A systematic approach to numerical analysis and validation for industrial oven design and optimization – A case study

Abstract

The findings of this research not only provide valuable insights into industrial oven design but also demonstrate the broader importance of adopting systematic approaches and incorporating numerical analysis techniques to achieve clean energy goals. By leveraging such approaches across various industrial sectors, we can pave the way for a greener future, where energy efficiency, environmental sustainability, and economic growth can harmoniously coexist. In today's rapidly evolving world, where the need for sustainable practices and clean energy solutions is more critical than ever, research plays a pivotal role in driving innovation and addressing environmental challenges. The study presented in this article aligns with this overarching goal by focusing on the optimization of industrial oven design, aiming to achieve energy efficiency and high-quality product outcomes. Efficient oven design and optimization hold significant implications for energy conservation, reducing greenhouse gas emissions, and minimizing environmental footprints. By precisely controlling heat distribution and velocity within industrial ovens, such as the one investigated in this study, resource consumption can be minimized, resulting in reduced energy usage and improved operational efficiency. Moreover, the enhanced uniformity in temperature and airflow distribution ensures optimal product quality, reducing waste and promoting sustainable production practices. A systematic approach to numerical analysis and validation for industrial oven design and optimization is developed. Computational fluid dynamics (CFD) and the Taguchi design of experiment methods were employed to determine the influential design variables. The 3D CFD model was then compared with experimental results to validate its accuracy. An experimental oven design was developed based on optimal signal-to-noise (S/N) ratios, and the numerical findings were corroborated through experimental measurements, demonstrating a strong agreement. The proposed approach, encompassing the design, manufacturing, and analysis stages, can be applied to diverse industrial oven designs.

Keywords

• Taguchi DOE
• design of experiments
• orthogonal arrays
• computational fluid dynamics (CFD)
• optimization
• furnace
• forced convection
• heat transfer
• optimization
• CFD

Project Number

7160496

Endüstriyel fırın tasarımı ve optimizasyonuna yönelik sayısal analiz ve doğrulamaya sistematik bir yaklaşım – Bir örnek olay çalışması

Abstract

Bu araştırmanın bulguları yalnızca endüstriyel fırın tasarımına dair değerli bilgiler sağlamakla kalmıyor, aynı zamanda temiz enerji hedeflerine ulaşmak için sistematik yaklaşımları benimsemenin ve sayısal analiz tekniklerini birleştirmenin büyük önemini de gösteriyor. Çeşitli endüstriyel sektörlerde bu tür yaklaşımlardan yararlanarak enerji verimliliğinin, çevresel sürdürülebilirliğin ve ekonomik büyümenin uyumlu bir şekilde bir arada var olabileceği daha yeşil bir geleceğin yolu açılabilir. Verimli fırın tasarımı ve en iyileştirilmesi, enerji tasarrufu, sera gazı emisyonlarının azaltılması ve çevresel ayak izlerinin en aza indirilmesi gibi önemli etkilere sahiptir. Bu çalışmada endüstriyel fırın tasarımı ve en iyileştirilmesine yönelik sayısal analiz ve doğrulamaya yönelik sistematik bir yaklaşım geliştirilmiştir. Etkili tasarım değişkenlerini belirlemek için hesaplamalı akışkanlar dinamiği (HAD) ve Taguchi deney tasarım yöntemleri kullanılmıştır. 3 boyutlu HAD modellerinden çıkan sonuçlara bağlı olarak, sinyal-gürültü (S/N) oranları belirlenmiş, en yüksek verimlilik için, tasarım değişkenlerinin değerleri tespit edilmiş ve bu değerlere bağlı olarak deneysel bir fırın tasarımı geliştirilmiştir. HAD analizlerinden elde edilen sayısal değerler ile deneysel ölçümlerden elde edilen değerler arasında güçlü bir uyum görülmüştür. Tasarım, üretim ve analiz aşamalarını kapsayan önerilen yaklaşım, çeşitli endüstriyel fırın tasarımlarına uygulanabilir.

Keywords

• Taguchi DOE
• deney tasarımı
• ortogonal diziler
• hesaplamalı akışkanlar dinamiği (HAD)
• optimizasyon
• fırın
• zorlanmış konveksiyon
• ısı transferi
• en iyileştirme
• CFD

Supporting Institution

The Scientific and Technological Research Council of Turkey (TUBİTAK)

Project Number

7160496

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