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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation1
Electrostatic Precipitator PerformanceImprovement Through Computational
Fluid Dynamic Modeling
PowerGen InternationalDecember 11, 2002
Authors:Brian J. Dumont
Robert G. Mudry, P.E.
Airflow Sciences Corporation
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation2
Introduction
½ Flow modeling is an established practice to optimize gas flow patterns within industrial equipment
½ Little published data exists on the accuracy of flow models, particularly for electrostatic precipitators (ESPs)
½ Available data was analyzed in detail to compare model results to actual plant test data
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation3
Fluid Flow Modeling
½ Computational Fluid Dynamics (CFD)½ Physical scale modeling
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PowerGen 2002 December 11, 2002
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Testing Methods
½ ESP cold-flow velocity distribution measurement
Flow Flow
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PowerGen 2002 December 11, 2002
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Objectives of Analysis
½ Assess all available data for ESP testing and modeling acquired over the past 7 years
• ESP field test data• CFD model results• Physical model results
½ Perform statistical comparisons of the data
½ Obtain quantitative information relating model correlation to test data
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation6
Cases Analyzed
½ Ten cases where field data and CFD data exist for the same configuration
½ Five cases where corresponding physical model data also exist
½ All cases from coal-fired electric power stations• U.S. and Canadian plants• Unit size ranges from 326 MW to 952 MW
½ One case study is presented in detail, 326MW Unit in the Western U.S.
½ All cases are summarized
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation7
Data Comparisons
½ Contour plots
½ Flow distribution statistics• % RMS• ICAC Standards
½ Point-by-point deviations
½ Overall Correlation Factor(%RMS of point-by-point deviations)
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Case Study 2 - Inlet PlaneNormalized Streamwise Velocity Component
½ Both models capture trends½ CFD model captures peak
velocity better, but overpredicts the size of the high velocity region
Phys
ical
Tes
t Dat
a
CFD
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PowerGen 2002 December 11, 2002
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Case Study 2 - Inlet PlaneFlow Statistics - Deviations from Goal Velocities
½ Physical model overpredicts flow compliance to goal as shown by all 3 analyses
½ CFD model underpredicts flow compliance to goal as shown by all 3 analyses
%RMS Modified ICAC 115% Modified ICAC 140%0
10
20
30
40
50
60
70
80
90
100
20.1
86.5
99.7
33.4
63.5
93.7
42
61.5
91Physical Model
Test Data
CFD ModelTest Data
CFD Model
Physical Model
42.0
33.4
20.1
63.561.5
86.5
99.793.791.0
% RMS ICACm 115% ICACm 140%
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PowerGen 2002 December 11, 2002
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Case Study 2 - Inlet PlaneHistograms – Point-By-Point Deviations from Test Data
½ Correlation Factors:CFD: 37.0Physical: 32.4
½ 65% of CFD points within +/-25% band
½ 61% of physical model points within same band Percent Deviation from Test Data
30
25
20
15
10
5
0
Per
cen
tag
e o
f D
ata
Po
ints
-100 -80 -60 -40 -20 0 20 40 60 80 100
CFD ModelPhysical Model
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation11
Case Study 2 - Outlet PlaneNormalized Streamwise Velocity Component
½ Both models capture trends½ CFD model captures peak
velocity betterPh
ysic
al
Tes
t Dat
a
CFD
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation12
Case Study 2 - Outlet PlaneFlow Statistics - Deviations from Goal Velocities
½ Both models underpredict %RMS, especially the physical model
½ Both models predict modified ICAC conditions fairly well
%RMS Modified ICAC 115% Modified ICAC 140%0
10
20
30
40
50
60
70
80
90
100
17.8
72.6
92
34.7
78.8
86.8
27.8
76.7
90.6Physical Model
Test Data
CFD Model
Test Data
CFD Model
Physical Model
27.834.7
17.8
78.8 76.772.6
92.0 90.6
% RMS ICACm 115% ICACm 140%
86.8
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation13
Case Study 2 - Outlet PlaneHistograms - Point-By-Point Deviations from Test Data
½ Correlation Factors:CFD: 27.2Physical: 40.8
½ 75% of CFD points within +/-25% band
½ 48% of physical model points within same band Percent Deviation from Test Data
30
25
20
15
10
5
0
Per
cen
tag
e o
f D
ata
Po
ints
-100 -80 -60 -40 -20 0 20 40 60 80 100
CFD ModelPhysical Model
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation14
Case Study 2 - Summary
½ ESP Inlet� Both models correlate fairly well� Physical model has a lower correlation coefficient� CFD model matches flow statistics better and has a
larger number of points within +/-25% deviation band on histogram
½ ESP Outlet� CFD model agrees better with test data under all
comparisons� Both models capture correct trends
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation15
All Case Studies - Correlation Factor½ In some cases, the CFD model has a better correlation factor½ In others, the physical model is better½ There is no clear trend as to why this occurs½ The CFD model correlates better on average
Correlation Factor Summary
0
5
10
1520
2530
35
40
45
1I 1O 2I 2O 3I 3AB 3O 4AB 5O 6I 6O 7I 7O 8I 8O 9I 9O 10AB
Case
Co
rrel
atio
n F
acto
r
CFD Model Physical Model
40
30
20
10
0Co
rrel
atio
n F
acto
r
Correlation Factor Summary
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation16
All Case Studies - Overall Summary
½ On average, the Correlation Factor for CFD models is 23.5 (27.8 using only studies where the physical model also existed)
½ On average, the Correlation Factor for physical models is 32.6
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation17
Analysis Conclusions
½ On the whole, correlation is not as strong as desired
½ Experience indicates that this level of correlation is enough to make CFD modeling a useful engineering tool for ESPs
½ Additional research and development in CFD technology will allow for increased accuracy
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Case Study
½ Two identical 790 MWunits
½ Western U.S. ½ Cold side chevron ESPs½ SCA=125½ Avg. vel 7.2 ft/s½ Both units regularly derated by 240 MW to
operate within opacity limits
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PowerGen 2002 December 11, 2002
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Baseline CFD Model Results
½ Velocity pattern at ESP inlet shows non-uniform• High velocity on top and bottom, low velocity in center• RMS deviation = 26 %
½ Outlet plane poor distributionas well• RMS deviation = 20 %
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PowerGen 2002 December 11, 2002
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Design Optimization
½ Design modifications developed using CFD model• New inlet and outlet perforated plates• Slight alteration to inlet duct turning vanes
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PowerGen 2002 December 11, 2002
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Final Design CFD Model Results
½ ESP inlet velocity profile now uniform• RMS deviation = 7 %
½ Outlet plane also improved• RMS deviation = 7 %
½ Change to system pressure drop = +0.3 ”H2O
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PowerGen 2002 December 11, 2002
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Resulting ESP Performance
½ ESP efficiency testing performed• 23% reduction in particulate emissions compared to original
ESP geometry
½ At same opacity, plant output increases by 150 MW per unit
½ Payback for model study and installation costs = 1 year
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PowerGen 2002 December 11, 2002
Airflow SciencesCorporation23
Questions