Babcock & Wilcox 1

Enhancing the Circulation Analysis of a Recovery

Boiler Through the Incorporation of 3-D Furnace Heat
Transfer Results from COMO
M.J. Albrecht
The Babcock & Wilcox Company
Barberton, Ohio, U.S.A.
Presented to:
2002 TAPPI Fall Technical Conference
September 8-12, 2002
San Diego, California, U.S.A.
BR-1729
Abstract
In the design of a highly loaded new or upgraded recovery
boiler, the heat absorption profile distribution in the furnace
becomes an important design parameter in evaluating the circu-
lation adequacy of the unit.
To enhance the current circulation analysis for recovery boil-
ers, furnace heat transfer results from the computational three-
dimensional combustion analysis program, COMO
SM
, have been
incorporated into the companys circulation analysis program.
The evaluation of circulation results for a highly loaded recov-
ery boiler, which incorporated the heat transfer results from the
computational combustion model, is compared to calculations
generated using typical heat transfer analysis procedures in an
effort to offer a less conservative and more accurate evaluation
of the unit.
Introduction
Todays recovery boilers are being designed for higher heat
inputs and solids flows per plan area compared to previous boiler
designs. The circulation design margin for these boilers has been
reduced due to increased performance and capacity require-
ments. At specific heat and solids inputs per plan area, the re-
covery boilers performance reaches a level that can be defined
as highly loaded. Table 1 provides general guidelines used to
determine if the recovery boiler is highly loaded.
For highly loaded boilers, circulation design aspects need to
be carefully evaluated to determine if the boiler has adequate
circulation flow to sufficiently cool the furnace enclosure and
the water-cooled surfaces in the convection pass, i.e. generat-
ing bank. The circulation adequacy of a highly loaded recovery
boiler can only be evaluated accurately if the furnace heat in-
puts are correctly determined.
In optimizing emissions from a recovery boiler, combustion
modeling is typically requested for evaluating and advancing
the design of original- or retrofit-boiler equipment. Furnace heat
transfer results for a highly loaded recovery boiler were generated
from the proprietary Combustion ModelCOMO
SM
and where
used in the companys proprietary circulation analysis program.
Since 1980, The Babcock & Wilcox Company (B&W) has
invested considerable resources developing the proprietary Com-
bustion ModelCOMO. The types of fuels considered in the
combustion model include black liquor, wood, refuse-derived
fuel, other biomass fuels, and fossil fuels (coal, oil and natural
gas). The physical processes modeled are three-dimensional
turbulent gas flow, particle motion (turbulent dispersion, depo-
sition, and re-entrainment), chemical reactions, and heat trans-
fer (radiation, convection, and conduction). Advanced capabili-
ties such as unstructured mesh generation, adaptive mesh re-
finement, parallel processing and graphical visualization soft-
ware are used to enhance the accuracy and interpretation of
modeling results.
2 Babcock & Wilcox
The circulation analysis program is a company-developed
furnace enclosure evaluation program that utilized the most
advanced techniques to calculate heat transfer and both single
and two-phase fluid flow parameters. With this program, a cir-
culation model of the entire boiler is evaluated. The results pro-
vide detailed information on thermodynamic characteristics (i.e.
fluid properties, pressure drop, flow rates, etc.) for each circuit
of the model. Program results are compared to the companys
design criteria to determine adequacy of the circulation design.
The circulation results generated using a computational com-
bustion models heat absorption inputs are compared to circu-
lation results generated using typical heat transfer analysis pro-
cedures. To offer a less conservative and more accurate circula-
tion evaluation of recovery boilers, the heat absorption results
from combustion modeling are shown to be an enhancement for
evaluating the circulation on recovery units that are highly
loaded and sensitive to operational conditions caused by com-
bustion and air system changes.
Prediction of Local Furnace
Heat Absorption Rates
No simple method exists to accurately predict local furnace
absorption rates. In a recovery boiler circulation study, heat ab-
sorption in the furnace is determined using empirical methods
that have been enhanced by field measurements. The total heat
absorbed is a function of the fuel characteristics, the furnace
surface area and the gas temperature leaving the furnace. The
vertical distribution of the total heat absorbed in the furnace is
accomplished by empirical distribution methods. Using these
methods, the furnace is divided into zones of similar absorp-
tion characteristics, and average absorption rates are calculated
for each of these zones. For a typical recovery boiler, the num-
ber of zones can vary from one to as many as six. Also, in most
cases, no horizontal variation to the heat absorption in each zone
is applied. In the lower furnace, the heat absorbed in a side,
front or rear tube would be the same regardless of the tubes
location in the wall.
Figure 1 shows a typical set of heat absorption zones for a
recovery boiler when calculated using an empirical method.
Zone X represents the heat absorbed into the floor tubes. Zone
A
1
is the heat absorbed in the smelt bed region of the furnace.
Zone A
2
is the furnace zone immediately after the tertiary air
ports. At the base of the arch Zone A
3
starts and ends at the
upper knee point of the arch. Zone A
4
is the upper furnace zone
that exists from the upper knee of the arch to the roof; the ver-
tical plane of this zone forms the furnace exit gas plane. Zone B
is the convective and radiative zone immediately above the up-
per floor of the arch. Zone C is the convective heat transfer
zone that encloses the units generating bank.
