55 resultados para Termal furnace

em Doria (National Library of Finland DSpace Services) - National Library of Finland, Finland


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The aim of this thesis is to study the mixing of fuel and, also to some extent, the mixing of air in a circulating fluidized bed boiler. In the literature survey part of this thesis, a review is made of the previous experimental studies related to the fuel and air mixing in the circulating fluidized beds. In the simulation part of it the commercial computational fluid dynamics software (FLUENT) is used with the Eulerian multiphase model for studying the fuel mixing in the two and three-dimensional furnace geometries. The results of the three-dimensional simulations are promising and, therefore suggestions are made for the future simulations. The two-dimensional studies give new information of the effects of the fluidization velocity, fuel particle size and fuel density on the fuel mixing. However, the present results show that three-dimensional models produce more realistic representation of the circulating fluidized bed behavior.

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The aim of this thesis was to develop a model, which can predict heat transfer, heat release distribution and vertical temperature profile of gas phase in the furnace of a bubbling fluidized bed (BFB) boiler. The model is based on three separate model components that take care of heat transfer, heat release distribution and mass and energy balance calculations taking into account the boiler design and operating conditions. The model was successfully validated by solving the model parameters on the basis of commercial size BFB boiler test run information and by performing parametric studies with the model. Implementation of the developed model for the Foster Wheeler BFB design procedures will require model validation with existing BFB database and possibly more detailed measurements at the commercial size BFB boilers.

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This thesis presents a three-dimensional, semi-empirical, steady state model for simulating the combustion, gasification, and formation of emissions in circulating fluidized bed (CFB) processes. In a large-scale CFB furnace, the local feeding of fuel, air, and other input materials, as well as the limited mixing rate of different reactants produce inhomogeneous process conditions. To simulate the real conditions, the furnace should be modelled three-dimensionally or the three-dimensional effects should be taken into account. The only available methods for simulating the large CFB furnaces three-dimensionally are semi-empirical models, which apply a relatively coarse calculation mesh and a combination of fundamental conservation equations, theoretical models and empirical correlations. The number of such models is extremely small. The main objective of this work was to achieve a model which can be applied to calculating industrial scale CFB boilers and which can simulate all the essential sub-phenomena: fluid dynamics, reactions, the attrition of particles, and heat transfer. The core of the work was to develop the model frame and the required sub-models for determining the combustion and sorbent reactions. The objective was reached, and the developed model was successfully used for studying various industrial scale CFB boilers combusting different types of fuel. The model for sorbent reactions, which includes the main reactions for calcitic limestones, was applied for studying the new possible phenomena occurring in the oxygen-fired combustion. The presented combustion and sorbent models and principles can be utilized in other model approaches as well, including other empirical and semi-empirical model approaches, and CFD based simulations. The main achievement is the overall model frame which can be utilized for the further development and testing of new sub-models and theories, and for concentrating the knowledge gathered from the experimental work carried out at bench scale, pilot scale and industrial scale apparatus, and from the computational work performed by other modelling methods.

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This thesis presents an experimental study and numerical study, based on the discrete element method (DEM), of bell-less charging in the blast furnace. The numerical models are based on the microscopic interaction between the particles in the blast furnace charging process. The emphasis is put on model validation, investigating several phenomena in the charging process, and on finding factors that influence the results. The study considers and simulates size segregation in the hopper discharging process, particle flow and behavior on the chute, which is the key equipment in the charging system, using mono-size spherical particles, multi-size spheres and nonspherical particles. The behavior of the particles at the burden surface and pellet percolation into a coke layer is also studied. Small-scale experiments are used to validate the DEM models.

