Search Results (55)

This study investigates the thermal dynamics and material behavior involved in the baking process for Lebanese flatbread, focusing on the heat transfer mechanisms, water loss, and dough expansion under high-temperature conditions. Despite previous studies on flatbread baking using impingement or conventional ovens, this work presents the first experimental investigation of the traditional Lebanese flatbread baking process under realistic industrial conditions, specifically using a high-temperature tunnel oven with direct flame heating, extremely short baking times (~10–12 s), and peak temperatures reaching ~650 °C, which are essential to achieving the characteristic pocket formation and texture of Lebanese bread. This experimental study characterizes the baking kinetics of traditional Lebanese flatbread, recording mass loss pre- and post-baking, thermal profiles, and dough expansion through real-time temperature measurements and video recordings, providing insights into the dough’s thermal response and expansion behavior under high-temperature conditions. A custom-designed instrumented oven with a steel conveyor and a direct flame burner was employed. The dough, prepared following a traditional recipe, was analyzed during the baking process using K-type thermocouples and visual monitoring. Results revealed that Lebanese bread undergoes significant water loss due to high baking temperatures (~650 °C), leading to rapid crust formation and pocket development. Empirical equations modeling the relationship between baking time, temperature, and expansion were developed with high predictive accuracy. Additionally, an energy analysis revealed that the total energy required to bake Lebanese bread is approximately 667 kJ/kg, with an overall thermal efficiency of only 21%, dropping to 16% when preheating is included. According to previous CFD (Computational Fluid Dynamics) simulations, most heat loss in similar tunnel ovens occurs via the chimney (50%) and oven walls (29%). These findings contribute to understanding the broader thermophysical principles that can be applied to the development of more efficient baking processes for various types of bread. The empirical models developed in this study can be applied to automating and refining the industrial production of Lebanese flatbread, ensuring consistent product quality across different baking environments. Future studies will extend this work to alternative oven designs and dough formulations. Full article

Channel fire poses a great threat to personnel safety and structural strength, in which the temperature profile is worthy of attention. In this paper, the longitudinal temperature profile of a ceiling jet induced by a wall-attached fire with different channel slopes was experimentally investigated using a 1:8 reduced-scale channel. The results show the following: (1) For channel fire with a horizontal ceiling, the influence of the burner aspect ratio and source-ceiling height on the temperature profile is monotonous in the cases considered in this work. With a larger burner aspect ratio and larger source-ceiling distance, more ambient air could be entrained; hence, the longitudinal temperature under the ceiling decays faster. (2) For channel fire with an inclined ceiling, when the burner aspect ratio and source-ceiling distance remain constant, the asymmetric entrainment induced by the flame under larger channel slope leads to more hot smoke being transported upstream. Consequently, the temperature profile is not symmetric, with higher temperatures upstream and lower temperatures downstream. (3) Combining the influence of the burner aspect ratios, source-ceiling distance, and burner aspect ratio, the characteristic length scale was modified. Based on this, a model describing the ceiling temperature profile was proposed and then verified with previous data. Full article

The combustion behavior and thermal performance of industrial-scale borax pentahydrate (Na₂B₄O₇·5H₂O) melting furnaces remain underexplored despite their critical role in boric oxide (B₂O₃) production, a key input for high-performance manufacturing. This study addressed this gap by employing three-dimensional computational fluid dynamics (CFD) simulations to model two operational natural gas-fired furnaces with distinct burner configurations (four-burner and six-burner systems). The analysis focused on optimizing burner placement, specifically, the axial distance and inclination angle, to enhance thermal uniformity and reduce refractory wall damage caused by aggressive high-temperature borate corrosion. A comprehensive parametric study of twelve burner configurations revealed that tilting the burners at 5–10° significantly improved temperature uniformity while reducing peak wall temperatures and mitigating localized hot spots. The optimal design, incorporating a 10° burner angle and a staggered burner arrangement (Case 11), attained a melt pool temperature of 1831.3 K and a charging average wall temperature of 1812.0 K. These values represent essential benchmarks for maximizing furnace efficiency and operational stability. The modified designs for the four- and six-burner systems led to improved temperature distributions and a notable reduction in maximum wall temperatures, directly contributing to longer maintenance intervals and improved refractory durability. The findings of this study confirm that minor geometrical and angular adjustments in burner placement can yield significant performance gains. The validated CFD approach and proposed design modifications offer a scalable, low-cost strategy for improving combustion efficiency and furnace lifespan in borax processing facilities. Full article

Nowadays, as a result of the increasing awareness of European societies and new legal regulations, the role of renewable energy sources in individual heating is growing. One of the forms of renewable heat and electricity production is the use of biomass pellet burners coupled with Stirling engines. To ensure high system efficiency, the combustion process of this type of fuel requires an appropriate design of the burners, which can provide high-temperature flue gases. This requirement may be challenging, as the long operation of such a burner may cause the thermal degradation of its components, mainly the upper burner wall. The subject of this analysis was a burner with a nominal power of 10 kW. As the analysis tool, a previously validated CFD model was used. In this work, two ways of thermal degradation prevention are presented. The first one is geometry optimization via secondary air hole distribution. The results show that an appropriate geometrical design of the burner may be an efficient way of shifting the high-temperature zone to the burner axis, which may mitigate the thermal degradation risk. Secondly, the inlet air mass flow is changed to show its impact on the presence and location of the high-temperature zone. Both methods can be treated as interesting ways for solving the challenge of the long-term operation of high-temperature biomass burners by avoiding thermal degradation. Full article

The interaction mechanism of multi-physical fields in a 330 MW tangentially fired boiler is explored by coupling the CFD (computational fluid dynamics) model and the working fluid side hydrodynamic model under steady-state conditions. The research focuses on the flue gas flow field, the hydrodynamic safety of the water wall, the variation of the working fluid parameters and the formation and distribution characteristics of sulfide (SO₂, H₂S) under different steady loads (35%, 50%, 75%, 100% Boiler Maximum Continuous Rating). The results show that under high load, the flue gas attaches to the wall. The overall stagnation differential pressure ratio (1.85–2.07) and reversal differential pressure ratio (1.22–1.30) of the G1 tube group with the lowest heat flux are higher than the safety threshold (1.05), proving reliable operational safety under equilibrium conditions. The temperature distribution of the furnace center obtained by numerical simulation is consistent with the actual situation. The mass fraction of sulfide increases significantly with the increase in load. SO₂ is mainly distributed in the wall area of the middle and upper burners, while H₂S is mainly distributed in the wall area between the secondary air and the main burner. The maximum mass fractions of SO₂ and H₂S at 330 MW are 0.120% and 0.0524%, respectively. It is suggested that a wall-attached air system be added to inhibit the enrichment of corrosive gases. This work may provide theoretical support and engineering guidance for multi-objective optimization design and high temperature corrosion prevention and control of tangentially fired boilers. Full article

Both single-skin and double-skin glass facades are extensively employed in commercial high-rise buildings and are gaining increasing popularity. However, the capability to deploy firefighting agents in such ultra-high structures remains limited and has been minimally investigated. To provide guidance for single-layer exterior wall fire protection, this study examines the impact of vertical walls on window ejected plumes by simulating the upper portion of jet plumes using a square burner flame. Experimental and numerical simulations were conducted. The findings revealed that plumes from propane burners could attach to the wall even when L_{E. burner fire} > 0.7W, contradicting previous criteria. This discrepancy arises because prior studies underestimated the induced pressure difference in large fires. This pressure difference propels the plume toward the wall, behaving like a rigid body. Full article

