CFD Analysis of Regenerative Chambers for Energy Efficiency Improvement in Glass Production Plants

Basso, Davide; Cravero, Carlo; Reverberi, Andrea P.; Fabiano, Bruno

doi:10.3390/en8088945

Cited by 17 publications

(26 citation statements)

References 14 publications

(20 reference statements)

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“…One technique for deriving the appropriate constants involves the use of the Ergun equation [18], applicable over a wide range of Reynolds numbers and for many types of packing. This correlation has been validated in several works dealing with packed bed [19][20][21], but also by the authors in applications of regenerative chambers [5,6] and thermal storage CSP [22]. The coefficients C1 and C2 have been defined as follows, Eq.…”

Section: Direct Methodsmentioning

confidence: 79%

“…This system has been optimized to reach high efficiency values thanks to several numerical and experimental studies [2][3][4]. The research team from the University of Genoa has gained relevant experience in the simulation of regenerative glass production plants [5][6][7], but also in gas recirculation strategies for the reduction of NOx emissions [8,9].…”

Section: Introductionmentioning

confidence: 99%

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Strategies for the Numerical Modelling of Regenerative Pre-heating Systems for Recycled Glass Raw Material

Domenico¹,

Leutcha²,

Cravero³

2019

MMEP

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The rules on energy consumption and pollutant emissions impose increasingly restrictive limitations in today's industrial sectors. The glass production sector is one of the highest sources of energy consumption in Europe, but also in Italy. For this reason it is very important to develop strategies for consumption reduction in a glass production plant. A glass furnace is in fact conceived with systems to recover heat from the combustion gases through regenerative and recuperative systems in order to increase the efficiency of the plant. Several systems to reduce nitrogen oxides emissions have been also developed and designed. A further method to exploit the residual heat from the exhausted gases is to pre-heat the recycled glass raw material to be introduced into the furnace so as to require a smaller amount of energy for its melting. This paper shows various numerical strategies for the design of a pre-heating system for the recycled glass raw material through CFD techniques. In this regard, numerical models have been developed for systems with direct (hot gases come directly into contact with the raw material) and indirect heat exchange (the raw material is heated through the diffusion of heat from a tube bundle).

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Section: Direct Methodsmentioning

confidence: 79%

Section: Introductionmentioning

confidence: 99%

Strategies for the Numerical Modelling of Regenerative Pre-heating Systems for Recycled Glass Raw Material

Domenico¹,

Leutcha²,

Cravero³

2019

MMEP

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“…Moreover, in case of WGR activation, an increase in the channel length implies an increase of the total heat transfer coefficients and a reduction of the volumetric heat transfer performance due to the reduction of the heat transfer surface. In conclusion, the WGR system, in addition to its primary function of NOx abatement [3,6] can increase the heat transfer performance of the regeneration system compared to the system without WGR.…”

Section: Discussionmentioning

confidence: 99%

Simulation strategies for regenerative chambers in glass production plants with strategic exhaust gas recirculation system

Cogliandro¹,

Cravero²,

Marini³

et al. 2017

IJHT

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Glass production is an energy-intensive and a high-polluting industry. This study has the aim to describe the computational approaches developed and set up for the analysis of the innovative Strategic Waste Gas Recirculation (WGR) System applied to the glass industry to new or existing furnaces. The final goal is to reduce the production of NOx during combustion making a primary combustion zone poor of oxygen. In order to have a controlled combustion in the primary zone it is of utmost importance to properly design the recirculation system to get the desired distribution of the recirculated gases in a specific zone over the methane injection. Moreover, the WGR system can have a second positive effect: it enhances the thermal performance of the regeneration system due to the radiating capacity of the exhaust flow recirculated that contains CO2 and H2O molecules. A CFD approach is presented and its applications to the design and optimization of WGR system are discussed. A numerical model for the evaluation of the emissive properties of radiant gases is developed and used for a parametric analysis on the thermal effects introduced by the WGR system.

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“…In order to achieve a good effectiveness of the regenerative heat recovery system, it is necessary to provide a uniform flow distribution into the system starting from the chambers entrance [5][6][7][8].…”

Section: Introductionmentioning

confidence: 99%

“…The above situation will certainly affect the flow solution details from the CFD analysis with respect to the reference "ideal" case of a CAD design with sharp edges. The CFD approach has proven to be an effective tool for flow simulation inside components of industrial systems [5][6][7][8] and also enhanced CFD approaches with specific models for gas emissivity [6] and real gas effects [9] have been developed, especially for heat transfer or combustion applications. The paper is aimed at verifying the effects of the geometrical details of the edges on the flow structure to understand if the standard CFD approach with sharp edges is actually representative of the flow structure and if the above geometrical details need to be taken into account into the CFD based design strategy for glass production plant components.…”

Section: Introductionmentioning

confidence: 99%

Numerical Prediction of the Flow Structure Inside Components of Industrial Glass Furnace Systems

Cravero

Domenico

Kenfack

et al. 2020

Wseas Transactions on Fluid Mechanics

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An important aspect in the glass production industry is related to the heat recovery of the combustion gases. It is usually obtained throughout the use of well-tested technologies, such as regenerative towers with refractory material. For an effective heat recovery, a good distribution of the flow rate at the entrance of the chambers is crucial. The use of Computational Fluid Dynamics (CFD) allows the detailed analysis of the gas evolution during the process; the same would be impractical with experimental measurements, due to prohibitive ambient local conditions. The CFD approach during the design phase typically considers CAD geometries without the level of details related to technological features of the actual installed configuration (i.e. sharp edges vs rounded edges). A brand new built furnace has blunt edges in every connection between 3D walls of refractory blocks. The above edges will be rounded by the erosion-corrosion process due to the harsh chemical/mechanical/thermal environmental conditions inside the plant components (i.e. regenerative chambers, connecting ducts, furnace). The purpose of this work is to evaluate the influence of the geometrical details of the CAD (with focus on the edges connecting adjacent walls), due to technological or erosion aspects, on the flow structure in the furnace components.

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CFD Analysis of Regenerative Chambers for Energy Efficiency Improvement in Glass Production Plants

Cited by 17 publications

References 14 publications

Strategies for the Numerical Modelling of Regenerative Pre-heating Systems for Recycled Glass Raw Material

Strategies for the Numerical Modelling of Regenerative Pre-heating Systems for Recycled Glass Raw Material

Simulation strategies for regenerative chambers in glass production plants with strategic exhaust gas recirculation system

Numerical Prediction of the Flow Structure Inside Components of Industrial Glass Furnace Systems

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