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In all cases we have filmed the best available copy. University Microfilms International 300 N. ZEEB RD„ ANN ARBOR, Ml 48106 8129028 K a d u n c , D o n a l d A l b e r t COMPUTER MODEL OF COMBUSTION AND RADIATION PROCESSES IN REFUSE DERIVED FUEL FIRED STOKER BOILERS The Ohio State University Ph.D. 1981 University Microfiîms Intern etionel m N. Zeeb Road, Ann Arbor, Ml 48106 Copyright 1981 by Kadunc, Donald Albert All Rights Reserved PLEASE NOTE: In all cases this material has been filmed in the best possible way from the available copy. Problems encountered with this document have been identified here with a check mark__ 1. Glossy photographs or pages. 2. Colored illustrations, paper or print. 3. Photographs with dark background i/" 4. Illustrations are poor copy 5. Pages with black marks, not original copy. 6. Print shows through as there is text on both sides of page. 7. Indistinct, broken or small print on several pages 1/^ 8. Print exceeds margin requirements _j ____ 9. Tightly bound copy with print lost in spine ____ 10. Computer printout pages with indistinct print i / 11. Page(s) ________■ lacking when material received, and not available from school or author. 12. Page(s) seem to be missing in numbering only as text follows. 13. Two pages num bered ____________. Text follows. 14. Curling and wrinkled p a g es ______ 15. Other_____________________________________________________________:____________ University Microfilms International COMPUTER MODEL OF COMBUSTION M D RADIATION PROCESSES IN REFUSE DERIVED FUEL FIRED STOKER BOILERS DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Donald Albert Kadunc, B.S.M.E., M.Sc., M.B.A, * * * * * The Ohio State University 1981 Reading Committee; Approved by: Helmuth W, Engelman Robert H, Essenhigh isn-r- — -- ^ U Donald R, Houser Department of Mechanical Engineering James E, A. John T o Mom 11 ACKNOWLEDGMENTS I would like to thank-my wife, Barb, for all these years and son, Michael for his curiosity, I want to thank my parents, Albert and Barbara Kadunc, for helping in the beginning, I want to thank my long-term adviser, Charles F, Sepsy, and my current adviser, Robert H, Essenhigh, for their assistance in my academic career. Finally, I would like to thank Leslie Oswald Akers, Monica Merriman, and Kathy Howard for putting this work together. 111 VTTA July 2, 1944 Born - Cleveland, Ohio EDUCATION 1967 B.S. Mechanical Engineering; The Ohio State University, Columbus, Ohio. 1968 M. Sc. Industrial Engineering; The Ohio State University, Columbus, Ohio. 1971 M.Sc. Mechanical Engineering; The Ohio State University, Columbus, Ohio. 1974 Master of Business Administration; The Ohio State University, Columbus, Ohio. WORK RECORD 1968-72 Industrial Engineer, Western Elec tric Company, Columbus, Ohio. 1972-74 Assistant Professor, Electrical En gineering, The Ohio Institute of Technology, Columbus, Ohio. 1974-78 Senior Mechanical Engineer, Rockwell International, Columbus, Ohio. 1978-Present Consulting Engineer, Alden E. Stilson & Associates, Columbus, Ohio. IT TABLE OF CONTENTS Acknowledgments iii Vita. iT -•V • List of Tables vi List of Figures vii 1. Introduction 1 2. Energy and Refuse 6 3. Refuse Incineration 17 4. Related Research 32f 5. Combustion Model ^3 6 . Results and Discussion 97 7. Conclusions and Further Work 156 3. References 9. Appendices A. Fuels 167 B. Resource Recovery Activities 172 C. Derivation of Radiation Intensity 185 D. Derivation of One-dimensional Flux Equation B. Derivation of Surface Flux ^93 F.. Derivation of One-dimensional Equa- ' tions for a Stirred Reactor G. Index of Computer Output 100 10. Bibliography 31 A- LIST OF TABLES Page 1. Projected Refuse Properties and Statistics lif 2. Projected Refuse Compositions (%) 15 3.. Effect of Frequency Factor 10Ô 4. Effect of Activation Energy 5. Frequency Factor