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Keywords = heat calculation

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16 pages, 1541 KiB  
Article
Economic Dispatch Strategy for Power Grids Considering Waste Heat Utilization in High-Energy-Consuming Enterprises
by Lei Zhou, Ping He, Siru Wang, Cailian Ma, Yiming Zhou, Can Cai and Hongbo Zou
Processes 2025, 13(8), 2450; https://doi.org/10.3390/pr13082450 (registering DOI) - 2 Aug 2025
Abstract
Under the construction background of carbon peak and carbon neutrality, high-energy-consuming enterprises, represented by the electrolytic aluminum industry, have become important carriers for energy conservation and emission reduction. These enterprises are characterized by significant energy consumption and high carbon emissions, greatly impacting the [...] Read more.
Under the construction background of carbon peak and carbon neutrality, high-energy-consuming enterprises, represented by the electrolytic aluminum industry, have become important carriers for energy conservation and emission reduction. These enterprises are characterized by significant energy consumption and high carbon emissions, greatly impacting the economic and environmental benefits of regional power grids. Existing research often focuses on grid revenue, leaving high-energy-consuming enterprises in a passive regulatory position. To address this, this paper constructs an economic dispatch strategy for power grids that considers waste heat utilization in high-energy-consuming enterprises. A typical representative, electrolytic aluminum load and its waste heat utilization model, for the entire production process of high-energy-consuming loads, is established. Using a tiered carbon trading calculation formula, a low-carbon production scheme for high-energy-consuming enterprises is developed. On the grid side, considering local load levels, the uncertainty of wind power output, and the energy demands of aluminum production, a robust day-ahead economic dispatch model is established. Case analysis based on the modified IEEE-30 node system demonstrates that the proposed method balances economic efficiency and low-carbon performance while reducing the conservatism of traditional optimization approaches. Full article
(This article belongs to the Section Energy Systems)
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17 pages, 2920 KiB  
Article
Device Reliability Analysis of NNBI Beam Source System Based on Fault Tree
by Qian Cao and Lizhen Liang
Appl. Sci. 2025, 15(15), 8556; https://doi.org/10.3390/app15158556 (registering DOI) - 1 Aug 2025
Abstract
Negative Ion Source Neutral beam Injection (NNBI), as a critical auxiliary heating system for magnetic confinement fusion devices, directly affects the plasma heating efficiency of tokamak devices through the reliability of its beam source system. The single-shot experiment constitutes a significant experimental program [...] Read more.
Negative Ion Source Neutral beam Injection (NNBI), as a critical auxiliary heating system for magnetic confinement fusion devices, directly affects the plasma heating efficiency of tokamak devices through the reliability of its beam source system. The single-shot experiment constitutes a significant experimental program for NNBI. This study addresses the frequent equipment failures encountered by the NNBI beam source system during a cycle of experiments, employing fault tree analysis (FTA) to conduct a systematic reliability assessment. Utilizing the AutoFTA 3.9 software platform, a fault tree model of the beam source system was established. Minimal cut set analysis was performed to identify the system’s weak points. The research employed AutoFTA 3.9 for both qualitative analysis and quantitative calculations, obtaining the failure probabilities of critical components. Furthermore, the F-V importance measure and mean time between failures (MTBF) were applied to analyze the system. This provides a theoretical basis and practical engineering guidance for enhancing the operational reliability of the NNBI system. The evaluation methodology developed in this study can be extended and applied to the reliability analysis of other high-power particle acceleration systems. Full article
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37 pages, 7429 KiB  
Article
Study on the Influence of Window Size on the Thermal Comfort of Traditional One-Seal Dwellings (Yikeyin) in Kunming Under Natural Wind
by Yaoning Yang, Junfeng Yin, Jixiang Cai, Xinping Wang and Juncheng Zeng
Buildings 2025, 15(15), 2714; https://doi.org/10.3390/buildings15152714 (registering DOI) - 1 Aug 2025
Abstract
Under the dual challenges of global energy crisis and climate change, the building sector, as a major carbon emitter consuming 33% of global primary energy, has seen its energy efficiency optimization become a critical pathway towards achieving carbon neutrality goals. The Window-to-Wall Ratio [...] Read more.
