Search Results (26)

The electric arc furnace (EAF) process includes key stages: charging scrap metal, melting using electric arcs, refining through oxygen injection and slag formation, and tapping molten steel. Recently, EAF steelmaking has become increasingly important due to its flexibility with recycled materials, lower environmental impact, and reduced investment costs. This study focuses specifically on select aspects of the refining stage, analysing decarburization and the associated exothermic oxidation reactions following the removal of carbon with oxygen injection. Particular attention is given to FeO generation during refining, as it strongly affects slag chemistry, yield losses, and overall efficiency. Using a Computational Fluid Dynamics (CFD)-based refining simulator validated with industrial data from EVRAZ North America (showing an 8.57% deviation), this study investigated the impact of oxygen injection rate and burner configuration. The results in a three-burner EAF operation showed that increasing oxygen injection by 10% improved carbon removal by 5%, but with an associated increase of FeO generation of 22%. Conversely, reducing oxygen injection by 15% raised the residual carbon content by 43% but lowered FeO by 23%. Moreover, the impact of the number of burners was analysed by simulating a second scenario with 6 burners. The results show that by increasing the number of burners from three to six, the target carbon is reached 33% faster while increasing FeO by 42.5%. Moreover, by reducing the oxygen injection in the six-burner case, it is possible to reduce FeO generation from 42.5 to 28.5% without significantly impacting carbon removal. This set of results provides guidance for burner optimization and understanding the impact of oxygen injection on refining efficiency. Full article

The combustion behavior and thermal performance of industrial-scale borax pentahydrate (Na₂B₄O₇·5H₂O) melting furnaces remain underexplored despite their critical role in boric oxide (B₂O₃) production, a key input for high-performance manufacturing. This study addressed this gap by employing three-dimensional computational fluid dynamics (CFD) simulations to model two operational natural gas-fired furnaces with distinct burner configurations (four-burner and six-burner systems). The analysis focused on optimizing burner placement, specifically, the axial distance and inclination angle, to enhance thermal uniformity and reduce refractory wall damage caused by aggressive high-temperature borate corrosion. A comprehensive parametric study of twelve burner configurations revealed that tilting the burners at 5–10° significantly improved temperature uniformity while reducing peak wall temperatures and mitigating localized hot spots. The optimal design, incorporating a 10° burner angle and a staggered burner arrangement (Case 11), attained a melt pool temperature of 1831.3 K and a charging average wall temperature of 1812.0 K. These values represent essential benchmarks for maximizing furnace efficiency and operational stability. The modified designs for the four- and six-burner systems led to improved temperature distributions and a notable reduction in maximum wall temperatures, directly contributing to longer maintenance intervals and improved refractory durability. The findings of this study confirm that minor geometrical and angular adjustments in burner placement can yield significant performance gains. The validated CFD approach and proposed design modifications offer a scalable, low-cost strategy for improving combustion efficiency and furnace lifespan in borax processing facilities. Full article

The last decades have offered new challenges to researchers worldwide through the problems our planet is facing both in the environmental protection field and the need to replace fossil fuels with new environmentally friendly alternatives. Bioenergy, as a form of renewable energy, is an acceptable option from all points of view, and biofuels, due to their biological origin, have the ability to satisfy the new needs of humanity. As they release non-polluting combustion products into the atmosphere, biofuels have already been adopted as additives in traditional liquid fuels, intended mainly for the internal combustion engines of automobiles. The current work proposes an extension of the biofuel application in combustion processes specific to industrial furnaces. This technical concern has not been found in the literature, except for the achievements of the research team involved in this work, who performed the previous investigations. A 51.5 kW burner was designed to operate with glycerin originating from the triglycerides of plants and animals, mixed with ethanol, an alcohol produced by the chemical industry recently used as an additive in gasoline for automobile engines. Industrial oxygen was chosen as the oxidizing agent necessary for the liquid mixture combustion, allowing us to obtain much higher flame temperatures compared with the usual combustion processes using air. Mixing glycerin with ethanol in an 8.8 ratio allowed for growing flame stability, also accentuated by creating swirl currents in the flame through the speed regime of fluids at the exit from the burner body. Results were excellent in both the flame stability and low level of polluting emissions. Full article

