Title: Different Methods Obtained by PHOENICS Simulation to Improve the Performance of Pusher- Type Steel Slab Reheating Furnace Author : Yong Tang Jarmo Laine Timo Fabritus Jouko Härkki Affiliation: Process metallurgy laboratory, PL4300, Oulu University, 90014 Finland Fax: +358 8 553 2339 Tel: +358 8 553 2423 Email: yong.tang@oulu.fi Website: http://cc.oulu.fi/~pometwww/ Date: 6th,June,2002 Computer and operating system used: Intel Pentium 1.7 GHz, 128 RAM, Windows 98 second edition Abstract: Phoenics3.1 was used to simulate the gas temperature and flow velocity distribution in the pusher-type steel slab-reheating furnace Extended Simple Chemically-Reacting System (ESCRS), k-ε model and composite-flux radiation model were included in the numerical computing. Author coded some special boundary conditions in the Phoenics GROUND file. Performance of the reheating furnace in a steel industry company was analysed according to the simulation results. In order to obtain a better heating performance of slab and reduce the possibility of scale accumulation near the lower burner in the heating zone, a block wall was added in front of the burners during the simulation. Contents list: Title and Abstract Target Model Description PHOENICS Settings and Iteration Process Results Verification of the Model Conclusions Reference and Nomenclature Appendix of Q1 and GROUND files Page 1 Page 2 Page 2 Page 6 Page 7 Page 9 Page 9 Page 10 Page 12 1 Target The pusher-type reheating furnace is installed to heat steel plates before they enter the mill. The uniform slab temperature profile is the most concern of the furnace operators. Consequently, it is necessary to understand the temperature distribution and flow type in the furnace. This CFD simulation include two parts: modelling the gas temperature and velocity in the furnace; investigate the gas flow modification while a block wall is built in front of the lower burners in the heating zone. Model Description a. The Structure of the Pusher-Type Furnace The furnace modelled is shown in Fig. 1 and its highest roof is about 6 meters inside. There are eight burners in the soaking zone. In the heating zone, six burners are arranged on the upper side while seven burners are set up on the lower part as shown in the picture. Flows from upper part burners are injected 11o downwards. Coke oven gas is used as the fuel. Since it is symmetric, half of the furnace was simulated. Three-dimensional modeling and Cartesian coordinate is employed in this furnace CFD simulation. Y Z X 8.5 m Fig.1 Schematic of the pusher type slab-reheating furnace The calculation domain is 28.07 metres in z direction, 4.25 metres in x direction and 5.66 metres in y direction. A rectangle grid is chosen, and so the irregular geometry parts of furnace, such as transition between heating zone and convection zone, are simplified by dividing them into several rectangular cuboids. The total number of cells is about 313968=82212,as shown in Fig.2. In the calculation, some cells are blocked according to the structure of the furnace. Supporting pillars are considered in this simulation if compared with previous work done by Maki and Yang[1-3]. 2 Fig.2 Grids of furnace modelled b. Mathematical models applied in this simulation According to the models provided by the PHOENICS3.1 and the real situation of the pusher-type furnace, standard K- model is chosen for the turbulent flow, Extended Simple Chemically-Reacting System (ESCRS) is selected to simulate the combustion and the radiation model is composite-flux. Flow in the furnace is considered as a single phase, steady state, and Newtonian fluid. The following is the simple mathematic descriptions of models mentioned above. Continuity equation: ( u ) 0 Momentum conservation equation: u u g p 2 u f Energy conservation equation: u H (kT ) S h Chemical species conservation equation: u Cl (Cl ) Rl K- equation: e K (u i K ) ( ) ( Pk ) xi xi k xi xi (u i ) (1) (2) (3) (4) (5) e ) (C 1 Pk C 2 ) xi xi K (6) ( The combustion model used is ESCRS in PHOENICS and the reaction is assumed as irreversible, i.e. the rate of the reverse reaction is presumed to be very low [4]. The diffusion coefficients of fuel, oxidant and product are presumed equal to each other, and to the diffusivity of heat. Consequently, their Prandtl/Schmidt numbers are equal, which is a good approximation for turbulent flow. In this reheating furnace, fuel is coke oven gas with component of H2, CO and CH4. (Table 1). The oxidizer is air (21%O2 and 79% N2). The chemical reactions defined as 2 steps 3 reactions finite-rate, are expressed below: 2CH4 O2 2CO 4H 2 (7) 2CO O 2 2CO2 2H 2 O 2 2H 2 O (8) (9) According to the Eddy-Break-Up (EBU) model, this kind of hydrocarbon combustion reaction is assumed rather fast