Powder Technology 235 (2013) 590598

Contents lists available at SciVerse ScienceDirect

Powder Technology
journal homepage: www.elsevier.com/locate/powtec

The thermal-hydraulic calculation and analysis of the medium temperature platen

superheater in a 300 MWe CFB boiler
Wu Haibo a, b, Zhang Man c,, Sun Yunkai a, Lu Qinggang a
a
b
c

Institute of Engineering Thermophysics, Chinese Academy of Sciences, Haidian District, Beijing 100190, China
Graduate University of Chinese Academy of Sciences, Haidian District, Beijing 100049, China
Department of Thermal Engineering , Tsinghua University

a r t i c l e

i n f o

Article history:
Received 22 June 2012
Received in revised form 8 October 2012
Accepted 1 November 2012
Available online 8 November 2012

a b s t r a c t
The characteristics of outlet steam temperature and the metal temperature of the medium temperature platen superheater at different boiler loads was obtained in a 300 MWCFB boiler, the result shows that the imbalance rate of tube mass ux is determined by the structure of header and tube. Generally Z type
arrangement is one of the reasonable types arrangement.
2012 Elsevier B.V. All rights reserved.

Keywords:
300 MWe CFB boiler
Medium temperature platen superheater
Hydrodynamics
Metal temperature

1. Introduction
During the last two decades circulating uidized bed (CFB) boiler
has been greatly developed and CFB combustion is a kind of clean coal
technology with the advantages of wide fuel exibility, high efcient
sulfur removal, low NOX emission, large turn-down ratio of boiler
load, comprehensive ash utilization, etc. [1]. As a technology with
bright prospect, CFB boiler with high steam parameters can further
improve the boiler efciency and reduce the pollution emissions [2],
it becomes an important power generation way for power industry
in China. With the scaling-up of CFB boilers, it is necessary to install
additional heating surface to insure adequate heat absorption and
the platen heating surface is generally arranged in the furnace [3].
Because of the deviation of thermal calculation during boiler design
or the operational conditions change during peak load regulation [4], it
directly affects the in-tube heat transfer of platen heating surface and
then affect the wall temperature of the tube, which may seriously restrict
the safe operation of the units. The appearance frequency of tube damage
accidents, up to approximately 40% in some power plant, of platen
heating surface is the highest among all of the heating surfaces [5] and
overtemperature is an important factor leading to tube damage accidents. Due to complex structures and harsh operating conditions (high
steam parameters, large boiler capability, low mass ux and sliding pressure mode), it required higher requirement for heating surface design
and boiler operation conditions. Therefore, accurate calculation of the

Corresponding author.
E-mail addresses: zhmzhm2004@126.com, hbcperformance2@tom.com (M. Zhang).
0032-5910/$ see front matter 2012 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.powtec.2012.11.001

wall temperature of the platen heating surface in furnace is vitally significant in practice [6]. The wall temperature calculation is related to heat
nonuniformity, hydraulic nonuniformity, structure nonuniformity and
the heat transfer, it is assumed that the structure is uniform, the hydrodynamics, heat deviation, the heat transfer is considered in this paper.
Operational conditions, structure characteristics, and resistance
characteristics are generally considered in the hydrodynamic calculation. Conventional hydrodynamic calculation method cannot correctly
reect the ow conditions of tube. Some scholars have built different
mathematical models to calculate the mass ux distribution and the
wall temperature in natural circulation boiler and once-through boiler,
such as Kim and Choi [7], Yang Dong [8], Tucakovic [9], Lin Zonghu [10],
etc. Because these works were either done for pulverized coal-red
boiler or done for waterwall, little literature is done for the platen
heating surface in CFB boiler. Therefore, it is very meaningful to research
the thermal-hydraulic characteristics and wall temperature of platen
heating surface in CFB boiler. The heat transfer of the platen heating
surface of CFB boilers is also a complex process. Properly selecting the
heat transfer coefcients between bed and external tube wall and
between steam and internal tube wall of platen heating surface are
very important.
In this paper,discrete method [11] is used to solve the hydraulic
calculation and some key factors taken were corrected. Heat transfer
coefcient is calculated by heat transfer coefcient model [12]. This
paper explored the mass ux, the outlet steam temperatures and
the metal temperatures in platen superheater at 51%, 75% and 94%
BMCR load in a 300 MW CFB Power Plant, respectively, and its operating safety was evaluated. The result shows that the calculation
results agree well with the operational results on site.

