Eckehard Specht

CFD (computational fluid dynamics) simulation using a commercial package (Fluent-ANSYS) on industrial rotary kilns using annulus-type burners and methane gas was carried out to examine the characteristics of the flame length and flow visualization. New influencing design and operating parameters—primary air swirl number, primary air inlet annulus diameter, and secondary air temperature—were investigated and discussed. The influence of these parameters on axial temperature distribution, axial mean mixture fractions, velocity vectors, mixture fractions, and temperature contours were investigated. The current numerical findings were compared with existing experimental results to validate the simulation approach. The results showed that the primary air swirl number had a remarkable influence on the flame length at a lower primary air inlet annulus diameter ratio of 2.3. Moreover, the flame length increased by 20% and 6% with increasing the swirl number from zero to one for primary air inlet annulus diameter ratios of 2.3 and 5, respectively, and it also increased by 19% with increasing primary air inlet annulus diameter ratio from 2.3 to 5.

A model has been developed that describes the dependence of the moisture diffusion coefficient on the water fraction. Until the end of shrinkage has been achieved, the moisture diffusion coefficient is proportional to the second power of the water fraction. Due to shrinkage, the relevant capillary spaces available for water transport become smaller. Consequently, the moisture diffusion coefficient decreases continually. After the end of shrinkage, the flow resistance to the water moving toward the surface increases sharply due to penetrating air. This leads to a steep drop of the moisture diffusion coefficient by several powers of ten. Measurements were carried out with specimens of defined geometry to determine the moisture diffusion coefficient. On the basis of a specified limiting value, the model is capable of calculating the moisture diffusion for all initially specified raw materials moistures. The moisture can also be determined if the degree of drying shrinkage is known. Using the determined moisture diffusion coefficient, the first and the second drying section can be located. Drying tests were carried out in a laboratory dryer and the experimental results obtained were compared to the simulation results. The simulation results are in good agreement with the experimental results.

A complex thermomechanical model for simulating the transient fields of the temperature, microstructure, stress, strain, and displacement during quenching of steel profiles is introduced. The thermoplastic material model is formulated on the basis of J2-plasticity theory with a temperature- and phase fraction-dependent yield limit. Coupling effects such as dissipation, phase transformation enthalpy, and transformation-induced plasticity are considered. The validity of the model is verified by comparing the simulation results with available experimental measurements. The introduced model serves as a basis for optimizing the cooling conditions for reducing residual stresses and distortions. The simulation results for T and L profiles of two different types of steel are described.