E fficient D ry a nd B urn Michael Harasek Andras Horvath Jozsef Nagy Christian Jordan Amal ElGohary michaelharasektuwienacat EDAB Efficient Dry and Burn ID: 605921
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Slide1
EDAB Efficient Dry and BurnMichael Harasek, Andras HorvathJozsef Nagy, Christian Jordan, Amal El-Goharymichael.harasek@tuwien.ac.at
EDAB – Efficient Dry and BurnSlide2
Goals of the projectEnergy balancing of individual and combined processesRun times and cycle times of drying and firing are not equalReuse of waste energy – high temperature heat exchangers, energy
storageOptimize drying process
Reduce losses due to
drying cracks
Optimize firing process
(tunnel
kiln and batch furnace)Reduce cycle time to increase production capacity without investmentReduce specific energy consumption and CO2 emissionsIncrease quality by ensuring homogeneous heat distributionPractical implementation of the suggested improvements on site (Rath GmbH, Krummnußbaum)Investigation of pore forming agents (TGA/DSC)
EDAB –
Efficient
Dry
and
BurnSlide3
EDAB – Efficient Dry and BurnCFD modeling
3D
geometry
implementation
of a small batch high temperature furnaceFull 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
materialSlide4
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
atmosphereSlide5
EDAB – Efficient Dry and Burn b)
Numerical Modeling of Firing process
(CFD)
High Temperature in Process
Measurements
Cooling
HeatingHolding TmaxVariation of cooling rateVariation of heating rateCFD 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
energySlide6
Targets reached so farCycle time decreased by 10 % (further potential)Specific energy consumption reduced by 4 % - about 10 % is possible with further optimizationImproved 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
consumptionimproved quality(smaller deviation of dimensions)Slide7
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