S IMULATIONS O F 1.5 MW O XY -C OAL F IRED F URNACE U SING STAR-CCM+ - - PowerPoint PPT Presentation

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S IMULATIONS O F 1.5 MW O XY -C OAL F IRED F URNACE U SING STAR-CCM+ - - PowerPoint PPT Presentation

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S IMULATIONS O F 1.5 MW O XY -C OAL F IRED F URNACE U SING STAR-CCM+ AND ARCHES C OUPLING A PPROACH O SCAR H. D IAZ -I BARRA - M ICHAL H RADISKY - J ENNIFER S PINTI - P HILIP J. S MITH STAR Global Conference Prague March 7, 2016 Mission of CCMSC -

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SIMULATIONS OF 1.5 MW OXY-COAL FIRED FURNACE USING STAR-CCM+ AND ARCHES COUPLING APPROACH

STAR Global Conference Prague March 7, 2016

OSCAR H. DIAZ-IBARRA - MICHAL HRADISKY - JENNIFER SPINTI - PHILIP J. SMITH

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SLIDE 2
  • Demonstrate exascale computing with the use of Verification, Validation and

Uncertainty Quantification (VV&UQ) to accelerate deployment of technology for reduced cost and emission of electric power generation to meet US and world’s energy needs

Mission of CCMSC Motivation

  • Cessation of nuclear testing by Department of Energy’s (DoE) National Nuclear

Security Administration (NNSA)

  • Need to use simulation and modeling tools and capabilities to support assessment

and certification of the nuclear weapons stockpile

  • NNSA’s Predictive Science Academic Alliance Program (PSAAP II)
  • Develop the science and engineering models and software for large-scale

simulations utilizing methods of verification and validation and uncertainty quantification

  • Additional focus on extreme-scale computing
  • Goal: enable scientists to make precise statements about the degree of confidence

in simulation-based predictions where experimental data is not feasible

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SLIDE 3

V&V/UQ surrogate model verification & sim experimental data validation / UQ tools creation Exascale Computing DMAV exascale runtime TASC EDSL Predictive Science LES environment multiphase flow particle combustion radiation

DOE - NNSA - PSAAP II

  • $25 million over 5 years
  • exascale

P r

  • v

i d e e v i d e n c e

  • f

p r e d i c t i v i t y

31m 63m 91m

Tower Two pass Horizontal

Figure 6. Size comparison

  • f coal fired boilers for

550 MW output

AUSC-

Demonstration-scale prediction Pilot-scale validation Lab-scale validation Tom Sean Andy David Jeremy Michael Jeremy Phil Jennifer Bench-scale validation

1.5 MWth oxy- coal furnace 5 MWth oxy- gas furnace char oxidation ash transformation multiphase flow soot formation radiation devolatilization

500 MWe

  • xy-AUSC

Design Boiler 1000 MWe USC 8-corner Boiler

15 MWth oxy-coal boiler

Sean

  • bjectives

science of simulation

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SLIDE 4

physical scale

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SLIDE 5

coal gas nuclear hydro, renewable & other

Coal Diesel / Heating Oil Gasoline Propane Natural Gas Pounds of CO2 emitted per million Btu of energy

55 110 165 220

7794Mt (global) 7823Mt (global)

U.S. Electric Power Generation (%)

4677Mt (global)

why coal?

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SLIDE 6

CO2 Emissions (metric tons per capita) - 2011-2015 all fuel sources (solid, liquid, gas) 12.5 25 37.5 50 Qatar Trinidad and Tobago Kuwait Brunei Darussalam Aruba Luxembourg United Arab Emirates Oman Saudi Arabia Bahrain United States Australia Kazakhstan New Caledonia Canada Estonia Russian Federation Greenland Czech Republic China

23 49

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SLIDE 7

L1500 Test facility

  • NOx control strategies
  • Low NOx burners/staging
  • Oxygen injection
  • Corrosion / deposition
  • Coal blends / cofiring
  • Fuel characterization
  • Turbulent mixing scales
  • Swirl effects (0 - 100%)
  • Radiative conditions
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SLIDE 8

Simulation Strategy

STAR-CCM+ARCHES

  • Simulation tool to reach exascale
  • Finite-volume LES code
  • Build on top of Uintah framework
  • Set of software components and

libraries to solve PDE using 100,000’s of processors

  • Task-graph parallelization approach
  • In-house code
  • Flexibility to test and implement new

models not currently available/ feasible for commercial programs

  • Free to download
  • Structured mesh
  • Detailed geometry more

complicated to capture and resolve

Hand-off planes Resolve detailed geometry and flow field using STAR-CCM+ Input to ARCHES for computation Create Averaged Boundary Condition

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SLIDE 9

L1500

ST AR-CCM+ ARCHES

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SLIDE 10
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SLIDE 11
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SLIDE 12
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SLIDE 13

Primary - coal feed

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SLIDE 14

Gas feed

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SLIDE 15

Inner secondary

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SLIDE 16

Outer secondary

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SLIDE 17
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SLIDE 18

0% Swirl 100% Swirl

Gas Phase

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SLIDE 19

Gas Phase Instantaneous Velocity Averaged Velocity

0% Swirl

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SLIDE 20

Gas Phase Instantaneous Velocity Averaged Velocity

100% Swirl

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SLIDE 21

100% Swirl 0% Swirl

  • LES
  • Dynamic Smagorinsky Subgrid
  • 30 million trimmer mesh
  • 1e-5 second time step
  • 3,600 cores
  • 100,000 CPU hours / simulation
  • 170 days on 24-core workstation
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SLIDE 22
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SLIDE 23

Rosin-Rammler Distribution Dref = 53.1 𝜈m q = 0.87 Particle size range 15 - 200 𝜈m

Solid Phase

Modeling only center pipe

  • Obtained averaged flow field
  • Lagrangian method
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SLIDE 24

ARCHES Simulation Geometry

Burner tip Hand-off plane from ST AR-CCM+

  • Model details
  • LES w/ Dynamic Smagorinsky SGS
  • DOM/S8 every 10 iterations
  • Direct Quadrature Method of Moments (DQMOM)
  • u, v, w, raw coal mass, char mass, particle

enthalpy

  • Shadix/Murphy char oxidation model
  • Gas-phase reactions
  • Three stream mixture fraction approach
  • RFG
  • O2
  • Coal off gas

Sufco Utah Coal

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SLIDE 25

100% Swirl 0% Swirl

T emperature

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SLIDE 26

100% Swirl 0% Swirl

Large Particle Distribution

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SLIDE 27

Particle Distribution 0% Swirl Case large small

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SLIDE 28

Comparison with Experimental Data / Consistency Analysis L1500 Experimental Campaign

  • Repeated every year for 5 years
  • 1 to 2 week long
  • Study different conditions/models/

coal types

  • Integrate with simulations
  • Complete full VUQ cycle every year
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SLIDE 29 Demonstration-scale prediction Pilot-scale validation Lab-scale validation Tom Sean Andy David Jeremy Michael Jeremy Phil Jennifer Bench-scale validation 1.5 MWth oxy- coal furnace 5 MWth oxy- gas furnace char oxidation ash transformation multiphase flow soot formation radiation devolatilization

500 MWe

  • xy-AUSC

Design Boiler 1000 MWe USC 8-corner Boiler 15 MWth oxy-coal boiler

Sean

STAR-CCM+ARCHES

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SLIDE 30

Acknowledgements