Using computational fluid dynamics to predict the erosion rates on the cyclones wall for coal boiler plant
DOI:
https://doi.org/10.15282/jmes.14.4.2020.16.0590Keywords:
Computational fluid dynamics, erosion rate, cyclone, coal boilerAbstract
In the industrial coal boiler, cyclone is used to separate the silica sands (as fluidizing medium) from the furnace combution gas. A gas-solid separation system with turbulent swirling flow that occurs in the cyclone will cause erosion on the cyclone wall. The erosion will cause a decrease in the cyclone performance and increase the maintenance cost. CFD simulation was conducted to predict this erosion using industrial cyclone in the coal boiler industry on its actual dimensions. The dimensions were 5120 mm in diameter and 13970 mm in height. It was performed using the Reynolds Stress Model (RSM) for turbulence flow in the gas phase and the Oka erosion model. The erosion rate on the cyclone wall was investigated at various gas inlet velocity and solid rate. The inlet velocities ranged from 6 to 8 m/s and the solid rates ranged from 30 to 40 kg/s with silica sands as solid particles (0.075 and 1.5 mm in diameter). At the selected local area, the results showed that the higher gas inlet velocity for the same solid rate would increase the erosion rate (about 25%). However, the higher solid rate for the same velocity will also increase the erosion rate on the cyclone wall (about 18%). These results indicate that cyclone wall errosion are significantly affected by inlet gas velocity.
References
Z. Gao, J. Wang, J. Wang, and Y. Mao, "Time-frequency analysis of the vortex in cylindrical cyclone separator," Chemical Engineering Journal, vol. 373, pp. 1120-1131, 2019, doi: 10.1016/j.cej.2019.05.054.
S. Demir, A. Karadeniz, and M. Aksel, "Effects of cylindrical and conical heights on pressure and velocity fields in cyclones," Powder Technology, vol. 295, pp. 209-217, July 2016, doi: 10.1016/j.powtec.2016.03.049.
S. Danyluk, W. J. Shack, and J. Y. Park, "The erosion of a type 310 stainless steel cyclone from a coal gasification pilot plant," Wear, vol. 63, pp. 95-104, August 1980, doi: 10.1016/0043-1648(80)90076-9.
A. Huang, K. Ito, T. Fukasawa, K. Fukui, and H. Kuo, "Effects of particle mass loading on the hydrodynamics and separation efficiency of a cyclone separator," Journal of the Taiwan Institute of Chemical Engineers, vol. 90, pp. 61-67, September 2018, doi: 10.1016/j.jtice. 2017.12.016.
P. Liu, Y. Ren, M. Feng, D. Wang, and D. A. Hu, "Performance analysis of inverse two-stage dynamic cyclone separator," Powder Technology, vol. 351, pp. 28-37, 1 Juni 2019, doi: 10.1016/j.powtec.2019.04.002.
S. Y. Noh, J. E. Heo, S. H. Woo, S. J. Kim, M. H. Ock, Y. J. Kim, and S. Yook, "Performance improvement of a cyclone separator using multiple subsidiary cyclones," Powder Technology, vol. 338, pp. 145-152, October 2018, doi: 10.1016/ j.powtec.2018.07.015.
D. Misiulia, A. G. Andersson, and T. S. Lundström, "Computational investigation of an industrial cyclone separator with helical-roof inlet," Chemical Engineering & Technology, vol. 38, no. 8, pp. 1425–1434, 2015, doi: 10.1002/ ceat.201500181.
S. Wang, H. Li, R. Wang, X. Wang, R. Tian, and Q. Sun, "Effect of the inlet angle on the performance of a cyclone separator using CFD-DEM," Advanced Powder Technology, vol. 30, pp. 227-239, February 2018, doi: 10.1016/j.apt.2018.10.027.
A. C. Hoffman and L. E. Stein, "Gas cyclone and swirl tubes," Springer, Chapter 2, pp. 45-48, 2008.
M. Jia, D. Wang, C. Yan, J. Song, Q. Han, F. Chen, and Y. Wei, "Analysis of the pressure fluctuation in the flow field of a large-scale cyclone separator," Powder Technology, vol. 343, pp. 49-57, 1 February 2018, doi: 10.1016/j.powtec.2018. 11.007.
K. S. Lim, H. S. Kim, and K. W. Lee, "Characteristics of the collection efficiency for a cyclone with different vortex finder shapes," Journal of Aerosol Science, vol. 35, pp. 743-754, 2004, doi: 10.1016/j.jaerosci.2003.12.002.
Y. Li, G. Qin, Z. Xiong, Y. Ji, and L. Fan, "The effect of particle humidity on separation efficiency for an axial cyclone separator," Advanced Powder Technology, vol. 30, no. 4, pp. 724-731, April 2019, doi: 10.1016/j.apt.2019.01.002.
I. Karagoz and A. Avci, "Modelling of the pressure drop in tangential inlet cyclone separators," Aerosol Science and Technology, vol. 39, pp. 857-865, 2005, doi: 10.1016/j.jaerosci.2003.12.002.
