Zone modelling of the thermal performances of a large-scale bloom reheating furnace

This paper describes the development and comparison of a two- (2D) and three-dimensional (3D) mathematical models, based on the zone method of radiation analysis, to simulate the thermal performances of a large bloom reheating furnace. The modelling approach adopted in the current paper differs from previous work since it takes into account the net radiation interchanges between the top and bottom firing sections of the furnace and also allows for enthalpy exchange due to the flows of combustion products between these sections. The models were initially validated at two different furnace throughput rates using experimental and plant's model data supplied by Tata Steel. The results to-date demonstrated that the model predictions are in good agreement with measured heating profiles of the blooms encountered in the actual furnace. It was also found no significant differences between the predictions from the 2D and 3D models. Following the validation, the 2D model was then used to assess the impact of the furnace responses to changing throughput rate. It was found that the potential furnace response to changing throughput rate influences the settling time of the furnace to the next steady state operation. Overall the current work demonstrates the feasibility and practicality of zone modelling and its potential for incorporation into a model based furnace control system. (C) 2012 Elsevier Ltd. All rights reserved.