Development of a CFD Model to Study the Fundamental Phenomena Associated with Biomass Combustion in a Grate-Fired Boiler

Usually, biomass combustion in grate-fired boilers presents significant challenges due to the heterogeneous nature of the fuel, chemical composition variability, and complex thermal and chemical conversion processes along the grate. Accurate modeling of the fuel bed conversion is critical for optimizing combustion performance and reducing emissions. However, detailed bed models are often computationally intensive and time-consuming. To address this issue, the present work details a simplified empirical bed model that is integrated into a 3D computational fluid dynamics (CFD) simulation of a 35 MW industrial grate-fired boiler. The model successfully reproduced the flue gas mass flow rate, temperature, and chemical composition across different grate sections, predicting an average furnace outlet temperature of 994 °C, CO mass fraction of 779 mg/m3, CO2 concentration of 12 vol.%, and O2 concentration of 9.5 vol.%. These results fall within the range reported in recent CFD studies of similar systems and are consistent with operational monitoring data from the same plant. Sensitivity analyses showed that modifying the primary-to-secondary-air split ratio from 79/21 to 40/60 reduced the average CO mass fraction at the furnace outlet by more than 50%. Additionally, the average furnace temperature increased up to 1050 °C, enhancing combustion efficiency. The CFD model also demonstrated that relocating char combustion to later grate sections led to temperature imbalances near the boiler walls, emphasizing the importance of grate-specific conversion profiles. These results underscore the model’s ability to guide air distribution optimization, improve combustion performance, and reduce pollutant emissions in biomass boilers.