S. Hoseinzadeh and P. S. Heyns, "Thermo-structural fatigue and lifetime analysis of a heat exchanger as a feedwater heater in power plant," Engineering Failure Analysis, vol. 113, pp. 104548, July 2020, doi: 10.1016/j.engfailanal.2020.104548.
S. Hoseinzadeh, A. Moafi, A. Shirkani, and A. J. Chamkha, "Numerical validation heat transfer of rectangular cross-section porous fins," Journal of Thermophysics and Heat Transfer, vol. 33, 2019, doi: 10.2514/1.T5583.
S. Hoseinzadeh, R. Ghasemiasl, D. Havaei, and A. J. Chamkha, "Numerical investigation of rectangular thermal energy storage units with multiple phase change materials," Journal of Molecular Liquids, vol. 271, pp. 655-660, 1 December 2018, doi: 10.1016/ j.molliq.2018.08.128.
M. S. Masnadi, J. R. Grace, S. Elyasi, and X. Bi, "Distribution of multi-phase gas–solid flow across identical parallel cyclones: Modeling and experimental study," Separation and Purification Technology, vol. 72, no. 1, pp. 48-55, 30 March 2010, doi: 10.1016/ j.seppur.2009.12.027.
A. Kepa, "The effect of a counter-cone position on cyclone performance," Separation Science and Technology, vol. 47, no. 16, pp. 2250-2255, November 2012, doi: 10.1080/01496395.2012.671878.
T. C. Hsiao, D. R. Chen, P. S. Greenberg, and K. W. Street, "Effect of geometric configuration on the collection efficiency of axial flow cyclones," Journal of Aerosol Science, vol. 42, no. 2, pp. 78-86, February 2011, doi: 10.1016/j.jaerosci.2010.11.004.
H. Safikhani, "Modeling and multi-objective Pareto optimization of new cyclone separators using CFD, ANNs and NSGA II algorithm," Advanced Powder Technology, vol. 27, no. 5, pp. 2277-2284, September 2016, doi: 10.1016/ j.apt.2016.08.017.
M. Wasilewski and L. S. Brar, "Effect of the inlet duct angle on the performance of cyclone separators," Separation and Purification Technology, vol. 213, pp. 19-33, 15 April 2019, doi: 10.1016/j.seppur.2018.12.023.
Q. Wei, G. Sun, and J. Yang, "A model for prediction of maximum-efficiency inlet velocity in a gas-solid cyclone separator," Chemical Engineering Science, vol. 204, pp. 287-297, 31 August 2019, doi: 10.1016/j.ces.2019.03.054.
L. S. Brar, R. P. Sharma, and K. Elsayed, "The effect of the cyclone length on the performance of stairmand high-efficiency cyclone," Powder Technology, vol. 286, pp. 668-677, December 2015, doi: 10.1016/j.powtec.2015.09.003.
A. Sakin, I. Karagoz, and A. Avci, "Performance analysis of axial and reverse flow cyclone separators," Chemical Engineering and Processing: Process Intensification, vol. 144, p. 107630, October 2019, doi: 10.1016/j.cep.2019.107630.
M. Parsi, M. Agrawal, V. Srinivasan, R. E. Vieira, C. F. Torres, B. S. McLaury, and S. A. Shirazi, "CFD simulation of sand particle erosion in gas-dominant moltiphase flow," Journal of Natural Gas Science and Engineering, vol. 27, no. 2, pp. 706-718, November 2015, doi: 10.1016/j.jngse.2015.09.003.
T. A. Sedrez, R. K. Decker, M. K. Da Silva, D. Noriler, and H. F. Meier, "Experiments and CFD-based erosion modeling for gas-solids flow in cyclones," Powder Technology, vol. 311, pp. 120-131, 15 April 2017, doi: 10.1016/j.powtec.2016.12.059.
B. Zhao, Y. Su, and J. Zhang, "Simulation of gas flow pattern and separation efficiency in cyclone with conventional single and spiral double configuration," Chemical Engineering Research and Design, vol. 84, no. 12, pp. 1158-1165, December 2006, doi: 10.1205/ cherd06040.
S. G. Bogodage and A. Y. T. Leung, "CFD simulation of cyclone separators to reduce air pollution," Powder Technology, vol. 286, pp. 488-506, December 2015, doi: 10.1016/j.powtec.2015.08.023.
F. Parvaza, S. H. Hosseinib, K. Elsayedc, and G. Ahmadid, "Numerical investigation of effects of inner cone on flow field, performance and erosion rate of cyclone separators," Separation and Purification Technology, vol. 201, pp. 223-237, August 2018, doi: 10.1016/ j.powtec.2015.08.023.
I. ANSYS, ANSYS Fluent Theory Guide, Technology Drive Canonsburg, PA 15317, November 2013.
Y. I. Oka, K. Okamura, and T. Yoshida, "Practical estimation of erosion damage caused by solid particle impact. Part 1: effects of impact parameters on predictive equation," Wear, vol. 259, no. 1-6, pp. 95-101, July-August 2005, doi: 10.1016/ j.wear.2005.01.039.
Downloads
Published
How to Cite
Issue
Section
License
Copyright (c) 2024 The Author(s)
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
