Developing a simulation-based toolset to understand the interconnectivity of an entire coal combustion system

Design optimization enables efficient use of local resources

Meeting energy needs requires a diversified solution, and coal continues to be part of the portfolio. The challenge, then, is to make the process as efficient as possible, to minimize pollutants while maximizing energy output and asset integrity. But with the deteriorating quality of coal resources globally, the existing technology used to extract energy from coal for industrial and utility use suffers from problems which result in a drop in efficiency and an increase in plant maintenance costs. 

In this webinar, you'll learn about a simulation-based tool that was developed to establish a foundation for future design optimization to make economic and environmentally responsible use of poor quality coal. This holistic tool consists of an integrated thermal and CFD model representing a large coal combustion system that was built up from various sub-components in order to analyze the complex interaction between them. For example, the tool was used to examine the air and coal distribution, which are fundamental to efficient combustion and reducing emissions like dust, NOx and SOx.

A validated, integrated digital twin of coal mill subcomponents

The pilot project for this toolset involved a detailed investigation of the characteristics of a utility scale coal-fired boiler system utilizing different coal qualities and operating under various real-life conditions. The simulation models representing several coal mill subcomponents were integrated to investigate the complex interconnectivity between all parts of the combustion system. This approach mitigates the risks associated with unrealistic or oversimplified assumptions regarding boundary conditions.

Robust models created from similar projects may be the foundation for the development of “digital twins” of the existing installed equipment.

What you will learn in this webinar:

This webinar will give an overview of the toolset and how Simcenter was used to model the various subcomponents that included the following:

• Pulverizer/mill
• Coal dust (pulverized fuel) distribution system
• Combustion air distribution system
• Detailed burners
• Furnace (where the combustion and radiant heat transfer occurs)
• Boiler and convective heat transfer surfaces
• Air heater

Presenters:

• Ignus le Roux, Director, Engineering Services, Aerotherm
• Warwick Ham, Boiler Process Group Leader, Steinmüller Africa
• Ravi Aglave, PhD, Director, Energy & Process Industries at Siemens Digital Industries Software

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