scholarly journals The Impact of Critical Operational Parameters on the Performance of the Aluminum Anode Baking Furnace

2020 ◽  
Vol 143 (6) ◽  
Author(s):  
Abdul Raouf Tajik ◽  
Tariq Shamim ◽  
Ahmed F. Ghoniem ◽  
Rashid K. Abu Al-Rub
Keyword(s):  
Response Surface ◽  
Oxygen Concentration ◽  
Soot Formation ◽  
Pollutant Emissions ◽  
Carbon Anode ◽  
Inlet Temperature ◽  
Operational Parameters ◽  
Baking Process ◽  
Refractory Wall ◽  
The Impact

Abstract Minimizing energy consumption and reducing pollutant emissions during the carbon anode baking process are critically important for the aluminum industry. The present study investigates the effects of oxidizer inlet temperature, inlet oxygen concentration, equivalence ratio, refractory wall thermal conductivity, and refractory wall emissivity on the baking process using unsteady Reynolds-averaged Navier–Stokes (URANS)-based simulations in conjunction with the presumed probability density function method. Numerical results are combined with a response surface methodology (RSM) to optimize the anode baking process. The advantage of the coupled method is that it can adequately provide information on interactions of different input parameters. It is remarked that the significance level of the studied parameters varies drastically for different outputs. It is noted that diluting inlet oxygen concentration (from 23% in atmospheric air to 15%) at an elevated oxidizer temperature leads to enhanced furnace fuel efficiency, more uniform temperature distribution, and lower pollutant emissions. A linear model is detected to be adequate for response surface modeling of the anode baking furnace NOx formation. On the other hand, furnace soot formation is modeled with a higher-order model due to the quadratic behavior of the response.

scholarly journals Optimizing Pulse Combustion Parameters in Carbon Anode Baking Furnaces for Aluminum Production

2019 ◽  
Author(s):  
Abdul Raouf Tajik ◽  
Tariq Shamim ◽  
Ahmed F. Ghoniem ◽  
Rashid K. Abu Al-Rub
Keyword(s):  
Energy Efficiency ◽  
Response Surface ◽  
Oxygen Concentration ◽  
Fractional Factorial ◽  
Pollutant Emissions ◽  
Aluminum Production ◽  
Carbon Anode ◽  
Physical Parameters ◽  
Inlet Temperature ◽  
Pulse Combustion

Abstract Pulsating flame jets have been widely used in open-top carbon anode baking furnaces for aluminum electrolysis. Reducing energy consumption and pollutant emissions are still major challenges in baking (heat-treatment) carbon anode blocks. It is also of immense significance to bake all the anodes uniformly irrespective of their position in the furnace. Baking homogeneity can be enhanced noticeably by optimizing anode baking operational, geometrical, and physical parameters. In the present study, CFD simulations are combined with a response surface methodology to investigate and optimize the effects of pulse pressure, pulse frequency, and mainstream inlet oxygen concentration and mainstream inlet temperature. Two-levels half fractional factorial design with a center point is employed. It is perceived that pulse combustion with short pulse time and high momentum results in significant enhancement of the anode baking furnace energy efficiency. The temperature homogeneity is also significantly improved. It is found that the oxygen concentration is statistically the most significant parameter on NOx and soot formations, followed by the fuel flow rate. For NOx formation, air inlet oxygen concentration has a strong interaction with pulse duration. Coupling CFD models with the response surface methodologies demonstrated great potential in multi-objective optimization of the anode baking process with enhanced energy efficiency and baking uniformity.

