CFD analysis of a pusher type reheating furnace and the billet heating characteristic

Mayr, Bernhard; Prieler, René Josef; Demuth, Martin; Moderer, Luca; Hochenauer, Christoph

doi:10.1016/j.applthermaleng.2017.01.028

Cited by 75 publications

(18 citation statements)

References 26 publications

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“…[19] using CFD, with a focus on modeling of pulse combustion in a reheating furnace, proposed a model for increasing the temperature uniformity of products in these furnaces. While, Mayr et al [20] proposed and validated a one-step steady state CFD approach for process optimization. Also, Tang et al [21] employing an approach consisting of 3D CFD and 2D finite difference methods (validated by experimental measurements) could report reliable results in the prediction of heating history of products within a pusher type gas-fired furnace.…”

Section: Introductionmentioning

confidence: 99%

Optimization of furnace residence time and loading pattern during heat treatment of large size forgings

Arkhazloo

Bazdidi–Tehrani

Morin³

et al. 2021

Int J Adv Manuf Technol

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A combination of unsteady 3D CFD simulations and experimental temperature measurements was employed to determine the effect of loading patterns on the temperature distribution within steel forgings inside a gas-fired heat treatment furnace. This was aimed to obtain a more homogenous temperature distribution. Besides, a hybrid methodology using 3D numerical simulations and a high-resolution dilatometer allowed improving residence time of forgings inside the heat treatment furnace. The influence of the loading patterns and skids on temperature distribution and residence time of forgings was examined using thermal analysis four different loading patterns.Comprehensive unsteady thermal analysis of the products heating allowed quantifying the impact of skids usage and their dimensions on the extent of the uniformity of temperature distribution.The results were interpreted in terms of the inter-relationship between the skids usage, their geometry, absorbed radiation and convective heat fluxes. The analysis showed that temperature non-uniformities of up to 331 K could be produced for non-optimum loading patterns. Using the developed CFD approach it was possible to reduce the temperature non-uniformity of different sizes of blocks up to 32% via changing the loading pattern inside the furnace. Further, the slab's residence time was improved by almost 15.5% when employing the proposed hybrid approach. This approach could directly be applied to the optimization of different heat treatment cycles of forged blocks in different grades of steels.

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Section: Introductionmentioning

confidence: 99%

Optimization of furnace residence time and loading pattern during heat treatment of large size forgings

Arkhazloo

Bazdidi–Tehrani

Morin³

et al. 2021

Int J Adv Manuf Technol

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“…The curves with different colors in Figure correspond to the temperature function polynomials for the simulation. A constant heat flux is applied to the roller boundary conditions, which is calculated from the absorbed energy of the cooling water …”

Section: Numerical Modelsmentioning

confidence: 99%

“…A constant heat flux is applied to the roller boundary conditions, which is calculated from the absorbed energy of the cooling water. 46 The initial conditions of transient calculation in an indirect reheating furnace were obtained from the convergent steady solutions of the temperature field in the furnace based on the initial slab temperature. The initial slab temperature was determined according to the level 2 model prediction in production, as shown in Figure 4.…”

Section: Numerical Modelsmentioning

confidence: 99%

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Numerical Analysis of the Effects of Oxygen-Enriched and Different Inlet Conditions on Performance of an Indirect Reheating Furnace with Pulse Combustion

et al. 2021

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The requirement of improving efficiency and performance leads to the continuous development of furnaces and burners. For this purpose, it is necessary to establish a model suitable for industrial production and adjust it according to industrial demand. In this paper, a comprehensive numerical model is developed to characterize the combustion, heat transfer, and slab heating in an indirect reheating furnace with pulse combustion. To realize the pulse combustion process, a pulse control approach based on a user-defined function (UDF) was proposed to control the radiant tube burner state. Indirect heat transfer in the furnace was realized by coupling the radiant tubes and the furnace as a whole. In a simulation with the eddy dissipation concept (EDC) model, results from the four-step mechanism were in close accordance with those of the GRI 3.0 mechanism, and both mechanisms could describe the combustion process in detail. However, the calculation time of the EDC model with the four-step mechanism was reduced significantly. Thus, the EDC model with the four-step mechanism was selected as the ideal combustion model used for further simulation research. Through experimental validation, the simulation results of the developed model using the EDC model with the four-step mechanism showed a good agreement with the experimental results. Additionally, with this model, the effects of oxygen-enriched combustion with 74 vol % N2 and 26 vol % O2 in the oxidizer and inlet-change case with a fuel inlet and a primary air inlet on the performance of an indirect reheating furnace with pulse combustion were specially studied. The maximum flame temperature and the average temperature of the furnace atmosphere increased from 2046 to 2175 K and from 1241 to 1279 K for increased oxygen concentration, respectively. Compared with air-fuel combustion, the discharging slab temperature reached a growth of 2.9% in oxygen-enriched combustion. After changing the inlet boundary of the radiant tube burners, since the excessive combustion in the burner’s combustion chamber was avoided and the full combustion of fuel in the radiant tubes was promoted, the flame intensity in the radiant tubes was enhanced and the maximum flame temperature reached 2196 K. At the same time, the mole fraction of CO at the outlet became smaller and the slab temperature in all zones of the furnace increased by more than 3.5%. This study showed that higher efficiency of an indirect reheating furnace with pulse combustion can be achieved by oxygen-enriched combustion and changing the inlet boundary of the burners.

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“…Convection only has a greater influence on the start of the furnace. Due to the high temperature, experiments on reheating furnaces are difficult and have limited significance [4].…”

Section: Introductionmentioning

confidence: 99%

Performance Analysis of Reheating Furnace on Billet Heating Production of Reinforced Iron

Setiawan¹,

Arsana²,

Soeryanto³

2022

Proceedings of the International Joint Conference on Science and Engineering 2022 (IJCSE 2022)

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Hanil Jaya Steel company is engaged in reinforcing steel fins with various deformed and according to the Indonesian National Standard (SNI). The product produced by this company is Reinforced Iron or commonly known as Esser Concrete. One of the most important processes in the manufacturing stage of reinforcing steel is the Furnace Billet Reheating process to be processed into reinforcing steel. This study aims to analyze the performance of the reheating furnace on billet production of reinforcing iron in the Rolling Mill III area of PT. Hanil Jaya Steel. This study uses the observation method. This research results that RHF heating is carried out to change the material properties, and carry out the machining process (heat treatment). The type of furnace used at PT. Hanil Jaya Steel is a pusher type, the furnace is used to heat billets measuring 150 × 150 × 6000 mm with temperatures reaching 1100 ºC -1250 ºC. The nominal capacity of the furnace used is 30 tons/hour. The fuel used in the reheating furnace is natural gas from PGN. The process of making reinforced concrete steel, reheating furnace process is the initial process that must be carried out to change the billet into a material that is easily shaped into reinforcing steel according to SNI standards. Heating process billet is carried out by inserting billets one by one into the RHF with a temperature of up to 1100 ºC for 2 h. With this process the billet changes, which is useful for the next process, namely the rolling process.

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CFD analysis of a pusher type reheating furnace and the billet heating characteristic

Cited by 75 publications

References 26 publications

Optimization of furnace residence time and loading pattern during heat treatment of large size forgings

Optimization of furnace residence time and loading pattern during heat treatment of large size forgings

Numerical Analysis of the Effects of Oxygen-Enriched and Different Inlet Conditions on Performance of an Indirect Reheating Furnace with Pulse Combustion

Performance Analysis of Reheating Furnace on Billet Heating Production of Reinforced Iron

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