Numerical model and optimization strategy for the annealing process of 3D coil cores

Dou, Ruifeng; Zhao, Haoxiang; Zhao, Peng; Wen, Zhi; Li, Xianhao; Zhou, Liang; Zhang, Rongzhao

doi:10.1016/j.applthermaleng.2020.115517

Cited by 3 publications

(1 citation statement)

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“…Therefore, it is necessary to develop an accurate operational model for predicting and improving the furnace performance and energy consumption. Computational fluid dynamics (CFD) has been widely applied as a powerful tool for analyzing the heat transfer and fluid flow in heat treatment furnaces [7][8][9][10][11][12]. A three-dimensional CFD model simulates the heat and mass transfer through the specified domain by numerically solving the governing equations in discrete zones called finite volumes.…”

Section: Introductionmentioning

confidence: 99%

Improved Waste Heat Management and Energy Integration in an Aluminum Annealing Continuous Furnace Using a Machine Learning Approach

Andayesh,

Flórez-Orrego,

Germanier

et al. 2023

Entropy

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Annealing furnaces are critical for achieving the desired material properties in the production of high-quality aluminum products. In addition, energy efficiency has become more and more important in industrial processes due to increasing decarbonization regulations and the price of natural gas. Thus, the current study aims to determine the opportunities to reduce energy consumption in an annealing continuous furnace and the associated emissions. To this end, the heat transfer phenomenon is modeled and solutions for the decreasing fuel consumption are evaluated so that the overall performance of the process is enhanced. A heat transfer model is developed using the finite difference method, and the heat transfer coefficient is calculated using machine learning regression models. The heat transfer model is able to predict the heat transfer coefficient and calculate the aluminum temperature profile along the furnace and the fuel consumption for any given operating condition. Two solutions for boosting the furnace exergy efficiency are evaluated, including the modulation of the furnace temperature profiles and the energy integration by the recycling of exhaust flue gases. The results show that the advanced energy integration approach significantly reduces fuel consumption by up to 20.7%. Sensitivity analysis demonstrates that the proposed strategy can effectively reduce fuel consumption compared with the business-as-usual scenario for a range of sheet thicknesses and sheet velocities.

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