Numerical Prediction of Erosion in Coal Burner of 210 MW Boiler Through Computational Fluid Dynamics Modeling


Kumar R K
Raghavendra Naik
Saravanan V
Janardhana M


The splitter plates of coal burners in Indian thermal plants are subjected to severe erosion and erosioncorrosion conditions owing to the combined effect of abrasive nature of coal and elevated service temperature environment. During service, tilting of splitter plates is adopted to achieve the desired final steam outlet temperature which shifts the fireball location and heat release area in the combustion zone. The tilt condition gives rise to a change in the incidence angle of the coal particle as well as the change in flow profile. The erosion life of these plates is predominantly affected by the coal particle velocity, impact angle, particle size and steady state metal temperature during service. The sensitivity of burner tilt angle on the erosion life requires an understanding of primary air with coal particle flow phenomenon within the burners. The effect of burner tilt angle on the erosion of presently used SS310 grade splitter material was studied through computational fluid dynamics. The erosion sensitive velocity exponent was calculated based on the laboratory simulated erosion tests at elevated temperatures upto 700°C. The life of the splitter plates was calculated based on the predicted erosion rate intensity.


How to Cite
R K, K., Naik, R., V, S., & M, J. (2016). Numerical Prediction of Erosion in Coal Burner of 210 MW Boiler Through Computational Fluid Dynamics Modeling. Power Research - A Journal of CPRI, 12(2), 325–334. Retrieved from


  1. D Moumakwa, K Marcus, Tribology in coal-fired power plants, Tribol. Int. Vol. 38, pp. 805–811, 2005
  2. K Szyma, A Hernas, G Moskal, H Myalska, Thermally sprayed coatings resistant to erosion and corrosion for power plant boilers - A review, Surface & Coatings Technology, Vol. 268, pp. 153-164, 2015
  3. C Katsich, E Badisch, M Roy, G R Heath, F Franek, Erosive wear of hardfaced Fe-Cr-C alloys at elevated temperature, Wear, Vol. 267, pp. 1856–1864, 2009.
  4. E Citirik, Root-cause analysis of burner tip failures in coal-fired power plants, Appl. Therm. Eng. Vol. 73, pp.831–841, 2014.
  5. L K I A W Ruff, Measurement of solid particle velocity in erosive wear, Wear, Vol. 35, pp.195–199, 2003.
  6. G Sundararajan, M Roy, Solid particle erosion behaviour of metallic materials at room and elevated temperatures, Tribol. Int. Vol. 30, pp. 339–359, 1997.
  7. S K Das, K M Godiwalla, S P Mehrotra, K K M Sastry, P K Dey, Analytical model for erosion behaviour of impacted fly-ash particles on coal-fired boiler components, Vol. 31 pp. 583–595, 2006.
  8. G Sundararajan, P G Shewmon, A new model for the erosion incidence of metals at normal, Vol. 84, pp. 237–258, 1983.
  9. B Bozzini, M E Ricotti, M Boniardi, C Mele, Evaluation of erosion-corrosion in multiphase flow via CFD and experimental analysis, Wear, Vol. 255, pp. 237–245, 2003.
  10. F Jianren, Z Dadong, Z Keli, C Kefa, Numerical and experimental study of finned tube erosion protection methods, Wear, Vol. 152, pp.1–19, 1992.
  11. D Dodds, J Naser, Numerical study of the erosion within the pulverised-fuel mill-duct system of the Loy Yang B lignite fuelled power station, Powder Technol. Vol. 217, pp. 207–215, 2012.