,
Kshaurad Kranti Kumar,
Narasimhe Gowda Kiran Kumar,
Mandya Kempadasappa Venkatesh
This research presents a comprehensive evaluation of Unit #4, a 210 MWe BHEL-designed boiler in a thermal power station, focusing on Flue Gas Duct Airflow Assessment (FGDAA) and Computational Fluid Dynamics (CFD) analysis of the associated flue gas duct system. The unit operates with six Electrostatic Precipitators (ESPs), three Induced Draft (ID) fans, and two Forced Draft (FD) fans, and the primary objective is to optimize flue gas distribution among ESPs to enhance plant efficiency and reliability. Cold air velocity measurements using calibrated S-type Pitot tubes provided accurate estimation of mass flow distribution in various ducts, while FGDAA under different ID fan operating conditions highlighted important operational efficiency considerations. The study identified non-uniform mass flow distribution across ESPs, which motivated detailed CFD simulations and the development of improved engineering designs for baffle and guide plates to regulate flow. In addition, material selection for these components was investigated through cost analysis and mechanical characterization. Results showed that tungsten carbide-clad plates are significantly more expensive than ceramic guide plates, while microhardness testing indicated silicon carbide as a superior material due to its higher hardness and wear resistance. Wear testing on AISI 1018 steel further demonstrated the influence of mass concentration on erosive damage, underscoring the importance of optimized flow management in flue gas environments. Overall, the study provides valuable insights into airflow control, material selection, and design optimization to improve the performance and service life of flue gas duct systems in thermal power plants.
| Published in | Science Discovery Materials (Volume 1, Issue 1) |
| DOI | 10.11648/j.sdm.20260101.11 |
| Page(s) | 1-24 |
| Creative Commons |
This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited. |
| Copyright |
Copyright © The Author(s), 2026. Published by Science Publishing Group |
Flue Gas Duct Airflow Assessment (FGDAA), Computational Fluid Dynamics (CFD) Analysis, ElectroStatic Precipitators (ESPs), Engineering Modifications of Baffle Plates, Silicon Carbide (SiC), Tungsten Carbide
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APA Style
Arunkumar, K. H., Kumar, K. K., Kumar, N. G. K., Venkatesh, M. K. (2026). Comprehensive Approach to Flue Gas Flow Optimization in Electrostatic Precipitators and Material Selection for Baffle Plates. Science Discovery Materials, 1(1), 1-24. https://doi.org/10.11648/j.sdm.20260101.11
ACS Style
Arunkumar, K. H.; Kumar, K. K.; Kumar, N. G. K.; Venkatesh, M. K. Comprehensive Approach to Flue Gas Flow Optimization in Electrostatic Precipitators and Material Selection for Baffle Plates. Sci. Discov. Mater. 2026, 1(1), 1-24. doi: 10.11648/j.sdm.20260101.11
AMA Style
Arunkumar KH, Kumar KK, Kumar NGK, Venkatesh MK. Comprehensive Approach to Flue Gas Flow Optimization in Electrostatic Precipitators and Material Selection for Baffle Plates. Sci Discov Mater. 2026;1(1):1-24. doi: 10.11648/j.sdm.20260101.11
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Download@article{10.11648/j.sdm.20260101.11,
author = {Karennanavar Hanumantappa Arunkumar and Kshaurad Kranti Kumar and Narasimhe Gowda Kiran Kumar and Mandya Kempadasappa Venkatesh},
title = {Comprehensive Approach to Flue Gas Flow Optimization in Electrostatic Precipitators and Material Selection for Baffle Plates},
journal = {Science Discovery Materials},
volume = {1},
number = {1},
pages = {1-24},
doi = {10.11648/j.sdm.20260101.11},
url = {https://doi.org/10.11648/j.sdm.20260101.11},
eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.sdm.20260101.11},
abstract = {This research presents a comprehensive evaluation of Unit #4, a 210 MWe BHEL-designed boiler in a thermal power station, focusing on Flue Gas Duct Airflow Assessment (FGDAA) and Computational Fluid Dynamics (CFD) analysis of the associated flue gas duct system. The unit operates with six Electrostatic Precipitators (ESPs), three Induced Draft (ID) fans, and two Forced Draft (FD) fans, and the primary objective is to optimize flue gas distribution among ESPs to enhance plant efficiency and reliability. Cold air velocity measurements using calibrated S-type Pitot tubes provided accurate estimation of mass flow distribution in various ducts, while FGDAA under different ID fan operating conditions highlighted important operational efficiency considerations. The study identified non-uniform mass flow distribution across ESPs, which motivated detailed CFD simulations and the development of improved engineering designs for baffle and guide plates to regulate flow. In addition, material selection for these components was investigated through cost analysis and mechanical characterization. Results showed that tungsten carbide-clad plates are significantly more expensive than ceramic guide plates, while microhardness testing indicated silicon carbide as a superior material due to its higher hardness and wear resistance. Wear testing on AISI 1018 steel further demonstrated the influence of mass concentration on erosive damage, underscoring the importance of optimized flow management in flue gas environments. Overall, the study provides valuable insights into airflow control, material selection, and design optimization to improve the performance and service life of flue gas duct systems in thermal power plants.},
year = {2026}
}
TY - JOUR T1 - Comprehensive Approach to Flue Gas Flow Optimization in Electrostatic Precipitators and Material Selection for Baffle Plates AU - Karennanavar Hanumantappa Arunkumar AU - Kshaurad Kranti Kumar AU - Narasimhe Gowda Kiran Kumar AU - Mandya Kempadasappa Venkatesh Y1 - 2026/02/09 PY - 2026 N1 - https://doi.org/10.11648/j.sdm.20260101.11 DO - 10.11648/j.sdm.20260101.11 T2 - Science Discovery Materials JF - Science Discovery Materials JO - Science Discovery Materials SP - 1 EP - 24 PB - Science Publishing Group UR - https://doi.org/10.11648/j.sdm.20260101.11 AB - This research presents a comprehensive evaluation of Unit #4, a 210 MWe BHEL-designed boiler in a thermal power station, focusing on Flue Gas Duct Airflow Assessment (FGDAA) and Computational Fluid Dynamics (CFD) analysis of the associated flue gas duct system. The unit operates with six Electrostatic Precipitators (ESPs), three Induced Draft (ID) fans, and two Forced Draft (FD) fans, and the primary objective is to optimize flue gas distribution among ESPs to enhance plant efficiency and reliability. Cold air velocity measurements using calibrated S-type Pitot tubes provided accurate estimation of mass flow distribution in various ducts, while FGDAA under different ID fan operating conditions highlighted important operational efficiency considerations. The study identified non-uniform mass flow distribution across ESPs, which motivated detailed CFD simulations and the development of improved engineering designs for baffle and guide plates to regulate flow. In addition, material selection for these components was investigated through cost analysis and mechanical characterization. Results showed that tungsten carbide-clad plates are significantly more expensive than ceramic guide plates, while microhardness testing indicated silicon carbide as a superior material due to its higher hardness and wear resistance. Wear testing on AISI 1018 steel further demonstrated the influence of mass concentration on erosive damage, underscoring the importance of optimized flow management in flue gas environments. Overall, the study provides valuable insights into airflow control, material selection, and design optimization to improve the performance and service life of flue gas duct systems in thermal power plants. VL - 1 IS - 1 ER -
Mechanical Engineering, CMR University, Bangalore, India
Mechanical Engineering, Dayananda Sagar College of Engineering, Bangalore, India
Mechanical Engineering, Vemana Institute of Technology, Bangalore, India
Mechanical Engineering, Dayananda Sagar College of Engineering, Bangalore, India
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