Simulation and experimental research on uniform heating of roller-hearth furnace with oxygen-enriched pulse combustion
In order to achieve sustainable development of the ceramic industry, it is necessary to ensure the quality of product firing under the premise of energy saving and consumption reduction. This study presents the development of an oxygen-enriched pulse combustion test system for roller kilns, designed...
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Elsevier
2025-07-01
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| Series: | Fuel Processing Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S0378382025000372 |
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| author | Pengjin Chen Meng Sui Shuang Wang Fashe Li |
| author_facet | Pengjin Chen Meng Sui Shuang Wang Fashe Li |
| author_sort | Pengjin Chen |
| collection | DOAJ |
| description | In order to achieve sustainable development of the ceramic industry, it is necessary to ensure the quality of product firing under the premise of energy saving and consumption reduction. This study presents the development of an oxygen-enriched pulse combustion test system for roller kilns, designed to regulate the flow of fuel and combustion gas at varying oxygen concentrations (21 %, 24 %, 27 %, and 30 %) using a continuous wave function. The pulse combustion tests, which involved multiple variations in amplitude and period, were complemented by simulations of the flow and temperature fields within the kiln using Ansys Fluent. The results demonstrated that the highest energy savings were achieved at an oxygen concentration of 30 %, with reductions of approximately 52 % and 36 % in energy consumption during the warming and constant temperature phases, respectively. Under conditions of low amplitude and long period (A = 30, T = 135), the temperature uniformity of the JFCC thermos block within the furnace was improved by 55 %. The pulsed combustion process was found to extend the diffusion period of the return vortex, thereby increasing the strength of the vortex ring and enhancing the churning capability of the kiln airflow. Oxygen-enriched pulse combustion facilitated the distribution of heat from localized high-temperature zones throughout the furnace by increasing the period and decreasing the amplitude, thereby reducing temperature stratification. This study effectively addresses the issue of uneven temperature distribution caused by oxygen-enriched combustion in roller kilns. |
| format | Article |
| id | doaj-art-208d9e45a46c40239a4d15a5d39224a2 |
| institution | DOAJ |
| issn | 0378-3820 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Fuel Processing Technology |
| spelling | doaj-art-208d9e45a46c40239a4d15a5d39224a22025-08-20T02:55:13ZengElsevierFuel Processing Technology0378-38202025-07-0127210821310.1016/j.fuproc.2025.108213Simulation and experimental research on uniform heating of roller-hearth furnace with oxygen-enriched pulse combustionPengjin Chen0Meng Sui1Shuang Wang2Fashe Li3Yunnan Key Laboratory of Clean Energy and Energy Storage Technology, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China; Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR ChinaYunnan Key Laboratory of Clean Energy and Energy Storage Technology, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China; Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China; State Key Laboratory of Complex Nonferrous Metal Resources Clean Utilization, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China; Corresponding authors at: Yunnan Key Laboratory of Clean Energy and Energy Storage Technology, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China.Yunnan Key Laboratory of Clean Energy and Energy Storage Technology, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China; Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China; Corresponding authors at: Yunnan Key Laboratory of Clean Energy and Energy Storage Technology, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China.Yunnan Key Laboratory of Clean Energy and Energy Storage Technology, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China; Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR China; State Key Laboratory of Complex Nonferrous Metal Resources Clean Utilization, Kunming University of Science and Technology, Kunming 650093, Yunnan, PR ChinaIn order to achieve sustainable development of the ceramic industry, it is necessary to ensure the quality of product firing under the premise of energy saving and consumption reduction. This study presents the development of an oxygen-enriched pulse combustion test system for roller kilns, designed to regulate the flow of fuel and combustion gas at varying oxygen concentrations (21 %, 24 %, 27 %, and 30 %) using a continuous wave function. The pulse combustion tests, which involved multiple variations in amplitude and period, were complemented by simulations of the flow and temperature fields within the kiln using Ansys Fluent. The results demonstrated that the highest energy savings were achieved at an oxygen concentration of 30 %, with reductions of approximately 52 % and 36 % in energy consumption during the warming and constant temperature phases, respectively. Under conditions of low amplitude and long period (A = 30, T = 135), the temperature uniformity of the JFCC thermos block within the furnace was improved by 55 %. The pulsed combustion process was found to extend the diffusion period of the return vortex, thereby increasing the strength of the vortex ring and enhancing the churning capability of the kiln airflow. Oxygen-enriched pulse combustion facilitated the distribution of heat from localized high-temperature zones throughout the furnace by increasing the period and decreasing the amplitude, thereby reducing temperature stratification. This study effectively addresses the issue of uneven temperature distribution caused by oxygen-enriched combustion in roller kilns.http://www.sciencedirect.com/science/article/pii/S0378382025000372Oxygen enriched pulseUniform heatingEnergy conservationRoller conveyor kilns |
| spellingShingle | Pengjin Chen Meng Sui Shuang Wang Fashe Li Simulation and experimental research on uniform heating of roller-hearth furnace with oxygen-enriched pulse combustion Fuel Processing Technology Oxygen enriched pulse Uniform heating Energy conservation Roller conveyor kilns |
| title | Simulation and experimental research on uniform heating of roller-hearth furnace with oxygen-enriched pulse combustion |
| title_full | Simulation and experimental research on uniform heating of roller-hearth furnace with oxygen-enriched pulse combustion |
| title_fullStr | Simulation and experimental research on uniform heating of roller-hearth furnace with oxygen-enriched pulse combustion |
| title_full_unstemmed | Simulation and experimental research on uniform heating of roller-hearth furnace with oxygen-enriched pulse combustion |
| title_short | Simulation and experimental research on uniform heating of roller-hearth furnace with oxygen-enriched pulse combustion |
| title_sort | simulation and experimental research on uniform heating of roller hearth furnace with oxygen enriched pulse combustion |
| topic | Oxygen enriched pulse Uniform heating Energy conservation Roller conveyor kilns |
| url | http://www.sciencedirect.com/science/article/pii/S0378382025000372 |
| work_keys_str_mv | AT pengjinchen simulationandexperimentalresearchonuniformheatingofrollerhearthfurnacewithoxygenenrichedpulsecombustion AT mengsui simulationandexperimentalresearchonuniformheatingofrollerhearthfurnacewithoxygenenrichedpulsecombustion AT shuangwang simulationandexperimentalresearchonuniformheatingofrollerhearthfurnacewithoxygenenrichedpulsecombustion AT fasheli simulationandexperimentalresearchonuniformheatingofrollerhearthfurnacewithoxygenenrichedpulsecombustion |