Rising global energy demands have led to an increase in demand for clean, sustainable energy. A leading technology for reducing greenhouse gas (GHG) emission for existing coal-power infrastructure is gasification, which has sparked an interest in reactor modelling for design and performance analysis. Reduced order models (ROMs) have seen an increase in popularity for entrained flow gasifiers, as they offer a low-computational alternative to conventional computational fluid dynamic (CFD) modelling while maintaining the integrity of important operational parameters, such as carbon conversion and syngas yield. However, ROMs require more physical parameter inputs than are normally required for CFD modelling, such as the geometry of the gas-solid jet (specifically the jet half-angle). Experiments were conducted to understand the relation between the required input parameters for ROMs, such as fuel flow rate, transport gas flow rate, and jet half-angle, and develop useful correlations for ROM systems. A new configuration for pneumatic conveying was developed and tested at the pilot-scale system at NRCan CanmetENERGY. It was used to study the pneumatic conveying of pulverized fuels, specifically the influence of operating parameters such as pressure drop and gas flow rates on the fuel flow rate, and the geometry of the gas-solid fuel jet (notably the jet half-angle) injected into the gasifier. The mean fuel flow rate of pulverized fuels was shown to increase with increasing pressure drop and with decreasing gas flow rates in the fuel transfer line. The jet half-angle was shown to increase as the solid loading ratio in the jet core was decreased. Finally, the relative fuel flow variability was observed to be significantly influenced by the design of the pneumatic conveying system, with the fluctuations increasing with increasing pressure drop and with decreasing gas flow rate, similar to the mean flow rate.

Government regulations to reduce pollutants and increasing environmental awareness in the power generation industry have encouraged coal power plants to begin firing biomass in their boilers. Biomass generally consists of larger particles which produce longer flames than coal for a given burner. The length of the flame is important in fixed-volume boilers because of its influence on heat transfer, corrosion, deposition, and pollutant formation. Many pulverized fuel burners employ a series of co-annular tubes with various flows of fuel and air to produce a stabilized flame. A variable swirl burner with three co-annular tubes, each of variable diameter, has been used to collect flame length data for nearly 400 different operating conditions of varying swirl, fuel type, air flow rate, enhanced oxygen flow rate and oxygen addition location. A model based on the length required to mix fuel and air to a stoichiometric mixture was developed. Inputs to the model are the flow rates of fuel, air, and oxygen, swirl vane position and burner geometries. The model was exercised by changing flow rates and burner tube diameters one at a time while holding all others constant. Physical explanations for trends produced were given.The model also requires two constants, one of which is solved for given a case without swirl, and the other is found by fitting experimental data. The constants found in this study appear to be accurate exclusive to the BYU burner. Thus burner designers will need to obtain minimal amounts of data to predict constants for their reactor and then employ the model to predict flame length trends. The resulting correlation predicts 90% of the flame lengths to be within 20% of the measured value. The correlation provides insights into the expected impact of burner flow rates and geometry changes on flame length which impacts particle burnout, NOx formation and heat transfer.

