Industrial Rotary Hearth Furnace Model

Modelling rotary hearth furnace (RHF) using computational fluid dynamics (CFD) and multi-physics tools

• 0D and 1D kinetic models, and 3D multi-physics reactor models were developed to help with simulating boundary and reduction conditions influencing the degree of metallization at industrial-scale rotary hearth furnaces.

• The model takes into consideration carbothermic reactions and heat transfer by convection, conduction, and radiation, coupled with the phenomena of turbulent flow of gases from the burners within the furnace freeboard, governing the physics involved in the operation of the furnace.

• The model enables assessment of energy and global mass balance, and evaluation of various rotary hearth furnace conditions on the reduction efficiency of chromite and comparison of different operating scenarios.

Gas velocity distribution in the furnace freeboard

Chromium metallization profiles as Cr2O3 and Cr7C3 concentrations as viewed on the lowermost pellet bed

Cr7C3 concentrations with 5 and 6 pellet layers – Complete metallization with 5 pellet layers at the exit

Concentration of Cr2O3 in a single pellet measuring 15 mm (top) and 25 mm (bottom) with effective thermal conductivities of 0.1 (right) and 0.5 W/(m K) (left)