Natural and liquefied petroleum gases are widely used in industrial heat treatment. However, the rising cost of gas, combined with increased demand, has significantly impacted production costs and the environment. The annealing process typically relies on natural or liquefied petroleum gases as the primary heat source. In this study, we aimed to investigate the use of biomass fuel as a replacement for fossil fuels and to evaluate the mechanical properties and microstructure of wire rod steel after annealing using indirect heat from a gasifier. We experimented to examine the effects of annealing temperatures of 650 °C, 700 °C (below the critical temperature Ac1), and 750 °C (above Ac1 but below the upper temperature Ac3). The batch furnace, made of stainless steel, was modified from a traditional wire annealing furnace that originally used CNG and LPG gas burners. It was adapted into a wire annealing furnace connected to a cross-draft gasifier. The furnace’s interior was designed with spiral cooling fins to minimize energy consumption and shorten annealing time. Additionally, it was modified to use biomass as a substitute fuel, reducing environmental pollution. The furnace was coated with thermal insulation, and the biomass gasifier stove was a cross-draft device with primary air feeding at 20 m³/h and secondary air supplied at a constant flow rate of 32 m³/h, 36 m³/h, or 40 m³/h. As a fuel source, we used eucalyptus. The mechanical properties of wire rod steel were measured in terms of tensile strength and torsion, following the TIS 138-2562 standard. This standard specifies that the tensile strength must be at least 260 MPa. Regarding torsion, the TIS 138-2562 requirements state that the wire must withstand at least 75 rounds of twisting without breaking. Our results showed that after annealing at 650 °C, 700 °C, or 750 °C, with a soaking time of 30 min and subsequent cooling in the furnace at natural temperature for 24 h, the tensile strength values were 494.82, 430.87, and 381.33 MPa, respectively. The torsion values were 126.92, 125.8, and 125.76 rounds, respectively. Additionally, ferrite grain size increased with annealing temperature, reaching a maximum of 750 °C. The total annealing duration for each batch was 2 h and 40 min at 650 °C, 2 h and 10 min at 700 °C, and 2 h at 750 °C. Full article

For centuries, fossil fuels have been the primary energy source, but their unchecked use has led to significant environmental and economic challenges that now shape the global energy landscape. The combustion of these fuels releases greenhouse gases, which are critical contributors to the acceleration of climate change, resulting in severe consequences for both the environment and human health. Therefore, this article examines the potential of hydrogen as a sustainable alternative energy source capable of mitigating these climate impacts. It explores the properties of hydrogen, with particular emphasis on its application in industrial burners and furnaces, underscoring its clean combustion and high energy density in comparison to fossil fuels, and also examines hydrogen production through thermochemical and electrochemical methods, covering green, gray, blue, and turquoise pathways. It discusses storage and transportation challenges, highlighting methods like compression, liquefaction, chemical carriers (e.g., ammonia), and transport via pipelines and vehicles. Hydrogen combustion mechanisms and optimized burner and furnace designs are explored, along with the environmental benefits of lower emissions, contrasted with economic concerns like production and infrastructure costs. Additionally, industrial and energy applications, safety concerns, and the challenges of large-scale adoption are addressed, presenting hydrogen as a promising yet complex alternative to fossil fuels. Full article

The aim of this research is to investigate the environmental emission effects and combustion properties of burning different types of FAME biodiesel fuels in an industrial oil burner. These burner heads are used in many areas of industry for heating various boilers and tube furnaces. The fuels used, the area of use, the emission norm values, and the climatic conditions are key factors in this investigation. In this research, two plant-based oils are examined, the properties of which have been compared to standard commercial heating oil. The raw material of the two tested bio-based components was rapeseed. The main gas emission parameters CO, THC, CO₂, O₂, HC, water content, and consumption data were measured. The measurements were performed in an AVL engine brake platform infrastructure, where gas emissions were measured with an AVL AMA i60 FTIR emission gas analyzer, fuel consumption was meticulously gauged using a fuel flow meter, fuel temperature was monitored using an AVL 745 fuel temperature conditioning system, and air consumption was measured with an AVL Flowsonix intake air flow meter. The measurement results showed that both tested biofuels can be burned stably in industrial oil burners, have favorable properties in terms of ignition and flame extinction tendencies, and there is no significant difference in emission parameters compared to standard fuel oil. Full article