CCPP Operational Flexibility Extension Below 30% Load Using Reheat Burner Switch-Off Concept

2015 ◽  
Author(s):  
Dirk Therkorn ◽  
Martin Gassner ◽  
Vincent Lonneux ◽  
Mengbin Zhang ◽  
Stefano Bernero
Keyword(s):  
Gas Turbine ◽  
Power Plants ◽  
Fast Response ◽  
Combined Cycle ◽  
Pollutant Emissions ◽  
Inlet Temperature ◽  
Operational Flexibility ◽  
Part Load ◽  
Combustion Technology ◽  
The Impact

Highly competitive and volatile energy markets are currently observed, as resulting from the increased use of intermittent renewable sources. Gas turbine combined cycle power plants (CCPP) owners therefore require reliable, flexible capacity with fast response time to the grid, while being compliant with environmental limitations. In response to these requirements, a new operation concept was developed to extend the operational flexibility by reducing the achievable Minimum Environmental Load (MEL), usually limited by increasing pollutant emissions. The developed concept exploits the unique feature of the GT24/26 sequential combustion architecture, where low part load operation is only limited by CO emissions produced by the reheat (SEV) burners. A significant reduction of CO below the legal limits in the Low Part Load (LPL) range is thereby achieved by individually switching the SEV burners with a new operation concept that allows to reduce load without needing to significantly reduce both local hot gas temperatures and CCPP efficiency. Comprehensive assessments of the impact on operation, emissions and lifetime were performed and accompanied by extensive testing with additional validation instrumentation. This has confirmed moderate temperature spreads in the downstream components, which is a benefit of sequential combustion technology due to the high inlet temperature into the SEV combustor. The following commercial implementation in the field has proven a reduction of MEL down to 26% plant load, corresponding to 18% gas turbine load. The extended operation range is emission compliant and provides frequency response capability at high plant efficiency. The experience accumulated over more than one year of successful commercial operation confirms the potential and reliability of the concept, which the customers are exploiting by regularly operating in the LPL range.

scholarly journals Modeling diesel combustion with tabulated kinetics and different flame structure assumptions based on flamelet approach

2019 ◽  
Vol 21 (1) ◽  
pp. 89-100 ◽  
Author(s):  
Tommaso Lucchini ◽  
Daniel Pontoni ◽  
Gianluca D’Errico ◽  
Bart Somers
Keyword(s):  
Soot Formation ◽  
Flame Structure ◽  
Combustion Process ◽  
Computational Cost ◽  
Pollutant Emissions ◽  
Diesel Combustion ◽  
Flamelet Generated Manifold ◽  
Tabulated Chemistry ◽  
Computational Fluid Dynamics Analysis ◽  
The Impact

Computational fluid dynamics analysis represents a useful approach to design and develop new engine concepts and investigate advanced combustion modes. Large chemical mechanisms are required for a correct description of the combustion process, especially for the prediction of pollutant emissions. Tabulated chemistry models allow to reduce significantly the computational cost, maintaining a good accuracy. In the present work, an investigation of tabulated approaches, based on flamelet assumptions, is carried out to simulate turbulent Diesel combustion in the Spray A framework. The Approximated Diffusion Flamelet is tested under different ambient conditions and compared with Flamelet Generated Manifold, and both models are validated with Engine Combustion Network experimental data. Flame structure, combustion process and soot formation were analyzed in this work. Computed results confirm the impact of the turbulent–chemistry interaction on the ignition event. Therefore, a new look-up table concept Five-Dimensional-Flamelet Generated Manifold, that accounts for an additional dimension (strain rate), has been developed and tested, giving promising results.

Influence of Main Stage Air Splits on the Ignition Performance of TeLESS-II Combustor

2017 ◽  
Author(s):  
Xiaotong Mi ◽  
Chi Zhang ◽  
Bo Wang ◽  
Yuzhen Lin
Keyword(s):  
Flow Field ◽  
Air Flow ◽  
Pollutant Emissions ◽  
Recirculation Region ◽  
Stable Operation ◽  
Inlet Temperature ◽  
Main Stage ◽  
Fuel Distribution ◽  
Baseline Case ◽  
The Impact