Under the dual challenges of global energy crisis and climate change, the building sector, as a major carbon emitter consuming 33% of global primary energy, has seen its energy efficiency optimization become a critical pathway towards achieving carbon neutrality goals. The Window-to-Wall Ratio (WWR), serving as a core parameter in building envelope design, directly influences building energy consumption, with its optimized design playing a decisive role in balancing natural daylighting, ventilation efficiency, and thermal comfort. This study focuses on the traditional One-Seal dwellings (Yikeyin) in Kunming, China, establishing a dynamic wind field-thermal environment coupled analysis framework to investigate the impact mechanism of window dimensions (WWR and aspect ratio) on indoor thermal comfort under natural wind conditions in transitional climate zones. Utilizing the Grasshopper platform integrated with Ladybug, Honeybee, and Butterfly plugins, we developed parametric models incorporating Kunming’s Energy Plus Weather meteorological data. EnergyPlus and OpenFOAM were employed, respectively, for building heat-moisture balance calculations and Computational Fluid Dynamic (CFD) simulations, with particular emphasis on analyzing the effects of varying WWR (0.05–0.20) on temperature-humidity, air velocity, and ventilation efficiency during typical winter and summer weeks. Key findings include, (1) in summer, the baseline scenario with WWR = 0.1 achieves a dynamic thermal-humidity balance (20.89–24.27 °C, 65.35–74.22%) through a “air-permeable but non-ventilative” strategy, though wing rooms show humidity-heat accumulation risks; increasing WWR to 0.15–0.2 enhances ventilation efficiency (2–3 times higher air changes) but causes a 4.5% humidity surge; (2) winter conditions with WWR ≥ 0.15 reduce wing room temperatures to 17.32 °C, approaching cold thresholds, while WWR = 0.05 mitigates heat loss but exacerbates humidity accumulation; (3) a symmetrical layout structurally constrains central ventilation, maintaining main halls air changes below one Air Change per Hour (ACH). The study proposes an optimized WWR range of 0.1–0.15 combined with asymmetric window opening strategies, providing quantitative guidance for validating the scientific value of vernacular architectural wisdom in low-energy design. Full article
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20 pages, 3271 KiB  
Article
Calculation Model for the Degree of Hydration and Strength Prediction in Basalt Fiber-Reinforced Lightweight Aggregate Concrete
by Yanqun Sun, Haoxuan Jia, Jianxin Wang, Yanfei Ding, Yanfeng Guan, Dongyi Lei and Ying Li
Buildings 2025, 15(15), 2699; https://doi.org/10.3390/buildings15152699 (registering DOI) - 31 Jul 2025
Viewed by 38
Abstract
The combined application of fibers and lightweight aggregates (LWAs) represents an effective approach to achieving high-strength, lightweight concrete. To enhance the predictability of the mechanical properties of fiber-reinforced lightweight aggregate concrete (LWAC), this study conducts an in-depth investigation into its hydration characteristics. In [...] Read more.
The combined application of fibers and lightweight aggregates (LWAs) represents an effective approach to achieving high-strength, lightweight concrete. To enhance the predictability of the mechanical properties of fiber-reinforced lightweight aggregate concrete (LWAC), this study conducts an in-depth investigation into its hydration characteristics. In this study, high-strength LWAC was developed by incorporating low water absorption LWAs, various volume fractions of basalt fiber (BF) (0.1%, 0.2%, and 0.3%), and a ternary cementitious system consisting of 70% cement, 20% fly ash, and 10% silica fume. The hydration-related properties were evaluated through isothermal calorimetry test and high-temperature calcination test. The results indicate that incorporating 0.1–0.3% fibers into the cementitious system delays the early hydration process, with a reduced peak heat release rate and a delayed peak heat release time compared to the control group. However, fitting the cumulative heat release over a 72-h period using the Knudsen equation suggests that BF has a minor impact on the final degree of hydration, with the difference in maximum heat release not exceeding 3%. Additionally, the calculation model for the final degree of hydration in the ternary binding system was also revised based on the maximum heat release at different water-to-binder ratios. The results for chemically bound water content show that compared with the pre-wetted LWA group, under identical net water content conditions, the non-pre-wetted LWA group exhibits a significant reduction at three days, with a decrease of 28.8%; while under identical total water content conditions it shows maximum reduction at ninety days with a decrease of 5%. This indicates that pre-wetted LWAs help maintain an effective water-to-binder ratio and facilitate continuous advancement in long-term hydration reactions. Based on these results, influence coefficients related to LWAs for both final degree of hydration and hydration rate were integrated into calculation models for degrees of hydration. Ultimately, this study verified reliability of strength prediction models based on degrees of hydration. Full article
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23 pages, 2950 KiB  
Article
Thermal Conductivity of UO2 with Defects via DFT+U Calculation and Boltzmann Transport Equation
by Jiantao Qin, Min Zhao, Rongjian Pan, Aitao Tang and Lu Wu
Materials 2025, 18(15), 3584; https://doi.org/10.3390/ma18153584 - 30 Jul 2025
Viewed by 184
Abstract
Accurate evaluation of the thermal conductivity of UO2 with defects is very significant for optimizing fuel performance and enhancing the safety design of reactors. We employed a method that combines the Boltzmann transport equation with DFT+U to calculate the thermal conductivity of [...] Read more.