in the furnace and the combustion stage is controlled by the 3 mixing rate of reactant in a turbulent scale. So the reaction rate of the fuel species can be deduced from: R C EBU Min ( M Fu , M O 2 / s ) k (10) The Min (…) argument implies that R is dependent on the species in the shortest supply. Significantly, the reaction rate and further enthalpy source are linked with the momentum and continuity equations mentioned above. The mass fractions of fuel and oxidizer will be obtained from those equations automatically when the fuel input data is added to the model in PHOENICS. Table 1. The composition of gas fuel used in the steel-reheating furnace CO % 7.4 H2 % 54 CH4 % 28 N2 % 10.6 The thermodynamic data of the gas, such as the specific heat and heats of formation, are deduced by the CHEMKIN interface in PHOENICS, while the gas composition and temperature are solved. The composite-flux model of Spalding is chosen [5] for radiation calculation, which has been widely used in combustion chambers and furnaces. The difficult part of radiation calculation is how to treat the radiation angle. There are different ways for such radiation angle discretisation. One method is to divide the radiation direction from arbitrary angles into six directions in Cartesian coordinates, as used in composite-flux model (six-flux). The following assumptions are given for the radiation model: radiation is transmitted in coordinate directions only; no interlinkages, apart from scattering, arise between the radiation fluxes in the respective coordinate directions; the scattering term presumes that the scattering is isotropic with angle, which is probably reasonable only if the total contribution of scattering is not large. Thus, the differential equations describing the variations of the six radiation fluxes in Cartesian coordinates are: dI ( K a K S ) I K a I b K S SUM (11) dy dJ ( K a K S ) J K a I b K S SUM (12) dy dK ( K a K S ) K K a I b K S SUM (13) dz dL ( K a K S ) L K a I b K S SUM (14) dz dM ( K a K S ) M K a I b K S SUM (15) dx dN ( K a K S ) N K a I b K S SUM (16) dx The term SUM in equation (11)-(16) is the average of all the fluxes in the modelled system. For three-dimensions: SUM ( I J K L M N ) / 6 (17) 4 The composite radiation fluxes are defined as: Ry = (I+J)/2 ; Rz = (K+L)/2 ; and Rx = (M+N)/2 (18) The contribution of radiation to the energy equation source terms is given by: S radiation 2 K a R i ,i x , y , z 3I b (19) K a I J K L M N 6 I b The absorption coefficient Ka=0.1, the scattering coefficient Ks=0.1, and the emissivity coefficient of the walls which enters through the boundary conditions, is w=0.85. C. Boundary conditions In the simulation, the slabs are in contact with each other and form a whole block region along the longitudinal direction, as shown in Fig.1. Since the main target is to understand the gas flow and temperature distribution in the reheating furnace, the following boundary conditions should be known before the calculation: surface temperature of slabs, temperature of walls in the furnace, the mass flux (or velocity), temperature and composition of gas flow from the burners. The outlet boundary conditions for the furnace also need to be specified. The surface temperature of slabs was measured in the furnace modelled. Because the furnace is considered steady, the temperature measured at different time can be referred to as the surface temperature of the slabs at different sections along the furnace. The inlet boundary conditions such as mass flux, velocity, chemical composition, enthalpy and turbulent kinetic energy k, dissipation rate can be obtained by certain calculations from the specific inlet gas composition, temperature and mass inflow, which are coded in Phoenics Q1 file. Since the circle inlet is assumed as square, the equivalent length of each square side can be described as follows: D (20) Lsquare ( ) 2 2 Here D is the diameter of the circular inlet; Lsquare is the equivalent length of each square inlet side. The kinetic energy K and dissipation rate are obtained from the equations given below: 3 2 K TInt U (21) 2 3 0.09 0.75 K 2 (22) Lsquare 0.07 2 Where TInt is turbulence intensity, its value is 2% in this furnace simulation. U is the gas velocity from the inlet. The composition of gas fuel has been given in Table 1, and Table 2 provides the burner conditions for the inlet flow. Table 2 Conditions of the burners inlet flow 5 Position of burners Soaking zone Upper heating zone Lower heating zone Number Of burners 8 6 Burner’s Diameter [mm] 380 380 Coke gas [Nm3/h] 900 2200 Air [Nm3/h] 7 300 2100 10800 3800 11200 Flow Velocity [m/s] Uz Uy 4.3 0 10.3 2.0 8.6 0 The temperature of air and coke gas inflow is 350 and 50 Celsius degree separately. There are two outlets (exhaust