Heat integration and operational optimization of an austenitization furnace using concentric‐tube radiant recuperators

Journal Article · Fri Oct 26 00:00:00 EDT 2018 · AIChE Journal

DOI:https://doi.org/10.1002/aic.16414· OSTI ID:1479581

Ganesh, Hari S. ^[1]; Ezekoye, Ofodike A. ^[2]; Edgar, Thomas F. ^[3]; Baldea, Michael  ^[4]

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1. McKetta Dept. of Chemical Engineering The University of Texas at Austin Austin Texas 78712
2. Dept. of Mechanical Engineering The University of Texas at Austin Austin Texas 78712
3. McKetta Dept. of Chemical Engineering The University of Texas at Austin Austin Texas 78712, Energy Institute The University of Texas at Austin Austin Texas 78712
4. McKetta Dept. of Chemical Engineering The University of Texas at Austin Austin Texas 78712, Institute for Computational Engineering and Sciences The University of Texas at Austin Austin Texas 78712

This paper presents a model‐based study of the impact of implementing radiant (radiation‐dominated) concentric‐tube recuperators on fuel use in an indirectly‐fired industrial heat treating (austenitization/quench hardening) furnace. The recuperators recover some of the waste heat from the burner exhaust to preheat the inlet air to the burners, thus reducing the amount of fuel required for combustion. The novelty of this work consists of developing a physics‐based model of a recuperator, which captures local gas‐to‐surface convective heat transfer and long‐range surface‐to‐surface radiation interactions, and using the model to analyze and optimize the energy use of the furnace. An iterative algorithm is proposed to solve the poorly‐conditioned energy balance equations. The steady‐state system operation is optimized using surrogate models. Extensive simulation studies demonstrate that heat integration reduces fuel consumption significantly without affecting product quality. © 2018 American Institute of Chemical Engineers AIChE J , 65: e16414 2019

• Sponsoring Organization: USDOE
• Grant/Contract Number: DE‐EE0005763
• OSTI ID: 1479581
• Journal Information: AIChE Journal, Journal Name: AIChE Journal Vol. 65 Journal Issue: 7; ISSN 0001-1541
• Publisher: Wiley Blackwell (John Wiley & Sons)
• Country of Publication: United States
• Language: English