Enhancing the combustion efficiency and flame stability in conventional systems is essential for reducing carbon emissions and advancing sustainable energy solutions. In this context, electrohydrodynamic plasma actuators offer a promising active control method for modifying and regulating flame characteristics. This study presents a numerical investigation into the effects of a ring-type plasma actuator positioned on the co-flow air side of a non-premixed turbulent methane/air combustion system—an approach not previously reported in the literature. The ring-type plasma actuator was designed by placing electrodes along the perimeter of the small diameter wall of the air duct. The impact of the plasma actuator on the reacting flow field within the burner was analyzed, with a focus on its influence on the flow dynamics and flame structure. The results, visualized through velocity and temperature contours, as well as flow streamlines, provide insight into the actuator’s effect on flame behavior. Two operating modes of the plasma actuators were evaluated: co-flow mode, where the aerodynamic effect of the plasma actuators was directed downstream; and counter-flow mode, where the effects were directed upstream. The findings indicate that the co-flow actuation positively reduces the flame height and enhances the flame anchoring at the root, whereas counter-flow actuation slightly weakens the flame root. Numerical simulations further revealed that co-flow actuation marginally increases the energy release by approximately 0.13%, while counter-flow actuation reduces the energy release by around 7.8%. Full article

This study aims to investigate the characteristics of ash accumulation and slagging in boilers during low- and medium-load operation and to analyse the migration pattern of alkali metals in high-alkali coal. In this paper, the ash accumulation characteristics and slagging trend of the furnace interior under a 500 MW load were investigated using numerical simulation by comparing the ash accumulation and slagging characteristics under two different burner configurations, and analysing the slagging trend of the furnace with upper burner arrangement and lower burner arrangement by taking the deposition location on the furnace wall and the deposition rate and the temperature of the furnace wall as the indices. The existing formation of sodium in Jundong coal at different temperatures was investigated using computational methods; SiO₂, Al₂O₃, and kaolin were doped separately; and the migration and transformation characteristics of their different additives on the sodium-based compounds in Jundong coal were explored. The results showed that, under a 500 MW load, the size of the tangent circle formed in the furnace by commissioning the upper burner condition was larger than the lower burner, and the main combustion zone was larger than the lower burner. The ash accumulation of coal ash particles in the boiler was mainly concentrated in the hearth region, and the deposition rate was higher at the height regions of 10 m and 25 m in the hearth. The solid-phase NaCl transition temperature was reduced to 350 °C after the doping of SiO₂ in Jundong coal, and the doping of Al₂O₃ inhibited the transition of solid-phase NaCl, promoted the generation of gas-phase NaCl, and had certain inhibitory effects on the generation of sodium-based silica–aluminium compounds, the content of which at all temperatures was inversely proportional to the proportion of doping. The doping of kaolin promotes the transformation of solid-phase NaCl and inhibits the generation of gas-phase NaCl. Full article

To investigate the safe, stable, and economically viable operation of a boiler under ultra-low-load conditions during the deep peaking process of coal-fired units, a numerical simulation study was conducted on a 660 MW front- and rear-wall hedge cyclone burner boiler. The current research on low load conditions is limited to achieving stable combustion by adjusting the operating parameters, and few effective boiler operating parameter predictions are given for very low-load conditions, i.e., below 20%. Various burner operation modes under ultra-low load conditions were analyzed using computational fluid dynamics (CFDs) methods; this operation was successfully tested with six types of pulverized coal combustion in this paper, and fitting models for outlet flue gas temperature and NO_x emissions were derived based on the combustion characteristics of different types of pulverized coal. The results indicate that under 20% ultra-low-load conditions, the use of lower burners leads to a uniform temperature distribution within the furnace, achieving a minimum NO_x emission of 112 ppm and a flue gas temperature of 743 K. Coal type 3, with the highest carbon content and a calorific value of 22,440 kJ/kg, has the highest average section temperature of 1435.76 K. In contrast, coal type 1 has a higher nitrogen content, with a maximum cross-sectional average NO_x concentration of 865.90 ppm and an exit NO_x emission concentration of 800 ppm. The overall lower NO_x emissions of coal type 3 are primarily attributed to its reduced nitrogen content and increased oxygen content, which enhance pulverized coal combustion and suppress NO_x formation. The fitting models accurately capture the influence of pulverized coal composition on outlet flue gas temperature and NO_x emissions. This control strategy can be extended to the stable combustion of many kinds of coal. For validation, the fitting error bar for the predicted outlet flue gas temperature based on the elemental composition of coal type 6 was 8.09%, whereas the fitting error bar for the outlet NO_x emissions was only 1.45%. Full article