Recovery Boiler Modeling
The combustion model for recovery boilers has unique ca-
pabilities to simulate combustion of black liquor, including
coarse sprays burning in suspension and black liquor deposits
burning on the furnace walls and char bed. The model is rou-
tinely used to optimize fuel and air delivery systems, provide
higher black liquor processing capacity with tighter design
margins, and minimize pulp mill production costs. Modeling
has successfully improved recovery boiler design and opera-
tion in a large number of applications. Visual observations of
the furnace conditions combined with supporting operation data
provide a high level of confidence that the results are indeed an
accurate representation of the actual processes in the boiler. A
few of these cases have been described in the literature.
[1,2,3]
Figure 2 shows the furnace wall heat fluxes that are gener-
ated for a highly loaded recovery boiler using the combustion
model. The heat fluxes are shown from different perspectives
from the side, front and plan views. The heat absorption can
vary from wall to wall. Also, the total heat absorbed by a tube
on a specific wall will vary depending on the location of the
tube along the wall. Tubes located in the center region of the
wall will absorb more heat than tubes located in the corner lo-
cations of the wall. Knowing the variation in the heat absorp-
tion across the wall and the changes in the vertical heat absorp-
tion from top to bottom of the wall allows for a more accurate
set of heat inputs for the circulation analysis of the furnace.
Table 1
Criteria for a Highly Loaded Recovery Boiler
Heat input per plan area >11360 MJ/hr-m
2
(>1,000,000 Btu/hr-ft
2
)
Solids flow per plan area >21.96 t
m
/day-m
2
(>4500 lb/day-ft
2
)
Volume per B&W ton < 1.25 m
3
/t
m
dry solids
(<60 ft
3
/B&W ton)
Furnace exit gas temperature >927C
(>1700F)
Generating Bank Inlet Temperature >704C
(>1300 F)
Figure 1 Sectional side view of typical heat absorption
zones for a recovery boiler.

Zone A
2
Zone A
3
Zone A
4
Zone X
Tertiary Air Ports
Zone A
1
Zone C Zone B
Babcock & Wilcox 3
Wall Heat
Absorption
Max
Min
TA
BL
PA
SA
R
ig
h
t S
id
e
W
a
ll
Rear W
all
TA
BL
PA
SA
Left Side Wall F
ro
n
t W
a
ll
Figure 2 Heat flux patterns along each wall of a recovery
boiler.
Comparison of Empirical and
Numerical Heat Absorptions
The furnace heat absorption values for a 1724 t
m
/day
(3.8 Mlb/day) highly loaded recovery boiler were determined
using an empirical calculation procedure and through a three-
dimensional combustion model. The results from these two
methods are compared using the same furnace zone selections
shown in Figure 1. In the combustion model of the furnace, a
large number of surface elements existed in each of the zones given
in Figure 1. Summation of the heat transfer for each zone was
obtained for comparison to the empirical calculated heat absorp-
tion values. The results of this comparison are given in Table 2.
Overall, the empirical method and numerical combustion
model in this comparison were 3% and 1% respectively to the
theoretical calculated total heat absorption for the furnace. The
combustion model located 5.6% less absorption above the ter-
tiary air ports than the empirical method and 27% more absorption
below the tertiary air ports. The distribution effects from each
method were incorporated into a circulation model of the furnace
and the circulation results were compared for differences.
Circulation Evaluation of a
Recovery Boiler
The circulation evaluation of the recovery boiler is accom-
plished by incorporating boiler geometry and heat absorption
information into a specific format that can be recognized by the
circulation program. At the heart of the companys circulation
program are the most advanced techniques for calculating heat
transfer and both single and two-phase fluid flow parameters.
With this computer program, a detailed circulation model of
the entire boiler is evaluated.
The geometric description of each boiler circuit is input into
the program. The geometric description includes the descrip-
tion of downcomers, downcomer supplies, circuit supplies, ris-
ers, orifices, bends, and swages as well as the individual tubes
making up the circuit. Circuits within the boiler are subject to
the variations in heat absorption. The computer program handles
this by allowing the user to divide each circuit into zones and to
input different heat absorption rates for each zone. Given the
geometry description and the absorption profile, the computer
program determines the balanced water and steam flow in each
circuit by solving the energy, mass, and momentum equations
for the model of the unit. The results from the program provide
detailed information on fluid properties, pressure drop, and flow
rates for every zone in every circuit. Figure 3 is an example of a
nodal diagram of a circulation model for a typical two drum
recovery boiler.
At the balanced flow condition, design criteria are examined
to determine whether circulation characteristics are adequate.
For each condition analyzed, adjustments are made to individual
circuits, when necessary, to bring their flow characteristics
within limits. These limits are based on the companys experi-
ence and knowledge from field and laboratory testing. Each cir-
culation analysis is unique and the requirements to achieve ac-
ceptable circulation characteristics are case-specific to the boiler
and the operating conditions being examined.
