مطالعه تجربی و شبیه‌سازی سه‌بعدی کوره‌ دوار ریخته‌گری چدن با یک مشعل گازسوز

نوع مقاله : مقاله پژوهشی

نویسندگان

1 دانشگاه تهران

2 امور پژوهش و فناوری شرکت گاز استان تهران

چکیده

در این پژوهش، شبیه‌سازی عددی یک کوره‌ دوار ریخته‌گری گازسوز 350 کیلوگرمی چدن و بهینه‌سازی مصرف سوخت آن به روش دینامیک سیالات محاسباتی بررسی می‌شود. برای شبیه‌سازی، این کوره‌ به سه ناحیه مجزا تقسیم می‌شود: الف) ناحیه بار جامد با فاز مایع-جامد، ب) ناحیه احتراقی با فاز گازی و ج) ناحیه جامد دوار یا دیواره‌ی نسوز کوره. این سه ناحیه به صورت سه‌بعدی و گذرا با لحاظ برهمکنش‌های بین فصول مشترک نواحی فوق، شبیه‌سازی شده‌اند. در هر ناحیه، شبیه‌سازی بر مبنای حل هم زمان معادلات هیدرودینامیکی از جمله اتلاف گردابه و معادلات مربوط به واکنش‌های شیمیایی صورت می‌گیرد. نتایج شبیه‌سازی دمای جداره بیرونی بدنه کوره با داده های صنعتی مطابقت دارند که اعتبار مدل عددی را اثبات می‌کنند. در این شبیه سازی، نرخ ذوب‌دهی، تولید آلاینده‌های NOx و CO و مصرف ویژه‌ی سوخت،. سرعت دورانی، پیش‌گرمایش هوای احتراق، تغییر درصد هوا و تولید آلاینده‌‌های آنها نیز بررسی شد. تغییر پیکره‌بندی کوره دوار موجب کاهش 5% مصرف سوخت می‌شود که از نظر بهینه سازی مصرف سوخت و کیفیت آلیاژ تولیدی در این کوره حائز اهمیت است.

کلیدواژه‌ها

موضوعات


عنوان مقاله [English]

An experimental study and 3D simulation of a cast iron rotary

نویسندگان [English]

  • Behzad Bayramlou 1
  • Seyed Mohammad Mirnajafi 2
  • Rahmat Sotudeh-Gharebagh 1
1 University of Tehran
2 NIGC
چکیده [English]

 In this study, the computational fluid dynamics (CFD) simulation of an experimental 350 kg cast iron rotary furnace was conducted for the aim of optimizing its fuel consumption and pollutants reduction. The furnace is divided into 3 distinct simulation zones: a) solid charge zone with liquid-solid phase, b) combustion zone with gas phase, and c) solid rotating zone or furnace refractory wall. These three zones are three-dimensionally and transiently modeled in terms of the leading phenomena within each zones and interfaces. The simulation in each region is based on the simultaneous solution of hydrodynamic equations, including vortex dissipation and chemical reaction kinetics equations. The simulation results for the outside wall temperature of the furnace body are in close agreement with the data obtained from experimental units. Furthermore, melting rate, NOx and CO pollutant generation, specific fuel consumption, rotating speed, preheating of combustion air, excess air percentage, and pollutant production were all evaluated in this simulation. Changing the furnace configuration decreases fuel consumption by 5%, which is important in terms of improving fuel consumption and alloy product quality in this furnace.  The results of this study can be used to optimize the industrial rotary furnace operations.
 

کلیدواژه‌ها [English]

  • rotary furnace
  • Natural gas
  • Computational Fluid Dynamics
  • Combustion
  • Melting
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