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Volume 109
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Optimization of honeycomb anti-wear structures for water-cooled walls in circulating fluidized beds
Ruiqi Bai a, Tuo Zhou a, Tong Wang a, Xinyun Wan a, Xin Meng b, Man Zhang a, Hairui Yang a *
a Department of Energy and Power Engineering, Tsinghua University, Beijing 100084, China
b Huaneng Jilin Power Generation CO., LTD., Changchun 130012, China
10.1016/j.partic.2025.12.007
Volume 109, February 2026, Pages 282-291
Received 2 November 2025, Revised 9 December 2025, Accepted 10 December 2025, Available online 2 January 2026, Version of Record 16 January 2026.
E-mail: yhr@mail.tsinghua.edu.cn
Highlights

• A novel honeycomb anti-wear structure was optimized for CFB water-cooled walls.

• CPFD simulations were conducted to analyze gas–solid flow and wall erosion behavior.

• The honeycomb reduced erosion by over one order of magnitude in dense phase regions.

• Optimal installation height and thickness were identified for efficient protection.


Abstract

Erosion of water-cooled walls is a major challenge affecting the reliability and efficiency of circulating fluidized bed (CFB) boilers. To mitigate this issue, this study employs computational particle fluid dynamics (CPFD) simulations to optimize the design of a novel honeycomb anti-wear structure. The results show that honeycomb installation slightly modifies local wall flow but has negligible influence on the overall pressure drop. When positioned in the dense phase region, the honeycomb effectively reduces wall erosion to less than 10 % of its original value at most locations through shielding against particle impingement. Increasing the installation height weakens this effect due to stronger lateral particle motion. Thicker honeycombs enhance protection, with 7 cm achieving optimal performance, while 5 cm is sufficient in the dense phase region. The findings demonstrate that an appropriately designed honeycomb structure can serve as an innovative and effective method to mitigate erosion and extend wall service life. The synergistic combination of this structural design with metallic–ceramic coatings presents a promising strategy for enhancing both durability and heat transfer efficiency in industrial CFB boilers.

Graphical abstract
Keywords
Circulating fluidized bed; Water wall; Erosion; Anti-wear
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