Development and application of a numerically efficient model describing a rotary hearth furnace using CFD

Landfahrer, Martin; Schluckner, Christoph; Prieler, René Josef; Gerhardter, Hannes; Zmek, Thomas; Klarner, Jürgen; Hochenauer, Christoph

doi:10.1016/j.energy.2019.04.091

Cited by 21 publications

(8 citation statements)

References 31 publications

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“…Combustion is another extremely complex process in which numerous intermediate products are produced and a large number of chain reactions occur. Eddy dissipation model (EDM) and eddy dissipation concept model (EDC) are turbulence-chemistry reaction models which have been widely adopted in combustion simulations [42,47,48]. The EDM assumes that the chemical reaction rate is much faster than reactants mixing which mainly depends on the turbulence and the reaction occurs in large turbulence structures.…”

Section: Models and Simulation Setupmentioning

confidence: 99%

“…Whereas the EDC includes detailed chemical mechanisms, accordingly, it is very time-consuming. Landfahrer et al [48] presented a comparison between the two models by means of a premixed combustion simulation in a rotary furnace simulation and the results showed a negligible difference. By using EDM, Cellek [42] accomplished simulations of gas interchangeability in a swirl burner burning various gaseous fuels, such as natural gas, methane and hydrogen.…”

Section: Models and Simulation Setupmentioning

confidence: 99%

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Design optimization and CFD evaluation of a volute swirl burner with central gas supply

Jia

Tang

2020

J Braz. Soc. Mech. Sci. Eng.

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The reasonable design and optimization can be useful tools to solve issues in several industrial applications. Since it is timeconsuming and costly to do the experimental performance assessment using various equipments, computational fluid dynamics (CFD) with suitable models has been widely used due to the good agreement with experiments. This paper presented a universal design calculation method of a volute swirl burner with central gas supply. Then, CFD simulations with standard k-ε model, under non-reacting and reacting conditions, were carried out to verify the design feasibility. The mixedness of gas/air under non-reacting condition was evaluated from the perspective of normal distribution in statistics and checked by the designed excess air factor. A parametric study for various mixing section lengths and outlet diameters of the burner block was conducted to investigate their influence on the central recirculation zone and the temperature distribution. Simulation results show good agreement with empirical formula calculation. The gas and air have been mixed uniformly around the location that is 60 times of the gas orifice diameter. Additionally, an enlarged recirculation zone with increased recirculation strength can be formed with the increasing mixing length and block outlet diameter. In combustion simulation, the longer mixing length improves the flame stabilization but makes the combustion center move to the upstream of the burner due to the strengthened recirculation zone. The larger outlet diameter of the block stretches the flame and moves the high-temperature zone inside the flame to the downstream of the block wall.

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Section: Models and Simulation Setupmentioning

confidence: 99%

Section: Models and Simulation Setupmentioning

confidence: 99%

Design optimization and CFD evaluation of a volute swirl burner with central gas supply

Jia

Tang

2020

J Braz. Soc. Mech. Sci. Eng.

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“…With this model, Prieler et al showed that the efficiency of the furnace is increased from 57.6 to 61.4% in oxygen-enriched combustion. Landfahrer et al developed a model to investigate the combustion and heat transfer in a rotary hearth direct-fired furnace using a numerical method similar to that used by Prieler et al The model revealed the existing problems of this type of furnace and provided reasonable suggestions. Further investigations on the impacts of different oxidizers in a direct-fired furnace were performed by Landfahrer et al They considered various oxidizers and fuels in these parts of the furnace by dividing the whole domain into several parts.…”

Section: Introductionmentioning

confidence: 99%

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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“…[2][3][4][5] In this process, dried carbon-containing pellets are added to the rotary hearth furnace at about a furnace temperature of 1000°C to 1400°C, in which the iron oxides inside the pellets will be directly reduced to economically valuable iron. 6,7 At present, the mature rotary hearth furnace technologies include Fastmelt, Itmk3, Comet, HI-QIP, and so forth. [8][9][10][11] In the rotary hearth furnace, research on the carbon-containing pellet internal composition changes, heat transfer, and reaction process is particularly important.…”

Section: Introductionmentioning

confidence: 99%

“…The rotary hearth furnace (RHF) process can effectively process these metallurgical powders while achieving sustainable development of environmental protection and economic benefits 2‐5 . In this process, dried carbon‐containing pellets are added to the rotary hearth furnace at about a furnace temperature of 1000°C to 1400°C, in which the iron oxides inside the pellets will be directly reduced to economically valuable iron 6,7 . At present, the mature rotary hearth furnace technologies include Fastmelt, Itmk3, Comet, HI‐QIP, and so forth 8‐11 …”

Section: Introductionmentioning

confidence: 99%

Numerical analysis of the carbon‐containing pellet direct reduction process with central heat transfer enhancement

Wang

2020

Heat Trans

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Pellet heat transfer has always been one of the biggest limiting factors in its direct reduction process in the rotary hearth furnace (RHF). Therefore, strengthening its heat transfer process is very important for productivity in RHF. In this study, a coupling model How to cite this article: Li N, Wang F. Numerical analysis of the carbon-containing pellet direct reduction process with central heat transfer enhancement.

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Development and application of a numerically efficient model describing a rotary hearth furnace using CFD

Cited by 21 publications

References 31 publications

Design optimization and CFD evaluation of a volute swirl burner with central gas supply

Design optimization and CFD evaluation of a volute swirl burner with central gas supply

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

Numerical analysis of the carbon‐containing pellet direct reduction process with central heat transfer enhancement

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