<p>This licentiate thesis describes development of modellingtools, experimental physical modelling and numerical modellingto simulate real combustion processes for advanced industrialutility boiler before and after retrofit.</p><p>The work presents extended study about formation,destruction and control of pollutants, especially NOx, whichoccur during combustion process.</p><p>The main aim of this work is to improve mixing process incombustion chamber. To do this, the optimization of placementand direction of additional air and fuel nozzles, the physicalmodelling technique is used. By using that method, it ispossible to obtain qualitative information about processes,which occur in the real boiler. The numerical simulationsverify the results from physical modelling, because duringmathematical modelling quantitative informations about flow andmixing patterns, temperature field, species concentration areobtained.</p><p>Two 3D cases, before and after retrofit, of pulverized fuelfired boiler at 125 MW output thermal power are simulated. Theunstructured mesh technique is also used to discretize theboiler. The number of grid was 427 656 before retrofit and 513362 after retrofit. The comparisons of results of numericalsimulation before and after retrofit are presented. The resultsfrom physical modelling and numerical simulation are alsoshown.</p><p>Results present that nozzles of additional air and fuel givea considerably better mixing process, uniform temperature fieldand CO2 mass fraction. The whole combustion chamber worksalmost as a "well stirred reactor", while upper part of boilerworks as a "plug flow reactor".</p><p>Differences between from measured of temperatures andpredicted temperatures are not too big, the maximum differenceis about 100 K. It seems, that calculated temperatures showgood agreement with measurement data.</p><p>The results illuminate the potential of physical andnumerical modelling methods as promising tools to deal with thecomplicated combustion processes, even for practicalapplication in the industry.</p><p><b>Keywords:</b>air staging, fuel staging, boiler, furnace,computational fluid dynamics, numerical simulation, pollutants,physical modeling, pulverized fuel combustion.</p>

This licentiate thesis describes development of modellingtools, experimental physical modelling and numerical modellingto simulate real combustion processes for advanced industrialutility boiler before and after retrofit. The work presents extended study about formation,destruction and control of pollutants, especially NOx, whichoccur during combustion process. The main aim of this work is to improve mixing process incombustion chamber. To do this, the optimization of placementand direction of additional air and fuel nozzles, the physicalmodelling technique is used. By using that method, it ispossible to obtain qualitative information about processes,which occur in the real boiler. The numerical simulationsverify the results from physical modelling, because duringmathematical modelling quantitative informations about flow andmixing patterns, temperature field, species concentration areobtained. Two 3D cases, before and after retrofit, of pulverized fuelfired boiler at 125 MW output thermal power are simulated. Theunstructured mesh technique is also used to discretize theboiler. The number of grid was 427 656 before retrofit and 513362 after retrofit. The comparisons of results of numericalsimulation before and after retrofit are presented. The resultsfrom physical modelling and numerical simulation are alsoshown. Results present that nozzles of additional air and fuel givea considerably better mixing process, uniform temperature fieldand CO2 mass fraction. The whole combustion chamber worksalmost as a "well stirred reactor", while upper part of boilerworks as a "plug flow reactor". Differences between from measured of temperatures andpredicted temperatures are not too big, the maximum differenceis about 100 K. It seems, that calculated temperatures showgood agreement with measurement data. The results illuminate the potential of physical andnumerical modelling methods as promising tools to deal with thecomplicated combustion processes, even for practicalapplication in the industry. <b>Keywords:</b>air staging, fuel staging, boiler, furnace,computational fluid dynamics, numerical simulation, pollutants,physical modeling, pulverized fuel combustion. / NR 20140805

In power plants using large utility coal-fired boilers for generation of electricity the coal is pulverised in coal mills and then it has to be pneumatically transported and distributed to a larger number of burners (e.g. 30-40) circumferentially arranged in several rows around the burning chamber of the boiler. Besides the large pipework flow splitting devices are necessary for distribution of an equal amount of pulverised fuel (PF) to each of the burners. So called trifurcators (without inner fittings or guiding vanes) and ''riffle'' type bifurcators are commonly used to split the gas-coal particle flow into two or three pipes/channels with an equal amount of PF mass flow rate in each outflow cross section of the flow splitting device. These PF flow splitting devices are subject of a number of problems. First of all an uneven distribution of PF over the burners of a large utility boiler leads to operational and maintenance problems, increased level of unburned carbon and higher rates of NOX emissions. Maldistribution of fuel between burners caused by non