A Model Study of Thermal Characteristics of Decarburization Annealing Furnace For Silicon Steel Strip PDF
A Model Study of Thermal Characteristics of Decarburization Annealing Furnace For Silicon Steel Strip PDF
Research Paper
H I G H L I G H T S
• Temperature distributions and power inputs of furnace are calculated by Zonal modeling.
• PH2 PH2O , strip speeds, and strip thicknesses have a significant influence on temperature distributions and power inputs.
• Radiation dominates the whole heat transfer.
A R T I C L E I N F O A B S T R A C T
Article history: The zonal modeling is proposed in this work to predict temperature distribution and power inputs of
Received 8 July 2015 SF. The situations of production involve three PH2 PH2O , three strip speeds, and three strip thicknesses to
Accepted 1 January 2016 get the variation of temperature and electric power during decarburization process. The ways of heat
Available online 21 January 2016
transfer used in zonal modeling are used to explain the temperature tendency very well and validate
the applicability of this model in production. Results demonstrate that initial temperature of strip reduces
Keywords:
with the increase of strip speed and thickness, power inputs ascend with the increase of each parame-
Temperature distribution
ter individually, and the proportion of radiation heat transfer is more than 80% of the heat transfer.
Heat transfer
Zonal modeling © 2016 Elsevier Ltd. All rights reserved.
Decarburization annealing furnace
http://dx.doi.org/10.1016/j.applthermaleng.2016.01.008
1359-4311/© 2016 Elsevier Ltd. All rights reserved.
538 Y. Guo et al./Applied Thermal Engineering 99 (2016) 537–544
concentration in SF is still limited to avoid excessive oxidation. Hence, and Ts are surface temperature of resistor, gas, walls and strip, re-
gas radiation could be ignored. spectively (K).
Heat exchange in SF is shown in Fig. 1. A zonal modeling has Heat on furnace walls is exchanged with strip and resistor by
been build and heat exchange field is divided into several small radiation, and with gas by convection. Meanwhile heat is trans-
surface zones. Assumptions of each zone are as following: (1) the ferred from walls to outside furnace by conduction. The heat
temperature of furnace gas, walls, strip and heating elements are absorbed by walls is equal to its heat loss. Therefore furnace wall
uniform within each model segment; (2) resistance band plays a is in a stable state of thermal equilibrium, which is written as:
role in intermediate heat vector, and its thermal resistance and
regenerative heat can be ignored; (3) furnace gas is treated as steady σ WR (Tw4 − Tr4 ) + σ SW (Tw4 − Ts4 ) + hw , g Aw (Tw − Tg )
flow; (4) inter-segment radiation is shielded. Physical properties + (Tw − Tatm ) Aw (δ i λi + 1 a ) = 0 (2)
of gas are listed by James et al. [6]. Heat losses for firebrick are
expressed by Trinks [7]. The prototype of one section of the furnace Where, WR is total radiative exchange area between walls and re-
is presented in Fig. 2. SF is composed of 15 sections; the length of sistor; SW is total radiative exchange area between strip and walls;
one section is 9300 mm; the power installed of one section is hw,g is convective heat transfer coefficient between walls and gas
240 kW. (W/m2·K); Tatm is environment temperature; Aw is area of walls (m2);
δi is thickness of firebrick (m); λi is thermal conductivity of fire-
2.1. Energy balance of heat transfer process brick (W/s); a is convective heat transfer coefficient outside walls
(W/m2·K).
