Analysis of the aerodynamics in the heating section of an anode baking furnace using non-linear finite element simulations

The emissions from the industrial furnaces impact the environment. Among the various factories, those having anode baking furnaces are working on reducing the pollutant emissions. The aerodynamics in the furnace influences the emissions due to the high dependence of combustion and radiation phenomena on the mixing characteristics. Therefore, this paper aims to establish the numerical simulation results for the three-dimensional turbulent flow in a single section of an anode baking furnace with a high rate of fuel injection. The stabilized non-linear finite element approach on the Reynolds-averaged Navier-Stokes (RANS) equation is used with COMSOLMultiphysics. The turbulent viscosity ratio is highly sensitive to the mesh for the standard k-ε model. The requirements of the Cartesian and refined mesh near the jet development region is explained. The comparison of meshes generated by two meshing tools namely cfMesh and COMSOL Multiphysics default Mesher is carried out. The high numerical diffusion in the flow models due to the coarser mesh leads to convergence but deficit the precision in the results. This paper shows that the mesh generated by cfMesh with flow aligned refinement combined with the non-linear finite element solver in COMSOL Multiphysics proves to provide accurate results of turbulent quantities.