pipes) in the reheating furnace. In the modelling process the external pressure is assumed to be atmosphere pressure (1.01105 Pa), or the relative pressure is 0 Pa. The discharge door area is about 1.856m2.The estimation relative pressure in the furnace near the discharge door is 0.3 Bar (0.2999105 Pa). The discharge door is assumed be open in the model. Several temperature measurement points are projected in the furnace, which are just near the inside walls. The measured temperature is used as the reference inner surface temperature of wall without further consideration of heat transfer through the wall. The walls in the furnace were divided into several parts. Each part was given an estimated boundary temperature according to the measured value. Since the heat capacity of the gas varies with temperature and composition, the gas enthalpy near the wall is obtained in the Ground file of Phoenics. This method is simply described as follows. The gas component in the furnace includes N2, H2, CH4, H2O and CO2. Their heat capacity, for example CpN2(T), CpH2(T), CpCH4(T), CpH2O(T) and CpCO2(T) , is the function of temperature T. After the composition data of gas near the wall, such as YN2,YH2, YCH4,YH2O and YCO2 are obtained in the iteration process, the heat capacity of gas at temperature T is: Cp gas Cp N 2 YN 2 Cp H 2 YH 2 CpCH 4 YCH 4 Cp H 2O YH 2O CpCO2 YCO2 (23) The enthalpy of gas attached to the boundary wall (gas near the wall), Hgas,wb can be obtained from: H gas,bw Cp gasT H refer H form (24) PHOENICS Settings and Iteration Process Phoenics Version 3.1 of MS-DOS was used in this simulation. a. SATELLITE Please see the appendix1 of Q1 files that satellite read. The satellite module operates in the batch model and stop at the first STOP line. There are no other special requirements for SATELLITE. b. GROUND 6 The thermal boundary conditions are determined in the calculation and coded in the GROUND file as shown in the appendix 2. After the GROUND file is compiled and re-link, private executables (earexe.exe) is created. Type “ run77 earexe” to start private EARTH. c. Iteration More than 2000 sweeps was applied in the iteration for this simulation. Variables, such as P1,KE, EP and H1 use the linear relaxation and , velocity components, chemical species CO, H2 and CH4, use the false step time relaxation. At the beginning of the iteration, the relaxation coefficients are big and then set small values while the iteration proceeding. The number of F-array locations available is about 15 MB. It took more than 12 hours for this calculation in the IBM compatible personal computer with Intel Processor PIV 1.7 GHZ. The convergence is good in the calculation. Errors of all the variables concerned except chemical composition of gas drop three orders during the iteration. (from 104-6 to 101-3). However, the calculation errors of chemical composition of gas only fall 2 orders. When all the values of the monitored spot are not changed significantly, convergence is archived. Several special monitor spots were chosen in the calculation, all the results showed a satisfied convergence. Some calculation grids were modified to study its influence on the simulation results. No significant result changes occur in this kind of modification. Results a. Flow Pattern and Gas Temperature Distribution Fig.3 shows the gas flow pattern and gas temperature distribution along the longitudinal direction, which crosses the burners in the heating zone. Flow pattern obtained in this numerical model is like the type of the physical model carried out by Matsunaga[6]. Reverse flow near the roof close to the burners, exists either in the heating zone or soaking zone. There is also reverse flow in the corner between floor and lower burners wall. However, simulation results indicate that there is a strong reverse flow under the slab and near the lower burners, which did not appear in the water model. This difference owes to the floor step in the current furnace, while bottom floor of heating zone is flat in the previous physical model according to the report. Fig.3 (a) shows that flames from the lower burners slant upwards when they bounce the step of floor in heating zone. Flames of upper burners inject downward because of the burners installation angle. This arrangement of flames is good for the efficient heating and would not overheat the surface of slab. The gas temperature in heating zone is more than 1260 oC except the regions near the convection zone. b. The flow modification when a block wall is installed in the heating zone This CFD simulation results indicate situation could be improved if proper block wall is installed in front of the lower burners in the furnace. Fig.4 (a) is the gas flow distribution in the pusher-type reheating furnace. Fig.4 (b) shows the flow vector of plane x=8 with one block wall in the furnace. Flow patterns modeled suggest that reverse flow strength is weakened when one block wall is installed near the burners in the heating zone. Weak reverse flow is a good sign in reducing scale accumulating near the lower burners. 