Numerical simulation and optimization of a heat storage process in a layered regenerator

This numerical study aims to reduce pressure loss and improve thermal efficiency of a regenerator of an aluminum smelting furnace. A porous medium based model with a modified source item of the momentum equation, coupled with energy equations for both gas and solid phases, which upon using suitable, was established for modelling the regenerative process in Fluent environment. The mathematical model was used to investigate the effects of 4 main parameters on the thermal storage process, storage efficiency and pressure loss of the stratified regenerator. The results were analyzed by using the orthogonal experiments and variance analysis, and the collocation scheme for an optimal regenerative efficiency and pressure loss minimization. It was found that an optimal regenerative efficiency occurs with an entrance mass flow of 1.65 kg·s^-1, a particle size combination of 26 mm-18 mm-26 mm, whereas the optimal pressure drop takes place with an entrance mass flow of 1.65 kg·s^-1, a particle size combination of 32 mm-24 mm-32 mm, and the upper middle and lower layer high ratio at 2:1:2.