Abstract
The paper focuses on the CFD analysis of a full-scale module of an industrial ceramic kiln under actual operating conditions. The multi-dimensional analysis includes the real geometry of a ceramic kiln module employed in the preheating and firing sections and investigates the heat transfer between the tiles and the burners’ flame as well as the many components that comprise the module. Particular attention is devoted to the simulation of the convective flow field in the upper and lower chambers and to the effects of radiation on the different materials is addressed. The assessment of the radiation contribution to the tiles temperature is paramount to the improvement of the performance of the kiln in terms of energy efficiency and fuel consumption. The CFD analysis is combined to a lumped and distributed parameter model of the entire kiln in order to simulate the module behaviour at the boundaries under actual operating conditions. Finally, the CFD simulation is employed to address the effects of the module operating conditions on the tiles’ temperature distribution in order to improve the temperature uniformity as well as to enhance the energy efficiency of the system and thus to reduce the fuel consumption.
Highlights
The ceramic industry is well known to be characterized by energy intense processes and among them the kiln is one of the main responsible of the primary energy consumption
If this effect could be expected for the preheating module, it is less trivial for the firing section
In the analysis the combustion in the burners of the firing module has been addressed by using the Eddy Brake Up model for the oxidation of natural gas with air; the Surface-to-Surface (S2S) radiation model has been adopted for calculating the thermal radiative heat transfer between surfaces of the ambient surrounding the tiles
Summary
The ceramic industry is well known to be characterized by energy intense processes and among them the kiln is one of the main responsible of the primary energy consumption. Radiation is accounted for in the modelling in order to assess the contribution of the radiative heat transfer in the total heat absorbed by the ceramic tiles during the preheating and firing regions of the kiln.
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