The centrally staged layout is preferred in the advanced aero-engine combustor to achieve low pollutant emissions as well as stable operation in lean premixed prevaporized combustion. However, because the high-speed main stage airflow prevents the pilot fuel droplets arriving at igniter tip and has a strong convection effect on the initial flame kernel, the application of centrally staged combustor is restricted by its poor ignition and lean blow-out performance. In the centrally staged combustor, the main stage and pilot stage have strong coupled influences on the flow field and fuel distribution. The aim of this paper is to research the impact of the main stage air split on the ignition performance for the baseline case and the comparison case of the main swirler in the TeLESS-II combustor. The main stage air flow rate of the comparison case is about 8 percent less than that of the baseline case. The results of the ignition test at room inlet temperature and pressure indicate that the ignition performance of the comparison case is significantly better than that of the baseline case. The results of the lean blow-out tests show that the main stage air splits do not make the lean blow-out performance worse. To achieve a better understanding of the test results, PLIF technology and CFD analysis were used to measure the fuel distribution and non-reacting flow field. The PLIF and CFD results demonstrate that the most of the fuel spray disperse outward into the main stage cold airflow in the baseline case so that the pilot flame is hard to be established, which leads to poor ignition performance. On the other hand, in the comparison case, the most of the fuel is confined in the recirculation region, which gives a better ignition performance. Compared with the baseline case, the main stage airflow velocity decays faster in the comparison case. It changes the direction of the instantaneous velocity in the spark vicinity, which makes it more likely for the ignition kernel to be captured by the recirculation stream in the comparison case. Therefore, the different fuel distribution and flow field characteristics cause the ignition performance improvement in the comparison case. The improvement is due to the different main stage air flow rates, which is the consequence of the main stage air split.

Quantitative investigation on the impact of injection timing on soot formation in a GDI engine with a customized sectional method

2021 ◽  
pp. 146808742199395
Author(s):  
Stefano Fontanesi ◽  
Marco Del Pecchia ◽  
Valentina Pessina ◽  
Simone Sparacino ◽  
Silvana Di Iorio
Keyword(s):  
Particle Size ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Soot Formation ◽  
Size Distribution Function ◽  
Injection Timing ◽  
Operational Parameters ◽  
Development Tool ◽  
Soot Mass ◽  
The Impact

Soot engine-out emissions are no longer a prerogative of Diesel engines. Emission regulations related to Gasoline units aim to curb the soot emissions along with other pollutants. In this scenario, Computational Fluid Dynamics (CFD) is a very promising research and development tool to explore the influence of engine design and operational parameters, as well as of the fuel chemical nature, on the particulate matter formation. Among the soot models, the Sectional Method is an advanced resource to provide information on Particle Number, Particulate Mass and Particle Size Distribution. In this study, the Sectional Method is applied in conjunction with a customized soot library, where the source terms governing the soot sections transport equations are stored. The library is computed via chemical kinetics simulation of a 0D constant pressure reactor, which provides fuel-related coefficients for each individual source term over the entire range of conditions experienced by the 3D-CFD model. 3D-CFD simulations are then carried out for three different injection timings without case-by-case tuning. Numerical results are then compared to the experimental dataset by using a consistent methodology. A satisfactory agreement between 3D-CFD results and experimental measurements is reached for soot mass and particle numbers, while the particle size distribution function is only partially reproduced. Soot-related quantities are thoroughly analyzed for each of the examined injection strategies to understand the mechanisms leading to soot formation and emissions.

Mild Combustion in a Novel CCGT Cycle With Partial Flue Gas Recirculation

2003 ◽  
Author(s):  
S. M. Camporeale ◽  
F. Casalini ◽  
A. Saponaro
Keyword(s):  
Combustion Chamber ◽  
Gas Turbine ◽  
Soot Formation ◽  
Combustion Process ◽  
Combined Cycle ◽  
Pollutant Emissions ◽  
Inlet Temperature ◽  
Heavy Fuel Oil ◽  
Mild Combustion ◽  
Turbine Exhaust