H. Wu et al. / Powder Technology 235 (2013) 590598

2. Arrangement of medium temperature platen heating surface I

Medium temperature platen superheater of a commercial 300
MWe CFB boiler with a pantleg type furnace, natural circulation and
circulating uidized bed combustion was studied. The boiler is composed of three main parts a furnace with a waterwall membrane,
two hot cyclone separators on each side of the furnace, a twin-exit
loop seal at the end of each cyclone standpipe and the convection
pass. There are 16 pieces of platen superheater in the furnace including
8 pieces of platen superheater I arranged in the front wall and 8 pieces
of platen superheater II arranged in the back wall. Medium temperature
platen superheater is composed of a series of single tubes, the inlet and
outlet steam is collected to header through tubes. The tube number in
the same piece of platen superheater is 37, the inner diameter of the
tubes is 0.038 m.
The tube of medium temperature platen superheater I closed to
the centre of the furnace is named number 37 tube (hereafter called
No. 37 tube), the tube closed to the front wall of the furnace is
referred to as the No. 1 tube. The number of other tubes can be obtained
based on it.
The arrangement of platen superheater I is shown in Fig. 1.
The main parameters at different operation loads are shown in
Table 1.

591

Table 1
Boiler main parameters.
Items

Unit

Steam ow rate
Inlet steam temperature
Outlet steam temperature
Inlet steam pressure
Outlet steam pressure

Load

t/h
C
C
MPa
MPa

94% BMCR

75% BMCR

51% BMCR

991
378.6
433
17.65
17.3

730
370
436
14.6
14.3

543
360
420
12.91
12.78

the boiler load, the header diameter, the tube diameter, the tube
number in the same piece of platen superheater, resistance of inner
tube,the pitch of tube and header connection type arrangement, etc.
Discrete model [11] was applied in this paper. It can simulate the
actual structure of parallel tubes. Each parameter mentioned above
was fully considered, the static pressure characteristics of distribution
header and collection header and mass ux and mass ux deviation
factor of tubes were calculated. The calculation chart can be seen in
Fig. 2.
(1) Momentum equation at tube inlet and outlet (at 1,3 area
respectively in the Fig. 2)
Distribution header (at 1 area)



2
2
P fq;i P fh;i P f;i f K f V fh;i V fq;i

3. Mathematical model

i 1; 2; :; n
1

3.1. Calculation model of mass ux

Pf,i can be calculated by the following fomula:

The ow characteristics of header is affected by many factors

including operating conditions and structural parameters, such as

P f;i

7
P

2
j df

V f q;i V fh;i
8D

Collection header (at 3 areas)


2
2
P hq;i P hh;i P h;i h K h V hh;i V hq;i

i 1; 2; :; n
3

P h;i

2
j dh

V hq;i V hh;i
8D

3
Vhq, i

Vhh, i

Phq, i - 1

6
T

Phq, i

Phh, i

Vhq, i - 1

Vi - 1

Vi

Vi + 1

Vf q, i

Vf h, i
Vf q, i - 1
Pf q, i - 1

v
the front wall of the furnace the rear wall of the furnace Medium
Temperature Platen Superheater I steam inlet steam outlet temperature
measurement point pressure measurement point the furnace
Fig. 1. The arrangement of medium temperature platen superheater I.

