Modelling and simulation of steel reheating processes under oxy-fuel combustion conditions – Technical and environmental perspectives

Highlights: • Previous work on reheating furnace modelling, control, and optimisation was reviewed. • A mathematical model was further developed to simulate the oxy-fuel reheating furnace. • The model was validated using the heating curves collected during real trials. • The specific energy consumption reduces by about 16% (0.18 GJ tonne⁻¹). • Should CO₂ capture be considered, the cost can be as low as 0.96 MJ kg⁻¹. -- Abstract: This paper investigates the impact of flameless oxy-fuel combustion on the thermal performance of a pilot-scale steel reheating furnace. A comprehensive mathematical model, based on the zone method of radiation analysis, was developed, which takes into account the non-grey behaviour of the furnace atmosphere under oxy-fuel combustion conditions. The model was subsequently used to simulate the temperature profile of an instrumented slab used in the experiment. The results showed that the predicted slab temperature profile along the furnace is in good agreement with measurement. However the model over predicted the absolute slab temperatures due to the influence of formation of oxide scales on the slab surface, which was not taken into account in the current model. When compared to air-fuel combustion simulation, the results of oxy-fuel combustion also indicated a marked improvement in the furnace specific fuel consumption (approximately 16%). This was mainly due to the enhanced radiative properties of the furnace atmosphere and reduced exhaust energy losses as the result of less dilution effect from nitrogen. This resulted in reduction in the overall heating time by approximately 14 min. Furthermore, if the economics of carbon capture is taken into consideration, theoretically, the energy consumption per kilogram of CO₂ captured can be reduced from 3.5 to 4.2 MJ kg⁻¹ to 0.96 MJ kg⁻¹. In conclusion, the current studies support the view that oxy-fuel combustion retrofitting to reheating furnaces is a promising option, both from a technical and from an environmental point of view.