Industrial Combustion Processes | Modelling Support Services

CanmetENERGY’s combustion modelling capability (Computational Fluid Dynamics or CFD) is available to industries to serve their needs. This modelling capability can be used to predict in-service performance of combustion equipment, providing detailed information on combustion characteristics, pollutant formation, fuel consumption, heat transfer and fluid flow. Analyses and visualization of these data are used in the decision-making process and can greatly assist in:

• Identification and remedy of operational difficulties or problems
• Performance optimization
• Evaluation of retrofit options
• Design analysis
• Scale-up of prototypes

The CanmetENERGY modelling capability is intended to generate time and cost savings in support of the Canadian private sector and other government departments. Below are 2 examples of its use, demonstrating performance optimization and new design concepts to reduce both CO2 emissions and cost.
Example 1: Adjusting Burner Firing Rates on a Refinery Furnace
The combustion modelling capability was employed to understand and improve the operation of a heater used to provide energy for a catalytic cracking process at a petroleum refinery. In this case, uneven heating of two process fluid streams compromised production and safety. The study confirmed the uneven heat distribution in the furnace and identified the cause of the problem. Further analysis of the model revealed that there was inherent flow instability within the unit due to unforeseen sensitivity to burner firing rates. This information prompted the furnace operators to modify the burner firing rates based on the model results. The change led to an improved heat distribution and operating cost savings of $100,000 - $300,000 per year, generating a payback on the cost of the study within 3 months.

Example 2: Designing a New Multi-Fuel Injection System for a Blast Furnace
CanmetENERGY staff worked with engineers at Canadian steel mills to help design new strategies for injecting hydrocarbon fuels into blast furnaces. Injecting hydrocarbon fuels in strategic locations of a blast furnace can potentially reduce coke consumption in the steelmaking process, resulting in cost benefits and mitigation of greenhouse gas emissions.
Engineers used the models to design and assess over 10 different injection strategies for various fuel and oxidant combinations using pulverized coal, natural gas, waste oil and pure oxygen. The 2 most promising designs were chosen for prototyping and field testing. Utilizing modelling in the design process helped save time and costs in identifying the most promising designs for application.

Using CanmetENERGY’s Simulation Capability
CanmetENERGY experts collaborate with leading CFD vendors to jointly develop state-of-the-art modelling capabilities that meet the needs of industrial energy systems. We can also customize our modelling approaches to match our clients’ specific physical process of interest. Best model results are typically achieved via a project team with input from equipment operators and modelling experts to ensure that the most appropriate modelling approaches and input are used.
CanmetENERGY’s combustion modelling capability is the product of 20 years of research and collaborations with the academic community and commercial software developers. Its development is based on work initiated at the University of London’s Imperial College , the University of Waterloo  and ANSYS Canada Ltd. 
Funding support is available for modelling projects that aim to improve energy efficiency in industrial facilities. For more information please contact us.