1. Your Success is Our Goal www.siemens.com/itps1 www.chemtech.com.br FURNACE TROUBLESHOOTING WITH PHOENICS IX International PHOENICS Users Conference Moscow, 25 th September 2002

2. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 2 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference Chemtech - A Siemens Company, Rio de Janeiro / RJ – Brazil Petrobras / CENPES, Rio de Janeiro / RJ – Brazil AUTHORS Flávio Martins de Queiroz Guimarães Bruno de Almeida Barbabela Luiz Eduardo Ganem Rubião Ricardo Serfaty

3. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 3 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference INTRODUCTION – THE SYSTEM Distribution-chamber Plenum Combustion-chamber Underground-duct

4. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 4 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference INTRODUCTION – THE PROBLEM The increase in the pre-heated air mass-flow lead to several problems during the furnace operation: Problem 1: Hot air has a high swirl flow inside the underground duct; Problem 1: Hot air has a high swirl flow inside the underground duct; Problem 2: The mass flux distribution between the two plenum is not uniform; Problem 2: The mass flux distribution between the two plenum is not uniform; Problem 3: The mass flux distribution between the burners within the plenum is not uniform; Problem 3: The mass flux distribution between the burners within the plenum is not uniform; Problem 4: The flames in the two combustion chambers are leading. Problem 4: The flames in the two combustion chambers are leading.

5. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 5 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 1 – UNDERGROUND DUCT Description

6. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 6 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 1 – UNDERGROUND DUCTS Geometry

7. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 7 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 1 – UNDERGROUND DUCT General Settings All simulations were run on PHOENICS v3.3. The follow configuration was setting: Grid: cartesian Grid: cartesian PARSOL: no PARSOL: no Energy Equation: no Energy Equation: no noCombustion: noCombustion: Turbulence Model: standard k-, Chen-Kim k- and RNG k- Turbulence Model: standard k-, Chen-Kim k- and RNG k- Transient: no Transient: no

8. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 8 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 1 – UNDERGROUND DUCT Original Case Simulation

9. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 9 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 1 – UNDERGROUND DUCT Problem Identification 1 2

10. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 10 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 1 – UNDERGROUND DUCT Problem Solution 1 2

11. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 11 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 1 – UNDERGROUND DUCT Problem Solution Results 1 2

12. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 12 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 2 – UNDERGROUND DUCT Description

13. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 13 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 2 – UNDERGROUND DUCTS Geometry

14. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 14 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 2 – UNDERGROUND DUCT General Settings All simulations were run on PHOENICS v3.3. The follow configuration was setting: Grid: cartesian Grid: cartesian PARSOL: no PARSOL: no Energy Equation: no Energy Equation: no Combustion: no Combustion: no Turbulence Model: standard k-, Chen-Kim k- and RNG k- Turbulence Model: standard k-, Chen-Kim k- and RNG k- Transient: no Transient: no

15. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 15 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 2 – UNDERGROUND DUCT Original Case Simulation

16. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 16 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 2 – UNDERGROUND DUCT Problem Identification Mass Flow 35% Greater

17. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 17 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 2 – UNDERGROUND DUCT Problem Solution 2 1

18. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 18 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 2 – UNDERGROUND DUCT Problem Solution Results

19. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 19 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 2 – UNDERGROUND DUCT Problem Solution Results

20. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 20 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEMS 3 & 4 – PLENUM Description

21. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 21 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 3 & 4 – PLENUM Geometry

22. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 22 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 3 & 4 – PLENUM General Settings All simulations were run on PHOENICS v3.3 and v.3.4. The follow configuration was setting: Grid: cartesian Grid: cartesian PARSOL: active (on some cases) PARSOL: active (on some cases) Energy Equation: no Energy Equation: no Combustion: no Combustion: no Turbulence Model: standard k-, Chen-Kim k- and RNG k- Turbulence Model: standard k-, Chen-Kim k- and RNG k- Transient: no Transient: no

23. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 23 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 3 & 4 – PLENUM Problem Identification

24. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 24 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 3 & 4 – PLENUM Problem Identification 1 2 3 4

25. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 25 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 3 & 4 – PLENUM Problem Solution 1 2 3

26. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 26 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 3 & 4 – PLENUM Problem Identification

27. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 27 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 3 & 4 – PLENUM Problem Solution Results

28. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 28 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 3 & 4 – PLENUM Problem Solution Results 1 2 3 4

29. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 29 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 4 – COMBUSTION CHAMBER Description

30. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 30 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 4 – COMBUSTION CHAMBER Geometry

31. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 31 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 4 – COMBUSTION CHAMBER General Settings All simulations were run on PHOENICS v3.4. The follow configuration was setting: Grid: cartesian Grid: cartesian PARSOL: active PARSOL: active Energy Equation: active Energy Equation: active Combustion: active (SCRS) Combustion: active (SCRS) Turbulence Model: Chen-Kim k- Turbulence Model: Chen-Kim k- Transient: no Transient: no

32. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 32 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 4 – COMBUSTION CHAMBER Original Case Simulation

33. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 33 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference PROBLEM 4 – COMBUSTION CHAMBER Problem Solution Results

34. Your Success is Our Goal INERTARGON_IX_IPUC_MOSKOW2002.ppt Slide 34 © IT PS 2002 Furnace Troubleshooting IX International PHOENICS Users Conference CONCLUSIONS The results showed good qualitative agreement with observed behavior during furnace operation. The results showed good qualitative agreement with observed behavior during furnace operation. Although the Chen-Kim and RNG k- models converged to the same solution behavior, the standard k- one seems to under- predict the recirculation zones and the flames inclination. Although the Chen-Kim and RNG k- models converged to the same solution behavior, the standard k- one seems to under- predict the recirculation zones and the flames inclination. That result indicates that the leaning flames are not only caused by bad distribution of air but may also be caused by the number of firing ports in each burner. Decreasing the number of ports might lead to a higher momentum jet from the residing ports, which might in turn mix the fuel better with the preheated air stream and create shorter flames. This would result in a smaller, more compact flame envelope, which would have less tendency of leaning to either side of the furnace That result indicates that the leaning flames are not only caused by bad distribution of air but may also be caused by the number of firing ports in each burner. Decreasing the number of ports might lead to a higher momentum jet from the residing ports, which might in turn mix the fuel better with the preheated air stream and create shorter flames. This would result in a smaller, more compact flame envelope, which would have less tendency of leaning to either side of the furnace