Comparison of Circulation Results
Using the heat absorption results for the 1724 t
m
/day (3.8
Mlb/day) recovery boiler, a circulation model that incorporated
the heat absorption input values from the combustion model
was compared to a circulation model that utilized the empiri-
cally generated heat absorption inputs. In each model, the cir-
culation characteristics of each furnace circuit were compared to
design criteria in order to establish a gauge of conservatism and
accuracy. The design criteria used consisted of the following:
Exit quality
Flow velocity
Flow stability
Flow sensivitity
Departure from Nucleate Boiling (DNB)
These limits are a few of the critical limts necessary for ad-
equate circulation conditions. More details on these circulation
design limits are available in the literature.
[4,5]
Since the combustion models heat absorption results showed
an increase in heat absorption below the tertiary air ports and a
decrease in heat absorption above the tertiary air ports, a differ-
ence in the circulation models was expected. The circulation
model that utilized the combustion models heat inputs resulted
in higher velocities and lower exit qualities for circuits in the
Table 2
Comparison of Combustion Model Heat Absorption
Values to Empirical Calculated Values
Furnace Zone Percent Change in Absorption from
Empirical Method Calculation
(( Q
comb model
Q
emp
)/Q
emp
)x100%
X (floor) 91.7 %
A
1
(below tertiary ports) 16.6 %
A
2
(above tertiary ports) 23.2 %
A
3
(below arch nose ) -24.5 %
A
4
(between arch nose and roof) -65.3 %
B (above arch) No change
C (heat Absorbed by generating bank) No change
4 Babcock & Wilcox
front and rear walls of the unit. This was due to the higher over-
all heat absorptions that were calculated by the combustion
model versus the empirical calculation model. However, even
with the horizontal variation in heat absorptions from the com-
bustion model, the circulation pressure drops for all the circuits
were within 3% of the empirically calculated circuit pressure
drops. The major circulation design criteria most affected by
the heat absorptions from the combustion model were flow sta-
bility, flow sensitivity and departure from nucleate boiling.
The furnace wall circuits in the circulation model that uti-
lized the combustion models heat inputs exhibited less conser-
vatism towards flow stability and flow sensitivity problems than
the similar furnace wall circuits in the circulation model that
utilized empirically generated heat absorptions. In several cases,
indications for flow instability were uncovered in the circula-
tion model that utilized the combustion models heat inputs;
these were not indicated in the circulation model that utilized
empircally generated heat absorptions. Also, the departure from
nucleate boiling limits for the furnace floor were affected by
the 90+% increase in heat absorption (see Table 2) that was
calculated in the combustion model. The departure from nucle-
ate boiling flow criteria for the increased heat absorption re-
sulted in a required floor design velocity that was 14% greater
than the velocity required based upon the empirical calculation
heat flux. For a highly loaded recovery boiler, maintaining ac-
ceptable flow velocities in the floor is critical to successful op-
eration of the unit without concern for reduced floor life, tube
cracking, tube overheating and/or tube failure.
The difference in the heat absorptions in the furnace between
the two models resulted in a circulation difference in the gener-
ating bank of the unit. The total circulation flow for the furnace
in the circulation model that utilized the combustion models
heat inputs was 4% more than the total furnace circulation flow
calculated in the circulation model that used the empirically
generated heat inputs. The increase in the total flow in the fur-
nace resulted in less flow for the generating bank circuits, which
could lead to flow stability and/or flow sensitivity problems.
Assuring good flow characteristics in the generating bank cir-
cuits is required for stable drum level and operational control
of the unit.
Conclusions
The heat absorption input used in a recovery boiler circula-
tion evaluation is an important parameter for determining the
overall adequacy of the circulation system. For recovery boiler
designs that meet the highly loaded criteria, a circulation model
that incorporates combustion model heat inputs is recommended
for obtaining a more accurate description of the units circula-
tion characteristics.
Combustion modeling is a powerful engineering tool for pre-
dicting jet penetration, mixing, combustion, particle carryover,
gas species (e.g. O
2
, CO, and NO
x
), gas flow/temperature uni-
formity in the boiler, and furnace wall heat absorption. For a
highly loaded recovery boiler, changes to fuel and air systems
can be simulated and optimized so that the performance results
can be considered in the circulation design of the boiler. Circu-
lation models that utilize combustion model heat absorption rates
will be more accurate and less conservative that empirical cal-
culation methods. In addition, circulation models that utilize
combustion heat transfer values will incorporate horizontal heat
distribution variations that are important for identifying flow
stability and sensitivity problems in the furnace circuits. The
incorporation of combustion model heat input values into a cir-
culation model of a recovery boiler eliminates the need for costly
circulation testing of a troubled unit.
Figure 3 Nodal description of recovery boiler circulation model.
Babcock & Wilcox 5
Copyright 2002 by The Babcock & Wilcox Company,
a McDermott company.
All rights reserved.
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Disclaimer
Although the information presented in this work is believed to be reliable, this work is published with the understanding that The Babcock &
Wilcox Company and the authors are supplying general information and are not attempting to render or provide engineering or professional
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use of, or the inability to use, any information, product, process or apparatus discussed in this work.
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References