Industrial process heating furnace operations consume considerable energy in the U.S. manufacturing sector, making it crucial to identify energy efficient strategies due to the growing need to minimize energy usage and emissions. It is important to identify the potential impact of these factors to enable process engineers to operate process heating systems at the maximum possible efficiency. This study examines and identifies the key impact factors that influence the efficiency of process heating systems using MEASUR (v1.4.0), the DOE software tools such as the insulation effectiveness, the burner stoichiometry, cooling medium, thermal storage, and atmospheric gases. Data from a two-fuel-fired heat treatment furnace and an electric arc furnace (EAF) for steelmaking were employed to establish the baseline heat balance models in MEASUR. The fractional factorial design experiment was developed with two-level parameter values and energy efficiency strategies for the heat input into industrial furnaces. The three most significant parameters for the heat input for a fuel-fired industrial furnace, Industrial Furnace A, are excess air percentage or the oxygen percentage in flue gas (OF), average surface temperature (ST), and combustion air temperature (CT). Similarly, for an electric industrial furnace, Industrial Furnace B, the parameters are charge temperature (CHT), average surface temperature (ST), and time open (TO). A comparative analysis was carried out for the fuel-fired and equivalent electric resistance furnaces to identify the prospect of electrification of industrial furnaces relying upon fossil fuels. The study aims to assist industries and designers in making informed decisions regarding industrial furnace upgrades, process optimization, and maintenance investments, resulting in substantial energy and cost savings, and a reduced environmental impact. Full article

During the refining stage of electric arc furnace (EAF) operation, molten steel is stirred to facilitate gas/steel/slag reactions and the removal of impurities, which determines the quality of the steel. The stirring process can be driven by the injection of oxygen, which is carried out by burners operating in lance mode. In this study, a computational fluid dynamics (CFD) platform is used to simulate the liquid steel flow dynamics in an industrial-scale scrap-based EAF. The CFD platform simulates the three-dimensional, transient, non-reacting flow of the liquid steel bath stirred by oxygen injection to analyze the mixing process. In particular, the CFD study simulates liquid steel flow in an industrial-scale EAF with three asymmetric coherent jets, which impacts the liquid steel mixing under different injection conditions. The liquid steel mixing is quantified by defining two variables: the mixing time and the standard deviation of the flow velocity. The results indicate that the mixing rate of the bath is determined by flow dynamics near the injection cavities and that the formation of very low-velocity regions or ‘dead zones’ at the center of the furnace and the balcony regions prevents flow mixing. This study includes a baseline case, where oxygen is injected at 1000 SCFM in all the burners. Two sets of cases are also included: The first set considers cases where oxygen is injected at a reduced and at an increased uniform flow rate, 750 and 1250 SCFM, respectively. The second set considers cases with non-uniform injection rates in each burner, which keep the same total flow rate of the baseline case, 3000 SCFM. Comparison between the two sets of simulations against the baseline case shows that by increasing the uniform flow rate from 1000 to 1250 SCFM, the mixing time is reduced by 10.9%. Moreover, all the non-uniform injection cases reduce the mixing time obtained in the baseline case. However, the reduction in mixing times in these cases is accompanied by an increase in the standard deviations of the flow field. Among the non-uniform injection cases, the largest reduction in mixing time compared to the baseline case is 10.2%, which is obtained when the largest flow rates are assigned to coherent jets located opposite each other across the furnace. Full article

A two-step numerical concept was developed for modelling combustion and predicting nitrogen oxide emissions. The model was validated by the Sandia flame D experiment and with measurement data from burners on industrial furnaces. In this paper, the developed model was implemented to evaluate the influence of hydrogen blending with natural gas up to 40 vol.% on an industrial burner with oxidizer temperatures at 300 K and 813 K to assess the performance of the burner without altering the power output of the burner. An experimental test facility is under construction, and the feasibility of using this industrial burner on the test facility with different fuel mixtures was analyzed. Temperature, flow field, and emission characteristics were investigated. Using 40 vol.% hydrogen with natural gas resulted in a decrease of 14.82% in CO₂ emissions and an increase of in 16.1% NO emissions when combusted with air at 300 K. The temperature profile indicated that the burner produces a symmetrical flame profile with preheated air and an asymmetrical flame profile with ambient air. Full article

