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DESIGN AND DEVELOPMENT OF A MILD FURNACE

Technical Report · November 2015

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Choo Chee Jie

Universiti Malaysia Pahang Al-Sultan Abdullah
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 DESIGN AND DEVELOPMENT OF A MILD FURNACE

[Link]

Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP), 26600 Pekan, Pahang,
Malaysia.
Email: Cheejiechoo@[Link]

ABSTRACT

The MILD combustion furnace is performance by both an elevated temperature of reactants and low
temperature increase in the combustion process. The paper emphasizes the development of a
mathematical model for MILD combustion in a closed furnace. The details are including computational
fluid dynamic process and sequence step from designing the model to post processing. The furnace is
required a non-premixed open burner. Besides that, an external EGR pipe is used to transport the exhaust
gas which is mixed with the fresh oxidant. The butterfly shape valves are installed at the top opening as
a damper to close the exhaust gas flow at a specific ratio for EGR and exhaust out to the atmosphere in
order to control EGR and exhaust flow. Results showed that the furnace in four sectors: a central
injection area (a), the ignition area (b), the combustion reaction zone (c) and flue gas area (d), according
to H2CO and OH-of the distribution curve. The baffle reaction jets and it is useful to the deflector before
and after longer residence time of flue gas of CO oxidation. Normalized space temperature change is
less than 10.5%, so the distribution of temperature in the furnace is very uniform. In addition, lower
emissions, less than 10ppm. Therefore, the mild regime realized in downstream of furnace.

INTRODUCTION

Furnace is used for heat treatment or melting of materials. In traditional furnaces electrical heating is
used for this purpose [1]. In this furnace, recycling waste heat from the oven Chamber, which they
mixed with the fresh products of the combustion system when used in particular is difficult to provide a
material, combustion chamber wall will withstand very high operating temperatures. Lined with
refractory The'costliest stainless steel gas bottle lasted only a short time in regular service[2].
The high and growing demand for energy in today’s world has been met to approximately 80% by
the fossil fuel supply (IEA, 2009; Maczulak, 2010) [3-5]. Fossil fuel reserves are questionable by
Shafiee and Topal, 2009, and the use of fossil fuel has resulted in an increase in the emission of
unwanted pollutants investigate by Khelil, Naji, and Loukarfi, 2007; Yusaf, Noor, and Wandel, 2013 [3,
4, 6]. Among the fossil fuels, natural gas combustion is the most attractive as it produces less harm to the
environment because it releases less carbon dioxide, nitrogen oxide, sulphur dioxide, particulate and
mercury per unit energy compared to oil and coal (US EIA, 1999) [7]. Table 1 compares the pollutants
from natural gas, oil and coal. The use of natural gas will reduce the impact of fossil fuel combustion on
climate change. In order to further reduce NOx and other harmful pollutants, lean mixtures will reduce
the combustion temperature and decrease the formation of NOx [5, 7-9].
 Table 1. Pollutant from fossil fuel (US EIA,1999) [7]

Gas Oil Coal

no pollutant
(kg of pollutant per 109 kJ of engery input
1 carbon dioxide 273,780 383,760 486,720
2 carbon monoxide 94 77 487
3 nitrogen oxide 215 1,048 1,069
4 sulphur dioxide 2.34 2,625 6,063
5 particulate 16.4 197 6,420
6 mercury 0 0.016 0.037

At present, biomass-derived fuels, also known as bio-fuel seems to be alternative solutions of the future
shortage of fossil fuels, in many countries they are a very good possibility of generating energy from
renewable resources. This is why biofuel consumption is thought to grow steadily in the coming years in
order to achieve sustainable energy [10, 11].
Moderate or severe hypoxic dilution (mild) burning has become the most promising for low NOx
combustion technology in industrial heating emissions and high combustion efficiency. MILD thermal
flue-gas recycling combustion characteristics as heated furnace, which on the one hand to improve agent
higher than the ignition temperature of the reaction, while dilution of the reactant mixture before
combustion. In this regard, combustion occurs in highly diluted reaction, including automatic ignition
will not allow environmental. Under mild conditions of the combustion process is very different from
conventional combustion, because internal recycling is so strong, so that combustion reaction diffusion
to wider spaces. Therefore, both the temperature and chemical substances are evenly distributed, and
peak temperatures and NOx emissions are reduced [12-15].