7 (a) Gas temperature distribution (b) Gas flow pattern in the furnace Fig.3 — Gas flow pattern and temperature along longitudinal furnace (Cross burners in the heating zone) (a) Without block wall (b) With a block wall Fig.4 Gas velocity distribution near the burners in the heating zone 8 Verification Industry verification was carried out in this furnace since there are several measuring points installed in the furnace. Gas temperature close to the flame cannot be measured because the flame temperature injected from the burners is very high and work conditions are serious. More attentions are focused on the mixture gas temperature above the plane of slab, gas temperature near the roof and sidewall. Fig.5 is the comparison of modeled results with measured gas temperature at different positions in the furnace. The head of curve through grids x=17 and y=29 crosses area near roof in soaking zone. The middle part of curve of grids through x=17 and y=39 pass the area near the roof in the heating zone. Tail of curve with grids x=17 and y=30 is near the roof of the convection zone. The results show that calculated gas temperatures in the soaking zone and fore part of the heating zone are very close to the measured values. However, in the transition areas from the heating zone to the convection zone, calculated values are higher than measured gas temperature. Overestimate radiation in these transition areas maybe the reason for this kind of deviation. Although the calculation error for chemical components in the furnace is a little high, comparison between the oxygen distribution in the furnace and modelled oxygen values is implemented. It seems that calculated oxygen near the furnace wall is not so far away from the measured data, as shown in Fig.6. Conclusions Computational fluid dynamics is applied to predict gas flow pattern and temperature distribution in the pusher-type reheating furnace. Since until now available measurements are limited for the details of the gas temperature distribution and flow pattern, CFD simulation plays an important role in the investigation. In the present, momentum, combustion and radiation models are combined together. Results of the model were verified with the plant data. Situations related to heating improvement and reducing reverse flow under the slab near the lower burners is modeled. Fig.5 — Comparison of calculated gas temperature with measured results at different positions in the furnace 9 Fig.6 — Comparison of modeled O2 distribution with measured values in the furnace Reference 1. Anne Mäki: Aihioiden Kuumennusuunin Numeerinen Virtausmallinnus.Lisensiaatintyö,Oulu University,2001 2.Yongxiang Yang, Ari Jokilaakso: Modeling non-isothermal flows and air leakage in a steel reheating furnace. Helsinki University of Technology ,Espoo, Finland, 1997,pp 1-7 3. Anne Mäki, Pekka J.Österman and Matti J.Luomala: Numerical Study of the Pusher type reheating furnace. Scand.J. Metall,2002,Vol.31, pp81-87 4..Combustion. Phoenics Encyclopaedia, online electric manual of Phoenics software, 1997. 5. Radiation. Phoenics Encyclopaedia, online electric manual of Phoenics software, 1997. 6. S.Matsunaga and B.Hiraoka: Transactions ISIJ, 1972,Vol.12, pp.72-78 Nomenclature Cp specific heat at constant pressure C l chemical component fraction of species l D diameter of circle fuel burner in the furnace f momentum source term in momentum governing equation C EBU empirical constant for eddy-break-up model H enthalpy of fluid H refer reference enthalpy of mixture gas at temperature of 298 K H form chemical formation energy of mixture gas with composition derived from iteration I b black-body emissive power at the absolute temperature of mixture gas in the furnace 10 I , J radiation fluxes in the positive and negative y direction, respectively k turbulent kinetic energy of fluid flow K a absorption coefficient of mixture gas in furnace K S scattering coefficient of mixture gas in furnace K, L radiation fluxes in the positive and negative z direction, respectively m fu mass concentration of fuel mO 2 mass fraction of oxygen in the furnace M , N radiation fluxes in the positive and negative z direction, respectively P pressure of fluid in furnace Pk volumetric production rate of k by shear forces Rl source term in chemical concentration conservation equation for species l S h source term in energy conservation equation s stoichiometric requirement for chemical reaction diffusion