Pf q, i

Pf h, i

1
Fig. 2. The calculation chart.

592

H. Wu et al. / Powder Technology 235 (2013) 590598

Where: d is the inner diameter of tube, m; D is the inner diameter of header, m; f, h is the uid density in distribution
header and collection header, respectively, kg/m 3; pfq,i, phq,i is
the upper static pressure of number i tube in distribution header and collection header, respectively, Pa; pfh,i, phh,i is the lower
static pressure of number i tube in distribution header and
collection header, respectively, Pa; Pf,i,Ph,i is friction loss
along the ow way in distribution header and collection header,
respectively, Pa; j is friction resistance coefcient along the ow
way in header; Vfq,i, Vhq,i is the upper velocity of number i tube in
distribution header and collection header, respectively, m/s; Vfh,i,
Vhh,i is the lower velocity of number i tube in distribution header
and collection header, respectively, m/s; Kf is the static pressure
variation coefcient in distribution header which considers the
impacts of various losses and tube velocity, refer to the literature
[13] and take Kf = 0.4 at 95% BMCR load. Kh is static pressure
variation coefcient in collection header,take Kh = 0.9 at 95%
BMCR load [13].
(2) Momentum equation between two tubes (at 2,4 area respectively
in Fig. 2).
Distribution header (at 2 area)
P fq;i P fh;i1 0:5f V fq;i j

Ld
D

i 1; 2; :; n

Ld
D

V fq;n 0

13

V fq;1 V 0

14

Collection header:
V hh;n V out

15

V hq;1 0

16

In the same boiler load, the temperature and density of working

uid in the header and tube is considered as constant, it is taken as
the steam parameter average value of inlet of distribution header
and outlet of collection header on site. In different boiler loads,
through calculation of static pressure distribution and tube mass
ux under different header type arrangement, how the operation
condition and header arrangement type affect on ow deviation is
obtained.
The calculation process is shown Fig. 3.
3.2. Calculation of pressure drop

Collection header (at 4 area)

P hq;i P hh;i1 0:5h V hq;i j

(5) Boundary conditions.

Distribution header:

i 1; 2; :; n

(3) Bernoulli equation of tube.


2
0:5 P fq;i P fh;i 0:5g V i 0:5 C in C out C wt C m



i 1; 2; :; n
0:5 P hq;i P hh;i

The local momentum balance for tube ow is expressed as the

pressure change that consists of the friction pressure drop, gravitation
pressure change, local pressure drop and acceleration pressure
change. Acceleration pressure drops is neglected. The total pressure
drop p can be expressed as:
p pf pg pl

17

Where:
Cm can be obtained by following formula:
Cm

l
m
d

Where: Cin is local resistance coefcient at the inlet of tube. Cout

is local resistance coefcient at the outlet of tube. Cwt is local
resistance coefcient at the elbow department, referred to
relevant reference[14]. Cm is friction resistance coefcient. is
friction coefcient of tube along the ow way; l is the length of
tube, m.
(4) Continuity equation.
Distribution header
f Af V f

37
X

g Ag V i

pf is the friction pressure drop, Pa;

pg is the gravitation pressure drop, Pa;
pl is local pressure drop, Pa;
The frictional pressure drop is calculated as following:
pf

l
dn

18

The friction coefcient of tube can be calculated by following

fomula:
1

2
4 lg3:7 dk

19

i1

V fq;i V fh;i1

i 1; 2; :; n

10

Collection header
h Ah V h

37
X

g A g V i

11

i1

V hq;i V hh;i1

where k is absolute roughness of inner tube, mm; for carbon steel and
pearlitic steel tube it is 0.06 mm, for austenitic steel tube it is 0.008 mm,
taking k=0.06 mm in this paper.
Gravitational pressure drop can be obtained as following:
pg gh

20

Local pressure drop coefcient is calculated by the formula:

i 1; 2; :; n

12

Where: Af and Ag are the cross-sectional area of distribution

header and tube, respectively, m 2; Ah is the cross-sectional area
of distribution header, m 2; Vf is the inlet velocity in the distribution header, m/s; Vh is the outlet velocity in the distribution
header, m/s.

l i o

n
X

21

i o is the local resistance loss coefcient of the inlet and outlet tube,
respectively. e is the local loss coefcient of each elbow, they are
evaluated through lookup.

