Transcript No Slide Title

IX International PHOENICS Users Conference
FURNACE
TROUBLESHOOTING
WITH PHOENICS
Moscow, 25th September 2002
www.siemens.com/itps1
www.chemtech.com.br
Your Success is Our Goal
Furnace Troubleshooting
Chemtech - A Siemens Company, Rio de Janeiro / RJ – Brazil
© IT PS 2002
AUTHORS
Flávio Martins de Queiroz Guimarães
Slide 2
Bruno de Almeida Barbabela
Luiz Eduardo Ganem Rubião
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Petrobras / CENPES, Rio de Janeiro / RJ – Brazil
Ricardo Serfaty
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
© IT PS 2002
INTRODUCTION – THE SYSTEM
Combustion-chamber
Slide 3
Plenum
Underground-duct
IX International PHOENICS Users Conference
Your Success is Our Goal
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Distribution-chamber
Furnace Troubleshooting
IX International PHOENICS Users Conference
Your Success is Our Goal
Slide 4
 Problem 1: Hot air has a high swirl flow inside
the underground duct;
 Problem 2: The mass flux distribution between
the two plenum is not uniform;
 Problem 3: The mass flux distribution between
the burners within the plenum is not uniform;
 Problem 4: The flames in the two combustion
chambers are leading.
INERTARGON_IX_IPUC_MOSKOW2002.ppt
The increase in the pre-heated air mass-flow lead
to several problems during the furnace operation:
© IT PS 2002
INTRODUCTION – THE PROBLEM
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 5
© IT PS 2002
PROBLEM 1 – UNDERGROUND DUCT
Description
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 6
© IT PS 2002
PROBLEM 1 – UNDERGROUND DUCTS
Geometry
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
Grid: cartesian
PARSOL: no
Energy Equation: no
noCombustion:
Turbulence Model: standard k-, Chen-Kim k-
and RNG k-
 Transient: no
IX International PHOENICS Users Conference
Your Success is Our Goal
Slide 7





INERTARGON_IX_IPUC_MOSKOW2002.ppt
All simulations were run on PHOENICS v3.3. The
follow configuration was setting:
© IT PS 2002
PROBLEM 1 – UNDERGROUND DUCT
General Settings
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 8
© IT PS 2002
PROBLEM 1 – UNDERGROUND DUCT
Original Case Simulation
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
1
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 9
© IT PS 2002
PROBLEM 1 – UNDERGROUND DUCT
Problem Identification
2
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
Slide 10
© IT PS 2002
PROBLEM 1 – UNDERGROUND DUCT
Problem Solution
INERTARGON_IX_IPUC_MOSKOW2002.ppt
1
2
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
1
IX International PHOENICS Users Conference
2
Your Success is Our Goal
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 11
© IT PS 2002
PROBLEM 1 – UNDERGROUND DUCT
Problem Solution Results
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 12
© IT PS 2002
PROBLEM 2 – UNDERGROUND DUCT
Description
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 13
© IT PS 2002
PROBLEM 2 – UNDERGROUND DUCTS
Geometry
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
Grid: cartesian
PARSOL: no
Energy Equation: no
Combustion: no
Turbulence Model: standard k-, Chen-Kim k-
and RNG k-
 Transient: no
IX International PHOENICS Users Conference
Your Success is Our Goal
Slide 14





INERTARGON_IX_IPUC_MOSKOW2002.ppt
All simulations were run on PHOENICS v3.3. The
follow configuration was setting:
© IT PS 2002
PROBLEM 2 – UNDERGROUND DUCT
General Settings
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 15
© IT PS 2002
PROBLEM 2 – UNDERGROUND DUCT
Original Case Simulation
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
© IT PS 2002
PROBLEM 2 – UNDERGROUND DUCT
Problem Identification
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 16
Mass Flow
35% Greater
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Furnace Troubleshooting
1
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 17
© IT PS 2002
PROBLEM 2 – UNDERGROUND DUCT
Problem Solution
2
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 18
© IT PS 2002
PROBLEM 2 – UNDERGROUND DUCT
Problem Solution Results
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 19
© IT PS 2002
PROBLEM 2 – UNDERGROUND DUCT
Problem Solution Results
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 20
© IT PS 2002
PROBLEMS 3 & 4 – PLENUM
Description
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 21
© IT PS 2002
PROBLEM 3 & 4 – PLENUM
Geometry
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
Grid: cartesian
PARSOL: active (on some cases)
Energy Equation: no
Combustion: no
Turbulence Model: standard k-, Chen-Kim k-
and RNG k-
 Transient: no
IX International PHOENICS Users Conference
Your Success is Our Goal
Slide 22





