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Optimizing Pulverized Fuel Duct Design for Uniform Burner Distribution Using Advanced CFD Modeling

Categories:

A detailed CFD study was performed to assess and optimize pulverized fuel (PF) duct distribution, ensuring uniform fuel delivery to all burner fingers and minimizing flow imbalances that could compromise combustion efficiency and component longevity. A full 3D model of the duct system and burner geometry captured gas-solid interactions using Euler-Lagrange simulations with realistic particle size distributions (PSD) and inhomogeneous coal inlet conditions. Baseline and modified duct designs were compared across different coal mass flow rates, revealing design changes that significantly improved fuel distribution uniformity. The optimized layout reduces deviations, enhances combustion efficiency, and minimizes hotspots, delivering a robust and reliable solution for PF distribution.
PSD_diagram

Details:

Technology Used
  • Ansys Discovery, Ansys Fluent

Objective:

Evaluate PF duct performance and optimize duct entries to achieve balanced fuel delivery across all burner fingers while maintaining stable overall flow dynamics. 

Challenge:

The existing PF duct design resulted in uneven fuel distribution, causing imbalances that could lower combustion efficiency, create localized hotspots, and shorten component lifespan. The challenge was to identify modifications that improved fuel balance without disrupting the overall flow behavior. 

Solution:

A detailed 3D CFD model of the PF duct system and burner fingers was developed using full operational and geometric data. Two-phase Euler-Lagrange simulations accurately captured gas-solid interactions, incorporating real particle size distributions via the Rosin-Rammler model and inhomogeneous coal inlet conditions. Baseline simulations of the existing duct design were compared with modified configurations to analyze gas and coal distribution patterns. Sensitivity analyses across multiple coal mass flow rates, including 100% and 75% conditions, ensured robustness of the optimized design. The final modifications reduced coal mass flow deviations per burner finger to a satisfactory range, achieving more uniform fuel distribution and stable flow behavior. 

Conclusion:

The optimized PF duct design successfully balanced fuel delivery across all burner fingers while preserving overall flow stability. This improvement increases combustion efficiency, reduces hotspot formation, and extends component life, providing a reliable and effective fuel distribution solution. 

Figure 1: Photorealism Pictures of the Project.
Figure 1: Photorealism Pictures of the Project.
Figure 1: Photorealism Pictures of the Project.

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