Efficient Dry and Burn - TU Wien

Report
Thermal Process Engineering
EDAB – Efficient Dry and Burn
EDAB
Efficient Dry and Burn
Michael Harasek, Andras Horvath
Jozsef Nagy, Christian Jordan, Amal El-Gohary
[email protected]
Achema 2012
Institute of Chemical Engineering
page 1
Thermal Process Engineering
EDAB – Efficient Dry and Burn
Goals of the project
 Energy balancing of individual and combined processes
• Run times and cycle times of drying and firing are not equal
• Reuse of waste energy – high temperature heat exchangers, energy storage
 Optimize drying process
• Reduce losses due to drying cracks
 Optimize firing process (tunnel kiln and batch furnace)
• Reduce cycle time to increase production capacity without investment
• Reduce specific energy consumption and CO2 emissions
• Increase quality by ensuring homogeneous heat distribution
 Practical implementation of the suggested improvements on site
(Rath GmbH, Krummnußbaum)
 Investigation of pore forming agents (TGA/DSC)
Achema 2012
Institute of Chemical Engineering
page 2
Thermal Process Engineering
EDAB – Efficient Dry and Burn
CFD modeling
 3D geometry implementation of
a small batch high temperature
furnace
• Full resolution of bricks
•
•
(yellow) and support material
(grey/green)
Separate simulation of the
burners in OpenFOAM and
Fluent
Simplified methane
combustion including radiative
heat transfer
 Modifications of the geometry
of the support material
Achema 2012
Institute of Chemical Engineering
page 3
Thermal Process Engineering
EDAB – Efficient Dry and Burn
 CFD Simulation of the Furnace Burners using open
source CFD tools (OpenFOAM)
Measurement of the gas flame temperature at
different oxygen levels in the primary air
CFD model of the burner – contour plot of
velocity magnitude in symmetry plane
Oxygen enrichment – homogeneous atmosphere
Achema 2012
Institute of Chemical Engineering
page 4
Thermal Process Engineering
EDAB – Efficient Dry and Burn
Optimization Process
 CFD modeling – brick and
support material positioning,
homogeneous flow
 Measurements of gas and
brick core temperatures
 Adaptiation of the burning
curve – save time and energy
Holding Tmax
Heating
b)
Cooling
Variation of
heating rate
Variation of cooling rate
Numerical Modeling of Firing process (CFD)
CFD model of the furnace
contours of gas velocity
Achema 2012
High Temperature in Process Measurements
Institute of Chemical Engineering
page 5
Thermal Process Engineering
a)
EDAB – Efficient Dry and Burn
 Targets reached so far
• Cycle time decreased by 10 % (further
•
•
potential)
Specific energy consumption reduced
by 4 % - about 10 % is possible with
further optimization
Improved quality of the high density
bricks due to CFD optimized positioning
of the support material
decreased cycle time
b)
(higher capacity)
decreased specific
energy consumption
improved quality
(smaller deviation of dimensions)
Achema 2012
Institute of Chemical Engineering
page 6
Thermal Process Engineering
EDAB – Efficient Dry and Burn
This project was supported by the Climate and Energy Fund and was performed
under the program "NEUE ENERGIEN 2020".
Dieses Projekt wurde aus Mitteln des Klima- und Energiefond gefördert und
im Rahmen des Programms “NEUE ENERGIEN 2020” durchgeführt.
http://www.klimafonds.gv.at
Achema 2012
Institute of Chemical Engineering
page 7

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