Performance analysis of the aluminum casting furnace
Authors
 Received:
DOI: 10.1007/BF02654201
 Cite this article as:
 Bui, R.T. & Perron, J. MTB (1988) 19: 171. doi:10.1007/BF02654201
Abstract
The casting furnace plays a central role in the production of aluminum. Its design and operation are complex and involve some 450 parameters. There is a need for a model to predict and analyze its performance. We propose a simplified model in which each main component of the furnace is treated as a 1D heat conduction medium. Based on the equations of conservation of mass, energy, and chemical species, complemented by the equations of conduction and the Hottel’s formulation of radiative heat transfer, this dynamic model can simulate any sequence of operations such as loading, heating, stirring, skimming … that constitutes a batch, and can take into account other operational details such as the opening of doors. It is validated on a real furnace, then used to predict furnace performance in other modes of operation, and also to determine an optimal fuel flow that minimizes a chosen cost function.
Table of Symbols
 A

area m^{2}
 c

specific heat of solid kJ/(kg · K)
 c _{p}

specific heat at constant pressure kJ/(kg · K)
 c _{p}

specific heat at constant pressure kJ/(kmole · K)
 c _{v}

specific heat at constant volume kJ/(m^{3} · K)
 h

convective heat transfer coefficient kW/(m^{2} · K)
 h _{f} ^{o}

enthalpy of formation kJ/kmole
 H

enthalpy per unit volume kJ/m^{3}
 k

thermal conductivity kW/(m · K)
 K

equivalent thermal conductivity kW/(m · K)
 L

latent heat of fusion of aluminum kJ/kg
 M

equivalent mass kg
 n

mass flowrate kmole/s
 q

heat flux kW/m^{2}
 Q

heat flowrate kW
 T

temperature K
 U

internal energy kJ
 V

volume m^{3}
 GS

total exchange area, gas to surface m^{2}
 SS

total exchange area, surface to surface m^{2}
 η

efficiency 1
 ρ

density kg/m^{3}
 σ

StefanBoltzmann constant kW/(m^{2} · K^{4})
 θ

Kirchhoff transform of conductivity kW/m