Work

Model order reduction for CAE simulation of the windbox in a 500 MW tangentially fired coal boiler

Year: 2025

Type: article

Abstract: A non-intrusive reduced-order model (ROM) is developed to reproduce the steady-state three-dimensional velocity field in the windbox of a 500 MW tangentially fired coal boiler. The model is constructed using proper orthogonal decomposition (POD) of simulation results obtained under various sampled operating conditions. These conditions are defined by six key operational parameters: boiler power, coal heating value, excess air ratio, and damper angles for burner, separated over-fire air (SOFA), and under-fire air (UFA) nozzles. POD mode coefficients are predicted using Kriging regression. The ROM demonstrates high accuracy, achieving a normalized root mean square error (NRMSE) below 1%, and a maximum normalized error (MNE) approximately an order of magnitude higher. A sensitivity analysis reveals that the steady-state convergence criterion has the greatest impact on accuracy, with NRMSE reduced by up to fourfold when tightening the criterion from 10⁻⁴ to 10⁻⁶. Increasing the sample size from 100 to 150 reduces the NRMSE by 30–50%, while increasing the POD energy level from 99% to 99.9% has little effect. The ROM can generate accurate 3D velocity fields in seconds, compared to 28 hours per full-order CFD simulation, supporting its potential as a real-time digital twin for thermal-fluid systems in complex industrial environments.

Source: Case Studies in Thermal Engineering

DOI: 10.1016/j.csite.2025.106535

Authors: Hyesu Yu, Woojoo Han, Jihyun Lim, Kang Y. Huh, Donghyun You

Institutions: Pohang University of Science and Technology, Samsung Electronics (South Korea), Korea Electric Power Corporation (South Korea)

Language: English

Topic: Model Reduction and Neural Networks

Subfield: Statistical and Nonlinear Physics

Field: Physics and Astronomy

Domain: Physical Sciences

SDG: Affordable and clean energy

Open Access status: gold

Estimated APC paid: $1,620