Energy Efficiency Simulations Using Fully Coupled And Controlled Regenerative Furnace Model

Full 3D CFD modeling of glass furnaces is increasingly becoming a standard tool for predictions of energy balance and glass quality. State of the art 3D furnace models usually include energy transfer inside the furnace and between the furnace and surroundings. Real regenerative furnaces are complex systems with complex interactions among regenerators, combustion chambers, glass melt and control systems. To achieve accuracy and realistic response of numerical models of glass furnaces, especially in optimisation studies aimed at energy savings, the models should include all these interactions. GS Glass Furnace Model has been enhanced to have the 3D regenerator model integrated with the furnace model. Thus, changes inside the furnace influence behaviour of regenerators and vice versa. Behaviour of the control system is mimicked too - gas and air flow rates and other inputs are automatically adjusted to maintain specified temperatures at controlled thermocouple locations. An example case study, focused on energy savings, on an industrial size cross-fired regenerative float furnace, is presented. The study demonstrates how the model reacts on changes in furnace design and operating parameters. The cases are compared and differences in energy balance and glass quality are interpreted.