coefficient of species e kinematics viscosity k , , C 1 , C 2 empirical constant in k Appendix 1: equation Q1 file sample TALK=F;RUN( 1, 1);VDU=VGAMOUSE INTEGER(NPATCH) NPATCH=350 Group 1. Run Title TEXT(Furnace, consider poles) **************************************************************************** Model used: ESCRS(EBU) for combustion, six composite-flux model for radiation, Thermal data obtained by CHENKIM, K-e model for flow ***************************************************************************** **************************************************************************** Define reference pressure (PRESS, a), reference temperature (RTEMP,K), gas mole constant(RGAS,J/(mol*K) **************************************************************************** REAL(RPRESS,RTEMP,RGAS) RPRESS=1.01325*1.0E5;RTEMP=298;RGAS=8.3143 ****Define some pressure in the furnace OPRESS,Pa)************************** REAL(OPRESS) OPRESS=1.0*1.0e5 ********Define the mole mass (g/mol)***************************************** REAL(MO2,MH2,MN2,CH4,MCO,MCH4) MO2=32.00;MH2=2.02;MN2=28.01;MCH4=16.04;MCO=28.01 11 **********Temperature of gas and oxygen******************************** REAL(TFU,TOX) TFU=273+50;TOX=273+350 ******************************************************************** Real variable for coefficients of heat capacity calculation of gas ******************************************************************** REAL(CH4A,CH4B,CH4C,CH4D) ……………………………….(Omitted) ******Methane,CH4, T>298K *************** CH4A=12.447;CH4B=76.689;CH4C=1.448;CH4D=-18.004 **********Carbon monoxide, CO******** COA=25.694;COB=8.293;COC=1.109;COD=-1.477 ******Hydrogen, H2, T<400K************* H2A=16.920;H2B=61.459;H2C=0.590;H2D=-79.559 ****** Hydrogen, H2, T>400K************* H2A2=28.280;H2B2=0.418;H2C2=0.820;H2D2=1.469 *******Nitrogen N2, T<400K************** N2A=29.192;N2B=-1.121;N2C=0.000;N2D=3.092 ***Nitrogen N2,T>400K************ N2A2=22.552;N2B2=13.209;N2C2=23.130;N2D2=-3.389 *****Oxygen************** O2A=31.321;O2B=3.895;O2C=-3.105;O2D=-0.335 *******Calculation of heat capacity of CH4 injected from the inlet***** CCH4=CH4A+CH4B*10**-3*TFU+CH4C*10**5*TFU**-2+CH4D*10**-6*TFU**2 CPCH4=CCH4/MCH4*1e3 *******Calculation of heat capacity of CO injected from the inlet***** CCO=COA+COB*10**-3*TFU+COC*10**5*TFU**-2+COD*10**-6*TFU**2 CPCO=CCO/MCO*1e3 *******Calculation of heat capacity of H2 injected from the inlet***** C1H2=H2A+H2B*10**-3*TFU+H2C*10**5*TFU**-2+H2D*10**-6*TFU**2 CP1H2=C1H2/MH2*1e3 *******Calculation of heat capacity of N2 injected from the inlet,T<400k***** C1N2=N2A+N2B*10**-3*TFU+N2C*10**5*TFU**-2+N2D*10**-6*TFU**2 CP1N2=C1N2/MN2*1e3 *******Calculation of heat capacity of N2 injected from the inlet,T>400k***** C2N2=N2A2+N2B2*10**-3*TOX+N2C2*10**5*TOX**-2+N2D2*10**-6*TOX**2 CP2N2=C2N2/MN2*1e3 *******Calculation of heat capacity of O2 injected from the inlet***** CO2=O2A+O2B*10**-3*TOX+O2C*10**5*TOX**-2+O2D*10**-6*TOX**2 CPO2=CO2/MO2*1e3 ************************************************************************* Calculate the boundary conditions from the inlets of the up burners in the Heating zone ************************************************************************* ************************************************************************** Define the gas volume flow rate from the inlets (m^3/h),fuel and oxygen ************************************************************************** REAL(QFUELy,QOXy) **************** State the variables of volume rate of each component in the gas injected **************** REAL(INCOy,INH2y,INCH4y,INN2y,INO2y) *************************************************************************** 12 State the variables of mass proportion of each component in the gas injected **************************************************************************** REAL(mINCOy,mINH2y,mINCHy,mINN2y,mINO2y,XMy) REAL(WGIy,ABRy,CHECKy) ************ Define the whole flow rate, composition of gas and air in all 6 burners (m3/s) 350 C ************ fuel 2200 (m3/h) CO=7.4, H2=54.0, CH4=28.0, N2=10.6 t-% air 11200 (m3/h) O2=79, N2=21 ****** REAL(xFCOy,xFH2y,xFCH4y,xFN2y,xOO2y,xON2y) xFCOy=.074;xFH2y=.54;xFCH4y=.28;xFN2y=.106;xOO2y=.21;xON2y=.79 QFUELy=2200;QOXy=11200 *****Calculate the composition of mixed flow(gas and air)******* INCOy=QFUELy*(xFCOy)/(QFUELy+QOXy);INH2y=QFUELy*xFH2y/(QFUELy+QOXy) INCH4y=QFUELy*xFCH4y/(QFUELy+QOXy);INO2y=QOXy*xOO2y/(QFUELy+QOXy) INN2y=1.