Performance Analysis of SG Furnace

P M V Subbarao Associate Professor

Mechanical Engineering Department I I T Delhi

Thermal Performance analysis of A complex Geometry..

Analysis of the Last but One Effect

Final effect : Tfl gets changed to Furnace Exit GasTemperature. Due to energy lost by hot gases. Loss due to Environment Energy absorbed by water walls Energy lost by hot gasses from flame to exit.
y

Tfe

Q g ,loss
y y

y y ! Qad  Q fe

Q g ,loss ! m g C p _ ad  TFEGT a kW T
y

Tflame

Q g ,loss

A T ! m fuel 1  C p _ ad  TFEGT a kW F act

y

X
i

Ri Ri

h YPj hPj
j

Mixed Adiabatic Temperature of the Gases

h i Y jh
j

X c
Ri i Tref

TR

p , Ri

dTR YPj c p , Pi dTP

j Tref
2 3

Tad

cp

1000

2 1000

kJ / kgK 3 1000

Analyses of Coal

Computation of Adiabatic Temperature

Moles of Products of o bustion

7yipi
kJ/k ol.K

Analysis of the Last Effect

Heat absorbed = K (energy liberated energy of gas at furnace exit).
y

Tfe

Define

K !

Q abs
y

Q g , loss
y

Q abs
Tflame

! K Qad  Q fe

K is a loss factor.

Q abs ! m steam _ steam  h fw akW h

Finally the successful radiative action to the water walls:

Qabs ! AFWI eff T  T

4 fl
y

4 wa

A! m _ h
steam
y

steam

 h fw a

Qabs ! AFWI eff T  T

4 fl

4 a

A kW ! K m fuel 1  C p _ ad  TFEGT a T F act

Divide thought by Tad4:

y

Qabs

4 4 y T fl Twa A C p TFEGT ! AFWI eff 4  4 kW ! K m fuel 1  1 3 F act Tad Tad Tad Tad

Define :

U fl !

T fl Tad

, U FEGT

TFEGT Twa ! & U wa ! Tad Tad

Qabs ! AFWI eff U  U

4 fl

4 wa

A Cp _  U FEGT a ! K m fuel 1 1 3 F act Tad

y

1  U FEGT !

AFWI eff A Cp K m fuel 1 3 F act Tad

y

? U

4 fl

4  U wa

Furnace exit temperature is proportional to Flame Temperature.

U fl w U

n FEGT

&U

n wa

n fl

Furnace Exit Gas Temperature

Temperature of gasses leaving the furnace. An important furnace performance parameter. Defines the ratio of furnace heat absorption to later (convective) heat absorption. High FEGT Compact furnace. Due to increase in fouling of water wall tubes: FEGT < Ash Deformation Temperature. FEGT = AST 100 FEGT < 1100 0C Strong slag FEGT < 1200 0C Moderate slag

It is very essential to know the mass flow rates of 1225 Fuel, Air and various flue gases for further Performance Analysis! 0C 1200 1175

1150

1125

1100

Computation of FEGT for Indian SG

Coals

Performance of Analysis of Furnace

Get Fuel Ultimate Analysis. Compute Equivalent Chemical Formula. Select recommended Exhaust Gas composition. Carry out first law analysis to calculate Adiabatic Combustion Temperature. Total number of moles of wet exhaust gas for 100 kg of fuel : nex.gas HV of fuel +nair hair = 7nex. Gashf,gas Calculate Adiabatic Flame Temperature. Calculate total heat transfer area of furnace, Afur cross sectional area of furnace Across

FEGT of A Clean Furnace : A Correlation

A fur  Across

A y J 1 mc C p F ! 3 WI fu]Tad

1 Tad  1 M TFEGT

1 / 0. 6

Thermal efficiency factor, ] M Temperature Field Coefficient Tad Adiabatic combustion temperature TFEGT Furnace Exit Gas Temperature Afur Total surface area of furnace mc Flow rate of fuel

Final Super Heater TIT

Economizer Feed Water Thermal Structure of Steam Generator

FEGT : A Measure of Instantaneous Cleanliness of Furnace Walls

Turbine Inlet Steam Temperature Control System

In practice, the turbine governing system maintains required main steam flow rate for a given load on the turbine. An appropriate control system is used to maintain turbine inlet temperature(TIT) within specified safe limits. The control of TIT is generally carried out by injecting water in the path of super heaters. This mixing chamber (attemperator) is placed at upstream of final super heater.

 msat

 mTI

 mattemp
Flow controller

 mattemp    msat ! mTI  mattemp

  Qabs , act ! mainsteam  mspray v  evaporation  (hPSH m h

y

Q g ,loss

A ! m fuel 1  C p _ ad  TFEGT ,act a T F act

y
y

K !
TFEGT ,act

Q abs
y

Q g , loss

K

Tad

A  m fuel 1  c p dT ! mainsteam  mspray  evaporation  (hPSH m vh F act

y

Furnace Cleanliness Factor

Thus the Real FEGT and capacity FEGT can be calculated using the plant data and instantaneous cleanliness factor can be calculated using following formula:

  m h Qabs , act mainsteam  mspray v  evaporation  (hPSH CF ! ! TFEGT  Qabs ,cap  mgas c p dT
Tad

Uses of Actual FEGT Calculations for Performance Monitoring and Analysis

Superheat steam temperature control : The final steam temperature is maintained by keeping the FEGT within the allowable limit. Coal ash corrosion control: Maintaining the FEGT a minimum of 600C, below the ash softening temperature can reduce the potential of super heater coal ash corrosion . Control of NOx production : It is essential for the operator to maintain the original design FEGT to minimize other side effects.

Effect of FEGT on NOx Emissions

16% rise in NOx due to 3% increase in FEGT.

1504

1550

Uses of Real FEGT Calculations for Performance Monitoring and Analysis

Soot blowing :FEGT can be used as the primary indicator to establish the scheme for automatic soot blowing (cleaning of heat transfer surfaces) or to alert the operator to start the manual sootblowing operation. If FEGT exceeds the original design value, this indicates that the furnace is dirty and the operator should initiate the furnace soot blowing and the soot blowing should be stopped when FEGT has been reduced below the original design value. The over-blowing in the furnace is wasting the energy and can also create soot blower erosion problem in the water wall tube

ARRANGEMENT OF SOOT BLOWERS IN A 500MW

Basic Geometry of A Furnace

y

m c LHV A furnace.top ! a v b ! qA

A furnace.bottm ! E

Heat exchange by Radiation Through Top opening of furnace:

  Qtop ,rad ! Qad , gas

A furnace .top A furnace .top  Abottom  Asurface