Modeling Large-Size Boilers As a Set of Heat Exchangers: Tips and Tricks

Abstract

Practical calculation of the heat-recovery sections of large-size boilers is still based on approximate methods. On the one hand, CFD-based models cannot directly handle the geometric intricacy of tube bundles, and thus rely on volume-averaged source terms that demand empirical input. On the other hand, the standard, lumped heat exchanger calculation, which can be a far simpler and more robust alternative, fails in several important aspects, mainly related to the effects of thermal radiation and the coupling between several sections. In this paper, we consider the diverse sections of a coal-fired utility boiler as a case study to show how to deal with these shortcomings. Under the objective of developing a simple monitoring method, we extend the traditional heat exchanger model to take into account most of the peculiarities of boiler superheaters, reheaters and economizers. Techniques range from the re-examination of analytical solutions to the auxiliary use of CFD calculations. The models are assembled to simulate the thermal performance of the boiler as a whole unit. Results are validated against actual measurements taken at a thermoelectric plant.