H. Wu et al. / Powder Technology 235 (2013) 590598

to ty

initialization

593

q
1

24

Where:
2 is the heat transfer coefcient between tube wall and steam,
W/(m 2C);
1 is the heat transfer coefcient between tube wall and ue gas,
W/(m 2C);

set pressure of
Collecting Header

The metal temperatures in the middle of tube walls are calculated

as:
tm

solution of the
nonlinear equations

ti to
2

25

Based on heat transfer principle [16], the metal temperature in the

root of n is conrmed by:
t fr t f qw fr

  

dw
d
d
1
ln w

d
d 2 2

26

Where: tf is the steam temperature, C; qw is the outer wall heat

ux, W/m 2; fr is the balance coefcient of heat ux in the root of
n; d is the inner diameter, m; dw is the external diameter, m.
Through solving the heat conduction equations of straight ns
with constant cross section, the metal temperature in the tip of ns
is obtained. The formula is given by ref. [17]:

obtain the velocity and

pressure distribution

t ft t fr

boundary
conditions
coincidence



qft sdw 2
2
2

27

where tft is the metal temperature in the tip of n, C; q is the furnace

heat ux, W/m 2; ft is the balance coefcient of heat ux in the tip of
n; s is the pitch between adjacent tubes, m.
3.5. Heat load distribution
3.5.1. Heat load distribution along the furnace depth direction
There is little public literature reported on the nonuniform coefcient of heat load along furnace depth direction in CFB boiler, the
following formula is used [18] in the calculation. It is obtained
through combining the research result about the nonuniform coefcient of heat load in pulverized coal red boiler with the test results
of CFB boilers [18].

end
Fig. 3. Computation process.

3.3. Calculation of heat transfer coefcient

In this paper the HTC of steam 2, W/(m 2C), is calculated with

SiederTate formula [15]:

Y 0:3574X 0:0733X 0:1201X 1:1998

 
0:8 0:33 0:14
2 0:023 Re Pr
d
w

Where, Y is the nonuniform coefcient of heat load; X is the relative

distance which deviate the tube in the centre of furnace, m.

22

28

Where Re is Reynolds number of steam; Pr is Prandtl number of

steam; is heat conductivity coefcient; d is tube internal diameter;
is steam viscosity at average temperature, kg/(ms); is steam
viscosity at the metal temperature, kg/(ms).
The heat transfer coefcient from ue gas to tube wall is calculated
referring to the reference [12].

3.5.2. Heat load distribution along the furnace height direction

In the region of platen heating surface, the furnace temperature
along the height direction does not change obviously, so heat load is
calculated though the temperature average value along the height.
The distance from the bottom of platen heating surface to Air distribution plate is 18.2 m. The distance from the top of platen heating
surface to Air distribution plate is 39 m.

3.4. Calculation of metal temperature

4. Results and discussion

If the steam temperature is tf and ue gas temperature is ty, then

tube inner wall temperature ti and outer wall temperature to can be
calculated respectively as followings [14]:

According to the different types arrangement of header, it can be

generally divided into U, Z, L, reverse L, J, reverse J types arrangement
of header, etc. and U and Z types are the most commonly used in the
design for Power Plant. The working medium mass ux of tube is
different in different types arrangement. U type arrangement and Z
type arrangement have been successively arranged in the 300 MW

