Numerical simulation of heat and mass transfer in fluidised bed heat treatment furnaces

In this paper, a novel combined theoretical and computational model is developed to simulate the heat and mass transfer between a fluidised bed and a workpiece surface, and within the workpiece by considering the fluidised bed as a medium consisting of a double-particle layer and an even porous layer. The heat and mass-transfer flux from the fluidised bed to the workpiece surface is contributed by dense and bubble phases, respectively. The convective heat and mass transfer is simulated by analysing the gas dynamics in the fluidised bed, while radiative heat transfer is modelled by simulating photon emission in a three-dimensional particle array. The simulation shows that convection is approximately constant, while radiation contributes significantly to the heat transfer. The heat-transfer coefficient on an immersed surface near particles is about 6–10 times that on other areas. The transient heat and mass-transfer coefficient, heat and mass-transfer flux on any surface of the workpiece, transient temperature and carbon distributions at any position of the workpiece during the metal carburising process are studied with the simulation.

Measurement of the mass transfer coefficient at workpiece surfaces in heat treatment furnaces

The mass (e.g. carbon) transfer coefficient at a workpiece surface is an important kinetic factor to control the heat treatment process of the workpiece and to evaluate heat treatment equipment. The coefficient can be calculated from the carbon concentration at the surface of a sample carburized in a carburizing furnace for a given time. Two common measurement methods which use a thin plate and employ a component as samples respectively are evaluated and compared for sensitivity and uncertainty. The comparison shows that the use of a component produces higher measurement precision and also has the advantage in measuring the carbon transfer coefficients at different treated positions. This method is then extended and discussed methodologically. Also two equations are proposed to calculate the carbon transfer coefficient and its uncertainty, respectively. This method is also applied to measure the carbon transfer coefficient in a fluidized bed heat treatment furnace.

Heat and mass transfer in fluidised-bed heat-treatment furnaces

The mechanisms of heat and mass transfers between heat-treatment fluidised beds and immersed workpiece were studied by using computational simulation and experimental validation. A model called Double Particle-layer and Porous Medium was developed to simulate the gas flow and heat transfer between fluidised beds and immersed workpiece.

A method and its optimal parameters for the measurement of mass transfer coefficient in heat treatment furnaces

The mass transfer coefficient is an important kinetic factor to control the thermo-chemical treatment processes of metals and alloys. More importantly, the mass transfer coefficient is different at different surface positions of a metallic part treated, which depends on the dynamic characteristics of the atmosphere close to the treated surface. Understanding the local mass transfer coefficient would be significant to approach the expected physical and mechanical properties of treated surfaces. In this paper, a reverse method was proposed to measure the mass transfer coefficient at component surface and the diffusivity in metal during heat treatment. The methodology of the reverses method and the optimal parame-ters are discussed in some detail. This method was successfully used to determine the car-bon transfer coefficient at the surface of a part in a carburizing furnace and carbon diffusiv-ity from the carbon distribution within the diffusion layer.

Cr(N,C) diffusion coating formation on pre-nitrocarburised H13 tool steel

The microstructural processes of Cr(N,C) coating formation by thermoreactive deposition and diffusion (TRD) on pre-nitrocarburised H13 tool steel were studied. Both nitrocarburising and TRD were performed in fluidized bed furnaces at 570 °C. During TRD, chromium was transferred from chromium powder in the fluidized bed, to the nitrocarburised substrates by gas-phase reactions initiated by reaction of HCl gas with the chromium. Addition of 30% H2 to the input inert gas was found to increase the rate of coating formation, although hydrogen reduction resulted in rapid loss of nitrogen to the surface. The reason for the increased rate of coating formation could not be established without further investigation, although several possible explanations have been proposed. It was found that porosity and the formation of an iron nitride ‘cover layer’ during nitrocarburising were the biggest influences on the microstructure of the Cr(N,C) coating. Microstructural characterization of the coatings was performed by scanning electron microscopy (SEM), X-ray diffraction (XRD) and glow discharge optical emission spectroscopy (GDOES).

Reduction of fuel consumption in an industrial glass melting furnace

Reduction of fuel consumption in glass melting furnaces can cut the cost of production, and tackle the global warming. This paper presents three independent solutions to reduce the fuel consumption in industrial glass melting furnaces. The solutions include air preheating, raw material preheating, and improving the insulation of combustion space refractory. Energy balance equations are derived and used to identify the effects of each solution. The results indicate that the three solutions reduce the fuel consumption by 9.5%, 17%, and 34%, respectively.

A life cycle inventory of aluminium die casting

As part of an ongoing project, a life cycle inventory (LCI) of aluminium high pressure die casting (HPDC) has been collected. This has been conducted from the view of an individual product and also the entire process. The objective of the study was to analyse the process and suggest changes to reduce environmental impacts. One modem aluminium high pressure die casting plant located in Victoria, Australia was evaluated and modelled. Site specific data on energy and materials was gathered and the process was modelled using a typical automotive component. The paper also presents our experience and methodology used in this inventory data collection process from the real industry for LCA purposes. The inventory data collected itself reveals that the HPDC process is energy intensive and as such the major emissions were from the use of natural gas fired furnaces and from the brown coal derived electricity. It is also found the large environmental benefits of using secondary aluminium over primary aluminium in the HPDC process. A detailed LCA is being cal1ied out based on the inventory obtained.

