STAR-CCM+® Usage for Sorbent Injection Optimization

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ENGINEERING PROBLEM: For the sorbent injection system’s ADA installs for coal fired power plant units, the injection array that transports the sorbent into the power plant’s flue gas stream needs to be optimized to achieve the best distribution as possible into the plant’s particulate collection stream.

METHOD FOR SOLUTION: The STAR-CCM+ software and model built was used to locate and optimize the best horizontal and vertical position for the injection lances in the duct to provide as uniform a distribution of PAC as possible across the particulate collection device inlet plane. The method ADA used to begin and finish this optimization effort, was to utilize point injectors at a baseline array and depth design, determined specifically for the duct arrangement, as no two are every the same. From there the flue gas flow field patterns are analyzed, including velocity streamlines and cross sections of high and low velocity regions to place the point injectors in the correct position to achieve the even distribution at the given reference plane in the model. The metric for determining a converged solution is % Root Mean Square (% RMS). The goal with utilizing this metric is to minimize it as much as possible from the baseline solution. The closer the % RMS value is to zero the more even the distribution is in the gas stream at that given plane.

BENEFIT TO ADA: Utilizing STAR-CCM+ for this analysis, allows ADA to achieve an engineered solution for the sorbent injection array design. An optimized grid design aids with the usage of sorbent injection chemical. The better the distribution, the more efficient the pollutant capture is, which translates to less sorbent costs for ADA’s customers.

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Tyler Derritt