Numerical simulation and optimization of the melting process for the regenerative aluminum melting furnace

In this study, a coupled heat transfer model for describing the multi-physics process is successfully established for a representative rectangular regenerative aluminum melting furnace (AMF) with diagonally arranged and periodically opened burners. The gas flow field and temperature field in the furnace are vividly rendered. The heat flux at the fluid-solid coupling surface between the high temperature flue gas and the aluminum is analyzed in detail, in order to illustrate the melting and the heat transfer process within the aluminum. It is found that the relative standard deviation of furnace temperature reduced to 9%, indicating a more uniform furnace temperature compared with the circular AMF with circumferential burners, which is beneficial to the practical operation. Significantly, by using the uniform design and response surface method, a multi-objective optimization is carried out based on twenty tests and five factors (burner installation height, angle, inter-burner spacing, gas flow rate, and air preheating temperature). After the optimization, the melting time reduces to 5.25 h, which is 16.5% smaller than the design value. The coefficient of temperature uniformity for the complete melting is 10.01%, quite close to the design value. In addition, the fuel consumption decreases by 12.3% compared with the design value. The progress made so far could provide guidance for the high-efficiency operation of the representative regenerative aluminum melting furnace, and pave a way to energy-saving and emission reduction in aluminum production.