-(INCOy+INH2y+INCH4y+INO2y) *******Calculate the mass portion in the mixed flow*************** XMy=INCOy*MCO+INH2y*MH2+INCH4y*MCH4+INN2y*MN2+INO2y*MO2 *******Mass portion************* mINCOy=INCOy*MCO/XMy mINH2y=INH2y*MH2/XMy mINCHy=INCH4y*MCH4/XMy mINN2y=INN2y*MN2/XMy mINO2y=INO2y*MO2/Xmy ************************************ Calcualte enthalpy ************************************ ****Mass portion in the fuel******** REAL(FUCOy,FUCH4y,FUH2y,FUN2y,FUMy) FUMy=xFCOy*MCO+xFH2y*MH2+xFCH4y*MCH4+xFN2y*MN2 FUCOy=xFCOy*MCO/FUMy FUH2y=xFH2y*MH2/FUMy FUCH4y=xFCH4y*MCH4/FUMy FUN2y=xFN2y*MN2/FUMy *******Mass portion in the air*********** REAL(OXO2y,OXN2y,OXMy) OXMy=xOO2y*MO2+xON2y*MN2 OXO2y=xOO2y*MO2/OXMy OXN2y=xON2y*MN2/OXMy REAL(HLy,HLFUy,HLOXy,FUy,OXy,HLTOTy) *****Fuel mass portion in the mixed flow (gas and air)******* FUy=QFUELy*FUMy/(QFUELy*FUMy+QOXy*OXMy) *******Oxygen mass portion in the mixed flow***************** OXy=QOXy*OXMy/(QFUELy*FUMy+QOXy*OXMy) *******Enthalpy of fuel gas in the mixed flow******************** HLFUy=(FUCOy*CPCO+FUCH4y*CPCH4+FUH2y*CP1H2+FUN2y*CP1N2)*TFU*FUy *******Enthalpy of air in the mixed flow**************** HLOXy=(OXO2y*CPO2+OXN2y*CP1N2)*OXy*TOX HLTOTy=HLOXy+HLFUy *****Reference enthalpy at 298 K ************************** REAL(HREFy,CPy) CPy=mINCOy*CPCO+mINH2y*CP1H2+mINCHy*CPCH4+mINO2y*CPO2+mINN2y*CP1N2 HREFy=(CPy*298) 13 *****Reference chemical formation enthalpy*************** REAL(STDHy,STDSy,HTOTy,FSTDSy,OSTDSy) STDHy=(mINCOy/MCO*110.541+mINCHy/MCH4*74.873)*1000*1000 ******Enthalpy from the inlet************ HTOTy=HLTOTy-HREFy-STDHy ******Calculate the dynamics variables of the inlet********** ****Define the diameter of inlet (m) and pii REAL(DIAMy,PII) DIAMy=.38;PII=3.141 *****Calculate the equivalent diameter of a inlet (m)************** ABRy=((DIAMy/2)**2*PII)**0.5 *****Calculate the flow volume rate ******** REAL(FWGIy,OWGIy) FWGIy=((QFUELy)/3600/(ABRy**2*6))*(TFU*RPRESS)/(RTEMP*OPRESS) OWGIy=((QOXy)/3600/(ABRy**2*6))*(TOX*RPRESS)/(RTEMP*OPRESS) WGIy=OWGIy+FWGIy *******Calculate the mole mass and mass portion of fuel and air**** REAL(YMSUMy,OMSUMy,FMSUMy) YMSUMy=mINCOy/MCO+mINH2y/MH2+mINCHy/MCH4+mINN2y/MN2+mINO2y/MO2 FMSUMy=FUCOy/MCO+FUH2y/MH2+FUCH4y/MCH4+FUN2y/MN2 OMSUMy=OXN2y/MN2+OXO2y/MO2 ****Calculate the mixed gas sensity (kg/m^3)************* REAL(RHOINy,FRHOy,ORHOy) FRHOy=OPRESS/(RGAS*TFU*FMSUMy)/1000 ORHOy=OPRESS/(RGAS*TOX*OMSUMy)/1000 RHOINy=(QFUELy*FRHOy+QOXy*ORHOy)/(QFUELy+QOXy) ****Calculate the mass flow rate (kg/(m^2*s))************** REAL(PRINy) PRINy=WGIy*RHOINy ****Check Enthalpy******* real(H1N2OXy,H1N2FUy) H1N2FUy=(QFUELy*.106/(QFUELy*.106+QOXy*.21))*mINN2y*CP1N2*TFU H1N2OXy=(QOXy*.21/(QFUELy*.106+QOXy*.21))*mINN2y*CP1N2*TOX REAL(H1FUy) H1FUy=mINCOy*CPCO*TFU+mINH2y*CP1H2*TFU+mINCHy*CPCH4*TFU+H1N2FUy REAL(H1OXy) H1OXy=mINO2y*CPO2*TOX+H1N2OXy REAL(H1INy) H1INy=H1OXy+H1FUy *********Calculate turbulent energy KEy and dissipate rate EPy******** REAL(KEy,EPy,TINT) *******Define Turbulent intensity TINT**************** TINT=0.02 KEy=3/2*(TINT*WGIy)**2 EPy=0.09**0.75*KEy**(3/2)/(0.07*(DIAMy/2)) ********************************************************************************* Calculate the boundary conditions from the inlets of the lower burners in the Heating zone *********************************************************************************** ……………………………….(Omitted) ********************************************************************************* Calculate the boundary conditions from the inlets of the burners in the Soaking zone *********************************************************************************** 14 …………………………………..(Omitted) ******Radiation defining *************** REAL(CPGAS) CPGAS=1005 **************************************** Define Stefan-Bolzman constant, absorption coefficient, scatter coefficient and emissivity coefficient ***************************************** REAL(GSIGMA, ABSORB, SCAT,EMISS,EG) GSIGMA=5.6697E-08; ABSORB=0.10; SCAT=0.10; EMISS=0.85;EG=0.20 ************************************************************************ Groups 3, 4, 5 Grid Information * Overall number of cells, RSET(M,NX,NY,NZ,tolerance) RSET(M,34,39,59) * Set overall domain extent: * xulast yvlast zwlast name XSI= 4.250000E+00; YSI= 5.660000E+00; ZSI= 2.807000E+01 RSET(D,CHAM ) * Set objects: x0 y0 z0 * dx dy dz name XPO= 0.000000E+00; YPO= 4.340000E+00; ZPO= 0.000000E+00 XSI= 3.750000E+00; YSI= 1.320000E+00; ZSI= 3.730000E+00 RSET(B,BLK1 ) ……………………………….