On a cold single-phase test stand, the effect of central air on the exit flow field of Babcock, Germany, burner was investigated. Industrial measurements were taken for a 700 MW wall-fired pulverized-coal utility boiler with above burners. Gas temperature, gas composition and concentration in the burner area were measured at 444 MW, 522 MW and 645 MW loads, respectively. Only when the central air mass flow was zero did a center reflux zone exist in the burner outlet area. The steady combustion of faulty coal was aided by early mixing of primary and secondary air, which was made possible by the decreased central air mass flow. At all different loads, the pulverized coal in center region took a long distance to ignite. The temperature in center steadily dropped as central air mass flow decreased, while the temperature in secondary air region gradually rose. Within 1.5 m from the primary air duct outlet, the highest CO concentration was 25 ppm and the highest O₂ concentration was close to 21% under all loads. The gas concentration near sidewall was more influenced by load. With all valves opening of burner center air at 30%, the boiler was able to operate safely and stably without oil at a load of 262 MW. The furnace chamber temperature in burner area reached 1056.1 °C. Full article

The increasing global demand for energy- and resource-efficient, environmentally friendly products has led the European Union (EU) to develop a sustainable product policy, incorporating ecodesign legislation and energy labeling as effective tools for promoting energy efficiency and sustainability. Recent European energy policies, such as the Energy Efficiency Directive (EED) and the Ecodesign Directive (EDD), have set new objectives for enhancing energy efficiency. This study focuses on the 2012 Lot 4: Industrial and Laboratory Furnaces and Ovens, Tasks 1–7 Final Report, which informed the European Commission’s 2014 working document for the Ecodesign Consultation Forum on industrial and laboratory furnaces and ovens. The working document proposed initial draft measures and requirements for this product group, aiming to achieve specific energy savings and related greenhouse gas (GHG) emissions reductions. The findings of the investigations on energy consumption and GHG emissions are presented in this work, with draft calculations and projections serving as the foundation for discussions on future measures. The BAT (best available technologies) scenario would result in lower environmental impacts. The initial and indicative draft Lot 4 impact assessment predictions for energy savings demonstrate the positive influence of prospective ecodesign measures in reducing energy consumption. These deliberations will ultimately contribute to the formulation of an official mandatory regulation for industrial and laboratory furnaces and ovens, in line with the EU’s sustainable product policy objectives. Full article

Using lightweight fire-rated board (LFRB) presents cost-effective opportunities for various passive fire protection measures. The aim of the project is to develop an LFRB with enhanced fire resistance, acoustic properties, and mechanical properties. These properties were determined using a Bunsen burner, furnace, energy-dispersive X-ray, impedance tube instrument, and Instron universal testing machine. To fabricate the LFRBs, vermiculite and perlite were blended with flame-retardant binders, and four types of LFRBs were produced. A fire test was conducted to compare the fire-resistance performance of the LFRBs with a commercially available flame-retardant board. The B2 prototype showed exceptional fire-resistant properties, with a temperature reduction of up to 73.0 °C, as compared to the commercially available fire-rated magnesium board. Incorporating nano chicken eggshell into the specially formulated flame-retardant binder preserved the LFRBs’ structural integrity, enabling them to withstand fire for up to 120 min with an equilibrium temperature of 92.6 °C. This approach also provided an absorption coefficient of α = 2.0, a high flexural strength of 3.54 MPa, and effective flame-retardancy properties with a low oxygen/carbon ratio of 2.60. These results make the LFRBs valuable for passive fire protection applications in the construction and building materials industry. Full article

