Numerical simulation of a metallurgical transformation furnace using residual mixtures of industrial and automotive oils with added maintenance solvents

Abstract This article presents the exciting results of a numerical analysis of combustion and energy efficiency parameters in an IDR (adjustable direct injection) oscillating furnace, used in a combined metallurgical process and operated with a unique blend of automotive, industrial, and aggregate oils. The simulation process kicks off with the design of the real-world CAD (computer-aided design) environment, the programming in CFD (Computational Fluid Dynamics), and the validation in field-based PAT (Process Analytical Technology) experiments. This methodology was a total game-changer! It allowed us to predict the injection behavior of the mixture, as well as the temperature ranges, wind tunnel effects within combustion, pressures in the working zones, and heat release. We then compared the data with the experimental scenario, which was a great way to measure the efficiency and performance of the mixture, observe the thermal combustion behaviour within the oven, and compare the results with other fuels commonly used in this type of transformation. The experimental results were astounding! The thermal performance was found to be a whopping 73% higher than other fuels and combined cycles. The efficiency improvement was even more impressive, reaching 84.6%. That means the process is not only more efficient, but it's also 54.76% faster than traditional times with fossil fuels. And that's not all! The cost reduction was an incredible 76.43%. It also meant an affectation of 10.5% since these must be adjusted to the requirements of the process terms. The simulated and experimental results show the thermal ranges, fuel efficiency, percentage efficiency of the cycle, implications in the process tasks, costs and impact of migration by fuel type. The deviation between experimental and simulation values of process temperatures on a common fuel is diesel or gas, showed the advantages of using predictive tools in the use of reidual fuels and the importance of the conservation of the aggregates to the mixtures. The CFD analysis together with experimental studies proved to be an effective method to predict the process parameters inside the furnace operating with new energy sources fueled with waste blends.