NITHIYANANDAM B.MOHITH RA
nithidte@gmail.com mohitraj.b@gmail.com
Phone: 9791726620
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,#R-R.
SYNOPSIS
.he /roce00 o1 heat and ma00 tran01er' 1l2id 1lo3' chemical reaction0 etc /la4
a 5ital role in a 3ide 5ariet4 o1 Ind20trial a//lication0. )ince all the engineering
acti5itie0 and /roce00 are ba0icall4 con1ig2red on the0e e00ential /roce00e0 the
de0igner and engineer0 m20t be armed 3ith the 6no3ledge and methodolog4 to
/redict them 72antitati5el4. .hi0 3ill al0o enable them to o/erate e8i0ting
e72i/ment e11icientl4' o/timi9e the re02lt0' /recl2de and or minimi9e /otential
danger0.
.hro2gho2t mo0t o1 the t3entieth cent2r4 the 0t2d4 and /ractice o1 the 1l2id
d4namic0 in5ol5ed the 20e o1 /2re theor4 on one hand and /2re e8/eriment on the
other hand. :2ll 0cale e8/erimental in5e0tigation0 in mo0t ca0e0 are /rohibiti5el4
e8/en0i5e' 3herea0 /rotot4/e model do not al3a40 0im2late all the 1eat2re0 o1 the
act2al e72i/ment. .heoretical /rediction o1ten em/lo4 02itable 0et2/ mathematical
model' 3hich re/re0ent the /h40ic0 and chemi0tr4 o1 the 040tem o1 the beha5ior
20ing mathematical e72ation' embod4ing rele5ant 0cienti1ic and em/irical
6no3ledge.
"o3e5er ad5ent o1 the high-0/eed digital com/2ter combined 3ith the
de5elo/ment o1 acc2rate n2merical algorithm 1or 0ol5ing /h40ical /roblem ha0
re5ol2tioni9ed the ne3 third a//roach in 1l2id d4namic0 i.e. !om/2tational 1l2id
d4namic0.
.h20 !:; i0 /oi0ed to ma6e an entr4 in to the 3ider ind20trial
comm2nit4 and hel/0 to red2ce de5elo/ment time 0cale0 and co0t0 o1 ne3 de0ign.
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PROBLEM DEFINITION
.he t2b2lar air /re-heater <.#P"= o1 the 20M> baga00e 1ired boiler'
02//lied b4 *"%' trich4 i0 one o1 the contin2o20l4 a5ailable e72i/ment o1 the
/o3er 0tation at *#$$#RI #MM#$ !+&$R#.I+$ P%#$.. #t the
economi9er e8it o1 the boiler' the 1l2e ga0 d2ct /a00age into t3o 0ection0' one heater
0ection in 1ir0t bend and other heater in the other bend. .he 1l2e ga0 d2ct /a00age i0
arranged in 02ch a 3a4 to /reheat the 02//lied /rimar4 air.
.he t2b2lar air /reheater are b2ild and de0igned 3ith t3o 0ection named
a0 t2b2lar region 1 and t2b2lar region 2. ach bloc6 i0 made 2/ 3ith carbon 0teel
.&a0 1lo30 thro2gh the air heater at the rate o1 2?@ tAhr' 229.? tAhr'1B2.@tAhr at 1eed
rate0 o1 110C M!R' 100C M!R and 60C M!R re0/ecti5el4.
:l2e ga0 i0 entered into the air /re-heater at the tem/erat2re0 o1 271Dc' 262Dc'
2B1Dc and lea5e0 at 16?Dc' 160Dc' and 1?0 D c 1or 1eed rate0 o1 110C M!R' 100C
M!R' and 60C M!R re0/ecti5el4. .h20 ga0 tem/erat2re i0 dro//ed to 2@2Dc. :or
air it entered into the air /reheater at the tem/erat2re o1 BBDc and lea5e0 at 102 Dc.
.h20 the heater air .em/erat2re rai0ed to 200Dc' 196Dc' and 16? D c re0/ecti5el4 1or
5ario20 M!R.
Periodic in0/ection o1 the /lant re5eled locali9ed a0h de/o0ition in the air
/re-heater. In air /re-heater both %") and R") 3ere o/ened and in0/ected d2ring
the 0h2t do3n 1or 5a/o2r /i/e modi1ication 3or6.
.he ob0er5ation0 are recorded belo3:
B