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This thesis presents a set of methods and models for estimation of iron and slag flows in the blast furnace hearth and taphole. The main focus was put on predicting taphole flow patterns and estimating the effects of various taphole conditions on the drainage behavior of the blast furnace hearth. All models were based on a general understanding of the typical tap cycle of an industrial blast furnace. Some of the models were evaluated on short-term process data from the reference furnace. A computational fluid dynamics (CFD) model was built and applied to simulate the complicated hearth flows and thus to predict the regions of the hearth exerted to erosion under various operating conditions. Key boundary variables of the CFD model were provided by a simplified drainage model based on the first principles. By examining the evolutions of liquid outflow rates measured from the furnace studied, the drainage model was improved to include the effects of taphole diameter and length. The estimated slag delays showed good agreement with the observed ones. The liquid flows in the taphole were further studied using two different models and the results of both models indicated that it is more likely that separated flow of iron and slag occurs in the taphole when the liquid outflow rates are comparable during tapping. The drainage process was simulated with an integrated model based on an overall balance analysis: The high in-furnace overpressure can compensate for the resistances induced by the liquid flows in the hearth and through the taphole. Finally, a recently developed multiphase CFD model including interfacial forces between immiscible liquids was developed and both the actual iron-slag system and a water-oil system in laboratory scale were simulated. The model was demonstrated to be a useful tool for simulating hearth flows for gaining understanding of the complex phenomena in the drainage of the blast furnace.

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The work is mainly focused on the technology of bubbling fluidized bed combustion. Heat transfer and hydrodynamics of the process were examined in the work in detail. Special emphasis was placed on the process of heat exchange in a freeboard zone of bubbling fluidized bed boiler. Operating mode of bubbling fluidized bed boiler depends on many parameters. To assess the influence of some parameters on a temperature regime inside the furnace a simplified method of zonal modeling was used in the work. Thus, effects of bed material fineness, excess air ratio and changes in boiler load were studied. Besides the technology of combustion in bubbling fluidized bed, other common technologies of solid fuels combustion were reviewed. In addition, brief survey of most widely used types of solid fuel was performed in the work.

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The reduction of greenhouse gas emissions in the European Union promotes the combustion of biomass rather than fossil fuels in energy production. Circulating fluidized bed (CFB) combustion offers a simple, flexible and efficient way to utilize untreated biomass in a large scale. CFB furnaces are modeled in order to understand their operation better and to help in the design of new furnaces. Therefore, physically accurate models are needed to describe the heavily coupled multiphase flow, reactions and heat transfer inside the furnace. This thesis presents a new model for the fuel flow inside the CFB furnace, which acknowledges the physical properties of the fuel and the multiphase flow phenomena inside the furnace. This model is applied with special interest in the firing of untreated biomass. An experimental method is utilized to characterize gas-fuel drag force relations. This characteristic drag force approach is developed into a gas-fuel drag force model suitable for irregular, non-spherical biomass particles and applied together with the new fuel flow model in the modeling of a large-scale CFB furnace. The model results are physically valid and achieve very good correspondence with the measurement results from large-scale CFB furnace firing biomass. With the methods and models presented in this work, the fuel flow field inside a circulating fluidized bed furnace can be modeled with better accuracy and more efficiently than in previous studies with a three-dimensional holistic model frame.

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The blast furnace is the main ironmaking production unit in the world which converts iron ore with coke and hot blast into liquid iron, hot metal, which is used for steelmaking. The furnace acts as a counter-current reactor charged with layers of raw material of very different gas permeability. The arrangement of these layers, or burden distribution, is the most important factor influencing the gas flow conditions inside the furnace, which dictate the efficiency of the heat transfer and reduction processes. For proper control the furnace operators should know the overall conditions in the furnace and be able to predict how control actions affect the state of the furnace. However, due to high temperatures and pressure, hostile atmosphere and mechanical wear it is very difficult to measure internal variables. Instead, the operators have to rely extensively on measurements obtained at the boundaries of the furnace and make their decisions on the basis of heuristic rules and results from mathematical models. It is particularly difficult to understand the distribution of the burden materials because of the complex behavior of the particulate materials during charging. The aim of this doctoral thesis is to clarify some aspects of burden distribution and to develop tools that can aid the decision-making process in the control of the burden and gas distribution in the blast furnace. A relatively simple mathematical model was created for simulation of the distribution of the burden material with a bell-less top charging system. The model developed is fast and it can therefore be used by the operators to gain understanding of the formation of layers for different charging programs. The results were verified by findings from charging experiments using a small-scale charging rig at the laboratory. A basic gas flow model was developed which utilized the results of the burden distribution model to estimate the gas permeability of the upper part of the blast furnace. This combined formulation for gas and burden distribution made it possible to implement a search for the best combination of charging parameters to achieve a target gas temperature distribution. As this mathematical task is discontinuous and non-differentiable, a genetic algorithm was applied to solve the optimization problem. It was demonstrated that the method was able to evolve optimal charging programs that fulfilled the target conditions. Even though the burden distribution model provides information about the layer structure, it neglects some effects which influence the results, such as mixed layer formation and coke collapse. A more accurate numerical method for studying particle mechanics, the Discrete Element Method (DEM), was used to study some aspects of the charging process more closely. Model charging programs were simulated using DEM and compared with the results from small-scale experiments. The mixed layer was defined and the voidage of mixed layers was estimated. The mixed layer was found to have about 12% less voidage than layers of the individual burden components. Finally, a model for predicting the extent of coke collapse when heavier pellets are charged over a layer of lighter coke particles was formulated based on slope stability theory, and was used to update the coke layer distribution after charging in the mathematical model. In designing this revision, results from DEM simulations and charging experiments for some charging programs were used. The findings from the coke collapse analysis can be used to design charging programs with more stable coke layers.

