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Applied Energy
journal homepage: www.elsevier.com/locate/apenergy
a r t i c l e i n f o a b s t r a c t
Article history: Glass manufacturing is an energy intensive process where fossil fuel is used to maintain high tempera-
Received 26 January 2011 ture (about 1700 °C) for glass melting. Heat recovery from flue gas (1350–1500 °C) is usually in the form
Received in revised form 14 May 2011 of combustion air pre-heating (900–1200 °C) using a regenerator. Dust from flue gas which is carried over
Accepted 18 May 2011
from the furnace gets deposited in the regenerator storage matrix path. This leads to a deterioration of
Available online 16 June 2011
regenerator efficiency. A regenerator model is developed to estimate the actual performance of the regen-
erator and to compare it with the target performance. The proposed model is based on mass and energy
Keywords:
balance of streams along with heat transfer characteristic equations. The model is illustrated for a 130
Glass furnace
Regenerator
TPD (Ton per Day) furnace regenerator of an industrial glass plant at Mumbai, India. Model results for
Performance the regenerator studied indicate a blockage of 50% on the doghouse side and 22% on the non-doghouse
Blockage side of the regenerator. The actual performance of the regenerator is found to be 7% lower than its target
Air leakage performance for the doghouse side regenerator. The model developed can also be used in other industrial
sectors like steel, chemical etc.
Ó 2011 Elsevier Ltd. All rights reserved.
0306-2619/$ - see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.apenergy.2011.05.028
4452 V. Sardeshpande et al. / Applied Energy 88 (2011) 4451–4458
Nomenclature
In literature there is no methodology available for the estima- regenerator packings. The model is illustrated for an industrial
tion of regenerator blockage. There is also a need for a methodol- glass furnace operating in India.
ogy for estimation of overall regenerator efficiency based on
regenerator operating parameters. Accurate estimation of air in- 2. Regenerators in glass industry
gress into the regenerator is also required for calculating the outlet
flue gas enthalpy. The general arrangement of a glass furnace is shown in Fig. 1.
Regenerator modeling is essential to capture the performance The type of regenerator commonly used for waste heat recovery
for different designs and operating conditions. A model for regen- from flue gases in glass furnaces is of the stationary matrix type.
erator performance prediction is developed and presented in this The regenerative heat exchanger consists of two refractory-lined
paper. The model is based on the approach presented by Schack chambers, constructed of thermal storage brickwork (also called
[2], where the overall heat transfer coefficient is calculated for a ‘checker work’). For a period (usually 20–30 min) one of the stor-
steady state condition and corrected for cyclic operation. The mod- age matrices absorbs and accumulates heat from the flue gas, fol-
el also estimates the target performance of the regenerator and the lowed by release of the heat to the incoming air for a similar
blockage factor. duration after the reversal of flow direction.
The model enables decision for regenerator cleaning and air Generally a glass furnace is installed with a single raw material
leakage sealing. The model can be used for the estimation of regen- feeding port called ‘doghouse’ (the name is due to the shape of the
erator performance for different furnace loading conditions and feeding section).The regenerator chambers are generally called as
can also be extended for the estimation of performance of different left side and right side regenerator. In this paper regenerator
Exhaust
Burners
Air
Air preheating Working End
regenerator Melting Tank
Non-Doghouse
side regenerator Pour
+
Mou
Doghouse side
regenerator
Chimney
Diverter
Draft
damper
control
damper Flue gas heat accumulation
Doghouse (Raw
A pair of regenerator material feeding)
chambers are termed as doghouse side (feeding side) and non-dog- Combustion
Flue gas inlet
house side regenerator. air outlet
The glass furnace regenerators are exposed to some unique
operating conditions as follows:
System
Regenerator Regenerator
boundary under heating under cooling
The gas generated from glass reaction is added in the combus- Heat loss from
tion volume. This normally contributes to about 10–15% of total regenerator walls
Air leakage in
flue gas quantity.
side
The composition of flue gas in terms of CO2 and H2O is influ-
enced by glass reaction products.
The flue gas is dust laden and creates deposits in the path of the
storage matrix.
Bulkhead
Table 1 m _ air;leak;reg ¼ m
_ tot;f ;in þ m _ tot;f ;out ð1Þ
List of instruments used for study.
The energy balance for regenerator presented in Eq. (2) relates
Name of instrument Instrument Measured Least count of
heat coming in from furnace flue gas, heat absorbed by air, regen-
range parameter instrument
erator wall losses and heat loss from flue gas outlet of the regener-
Oxygen analyzer (Effi Pro) 0–21% Oxygen% 0.1%
ator. The regenerator performance is specified in terms of an
Contact type 0–800 °C Temperature 1 °C
thermocouple (K type) efficiency parameter in Eq. (3).
