Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler
The growth of renewable energy sources presents a pressing challenge to the operation and maintenance of existing fossil fuel power plants, given that fossil fuel remains the predominant fuel source, responsible for over 60% of electricity generation in the United States. One of the main concerns wi...
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MDPI AG
2023-12-01
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| Online Access: | https://www.mdpi.com/1424-8220/24/1/154 |
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| author | Tanuj Gupta Mahabubur Rahman Xinyu Jiao Yongji Wu Chethan K. Acharya Dock R. Houston Susan Maley Junhang Dong Hai Xiao Huijuan Zhao |
| author_facet | Tanuj Gupta Mahabubur Rahman Xinyu Jiao Yongji Wu Chethan K. Acharya Dock R. Houston Susan Maley Junhang Dong Hai Xiao Huijuan Zhao |
| author_sort | Tanuj Gupta |
| collection | DOAJ |
| description | The growth of renewable energy sources presents a pressing challenge to the operation and maintenance of existing fossil fuel power plants, given that fossil fuel remains the predominant fuel source, responsible for over 60% of electricity generation in the United States. One of the main concerns within these fossil fuel power plants is the unpredictable failure of boiler tubes, resulting in emergency maintenance with significant economic and societal consequences. A reliable high-temperature sensor is necessary for in situ monitoring of boiler tubes and the safety of fossil fuel power plants. In this study, a comprehensive four-stage multi-physics computational framework is developed to assist the design, optimization installation, and operation of the high-temperature stainless-steel and quartz coaxial cable sensor (SSQ-CCS) for coal-fired boiler applications. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. With the simulation-guided sensor installation plan, the newly designed SSQ-CCSs have been employed for field testing for more than 430 days. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations. |
| first_indexed | 2024-03-08T14:57:50Z |
| format | Article |
| id | doaj.art-ecea37e364124c66a6e96e37a1057759 |
| institution | Directory Open Access Journal |
| issn | 1424-8220 |
| language | English |
| last_indexed | 2024-03-08T14:57:50Z |
| publishDate | 2023-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Sensors |
| spelling | doaj.art-ecea37e364124c66a6e96e37a10577592024-01-10T15:08:48ZengMDPI AGSensors1424-82202023-12-0124115410.3390/s24010154Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired BoilerTanuj Gupta0Mahabubur Rahman1Xinyu Jiao2Yongji Wu3Chethan K. Acharya4Dock R. Houston5Susan Maley6Junhang Dong7Hai Xiao8Huijuan Zhao9Department of Mechanical Engineering, Clemson University, Clemson, SC 29634, USADepartment of Mechanical Engineering, Clemson University, Clemson, SC 29634, USADepartment of Electrical and Computer Engineering, Clemson University, Clemson, SC 29634, USADepartment of Electrical and Computer Engineering, Clemson University, Clemson, SC 29634, USASouthern Company, Birmingham, AL 35203, USAMachining and Technical Services, Clemson University, Clemson, SC 29634, USAElectric Power Research Institute, Charlotte, NC 28262, USACollege of Engineering and Applied Science, University of Cincinnati, Cincinnati, OH 45221, USADepartment of Electrical and Computer Engineering, Clemson University, Clemson, SC 29634, USADepartment of Mechanical Engineering, Clemson University, Clemson, SC 29634, USAThe growth of renewable energy sources presents a pressing challenge to the operation and maintenance of existing fossil fuel power plants, given that fossil fuel remains the predominant fuel source, responsible for over 60% of electricity generation in the United States. One of the main concerns within these fossil fuel power plants is the unpredictable failure of boiler tubes, resulting in emergency maintenance with significant economic and societal consequences. A reliable high-temperature sensor is necessary for in situ monitoring of boiler tubes and the safety of fossil fuel power plants. In this study, a comprehensive four-stage multi-physics computational framework is developed to assist the design, optimization installation, and operation of the high-temperature stainless-steel and quartz coaxial cable sensor (SSQ-CCS) for coal-fired boiler applications. With the consideration of various operation conditions, we predict the distributions of flue gas temperatures within coal-fired boilers, the temperature correlation between the boiler tube and SSQ-CCS, and the safety of SSQ-CCS. With the simulation-guided sensor installation plan, the newly designed SSQ-CCSs have been employed for field testing for more than 430 days. The computational framework developed in this work can guide the future operation of coal-fired plants and other power plants for the safety prediction of boiler operations.https://www.mdpi.com/1424-8220/24/1/154computational fluid dynamicsheat transferstructural mechanicsmulti-physics modelingboiler tubesensor design |
| spellingShingle | Tanuj Gupta Mahabubur Rahman Xinyu Jiao Yongji Wu Chethan K. Acharya Dock R. Houston Susan Maley Junhang Dong Hai Xiao Huijuan Zhao Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler Sensors computational fluid dynamics heat transfer structural mechanics multi-physics modeling boiler tube sensor design |
| title | Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler |
| title_full | Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler |
| title_fullStr | Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler |
| title_full_unstemmed | Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler |
| title_short | Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler |
| title_sort | four stage multi physics simulations to assist temperature sensor design for industrial scale coal fired boiler |
| topic | computational fluid dynamics heat transfer structural mechanics multi-physics modeling boiler tube sensor design |
| url | https://www.mdpi.com/1424-8220/24/1/154 |
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