INERTARGON_IX_IPUC_MOSKOW2002.ppt
All simulations were run on PHOENICS v3.3 and
v.3.4. The follow configuration was setting:
© IT PS 2002
PROBLEM 3 & 4 – PLENUM
General Settings
Furnace Troubleshooting
© IT PS 2002
PROBLEM 3 & 4 – PLENUM
Problem Identification
Slide 23
1.000
0.950
0.900
0.850
0.800
0.750
0.700
0.650
0.600
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Burners
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Your Success is Our Goal
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Mass Flow (kg/s)
Burners Mass Flow Profile
Furnace Troubleshooting
© IT PS 2002
PROBLEM 3 & 4 – PLENUM
Problem Identification
Slide 24
1
4
INERTARGON_IX_IPUC_MOSKOW2002.ppt
2
3
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
3
1
IX International PHOENICS Users Conference
Your Success is Our Goal
INERTARGON_IX_IPUC_MOSKOW2002.ppt
2
Slide 25
© IT PS 2002
PROBLEM 3 & 4 – PLENUM
Problem Solution
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 26
© IT PS 2002
PROBLEM 3 & 4 – PLENUM
Problem Identification
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
© IT PS 2002
PROBLEM 3 & 4 – PLENUM
Problem Solution Results
Slide 27
1.000
0.950
0.900
0.850
0.800
0.750
0.700
0.650
0.600
Q1
Q2
Q3
Q4
Q5
Q6
Q7
Q8
Burners
IX International PHOENICS Users Conference
Your Success is Our Goal
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Mass Flow (kg/s)
Burners Mass Flow Profile
Furnace Troubleshooting
© IT PS 2002
PROBLEM 3 & 4 – PLENUM
Problem Solution Results
Slide 28
1
4
INERTARGON_IX_IPUC_MOSKOW2002.ppt
2
3
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 29
© IT PS 2002
PROBLEM 4 – COMBUSTION CHAMBER
Description
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 30
© IT PS 2002
PROBLEM 4 – COMBUSTION CHAMBER
Geometry
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
All simulations were run on PHOENICS v3.4. The
follow configuration was setting:
IX International PHOENICS Users Conference
Slide 31
Grid: cartesian
PARSOL: active
Energy Equation: active
Combustion: active (SCRS)
Turbulence Model: Chen-Kim k-
Transient: no
INERTARGON_IX_IPUC_MOSKOW2002.ppt






© IT PS 2002
PROBLEM 4 – COMBUSTION CHAMBER
General Settings
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 32
© IT PS 2002
PROBLEM 4 – COMBUSTION CHAMBER
Original Case Simulation
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
INERTARGON_IX_IPUC_MOSKOW2002.ppt
Slide 33
© IT PS 2002
PROBLEM 4 – COMBUSTION CHAMBER
Problem Solution Results
IX International PHOENICS Users Conference
Your Success is Our Goal
Furnace Troubleshooting
 That result indicates that the leaning flames are not only caused
by bad distribution of air but may also be caused by the number
of firing ports in each burner. Decreasing the number of ports
might lead to a higher momentum jet from the residing ports,
which might in turn mix the fuel better with the preheated air
stream and create shorter flames. This would result in a smaller,
more compact flame envelope, which would have less tendency
of leaning to either side of the furnace
IX International PHOENICS Users Conference
Your Success is Our Goal
Slide 34
 Although the Chen-Kim and RNG k- models converged to the
same solution behavior, the standard k- one seems to underpredict the recirculation zones and the flames inclination.
INERTARGON_IX_IPUC_MOSKOW2002.ppt
 The results showed good qualitative agreement with observed
behavior during furnace operation.
© IT PS 2002
CONCLUSIONS