Ferrand, Ludovic (2003) Modélisation et expérimentation des fours de réchauffage sidérurgiques équipés de brûleurs régénératifs à Oxydation sans Flamme. PhD thesis Energétique, CENERG- Centre d'Energétique, ENSMP p.210.

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Abstract

Ces travaux ont pour objectif d'étudier l'intégration d'une technologie de combustion récente, les brûleurs régénératifs à Oxydation sans Flamme, sur les fours de réchauffage sidérurgiques. La modélisation numérique a été utilisée pour étudier les enceintes équipées de tels brûleurs. Un accent particulier a été porté sur la validation expérimentale des modèles. L'outil CFD a d'abord permis d'étudier finement les caractéristiques de la combustion. Les modèles de fermeture ont d'abord été pré-sélectionnés. Le modèle a ensuite été confronté à des mesures de vitesses, espèces chimiques et températures dans la flamme pour choisir définitivement les modèles les plus adéquats.Une méthodologie de simplification a ensuite été mise en place pour optimiser le ratio précision / temps de calcul du modèle CFD, dans l'optique d'étudier les enceintes multi-brûleurs. Cette approche a été validée par rapport au modèle CFD détaillé.Enfin la simulation des régimes transitoires, essentielle dans l'analyse des performances des fours, a été traitée par une approche nodale, consistant à représenter les éléments du système sous la forme d'un réseau de composants simples. Les phénomènes physiques sont inclus dans les échanges entre les composants du réseau par l'intermédiaire d'une conductance dépendant du mode de transfert. Cette formulation rend la résolution des transferts radiatifs compatible avec la méthode zonale. Les facteurs d'échange radiatifs ont été calculés par le logiciel MODRAY. Un régulateur a également été inclus dans le modèle. Le réseau a été décrit et résolu sous l'environnement THERMETTE. Des essais à l'échelle semi-industrielle ont permis de valider ce modèle nodal.

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NOH-2001 D.S.NOH, S.K.HONG, H.S.RYOU, S.H.LEE

An experimental and numerical study on thermal performance of a regenerator system with ceramic honeycomb , KSME International Journal, 2001, vol. 15, n° 3, pp. 357-365.

NSO-2001 E.C.NSOFOR, G.A.ADEBIYI

Measurements of the gas-particle convective heat transfer coefficient in a packed bed for high-temperature energy storage , Exp. Thermal and Fluid Science, 2001, vol. 24, pp. 1-9.

PAR-2003 P.M.PARK, H.C.CHO, H.D.SHIN

Unsteady thermal flow analysis in a heat regenerator with spherical particles , Int. J. Energy Research, 2003, vol. 27, n°2, pp. 161-172.

PAT-1980 S.V.PATANKAR

Numerical Heat Transfer and Fluid Flow , MacGraw-Hill, New York, 1980.

PES-2001 B.PESENTI, P.EVRARD, P.LYBAERT

NOx Production and radiative heat transfer from an autoregenerative flameless oxidation burner , 4th Symposium on High Temperature Air Combustion and Gasification, Rome, 2001.

PET-1995 A.A.F.PETERS, R.WEBER

Mathematical modelling of a 2.25MWt swirling natural gas flame. , Combust. Sci. and Tech., 1995, vol. 110, pp. 67-101.

PIE-1999a L.PIERROT, P.RIVIERE A.SOUFIANI, J.TAINE

A fictitious-gas-based absorption distribution function global model for radiative transfert in hot gases , J. of Quantitative Spectroscopy & Radiative Transfer, 1999, vol. 62, pp. 609-624.

PIE-1999b L.PIERROT, A.SOUFIANI, J.TAINE

Accuracy of narrow-band and global models for radiative transfer in H2O, CO2, and H2O-CO2 mixtures at high temperature , J. of Quantitative Spectroscopy & Radiative Transfer, 1999, vol. 62, pp. 523-548.

PIE-2001 O.PIEPERS, P.P.BREITHAUP, A.B.N.VAN BEELEN

Stability of flames close to auto-ignition temperatures generated by extreme separated gas-air inlets , ASME J. of Energy Resources Technology, 2001, vol. 123, pp. 50-58.

PLE-1998 T.PLESSING, N.PETERS, J.G.WUNNING

Laseroptical investigations of highly preheated combustion with strong exhaust gas recirculation , 27th International Sympsosium on Combustion / The Combustion Institute, 1998, pp. 3197-3204.

