THERMAL SCIENCE

International Scientific Journal

NUMERICAL STUDY ON AERODYNAMIC PERFORMANCE AND PARTICLE EROSION CHARACTERISTICS OF FLUE GAS TURBINE

ABSTRACT
The 3-D numerical simulation method is coupled with erosion and particle rebound models based on the results of high temperature erosion tests to systematically study the gas-solid two-phase flow characteristics of a flue gas turbine for the first time. The aerodynamic loss characteristics of the flue gas-steam mixtures and particle erosion mechanism in the flue gas turbine cascade under design and non-design conditions are investigated. The results indicate that the mixing loss of cooling steam and gas, secondary flow loss, and separation loss significantly affect the entropy increment of the rotor cascade. The isentropic efficiency of the flue gas turbine under the design condition is 78.74%. The radial inflow of wheel cooling steam from the axial clearance has a radial impact and mixing effect on the mainstream flue gas, enhancing the generation and development of the secondary flow vortex in the rotor cascade. When the dimensionless cooling steam flow rate is reduced from 1 to 0.6, the isentropic efficiency of the flue gas turbine increases by approximately 0.9%. By contrast, when the dimensionless cooling steam flow rate increases from 1 to 2, the isentropic efficiency decreases by 0.42%. The erosion rate of the leading and trailing edges of the rotor is higher than those at other streamwise locations. The erosion of the rotor leading edge and the blade-tip trailing edge is caused by the high speed impact of particles above 10 μm, while the erosion of the rotor root is caused by the grinding of 1-5 μm particles carried by the secondary flow.
KEYWORDS
PAPER SUBMITTED: 2022-11-25
PAPER REVISED: 2023-02-28
PAPER ACCEPTED: 2023-03-12
PUBLISHED ONLINE: 2023-04-22
DOI REFERENCE: https://doi.org/10.2298/TSCI221125072C
CITATION EXPORT: view in browser or download as text file
THERMAL SCIENCE YEAR 2023, VOLUME 27, ISSUE Issue 5, PAGES [4291 - 4305]
REFERENCES
  1. Maceli, N., et al., An Industrial Methodology for Erosion Analysis of FCC Expander Blades, Proceedings, ASME Turbo Expo 2020, Virtual, Online, 2020
  2. Chang, J., et al., Hydrodynamic Modelling of an Industrial Turbulent Fluidized Bed Reactor with FCC Particles, Powder Technology, 304 (2016), Dec., pp. 134-142
  3. Xiong H. Y., et al., Vibration Fault Signal Analysis and Diagnosis of Flue Gas Turbine, Engineering Failure Analysis, 134 (2022), 105981
  4. Liu, G. K., et al., Simulation Study on the Effect of Flue Gas on Flow Field and Rotor Stress in Gas Turbines, Energies, 14 (2021), 19, 6135
  5. Xu, W. W., et al., Modelling and Numerical Analysis of the Effect of Blade Roughness on Particle Deposition in a Flue Gas Turbine, Powder Technology, 347 (2019), Apr., pp. 59-65
  6. Gao, X. W., et al., Research Progress of Catalysts Fouling in Flue Gas Turbines Used in Catalytic Cracking Unit, China Powder Science and Technology, 21 (2015), 6, pp. 25-32
  7. Lin, G. Q., et al., Stress and strain Analysis of First Stage Rotating Blades of Flue Gas Turbine Blades, Applied Mechanics and Materials, 130-134 (2012), Oct., pp. 691-695
  8. Zheng, L. J., et al., Blades Fracture Failure Analysis of a Certain Flue Gas Turbine, Petro-Chemical Equipment, 47 (2018), 6, pp. 74-79
  9. Sun, J. G., et al., A Study into High-Temp Protective Coatings for Flue Gas Turbine Blades, Sino-Global Energy, 13 (2008), pp. 37-39
  10. Min, X. B., et al., Anatomy and Analysis of the Great Wall No. 1 Coating on The Rotor Blades of the in-Service Flue Gas Turbine, Proceedings, 2003 China Shanghai Hard Surface Technology Academic Exchange Conference, Shanghai, China, 2003
  11. Liu, W. C., Study on the Technology and Properties of Detonation Gun Sprayed Cr3C2-NiCr Coatings, M. Sc. thesis, Lanzhou University of Technology, Lanzhou, China, 2019
  12. Cai, L. X., et al., New Features of Solid Particle Erosion Damage of Control Stage Blades in Supercritical Steam Turbine, Proc. IMechE - Part A, Journal of Power and Energy, 230 (2016), 1, pp. 76-85
  13. Bennett, E., et al., Predicting Turbomachinery Erosion Rates, ANSYS Advantage, 2 (2011), 5, pp. 31-33
  14. Carbonetto, B., et al., Advances in Erosion Prediction of Axial Flow Expanders, Proceedings, 28th Turbomachinery Symposium, Texas A&M University, Colege Station, Tex., USA, 1999
  15. Du, Y. P., et al., Catalyst Fines Behavior among FCC Flue Gas Turbine Blade Rows-Effect of Gaseous Phase Flow Field Distribution, Chemical Engineering, 40 (2012), 7, pp. 57-60
  16. Du, Y. P., et al., Catalyst Fines Behavior among FCC Flue Gas Turbine Blade Rows-Erosion and Fouling on Blades, Chemical Engineering, 40 (2012), 9, pp. 52-55
  17. Gandhi, N., et al., Reliability Improvement in FCC Hot Gas Expander Using CFD Modelling, Proceedings, 16th International Symposium on Transport Phenomena and Dynamics of Rotating Machinery, Honolulu, Hi., USA, 2016
  18. Cai, L. X., et al., Gas-Particle Flows and Erosion Characteristic of Large Capacity Dry Top Gas Pressure Recovery Turbine, Energy, 120 (2017), Feb., pp. 498-506
  19. Cai, L. X., et al., The Influence of Nozzle Chamber Structure and Partial-Arc Admission on The Erosion Characteristics of Solid Particles in the Control Stage of a Supercritical Steam Turbine, Energy, 82 (2015), Mar., pp. 341-352
  20. Chen, S. F., et al., Model of Particle Deposition and Adhesion on Blade Surface of Flue Gas Turbine, The Chinese Journal of Process Engineering, 18 (2018), 3, pp. 447-453
  21. Fei, D., et al., Analysis of Scaling Reason and Simulation of Flow Field of FCCU Power Recovery Expander, M. Sc. thesis, East China University of Science and Technology, Shanghai, China, 2015
  22. Wang, Y., et al., Experiment Research on Scaling Mechanism of Catalyst in Fluid Catalytic Cracking Flue Gas Turbine, China Powder Science and Technology, 22 (2016), 1, pp. 92-96
  23. Fei, D., et al., Analysis of Mechanism of Fouling Increase on Blades of FCCU Power Recovery Expander, CIESC Journal, 66 (2015), 1, pp. 79-85
  24. Cai, L. X., et al., Experimental and Numerical Studies on Rebound Characteristics of Non-Spherical Particles Impacting on Stainless-Steel at High Temperature, Powder Technology, 381 (2021), Mar., pp. 110-121
  25. Wang, S. S., et al., Influence of the Inlet Channel Flow of a Steam Turbine on Solid Particle Erosion of the Control Stage Nozzles, Proc. IMechE - Part A, Journal of Power and Energy, 226 (2012), 5, pp. 636-649

© 2024 Society of Thermal Engineers of Serbia. Published by the Vinča Institute of Nuclear Sciences, National Institute of the Republic of Serbia, Belgrade, Serbia. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution-NonCommercial-NoDerivs 4.0 International licence