1. Institute of Chemical Engineering page 1 Achema 2012 Thermal Process Engineering EDAB Efficient Dry and Burn Michael Harasek, Andras Horvath Jozsef Nagy, Christian Jordan, Amal El-Gohary michael.harasek@tuwien.ac.at EDAB – Efficient Dry and Burn

2. Institute of Chemical Engineering page 2 Achema 2012 Thermal Process Engineering Goals of the project  Energy balancing of individual and combined processes Run times and cycle times of drying and firing are not equal Reuse of waste energy – high temperature heat exchangers, energy storage  Optimize drying process Reduce losses due to drying cracks  Optimize firing process (tunnel kiln and batch furnace) Reduce cycle time to increase production capacity without investment Reduce specific energy consumption and CO 2 emissions Increase quality by ensuring homogeneous heat distribution  Practical implementation of the suggested improvements on site (Rath GmbH, Krummnußbaum)  Investigation of pore forming agents (TGA/DSC) EDAB – Efficient Dry and Burn

3. Institute of Chemical Engineering page 3 Achema 2012 Thermal Process Engineering EDAB – Efficient Dry and Burn CFD modeling  3D geometry implementation of a small batch high temperature furnace Full resolution of bricks (yellow) and support material (grey/green) Separate simulation of the burners in OpenFOAM and Fluent Simplified methane combustion including radiative heat transfer  Modifications of the geometry of the support material

4. Institute of Chemical Engineering page 4 Achema 2012 Thermal Process Engineering  CFD Simulation of the Furnace Burners using open source CFD tools (OpenFOAM) EDAB – Efficient Dry and Burn CFD model of the burner – contour plot of velocity magnitude in symmetry plane Measurement of the gas flame temperature at different oxygen levels in the primary air Oxygen enrichment – homogeneous atmosphere

5. Institute of Chemical Engineering page 5 Achema 2012 Thermal Process Engineering EDAB – Efficient Dry and Burn b) Numerical Modeling of Firing process (CFD) High Temperature in Process Measurements Cooling Heating Holding Tmax Variation of cooling rate Variation of heating rate CFD model of the furnace contours of gas velocity Optimization Process  CFD modeling – brick and support material positioning, homogeneous flow  Measurements of gas and brick core temperatures  Adaptiation of the burning curve – save time and energy

6. Institute of Chemical Engineering page 6 Achema 2012 Thermal Process Engineering  Targets reached so far Cycle time decreased by 10 % (further potential) Specific energy consumption reduced by 4 % - about 10 % is possible with further optimization Improved quality of the high density bricks due to CFD optimized positioning of the support material EDAB – Efficient Dry and Burn a) b) decreased cycle time (higher capacity) decreased specific energy consumption improved quality (smaller deviation of dimensions)

7. Institute of Chemical Engineering page 7 Achema 2012 Thermal Process Engineering EDAB – Efficient Dry and Burn This project was supported by the Climate and Energy Fund and was performed under the program "NEUE ENERGIEN 2020". Dieses Projekt wurde aus Mitteln des Klima- und Energiefond gefördert und im Rahmen des Programms “NEUE ENERGIEN 2020” durchgeführt. http://www.klimafonds.gv.at