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www.zeeco.com Combustion and Environmental Solutions, Pure and Simple
www.zeeco.com Combustion and Environmental Solutions, Pure and Simple
Heater Geometry
2
Heater Radiant Section Burners
CFD Study of An Industrial Heater March 2013 Zhili (Alex) Qin, CFD - - PowerPoint PPT Presentation
CFD Study of An Industrial Heater March 2013 Zhili (Alex) Qin, CFD - - PowerPoint PPT Presentation
CFD Study of An Industrial Heater March 2013 Zhili (Alex) Qin, CFD Engineer Zeeco Inc. www.zeeco.com Combustion and Environmental Solutions, Pure and Simple Heater Geometry Heater Radiant Section
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SLIDE 3
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Heater Geometry
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Process Tubes
SLIDE 4
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Heater Geometry
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Combustion Air Distribution Duct
SLIDE 5
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Existing Issues of Heater Operation
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- Short run length for the heater
- Coking inside heater tubes
- Non uniform tube metal temperature readings
- Suspecting non uniform heat flux distribution on tubes
- Acceptable combustion flames
SLIDE 6
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Mesh
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Note:
- Mesh was prepared using STAR-CCM+ 7.04
- Trimmer with Prism Layers
- 13.4 Million cells for half of the heater
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STAR-CCM+ 7.04 Segregated Flow, Species, & Energy Multi-Component Species Combustion Turbulence Radiation
Model Setup
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Predicted Combustion Flame
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Left View
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Predicted Combustion Flame
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Front View
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Carbon Monoxide
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Unburnt Hydrocarbon
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Oxygen
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Temperature
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Tube Metal Temperature
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Left View
SLIDE 15
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Flue Gas Temperature @ Tubes
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Left View
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Heat Flux Profile @ Tubes
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Left View
Left Middle Right
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Weighted Heat Flux @ Various Locations
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Note: Weighted heat flux is the percentage of heat flux data relative to the overall average heat flux for all the tubes. 1 2 3 4 5 6 50% 70% 90% 110% 130% 150% 170% Elevation Above Floor, m Weighted Heat Flux, % Left Middle Right
SLIDE 18
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Predicted Air Flow Distribution to Burners
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Error of Air Flow Rate, % Burner 00 (Left)
- 4.20%
Burner 01 10.56% Burner 02 9.62% Burner 03 8.28% Burner 04 7.00% Burner 05 5.98% Burner 06 3.94% Burner 07 2.81% Burner 08 0.84% Burner 09
- 0.22%
Burner 10
- 1.38%
Burner 11
- 2.24%
Burner 12
- 3.14%
Burner 13
- 3.41%
Burner 14
- 4.56%
Burner 15
- 5.63%
Burner 16
- 6.02%
Burner 17
- 6.57%
Burner 18
- 8.67%
Burner 19 (Right)
- 2.99%
SLIDE 19
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Summary
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- CFD study of an industrial heater was successfully performed by
using STAR-CCM+.
- Heater operation under actual conditions was modeled and issues
were identified.
- Recommended solutions were provided (not included in this
presentation).
- STAR-CCM+ is an efficient and cost-saving engineering tool for