Thermocouples inserted into furnace exchange heat with strip, Heat generated by resistor P0 would be transferred to strip surface
furnace walls and heating elements by thermal radiation. Consid- and furnace walls by radiation, and to flowing atmosphere by con-
ering that surface area of thermocouple is much smaller relative to vection in SF. At the same time, some wet mixture gas is going into
other objects, thermocouples have a little impact on energy balance chamber continuously from outside furnace. This gas flow is small,
of the whole furnace. Therefore, the radiation heat transfer caused which can be heated to Tg immediately. And some gas flow to the
by thermocouples can be ignored. Energy balance equation of ther- outside of furnace. Resistors as the only heat source, provide all the
mocouple in steady state is as follows. heat for heating strip, walls and furnace gas. Energy balance equa-
tion of heating elements in steady state is expressed as:
σ ⎡⎣ RT (Tr4 − Tg4 ) + WT (Tw4 − Tg4 ) + ST (Ts4 − Tg4 )⎤⎦ = 0 (1)
σ RS (Tr4 − Ts4 ) + σ RW (Tr4 − Tw4 ) + hr , g Ar (Tr − Tg )
Where, σ is Boltzmann Constant (W/m2·K4); RT is total radiative ex- + Vg ,in ρ g ,in (C g Tg − C g ,iinTg ,in ) 3.6 + Vg ,out ρ g ,out C g Tg 3.6 = P0 (3)
change area between resistor and thermocouple; WT is total
radiative exchange area between walls and thermocouple; ST is total Where, RS is total radiative exchange area between strip and re-
radiative exchange area between strip and thermocouple; Tr, Tg, Tw sistor; RW is the same to WR ; hr,g is convective heat transfer
coefficient between resistor and gas (W/m2·K); Vg,in is flow of gas ⎧[ Asϕ s,s − As (1 − ε s )]s Rs + Asϕ s,w s Rw + Asϕ s,r s Rr = − Asϕ s,s ε s
going into furnace (m3/h); Vg,out is flow of gas flowing to outside of ⎪
furnace (m3/h); Cg is heat capacity of gas (kJ/kg·K);Tg,in is temper- ⎨ Asϕ s,w s Rs + [ Aw − Asϕ s,w − Arϕ r ,w − Aw (1 − ε w )]s Rw + Arϕ r ,w s Rr = − Asϕ s,w ε s
⎪ A ϕ R + A ϕ R + A ϕ − A 1− ε R = − A ϕ ε
ature of gas going into furnace (K); P0 is the opening power of heating ⎩ s s,r s s r r ,w s w [ r r ,r r ( r )]s r s s ,r s (14)
elements.
Where, As is area of strip surface; ϕ x ,y is view factor from surface
x to surface y; εs is emissivity of strip; s Rs and s Rw are reflection
2.2. Calculation of convective heat transfer coefficient and total
heat fluxes of strip surface and wall surfaces, respectively. SW and
radiative exchange area
WR are also calculated by this algorithm.
In resistor-wall-strip-thermocouple system, it is assumed that
2.2.1. Convection on furnace walls
thermocouples are the only radiation source and unit radiation in
Depree [8] has calculated heat transfer coefficients on inner walls
SF, and effective radiation of other surfaces is just reflection. The
by considering it as a duct-flow situation. Ghiaasiaan [9] has used
total radiative exchange area between strip and thermocouples is
classical Re equation as the basis for the solution of this airflow. Re
described as Eq. (15):
of furnace gas near walls can be calculated by the formula (4)
Where, Rew is Reynolds number of furnace gas near walls surface; Where, t Rs is reflection heat flux of strip surface, which can be ob-
vg is velocity of gas in furnace (m/s); DW is hydraulic diameter (m); tained by solving Eq. (16):
ξg is kinematic viscosity of gas (m2/s).