Accurate evaluation of the thermal conductivity of UO2 with defects is very significant for optimizing fuel performance and enhancing the safety design of reactors. We employed a method that combines the Boltzmann transport equation with DFT+U to calculate the thermal conductivity of UO2 containing fission products and irradiation-induced point defects. Our investigation reveals that the thermal conductivity of UO2 is influenced by defect concentration, defect type, and temperature. Fission products and irradiation defects result in a decrease in thermal conductivity, but they have markedly different impacts on phonon scattering mechanisms. Metal cations tend to scatter low-frequency phonons (less than 5.8 THz), while the fission gas xenon scatters both low-frequency and high-frequency phonons (greater than 5.8 THz), depending on its occupancy at lattice sites. Uranium vacancies scatter low-frequency phonons, while oxygen vacancies scatter high-frequency phonons. When uranium and oxygen vacancies coexist, they scatter phonons across the entire frequency spectrum, which further results in a significant reduction in the thermal conductivity of UO2. Our calculated results align well with experimental data across a wide temperature range and provide fundamental insights into the heat transfer mechanisms in irradiated UO2. These findings are essential for establishing a thermal conductivity database for UO2 under various irradiation conditions and benefit the development of advanced high-performance UO2 fuel. Full article
(This article belongs to the Section Energy Materials)
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14 pages, 2075 KiB  
Article
Quantifying Polar Mesospheric Clouds Thermal Impact on Mesopause
by Arseniy Sokolov, Elena Savenkova, Andrey Koval, Nikolai Gavrilov, Karina Kravtsova, Kseniia Didenko and Tatiana Ermakova
Atmosphere 2025, 16(8), 922; https://doi.org/10.3390/atmos16080922 - 30 Jul 2025
Viewed by 145
Abstract
The article is focused on the quantitative assessment of the thermal impact of polar mesospheric clouds (PMCs) on the mesopause caused by the emission of absorbed solar and terrestrial infrared (IR) radiation by cloud particles. For this purpose, a parameterization of mesopause heating [...] Read more.
The article is focused on the quantitative assessment of the thermal impact of polar mesospheric clouds (PMCs) on the mesopause caused by the emission of absorbed solar and terrestrial infrared (IR) radiation by cloud particles. For this purpose, a parameterization of mesopause heating by PMC crystals has been developed, the main feature of which is to incorporate the thermal properties of ice and the interaction of cloud particles with the environment. Parametrization is based on PMCs zero-dimensional (0-D) model and uses temperature, pressure, and water vapor data in the 80–90 km altitude range retrieved from Solar Occultation for Ice Experiment (SOFIE) measurements. The calculations are made for 14 PMC seasons in both hemispheres with the summer solstice as the central date. The obtained results show that PMCs can make a significant contribution to the heat balance of the upper atmosphere, comparable to the heating caused, for example, by the dissipation of atmospheric gravity waves (GWs). The interhemispheric differences in heating are manifested mainly in the altitude structure: in the Southern Hemisphere (SH), the area of maximum heating values is 1–2 km higher than in the Northern Hemisphere (NH), while quantitatively they are of the same order. The most intensive heating is observed at the lower boundary of the minimum temperature layer (below 150 K) and gradually weakens with altitude. The NH heating median value is 5.86 K/day, while in the SH it is 5.24 K/day. The lowest values of heating are located above the maximum of cloud ice concentration in both hemispheres. The calculated heating rates are also examined in the context of the various factors of temperature variation in the observed atmospheric layers. It is shown in particular that the thermal impact of PMC is commensurate with the influence of dissipating gravity waves at heights of the mesosphere and lower thermosphere (MLT), which parameterizations are included in all modern numerical models of atmospheric circulation. Hence, the developed parameterization can be used in global atmospheric circulation models for further study of the peculiarities of the thermodynamic regime of the MLT. Full article
(This article belongs to the Special Issue Observations and Analysis of Upper Atmosphere (2nd Edition))
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24 pages, 3325 KiB  
Article
Multi-Energy Flow Optimal Dispatch of a Building Integrated Energy System Based on Thermal Comfort and Network Flexibility
by Jian Sun, Bingrui Sun, Xiaolong Cai, Dingqun Liu and Yongping Yang
Energies 2025, 18(15), 4051; https://doi.org/10.3390/en18154051 - 30 Jul 2025
Viewed by 162
Abstract
An efficient integrated energy system (IES) can enhance the potential of building energy conservation and carbon mitigation. However, imbalances between user-side demand and supply side output present formidable challenges to the operational dispatch of building energy systems. To mitigate heat rejection and improve [...] Read more.