uniform concentration of the PF (particle roping) in pipe and channel bends prior to flow splitting devices leads to uncontrolled differences in the fuel to air ratio between burners. This results in localised regions in the furnace which are fuel rich, where insufficient air causes incomplete combustion of the fuel. Other regions in the furnace become fuel lean, forming high local concentrations of NOX due to the high local concentrations of O2. Otherwise PF maldistribution can impact on power plant maintenance in terms of uneven wear on PF pipework, flow splitters as well as the effects on boiler panels (PF deposition, corrosion, slagging). In order to address these problems in establishing uniform PF distribution over the outlet cross sections of flow splitting devices in the pipework of coal-fired power plants the present paper deals with numerical prediction and analysis of the complex gas and coal particle (PF) flow through trifurcators and ''riffle'' type bifurcators. The numerical investigation is based on a 3-dimensional Eulerian- Lagrangian approach (MISTRAL/PartFlow-3D) developed by Frank et al. The numerical method is capable to predict isothermal, incompressible, steady gas- particle flows in 3-dimensional, geometrically complex flow geometries using boundary fitted, block-structured, numerical grids. Due to the very high numerical effort of the investigated gas-particle flows the numerical approach has been developed with special emphasis on efficient parallel computing on clusters of workstations or other high performance computing architectures. Besides the aerodynamically interaction between the carrier fluid phase and the PF particles the gas-particle flow is mainly influenced by particle-wall interactions with the outer wall boundaries and the inner fittings and guiding vanes of the investigated flow splitting devices. In order to allow accurate quantitative prediction of the motion of the disperse phase the numerical model requires detailed information about the particle-wall collision process. In commonly used physical models of the particle-wall interaction this is the knowledge or experimental prediction of the restitution coefficients (dynamic friction coefficient, coefficient of restitution) for the used combination of particle and wall material, e.g. PF particles on steel. In the present investigation these parameters of the particle-wall interaction model have been obtained from special experiments in two test facilities. Basic experiments to clarify the details of the particle-wall interaction process were made in a test facility with a spherical disk accelerator. This test facility furthermore provides the opportunity to investigate the bouncing process under normal pressure as well as under vacuum conditions, thus excluding aerodynamically influences on the motion of small particles in the near vicinity of solid wall surfaces (especially under small angles of attack). In this experiments spherical glass beads were used as particle material. In a second test facility we have investigated the real impact of non-spherical pulverised fuel particles on a steel/ceramic target. In this experiments PF particles were accelerated by an injector using inert gas like e.g. CO2 or N2 as the carrier phase in order to avoid dust explosion hazards. The obtained data for the particle-wall collision models were compared to those obtained for glass spheres, where bouncing models are proofed to be valid. Furthermore the second test facility was used to obtain particle erosion rates for PF particles on steel targets as a function of impact angles and velocities. The results of experimental investigations has been incorporated into the numerical model. Hereafter the numerical approach MISTRAL/PartFlow-3D has been applied to the PF flow through a ''riffle'' type bifurcator. Using ICEM/CFD-Hexa as grid generator a numerical mesh with approximately 4 million grid cells has been designed for approximation of the complex geometry of the flow splitting device with all its interior fittings and guiding vanes. Based on a predicted gas flow field a large number of PF particles are tracked throughout the flow geometry of the flow-splitter. Besides mean quantities of the particle flow field like e.g. local particle concentrations, mean particle velocities, distribution of mean particle diameter, etc. it is now possible to obtain information about particle erosion on riffle plates and guiding vanes of the flow splitting device. Furthermore the influence of different roping patterns in front of the flow splitter on the uniformness of PF mass flow rate splitting after the bifurcator has been investigated numerically. Results show the efficient operation of the investigated bifurcator in absence of particle roping, this means under conditions of an uniform PF particle concentration distribution in the inflow cross section of the bifurcator. If particle roping occurs and particle concentration differs over the pipe cross section in front of the bifurcator the equal PF particle mass flow rate splitting can be strongly deteriorated in dependence on the location and intensity of the particle rope or particle concentration irregularities. The presented results show the importance of further development of efficient rope splitting devices for applications in coal-fired power plants. Numerical analysis can be used as an efficient tool for their investigation and further optimisation under various operating and flow conditions.