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Tämän työn tarkoituksena oli selvittää mekaanisen massan valmistuksen käsittävän paperitehtaan rejektija jätevirtojen poltettavuutta, jos paperitehtaan vesikiertojen sulkemisastetta lisätään. Jotta prosessin tilannetta sulkemisen jälkeen saatiin arvioitua, Anjalan paperitehtaan nykypäivän PK3:n prosessia tutkittiin kuorimolta jätevesilaitokselle. Kirjallisuusosassa käsiteltiin rejekti- ja jätevirtojen alkuperää mekaanista massaa käyttävässä paperitehtaassa. Myös tämän päivän jätevedenkäsittelyprosessit sekä sulkemisessa mahdolliset prosessiveden puhdistustekniikat esiteltiin lyhyesti. Lisäksikäytiin läpi nykypäivänä metsäteollisuudessa käytössä olevat polttotekniikat sekä polttoaineiden karakterisointi kattilan käytettävyyden ja päästöjen kannalta. Anjalan PK3:lla käytetään sekä peroksidi- että ditioniittivalkaistua tai pelkästään ditioniittivalkaistua hioketta riippuen tuotannossa olevasta lajista. PK3-prosessissa syntyneet jätevesi-, liete- ja muut jätevirrat selvitettiin molemmissa valkaisuolosuhteissa. Prosessin eniten liuennutta orgaanista ainesta sisältävät jätevesijakeet, 3-hiomon kuumankierron ja kirkassuodoksen ulosajot sekä kuoripuristimen suodos, valittiin puhdistettaviksi virroiksi prosessin sulkemista arvioitaessa. Kun peroksidivalkaisua käytettiin 3-hiomolla, TOC-kuorma jokeen oli 30 % suurempi kuin pelkällä ditioniittivalkaisulla. Jos prosessin sulkemisastetta lisättäisiin, TOC-kuorma olisi 30 %pienempi kuin tänäpäivänä peroksidivalkaisua käytettäessä (80 % puhdistustehokkuudella). Prosessin sulkemisastetta lisättäessä biolietettä muodostuisi n. 30 % vähemmän verrattuna nykytilanteeseen, sillä mikrobien ravintona käyttämää orgaanista ainesta päätyisi vähemmän jäteveteen. 3-hiomon peroksidivalkaisun vaikutus kattilan käytettävyyteen ja päästöihin oli pieni, sillä biolietteen osuus polttoaineen syötöstä oli vain 4 %. Vain osa biolietteestä muodostui 3-hiomolta peräisin olevaa orgaanista ainesta poistettaessa. Jos nykyisen pääpolttoaineen, PDF:n,osuuden jättää huomioimatta, SO2- ja NOx-päästöt sekä leijupedin sintrautuvuus ovat hiukan suuremmat käytettäessä peroksidivalkaisua 3-hiomolla kuin pelkästään ditioniittivalkaisulla. Jos kuoripuristimen ja hiomon suodosten puhdistuksen konsentraatit johdetaan poltettaviksi BFB-tyyppiseen kattilaan, leijupedin sintrautuminen tulisi olemaan suurin ongelma. Myös raskasmetalli-, SO2- ja NOx-päästöt lisääntyisivät merkittävästi verrattuna nykyiseen tilanteeseen. Sen sijaan kattilan korroosioriski tuskin lisääntyisi. Lisäksi konsentraattien kosteuspitoisuus olisi korkea, mikä tekisi poltosta kannattamatonta veden haihdutuksen vaatiessa paljon energiaa. Yksityiskohtaisempaa tutkimusta tarvitaan vielä prosessin sulkemisen vaikutuksista päästöihin ja kattilan käytettävyyteen. Myös muita konsentraattien hävittämismahdollisuuksia tulisi tutkia lisää.