An efficient integrated energy system (IES) can enhance the potential of building energy conservation and carbon mitigation. However, imbalances between user-side demand and supply side output present formidable challenges to the operational dispatch of building energy systems. To mitigate heat rejection and improve dispatch optimization, an integrated building energy system incorporating waste heat recovery via an absorption heat pump based on the flow temperature model is adopted. A comprehensive analysis was conducted to investigate the correlation among heat pump operational strategies, thermal comfort, and the dynamic thermal storage capacity of piping network systems. The optimization calculations and comparative analyses were conducted across five cases on typical season days via the CPLEX solver with MATLAB R2018a. The simulation results indicate that the operational modes of absorption heat pump reduced the costs by 4.4–8.5%, while the absorption rate of waste heat increased from 37.02% to 51.46%. Additionally, the utilization ratio of battery and thermal storage units decreased by up to 69.82% at most after considering the pipeline thermal inertia and thermal comfort, thus increasing the system’s energy-saving ability and reducing the pressure of energy storage equipment, ultimately increasing the scheduling flexibility of the integrated building energy system. Full article
(This article belongs to the Special Issue Energy Efficiency and Thermal Performance in Buildings)
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17 pages, 3620 KiB  
Article
Proposal of a Thermal Network Model for Fast Solution of Temperature Rise Characteristics of Aircraft Wire Harnesses
by Tao Cao, Wei Li, Tianxu Zhao and Shumei Cui
Energies 2025, 18(15), 4046; https://doi.org/10.3390/en18154046 - 30 Jul 2025
Viewed by 159
Abstract
The design of aircraft electrical wiring interconnection systems (EWISs) is central to ensuring the safe and reliable operation of aircraft. The calculation of the temperature rise characteristics of aircraft wire harnesses is one of the key technologies in EWIS design, directly affecting the [...] Read more.
The design of aircraft electrical wiring interconnection systems (EWISs) is central to ensuring the safe and reliable operation of aircraft. The calculation of the temperature rise characteristics of aircraft wire harnesses is one of the key technologies in EWIS design, directly affecting the safety margin of the system. However, existing calculation methods generally face a bottleneck in the balance between speed and accuracy, failing to meet the requirements of actual engineering applications. In this paper, we conduct an in-depth study on this issue. Firstly, a finite element harness model is established to accurately obtain the convective heat transfer coefficients of wires and harnesses. Based on the analysis of the influencing factors of the thermal network model for a single wire, an improved thermal resistance hierarchical wire thermal network model is proposed. A structure consisting of series thermal resistance within layers and iterative parallel algorithms between layers is proposed to equivalently integrate and iteratively calculate the mutual thermal influence relationship between each layer of the harness, thereby constructing a hierarchical harness thermal network model. This model successfully achieves a significant improvement in calculation speed while effectively ensuring useable temperature rise results, providing an effective method for EWIS design. Full article
(This article belongs to the Section F: Electrical Engineering)
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20 pages, 3890 KiB  
Article
Numerical Analysis of Pressure Drops in Single-Phase Flow Through Channels of Brazed Plate Heat Exchangers with Dimpled Corrugated Plates
by Lorenzo Giunti, Francesco Giacomelli, Urban Močnik, Giacomo Villi, Adriano Milazzo and Lorenzo Talluri
Appl. Sci. 2025, 15(15), 8431; https://doi.org/10.3390/app15158431 (registering DOI) - 29 Jul 2025
Viewed by 152
Abstract
The presented research examines the performance characteristics of Brazed Plate Heat Exchangers through computational fluid dynamics (CFD), focusing on pressure drop calculations for single-phase flow within full channels of plates featuring dimpled corrugation. This work aims to bridge gaps in the literature, particularly [...] Read more.