PEU-1990 B.PEUPORTIER, I.BLANC-SOMMEREUX

Simulation tool with its expert interface for the thermal design of multizone buildings , International Journal of Solar Energy, 1990, vol. 8, pp. 109-120.

QUI-1998 A.QUINQUENEAU, P.F.MIQUEL, L.M.DEARDEN, M.POURKASHANIAN, G.T.SPENCE, A.WILLIAMS, B.J.WILLS

Experimental and theoretical investigation of a low-NOx high temperature industrial burner , International Gas Research Conference, 1998, pp. 225-236.

QUI-2001 A.QUINQUENEAU, A.TOUZET, M.OGER

Experimental studies on regenerative industrial burners operating in the flameless oxidation mode , 13th IFRF Member's Conference, 16-18 mai 2001.

RAD-2002 Z.R.RADAKOVIC, V.M.MILOSEVIC, S.B.RADAKOVIC

Application of temperature fuzzy controller in an indirect resistance furnace , Applied Energy, 2002, vol. 73, pp. 167-182.

RAI-1990 G.D.RAITHBY, E.H.CHUI

A finite-volume method for predicting a radiant heat transfer in enclosures with participating media , ASME Journal of Heat Transfer, 1990, vol. 112, pp. 415-423.

RAY-1996 M.RAYNAUD

Le problème inverse de conduction de la chaleur. , Techniques de l'Ingénieur, traité Génie Energétique, 1996, n° BE8265.

REE-2001 J.S.REES, P.HAVES

A nodal model for displacement ventilation and chilled ceiling systems in office spaces , Building and Environment, 2001, vol. 36, n°6, pp. 753-762.

RHI-1991 J.M.RHINE, R.J.TUCKER

Modelling of Gas-Fired Furnaces and Boilers , McGraw Hill, 1991, 444 p.

RIC-1998 J.RICHALET

Pratique de l'identification , Ed. Hermès, collection Automatique, 2mathrmeme éd., Paris, 1998, 222 p.

RIG-2001 K.RIGBY, T.LIBUDA, A.KLATT, J.ZURBIG

SCR: the most effective technology for NOx reduction in large combustion plants , Proceedings de NOXCONF 2001: La Pollution Atmosphérique d'Origine Industrielle, Paris, 21-22 mars 2001.

ROM-1988 F.E.ROMIE, B.S.BACLIC

Methods for rapid calculation of the operation of asymmetric counterflow regenerators , ASME J. Heat Transfer, 1988, vol. 110, pp. 785-788.

ROM-1990 F.E.ROMIE

A table of regenerator effectiveness , ASME J. Heat Transfer, 1990, vol. 112, pp. 497-499.

ROM-1999 Combustion Science and Technology for sustainable Development - Italian Flame Days - Rome, Italie, 16-18 novembre 1999.

ROM-2001 4th Symposium on High Temperature Air Combustion and Gasification, Rome, Italie, 26-30 novembre 2001.

ROY-2001a D.ROY

Evaluation de l'impact de technologies de préconditionnement thermique d'un habitacle automobile sur la consommation en carburant ainsi que sur le confort thermique des passagers. ,

Thèse de Doctorat, Ecole des Mines de Paris, 2001.

ROY-2001b D.ROY, K. EL KHOURY, D.CLODIC, C.PETITJEAN

Modeling of in-vehicule heat transfers using zonal approach. , Society of Automotive Engineers, 2001, paper n°2001-01-288.

RUI-1995 R.RUIZ, S.DROGUE, H.ABBASI, J.WAGNER

Oscillating combustion: an innovative NOx emissions control approach. , Documents du Congrès International de la Recherche Gazière, Cannes, 6-9 novembre 1995, pp. 433-440.

SAU-1981 J.B.SAULNIER, A.ALEXANDRE, J.MARTINET

L'utilisation des logiciels en modélisation thermique. Deux exemples d'application. , Revue Générale de Thermique, 1981, n°230.

SAU-1985 J.B.SAULNIER, A.ALEXANDRE

La modélisation thermique par la méthode nodale: ses principes, ses succès et ses limites , Revue Générale de Thermique, 1985, n°280.

SCH-2001 F.SCHMITT, B.K.HAZARIKA, C.HIRSCH

LDV Measurements of the flow field in the nozzle region of a confined double annular burner , ASME Journal of Fluids Engineering, 2001, vol. 123, pp. 228-236.