In power plants using large utility coal-fired boilers for generation of electricity the coal is pulverised in coal mills and then it has to be pneumatically transported and distributed to a larger number of burners (e.g. 30-40) circumferentially arranged in several rows around the burning chamber of the boiler. Besides the large pipework flow splitting devices are necessary for distribution of an equal amount of pulverised fuel (PF) to each of the burners. So called trifurcators (without inner fittings or guiding vanes) and ''riffle'' type bifurcators are commonly used to split the gas-coal particle flow into two or three pipes/channels with an equal amount of PF mass flow rate in each outflow cross section of the flow splitting device. These PF flow splitting devices are subject of a number of problems. First of all an uneven distribution of PF over the burners of a large utility boiler leads to operational and maintenance problems, increased level of unburned carbon and higher rates of NOX emissions. Maldistribution of fuel between burners caused by non uniform concentration of the PF (particle roping) in pipe and channel bends prior to flow splitting devices leads to uncontrolled differences in the fuel to air ratio between burners. This results in localised regions in the furnace which are fuel rich, where insufficient air causes incomplete combustion of the fuel. Other regions in the furnace become fuel lean, forming high local concentrations of NOX due to the high local concentrations of O2. Otherwise PF maldistribution can impact on power plant maintenance in terms of uneven wear on PF pipework, flow splitters as well as the effects on boiler panels (PF deposition, corrosion, slagging). In order to address these problems in establishing uniform PF distribution over the outlet cross sections of flow splitting devices in the pipework of coal-fired power plants the present paper deals with numerical prediction and analysis of the complex gas and coal particle (PF) flow through trifurcators and ''riffle'' type bifurcators. The numerical investigation is based on a 3-dimensional Eulerian- Lagrangian approach (MISTRAL/PartFlow-3D) developed by Frank et al. The numerical method is capable to predict isothermal, incompressible, steady gas- particle flows in 3-dimensional, geometrically complex flow geometries using boundary fitted, block-structured, numerical grids. Due to the very high numerical effort of the investigated gas-particle flows the numerical approach has been developed with special emphasis on efficient parallel computing on clusters of workstations or other high performance computing architectures. Besides the aerodynamically interaction between the carrier fluid phase and the PF particles the gas-particle flow is mainly influenced by particle-wall interactions with the outer wall boundaries and the inner fittings and guiding vanes of the investigated flow splitting devices. In order to allow accurate quantitative prediction of the motion of the disperse phase the numerical model requires detailed information about the particle-wall collision process. In commonly used physical models of the particle-wall interaction this is the knowledge or experimental prediction of the restitution coefficients (dynamic friction coefficient, coefficient of restitution) for the used combination of particle and wall material, e.g. PF particles on steel. In the present investigation these parameters of the particle-wall interaction model have been obtained from special experiments in two test facilities. Basic experiments to clarify the details of the particle-wall interaction process were made in a test facility with a spherical disk accelerator. This test facility furthermore provides the opportunity to investigate the bouncing process under normal pressure as well as under vacuum conditions, thus excluding aerodynamically influences on the motion of small particles in the near vicinity of solid wall surfaces (especially under small angles of attack). In this experiments spherical glass beads were used as particle material. In a second test facility we have investigated the real impact of non-spherical pulverised fuel particles on a steel/ceramic target. In this experiments PF particles were accelerated by an injector using inert gas like e.g. CO2 or N2 as the carrier phase in order to avoid dust explosion hazards. The obtained data for the particle-wall collision models were compared to those obtained for glass spheres, where bouncing models are proofed to be valid. Furthermore the second test facility was used to obtain particle erosion rates for PF particles on steel targets as a function of impact angles and velocities. The results of experimental investigations has been incorporated into the numerical model. Hereafter the numerical approach MISTRAL/PartFlow-3D has been applied to the PF flow through a ''riffle'' type bifurcator. Using ICEM/CFD-Hexa as grid generator a numerical mesh with approximately 4 million grid cells has been designed for approximation of the complex geometry of the flow splitting device with all its interior fittings and guiding vanes. Based on a predicted gas flow field a large number of PF particles are tracked throughout the flow geometry of the flow-splitter. Besides mean quantities of the particle flow field like e.g. local particle concentrations, mean particle velocities, distribution of mean particle diameter, etc. it is now possible to obtain information about particle erosion on riffle plates and guiding vanes of the flow splitting device. Furthermore the influence of different roping patterns in front of the flow splitter on the uniformness of PF mass flow rate splitting after the bifurcator has been investigated numerically. Results show the efficient operation of the investigated bifurcator in absence of particle roping, this means under conditions of an uniform PF particle concentration distribution in the inflow cross section of the bifurcator. If particle roping occurs and particle concentration differs over the pipe cross section in front of the bifurcator the equal PF particle mass flow rate splitting can be strongly deteriorated in dependence on the location and intensity of the particle rope or particle concentration irregularities. The presented results show the importance of further development of efficient rope splitting devices for applications in coal-fired power plants. Numerical analysis can be used as an efficient tool for their investigation and further optimisation under various operating and flow conditions.