An experimental study and 3D simulation of a cast iron rotary

In this study, the computational fluid dynamics (CFD) simulation of an experimental 350 kg cast iron rotary furnace was conducted for the aim of optimizing its fuel consumption and pollutants reduction. The furnace is divided into 3 distinct simulation zones: a) solid charge zone with liquid-solid phase, b) combustion zone with gas phase, and c) solid rotating zone or furnace refractory wall. These three zones are three-dimensionally and transiently modeled in terms of the leading phenomena within each zones and interfaces. The simulation in each region is based on the simultaneous solution of hydrodynamic equations, including vortex dissipation and chemical reaction kinetics equations. The simulation results for the outside wall temperature of the furnace body are in close agreement with the data obtained from experimental units. Furthermore, melting rate, NOx and CO pollutant generation, specific fuel consumption, rotating speed, preheating of combustion air, excess air percentage, and pollutant production were all evaluated in this simulation. Changing the furnace configuration decreases fuel consumption by 5%, which is important in terms of improving fuel consumption and alloy product quality in this furnace.  The results of this study can be used to optimize the industrial rotary furnace operations.