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A Study of Scrap Heating by Burners: Part II—Numerical Modeling

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Abstract

A computational fluid dynamics code was developed to model the heating of a bed of porous steel scrap by combustion gases from a burner. The code accounted for nonuniform void fraction in the bed; turbulent, non-Darcian flow, heat transfer from the gas to the scrap; and radiation. The measured bed porosity values were used in the code. Because steel scrap pieces are very irregular in shape and size, the effective particle diameter was fitted to measurements made in a 1-m3 capacity furnace, as reported in part I. It was found that the lower porosity of the scrap was the most beneficial in increasing the efficiency of heat transfer to the scrap bed because the interfacial area is larger. The effect of particle size was much smaller. It was found that the configurations that increased the residence time or path length of the gases increased the efficiency. The measured porosity of the bed approached unity at the walls, so this provided an easy path for the gas to short-circuit the bed, which limited the effectiveness of decreasing the porosity to increase heat-transfer efficiency. Similarly, simulations of nonuniform scrap distributions reduced efficiency of heat transfer due to short circuiting. The implications of the findings for industrial operations are discussed.

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Abbreviations

ReP :

pore Reynolds number

Re:

Reynolds number

f:

fluid

s:

solid

β :

thermal expansion coefficient

φ :

local porosity

φ ∞ :

porosity from the far away from the boundary or wall

σ :

Stefan–Boltzmann constant

σ k :

k–ε model constant

σ ε :

k–ε model constant

ρ :

Fluid density

ε :

dissipation rate of turbulent kinetic energy

μ :

fluid viscosity

μ eff :

effective fluid viscosity

μ l :

laminar fluid viscosity

μ T :

turbulent fluid viscosity

ν f :

kinematic viscosity of the fluid

ΔP :

pressure gradient

ΔT :

temperature difference between the local and reference temperatures

a:

parameter

b:

parameter

A S :

surface area

C :

specific heat

C P(gas) :

specific heat of gas

C P(R) :

specific heat of refractory

C μ :

k–ε model constant

C k :

porous media k–ε model constant

d P :

particle diameter

E :

emissivity

F :

drag coefficient or Geometric factor

g :

acceleration due to gravity

G K :

volumetric rate of turbulent production

h v :

volumetric heat transfer coefficient

h fS :

heat transfer coefficient between fluid and solid

K :

permeability

K eff :

effective thermal conductivity

K s :

thermal conductivity of solid

K r :

radiative conductivity

K f :

thermal conductivity of fluid

K feff :

effective thermal conductivity of fluid

K seff :

effective thermal conductivity of solid

k :

turbulent kinetic energy

L :

characteristic length

q r :

heat flux due to radiation

S K :

source term in turbulent kinetic energy equation

S ε :

source term in the dissipation rate of turbulent kinetic energy equation

t :

time

T S :

solid temperature

T f :

fluid temperature

T flame :

flame temperature

T exhaust :

exhaust gas temperature

T ambient :

ambient temperature

u f :

fluid velocity in x-direction

v f :

fluid velocity in y-direction

V d :

Darcy velocity

V P :

pore velocity

w f :

fluid velocity in z-direction

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Acknowledgment

The authors would like to thank the Steel Research Centre for supporting this work and ArcelorMittal Dofasco for providing scrap samples.

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Authors and Affiliations

  1. Severstal Columbus, Columbus, MS, 39701, USA

    Kamalesh Mandal (Senior Metallurgist)

  2. Steel Research Centre, McMaster University, Hamilton, ON, L8S 4L7, Canada

    Gordon A. Irons (Dofasco Professor of Ferrous Metallurgy, Director)

Authors
  1. Kamalesh Mandal
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  2. Gordon A. Irons
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Correspondence to Kamalesh Mandal.

Additional information

Manuscript submitted September 13, 2012.

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Mandal, K., Irons, G.A. A Study of Scrap Heating by Burners: Part II—Numerical Modeling. Metall Mater Trans B 44, 196–209 (2013). https://doi.org/10.1007/s11663-012-9752-1

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