Research Papers

Numerical Analysis of Flow Fields and Temperature Fields in a Regenerative Heating Furnace for Steel Pipes

[+] Author and Article Information
Yi Han, Xin Ran

National Engineering Research Center for
Equipment and Technology of Cold Rolling Strip,
Yanshan University,
Qinhuangdao 066004, China

Feng Liu

National Engineering Research Center for
Equipment and Technology of Cold Rolling Strip,
Yanshan University,
Qinhuangdao 066004, China
e-mail: angle-jingjing@qq.com

1Corresponding author.

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF THERMAL SCIENCE AND ENGINEERING APPLICATIONS. Manuscript received March 21, 2017; final manuscript received August 27, 2017; published online March 28, 2018. Assoc. Editor: Srinath V. Ekkad.

J. Thermal Sci. Eng. Appl 10(3), 031010 (Mar 28, 2018) (10 pages) Paper No: TSEA-17-1085; doi: 10.1115/1.4038702 History: Received March 21, 2017; Revised August 27, 2017

In the production process of large-diameter seamless steel pipes, the blank heating quality before roll piercing has an important effect on whether subsequently conforming piping is produced. Obtaining accurate pipe blank heating temperature fields is the basis for establishing and optimizing a seamless pipe heating schedule. In this paper, the thermal process in a regenerative heating furnace was studied using fluent software, and the distribution laws of the flow field in the furnace and of the temperature field around the pipe blanks were obtained and verified experimentally. The heating furnace for pipe blanks was analyzed from multiple perspectives, including overall flow field, flow fields at different cross sections, and overall temperature field. It was found that the changeover process of the regenerative heating furnace caused the temperature in the upper part of the furnace to fluctuate. Under the pipe blanks, the gas flow was relatively thin, and the flow velocity was relatively low, facilitating the formation of a viscous turbulent layer and thereby inhibiting heat exchange around the pipe blanks. The mutual interference between the gas flow from burners and the return gas from the furnace tail flue led to different flow velocity directions at different positions, and such interference was relatively evident in the middle part of the furnace. A temperature “layering” phenomenon occurred between the upper and lower parts of the pipe blanks. The study in this paper has some significant usefulness for in-depth exploration of the characteristics of regenerative heating furnaces for steel pipes.

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Fig. 5

Inlet structure: (a) cross section of honeycomb and (b) cross section of perforated brick

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Fig. 4

Schematic diagram of gridding of the heating furnace

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Fig. 3

Diagram of burner structure of the heating furnace. 1—air burner; 2—coal gas burner; 3—cellular regenerator; 4—perforated brick; 5—coal gas passage; 6—air passage: (a) cutaway side view and (b) top view.

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Fig. 2

Single regenerative heating cycle: (a) phase 1 and (b) phase 2

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Fig. 1

Schematic diagram of the heating furnace. 1—left burners; 2—right burner; 3—furnace door; 4—inside of furnace chamber; 5—air passage; 6—coal gas passage; 7—backing brick: (a) top view, (b) front view, (c) external view, and (d) internal burner nozzle.

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Fig. 8

Contour diagrams of velocity fields at planes of different positions perpendicular to the X axis: (a) X = −2230, (b) X = −1250, (c) X = 270, and (d) X = 1740

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Fig. 6

Diagram of the flow field in the heating furnace: (a) flow diagram and (b) side view

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Fig. 7

Coordinate system for the heating furnace: (a) top view of heating furnace and (b) side view of heating furnace

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Fig. 11

Temperature fields of combustion at burners in the heating furnace. 1: low-temperature zone at the lower part of the furnace wall; 2: low-temperature zone at the lower part of the flame plane: (a) combustion at right burners and (b) combustion at left burners.

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Fig. 9

Velocity vectors at different planes perpendicular to the X axis: (a) X = −2230, (b) X = −1250, (c) X = 270, and (d) X = 1740

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Fig. 10

Contour diagrams of the flow field at different positions perpendicular to the Y axis: (a) Y = 1370, (b) Y = 2840, (c) Y = 4310, and (d) Y = 5780

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Fig. 20

Comparison between simulation data and measured data for the furnace top: (a) position of thermocouple 1, (b) position of thermocouple 2, (c) position of thermocouple 3, and (d) position of thermocouple 4

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Fig. 12

Schematic diagram of position and number of pipe blanks: (a) front view of heating furnace and position of cross section and (b) schematic diagram of the cross section of heating furnace and the position, number, and size of pipe blanks

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Fig. 13

Schematic diagram of points taken around pipe blanks

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Fig. 14

Diagrams of temperature rise and temperature difference at three upper points of different pipe blanks: (a) pipe blank 1, (b) pipe blank 2, (c) pipe blank 3, and (d) pipe blank 4

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Fig. 15

Comparison of temperature at middle point 4 among pipe blanks

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Fig. 16

Comparison of temperature in upper and lower parts of pipe blanks: (a) pipe blank 1, (b) pipe blank 2, (c) pipe blank 3, and (d) pipe blank 4

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Fig. 17

Extraction of onsite data from the heating furnace

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Fig. 18

Positions and mark numbers of thermocouples: (a) furnace top and (b) furnace side wall

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Fig. 19

Comparison between thermocouple measured values and calculated values: (a) middle part of pipe blank and (b) furnace side wall



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