ti tf

q
2

23

594

H. Wu et al. / Powder Technology 235 (2013) 590598

CFB Power Plant we studied. While operated in U type arrangement,

the No. 37 tube was damaged frequently, subsequently it was
changed into Z type arrangement, the arrangement of ow process
which can be seen in Fig. 4. The two types arrangement are simulated
and calculated respectively below.
4.1. Mass ux distribution
Fig. 5 shows the tube mass ux distribution of Z and U type
arrangement at 94%, 75%, 51% BMCR load,respectively. It can be
obtained that the ow velocity of inner tube under different conditions is different, the tube velocity is larger with the load increases.
But their changing law is similar. The ow velocity of inner tube
increases monotonously with the number of tube (the direction to
the center of the furnace) increasing in Z type arrangement, its
value varies from 8.82 m/s to 10.96 m/s at 94% BMCR load, from
8.09 m/s to 10.05 m/s at 75% BMCR load, from 6.91 m/s to 8.71 m/s
at 51% BMCR load. The ow velocity of inner tube decreases monotonously with the number of tube increasing in U type arrangement, its
value varies from 10.78 m/s to 9.09 m/s at 94% BMCR load, from
9.88 m/s to 8.33 m/s at 75% BMCR load, from 8.45 m/s to 7.20 m/s
at 51% BMCR load. The mass ux variation range from No. 1 tube to
No. 37 tube of Z type arrangement is greater than that of U type
arrangement. That is because the static pressure in collection header
decreases gradually along the ow way, the minimum value appears
at the outlet of header. In distribution header, the velocity of header
decreases gradually with the number of tube increasing and the static
pressure increases gradually. The static pressure at the outlet of
header is the maximum value which is completely opposite to that of
collection header. So in Z type arrangement header, the minimum static
pressure of distribution header and the maximum static pressure of
distribution header appear in the same side, the maximum static pressure of distribution header and the minimum static pressure of distribution header appear in the same side, this is not good for mass ux
distribution. In U type arrangement header, the maximum static pressure of distribution header is corresponding to the maximum static
pressure of collection header, the minimum static pressure of distribution header and the minimum static pressure of collection header are
in the same side. Therefore, the distribution of pressure difference
between distribution header and collection header is atter. So the
tube mass ux distribution of U type arrangement is more uniform.
4.2. Mass ux deviation coefcients distribution
Fig. 6 shows mass ux deviation coefcients of Z and U type
arrangement at 94%, 75%, 51% BMCR load, respectively. From the
calculation formula it is known that change tendency of mass ux
deviation coefcients is consistent with that of ow velocity of
inner tube. When header is arranged as Z type arrangement, the
mass ux in No. 1 tube is the least, its mass ux deviation coefcient
is 0.906, the mass ux in No. 37 tube is the largest, its mass ux deviation coefcient is 1.126. Static pressure characteristics lead to such
result. Analyze the reasons and there are two factors affecting the
static pressure characteristics: (a) the impact of friction resistance.
The length of tube increases with the number of tube increasing, so
the friction resistance increases gradually along the ow way which

Z Type Arrangement

U Type Arrangement

Fig. 4. The ow process of different type arrangement.

makes the mass ux of tube decrease. (b) The impact of tube conuence and difuence. In collection header, because of the impact of
conuence, the mass ux of header increases with the number of
tube increasing, the static pressure decreases along the ow way, in
distribution header, because of the impact of difuence, the static
pressure increases along the ow way.
Combination of these two factors mention above, in collection
header, the impacts of friction resistance and conuence both make
the static pressure decrease along the ow way. In distribution header,
the impact of friction resistance makes the static pressure decrease
while the impact of difuence makes the static pressure increase,
but losses produced by friction resistance are less than the impact of
the static pressure affected by difuence, combination of friction resistance and difuence, the static pressure of header increases along the
ow way in distribution header. So in Z type arrangement, due to the
static pressure characteristics, the pressure difference between inlet
and outlet of the tube increases monotonously along the ow way
which determine ow distribution and mass ux deviation coefcient
of tube increases with the number of tube increasing. When header
arranged as U type, the static pressure of distribution header and
collection header both increase along the ow way, but static pressure
of collection header increases more sharply, so the pressure difference
between inlet and outlet of tube decreases monotonously, so mass
ux deviation coefcient of tube decreases with the number of tube
increasing. From Fig. 6 we can see that the minimum mass ux deviation coefcient appears on the left of the header, its value is 0.933,
maximum value appears on the right of header, it is 1.107.
Fig. 6 also shows that the curves at different loads are almost coincident, that is to say, at different loads the static pressure of header
and tube velocity are different, but the mass ux deviation coefcients calculated are the same, therefore, in the condition that the
temperature and density of steam in the header and tube does not
change along the ow way, the mass ux deviation coefcient of
tube is constant. It does not change with the condition changing,
and it is determined by the structure of header and tube themselves.
The curves in Fig. 6 do not completely overlap, the reason is that the
static pressure change coefcients value of distribution header and
collection header at different loads taken is not accurate which
leads some deviation in calculation result. Because these coefcients
taken are complex, static pressure variation coefcients of distribution header Kf considers the impact of various losses after difuence
and velocity of tube, static pressure variation coefcients of collection
header Kh is related to the ratio of header diameter to tube diameter,
and the number of tubes in the same platen. Their impacts are small
and they can be neglected.
4.3. Metal temperature distribution
4.3.1. Metal temperature distribution along furnace height
Figs. 7 and 8 show the steam temperature and the metal temperature distribution of No. 1 and No. 37 tube at 94% BMCR load, 75%
BMCR load, 51% BMCR load under U type arrangement and Z type
arrangement, respectively. It is shown that the temperature distribution characteristics of the tubes are similar. The steam temperature
increases monotonously with absorbing heat process. And the metal
temperature of tube increases basically along the certain ow process.
The maximum value appears at the outlet of the tube. The wall temperature at 75% BMCR load is highest, under U type arrangement,
the outer wall temperature of No. 1 tube is 467.6 C and that of No.
37 tube is 571.2 C, under Z type arrangement the outer wall temperature of No. 1 tube is 491.7 C and that of No. 37 tube is 530.8 C.
The outer wall temperature of No. 37 tube under U type arrangement
has reached 571.2 C and the tube materials is 12Cr1MoVG, under
certain pressure its allowable working temperature is 580 C. The
outer wall temperature of No. 37 tube is very close to the material allowable working temperature, during operation, when boiler operates in