⎧[ Atϕ t ,t − At (1 − ε t )]t Rt + Atϕ t ,rt Rr + Atϕ t ,wt Rw + Atϕ t ,st Rs = − Atϕ t ,t ε t
Incropera and Dewit [10] have used Eqs. (5) and (6) to calcu- ⎪
late the average Nusselt Number for laminar duct flow and turbulent ⎪ Atϕ t ,rt Rt + [ Arϕ r ,r − Ar (1 − ε r )]t Rr + Awϕ w ,rt Rw + Asϕ s,rt Rs = − Atϕ t ,r ε t
⎨
duct flow. When 2300<Re<10,000, Nuw is calculated in proportion ⎪ Atϕ t ,wt Rt + Awϕ w ,rt Rr + [ Awϕ w ,w − Aw (1 − ε w )]t Rw + Awϕ w ,st Rs = − Atϕ t ,w ε t
to Eqs. (5) and (6). The convective heat transfer coefficient can be ⎪ Atϕ t ,st Rt + Asϕ s,rt Rr + Awϕ w ,st Rw + [ Asϕ s,s − As (1 − ε s )] Rs = − Atϕ t ,s ε t
⎩ t
calculated by Eq. (7): (16)
Nuw = 3.66 Tw = constant , Re ≤ 2300 (5) Where, t Rt , t Rw and t Rr are reflection heat flux of thermocouple
surface, wall surfaces and resistor surface, respectively. The algo-
Nuw = 0.023Rew4 5Pr 1 3 0.6 ≤ Pr ≤ 160, Re ≥ 10, 000 (6) rithm is equally applicable to WT and RT . Related equation
presented by Michael [11] is used to calculate view factor.
hw , g = Nuw × λ g Dw (7)
2.3. Control model for strip temperature and opening power
2.2.2. Convection on strip surface and heating elements
Convection on strip and resistor surface are considered as a plate- 2.3.1. Calculation of strip temperature
flow situation, the Reynolds number of gas around strip surface and The steel temperature is uniform in its width direction because
Reynolds number of gas near resistor surface are described by Eqs. of process requirements. The zone is very small, and the steel moves
(8) and (9), respectively. continuously in high speed. So the strip temperature is assumed
at the same value within the same zone at the same instant. Inter-
Res = ( v g + vs ) Ls ξ g (8) nal thermal resistance of silicon strip can be ignored since it is very
thin. Strip heating process is simplified as:
Rer = v g Lr ξ g (9)
dT dτ = Φ ρ (t )C (t ) (17)
Where, Res is Reynolds number of gas around strip surface; and Rer
Where, Φ is generalized heat source item. Heat exchanged
is Reynolds number of gas near resistor surface; vg is velocity of gas
in furnace; vs is velocity of strip; Ls and Lr are characteristic length. through the boundary of the strip should be seen as the heat source
The average Nusselt Number for plate flow is calculated by Eqs. throughout volume of the whole object:
(10), (11); the convective heat transfer coefficient for plate flow is
Φ V = Aqs (18)
calculated by Eq. (12).
1 1 Eq. (18) is fed into (17):
Nu = 0.664 Re 2 Pr 3
Pr ≥ 0.6, Re ≺ 5 × 105 (10)
dT dτ = qs δ s ρs (t )C s (t ) (19)
Nu = (0.037Re 4 5 − 871) Pr 1 3 0.6 ≤ Pr ≤ 60, 5 × 105 ≤ Re ≤ 108 (11)
With initial conditions: T (τ ) τ =0 = Ts0 (20)
h = Nu × λ g L (12)
And boundary condition:
2.2.3. Total radiative exchange area qs = ⎡⎣σ SR (Tr4 − Ts4 ) + σ SW (Tw4 − Ts4 ) + hs, g As (Tg − Ts )⎤⎦ As (21)
In resistor-wall-strip system, it is assumed that the only radia-
tion source in SF is steel, and effective radiation of other surfaces
is just reflection. The total radiative exchange area between strip 2.3.2. Calculation of opening power ratio
and heating elements is described as Eq. (13): SF consists of fifteen independent resistance furnaces. Resistor
is the only heat source in the furnace. The temperature on strip
SR = s Rr × Ar × ε r (1 − ε r ) (13) surface can be controlled more accurately by adjusting the power
inputs of the resistor. Furnace gas temperature is maintained at
Where, Ar is area of resistor surface; εr is emissivity of resistor; soaking temperature (835 ± 0.5 °C). Power ratio P is defined as:
sRr is reflection heat flux of resistor surface, which is got by
solving Eq. (14): P = P0 Pm (22)
540 Y. Guo et al./Applied Thermal Engineering 99 (2016) 537–544
Where P0 is the opening power of heating elements, Pm is its So as shown in Fig. 4b–d, the absorbed heat on the surface of strip,
maximum power. walls and resistor has begun to decrease. Then in the furnace length
about 37 m, electric power is opened about 26% to offset the heat
3. Results and discussion loss of the furnace. The temperature in chamber is Tr>Ts>Tg>Tw. As
show in Fig. 4c and d, the main heat transfer in furnace chamber
The proposed model is executed for predicting temperature and is radiation. Although power inputs may affect proportion of radi-
power inputs of furnace. The processing conditions are taken from ation and convection, heat transfer by radiation is still more than
the decarburization annealing line of “ PH2 PH2O ”, “strip speed” and 80%. The radiation dominates heat transfer. The trend of total heat
“strip thickness”. The heat transfer on accurate prediction of strip transfer and radiation heat transfer is same. The heat flow on strip
temperature includes radiation and convection. surface is almost zero when strip arrived at soaking temperature.