Contact type 0–1600 °C Temperature 1 °C
thermocouple (R type) m _ air;leak;reg hair;leak
_ f ;tot;in hf ;in þ m
Radiation pyrometer 500–1600 °C Temperature 1 °C
_ f ;tot;out hf ;out þ Q_ l;wall;reg þ m
¼m _ air;comb;reg ðhair;comb;reg;out
hair;comb;reg;in Þ ð2Þ
The blockage of the regenerator alters the pressure drop and the
flue gas flow pattern. The blockage reduces the heating surface
_ air;comb;reg ðhair;comb;reg;out hair;comb;reg;in Þ
m
greg ¼ _ f ;tot;in hf ;in
ð3Þ
area and cross sectional area of the regenerator which in turn leads m
to a reduction in the regenerator efficiency. The regenerator depos-
its on checkers surface are periodically cleaned by scrubbing.
3.1. Regenerator model
3. Regenerator mass and energy balance The regenerator modeling is based on the mass and energy bal-
ances of the heat supplied from flue gas and heat absorbed by air.
The flue gas and combustion air flow in the regenerator as two The regenerator design and operating characteristics determine
separate streams, without mixing. The negative pressure due to heat transfer rate between air and flue gas. The heat transfer rate
chimney draft on the flue gas side of the regenerator leads to an depends on regenerator surface area, heat transfer coefficient and
ingress of atmospheric air into the regenerator. The air leakage temperature difference between air and flue gas streams.
from combustion air is neglected. The inlet and outlet streams Two stream equations (Eqs. (4) and (5)) and one design charac-
for regenerator are presented in Fig. 3. The mass balance for the teristic equation (Eq. (6)) together determine the total heat transfer
regenerator is presented in following equation: from flue gas to combustion air.
4
5
1
Port neck
Glass level
2
Checkers
packing
3
Manual damper for
Rider arch airflow selection and
Diverter damper control
Combustion air
Measurement locations
650
600
Non-doghouse side
550
Temperature ( C )
o
500
Doghouse side
450
400
350
300
250
200
0 5 10 15 20 25
Time (min)
1450
Non-doghouse side
Temperature ( C)
1400
o
Doghouse side
1350
1300
1250
1200
0 4 8 12 16 20 24
Time (min)
Table 2
_ air C p;air ðT reg;air;out T reg;air;in Þ
Q reg;air ¼ m ð4Þ Oxygen measurement in regenerator.
Table 4 Table 6
Furnace operating variables input to model. Regenerator blockage prediction.
Table 5 The methodology for calculation of mass flow rate of flue gas and
Regenerator model output parameters. combustion air is discussed in Sardeshpande et al. [18]. The regen-
Particular Unit Doghouse Non-doghouse erator model estimates the air leakage quantity and corrects the
side side outlet flue gas temperature, which is used as the true outlet tem-
Mass of air leakage in regenerator kg/h 1840 1490 perature for regenerator performance estimation.
Corrected regenerator outlet °C 666 588 The regenerator performance estimated for the given design
temperature and operating conditions is used to estimate the actual area avail-
Air preheat temperature °C 1022 1040
Actual regenerator efficiency % 48.8% 52.8%
able for the heat transfer. The heat transfer area estimated is com-
Targeted regenerator efficiency % 55% 55% pared with the design heat transfer area to estimate the blockage
factor of the regenerator. The target performance based on design
area and the actual performance of regenerator are compared for
performance improvement. Fig. 5 shows of the information flow
diagram for the calculations in the regenerator performance
The ideal heat transfer coefficient calculated for steady state is model.
then corrected for the transient condition (Eq. (9)) using properties
of bricks, expressed by dimensionless factors f and v calculated
based on the method proposed by Schack [2]. 4. Performance estimation of a regenerator
f
U reg;act ¼ U reg;id ð9Þ A case study on the estimation of performance of a regenerator
v is presented here with experimental data and model runs. The
The regenerator storage matrix receives heat from the flue gas furnace in the case study is a 130 TPD (Ton per Day) regenerative
and releases this heat to the combustion air. During heat storage end fired glass furnace located in Mumbai, India.
and air heating, wall loss from regenerator is deducted from heat The experimental work is carried out mainly to measure the
stored in matrix. Eqs. (10)–(12) represent these calculations. The input parameters required for the regenerator performance model.
heat supplied from the flue gas to the combustion air is presented A set of portable instruments is used for this purpose. The
in Fig. 4. parameters monitored with existing instrumentation (installed
on furnace) are also measured during experimentation. The
Q reg;matrix ¼ Q reg;f Q reg;wall;heat ð10Þ list of instruments used during measurement is presented in
Table 1.
Q reg;matrix ¼ Q reg;air þ Q reg;wall;cool ð11Þ
80%
40
49
60%
40%
54
20% 46
0%
Actual performance Target performance
Heat recovered in air pre-heating Heat loss in flue gas Heat loss in regenerator wall losses
Fig. 9. Regenerator actual and target performance for doghouse side regenerator.
V. Sardeshpande et al. / Applied Energy 88 (2011) 4451–4458 4457
700 60%
650 55%
Efficiency
( C)
550 45%
o
500 40%
450 35%
400 30%
0% 10% 20% 30% 40% 50% 60% 70%
Blockage
Fig. 10. Variation of regenerator efficiency and flue gas outlet temperature as a function of blockage factor.
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