A novel Combined Cycle Gas Turbine layout is proposed for using heavy fuel oil in a combustion mode called “Mild Combustion”, characterized by a very low adiabatic flame temperature and flat temperature field in the combustion chamber and low pollutant emissions. “Mild Combustion” is obtained by means of the dilution of reactants with inert gas like combustion product resulting in a very low oxygen concentration of the mixture at the ignition. To stabilize the combustion process in such a condition the reactants temperature has to be raised above the self ignition value. In industrial application this particular preconditioning of the reactants can be reached partially before the combustion chamber and finally in process by means of a performed aerodynamic that further dilute and heat-up the mixture. An experimental analysis of the oil combustion behaviour inside the gas turbine exhaust flow has been arranged at Centro Combustione of Ansaldo Caldaie in Gioia del Colle (Italy). The turbine exhaust gases are simulated by mixing those produced in a gas burner with external air preheated at different temperatures in order to have different final oxygen concentrations and temperature levels. The influence of the main combustion parameters regarding the process feasibility and environmental impact are presented and analysed. Good results in terms of NOx emissions and soot formation have been obtained for heavy oil combustion in a 10% oxygen oxidizer concentration requiring a combustion chamber inlet temperature of about 900K. In order to meet these conditions, a novel CCGT cycle in which about 64% of combustion products are re-circulated before entering the combustion chamber, is proposed. The thermodynamic analysis shows that the efficiency that could be achieved by the proposed cycle is a few percent lower than the efficiency of a combined cycle power plant fuelling natural gas, with the same turbine inlet temperature and similar turbine blade cooling technology.

Optimization of the operational parameters of a picking-type pneumatic planter using response surface methodology

2019 ◽  
Vol 6 (1) ◽  
Author(s):  
SK PATEL ◽  
JB BHIMANI ◽  
P GUPTA ◽  
BK YADUVANSHI
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Important Variable ◽  
Vacuum Pressure ◽  
Forward Speed ◽  
Operational Parameters ◽  
Seed Spacing ◽  
Lady’S Finger ◽  
Multiple Regression Technique ◽  
Seed Metering Device

Singulation of seeds has been investigated extensively by researchers all over the world and a large number of precision seeding systems with design variations have been developed for different crops. A picking type metering mechanism was developed at CAET, AAU, Godhra, Gujarat, India. The performance of the picking type seed-metering device of a pneumatic planter was investigated under laboratory conditions to optimize the operating parameters for lady's finger seed. The picking of single seed the three operational parameters i.e. hole diameters for the nozzle: 1.0, 1.5, 2.5 and 3.0 mm; forward speed: 0.37, 0.56, 0.83, 1.11 and 1.30 m/s and vacuum pressure: 19.33, 39.32, 43.98, 58.64 and 68.63 kPa were selected for the study. The metering system of the planter was set to place the seed to seed spacing at 300 mm. The response surface methodology (RSM) technique was used to optimize the operational parameters of a precision planter. For optimizing the forward speed, vacuum pressure and nozzle size for developed machine was evaluated by examining the miss index, multiple index, quality of feed index and precision. The data obtained in the experiments were used to develop functions in polynomial form using multiple regression technique. The optimum value was found to be around 0.96 m/s, 36.25 kPa and 2.0 mm of forward speed, vacuum pressure and the holes diameter of nozzle, respectively. The most important variable that governs planting phenomenon is the combination of hole diameter of nozzle and vacuum pressure accounts 89.18 per cent.

scholarly journals Control of Oxygen Impurities in a Continuous-Feeding Czochralski-Silicon Crystal Growth by the Double-Crucible Method

Crystals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 264
Author(s):  
Wenhan Zhao ◽  
Jiancheng Li ◽  
Lijun Liu
Keyword(s):  
Oxygen Concentration ◽  
Silicon Crystal ◽  
Cost Effective ◽  
Czochralski Method ◽  
Crucible Wall ◽  
Oxygen Impurity ◽  
Continuous Feeding ◽  
The Impact ◽  
Oxygen Impurities ◽  
Crystal Interface

