Numerical analysis of the transient heating of steel billets and the combustion process under air-fired and oxygen enriched conditions

Prieler, René Josef; Mayr, Bernhard; Demuth, Martin; Holleis, Burkhardt; Hochenauer, Christoph

doi:10.1016/j.applthermaleng.2016.04.091

Cited by 51 publications

(18 citation statements)

References 31 publications

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“…Oliveira et al [15] explore the possibilities of oxy-fuel combustion as an alternative to combustion with air in metal reheating furnaces from a techno-economic point of view. Prieler et al [37] numerically analyse the reheating process under air-fired and oxygen enriched conditions by coupling steady state gas combustion in the furnace and the transient heat conduction within the steel billets. Han et al [38] analyse the efficiency of air-fuel and oxy-fuel combustion in a reheating furnace, considering only thermal radiation for the slab heating.…”

Section: Basic Chemicalsmentioning

confidence: 99%

Modelling and simulation of steel reheating processes under oxy-fuel combustion conditions – Technical and environmental perspectives

Tan

Niska

et al. 2019

Energy

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This paper investigates the impact of flameless oxy-fuel combustion on the thermal performance of a pilot-scale steel reheating furnace. A comprehensive mathematical model, based on the zone method of radiation analysis, was developed, which takes into account the non-grey behaviour of the furnace atmosphere under oxy-fuel combustion conditions. The model was subsequently used to simulate the temperature profile of an instrumented slab used in the experiment. The results showed that the predicted slab temperature profile along the furnace is in good agreement with measurement. However the model over predicted the absolute slab temperatures due to the influence of formation of oxide scales on the slab surface, which was not taken into account in the current model. When compared to air-fuel combustion simulation, the results of oxy-fuel combustion also indicated a marked improvement in the furnace specific fuel consumption (approximately 16%). This was mainly due to the enhanced radiative properties of the furnace atmosphere and reduced exhaust energy losses as the result of less dilution effect from nitrogen. This resulted in reduction in the overall heating time by approximately 14 minutes. Furthermore, if the economics of carbon capture is taken into consideration, theoretically, the energy consumption per kilogram of CO 2 captured can be reduced from 3.5-4.2 MJ kg-1 to 0.96 MJ kg-1. In conclusion, the current studies support the view that oxy-fuel combustion retrofitting to reheating furnaces is a promising option, both from a technical and from an environmental point of view.

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Section: Basic Chemicalsmentioning

confidence: 99%

Modelling and simulation of steel reheating processes under oxy-fuel combustion conditions – Technical and environmental perspectives

Tan

Niska

et al. 2019

Energy

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“…Recently, numerous studies have been done on heating furnace [3][4][5][6][7][8][9][10][11][12][13][14][15][16][17]. Relatively thorough studies were carried out on the reheating furnace by Han et al from 2007 to 2012 [3][4][5][6][7][8].…”

Section: Introductionmentioning

confidence: 99%

“…They developed numerical programs to study slab heating characteristics and thermal efficiency of small and full-scale furnaces. On the other hand, oxy-fuel combustion, which is an alternative method to enhance the energy efficiency of the furnace, has been investigated [10][11][12]. About the thermal performance of reheating furnace, Pepe et al [13] designed an Advanced Process Control system to control and optimize a walking beam billets reheating furnace.…”

Section: Introductionmentioning

confidence: 99%

Performance evaluation of a walking beam type reheating furnace based on energy and exergy analysis

Rong

2021

THERM SCI

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A walking beam type reheating furnace with advanced control technology has been evaluated by combined energy and exergy analysis. In order to gain insight into the performance of the present furnace, the results of energy analysis are compared with those in published papers and the irreversibility of the furnace is analyzed via exergy destruction calculation. The results show that slabs preheated before charged into the furnace can save fuel and improve energy utilization. The structure and material of the wall and roof show good thermal insulation. However, the oxidized scale is a little more and the temperature of flue gas is high in the present reheating furnace. The energy efficiency of the furnace is 71.01%, while exergy efficiency is 51.41%, indicating a potential for energy-saving improvements of the present furnace. The exergy destruction of the furnace accounts for 28.36% of total exergy input which is mainly caused by heat transfer through a finite temperature difference (14.71%), fuel combustion (11.66%) and scale formation (1.99%).

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“…On the other hand, authors found higher radiation in the oxyfuel case with lower flue gas recirculation because the CO 2 emissivity is higher than that for N2 of flue gases. These contrary effects allowed concluding that an optimum FGR that maximizes the energy transfer by convection and radiation to the load can be obtained Possamai et al [26] reported an experimental study on the thermal behavior of a continuous-operation sodium silicate furnace with pre-heated air as the oxidizer. They found that higher amount of energy can be absorbed by the load when oxy-combustion is used due to an increasing in the radiation heat transferred.…”

Section: Introductionmentioning

confidence: 99%

Effect of the combustion system on reduction of thermal specific energy consumption in an industrial high temperature process

Herrera

Rivas²,

Muñoz³

et al. 2021

DYNA

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This paper presents an experimental study carried out in an industrial furnace for frits production using different configurations of burners based on different combustion techniques such as enriched air combustion, flat-flame oxy-combustion and preheater air combustion. The residence time of combustion gases inside the furnace also was modified. Several combustion configurations were tested and its effects on productivity and thermal energy specific consumption and efficiency were determined. The results show that higher residence time of the combustion gases can decrease significantly the specific consumption of fuel, while the change of the burners and combustion techniques did not show significant effects on decreasing the energy consumption. However, it is highlighted that the oxy-combustion flat-flame burners produced the lowest specific consumption of fuel. Even though the experiments were conducted in a furnace for frit production, the corresponding results can also be applied to guide or improve other industrial high temperature processes.

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Numerical analysis of the transient heating of steel billets and the combustion process under air-fired and oxygen enriched conditions

Cited by 51 publications

References 31 publications

Modelling and simulation of steel reheating processes under oxy-fuel combustion conditions – Technical and environmental perspectives

Modelling and simulation of steel reheating processes under oxy-fuel combustion conditions – Technical and environmental perspectives

Performance evaluation of a walking beam type reheating furnace based on energy and exergy analysis

Effect of the combustion system on reduction of thermal specific energy consumption in an industrial high temperature process

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