The reduction of $\mathrm{C}{\mathrm{O}}_2$ emissions in hard-to-abate industries is described in several proposals on the European and National levels. In order to meet the defined goals, the utilization of sustainable, non-fossil fuels for process heat generation in industrial furnaces needs to be intensified. The focus mainly lies on hydrogen (${\mathrm{H}}_2$) and its derivates. Furthermore, biofuels, e.g., dimethyl ether (DME), are considered. Besides possible changes in the process itself when substituting natural gas (NG) with alternative fuels, the emission of nitrogen oxides ($\mathrm{N}{\mathrm{O}}_{\mathrm{x}}$) is a major topic of interest. In current European standards and regulations, the $\mathrm{N}{\mathrm{O}}_{\mathrm{x}}$ emissions are specified in mg per m³ of dry off-gas and refer to a reference oxygen concentration. Within this study, this limit specification is investigated for its suitability for the use of various fuel-oxidizer combinations in industrial combustion applications. Natural gas is used as a reference, while hydrogen and DME are considered sustainable alternatives. Air and pure oxygen (${\mathrm{O}}_2$) are considered oxidizers. It is shown that the current specification, which is built on the use of fossil fuels, leads to non-comparable values for alternative fuels. Therefore, alternative $\mathrm{N}{\mathrm{O}}_{\mathrm{x}}$ limit definitions are discussed in detail. The most suitable alternative was found to be mg per kWh. This limit specification is finally being investigated for its compliance with current regulations on various aspects of Continuous Emission Monitoring Systems.

One of the main reasons for metal loss of semi-finished metal products during heating in reheating and heat treatment furnaces is scale formation. In the presented project a burner is developed which produces a low oxidizing / reducing atmosphere in the furnace. The concept is realized by a recuperative burner, which generates a reducing furnace atmosphere due to fuel rich combustion of natural gas and air. The complete combustion of the furnace atmosphere is ensured by the injection of additional air and takes places in an open radiant tube resulting in a high energy efficiency. In this paper numerical and experimental results are presented and discussed. The numerical results showed the huge impact of the secondary air swirl on the post-combustion in the annular gap which is formed between the open radiant tube and the burner. Mixing phenomena in the annular gap results in a nearly complete post-combustion at low and high swirl angles of the additional combustion air (ω = 0°, ω = 90°). Instead of that, at a swirl angle of ω = 45° the entire reaction from CO to CO ₂ was not ensured within the boundaries of the numerical model. The quality of the post-combustion was experimentally evaluated by measuring the CO-emissions in the off-gas channel. These were lower than 50 mg/m ³ in a wide range of operation. The NO _x -emissions are lower than 121 mg/m ³ at all tested cases.

Self-recuperative burners are a common solution for efficient combustion systems in industrial furnaces. Due to the geometric complexity of the recuperators, a detailed CFD simulation is computationally expensive and not feasible for simulation models of burner-integrated systems such as radiant tubes. Especially in the FSI studies of radiant tubes, the temperature of the radiant tube surrounding the burner is decisive for the final results. The exclusion of the recuperator from the simulation models introduces significant uncertainties in the simulations results. The presented paper describes an innovative, efficient approach to model a fin-type recuperator in which the recuperator is geometrically reduced. The resulting acceleration of the numerical simulation makes a fully dynamic modelling of the recuperator in a radiant tube simulation possible. Specifically designed source terms are used to model pressure loss and heat transfer inside the recuperator to match results obtained with a detailed simulation model. The results show deviations in total heat transfer of less than 1.3% with a 98.5% reduction of numerical mesh size. The computational savings enable comprehensive modelling of air preheat for radiant tube simulations and accurately replicate flow and temperature profiles in the recuperator.

The effects of surrounding radiation—emanating from radiation exchange with neighboring partners in indirect-fired vertical strip annealing furnaces, such as the other radiant tubes, the passing strip, and the enclosing furnace chamber—on the radiant tube lifetime were studied. In-house developed and validated numerical models were used to calculate the thermomechanical behavior, especially creep deformations and the corresponding stresses as lifetime indicating parameters. Different setups of recirculating P-type radiant tubes were investigated, including a reference case of an isolated tube. The investigations could be broadly classified into the study of the effects of different tube arrangements, burner operations (synchronous/asynchronous on/off firing), and changes of strip parameters (width/temperature). Results showed higher creep deformation of the central radiant tube in the setup with three tubes arranged horizontally in a row compared to three tubes stacked in a vertical column, even though the respective characteristic temperature values in a firing cycle were similar. Furthermore, the cases with asynchronous burner firing resulted in lower creep rates than other cases, where the burners were operating in synchronous on/off firing modes. In addition, the change of strip width had a higher impact on radiant tube lifetime compared to locally changing strip temperatures across the furnace. Alternating temperatures, caused by burner operation or process changes, such as change of strip’s speed or cross-section, and local temperature gradients were observed to be the main factors influencing the tube’s service life.