Numerical Simulation And Experiment Study On The Baking Process Of The Anode Baking Furnace

Anode baking is one of the important steps in the aluminum industry. The qualities of anode directly affect the electricity efficiency and energy consumption of aluminum electrolysis productionTherefore, how to improve the baking technology has become a very important research issue. The only approach to solve this problem is to do systematic research of the fundamental theory of the anode baking furnace. At the same time, it's an urgent requirement to develop and to design new baking furnaces independently in China.Firstly, this thesis reviews the research work on the baking furnace fundamental theories up to date in detail. Through the systematic analysis of the advantages and its disadvantages in the latest developments in numerical simulation and experiment study on baking process of the baking furnace, the thesis proposes a synthetic research method to further the baking technology in China. Based on this idea, the relevant research work follows.In this thesis, synthetic test and analysis on the baking furnace are carried out, most of which is developed rarely in China. The measurements on flue gas composition also fill up the domestic blank. The test results provide a scientific guidance for the operation of a baking furnace. At the same time, those test data also can validate the model established hereafter. The application of test method for a baking furnace is very valuable for the diagnosis of baking operation in aluminum industry.Through the systematic analysis of ring anode baking process, a mathematical model is developed successfully from the viewpoint of a technical design, and simulation software package for the baking process of horizontal baking furnace is written. The prediction is in good agreement with experiment data. Furthermore, the processes are simulated under different operation conditions. The simulated results indicate that the fuel consumption are changed with different baking parameters, fuel type and anode size. According to this simulated results, we can choose an optimal baking parameters in actual operation. The software introduced in this thesis is the first computer aided design software in the aluminum industry of China, which is proved to be a very useful tool in the process optimization and design of baking furnaces.This thesis also considers the fume flow and combusting situation in flue with CFD package from the viewpoint of the structure design. The contours of velocity, temperature, pressure and gas concentration are discussed. The results show that the situation of fume flow in flue is very important to the distribution of flue temperature. The temperature distribution is uniform as long as the fume flow is uniform. Furthermore, the maximal temperature in flue increases, and the average temperature in whole flue will also increase. Based on those results mentioned above, five conclusions are summarized for flue structure optimization of a baking furnace, which is very useful for the scientific design of baking furnaces. According to the five conclusions, several simulations with different parameters are then realized. The results indicate that the temperature distribution, fuel combustion and average temperature in flue improve obviously after optimizing the flue structure.Finally, this thesis uses the international advanced PIV to study the essential characteristics of the complicated flow in flue of the baking furnace. It's a beneficial attempt to do research on cold flow, and also, we introduce a practical technique for the application of the PIV in industry.