Three-Dimensional CFD Model Development and Validation for Once-Through Steam Generator (OTSG): Coupling Combustion, Heat Transfer and Steam Generation

Ehsan Askari Mahvelati,Arthur Maesen,Laurent Fitschy,Mario Forcinito

doi:10.3390/chemengineering6020023

Ehsan Askari Mahvelati, Arthur Maesen + Show 2 more

Open Access

https://doi.org/10.3390/chemengineering6020023

Copy DOI

Abstract

The current research studies the coupled combustion inside the furnace and the steam generation inside the radiant and convection tubes through a typical Once-Through Steam Generator (OTSG). A 3-D CFD model coupling the combustion and the two-phase flow was developed to model the entire system of OTSG. Once the combustion simulation was converged, the results were compared to field data showing a convincing agreement. The CFD analysis provides the detailed flow behavior inside the combustion chamber and the stack, as well as the two-phase flow steam generation process in the radiant and convective sections. The flame shape and orientation, the velocity, the species, and the temperature distribution at the various parts of the furnace, as well as the steam generation and the steam distribution inside the pipes were investigated using the developed CFD model

Highlights

The flue gas passing the transition zone entering the convective section has a considerably high temperature, which is the consequence of combustion and the heat production in the radiant section
The prediction of the blue zone in the middle of the convective section confirms the cooling effect imposed by Boiler Feed Water (BFW) entering the tubes of the convective part
The results represented the shape of the jet and showed that the flue gas goes through the transition part and passes over the convective tubes and reaches the entrance of the stack

Summary

Introduction

OTSGs are usually composed of three main parts: the burner, the radiant section, and the convective section. The progress towards increasing efficiency and reliability of the equipment can be achieved only through the use of more advanced numerical simulations (Charles and Baukal [1]). Improvements in the modeling methodologies to make them faster, more reliable, and efficient for solving large problems are necessary to encourage the producers to adopt and deploy these tools widely. The development of such tools and approaches gives a competitive advantage in the marketplace and will help producers meet production; financial; and health, safety, environmental (HSE) goals in a more stringently regulated industry

Objectives

Results

Conclusion