Application of the steady flamelet model on a lab-scale and an industrial furnace for different oxygen concentrations

Prieler, René Josef; Mayr, Bernhard; Demuth, Martin; Spoljaric, Davor; Hochenauer, Christoph

doi:10.1016/j.energy.2015.08.070

Cited by 31 publications

(9 citation statements)

References 59 publications

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“…Schluckner et al [25] used a CFD model to predict the effect of oxygen enriched combustion atmosphere on the transient scale formation of steels in a lab scale heat treatment furnace. Prieler et al [26] investigated the heat distribution of a laboratory-scale furnace and proved the applicability of steady flamelet approach in the simulation of gas-fired furnaces. Also, Mayr et al [27] investigating the heat distribution in a semi-industrial gas-fired furnace proposed a time saving combustion modeling approach in this application.…”

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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“…In the numerical work of Mayer et al in [19], both the laminar steady flamelet model (SFM) and the eddy dissipation concept model (EDC) were used to study the influence of additional oxy-fuel jet burners in gas phase on the productivity of the investigated furnace. Also, Prieler et al in [20], in their oxy-combustion study, compared the same methods in a RANS context with the eddy dissipation model (EDM) for various oxygen enrichments. Both studies employed different chemical mechanisms.…”

Section: Introductionmentioning

confidence: 99%

Combustion Characteristics of a Non-Premixed Oxy-Flame Applying a Hybrid Filtered Eulerian Stochastic Field/Flamelet Progress Variable Approach

et al. 2019

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The oxidation of methane under oxy-fuel combustion conditions with carbon capture is attractive and deserves huge interest towards reducing CO2 and NOx emissions. The current paper reports on the predictions and analysis of combustion characteristics of a turbulent oxy-methane non-premixed flame operating under highly diluted conditions of CO2 and H2 in oxidizer and fuel streams, respectively. These are achieved by applying a novel, well-designed numerical combustion model. The latter consists of a large eddy simulation (LES) extension of a recently suggested hybrid model in Reynolds averaging-based numerical simulation (RANS) context by the authors. It combines a transported joint scalar probability density function (T-PDF) following the Eulerian Stochastic Field methodology (ESF) on the one hand, and a flamelet progress variable (FPV) turbulent combustion model under consideration of detailed chemical reaction mechanism on the other hand. This novel hybrid ESF/FPV approach removes the weaknesses of the presumed-probability density function (P-PDF)-based FPV modeling, along with the solving of associated additional modeled transport equations while rendering the T-PDF computationally less affordable. First, the prediction capability of the LES hybrid ESF/FPV was appraised on the well-known air-piloted methane jet flame (Sandia Flame D). Then, it was assessed in analyzing the combustion properties of a non-premixed oxy-flame and in capturing the CO2 dilution effect on the oxy-fuel flame behavior. To this end, the so-called oxy-flame B3, already numerically investigated in a RANS context, was analyzed. Comparisons with experimental data in terms of temperature, scalar distributions, and scatter plots agree satisfactorily. Finally, the impact of generating the FPV chemistry table under condition of unity Lewis number, even with CO2 dilution, was investigated on the general prediction of the oxy-fuel flame structure, stability and emissions. In particular, it turns out that 68% molar percentage of CO2 leads to 0.39% of CO formation near the burner fuel nozzle and 0.62% at 10 dfuel above the nozzle.

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“…Only one study has considered the residence time of flue gases in a high temperature process. In that study, Wang et al [27] used CFD simulations and a response surface method (RSM) to optimize operation conditions of an aluminum holding furnace. Among variables that they considered, combustion technology and location of the chimney were considered.…”

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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Application of the steady flamelet model on a lab-scale and an industrial furnace for different oxygen concentrations

Cited by 31 publications

References 59 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

Combustion Characteristics of a Non-Premixed Oxy-Flame Applying a Hybrid Filtered Eulerian Stochastic Field/Flamelet Progress Variable Approach

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

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