Research Papers: Multiphase Flows

Using CFD to Study Combustion and Steam Flow Distribution Effects on Reheater Tubes Operation

[+] Author and Article Information
Esmaeil Poursaeidi1

Mechanical Engineering Department, Faculty of Engineering,  Zanjan University, P.O. Box 45195-313, Zanjan, Iranepsaeidi@znu.ac.ir

Masoud Arablu

Mechanical Engineering Department, Faculty of Engineering,  Zanjan University, P.O. Box 45195-313, Zanjan, Iranarablu_m@yahoo.com


Author to whom correspondence should be addressed.

J. Fluids Eng 133(5), 051303 (Jun 07, 2011) (11 pages) doi:10.1115/1.4004081 History: Received December 20, 2009; Revised April 04, 2011; Published June 07, 2011; Online June 07, 2011

The thickness measurements showed that boilers of the Shahid Rajaee power plant have a non-uniform thickness in some regions of the final reheater tubes after 80,000 h of operation. Experimental tests on areas such as thickness, hardness, metallography, and recorded temperature showed that high temperature erosion is the most obvious reason for thinning in these tubes. Therefore, two possible reasons for the non-uniform tube thinning (problems due to combustion and steam mal-distribution in the tubes) were explored. This paper presents simulations of combustion, flow distribution in reheater tubes, and heat exchange process in Pass 1 of the boiler using FLUENT software. Combustion simulation results showed temperature distribution and mass flux of combustion products are not uniform at the chamber outlet. But these non-uniformities are not proportional to the tubes’ thickness non-uniformity; whereas, simulations showed steam is mal-distributed in the tubes so that steam maldistribution is proportional to the tubes’ thickness non-uniformities. Because steam maldistribution was due to mal-feeding and offloading of headers (U-type headers), all possible ways of feeding and offloading of headers were studied, and the results showed that the H-type configuration has the most uniform flow distribution.

Copyright © 2011 by American Society of Mechanical Engineers
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Figure 1

Lower bundle of final reheater tubes

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Figure 3

Combustion chamber meshes

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Figure 4

(a) Temperature field; (b) to (e) Temperature of horizontal planes at positions indicated by the arrows

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Figure 2

Metallography for tubes 11 (a), 37 (b), 66 (c)

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Figure 5

Schematic of various configurations of parallel channels

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Figure 6

Geometry of heat exchangers inside Pass 1

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Figure 7

Temperature distribution for the reheater tubes 11, 37, and 66

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Figure 8

Velocity vectors and positions around the tubes for which thicknesses are measured




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