E+n %") bloc6 o1 #P" F?C o1 the area a0h i0 clear. +nl4 1?C o1 the area
to3ard0 1ront d2ct 3all 3a0 co5ered b4 a0h.
E+n R")' it had hea/0 o1 the a0h 0ettlement' bloc6age o1 air /re-heater.
S!"e#$t%! d%$&r$# '( $%r )re"e$ter


.he *loc6age o1 #ir-Pre heater lead0 to'
E.em/erat2re gradient0 in 1l2e ga0 9one0 leading to tem/erat2re di11erence0 in
0team circ2it
E;i11erence0 in the e8it ga0 tem/erat2re0 and non 2ni1orm loading o1 I; 1an.
EIt 3ill mi0lead in the o/eration o1 b4/a00 air dam/er0 o1 :; 1an0.
.2b2lar
region 2
.2b2lar
region1
:l2e ga0
o2tlet
:l2e ga0
inlet
@
E!on0traint0 on loading o1 boiler ma4 occ2r.
.h20 anal40i0 o1 1lo3 /attern di0trib2tion and chec6ing o1 de0ign /arameter0 /la4 a
5ital role to increa0e the e11icienc4 o1 the t2b2lar air /reheater /er1ormance0. In thi0
c2rrent /a/er !:G 0o1t3are 3a0 20ed to model and anal49e o1 a t2b2lar air /re-
heater /er1ormance.
.he ta06 to 0ort o2t the rea0on0 1or a0h 0ettling' the ta06 o1 e8amining the
e11ect o1 1lo3 geometr4 and ;e0ign /arameter 1or a gi5en 0et o1 o/erating
condition-20ing !:; <com/2tational 1l2id d4namic0= anal40i0 i0 in0tit2ted a0 the
1ir0t 0te/ in 2nder0tanding the /henomenon at 3or6. :or thi0 the entire t2b2lar air
heater 3a0' modeled and /roce00ed thro2gh the three 0tage0
EPre-/roce00ing
E)ol5ing
EPo0t /roce00ing
.he re02lt0 o1 the abo5e anal40i0 in the 1orm o1 5ector /lot0' conto2r /lot0' gra/h0'
etc 5ie3ed and 0t2died.
INTRODUCTION TO CFD
!:; con0tit2te0 a ne3 third a//roach in the /hilo0o/hical 0t2d4 and
de5elo/ment o1 the 3hole di0ci/line o1 :l2id ;4namic0. .he ad5ent o1 high 0/eed
digital com/2ter combined 3ith a de5elo/ment o1 acc2rate n2merical algorithm0 1or
0ol5ing /h40ical /roblem0 on the0e com/2ter0 ha0 re5ol2tioni9ed the 3a4 3e 0t2d4
and /ractice :l2id ;4namic0 toda4.
!:; i0 toda4 an e72al /artner 3ith /2re theor4 and e8/eriment in the
anal40i0 and 0ol2tion o1 :l2id ;4namic0 /roblem.
CFD i0 /redicting 3hat 3ill ha//en 72antitati5el4' 3hen 1l2id0 1lo3' o1ten 3ith
the com/lication0 o1:
E)im2ltaneo20 1lo3 o1 heat'
EMa00 tran01er <e.g. /er0/iration' di00ol2tion='
?
EPha0e change <e.g. melting' 1ree9ing' boiling='
E!hemical reaction0 <e.g. comb20tion' r20ting='
EMechanical mo5ement <e.g. Pi0ton0' 1an0' r2dder0='
E)tre00e0 in and di0/lacement o1 immer0ed or 02rro2nding 0olid0
.hi0 com/2ter ba0ed 0im2lation techni72e i0 5er4 /o3er12l and 0/an0 3ide
range o1 ind20trial and non-ind20trial a//lication area0.
D%((erent Mes"%n& Te!"n%*+es
Me0hing
:inite ;i11erence :inite (ol2me :inite lement
*a0ic ;eri5ation
o1 :inite di11erence *a0ic ;eri5ation o1
order o1 acc2rac4 :inite (ol2me
72ation0
:inite di11erence
72ation0'
.r2ncation rror0
.4/e0 o1 0ol2tion0 -
8/licit and Im/licit
)tabilit4 #nal40i0
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!:; .echni72e0 in grid generation:
1. %a8->endro11H0 .echni72e
2. Maccormac6H0 .echni72e
AD,ANTAGES OF CFD O,ER E-PERIMENTAL BASED
APPROACHES TO FLUID SYSTEM DESIGN
E)2b0tantial red2ction o1 lead time0 and co0t0 o1 ne3 de0ign.
E#bilit4 to 0t2d4 040tem0 3here controlled e8/eriment0 are di11ic2lt or
im/o00ible to /er1orm <e.g. 5er4 large 040tem0=.
E#bilit4 to 0t2d4 040tem0 2nder ha9ardo20 condition at and be4ond their normal
/er1ormance limit0 <e.g. 0a1et4 and accident 0cenario0=
EPracticall4 2nlimited le5el o1 detail o1 re02lt0.
BASIC ELEMENTS.
!:; code0 are 0tr2ct2red aro2nd the n2merical algorithm that can tac6le
1l2id 1lo3 /roblem0.
#ll !:; !+;) contain three main element0
1. Pre-/roce00or
2. )ol5er
B. Po0t /roce00or
/. PRE-PROCESSOR

