CFD Simulation of industrial furnaces

For the creation or optimization of your furnace system

Technically sophisticated furnace solutions using CFD simulations - we offer model-based process and design optimization for high-performance products.

This has several advantages:

• optimization of the operating condition of your thermal process
• functional test of innovative ideas for your production furnace
• development and presentation of your customized production plant by ONEJOON

Computer-aided calculation methods have become increasingly important over the years. ONEJOON integrates the latest flow simulation methods into the comprehensive technical and practical company know-how. Thanks to CFD simulation, we develop very efficient, realistic and fail-safe thermal processes and an optimal furnace design.

Due to our well-founded CFD flow simulation expertise, we provide you with tailor-made furnace solutions for your challenges. Let us unleash the full potential of your process!

Advantages of CFD simulation by ONEJOON

Fail-safe and extensively validated simulation models

In order to meet our high standards, ONEJOON engineers consistently perform the following iterative process:

• We first create a simulation model in accordance with the design and specify boundary conditions.
• The model is meshed with a suitable computational grid and tested.
• The results are checked for plausibility and convergence.
• Subsequently the results of the simulation are compared with reality.
  For this purpose we use our test facilities and test setups in our ONEJOON test center in Bovenden, Germany, equipped with state-of-the-art measuring technology. If necessary we develop unconventional test setups.
• We critically compare the measurement results from the test with the results of the simulation.
• In this way we continuously improve our algorithms, boundary conditions and models.

Product development of furnace systems

CFD simulation for redesigning and optimizing industrial furnaces

Simulation can, in principle, be used to redesign products and processes as well as optimize and further develop existing plants.

The path to the new product

The product specification is decisive when developing a new product idea, as it allows possible process variants to be narrowed down in advance. In a first step, design studies are defined in cooperation with various experts from the relevant competence areas. These studies are then used to provide initial insights into the subsequent process. Having a complex system with conditions that are difficult to access, it is possible to develop test setups in our in-house Test Center. This helps us to understand the process flows more precisely and derive model parameters for the simulation. Models that already have been validated allow the results of the design study to be directly transferred to the final product design.

Optimization of existing furnace systems with CFD simulations

If the process of an already existing product has to be changed or optimized, the first step is to determine which variables have to be optimized. The quality of product optimization considerably depends on how accurately the status quo can be reproduced and the variables to be optimized can be determined. If this operation is successful, a virtual optimization can be performed in the next step using CFD simulation. If the results of the optimization show the desired improvements, the necessary technical modifications can be implemented and realized.

Customized and optimized industrial furnaces

Portfolio

• detailed prediction of flow fields in industrial furnaces or piping systems/fittings
• validated pressure loss calculations in the overall system
• sound fluid-mechanical and thermal evaluation of innovative process ideas or existing plants
• targeted flow optimization for optimal transfer of heat to the product
• precise, local detection of flow- or temperature-critical furnace areas
• realistic modeling of chemical reactions in the furnace chamber

Competence

• 40 years of industrial furnace construction expertise
• consistent integration of ONEJOON experts with many years of practical experience
• ongoing further development of the simulation models by comparing the CFD results in our in-house Test Center using state-of-the-art measurement technology
• validation of the simulation results based on practical measurements in the field
• outstanding references of cases of successful increase in performance based on past CFD simulations

Advantages

• Increase in efficiency:
  • use of tailor-made furnace technology for the respective application
  • optimization of media consumption
  • avoidance of costly and complex preliminary tests
  • fast and reliable design definition for new developments
  • fast problem analysis and specific solution finding
  • consistent product quality
  • maximization of product throughput

• Better process understanding:
  • higher plant availability
  • greater process control
  • improvement of product quality

Rapid cooling is used for products where the cooling rate has a critical effect on the subsequent microstructure and thus the product properties. Fast and efficient cooling requires correspondingly high gas velocities and impingement flows. Video 1 shows the flow lines of the rapid cooling process in an existing plant. Some of the cooling medium flows past the product and thus does not generate a cooling effect. This problem was remedied by making structural adjustments. The velocity measurements taken above the product show a close correlation between the simulation results and the measurement series.

Video: Flow lines during rapid cooling

Modeling of the heat transfer in a rotary kiln process

Rotary kiln processes enable the homogeneous, thermal treatment of flowable products. Mathematical models have to be used to understand the individual mechanisms in the rotary kiln. Heat is transferred to the bulk material via wall contact, convection and radiation. The internal transfer of heat in the bulk material is also affected by physical properties and process parameters such as speed or filling angle.

Implementation of the latest scientific calculation models enables realistic statements about dwell times and temperature distributions, which in turn results in high product quality.

As predicted by the model , increasing the speed of the rotary drum has a positive effect on the heat transfer to the bulk material. The material system tested here shows a high correlation between simulation and measurement. Simulation can thus be used to select and optimize the most favorable rotary kiln process for the respective customer requirements. 

Flow distribution in the Lift Bottom Kiln

Heat distribution was found to be clearly inhomogeneous in a lift-bottom-kiln for the production of ceramic sintered parts. Simulations were used to first reproduce the current state of the furnace and calculate the flow on the basis of the specified process parameters. The flow lines clearly indicated that considerable sections of the product are insufficiently reached by the flow and lag behind the specified heating rate (see images). By simulating a scenario with modified product stocking, the flow was influenced in a way that increased the efficiency of product heating.

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