At this time the percentage of radiation and convection on strip
3.1. Temperature and heat distribution of SF surface can be ignored.
Zonal modeling has been used to calculate temperature and 3.2. The effect of PH2 PH2O
power inputs of SF for silicon steel. Fig. 3 compares the power inputs
between production and calculation to verify the effectiveness of Stratton and Stanescu [12] discovered more H2O is blended into
this model. furnace atmosphere with the increase of H2 content. Marra et al.
Fig. 3 shows the average power of production and calculation is [13] found that decarburization reaction constant rises when H2O
almost same. The power input of production is just 36% at the en- partial pressure increases in initial state. But the high tempera-
trance of SF to control heating rate of strip. Then the power value ture would hinder decarburization due to the emergence of
of production is higher to make strip reach soaking temperature. oxidation. Assuming H2O content is a constant, the influence of H2
But under the conditions of this model, its heating rate is fastest content on heat transfer is presented in Fig. 5.
and the holding time is longest. There are fluctuant values of power Fig. 5a–c illustrate that there are little differences of tempera-
supply of production due to the process with different gas flow. In ture distribution, whole heat transfer and radiation heat exchange
the model the gas flow has been assumed a constant, so the elec- of strip at different H2 content atmosphere. Time step dτ and strip
tric power basically remains unchanged. Therefore the power thickness δs are set to be constants. ρs and Cs do not change abso-
distribution of production is different from the calculation results. lutely. The heat flow is so small that it has a little impact on
The error of average power of production and calculation is no more temperature difference of strip △TS calculated from Eq. (23). The main
than 5%. gas in furnace is diatomic H2 and N2, which radiation properties are
The results from simulation of temperature trends and heat trans- very low. So gas radiation could be ignored. Table 1 points out that
fer on strip, gas, walls and heating elements along its moving specific heat of atmosphere rises significantly by addition of H2,
direction are presented in Fig. 4. leading to the heat storage of gas increased. But its effect on the heat
Fig. 4a describes temperature distribution on the surface of re- transfer is very little because the different power makes up its heat
sistor, gas, wall and strip, and power inputs allocated along the strip loss.
moving direction. The initial temperature is 815 °C when it moves
dT = qsdτ [δ s ρs (t )C s (t )] (23)
from RTF into the SF. The absorbed heat of strip at initial time is
the most since electric power is set to be the maximum to in-
From Table 1, increasing H2 concentration in PH2 PH2O will affect
crease strip temperature rapidly. In the furnace length about 28 m,
density and kinematic viscosity of medium, which result in the re-
the strip temperature has been raised to its soaking temperature
duction of Re and Nu of SF. Then convective heat transfer coefficient
838 °C. There is a temperature drop of resistor. The reason is that
hs,g rises.
electric power is opened just for a small part to maintain strip tem-
Fig. 5d shows the electric power has been opened different values
perature near 838 °C and to eliminate the uneven strip temperature
caused by the heat storage of gas. When strip temperature reaches
caused by rapid heating. The heat provided by resistor decreases.
around soaking temperature, heating elements provide more heat
to keep the heat balance of SF for a higher H2 content.