Pre-/roce00or con0i0t0 o1 the in/2t o1 a 1lo3 /roblem to a !:;
/rogram b4 mean0 o1 an o/erating-1riendl4 inter1ace and the 02b0e72ent
tran01ormation o1 thi0 in/2t into a 1orm 02itable 1or 20e b4 the 0ol5er:
.he 20er acti5itie0 at the /re/roce00ing 0tage0 in5ol5e:
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a= ;e1inition o1 the geometr4 o1 the region o1 intere0t-the com/2tational domain
$ote: 3e had dra3n the model 3ith the hel/ o1 co-ordinate 040tem
b= )election o1 the /h40ical and chemical /henomena that need to be modeled.
!= ;e1inition o1 1l2id /ro/ert4
d= )/eci1ication o1 a//ro/riate bo2ndar4 condition <i.e. in/2t and o2t/2t
condition0=
e= Me0hing the model
TETRAHEDRAL MESHING IS DONE TO MODEL

:ig. me0hed model o1 air /re heater
0. SOL,ER

.he n2merical method that 1orm0 the ba0i0 o1 the 0ol5er /er1orm0 the
1ollo3ing 0te/0:
a= #//ro8imation o1 the 2n6no3n 1lo3 5ariable0 b4 mean0 o1 0im/le 12nction0.
b= ;i0crimination b4 02b0tit2tion o1 the a//ro8imation0 into the go5erning 1lo3
e72ation and 02b0e72ent mathematical mani/2lation.
c= )ol2tion o1 the algebraic e72ation0.

:inite 5ol2me method 3a0 originall4 de5elo/ed a0 a 0/ecial 1inite
di11erence 1orm2lation
F
>h4 1inite 5ol2me methodI
:inite 5ol2me method doe0nHt demand a 2ni1orm' rectang2lar grid 1or
com/2tation' 02ch 1inite 5ol2me calc2lation0 can be made directl4 in the /h40ical
on a non-2ni1orm me0h i.e. no tran01ormation i0 nece00ar4.
1. POST PROCESSING
!:; /ac6age are no3 e72i//ed 3ith 5er0atile data 5i02ali9ation
tool0. .he0e incl2de0
E;omain geometr4 J grid di0/la4
E(ector /lot
E%ine and 0haded conto2r /lot0
E2; J B; 02r1ace /lot0
E5ie3 mani/2lation <tran0lation' 0caling=
E!olor /o0t 0cri/t o2t/2t
RESULTS AND DISCUSSION

RESULTS FOR 234MCR5 MAXIMUM CAPACITY RATING 6
:I& .(%+!I.Y ;I)RI*-.I+$


:I&. PR))-R ;I).RI*-.I+$
9


RESULTS FOR //34MCR5 MAXIMUM CAPACITY RATING 6
:I& .(%+!I.Y ;I)RI*-.I+$
10
,ELOCITY 7 ,ECTOR PLOT FOR //34 MCR.

CONCLUSION.
M'd%(%!$t%'n S+&&ested

.o /re5ent a0h de/o0ition' certain modi1ication0 ha5e to be made
either in the geometr4 or the 1l2id 1lo3 /arameter' i1 there i0 an4 alteration in
the ma00 1lo3 rate 'then boiler in/2t 1eed rate '02//l4 o1 air al0o be 5aried.
.he /lant being an e8i0ting one' change o1 the o/erational condition0 i0
im/o00ible.
RESULT ,ALIDATION
.he re02lt 3e got i0 5alidatedK 3e got the o2t/2t /re002re o1 air-
/reheater 0ame a0 the 0/eci1ication 0/eci1ied b4 *"%' .rich4. )o o2r re02lt
can be ado/ted 1or de0ign modi1ication.
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