The presented research examines the performance characteristics of Brazed Plate Heat Exchangers through computational fluid dynamics (CFD), focusing on pressure drop calculations for single-phase flow within full channels of plates featuring dimpled corrugation. This work aims to bridge gaps in the literature, particularly regarding the underexplored behavior near the ports for the studied technology and establishing a framework for future conjugate heat transfer studies. A methodology for the domain generation was developed, integrating a preliminary forming simulation to reproduce the complex plate geometry. Comprehensive sensitivity analyses were conducted to evaluate the influence of different parameters and identify the optimal settings for obtaining reliable results. The findings indicate that the kε realizable turbulence model with enhanced wall treatment offers superior accuracy in predicting pressure drops, with errors within ±4.4%. Additionally, leveraging the information derived from CFD, a strategy to estimate contributions from different channel sections without a direct reliance on those simulations was developed, offering practical implications for plate design. Full article
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20 pages, 3137 KiB  
Article
The Heat Transfer Coefficient During Pool Boiling of Refrigerants in a Compact Heat Exchanger
by Marcin Kruzel, Tadeusz Bohdal, Krzysztof Dutkowski, Krzysztof J. Wołosz and Grzegorz Robakowski
Energies 2025, 18(15), 4030; https://doi.org/10.3390/en18154030 - 29 Jul 2025
Viewed by 173
Abstract
The results of experimental data on the heat transfer coefficient during the boiling of pro-ecological refrigerants in a compact tube-shell heat exchanger are presented. The boiling process occurred in the micro-space of the exchanger shell on the surface of horizontal tubes, which were [...] Read more.
The results of experimental data on the heat transfer coefficient during the boiling of pro-ecological refrigerants in a compact tube-shell heat exchanger are presented. The boiling process occurred in the micro-space of the exchanger shell on the surface of horizontal tubes, which were heated from the inside with warm water. The flow of the refrigerant was gravity-based. The heat exchanger was practically flooded with liquid refrigerant at a saturation temperature (ts), which flowed out after evaporation in a gaseous form. The tests were conducted for four refrigerants: R1234ze, R1234yf, R134a (a high-pressure refrigerant), and HFE7100 (a low-pressure refrigerant). Thermal characteristics describing the heat transfer process throughout the entire compact heat exchanger, specifically for the boiling process itself, were developed. It was found that in the case of micro-space boiling, there is an exponential dependence of the heat transfer coefficient on the heat flux density on the heated surface. Experimental data were compared to experimental and empirical data presented in other studies. Our own empirical models were proposed to determine the heat transfer coefficient for boiling in a mini-space for individual refrigerants. The proposed calculation models were also generalized for various refrigerants by introducing the value of reduced pressure into the calculation relationship. The developed relationship enables the determination of heat transfer coefficient values during boiling in a micro-space on the surface of horizontal tubes for various refrigerants with an accuracy of ±25%. Full article
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18 pages, 5270 KiB  
Article
Co-Pyrolysis of Bamboo and Rice Straw Biomass with Polyethylene Plastic: Characterization, Kinetic Evaluation, and Synergistic Interaction Analysis
by Munir Hussain, Vikul Vasudev, Shri Ram, Sohail Yasin, Nouraiz Mushtaq, Menahil Saleem, Hafiz Tanveer Ashraf, Yanjun Duan, Muhammad Ali and Yu Bin
Polymers 2025, 17(15), 2063; https://doi.org/10.3390/polym17152063 - 29 Jul 2025
Viewed by 240
Abstract
This study investigates the co-pyrolysis behavior of two lignocellulosic biomass blends, bamboo (B), and rice straw (R) with a plastic polyethylene (P). A total of 15 samples, including binary and ternary blends, were analyzed. Firstly, X-ray diffraction (XRD) analysis was performed to reveal [...] Read more.
This study investigates the co-pyrolysis behavior of two lignocellulosic biomass blends, bamboo (B), and rice straw (R) with a plastic polyethylene (P). A total of 15 samples, including binary and ternary blends, were analyzed. Firstly, X-ray diffraction (XRD) analysis was performed to reveal high crystallinity in the B25R75 blend (I/Ic = 13.39). Whereas, the polyethylene samples showed persistent ZrP2O7 and lazurite phases (I/Ic up to 3.12) attributed to additives introduced during the manufacturing of the commercial plastic feedstock. In addition, scanning electron microscopy with energy-dispersive X-ray (SEM-EDX) spectroscopy was performed to characterize the surface morphology and elemental composition of the feedstock. Moreover, thermogravimetric analysis (TGA) was employed at temperatures up to 700 °C at three different heating rates (5, 10, and 20 °C/min) under pyrolysis conditions. Kinetic analysis used TGA data to calculate activation energy via Friedman’s isoconversional method, and the blended samples exhibited a decrease in activation energy compared to the individual components. Furthermore, the study evaluated transient interaction effects among the components by assessing the deviation between experimental and theoretical weight loss. This revealed the presence of significant synergistic behavior in certain binary and ternary blends. The results demonstrate that co-pyrolysis of bamboo and rice straw with polyethylene enhances thermal decomposition efficiency and provides a more favorable energy recovery route. Full article
(This article belongs to the Topic Biomass for Energy, Chemicals and Materials)
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21 pages, 727 KiB  
Article
Cost-Effective Energy Retrofit Pathways for Buildings: A Case Study in Greece
by Charikleia Karakosta and Isaak Vryzidis
Energies 2025, 18(15), 4014; https://doi.org/10.3390/en18154014 - 28 Jul 2025
Viewed by 145
Abstract
Urban areas are responsible for most of Europe’s energy demand and emissions and urgently require building retrofits to meet climate neutrality goals. This study evaluates the energy efficiency potential of three public school buildings in western Macedonia, Greece—a cold-climate region with high heating [...] Read more.
Urban areas are responsible for most of Europe’s energy demand and emissions and urgently require building retrofits to meet climate neutrality goals. This study evaluates the energy efficiency potential of three public school buildings in western Macedonia, Greece—a cold-climate region with high heating needs. The buildings, constructed between 1986 and 2003, exhibited poor insulation, outdated electromechanical systems, and inefficient lighting, resulting in high oil consumption and low energy ratings. A robust methodology is applied, combining detailed on-site energy audits, thermophysical diagnostics based on U-value calculations, and a techno-economic assessment utilizing Net Present Value (NPV), Internal Rate of Return (IRR), and SWOT analysis. The study evaluates a series of retrofit measures, including ceiling insulation, high-efficiency lighting replacements, and boiler modernization, against both technical performance criteria and financial viability. Results indicate that ceiling insulation and lighting system upgrades yield positive economic returns, while wall and floor insulation measures remain financially unattractive without external subsidies. The findings are further validated through sensitivity analysis and policy scenario modeling, revealing how targeted investments, especially when supported by public funding schemes, can maximize energy savings and emissions reductions. The study concludes that selective implementation of cost-effective measures, supported by public grants, can achieve energy targets, improve indoor environments, and serve as a replicable model of targeted retrofits across the region, though reliance on external funding and high upfront costs pose challenges. Full article
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20 pages, 4093 KiB  
Article
A Reduced Order Model of the Thermal Profile of the Rolls for the Real-Time Control System
by Dmytro Svyetlichnyy
Energies 2025, 18(15), 4005; https://doi.org/10.3390/en18154005 - 28 Jul 2025
Viewed by 216
Abstract
Effective real-time control systems require fast and accurate models. The thermal profile models of the rolls presented in this paper are proposed for a real-time control system for the design of the rolling schedule. The thermal profile of the roll defines the shape [...] Read more.
