Efficient Modeling and Optimal Design of Coal Fired Pusher Type Reheating Furnace

Abstract

A coal fired pusher type reheating furnace is simulated with the help of an efficient numerical model. The authors have improved over a numerical model developed in previous work to save more than 50% of computational time and thus making it feasible to use the model in large number of parametric studies. The transient movement of the billets is modeled as a steady-state problem with suitable assumptions, thus enabling the entire model to be solved in steady-state and thereby save immense computational time and complexity. The result of this model compares well with that from the previous model considering transient movement of billets, which was also validated against experimental data. The model is utilized in optimal design of the furnace, which reduces use of fossil fuel, increases productivity of furnace and maintains standard quality of production. The effect of changing air inlet velocity through burners, height of furnace, soaking and heating zone lengths of the furnace on the billet heating characteristic, both quantitatively and qualitatively, is examined in this work. Suitable values are suggested for each parameter based on thorough physical analysis to enhance thermal efficiency of the furnace and maintain quality of production simultaneously.