Title

NOVEL BURNER DESIGN SUPPORTED BY CFD TO MINIMIZE DEPOSITS INSIDE COMBUSTION CHAMBERS OF SAMARCO PELLETIZING FURNACES

NOVEL BURNER DESIGN SUPPORTED BY CFD TO MINIMIZE DEPOSITS INSIDE COMBUSTION CHAMBERS OF SAMARCO PELLETIZING FURNACES

Authorship

Athayde, Maycon; Nunes, Sergio Fernando; Silva, Guilherme Araujo Lima da; Sousa, Francisco Domingues Alves de; Arima., Marcos Noboru

Athayde, Maycon

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Nunes, Sergio Fernando

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Silva, Guilherme Araujo Lima da

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Sousa, Francisco Domingues Alves de

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Arima., Marcos Noboru

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DOI

10.5151/2594-357X-22310

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Abstract

The present paper describes development aspects and results of a novel burner design to solve the operational difficulties caused by deposits inside pelletizing furnaces. After the conversion from liquid fuel oil to natural gas, some combustion chambers experienced significant increase in the deposited powder rate due to overdeflected flames. The downcomer air caused deflection and pushed the flame zone towards the wall due to high momentum unbalance among streams. Consequently, the high temperatures and CO concentrations caused sintering of deposited particles resulting in higher maintenance and cleaning frequency. To solve the problem, the present authors developed a novel burner based on analytical methods and field experience supported by a Computational Fluid Dynamics tool (CFD). The authors simulated a Reynolds-Averaged Navier-Stokes (RANS) and full turbulent flow field plus combustion reactions. The issue root causes were identified and few design configurations and operational conditions were defined as candidates to minimize the deposit. Then CFD tool was used to select the best configuration. The novel burner proposed by present authors was tested successfully in actual pelletizing furnaces and presented a significant minimization ore accretion rate. Therefore, the excellent operation performance validated the methodology and confirmed CFD predictions.

The present paper describes development aspects and results of a novel burner design to solve the operational difficulties caused by deposits inside pelletizing furnaces. After the conversion from liquid fuel oil to natural gas, some combustion chambers experienced significant increase in the deposited powder rate due to overdeflected flames. The downcomer air caused deflection and pushed the flame zone towards the wall due to high momentum unbalance among streams. Consequently, the high temperatures and CO concentrations caused sintering of deposited particles resulting in higher maintenance and cleaning frequency. To solve the problem, the present authors developed a novel burner based on analytical methods and field experience supported by a Computational Fluid Dynamics tool (CFD). The authors simulated a Reynolds-Averaged Navier-Stokes (RANS) and full turbulent flow field plus combustion reactions. The issue root causes were identified and few design configurations and operational conditions were defined as candidates to minimize the deposit. Then CFD tool was used to select the best configuration. The novel burner proposed by present authors was tested successfully in actual pelletizing furnaces and presented a significant minimization ore accretion rate. Therefore, the excellent operation performance validated the methodology and confirmed CFD predictions.

Keywords

Iron ore; Pelletizing; Flow simulation; Combustion; CFD; Burner design; Furnace; Deposits; Reactive flow; Simulation.

Iron ore; Pelletizing; Flow simulation; Combustion; CFD; Burner design; Furnace; Deposits; Reactive flow; Simulation.