(Omitted) Group 7. Variables: STOREd,SOLVEd,NAMEd ONEPHS = T * Non-default variable names * Solved variables list SOLVE(P1 ,U1 ,V1 ,W1 ,H1) * Stored variables list STORE(PRPS) STORE(CP1) STORE(VIST,DEN1,TMP1,SPH1,YSUM,IMB1) * Additional solver options SOLUTN(P1 ,Y,Y,Y,N,N,Y) SOLUTN(H1 ,Y,Y,Y,P,P,P) *Turbulent model TURMOD(KEMODL) *Radiation model RADIAT(ABSORB,SCAT,CP1) Group 8. Terms & Devices TERMS (H1 ,N,Y,Y,Y,Y,Y) Group 9. Properties ENUL=4.2E-5 PRNDTL(H1)=7.154E-01 *** START OF EXTENDED SCRS MODEL SETTINGS PRESS0=OPRESS INTEGER(NSPEC,NELEM);NSPEC=7;NELEM=4 INTEGER(NCSTEP,NCREAC);NCSTEP=2;NCREAC=3 SCRS(SYSTEM,NCSTEP,NCREAC,NELEM,FRATE*) SCRS(SPECIES,CH4,O2,H2,CO,H2O,CO2,N2) STORE(S1RS,S2RS,S3RS,MMWT) ** Define fuel & oxidizer composition & temperatures SCRS(FUIN,mINCHy,mINO2y,mINH2y,mINCOy,0.0,0.0,mINN2y,TFU) SCRS(OXIN,mINCHt,mINO2t,mINH2t,mINCOt,0.0,0.0,mINN2t,TOX) SCRS(PROP,CHEMKIN,SCRS) MESG(2 step 3 reactions finite-rate EBU model 15 MESG(2CH4 MESG(2CO MESG(2H2 *** END + + + OF O2 > 2CO+4H2 O2 > 2CO2 O2 > 2H2O EXTENDED SCRS MODEL SETTINGS Group 11.Initialise Var/Porosity Fields FIINIT(W1 ) = 3 FIINIT(KE ) = 1.000E-02 ;FIINIT(EP ) = FIINIT(H1 ) = 2.084E+06 ;FIINIT(RADX) = FIINIT(RADY) = 1.000E+04 ;FIINIT(RADZ) = FIINIT(F ) = 1.000 FIINIT(H2 ) = 1.0e-5 FIINIT(CO2) = 1.0e-5 FIINIT(CH4 ) = 1.0e-5 FIINIT(H1 ) = 1500*1005 1.079E-02 1.000E+04 1.000E+04 CONPOR(BLK1 , 0.00,VOLUME,#1,#17,#15,#18,#1,#2) CONPOR(BLK4 , 0.00,VOLUME,#1,#17,#11,#18,#4,#4) ……………………………….(Omitted) CONPOR(POL2 , 0.00,VOLUME,-#8,-#9,-#2,-#7,-#10,-#10) ……………………………….(Omitted) INIADD = F Group 13. Boundary & Special Sources PATCH COVAL COVAL COVAL COVAL (RADISO (RADISO (RADISO (RADISO (RADISO ,VOLUME,1,31,1,39,1,68,#1,#1) ,H1 , GRND1 , GRND1 ) ,RADX, GRND1 , GRND1 ) ,RADY, GRND1 , GRND1 ) ,RADZ, GRND1 , GRND1 ) PATCH COVAL COVAL COVAL (SCRSPRSO,PHASEM,1,31,1,39,1,68,#1,#1) (SCRSPRSO,H2 , FIXFLU , GRND2 ) (SCRSPRSO,CH4 , GRND2 , GRND2 ) (SCRSPRSO,CO , FIXFLU , GRND2 ) PATCH (SCRSSRSO,PHASEM,1,31,1,39,1,68,#1,#1) COVAL (SCRSSRSO,H2 , GRND5 , GRND5 ) COVAL (SCRSSRSO,CO , GRND5 , GRND5 ) ******Inlet (Burner)************** INLET(SCRSFy1,LOW,#14,#15,#17,#17,#5,#5,#1,#NREGT) VALUE(SCRSFy1,P1,PRINy) VALUE(SCRSFy1,V1,WGIy*-.190808) VALUE(SCRSFy1,W1,WGIy*.981627) VALUE(SCRSFy1,KE,KEy) VALUE(SCRSFy1,EP,EPy) VALUE(SCRSFy1,F,1.) VALUE(SCRSFy1,CO,mINCOy) VALUE(SCRSFy1,H2,mINH2y) VALUE(SCRSFy1,CH4,mINCHy) VALUE(SCRSFy1,H1,HTOTy) ……………………………….(Omitted) *******Outlet************** OUTLET(VUOTO1 ,LOW ,1,30,#7,#7,1,1,#1,#1) COVAL (VUOTO1 ,P1 , FIXVAL , 0.400E+00) COVAL (VUOTO1 ,KE , 0.000E+00, SAME ) COVAL (VUOTO1 ,EP , 0.000E+00, SAME ) COVAL (VUOTO1 ,H1 , 0.000E+00, SAME ) COVAL (VUOTO1 ,F , 0.000E+00, SAME ) COVAL (VUOTO1 ,O2 , FIXVAL, 0.233 ) COVAL (VUOTO1 ,N2 , FIXVAL, 0.766 ) 16 PATCH COVAL COVAL COVAL COVAL COVAL (OUTLET (OUTLET (OUTLET (OUTLET (OUTLET (OUTLET ,EAST ,P1 , ,KE , ,EP , ,H1 , ,F , ,#18,#18,#1,#13,#37,#37,#1,#1) FIXVAL , 0.000E+00) 0.000E+00, SAME ) 0.000E+00, SAME ) 0.000E+00, SAME ) ONLYMS ,SAME) **************Boundary wall************* store(hgas,hre,hst) RG(1)=1573 PATCH (TOPW1 ,NWALL ,#1,#17,#18,#18,#6,#11,#1,#1) COVAL (TOPW1 ,U1 , GRND3 , 0.000E+00) COVAL (TOPW1 ,W1 , GRND3 , 0.000E+00) COVAL (TOPW1 ,KE , GRND3 , GRND3 ) COVAL (TOPW1 ,EP , GRND3 , GRND3 ) COVAL (TOPW1 ,H1 , GRND3 , GRND) ……………………………….(Omitted) RG(121)=1473 PATCH (POL1-LW,LWALL ,#8,#9,#2,#7,#8,#8,#1,#1) COVAL (POL1-LW,U1 , GRND3 , 0.000E+00) COVAL (POL1-LW,V1 , GRND3 , 0.000E+00) COVAL (POL1-LW,KE , GRND3 , GRND3 ) COVAL (POL1-LW,EP , GRND3 , GRND3 ) COVAL (POL1-LW,H1 , GRND3 , GRND ) ……………………………….(Omitted) ******Radiation boundary conditions*********** PATCH (TOPWA1 ,NORTH ,#1,#17,#18,#18,#6,#11,#1,#1) COVAL (TOPWA1 ,RADY, 6.667E-01, 5.66978E-08*(1573**4) ) ……………………………….(Omitted) PATCH (SLABWWA1,WEST ,#17,#17,#8,#8,5,15,#1,#1) COVAL (SLABWWA1,RADX, 6.667E-01, 5.66978E-08*(1473**4) ) ……………………………….(Omitted) PATCH (POL12EW ,EAST ,#9,#9,#7,#7,#34,#34,#1,#1) COVAL (POL12EW ,RADX, 6.667E-01, 5.66978E-08*(873**4) ) Group 15. Terminate Sweeps LSWEEP = 2000 SELREF = T RESFAC = 1.000E-02 Group 17. Relaxation RELAX(P1 ,LINRLX, 8.00000E-01) RELAX(U1 ,FALSDT, 5.0000E-01) RELAX(V1 ,FALSDT, 5.000E-01) RELAX(W1 ,FALSDT, 5.0000E-01) RELAX(KE ,LINRLX, 5.00000E-01) RELAX(EP ,LINRLX, 5.00000E-01) RELAX(H1 ,LINRLX, 8.000000E-01) RELAX(CO,FALSDT,2.00E-1) RELAX(H2,FALSDT,2.00E-1) RELAX(CH4,FALSDT,2.00E-1) KELIN = 3 ************************************************************ ************************************************************ Group 19. EARTH Calls To GROUND Station GENK = T ASAP = T RADIA = 1.000E-01 ;RADIB = 1.000E-01 ************************************************************ Group 20. Preliminary Printout 17 ECHO = T ************************************************************ Group 21. Print-out of Variables OUTPUT(CH4 ,Y,N,Y,Y,N,N) OUTPUT(O2 ,Y,N,Y,Y,N,N) OUTPUT(H2O ,Y,N,Y,Y,N,N) OUTPUT(CO2 ,Y,N,Y,Y,N,N) OUTPUT(N2 ,Y,N,Y,Y,N,N) OUTPUT(KE ,N,N,N,Y,Y,Y) OUTPUT(EP ,N,N,N,Y,Y,Y) OUTPUT(RADX,N,N,N,Y,Y,Y) OUTPUT(RADY,N,N,N,Y,Y,Y) OUTPUT(RADZ,N,N,N,Y,Y,Y) ************************************************************ ************************************************************ Group 24. Dumps For Restarts ************************************************************ MENSAV(S,RELX,DEF,1.0119E-01,4.0870E+01,1) MENSAV(S,PHSPROP,DEF,200,0,1.1890E+00,1.0000E-05) MENSAV(S,FLPRP,DEF,K-E,CONSTANT) RESTRT(ALL) STOP Appendix 2: Ground file