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Four-Stage Multi-Physics Simulations to Assist Temperature Sensor Design for Industrial-Scale Coal-Fired Boiler.
Tanuj Gupta1, Mahabubur Rahman1, Xinyu Jiao2
1Department of Mechanical Engineering, Clemson University, Clemson, SC 29634, USA.
Sensors (Basel, Switzerland)
|January 11, 2024
Summary
A new computational framework aids in designing and operating high-temperature sensors for fossil fuel power plants. This innovation enhances boiler tube safety and predicts operational risks, ensuring reliable energy generation.
Area of Science:
- Engineering
- Materials Science
- Computational Science
Background:
- Fossil fuels dominate US electricity generation (>60%), posing operational challenges with renewable energy growth.
- Unpredictable boiler tube failures in fossil fuel plants cause costly emergency maintenance and societal disruption.
- In situ monitoring requires reliable high-temperature sensors for boiler tube safety in power plants.
Purpose of the Study:
- To develop a multi-physics computational framework for designing, optimizing, and installing high-temperature sensors.
- To ensure the safe operation and predict potential failures of boiler tubes in coal-fired power plants.
- To validate the framework's effectiveness through field testing of a novel sensor.
Main Methods:
- A four-stage multi-physics computational framework was developed.
- Simulations predicted flue gas temperatures, boiler tube-sensor correlations, and sensor safety under various conditions.
- A simulation-guided installation plan was used for field deployment.
Main Results:
- The computational framework successfully predicted operational parameters for coal-fired boilers.
- The stainless-steel and quartz coaxial cable sensor (SSQ-CCS) was designed and optimized using the framework.
- Field testing of the SSQ-CCS demonstrated successful operation for over 430 days.
Conclusions:
- The developed computational framework is effective for guiding the design, installation, and operation of high-temperature sensors.
- This approach enhances the safety and reliability of boiler operations in coal-fired and other power plants.
- The framework provides a valuable tool for predicting operational safety and preventing failures in power generation infrastructure.
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