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New industrial furnaces of higher thermal efficiency through intensification of heat transfer from flames

Objective



Large energy savings and therefore reduction of CO2 emissions may be achieved in industrial high temperature furnaces by heat recovery on flue gases, mainly for combustion air preheating. However, experience shows that available heat recovery techniques are seldom used at their maximum efficiency. This results from several drawbacks. Air preheating in conventional burners leads to an enhanced production of NOX. Furthermore, high temperature peaks may be locally reached resulting in load overheating. Therefore, temperature uniformity is more then often achieved by maintaining slow heating rates. The general purpose of the proposed research programme is the improvement of high temperature equipment i (mainly furnaces) through an optimised use of new techniques of intensification of heat transfer from flames. Among these techniques: Iow-NOx burners combining high air preheat with staged or flameless oxidation combustion, high velocity jet burners or pulsating burners, oxygen enrichment.

Optimisation of these techniques will be carried out in two very energy intensive sectors: glass and ceramics.

The programme proposes a theoretical and experimental study of the interaction between the burner design and the heat transfer to the charge. It proceeds through three consecutive steps:
1. Fundamental research
- Further developments and adaptation of advanced furnace models to cope with intensified combustion and heat transfer techniques. Improvement of NOX formation models.
- Validation of the models, measurement of heat transfer coefficients by convection and radiation in intensified conditions in laboratory-scale furnaces.
- Generation of model based rules for the design and operation of glass/ceramics intensive furnaces.

2. Application of intensification techniques in laboratory-scale furnaces (>200 kW). These tests are intended to check the satisfactory operation of the intensification techniques in presence of a load, to carry out measurements of the thermal field into the load, to analyse the load behaviour subjected to high heating rates.
Furnace tests will be carried out in universities, in research centres and in industrial conditions.

3. Predictive extrapolation to full-scale industrial furnaces. This task will be leadered by the numerous industrial partners of the project, who will evaluate the technical applicability and carry out an economical assessment. Heat and mass balances will be carried out on four furnaces currently in operation and considered as the state-of-the-art. Improvements of these furnaces by process intensification will be proposed.
The consortium embraces 4 universities, 3 research centres and 6 industrial partners (see application form). The industrial participation has been balanced in order to provide:
- advanced burner conceptor or manufacturers
- furnace manufacturers
- furnace users

Furthermore, three furnace users - not mentioned as partners - will provide heat and mass balances of "state-of-the-art furnaces": Steelite International (GB), Briqueteries de Ploegsteert (BE), Boral Doorwerth (NL).

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

CINAR LTD.
Address
11,Elvaston Place 11
SW7 5QG London
United Kingdom

Participants (7)

Faculté Polytechnique de Mons
Belgium
Address
56,Rue De L'epargne
7000 Mons
GASWAERME - INSTITUT E.V. ESSEN
Germany
Address
101,Hafenstrasse 101
45356 Essen
Hermann Heye KG
Germany
Address
1,Am Lohplatz
31683 Obernkirchen
INSTITUTO SUPERIOR TECNICO
Portugal
Address
Avenida Rovisco Pais, Pav. Mecanica 1-2°
1049-001 Lisboa
RUHR-UNIVERSITY BOCHUM
Germany
Address
150,Universitatsstrasse 150
44780 Bochum
Technische Universiteit Delft
Netherlands
Address
1,Lorentzweg
2628 CJ Delft
WS WARMEPROZESSTECHNIK GMBH
Germany
Address
14,Dornierstrasse 14
71272 Renningen