sample CXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX USER SECTION STARTS: C PARAMETER (NLG=100, NIG=200, NRG=200, NCG=100) C COMMON/LGRND/LG(NLG)/IGRND/IG(NIG)/RGRND/RG(NRG)/CGRND/CG(NCG) LOGICAL LG CHARACTER*4 CG C C 2 C C User dimensions own arrays here, for example: DIMENSION GUH(10,10),GUC(10,10),GUX(10,10),GUZ(10) PARAMETER (JDIM=150, IDIM=150) DIMENSION HLPN2(JDIM,IDIM),HLPO2(JDIM,IDIM),HLPH2(JDIM,IDIM), + HLPCH4(JDIM,IDIM),HLPCO(JDIM,IDIM),HLPCO2(JDIM,IDIM), + HLPH2O(JDIM,IDIM),HLPTMP1(JDIM,IDIM),HLP1(JDIM,IDIM), + HLP2(JDIM,IDIM),HLP3(JDIM,IDIM) REAL MO2,MH2,MN2,MCO,MCH4,CH4A,CH4B,CH4C,CH4D,COA,COB,COC, + COD,H2A,H2B,H2C,H2D,H2A2,H2B2,H2C2,H2D2,N2A,N2B,N2C,N2D, + N2A2,N2B2,N2C2,N2D2,O2A,O2B,O2C,O2D,CCH4,CCO,CH2,CH2O, + CN2,CCO2,CO2,CPCH4,CPCO,CPH2,CPN2,CPO2,CPH2O,CPCO2,HCH4, + HH2O,HCO2,H2OA,H2OB,H2OC,H2OD,H2OA2,H2OB2,H2OC2, + H2OD2,CO2A,CO2B,CO2C,CO2D,MH2O,MCO2,TGAS,HWAL,HST,HREF, + HGAS C******Mole mass kg/mol MO2=32.00/1000 ……………………………….(Omitted) c******The coefficients in the formula of gas heat capacity c Methane,CH4, T>298 CH4A=12.447 ……………………………….(Omitted) c******Standard free enthalpy J/mol HCH4=74.873*1000 ……………………………….(Omitted) c*****Calculate reference enthalpy at 298 K c heat capacity of O2 at 298 K CO2=(O2A+O2B*10.**(-3.)*298.+O2C*10.**5.*298.**(-2.)+ 18 + O2D*10.**(-6.)*298.**2.)/MO2 c heat capacity of N2 at 298 K ……………………………….(Omitted) C******Temperature of wall TW1=RG(1) ……………………………….(Omitted) C--- GROUP 13. Boundary conditions and special sources C Index for Coefficient - CO C Index for Value - VAL 13 CONTINUE GO TO (130,131,132,133,134,135,136,137,138,139,1310, 11311,1312,1313,1314,1315,1316,1317,1318,1319,1320,1321),ISC 130 CONTINUE C------------------- SECTION 12 ------------------- value = GRND c gas enthalpy closed to the wall C Mass portion of O2 CALL GETYX(LBNAME('O2'),HLPO2,JDIM,IDIM) C Mass portion of N2 CALL GETYX(LBNAME('N2'),HLPN2,JDIM,IDIM) C Mass portion of H2 CALL GETYX(LBNAME('H2'),HLPH2,JDIM,IDIM) C Mass portion of CH4 CALL GETYX(LBNAME('CH4'),HLPCH4,JDIM,IDIM) C Mass portion of CO CALL GETYX(LBNAME('CO'),HLPCO,JDIM,IDIM) C Mass portion of CO2 CALL GETYX(LBNAME('CO2'),HLPCO2,JDIM,IDIM) C Mass portion of H2O CALL GETYX(LBNAME('H2O'),HLPH2O,JDIM,IDIM) C Temperature of gas CALL GETYX(LBNAME('TMP1'),HLPTMP1,JDIM,IDIM) c*****Wall 1, Topwall***** IF((NPATCH(1:5).EQ.'TOPW1').AND.(INDVAR.EQ.LBNAME('H1')))THEN C wall temperature TW=TW1 L0FVAL=L0F(VAL) DO 3109 II=1,NX DO 3109 JJ=1,NY IICELL=JJ+NY*(II-1) C mass portion of O2 YO2=HLPO2(JJ,II) C mass portion of N2 YN2=HLPN2(JJ,II) C mass portion of H2 YH2=HLPH2(JJ,II) C mass portion of CH4 YCH4=HLPCH4(JJ,II) C mass portion of CO YCO=HLPCO(JJ,II) C mass portion of CO2 YCO2=HLPCO2(JJ,II) C mass portion of H2O YH2O=HLPH2O(JJ,II) C Gas temperature TGAS=HLPTMP1(JJ,II) c** Calculate heat capacity of different gas component c Heat capacity of O2 at the wall temperature CPO2=(O2A+O2B*10.**(-3.)*TW+O2C*10.**5.*TW**(-2.) 19 + c + + c + + c + c + c + + c + +O2D*10.**(-6.)*TW**2)/MO2 Heat capacity of N2 at the wall temperature IF(TW.LE.400.0)THEN CPN2=(N2A+N2B*10.**(-3.)*TW+N2C*10.**5.*TW**(-2.) +N2D*10.**(-6.)*TW**2)/MN2 ELSE CPN2=(N2A2+N2B2*10.**(-3.)*TW+N2C2*10.**5.* TW**(-2.)+N2D2*10.**(-6.)*TW**2)/MN2 ENDIF Heat capacity of H2 at the wall temperature IF(TW.LE.400.0)THEN CPH2=(H2A+H2B*10.**(-3.)*TW+H2C*10.**5.*TW**(-2.) +H2D*10.**(-6.)*TW**2)/MH2 ELSE CPH2=(H2A2+H2B2*10.**(-3.)*TW+H2C2*10.**5.*TW**(-2.) +H2D2*10.**(-6.)*TW**2)/MH2 ENDIF Heat capacity of CH4 at the wall temperature CPCH4=(CH4A+CH4B*10.**(-3.)*TW+CH4C*10.**5.*TW**(-2.) +CH4D*10.**(-6.)*TW**2)/MCH4 Heat capacity of CO at the wall temperature CPCO=(COA+COB*10.**(-3.)*TW+COC*10.**5.*TW**(-2.) +COD*10.**(-6.)*TW**2)/MCO Heat capacity of H2O at the wall temperature IF(TW.LE.600.0)THEN CPH2O=(H2OA+H2OB*10.**(-3.)*TW+H2OC*10.**5.*TW**(-2.) +H2OD*10.**(-6.)*TW**2)/MH2O ELSE CPH2O=(H2OA2+H2OB2*10.**(-3.)*TW+H2OC2*10.**5.*TW**(-2.) +H2OD2*10.**(-6.)*TW**2)/MH2O ENDIF Heat capacity of CO2 at the wall temperature CPCO2=(CO2A+CO2B*10.**(-3.)*TW+CO2C*10.**5.*TW**(-2.) +CO2D*10.**(-6.)*TW**2)/MCO2 C** c Gas enthalpy at wall temperature HGAS=(yO2*CPO2+yH2*CPH2+yN2*CPN2+yCH4*CPCH4+yCO*CPCO+yH2O + *CPH2O+yCO2*CPCO2)*TW c Reference enthalpy of gas at temperature of 298K HREF=(yO2*CO2+yH2*CH2+yN2*CN2+yCH4*CCH4+yCO*CCO+yH2O*CH2O+ + yCO2*CCO2)*298. c Chemical formation enthalpy HST=(yCH4*HCH4/MCH4+yCO*HCO/MCO+yH2O*HH2O/MH2O+yCO2* + HCO2/MCO2) c Enthalpy of the boundary wall HWAL=HGAS-HREF-HST F(L0FVAL+IICELL)=HWAL HLP1(JJ,II)=HGAS/TW HLP2(JJ,II)=HST HLP3(JJ,II)=HREF/298. 3109 CONTINUE ENDIF …………………………………(Other boundary walls) c CALL SETYX(LBNAME('HGAS'),HLP1,JDIM,IDIM) CALL SETYX(LBNAME('HST'),HLP2,JDIM,IDIM) CALL SETYX(LBNAME('HRE'),HLP3,JDIM,IDIM) RETURN 1312 CONTINUE 20