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In this study, a model for the unsteady dynamic behaviour of a once-through counter flow boiler that uses an organic working fluid is presented. The boiler is a compact waste-heat boiler without a furnace and it has a preheater, a vaporiser and a superheater. The relative lengths of the boiler parts vary with the operating conditions since they are all parts of a single tube. The present research is a part of a study on the unsteady dynamics of an organic Rankine cycle power plant and it will be a part of a dynamic process model. The boiler model is presented using a selected example case that uses toluene as the process fluid and flue gas from natural gas combustion as the heat source. The dynamic behaviour of the boiler means transition from the steady initial state towards another steady state that corresponds to the changed process conditions. The solution method chosen was to find such a pressure of the process fluid that the mass of the process fluid in the boiler equals the mass calculated using the mass flows into and out of the boiler during a time step, using the finite difference method. A special method of fast calculation of the thermal properties has been used, because most of the calculation time is spent in calculating the fluid properties. The boiler was divided into elements. The values of the thermodynamic properties and mass flows were calculated in the nodes that connect the elements. Dynamic behaviour was limited to the process fluid and tube wall, and the heat source was regarded as to be steady. The elements that connect the preheater to thevaporiser and the vaporiser to the superheater were treated in a special way that takes into account a flexible change from one part to the other. The model consists of the calculation of the steady state initial distribution of the variables in the nodes, and the calculation of these nodal values in a dynamic state. The initial state of the boiler was received from a steady process model that isnot a part of the boiler model. The known boundary values that may vary during the dynamic calculation were the inlet temperature and mass flow rates of both the heat source and the process fluid. A brief examination of the oscillation around a steady state, the so-called Ledinegg instability, was done. This examination showed that the pressure drop in the boiler is a third degree polynomial of the mass flow rate, and the stability criterion is a second degree polynomial of the enthalpy change in the preheater. The numerical examination showed that oscillations did not exist in the example case. The dynamic boiler model was analysed for linear and step changes of the entering fluid temperatures and flow rates.The problem for verifying the correctness of the achieved results was that there was no possibility o compare them with measurements. This is why the only way was to determine whether the obtained results were intuitively reasonable and the results changed logically when the boundary conditions were changed. The numerical stability was checked in a test run in which there was no change in input values. The differences compared with the initial values were so small that the effects of numerical oscillations were negligible. The heat source side tests showed that the model gives results that are logical in the directions of the changes, and the order of magnitude of the timescale of changes is also as expected. The results of the tests on the process fluid side showed that the model gives reasonable results both on the temperature changes that cause small alterations in the process state and on mass flow rate changes causing very great alterations. The test runs showed that the dynamic model has no problems in calculating cases in which temperature of the entering heat source suddenly goes below that of the tube wall or the process fluid.

