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High temperature processes are of vital importance in a number of industries, including cement, chemical, glass, metallurgy, refining and steel. With so many factors affecting the operational efficiency to consider, the stakes are pretty high for engineers to deliver a safe, reliable, efficient and environmentally friendly operation.

That is why computational fluid dynamics (CFD) and reaction kinetic simulations of combustion processes to design systems are being increasingly utilized. They not only give the necessary insight into the complex physics but also help to significantly lower the cost of iterating between trials and prototypes.

This is important when it comes to improving the current designs of processes and equipment such as gas and coal burners, glass and steel treatment furnaces, process and crude heaters, reformers and dryers and kilns.

For example, a given heater may need to achieve a certain thermal performance (uniformity of heat flux, radiation duty, heat transfer efficiency) while simultaneously achieving environmental performance (CO and NOx, wasted heat). To be able to perform on both fronts, the nonlinear interactions of flue gas flow patterns and peak temperatures which affect the thermal performance and pollutant values need to be not just understood, but the effect of various design and operating conditions on them need to be systematically explored. A sample chart of such effects (not a complete analysis) is shown below:

The real value of simulation is realized when you can explore your design space or operation space rather than doing a few point simulation. It makes the difference between having a simulation result versus providing an engineering solution. This approach is helping engineers optimize and predict performance and meet process requirements in high temperature processes.

For more, be sure to register for our upcoming complimentary webinar on March 2, 2017:

Achieving operational excellence in high temperature processes using simulation

Matthew Godo
STAR-CCM+ Product Manager
Stephen Ferguson
Marketing Director
James Clement
STAR-CCM+ Product Manager
Joel Davison
Lead Product Manager, STAR-CCM+
Dr Mesh
Meshing Guru
Ravindra Aglave
Director - Chemical Processing
Karin Frojd
Sabine Goodwin
Director, Product Marketing