Effective real-time control systems require fast and accurate models. The thermal profile models of the rolls presented in this paper are proposed for a real-time control system for the design of the rolling schedule. The thermal profile of the roll defines the shape of the roll surface, its convexity, and, finally, the shape of the final product of the flat rolling, its convexity, and flatness. This paper presents accurate semi-analytical and finite element (FE) models, which serve to obtain an accurate solution of the joint thermal and mechanical problem, that is, heat transfer and thermal expansion. The results of the FE simulation are used for training the developed thermal model based on the neural network (NN) and for the creation of a dynamic reduced order model (ROM) of the roll surface profile. The pre-trained NN model gives accurate results and is faster than the FE model, but the model is not very useful for fast calculations in a real-time control system, mainly because the temperature distribution inside the rolls is not explicitly used in further calculations. In contrast, the ROM is fast and accurate and provides surface-shaped results that can be immediately used by other models of the real-time control system. The results of the simulation of the real process are also shown. Calculations of the roll campaign (more than 9 h) by the FEM model last several hours, while by the ROM less than 20 s. Full article
(This article belongs to the Special Issue Heat Transfer Analysis: Recent Challenges and Applications)
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15 pages, 3051 KiB  
Article
Study on the Kinetics of Carbothermic Reduction of Stainless Steel Dust by Walnut Shell Biochar
by Guoyu Cui, Xiang Zhang, Yanghui Xu, Guojun Ma, Dingli Zheng and Ju Xu
Metals 2025, 15(8), 835; https://doi.org/10.3390/met15080835 - 26 Jul 2025
Viewed by 193
Abstract
Stainless steel dust (SSD) is a by-product generated during the smelting process of stainless steel, which is rich in valuable metals such as Fe, Cr, Ni, and Mn. To optimize the carbothermic reduction process of SSD, this study first conducted the thermodynamic analysis [...] Read more.
Stainless steel dust (SSD) is a by-product generated during the smelting process of stainless steel, which is rich in valuable metals such as Fe, Cr, Ni, and Mn. To optimize the carbothermic reduction process of SSD, this study first conducted the thermodynamic analysis of the carbothermic reduction of SSD and then employed walnut shell biochar as a reductant with non-isothermal thermogravimetric analysis with linear heating rates of 5 °C/min, 10 °C/min, 15 °C/min, and 20 °C/min. The activation energies of the carbothermic reduction reactions were calculated using the FWO method, KAS method, and Friedman method, respectively. Subsequently, the corresponding kinetic models were fitted and matched using the Málek method. The results indicate that before 600 °C, the direct reduction of SSD by carbon plays a dominant role. As the temperature increases, the indirect reduction becomes the main reduction reaction for SSD due to the generation of CO. The activation energies calculated by the Flynn–Wall–Ozawa (FWO) method, Kissinger–Akahira–Sunose (KAS) method, and Friedman method are 412.120 kJ/mol, 416.930 kJ/mol, and 411.778 kJ/mol, respectively, showing close values and a general trend of increasing activation energy as the conversion rate increased from 10% to 90%. Moreover, the reduction reaction is staged. In the conversion range of 10% to 50%, the carbothermic reduction reaction conforms to the shrinking core model within phase boundary reactions, coded as R1/4. In the conversion range of 50% to 60%, it conforms to the shrinking core model within phase boundary reactions, coded as R1/2; in the conversion range of 60% to 90%, the carbothermic reduction reaction follows the second-order chemical reaction model, coded as F2. Full article
(This article belongs to the Special Issue Separation, Reduction, and Metal Recovery in Slag Metallurgy)
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17 pages, 1915 KiB  
Article
Thermocouple Sensor Response in Hot Airstream
by Jacek Pieniazek
Sensors 2025, 25(15), 4634; https://doi.org/10.3390/s25154634 - 26 Jul 2025
Viewed by 211
Abstract
The response of a temperature sensor in a gas stream depends on several heat transfer phenomena. The temperature of the thermocouple’s hot junction in the hot stream is lower than the measured temperature, which causes a measurement error. Compensation for this error and [...] Read more.
The response of a temperature sensor in a gas stream depends on several heat transfer phenomena. The temperature of the thermocouple’s hot junction in the hot stream is lower than the measured temperature, which causes a measurement error. Compensation for this error and interpretation of the values indicated by the temperature sensor are possible by using a sensor dynamics model. Changes over time of the hot junction temperature as well as the entire thermocouple temperature in a stream are solved using the finite element method. Fluid flow and heat transfer equations are solved for a particular sensor geometry. This article presents a method for identifying a temperature sensor model using the results of numerical modeling of the response to temperature changes of the fluid stream, in which the input and output signal waveforms are recorded and then used by the estimator of a model coefficient. It is demonstrated that the dynamics of a bare-bead thermocouple sensor are well-described by a first-order transfer function. The proposed method was used to study the influence of stream velocity on the reaction of two sensors differing in the diameter of the wires, and the effect of radiative heat transfer on the model coefficients was examined by enabling and disabling selected models. The results obtained at several calculation points show the influence of the stream outflow velocity and selected geometric parameters on the value of the transfer function coefficients, i.e., transfer function gain and time constant. This study provides quantitative models of changes in sensor dynamics as functions of the coefficients. Full article
(This article belongs to the Section Industrial Sensors)
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