vs. Activation Energy i12 6 .. Furnance Temperature Profiles 115 7. Frequency Factor vs. Excess Air 119 8 . Fuel Leaving Slice vs. Bypass 126 9. Bypass vs. Heat Utilization Rate 133 10. Heat Utilization vs. Stirred Reactor Height 137 11. Heat Utilization Rate vs. Bypass and Stirred IZfif Reactor Height 12. Blackening vs. Heat Utilization and Burnout 147 VI LIST OF FIGURES Page 1. Boiler with Reciprocating Stoker 22 2. Boiler with "Martin" or Reverse Acting 24 Grate Stoker 3. Boiler with "Duesseldorf" or Barrel 26 Type Stoker 4. Boiler with Multiple Traveling Grata Stoker _2g 5. Boiler with Spreader Stoker 29 GV Plant Site 31 7. Boiler Section 33 8. • Modified Bragg Model 37 9. Physical Model. ' if6 10. Typical Section Through Furnace 33 11. One-dimensional Radiative Transfer 57 12. Radiation Balance Through a Slice 58 13. Bed Representation as a Specular Reflecting y2 Surface 14. Emissivity Curves for Mixtures 15. Slice Representation 86 16. Absorption by Slice 88 17. Typical Run Format 102 7 Ü LIST OF FIGURES (cont) 18. Typical Output Profiles 105 19. ff vs E^ Temperature Profiles 115 20. ff vs E^ Combustion Profiles 116 21. ff vs E_ Heat Absorption Profiles 117 22. Excess Air Temperature Profiles 120 23. Excess Air Combustion Profiles 121 24. Excess Air Heat Absorption Profiles 122 25. Bypass Factor Temperature Profiles 128 26. Bypass Factor Combustion Profiles 130 27. Bypass Factor Heat Absorption Profiles 131 28. Reactivity vs Bypass 135 29. Stirred Reactor Height Temperature Profiles 139 30. Stirred Reactor Height Combustion Profiles 14O 31. Stirred Reactor Height Heat Absorption Profiles 141 32. Blackening Factor Temperature Profiles 145 33. Blackening Factor Combustion Profiles 148 34. Blackening Factor Heat Absorption Profiles 149 33. Transient Temperature Profiles 151 36. Profiles of Combustion vs Temperature 152 37. Burnup Profiles 154 CHAPTER 1 INTRODUCTION This dissertation is primarily concerned with the development of a computer model of the combustion process in the furnace region of a fossil fuel fired boiler. The actual model developed is for a stoker fired refuse burning boiler that the City of Columbus, Ohio, will be using in its new Municipal Electric Plant, scheduled to be operational in 1982. However, the computer model is flexible and can be modified without a great deal of ef fort to represent both stoker and suspension fired furn aces. The model can also be modified to study the burn ing characteristics of any solid, liquid or gaseous fossil fuel. The computer program was developed to model the Columbus boilers to determine if the design was sound prior to putting the units on line. The computer model was used to study the effects of a number of variables on the burning characteristics of the refuse fuel in the 1 2' boiler furnace. It was hoped that this would give know ledge to trouble shoot the actual boilers when they went into operation. The Columbus boilers are a new design for the burn ing of refuse fuel. Rather than the usual method of mass burning of refuse, the Columbus boilers burn shredded re fuse that is blown into a well stirred section of the furnace above the stoker grate. The refuse is burned partially in suspension prior to dropping to the grate. There is very little mass inventory on the grate. The system allows a much faster response time and higher ef ficiency than mass burn boiler systems. This design was felt to be necessary since the boilers were to be used to produce steam and electricity in a "stand-alone", 90 megawatt municipal power plant. Since this was a new ap proach to the burning of refuse, it was felt that a com puter program could provide valuable information on the operation of the boilers prior to their actual introduc tion into service. The model is a slice, model with a long stirred reac tor slice followed by a series of smaller slices in the plug flow region.