H. Wu et al. / Powder Technology 235 (2013) 590598

11.0

Tube flow velocity(m/s)

10.0

Tube flow velocity(m/s)

94% boiler load

75% boiler load
51% boiler load

10.5

9.5
9.0
8.5
8.0
7.5
7.0
0

10

15

20

25

30

35

595

11.0
10.8
10.6
10.4
10.2
10.0
9.8
9.6
9.4
9.2
9.0
8.8
8.6
8.4
8.2
8.0
7.8
7.6
7.4
7.2

94% boiler load

75% boiler load
51% boiler load

40

10

15

20

25

Tube number

Tube number

Z Type Arrangement

U Type Arrangement

30

35

40

Fig. 5. Tube mass ux distribution of Z and U type arrangement at different boiler loads.

long time in such a temperature, the tubes are prone to damage. Moreover, if boundary conditions change such as the load uctuate or
combusted coal changes, it causes the furnace heat load uctuation,
the outer wall temperature of the tube may easily exceed 580 C
which can easily result in tube damage. This is because the oxide scale
may be formed in the tube surface, structure and properties of the
tube material may be changed in a long time operation, even the oxide
scale may shed, nally, the mechanical strength decline which leads to
the tube damage. When under Z type arrangement, the wall temperature of the each tube is much lower than the allowable working temperature at different loads, it is within the safe working condition and can
stably work for a long time. The calculated results agree well with the
actual operation situation on site. In the Power Plant, the accidents of
the tube overtemperature and damage frequently happened under U
type arrangement. Subsequently Z type arrangement is used instead of
U type arrangement, medium temperature platen superheater I has
been safely working in a long time which illustrates the rationality and
reliability of the calculation. In addition, it further illustrates that different types of arrangement of platen heating surface are vital for safe
operation in Power Plant.
4.3.2. Furnace depth
Fig. 9 shows the outlet steam temperature and the metal temperature distribution of platen heating surface along furnace depth at

94% BMCR load, 75% BMCR load and 51% BMCR load under Z and U
type arrangement, respectively. Under U type arrangement the outlet
wall temperature of each tube increases with the number of tube
increasing, while under Z type arrangement, the outlet wall temperature of each tube rstly increases with the number of tube increasing
and then decrease, The highest temperature appeared in the No. 24
and No. 25 tube, its temperature is 534.82 C, a phenomenon is that
the increasing trend is more shape than the decreasing trend, it is
combined result of mass ux deviation and heat load deviation. The
highest temperature appears at 75% BMCR load among these three
loads, the most dangerous tube under U type arrangement is the
No. 37 tube, and the most dangerous tube under Z type arrangement
is far lower than allowable working temperature. Under Z type
arrangement, the mass ux in No. 1 tube which located at the minimum heat load is lowest, the mass ux in No. 37 tube which located
at the maximum heat load is highest, so the maximum temperature
may not appear in the these two tubes on different sites. While
under U type arrangement, the mass ux in No. 37 tube is lowest
and it is located at the maximum heat load, so its wall temperature
is highest and that of No. 1 tube is lowest. The data show that the
maximum steam temperature appears at 94% BMCR load, the minimum steam temperature appear at 51% BMCR load, it illumines that
a tube heated strongly absorbs more heat, and the steam temperature
rises more markedly.

