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8/14/2019 Burner Wp111
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BURNER MODELING FOR THE DESIGN ENGINEER
In some cases, a good deal of useful information about air and fuel flow in a burner can be learned from a simple flow
solution without resorting to complex combustion modeling. For example, complete combustion with minimal generation
of CO and unburned hydrocarbons usually requires proper premixing of fuel and air. Also, appropriately preheating air
upstream of the burner can provide energy savings of 30 to 50%. Additional savings can be achieved by minimizing
pressure drop within the burner. Simulation can assist in optimizing all of these aspects of the burner by including only
flow and basic heat transfer in the model.
In one example, Astec Inc. used computer simulation to reduce the time
needed to develop a new aggregate drying burner, designed for use in
asphalt plants, from the normal 6 to 12 months to only 32 days. Under
unusually tight time constraints, the burner needed to meet stringent
requirements for highly efficient combustion and low emissions of NOx,
CO, and noise. Astec engineers developed an initial premix burner
design, and then confirmed through simulation that gas injection resulted
in near-ideal mixing, avoiding uneven concentrations of air and fuel that
would increase emissions levels and reduce combustion efficien-
cy. As seen in Figure 3, the fuel is brought into the mixing
chamber through holes in pipes arranged in a radial pat-
tern. Visualization such as this allowed the engineers not
only to evaluate the mixing performance, but also to gain
a clear physical understanding of the flow in the burner.
In a second example, Coen Company used flow modeling to evaluate
the design of a windbox for a 250MW utility boiler project in Buenos Aires, Argentina. The purpose of the study was to
ensure uniform distribution of flow to the burners with the lowest pressure drop possible. Initial results showed that veloc-
ity distributions at the outlet were uneven, which would have impacted performance. New simulation models including flow
vanes were built, and the new results showed less than a 4% variation in mass flow (Figure 2). These changes in the
design improved the burner performance and stability, reduced emissions, provided proper flame shaping, and mini-
mized overall fan power requirements. As a result, major modifications to the windbox were not necessary, and eventual
field test measurements confirmed the predicted performance.
Tools that make virtual modeling more accessible to the design engineer
have been under development for several years and are available
in the marketplace today. Flow simulation no longer requires an
advanced degree or a constant string of projects to maintain the
required skill set. Figure 3 shows the user interface for one such tool.
It displays pathlines colored by velocity magnitude for a windbox
similar to the one in Figure 2. A CAD drawing of the equipment
geometry is required as input. Clear guidance is given at each stage
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www.ansys.com
in the analysis, with “next” and “back” buttons available
for navigation between steps. Alternatively, movement
between set-up stages can be accomplished through
the navigator in the upper left of the screen. Green
checkmarks indicate which steps have been finished.This user friendly analysis capability allows small burn-
er manufacturers to benefit from in-house flow analysis
without requiring expertise in computational methods or
combustion models.
SUMMARY
Fluid flow modeling technology has been used for more than 20 years to analyze burners and combustors. In recent
years, the usability of the tools has improved such that design engineers can now take advantage of engineering
simulation, saving time and money for industrial burner manufacturers.
1 Improving Industrial Burner Design with Computational Fluid Dynamics Tools: Progress,
Needs, and R&D Priorities, Department of Energy Office of Industrial Technologies &
Sandia National Laboratory, 2002.
http://www.eere.energy.gov/industry/combustion/pdfs/cfd_wkshp_report.pdf