The continuous-feeding Czochralski method is a cost-effective method to grow single silicon crystals. An inner crucible is used to prevent the un-melted silicon feedstock from transferring to the melt-crystal interface in this method. A series of global simulations were carried out to investigate the impact of the inner crucible on the oxygen impurity distributions at the melt-crystal interface. The results indicate that, the inner crucible plays a more important role in affecting the O concentration at the melt-crystal interface than the outer crucible. It can prevent the oxygen impurities from being transported from the outer crucible wall effectively. Meanwhile, it also introduces as a new source of oxygen impurity in the melt, likely resulting in a high oxygen concentration zone under the melt-crystal interface. We proposed to enlarge the inner crucible diameter so that the oxygen concentration at the melt-crystal interface can be controlled at low levels.

scholarly journals How Does Environmental Regulation Affect the Relationship between FDI and Technological Innovation: From the Perspective of Technology Transactions

Processes ◽  
2021 ◽  
Vol 9 (8) ◽  
pp. 1264
Author(s):  
Meng Zeng ◽  
Lihang Liu ◽  
Fangyi Zhou ◽  
Yigui Xiao
Keyword(s):  
Environmental Regulation ◽  
Technological Innovation ◽  
Pollutant Emissions ◽  
Regulatory Effect ◽  
Host Countries ◽  
Regional Heterogeneity ◽  
Industrial Sectors ◽  
Reduction Effect ◽  
The Impact ◽  
The Relationship

Many studies have found that FDI can reduce the pollutant emissions of host countries. At the same time, the intensity of environmental regulation would affect the emission reduction effect of FDI in the host country. This study aims to reveal the internal mechanisms of this effect. Specifically, this paper studies the impact of FDI on technological innovation in China’s industrial sectors from the perspective of technology transactions from 2001 to 2019, and then analyzes whether the intensity of environmental regulation can promote the relationship. Results indicate that FDI promotes technological innovation through technology transactions. In addition, it finds that the intensity of environmental regulation significantly positively moderates the relationship between FDI and technological innovation, which is achieved by positively moderating the FDI–technology transaction relationship. Regional heterogeneity analysis is further conducted, and results show that in the eastern and western regions of China, FDI can stimulate technological innovation within regional industrial sectors through technology trading. Moreover, environmental regulation has a significant positive regulatory effect on the above relationship, but these effects are not supported by evidence in the central region of China.

scholarly journals The effect of heat treatment and impact angle on the erosion behavior of nickel-tungsten carbide cold spray coating using response surface methodology

2021 ◽  
Author(s):  
Marios Kazasidis ◽  
Elisa Verna ◽  
Shuo Yin ◽  
Rocco Lupoi
Keyword(s):  
Heat Treatment ◽  
Response Surface Methodology ◽  
Mass Loss ◽  
Tungsten Carbide ◽  
Response Surface ◽  
Spray Coating ◽  
Impact Angle ◽  
Control Factors ◽  
Heat Treated ◽  
The Impact

AbstractThis study elucidates the performance of cold-sprayed tungsten carbide-nickel coating against solid particle impingement erosion using alumina (corundum) particles. After the coating fabrication, part of the specimens followed two different annealing heat treatment cycles with peak temperatures of 600 °C and 800 °C. The coatings were examined in terms of microstructure in the as-sprayed (AS) and the two heat-treated conditions (HT1, HT2). Subsequently, the erosion tests were carried out using design of experiments with two control factors and two replicate measurements in each case. The effect of the heat treatment on the mass loss of the coatings was investigated at the three levels (AS, HT1, HT2), as well as the impact angle of the erodents (30°, 60°, 90°). Finally, the response surface methodology (RSM) was applied to analyze and optimize the results, building the mathematical models that relate the significant variables and their interactions to the output response (mass loss) for each coating condition. The obtained results demonstrated that erosion minimization was achieved when the coating was heat treated at 600 °C and the angle was 90°.

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