1.16

1.10

Tube mass flux deviation coefficient

Tube mass flux deviation coefficient

1.15

94% boiler load

75% boiler load
51% boiler load

1.05

1.00

0.95

0.90

1.14
1.12
1.10

94% boiler load

75% boiler load
51% boiler load

1.08
1.06
1.04
1.02
1.00
0.98
0.96
0.94
0.92

10

15

20

25

30

35

40

10

15

20

25

Tube number

Tube number

Z Type Arrangement

U Type Arrangement

Fig. 6. Tube mass ux deviation coefcients of Z and U type arrangement at different boiler loads.

30

35

40

596

H. Wu et al. / Powder Technology 235 (2013) 590598

570

460
440

tf

tft

to

ti

540
510

tm

420

480

tf

tft

to

ti

tm

450

400

420
380

390

360
480

360
600

Temperature (C)

Temperature (C)

570
460
440
420
400

540
510
480
450
420

380

390

480

360
570

460

540

440

510
480

420
450
400

420
390

380
20

30

40

20

30

Furnace height (m)

Furnace height (m)

No.1 tube

No.37 tube

40

Fig. 7. Metal temperature distribution of No. 1 and No. 37 tube at different boiler loads along furnace height under U type arrangement.

480
450

tf

tft

to

ti

510

tf

tft

480

to

ti

tm

tm
450

420

420
390
390
360
510

360

Temperature (C)

Temperature (C)

540
480
450
420
390

510
480
450
420
390
360
540

360
480

510
480

450

450
420
420
390

390
20

30

40

20

30

Furnace height (m)

Furnace height (m)

No.1 tube

No.37 tube

40

Fig. 8. Metal temperature distribution of No. 1 and No. 37 tube at different boiler loads along furnace height under Z type arrangement.

H. Wu et al. / Powder Technology 235 (2013) 590598

540

tf

tft

ti

tm

to

597

520
500

510

480

480

460

tf

tft

440

ti

tm

450

to

420
420
560
540

Temperature (C)

Temperature (C)

570
540
510
480
450

520
500
480
460
440

420
570

420
540

540

520

510

500
480

480

460
450
440
420
0

10

20

30

40

420

10

20

Tube number

Tube number

U Type Arrangement

Z Type Arrangement

30

40

Fig. 9. Metal temperature distribution from No. 1 to No. 37 tube at different boiler loads along furnace depth under different type arrangement.

In conclusion, for U type arrangement, the static pressure distribution of distribution header and collection header match very well and
the pressure difference between distribution header and collection
header is smaller, tube mass ux distribution is more uniform. At this
case the tube located in high heat load is prone to overtemperature
and damage in the furnace. So articially mass ux deviation of working
steam is to match heat deviation on ue gas side so that the wall temperature is in a safe working range which guarantee the safe operation
of the boiler. For Z type arrangement, the tube with the maximum mass
ux is located in the place with the maximum heat load, the tube with
the minimum mass ux is corresponding to the location with the
minimum heat load,so the outer wall temperature of tubes can meet
the boiler operating requirement, Z type arrangement is one of the
reasonable types arrangement.
5. Conclusions
At different boiler loads, the wall temperature characteristics of each
tube of the medium temperature platen superheater was obtained in a
300 MW CFB boiler, the calculation result shows that the wall temperature rstly increases with the boiler load increasing and then decrease,
it indicates that the platen superheater tube damage often occurs at
around 75% BMCR boiler load. So in the process of lifting load during
operation in Power Plant, the wall temperature of the most dangerous
tube should be monitored intensely to avoid tube damage accident. At
different loads, although the static pressure of header and the velocity
of tube are different, the mass ux deviation coefcient distribution of
the tubes is certain which do not change with the loads changing, the
tube mass ux imbalance rate is determined by the structure of header
and tube themselves. Through calculating and site operation situation,
when Z type arrangement substituted U type arrangement, The wall

temperature of platen superheater meets the operating demand and it

shows very good thermal-hydraulic characteristics. In 300 MW CFB
boiler, Z type arrangement header of medium platen superheater I is
better than U type arrangement. So generally Z type arrangement is
one of the reasonable types arrangement.
Acknowledgements
This study was supported by the technology support program in the
11th Five-year Plan (2006BAA03B06) and Strategic Priority Research
Program of the Chinese Academy of Sciences, grant no. XDA07030100.
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