Fluidised bed nitrocarburising of tool steels

The work examines how ferritic nitrocarburising, a common heat treatment process for steels, can be adapted to the fluidised bed furnace. The effect of fluidising powder contamination on repeatability, composition of the reactive gas mixture, the development of nitrocarburised tool steel microstructure and resulting wear properties were investigated.

Study of calcium and silicon migration in refractory magnesia

Studied the effect calcium and silicon impurities have on magnesia refractories, a material frequently used to line high-temperature furnaces. Advanced analytical techniques identified and mapped these impurities in both raw materials and finished magnesia refractories. This research considerably enhanced understanding of factors influencing refractory properties and quality.

Improving casthouse throughput using discrete-event modeling

The scheduling of metal to different casters in a casthouse is a complicated problem, attempting to find the balance between pot-line, crucible carrier, furnace and casting machine capacity. in this paper, a description will be given of a casthouse modelling system designed to test different scenarios for casthouse design and operation. Using discrete-event simulation, the casthouse model incorporates variable arrival times of metal carriers, crucible movements, caster operation and furnace conditions. Each part of the system is individually modelled and synchronised using a series of signals or semaphores. in addition, an easy to operate user interface allows for the modification of key parameters, and analysis of model output. Results from the model will be presented for a case study, which highlights the effect different parameters have on overall casthouse performance. The case study uses past production data from a casthouse to validate the model outputs, with the aim to perform a sensitivity analysis on the overall system. Along with metal preparation times and caster strip-down/setup, the temperature evolution within the furnaces is one key parameter in determining casthouse performance.

The development of bauxite at Gove, 1955–1975

In the early 1950s Australia mined little bauxite and produced no alumina, that being the chemically pure aluminium oxide which is extracted from bauxite and then smelted in electric furnaces to produce aluminium metal. The huge costs of aluminium production meant that, after World War II, six large companies dominated the aluminium industry worldwide, from mining bauxite through to fabricating and selling metal. These were Alcoa, Reynolds Metals and Kaiser in the United States, Alcan in Canada, Pechiney in France and Alusuisse in Switzerland. In the 1940s the Chifley government planned a small aluminium smelter in Tasmania largely for defence purposes, and originally dependent on imported bauxite. Government co-operation with industry to search for indigenous bauxite feedstock for the smelter saw two discoveries of bauxite at about the same time in northern Australia in the 1950s-the first at Gove in the Northern Territory and the second, much larger find, across the Gulf of Carpentaria in Queensland. These two discoveries and the proving of bauxite deposits of commercial grade in Western Australia a few years later meant that Australia possessed an astonishing one third of the world's bauxite by the early 1960s.

Dry sliding wear of active screen plasma carburised austenitic stainless steel

Low temperature diffusion treatments with nitrogen and carbon have been widely used to increase the tribological performance of austenitic stainless steels. These processes produce a layer of supersaturated austenite, usually called expanded austenite or S-phase, which exhibits good corrosion and wear resistance. The novel active screen technology is said to provide benefits over the conventional DC plasma technology. The improvements result from the reduction in the electric potential applied to the treated components, and the elimination of such defects and processing instabilities as edge effects, hollow cathode effects and arcing. In this study, AISI 316 coupon samples were plasma carburised in DC and active screen plasma furnaces. The respective layers of carbon expanded austenite were characterised and their tribological performance was studied and compared. Detailed post-test examinations included SEM observations of the wear tracks and of the wear debris, EDX mapping of the wear track, EBSD crystal orientation mapping of the cross sections of the wear tracks, and cross-sectional TEM. Based on the results of wear tests and post-test examinations, the wear mechanisms involved are discussed.

Study of active screen plasma processing conditions for carburising and nitriding austenitic stainless steel

Active screen (AS) is an advanced technology for plasma surface engineering, which offers some advantages over conventional direct current (DC) plasma treatments. Such surface defects and process instabilities as arcing, edge and hollow cathode effects can be minimised or completely eliminated by the AS technique, with consequent improvements in surface quality and material properties. However, the lack of information and thorough understanding of the process mechanisms generate scepticism in industrial practitioners. In this project, AISI 316 specimens were plasma carburised and plasma nitrided at low temperature in AS and DC furnaces, and the treated samples were comparatively analysed. Two diagnostic techniques were used to study the plasma: optical fibre assisted optical emission spectroscopy, and a planar electrostatic probe. Optimum windows of treatment conditions for AS plasma nitriding and AS plasma carburising of austenitic stainless steel were identified and some evidence was obtained on the working principles of AS furnaces. These include the sputtering of material from the cathodic mesh and its deposition on the worktable, the generation of additional active species, and the electrostatic confinement of the plasma within the operative volume of the furnace.