Optimal Design Of Combustion Simulation For Rectangular Regenerative Aluminum Melting Furnace Based On FLUENT

Smelting is the source process in the production and processing of aluminum and aluminum alloy products,and aluminum smelting furnace is its key equipment.With the development of society,the output of aluminum products is increasing,and energy consumption is increasing in our country.This puts forward higher requirements for energy saving and consumption reduction in the smelting process of aluminum smelting furnaces.The research and development of high-efficiency and energy-saving aluminum smelting furnace possesses important industrial application value and academic significance.Due to the complex working conditions of the aluminum smelting process and the high temperature in the furnace,in order to optimize the design of the working conditions of the smelting furnace,it is impossible to directly carry out the research by using conventional experimental methods.It is necessary to conduct data calculation and theoretical analysis of the combustion process,and then the optimization should be carried out according to the actual working conditions.Therefore,by applying the CFD(Computational Fluid Dynamics)numerical simulation research method,taking the on-site 25t rectangular regenerative aluminum smelting furnace as the research object,and taking the optimization of the process parameters and improving the efficiency of the smelting furnace as the ultimate goal,the combustion process was simulated and analyzed.The main parameters that affect the efficiency of the smelting furnace,including air preheating temperature,excess air coefficient,burner height,and burner inclination angle were optimized.The main contents are as follows:Based on the actual structural parameters of the smelting furnace,the geometric model of the rectangular regenerative aluminum melting furnace was established.The numerical model of the combustion process in aluminum melting furnace was established by setting up the corresponding boundary conditions,initial value conditions,discrete format and other parameters through ANSYS Fluent software.The simulation results showed that the maximum combustion temperature reached 2387 K.The temperature distribution in the furnace formed an obvious flame shape.Under the influence of the furnace wall and the aluminum material surface,the airflow gradually stabilized and circulated in the furnace.The circulating airflow increased the residence time of the high temperature flue gas in the furnace,which was conducive to the heat transfer in the furnace.For the temperature distribution of aluminum material,in the X direction(length)section,the high temperature zone was mainly distributed in the central part of the aluminum material.When the two burners were working,the temperature at the position far away from the burner was lower than other positions;on the Y direction(height)section,the temperature of the aluminum material of each section gradually decreased from the surface to the bottom of the furnace along the thickness direction;The temperature distribution of aluminum material was uniform on the section of Z direction(width),and the temperature at the section of Z=3.6m on the slag scraping slope was higher than that at other positions.In the horizontal two-burner combustion mode,the burners were alternately burned and heated at an angle of 15°from the center,and the alternate direction was 120 s,which is beneficial to reduce the temperature difference of the aluminum.Combined with the actual production process,the main operating parameters affecting the combustion process of the furnace were optimized.Based on the simulation results of the actual operating conditions of the furnace,the optimal values of each parameter were determined through the distribution of the temperature field after changing the single parameter.The optimized process parameters were obtained as follows:the burner height of 1600 mm,burner Angle of 10°,excess air coefficient of 1.2 and air preheating temperature of 600?.The thermal efficiency of the aluminum melting furnace before parameter optimization was analyzed by heat balance test,and the simulation results were verified by the temperature of the measuring point on the furnace top.After optimization of the parameters,the temperature of aluminum material in the furnace increased significantly;the temperature uniformity of the aluminum material increased;the average gas consumption of each furnace decreased from 64.6m~3/t to 60.9m~3/t;the average gas consumption decreased by 6%,and the thermal efficiency increased from 49%to 51%,thus achieving the purpose of energy saving and consumption reduction.