Under the background of achieving carbon dioxide peaking and carbon neutrality, the rapid development of renewable energy power generation poses new challenges to the flexible adjustment capabilities of traditional power plants. To explore the furnace combustion stability and optimal operation modes during deep peak shaving, a simulation of the combustion process under low-load conditions for a 600 MW wall-fired boiler is performed utilizing computational fluid dynamics (CFD) analysis. The impact of burner combination modes on the combustion process within the furnace is explored at 25% and 35% boiler maximum continuous ratings (BMCRs). This study investigates two configurations of burner combinations. One mode operates burners in layers A, B, and C, which include the lower layers of burners on the front and rear walls of the boiler, as well as the middle-layer burners on the rear wall, referred to as OM1. The other mode operates burners in layers A and C, which include the lower layers of burners on the front and rear walls of the boiler, referred to as OM2. The results indicate that OM2 exhibits superior capabilities in orchestrating the distribution of the airflow velocity field and temperature field under the premise of ensuring no more than a 1% decrease in the pulverized coal burnout rate. When OM1 is employed, the airflow ejected from the middle-level burners hinders the upward movement of pulverized coal sprayed from the lower-level burners, causing a larger proportion of pulverized coal to enter the ash hopper for combustion. Consequently, the ash hopper attains a peak mole fraction of CO₂ at 0.163. OM2 delays the blending of pulverized coal with air by enhancing the injection quantity of pulverized coal per burner. As a result, the generation of CO in the ash hopper reaches a notable mole fraction of up to 0.108. The decreased furnace temperature promotes the formation of fuel-based NO_x during low-load operation. Taking the 25% BMCR as an example, the NO_x emissions measured at the furnace outlet are 743 and 1083 ppm for OM1 and OM2, respectively. This study focuses on the impact of combustion combinations on the combustion stability when the boiler is operating at low loads. The findings could enrich previous research on combustion stability and contribute to the optimization of combustion schemes for power plant boilers operating at low loads. Full article

To accommodate the integration of renewable energy, coal-fired power plants must take on the task of peak regulation, making the low-load operation of boilers increasingly routine. Under low-load conditions, the phase transition point (PTP) of the working fluid fluctuates, leading to potential flow instability, which can compromise boiler safety. In this paper, a one-dimensional coupled dynamic model of the combustion and hydrodynamics of a supercritical boiler is developed on the Modelica/Dymola 2022 platform. The spatial distribution of key thermal parameters in the furnace and the PTP position in the water-cooled wall (WCW) are analyzed in a 660 MW supercritical boiler when parameters on the combustion side change under full-load and low-load conditions. The dynamic response characteristics of the temperature, mass flow rate, and the PTP position are investigated. The results show that the over-fire air (OFA) ratio significantly influences the flue gas temperature distribution. A lower OFA ratio increases the flue gas temperature in the burner zone but reduces it at the furnace exit. The lower OFA ratio leads to a higher fluid temperature and shortens the length of the evaporation section. The temperature difference in the WCW outlet fluid between the 20% and 60% OFA ratios is 11.7 °C under BMCR conditions and 7.4 °C under 50% THA conditions. Under the BMCR and 50% THA conditions, a 5% increase in the coal caloric value raises the flue gas outlet temperature by 32.7 °C and 35.4 °C and the fluid outlet temperature by 6.5 °C and 9.9 °C, respectively. An increase in the coal calorific value reduces the length of the evaporation section. The changes in the length of the evaporation section are −2.95 m, 2.95 m, −2.62 m, and 0.54 m when the coal feeding rate, feedwater flow rate, feedwater temperature, and air supply rate are increased by 5%, respectively. Full article

In this work, we attempt to explain the phenomenon of sulfur corrosion of power boiler water walls under the conditions of large fluctuations in carbon monoxide concentrations. To assess the conditions required for corrosion formation, a criterion based on the chemical and flow field parameters of the flue gas is proposed. The formulated sulfur corrosion criterion is based on the mixture fraction variance and the turbulence time scale. Numerical modeling of coal combustion in a 250 MW power boiler is performed using ANSYS. Two cases of combustion in a boiler are analyzed, with the first simulating the boiler operated using classic high-swirl burners and the second one accounting for boiler operation with modified low-swirl burners. Calculations of pulverized coal combustion are performed using the standard k-$\epsilon$ turbulence model and the combustion described by the mixture fraction. The simulation results reveal that the low-swirl burner is characterized by higher values of the mixture fraction variance and a higher frequency of fluctuation of the velocity field, which is strongly related to an increased corrosion rate. The study outcomes show the validity of using the criterion of the mixture fraction variance and velocity field fluctuations to determine the areas at risk of sulfur corrosion. Full article