EXPERIMENT SET UP

Design of Experiment

The furnaces are designed to perform detailed and operational parameters such as gas powered, air
preheat temperature, flue gas temperature and excess air independently of changes in the larger context.
It is show in Figure 1. Combustor geometry is similar to the industrial NFK regenerative burners [16], it
simply consists of three gas injections. For example, a central air jet and two off-axis fuel injection.
Temperature by changing its immersion in the combustion chamber control 4 water tube. Flue gas
leaving the combustion chamber slots 12 holes positioned on top of the vertical walls [17]. Therefore
decided to test two different sets of actions under each corresponding to one of the previous parameters
determine the topology, based on OH selfemission UV-visible through the Figure 1(a).
Figure 1: Furnace (a) schematic and position of measuring instruments (units in mm), (b) computational
geometry [18]

Experimental Procedure

The standard topology is one of the most stable, two regions, where thermal runaway is the largest,
called ' response ' below, located in the air between the jets and the meeting point. When reducing the
temperature low temperature topology is observed. In this case, heat along the axis air jet released
farther downstream, as the temperature continues to drop. Fuel for natural gas to fuel power 30-kilowatt,
has the following average volumetric composition: 0.8950 CH4, 0.0548 C2H6, 0.0134 C3H8, 0.0046
C4H10, 0.0019 C5H12, 0.0158 N2, 0.0145 CO2 with a lower heating value 37.2 MJ/m3 N Air preheat
temperature fixed at 800 °c, at the furnace outlet to maintain over 1120 c. At this temperature, cryogenic
topology so that excess air value equal to 10% is observed, e=20% of heat release distribution has a
standard topology. The e is used to refer to the value of one or another of the following topology [18,
19].

Figure 2: Diagram of MILD combustion furnace and supply system [19]

 MATHEMATICAL MODELlING

Computational fluid dynamics (CFD) is an important tool for exploring MILD burns [20]. CFD is
increasingly used in gas burners and combustion optimization of industrial gas stoves or coal. In this
study, the CFD software ANSYS FLUENT 13.0 on diffusion flames of methane air a bluff-body burner
with numerical simulation of premixed combustion, heat radiation and nitrogen oxide emissions. For
turbulence models and discrete ordinates (DO) model, radiative models of the k-ε turbulence model. DO
model is applicable to a wide range of optical depth. Optical thickness for mild burning flames DO no
clear brand model is a good choice for the radiation model. To ensure MILD combustion has produce
clean and efficient combustion [6]. The basic combustion process must be balanced as shown in
Equation (1) [5, 6, 8, 21, 22].

eq (1)

Besides that, the some others equation are also important to develop a MILD combustion. Modelling the
design is first stage to build up a combustion because to reduce high cost on the extensive experimental
work. The Taylor expansion was utilized to discretize the partial differential equation for the CMC
model. The modelling of CMC using explicit and implicit methods was successfully implemented using
FORTRAN as the simulation software [23, 24].

RESULT AND DISCUSSION

Flow Pattern and Fuel Consumption

Due to the amount of natural gas is methane 90%, this species has been chosen as the fuel mark.
Methane levels for the fuel injection track through the anchor point is that it's a given z value is the
largest location of information. Figure 3 experimental tracks, together with the numerical speed on a flat
surface and the flow pattern (X, Z). The jet trajectory is calculated in the injection area, the maximum
speed of the z-position [17, 25].
Test track is not completely symmetrical, because the hollow square, and the square's right hand
and the left hand side of the track is not in the same position. All numerical trajectories of coincidence
but less compared to bending towards the central air jet, experimental value. radius is defined as the
following air jet, which along the jet center in z speed decreased to half the value line and recycling
points to the areas with z speed for the area. Obviously from those elements, in the mode of selection
has not had a strong influence on flow field and, therefore, is mainly due to the differences observed in
the following model. Air flow rate of e = 20% is not significantly increased the flow pattern of any
change [18]. It can be seen, the consumption of fuel is slowly because methane 0.2% is still measured
halfway up. Thus, E = 10% methane is farther along the Jet axis in the lower case e = 20%, what means
the air jet carrying methyl did not oxidize the minimum excess air value.
 Figure 3: Flow pattern: air jet opening, recirculation zone and fuel jet trajectory

CONCLUSION

In conclusion, the CFD was successful utilized to develop a furnace for MILD combustion. MILD
detailed experimental data sets generated with typical laboratory scale furnace conditions in industry on
the injection system configurations, higher recycling levels and the presence of a load. The combustion
has to be enclosed to collect the exhaust gas and utilized to dilute the oxygen in the
oxidant stream and, at the same time, increase the oxidant temperature. Both air and fuel
play important role for the completed combustion.

ACKNOWLEDGMENTS

The contributions from those review paper authors are appreciated

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