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Achema 2012 Praesentation Tvt Edab2
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Institute of Chemical Engineering page 1Achema 2012
Thermal Process Engineering
EDAB Efficient Dry and Burn
Michael Harasek, Andras HorvathJozsef Nagy, Christian Jordan, Amal El-Gohary
EDAB – Efficient Dry and Burn
Institute of Chemical Engineering page 2Achema 2012
Thermal Process Engineering
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)
EDAB – Efficient Dry and Burn
Institute of Chemical Engineering page 3Achema 2012
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
Institute of Chemical Engineering page 4Achema 2012
Thermal Process Engineering
CFD Simulation of the Furnace Burners using open source CFD tools (OpenFOAM)
EDAB – Efficient Dry and Burn
CFD model of the burner – contour plot of velocity magnitude in symmetry plane
Measurement of the gas flame temperature at different oxygen levels in the primary air
Oxygen enrichment – homogeneous atmosphere
Institute of Chemical Engineering page 5Achema 2012
Thermal Process Engineering
EDAB – Efficient Dry and Burn
b)
Numerical Modeling of Firing process (CFD)
High Temperature in Process Measurements
CoolingHeating
Holding Tmax
Variation of cooling rate
Variation of
heating rate
CFD model of the furnace contours of gas velocity
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
Institute of Chemical Engineering page 6Achema 2012
Thermal Process Engineering
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
EDAB – Efficient Dry and Burn
a)
b)
decreased cycle time(higher capacity)
decreased specific energy consumption
improved quality(smaller deviation of dimensions)
Institute of Chemical Engineering page 7Achema 2012
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