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<p>Commercial computational fluid dynamics (CFD) packages lack the flexibility to integrate additional physics for developing packed-bed simulation tools for complex metallurgical processes such as pellet induration furnaces. These solutions are also unsuitable for online deployment in plant operation control rooms. As a result, many researchers have developed models using in-house codes, but these models often lack computational efficiency, parallel processing capabilities, and robustness. This work leverages the flexibility and parallelization potential of open-source codes by developing a three-dimensional comprehensive tool using OpenFOAM to simulate the straight-grate iron oxide pellet induration furnace. The induration furnace is designed for efficient heat and mass transfer between the moving pellet bed and the flowing gas. The model incorporates various heterogeneous gas–solid reaction kinetics and other relevant physicochemical phenomena. The developed model has been extensively validated against experimental and numerical data reported in the literature, as well as actual plant-scale measurement using a ThermoCar test. This confirms the model accuracy and reliability as a real-time monitoring tool in plant operational control rooms. Furthermore, a case study is presented to demonstrate the model capability by focusing on the effect of a blinded grate bar on the pellet bed thermal profile and gas flow distribution.</p>

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A Novel OpenFOAM-Based Approach for Numerical Modeling of Straight-Grate Pellet Induration Furnace

  • 期刊论文

  • 发表日期：

    2025年7月2日

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  • Sagar Dave,
  • Barun Harichandan,
  • Gautam Banerjee,
  • Sirshendu Chattopadhyay,
  • Nurni N. Viswanathan

摘要

Commercial computational fluid dynamics (CFD) packages lack the flexibility to integrate additional physics for developing packed-bed simulation tools for complex metallurgical processes such as pellet induration furnaces. These solutions are also unsuitable for online deployment in plant operation control rooms. As a result, many researchers have developed models using in-house codes, but these models often lack computational efficiency, parallel processing capabilities, and robustness. This work leverages the flexibility and parallelization potential of open-source codes by developing a three-dimensional comprehensive tool using OpenFOAM to simulate the straight-grate iron oxide pellet induration furnace. The induration furnace is designed for efficient heat and mass transfer between the moving pellet bed and the flowing gas. The model incorporates various heterogeneous gas–solid reaction kinetics and other relevant physicochemical phenomena. The developed model has been extensively validated against experimental and numerical data reported in the literature, as well as actual plant-scale measurement using a ThermoCar test. This confirms the model accuracy and reliability as a real-time monitoring tool in plant operational control rooms. Furthermore, a case study is presented to demonstrate the model capability by focusing on the effect of a blinded grate bar on the pellet bed thermal profile and gas flow distribution.