SEL-1976 N.SELCUK, R.G.SIDDAL, J.M.BEER

A comparison of mathematical models of the radiative behaviour of a large-scale experimental furnace , 16th Symp. (Int.) on Combustion, The Combustion Institute, 1976, pp. 53-62.

SEL-1997 N.SELCUK, N.KAYACOL

Evaluation of discrete ordinates method for radiative transfer in a rectangular furnace ,

Int. J. Heat Mass Transfer, 1997, vol. 40, n°2, pp. 213-222.

SEN-1998 S.SENNÉ

Modélisation globale des échanges thermiques dans un compartiment moteur de véhicule automobile ,

Thèse de Doctorat, Ecole des Mines de Paris, 1998, 224 p.

SID-1986 R.G.SIDDALL

Accurate evaluation of radiative direct-exchange areas for rectangular geometries ,

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SIE-1992 R.SIEGEL, J.R.HOWELL

Thermal radiation heat transfer ,

3 rd edition, Taylor & Francis, 1992.

SLO-1986 D.G.SLOAN, P.J.SMITH, L.D.SMOOT

Modeling of swirl in turbulent flow systems ,

Progress in Energy and Combustion Science, 1986, vol. 12, pp. 163-250.

SMI-1982 T.F.SMITH, Z.F.SHEN, J.N.FRIEDMAN

Evaluation of coefficients for the weighted sum of gray gases model , ASME J. Heat Transfer, 1982, vol. 104, pp. 602-608.

SON-1993 T.H.SONG

Comparison of engineering models of non-gray behaviour of combustion products , Int. J. Heat Mass Transfer, 1993, vol. 36, n°16, pp. 3975-3982.

SOR-1956 W.W.SOROKA

Analog methods in computation and simulation , Ed. McGraw Hill, 1954, 390 p.

SOU-1994 A.SOUFIANI, E.DJAVDAN

A comparison between weighted sum of gray gases and statistical narrow-band radiation models for combustion applications , Combustion and Flame, 1994, vol. 97, n°2, pp. 240-250.

SOU-1997 A.SOUFIANI, J.TAINE

High temperature gas radiative property parameters of statistical narrow-band model for H2O, CO2 and CO, and correlated-K model for H2O and CO2 , Int. J. Heat Mass Transfer, 1997, vol. 40, pp. 987-991.

SOU-2002 J.A.SOUSA, S.C.CORREIA, J.WARD, M.NOGUEIRA

A transient, multi-dimensional, zone model of a roller kiln used for firing ceramic tiles , 6th European Conf. on Industrial Furnaces and Boilers, Estoril, Portugal, 2-5 avril 2002.

STO-2000 2nd International Seminar on High Temperature Combustion in Industrial Furnaces, Stockholm, Sweden, 17-18 janvier 2000.

STR-2002 J.STROHLE, P.J.COELHO

On the application of the exponential wide band model to the calculation of radiative heat transfer in one- and two-dimensional enclosures , Int. J. Heat Mass Transfer, 2002, vol. 45, pp. 2129-2139.

STR-2002b J.STROHLE, P.J.COELHO, U.SCHNELL, K.R.G.HEIN

A non-grey radiation model for the simulation of coal-fired furnaces , 6th European Conf. on Industrial Furnaces and Boilers, Estoril, Portugal, 2-5 avril 2002.

SUG-1999 S-I.SUGIYAMA, T.ISHII, M.ISHIOKA, Y.HINO, T.OKAWA

Schedule-free heating in preheating furnace , NKK Technical Review, 1999, n° 80.

SUZ-1997 Y.SUZUKAWA, JS.SUGIYAMA, Y.HINO, M.ISIOKA, I.MORI

Heat transfer improvement and NOx reduction by highly preheated air combustion , Energy Convers. Mgmt., 1997, vol. 38, n° 10-13, pp. 1061-1071.

SUZ-1999 Y.SUZUKAWA, J.TAKAHASHI, M.UCHIO, Y.HINO, T.TAKAHARA, T.TADA

Application of direct-fired regenerative burners to a large-scale reheating furnace , NKK Technical Review, 1999, n° 80.

TAB-2001 D.TABACCO

Studio teorico e numerico sulla "Flameless Oxydation" , Master Thesis, University of Rome "La Sapienza", 2001, 357 p.

TAI-1999 2nd International High Temperature Air Combustion Symposium, Koahsing, Taïwan, 1999.

