A new study by researchers at the Shenyang University of Chemical Technology in China proposes a comprehensive technical framework for an industrial scale biomass powder suspension combustion furnace and establishes a multiphysics coupled theoretical system.

Based on computational fluid dynamics, a three-dimensional numerical model with the coupled treatment of pyrolysis gas generation, gas transport, and char combustion was incorporated into suspension combustion simulations. Using this model, the flow field evolution, temperature distribution, and species concentration characteristics inside an industrial-scale suspension furnace were systematically analysed. The effects of key operating parameters, including multi-stage air distribution strategy, particle size distribution, and particle injection velocity on combustion performance were also quantitatively investigated. Furthermore, a full-scale industrial test rig was constructed to conduct thermal combustion experiments for model validation.

The results demonstrated the high predictive accuracy of the CFD model, with maximum deviations between simulation and experimental data within 5%, while the tertiary air distribution scheme exhibited superior combustion characteristics. Biomass powder with a medium particle size range of 0.5–1.5 mm provided the optimal balance between combustion efficiency and operational economy. Optimal combustion performance was shown to be obtained when the particle injection velocity is 20-25 m/s and the air supply ratio of the high-pressure fan to additional air is 1.2-2.1.

Under optimised conditions, the improved suspension combustion furnace attained a thermal efficiency of 94.2% and a burnout efficiency of 96.8%, with combustible gas emissions at the outlet approaching zero.

The developed CFD analysis platform provides a reusable theoretical tool for furnace optimisation and efficient industrial application of biomass powder suspension combustion technology.