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In this study, equations for the calculation of erosion wear caused by ash particles on convective heat exchanger tubes of steam boilers are presented. Anew, three-dimensional test arrangement was used in the testing of the erosion wear of convective heat exchanger tubes of steam boilers. When using the sleeve-method, three different tube materials and three tube constructions could be tested. New results were obtained from the analyses. The main mechanisms of erosionwear phenomena and erosion wear as a function of collision conditions and material properties have been studied. Properties of fossil fuels have also been presented. When burning solid fuels, such as pulverized coal and peat in steam boilers, most of the ash is entrained by the flue gas in the furnace. In bubbling andcirculating fluidized bed boilers, particle concentration in the flue gas is high because of bed material entrained in the flue gas. Hard particles, such as sharp edged quartz crystals, cause erosion wear when colliding on convective heat exchanger tubes and on the rear wall of the steam boiler. The most important ways to reduce erosion wear in steam boilers is to keep the velocity of the flue gas moderate and prevent channelling of the ash flow in a certain part of the cross section of the flue gas channel, especially near the back wall. One can do this by constructing the boiler with the following components. Screen plates can beused to make the velocity and ash flow distributions more even at the cross-section of the channel. Shield plates and plate type constructions in superheaters can also be used. Erosion testing was conducted with three types of tube constructions: a one tube row, an inline tube bank with six tube rows, and a staggered tube bank with six tube rows. Three flow velocities and two particle concentrations were used in the tests, which were carried out at room temperature. Three particle materials were used: quartz, coal ash and peat ash particles. Mass loss, diameter loss and wall thickness loss measurements of the test sleeves were taken. Erosion wear as a function of flow conditions, tube material and tube construction was analyzed by single-variable linear regression analysis. In developing the erosion wear calculation equations, multi-variable linear regression analysis was used. In the staggered tube bank, erosion wear had a maximum value in a tube row 2 and a local maximum in row 5. In rows 3, 4 and 6, the erosion rate was low. On the other hand, in the in-line tube bank the minimum erosion rate occurred in tube row 2 and in further rows the erosion had an increasing value, so that in a six row tube bank, the maximum value occurred in row 6.

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Combustion of wood is increasing because of the needs of decreasing the emissions of carbon dioxide and the amount of waste going to landfills. Wood based fuels are often scattered on a large area. The transport distances should be short enough to prevent too high costs, and so the size of heating and power plants using wood fuels is often rather small. Combustion technologies of small-size units have to be developed to reach efficient and environmentally friendly energy production. Furnaces that use different packed bed combustion or gasification techniques areoften most economic in small-scale energy production. Ignition front propagation rate affects the stability, heat release rate and emissions of packed bed combustion. Ignition front propagation against airflow in packed beds of wood fuels has been studied. The research has been carried out mainly experimentally. Theoretical aspects have been considered to draw conclusions about the experimental results. The effects of airflow rate, moisture content of the fuel, size, shape and density of particles, and porosity of the bed on the propagation rate of the ignition front have been studied. The experiments were carried out in a pot furnace. The fuels used in the experiments were mainly real wood fuels that are often burned in the production of energy. The fuel types were thin wood chips, saw dust, shavings, wood chips, and pellets with different sizes. Also a few mixturesof the above were tested. Increase in the moisture content of the fuel decreases the propagation rates of the ignition front and makes the range of possible airflow rates narrower because of the energy needed for the evaporation of water and the dilution of volatile gases due to evaporated steam. Increase in the airflow rate increases the ignition rate until a maximum rate of propagation is reached after which it decreases. The maximum flame propagation rate is not always reached in stoichiometric combustion conditions. Increase in particle size and density transfers the optimum airflow rate towards fuel lean conditions. Mixing of small and large particles is often advantageous, because small particles make itpossible to reach the maximum ignition rate in fuel rich conditions, and large particles widen the range of possible airflow rates. A correlation was found forthe maximum rate of ignition front propagation in different wood fuels. According to the correlation, the maximum ignition mass flux is increased when the sphericity of the particles and the porosity of the bed are increased and the moisture content of the fuel is decreased. Another fit was found between sphericity and porosity. Increase in sphericity decreases the porosity of the bed. The reasons of the observed results are discussed.