Recently, growing environmental awareness has radically changed the way the problems and priorities of industry are dealt with. Energy issues have become an issue of primary importance, both in terms of consumption and polluting emissions. However, for the green transition to happen, the first step is to have a deeper knowledge of the phenomena involved in processes with a special focus on combustion. The glass industry is one of the most energy-intensive since a temperature of over 1400 °C is required to keep glass molten, with a large consumption of natural gas used for combustion. A fundamental element to control the process is the burner. In this study, the CFD (Computational Fluid Dynamics) prediction of the internal streams repartition and the velocity profile at the exit, at different geometrical setups and operating conditions, of an industrial burner for glass furnaces is presented, with the aim of developing a surrogate model to provide these two important quantities quickly. The study of the repartition of the mass flow inside a double impulse burner and the subsequential velocity profile outside the burner is a novelty in the glass industry. The CFD prediction of the operating conditions is a crucial aspect because it is an essential boundary condition for the simulation of the reactive process from the diffusive flame found in glass furnaces. Different operating and geometrical conditions of the burner have been tested using Ansys CFX code, and results (velocity profile and mass flow repartition) have been organized in surrogate models. Results showed that the repartition of the fuel streams is mainly influenced by the position of the barrel, while the total flow rate is strongly influenced by the total inlet pressure. The internal flow varies from 20% to 50% of the total mass flow inside the burner, while the velocity magnitude outside the burner varies from 80 to 300 m/s approximately. The reconstruction of velocity profiles at the exit of the burners with surrogate models showed an acceptable match with numerical simulations. Full article

No alternatives are currently available to operate industrial furnaces, except for hydrocarbon fuels. Plant managers, therefore, face at least two challenges. First, environmental legislation demands emission reduction. Second, changes in the origin of the fuel might cause unforeseen changes in the heat release. This paper develops the hypothesis for the detailed control of the combustion process using computational fluid dynamic models. A full-scale mock-up of a rotary cement kiln is selected as a case study. The kiln is fired by the non-premixed combustion of Dutch natural gas. The gas is injected at Mach $0.6$ via a multi-nozzle burner located at the outlet of an axially mounted fuel pipe. The preheated combustion air is fed in (co-flow) through a rectangular inlet situated above the attachment of the fuel pipe. The multi-jet nozzle burner enhances the entrainment of the air in the fuel jet. A diffusion flame is formed by thin reaction zones where the fuel and oxidizer meet. The heat formed is transported through the freeboard, mainly via radiation in a participating medium. This turbulent combustion process is modeled using unsteady Favre-averaged compressible Navier–Stokes equations. The standard k-$ϵ$ equations and standard wall functions close the turbulent flow description. The eddy dissipation concept model is used to describe the combustion process. Here, only the presence of methane in the composition of the fuel is accounted for. Furthermore, the single-step reaction mechanism is chosen. The heat released radiates throughout the freeboard space. This process is described using a P1-radiation model with a constant thermal absorption coefficient. The flow, combustion, and radiative heat transfer are solved numerically using the OpenFoam simulation software. The equations for flow, combustion, and radiant heat transfer are discretized on a mesh locally refined near the burner outlet and solved numerically using the OpenFoam simulation software. The main results are as follows. The meticulously crafted mesh combined with the outlet condition that avoids pressure reflections cause the solver to converge in a stable manner. Predictions for velocity, pressure, temperature, and species distribution are now closer to manufacturing conditions. Computed temperate and species values are key to deducing the flame length and shape. The radiative heat flux to the wall peaks at the tip of the flame. This should allow us to measure the flame length indirectly from exterior wall temperature values. The amount of thermal nitric oxide formed in the flame is quantified. The main implication of this study is that the numerical model developed in this paper reveals valuable information on the combustion process in the kiln that otherwise would not be available. This information can be used to increase fuel efficiency, reduce spurious peak temperatures, and reduce pollutant emissions. The impact of the unsteady nature of the flow on the chemical species concentration and temperature distribution is illustrated in an accompanying video. Full article

Measuring the heat flux in the furnace of industrial boilers is an urgent task in the power industry. Installing the measuring instruments directly into the furnace is a laborious and complex process. It requires a complete shutdown of the boiler, which incurs economic costs. It is most efficient to use portable probes with measuring insert. The created cooled probe with a heterogeneous gradient heat flux sensor is a unique and versatile tool that allows for the configuration and control of the operation of power boilers. This article compares experimental values with calculation methods. The obtained heat flux per unit area is in good agreement with the theoretical concepts when the values are averaged. The technique used in this paper makese it possible to determine the maximum heat-stressed zones and areas with stable or unstable combustion. The main combustion zones that are typical for the flaring of any fuel are identified. This approach allows us to consider various approaches to heat transfer enhancement during the combustion of both liquid and gaseous fuels. Comparison of experimental results with the data of other authors is not quite exact due to the complexity of the experiment. The study of burners in this configuration has not previously been considered in the literature. Full article