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EDAB – Efficient Dry and Burn

EDAB – Efficient Dry and Burn. EDAB E fficient D ry a nd B urn Michael Harasek , Andras Horvath Jozsef Nagy, Christian Jordan, Amal El-Gohary michael.harasek@tuwien.ac.at. EDAB – Efficient Dry and Burn. Goals of the project Energy balancing of individual and combined processes

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EDAB – Efficient Dry and Burn

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  1. EDAB – EfficientDry and Burn EDAB EfficientDryand Burn Michael Harasek, Andras HorvathJozsef Nagy, Christian Jordan, Amal El-Gohary michael.harasek@tuwien.ac.at

  2. EDAB – EfficientDry and Burn Goals oftheproject • Energybalancingof individual andcombinedprocesses • Run timesandcycletimesofdryingandfiringare not equal • Reuse ofwasteenergy – hightemperatureheatexchangers, energystorage • Optimizedryingprocess • Reducelosses due todryingcracks • Optimizefiringprocess (tunnel kilnandbatchfurnace) • Reducecycle time toincreaseproductioncapacitywithoutinvestment • Reducespecificenergyconsumptionand CO2emissions • Increasequalitybyensuringhomogeneousheatdistribution • Practicalimplementation of thesuggestedimprovements on site (Rath GmbH, Krummnußbaum) • Investigation of poreformingagents (TGA/DSC)

  3. EDAB – EfficientDry and Burn CFD modeling • 3D geometryimplementationof a smallbatchhightemperaturefurnace • Fullresolutionofbricks (yellow) andsupport material (grey/green) • Separatesimulationoftheburners in OpenFOAMandFluent • Simplifiedmethanecombustionincludingradiativeheattransfer • Modifications of thegeometry of thesupport material

  4. EDAB – EfficientDry and Burn • CFD Simulation of theFurnaceBurnersusingopensource CFD tools (OpenFOAM) Measurement of the gasflametemperature at different oxygenlevels in theprimary air CFD model oftheburner – contourplot of velocitymagnitude in symmetry plane Oxygenenrichment – homogeneousatmosphere

  5. EDAB – EfficientDry and Burn OptimizationProcess • CFD modeling – brickandsupport material positioning, homogeneousflow • Measurementsof gas andbrickcoretemperatures • Adaptiationoftheburningcurve – save time andenergy Holding Tmax Cooling Heating b) Variation of heating rate Variation of cooling rate NumericalModeling of Firingprocess (CFD) High Temperature in ProcessMeasurements CFD model ofthefurnace contours of gas velocity

  6. a) EDAB – EfficientDry and Burn • Targetsreached so far • Cycle time decreasedby 10 % (further potential) • Specificenergyconsumptionreducedby 4 % - about 10 % ispossiblewithfurtheroptimization • Improvedquality of the high densitybricksdue to CFD optimizedpositioning of thesupport material decreasedcycle time (highercapacity) b) decreasedspecific energyconsumption improvedquality (smallerdeviation of dimensions)

  7. EDAB – EfficientDry and Burn This project was supported by the Climate and Energy Fund and was performed under the program "NEUE ENERGIEN 2020". Dieses ProjektwurdeausMitteln des Klima- und Energiefondgefördert und imRahmen des Programms “NEUE ENERGIEN 2020” durchgeführt. http://www.klimafonds.gv.at

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