Fig. 4. (a) Temperature distribution and power inputs ratio; (b) Heat transfer of strip; (c) Heat transfer of furnace walls; (d) Heat transfer of resistors.
Table 2 displays that physical properties of gas would not be af- Fig. 6d presents increase of distance can ensure strip achieve
fected by strip speed. However, Re will increase with the increasing soaking temperature rapidly when it moves faster and the power
of strip speed according to Eq. (8). Then Nu and hs,g is raised based supply is P2>P1.5 > P1. Then, the strip temperature of line 1 is near
on Eqs. (10)–(12). 838 °C between the furnace length about 9m and 18m, so its opened
Table 1
Calculation results of strip at different H2 content atmosphere.
Table 2
Calculation results of strip at different strip speed.
Fig. 5. Calculation results of strip at different H2 content (a) Temperature; (b) Convection and radiation transfer; (c) Radiation transfer; (d) Power inputs.
power becomes 28%. The strip temperature of line 3 is far from thickness. ρs, Cs and dτ are constants. qs has changed as shown in
soaking temperature. Therefore its power input is 36%. At last elec- Fig. 7b. The △TS calculated from Eq. (23) becomes falling with the
tric power maintains 26% to supplement the same heat loss of SF increase of strip thickness. Fig. 7c represents that radiation heat is
at different strip speed. qs,0.285 > qs,0.23 > qs,0.18 caused by different power inputs at furnace en-
trance. Heat storage of strip rises with the increase of strip thickness.
3.4. The effect of strip thickness Heat exchange by irradiation and radiation still be qs,0.285 > qs,0.23 > qs,0.18
on rest strip surface.
Studies have shown that decarburization time is proportional to Table 3 displays strip thickness has almost no impact on gas prop-
the square of strip thickness in the same circumstances. Strip thick- erties, Re and Nu. The hs,g isn’t changed.
ness affects its heat storage, and changes temperature and heat Fig. 7d depicts that increasing the power supply can accelerate
transfer on strip surface. the process of strip reaching soaking temperature for a thick strip.
Fig. 7a describes that before the strip reaches soaking temper- Then, the strip temperature of line 1 is near 838 °C between the
ature 838 °C, temperature difference △TS declines with increase of furnace length about 9 m and 18 m. Its opened power becomes 29%.
Table 3
Calculation results of strip in different strip thicknesses.
Size of strip 1250 mm; Content of H2 35%; Velocity of strip 1.5 m/s.
Y. Guo et al./Applied Thermal Engineering 99 (2016) 537–544 543
Fig. 6. Calculation results of strip at different strip speed (a) Temperature; (b) Convection and radiation transfer; (c) Radiation transfer; (d) Power inputs.
The strip temperatures of line 2 and line 3 are far from soaking tem- different PH2 PH2O , strip speed and strip thickness in production. The
perature, so their power inputs are still higher than line 1. And last increase of strip speed and thickness will reduce its temperature;
the same power inputs are opened to make up for the heat loss of H2 concentration in PH2 PH2O has a little impact on strip tempera-
SF. ture. Increasing PH2 PH2O , strip speed or strip thickness individually
will increase the required opened power of SF. It is also observed
that heat transfer of strip by convection is in the laminar flow
4. Conclusions because of the low Re. Radiation dominates heat transfer, which is
accounted for more than 80% of heat transfer, and the heat is re-
The results indicates that zonal modeling is reliable to be used ceived from resistor and furnace walls without consideration of
to predict the trend of strip temperature and electric power of furnace gas.
544 Y. Guo et al./Applied Thermal Engineering 99 (2016) 537–544
Fig. 7. Calculation results of strip in different strip thicknesses (a) Temperature; (b) Convection and radiation transfer; (c) Radiation transfer; (d) Power inputs.