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MATHEMATICAL MODELING TO INCREASE HEATING EFFICIENCY

Goal: Increase efficiency on heating up refractory lined equipment.

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Project log

Isis Santos Costa
added a project goal
Increase efficiency on heating up refractory lined equipment.
 
Isis Santos Costa
added 2 research items
The heating of silica-lined furnaces in the frame of forced convection conditions combines fundamental and complex physical and chemical processes. In this work, a numerical investigation has been performed using CFD calculations, in order to gain more insight in involved processes. This work has been carried out using the capabilities of Glass Service GFM (Glass Furnace Model) software, which provides a framework for 3D-CFD simulations, including the solver COMBUSTOR for solving chemical kinetics. As a general methodology, this study is based on simulating combustion fumes injected into silica-lined furnaces, corresponding to the conditions of real heating operations carried out later by Thermojet. Specifically, this research checked the effect of quantity and positioning of burners on thermal homogeneity during transient heating. In addition, the 1D software ThermoSil 1.0 has been applied on the development of an optimised heat-up curve, designed to minimise thermal stresses. The results of this investigation led to the reduction of the number of allocated burners and supported the definition of positioning, including their inclination. Calculations results have been compared to field data, and good agreement has been observed.
Fuel savings have been increasingly climbing the priority agenda of a diversity of companies and the recent development of global economy speeds up the pace. Energy intensive industries are particularly engaged in finding out creative solutions towards efficiency. On addressing the trade-off between shortage of resources and the need for R&D investments, mathematical modelling arises as a sure solution. The present study applies GS-GFM (CFD software from Glass Service) to analyse several scenarios for the temperature hold of coke ovens, culminating on possible 40,8% savings in fuel consumption, compared to the common practice.