In this study, a novel gas burner combining air swirl and an inverse diffusion flame (IDF) is designed for industrial applications. Numerical simulations using the Reynolds-averaged Navier–Stokes (RANS) method and simplified reaction mechanisms are conducted to predict the turbulent flow and combustion performance of the burner. Detailed flow structures, flame structures and effects of burner configurations are examined. The simulation results indicate that the swirl action of the burner creates a central recirculation zone and two external recirculation zones at the burner head, which stabilize combustion. The tangential velocity is minimal at the center of the burner and decreases with increasing distance from the outlet. As the distance from the exit increases, the maximum tangential velocity gradually decreases, and the peak value shifts towards the wall. This decrease in tangential velocity with axial distance signifies the gradual dissipation of the swirl effect, which disappears near the chamber outlet. The comparisons reveal that altering the number of burner fuel nozzles is more effective in reducing NO emissions than changing the inclination angle of the fuel nozzles, in the given conditions. Favorable combustion conditions are achieved when there are 16 fuel nozzles and the nozzle inclination angle is 60°, resulting in a 28.5% reduction in NO emissions at the outlet, compared to the reference condition. Full article

Microchannel burners suffer from low combustion efficiency and poor stability in applications. In order to explore the effect of wall reaction on methane/air premixed combustion performances in the microchannel, the effects of wall activity, inlet velocity, pressure, and equivalence ratio on the temperature and radical distribution characteristics were studied by CFD computational simulations. It is found that as the reaction pressure increases, there are more free-radical collisions, causing the reaction temperature to rise. The OH radicals participate in the reaction at the active near wall so that the mass fraction of the OH radical on the active wall is lower than that on the inert wall. As the equivalence ratio increases from 0.6 to 1.2, the high-temperature regions increase but the maximum temperature decreases. The mass fraction of OH radical increases with the increase of the equivalence ratio, and the increase of OH radical near the inert wall is larger than that of the active wall. As the flow rate increases, the disturbance increases, and the combustion reaction becomes more intense, resulting in an increase in the temperature and the mass fraction of OH radicals. The mass fraction of H, O, OH, and CH₃ radicals in the inert wall was slightly higher than that in the active wall, in which the peak mass fraction of CH₃ radical appeared at the axial position closest to the entrance, while the other three radicals reached the peak at about the same axial position. This study provides a reference for combustion stability in microcombustors. Full article

Direct atomization of a free-flowing glass melt was carried out using a high-speed flame with the aim of producing tiny, self-expanding glass melt droplets to form hollow glass microspheres. Atomization experiments were carried out using a specially adapted free-fall atomizer in combination with a high-power gas burner to achieve sufficient temperatures to atomize the melt droplets and to directly expand them into hollow glass spheres. In addition, numerical simulations were carried out to investigate non-measurable parameters such as hot gas velocities and temperatures in the flame region by the finite volume-based software Star CCM+^® (v. 2022.1.1), using the Reynolds-Averaged Navier–Stokes (RANS) turbulence and the segregated flow model. To calculate the combustion process, the laminar flamelet method was used. The experiments and simulations indicated that a maximum gas velocity of about 170 m/s was achieved at the point of atomization in the flame. The particle size distribution of the atomized glass droplets, either solid or hollow, ranged from 2 µm to 4 mm. Mean particle sizes in the range of 370 µm to 650 µm were highly dependent on process parameters such as gas velocity. They were in good agreement with theoretically calculated median diameters. The formation of hollow glass microspheres with the proposed concept could be demonstrated. However, only a small fraction of hollow glass spheres was found to be formed. These hollow spheres had diameters up to 50 µm and, as expected, a thin wall thickness. Full article