Study and optimisation of an industrial furnace with refractory linings

PROJECT DETAILS

Clients: PROYCO Date: 2026 Simulation Technology: CFD

INTRODUCTION

The aim of this project is to investigate potential design optimisations for an oxidiser based on the client’s initial modification proposals, with a view to improving its performance and assessing the impact of these changes on the overall operation of the system. To this end, we first characterised the flow behaviour by comparing the velocity field, the temperature distribution inside the equipment and the mass flow of ash at different outlet flow rates with the experimental measurements provided for the currently built equipment. To carry out this analysis, we used Computational Fluid Dynamics (CFD) simulations requiring compressible flow models, the calculation of diffusive species, and the particle module with mass coupled to the fluid. The software used for the project is ScFlow, from MSC Cradle.

CFD MODELS

In this case, we started with the detailed geometries of the system and its components and generated models tailored to the flow analysis, enabling us to examine the regions of interest whilst reducing the meshing requirements in less relevant areas. We then configured the CFD models, taking into account the flow rates and compositions of the inlet and outlet gases, as well as the operating conditions and the particle size distribution and density of the ash. Finally, we selected a mesh that would allow us to capture small differences in flow and pressure drops with the level of detail required to validate the proposed methodology. The following image shows an overview of the mesh used in one of the studies:

STUDY USING CFD SIMULATION

Once the models have been defined, we can calculate the various scenarios by numerically solving the equations that govern gas flow for compressible flow, taking into account heat generation and turbulence in a transient analysis. We first evaluate the convergence criteria by monitoring the residuals and the stability of the parameters under study, particularly the velocities and mass balances. For the initial model, we verify that the velocity maps and flow distribution match the experimental data provided, thereby validating the study methodology. The following image shows the velocity field for one of the configurations studied: