Boiler Heating Tube Panel Deviation Prediction Using CFD Swirl Analysis
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The occurrence of overtemperature on the tube wall of boilers due to large heat absorption deviation or sudden disturbances in high temperature heating surface tube panels, threatening the safe operation of power stations, is a significant challenge in thermal power generation.
Innovation Solution
A method and apparatus for predicting wall temperature deviation using a three-dimensional boiler simulation model in CFD software, calculating swirl intensity and wall temperature deviation coefficients, and performing a quadratic fit to obtain a predicting model for wall temperature deviation, which is then used to control the operation of the combustion system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the boiler operates at high temperature and high speed flue gas conditions to increase power generation efficiency, then the thermal energy to electric energy conversion improves, but the wall temperature deviation and overtemperature risk of the heating surface tube panel increases, threatening safe operation
Solution Approach 1:
The patent establishes a predicting model that calculates wall temperature deviation in advance by analyzing operational parameters such as flue gas velocity, temperature, and swirl intensity. This preliminary prediction allows operators to take preventive actions before overtemperature occurs, resolving the contradiction by enabling proactive safety management while maintaining high-efficiency operation
Solution Approach 2:
The patent implements a feedback mechanism where the predicting model continuously monitors operational parameters and wall temperature deviation, providing real-time information to control systems. This feedback loop enables dynamic adjustment of operational conditions to prevent overtemperature while maintaining optimal power generation efficiency
2Strength
If heat-resisting material is used on the high temperature heating surface tube panel to improve resistance to thermal stress, then the material strength and heat resistance improve, but the cost and manufacturing complexity increase
Solution Approach 1:
The predicting model identifies high-risk areas and conditions before overtemperature occurs, allowing for targeted preventive measures rather than requiring universal heat-resisting materials throughout the entire tube panel. This reduces manufacturing complexity while maintaining safety through selective protection based on predicted temperature deviation
3Productivity
If the flue gas swirl intensity is increased to improve combustion efficiency, then the combustion performance improves, but the wall temperature deviation along the furnace width and height becomes more inconsistent, increasing overtemperature risk
Solution Approach 1:
The patent calculates swirl intensity as a key parameter in the predicting model and uses it to forecast wall temperature deviation patterns. This feedback information allows operators to optimize combustion efficiency while maintaining acceptable temperature uniformity by adjusting operational parameters within safe ranges
Solution Approach 2:
By predicting wall temperature deviation based on swirl intensity and other operational parameters before overtemperature occurs, the system enables proactive adjustment of combustion conditions to maintain both efficiency and temperature uniformity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively predicts and mitigates overtemperature risks on the tube wall, ensuring the safe operation of coal-fired generating units by controlling the combustion system based on the predicted wall temperature deviation.
Implementation Method 1
calculating swirl intensity at a furnace outlet of the boiler using a swirl momentum moment formula in the boiler simulation model
Implementation Method 2
calculating a wall temperature deviation coefficient of the high temperature heating surface tube panel of the boiler using a wall temperature deviation coefficient formula in the boiler simulation model
Data Source
AI summary
A method, apparatus and device for predicting wall temperature deviation of a high-temperature heating surface tube panel of a boiler. The method comprises: acquiring factor data that affects wall temperature deviation of a high-temperature heating surface tube panel of a boiler; according to the factor data and a boiler structure, establishing a three-dimensional boiler simulation model in CFD software, and in the boiler simulation model, calculating the swirl intensity of a boiler furnace outlet by using a swirl momentum moment formula, and calculating a wall temperature deviation coefficient of the high-temperature heating surface tube panel of the boiler by using a wall temperature deviation coefficient calculation formula; and performing quadratic fitting processing on the swirl intensity and the wall temperature deviation coefficient, so as to obtain a prediction model. Wall temperature deviation of a high-temperature heating surface tube panel of a boiler can be predicted by means of a prediction model, and the operation of a combustion system of a coal-fired generator set is controlled by means of the wall temperature deviation of the high-temperature heating surface tube panel, thereby solving the problem of a tube wall of the boiler being prone to overheating when high-temperature heating surface tube panels of existing boilers have excessive heat absorption deviation or sudden disturbance occurs.