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The total emissivities of luminous and non-luminous flames , Int. J. Heat Mass Transfer, 1974, vol. 17, pp. 1591-1605.

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Direct exchange areas for calculating radiation transfer in rectangular furnaces , ASME J. Heat Transfer, 1986, vol. 108, pp. 707-710.

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Mathematical modelling of heat transfer in a gas-fired reheating furnace operating under non-steady state conditions , Proc. 9th Int. Heat Transfer Conf., Jerusalem, Israël, 1990, vol. 6, pp. 221-226.

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Simulation of regenerative burner system and its application to walking beam reheat furnaces , Iron and Steel Engineer, 1999, vol. 76, pp. 68-71.

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Turbulent combustion modelling , Prog. in Energy and Comb. Science, 200

Table of content

Avant-propos i

Table des matières ii

Table des figures v

Liste des tableaux xii

Liste des abréviations xiii

Liste des notations xvi

Introduction 1

1 - Les méthodes de réduction des polluants atmosphériques émis par les grandes installations de combustion - 3

1.1 Enjeux - 3

1.2 Les fours de réchauffage sidérurgiques - 4

1.2.1 Description anatomique des fours - 4

1.2.2 Description des brûleurs industriels conventionnels - 7

1.3 Les techniques d'amélioration des performances des fours - 9

1.3.1 Réduction de la consommation énergétique - 9

1.3.2 Réduction des émissions de NOx - 12

1.4 L'Oxydation sans Flamme - 17

1.4.1 Historique - 17

1.4.2 Description de la technique - 18

2 Modélisation fine d'un brûleur à Oxydation sans Flamme et validation expérimentale - 23

2.1 Objectifs / Méthodologie - 23

2.2 Pré-sélection des modèles de fermeture - 24

2.2.1 Modélisation de la turbulence - 25

2.2.2 Modélisation du rayonnement - 33

2.2.3 Modélisation de la combustion - 40

2.3 Validation expérimentale par des mesures dans la flamme - 44

2.3.1 Dispositif expérimental - 44

2.3.2 Mise en œuvre de la simulation - 47

2.3.3 Confrontation expérimentale: bilan thermique - 51

2.3.4 Confrontation expérimentale: champ de vitesse - 53

2.3.5 Confrontation expérimentale: espèces chimiques - 54

2.3.6 Confrontation expérimentale: champ de température - 55

2.3.7 Choix des modèles - 56

2.4 Simplification de la représentation du brûleur - 58

2.4.1 Simplification des écoulements - 58

2.4.2 Simplification de la combustion - 62

2.4.3 Validation du modèle simplifié - 64

2.4.4 Optimisation du compromis précision / temps de calcul - 70

2.5 Synthèse et conclusions - 73

3 Modélisation nodale d'un four de réchauffage sidérurgique et validation sur un four prototype à l'échelle semi-industrielle - 75

3.1 Enjeux et choix de la stratégie de modélisation - 75

3.2 Développement d'un modèle nodal 3D instationnaire - 78

3.2.1 Description du solveur thermique THERMETTE® - 78

3.2.2 Représentation des éléments du four - 79

3.2.3 Contrôle/Commande - 87

3.2.4 Calcul des échanges radiatifs - 89

3.2.5 Architecture globale du modèle - 99

3.3 Description des essais sur un four prototype - 103

3.3.1 Objectifs - 103

3.3.2 Description du four d'essais - 103

3.3.3 Plan d'expérience - 114

3.3.4 Contrôle/Commande - 114

3.3.5 Résultats de la campagne d'essais - 118

3.3.6 Conclusions - 126

3.4 Validation expérimentale du modèle nodal - 127

3.4.1 Mise en œuvre du modèle du four prototype - 127

3.4.2 Etude de sensibilité - 135

3.4.3 Validation expérimentale - 142

3.5 Synthèse et conclusions - 159

Conclusions et perspectives 160

A Conversion des unités d'émissions de NOx 165

B Calcul de l'interaction entre jets 167

C Calcul des chaleurs massiques des espèces chimiques 171

D Confrontation des résultats du modèle CFD détaillé aux mesures effectuées dans la flamme 173

E Interface utilisateur développée pour le modèle nodal 181

F Composition des parois du four prototype 185

G Caractéristiques thermophysiques de l'acier BISRA n°1 187

H Calcul du bilan thermique `a partir des données expérimentales 189

I Calcul de la température de paroi par méthode inverse 191

Bibliographie 194

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