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Kehitettäessä leijupolttotekniikkaa entistä ympäristöystävällisemmäksi ja tehokkaammaksi tarvitaan lisää tietoa polttoaineen käyttäytymisestä tulipesässä. Polttoaineen palamisprofiili ja reaktiivisuus vaikuttavat oleellisesti esimerkiksi voimalaitoskattilan lämmönsiirtopintojen sijoitteluun ja suunnitteluun sekä ohjausjärjestelmän toteutukseen. Varsinkin monipolttoainekattiloilla ohjausjärjestelmän toimivuus joutuu koetukselle esimerkiksi kuormanmuutostilanteissa ja äkillisissä polttoaineen syöttöhäiriöissä. Tässä työssä on aluksi tutustuttu kiertoleijupolton ilmiöihin ja niiden matemaattiseen mallintamiseen. Lisäksi esitetään katsaus eri prosessiolosuhteiden vaikutuksesta palamiseen kiertoleijuolosuhteissa. Työn tutkimusosassa kehitettiin menetelmä polttoaineen reaktiivisuuden määrittämiseksi kiertoleijupoltossa. Kehitetty menetelmä koostuu koesarjasta ja matemaattisesta simulointimallista. Koetoiminta suoritettiin VTT Energian laboratoriokokoluokan kiertoleijukoelaitteella. Koesarja polttoaineen reaktiivisuuden määrittämiseksi sisältää eri kaasukomponenttien profiilimittauksia ja dynaamisia muutoskokeita. Menetelmän avulla voidaan tutkia eri polttoaineiden reaktiivisuuksia sekä polttoaineen reaktiivisuuden ja tietyn prosessiolosuhteen välistä riippuvuutta. Suorittamalla koeajomatriisin mukaiset kokeet tietyissä prosessiolosuhteissa voidaan polttoaineen reaktiivisuus selvittää koetulosten ja simulointimallin perusteella.

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Biopolttoaineiden käyttö energiantuotannossa lisääntyy ja syrjäyttää samalla fossiilisia polttoaineita. Etenkin puupohjaisten polttoaineiden käyttö pienenergiantuotannossa on lisääntynyt nopeasti. Tätä kehitystä puoltavat tiukentuneet päästörajat ja yleinen mielipide fossiilisia polttoaineita vastaan sekä biopolttoaineiden verottomuus. Tästä johtuen biopolttoainetta käyttävien laitosten kysyntä kasvaa jatkuvasti. Kysynnän kasvaessa biopolttolaitosten valmistajien on pystyttävä nopeaan, tehokkaaseen ja laadukkaaseen toimintaan, sekä täyttämään asiakkaan tarpeet pystyäkseen vastaamaan alan kasvavaan kilpailuun. Tässä diplomityössä kehitetään standardoitua moduulirakennetta Sermet BioGrate ja BioGrate compact kattilalaitoksille. Moduloinnin tarkoituksena on helpottaa laitoskonseptin kokoonpanon suunnittelua, tarjousten ja tarjouslaskelmien tekemistä sekä yhtenäistää toimintatapoja, mikä vähentää työmäärää ja nopeuttaa toimituksia.

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Työn tarkoituksena oli kehittää kerrosleijukattilan sekundääri-ilmansyöttöä. Työssä tutkittiin tulipesässä ilmasuihkujen käyttäytymiseen vaikuttavia tekijöitä sekä eri ilmansyöttömallien vaikutuksia tulipesäolosuhteisiin. Sekundääri- ja tertiääri-ilmasuihkujen tehtävänä on sekoittaa tulipesän kaasuja sekä tuoda happi leijupetin yläpuolelle haihtuneiden aineiden palamisen loppuun saattamiseksi. Kaasujen sekoittumiseen vaikuttavat ilmasuihkun ja ristivirtauksen liikemäärien suhde, suutinten koko ja sijoittelu toisiinsa nähden. Ilmasuihku saavuttaa paremman tunkeutuvuuden ja siten tehokkaamman sekoittumisen suuttimen koon kasvaessa. Lisäksi tunkeutuvuus paranee suutinten välisen etäisyyden sekä ilmasuihkun ja ristivirtauksen liikemäärien suhteen kasvaessa. Optimaalisen suutinten välisen etäisyyden osoitettiin riippuvan suuttimen ja tulipesän koosta sekä ilmasuihkun ja ristivirtauksen liikemäärien suhteesta. Saatujen tulosten mukaan sekundääri- ja tertiääri-ilmatasoilla tulee suosia suuria harvaan ja lomittain sijoitettuja suuttimia. Ilmansyöttömalleja tutkittiin numeerisesti mallintamalla, ja saatujen tulosten perusteella tehokkain sekoittuminen saavutettiin sijoittamalla sekundääri-ilmasuuttimet tulipesän kahdelle vastakkaiselle seinälle.