Fraunhofer ISC, Center for High Temperature Materials and Design HTL, Bayreuth
Project Cluster DiMaWert
Digitisation of material development along the value chains
Completed Funded Projects
Motivation
tunnel kiln for the firing of sanitary ceramics
The need to reduce CO2 emissions and the increasingly fluctuating energy supply from regenerative sources are a challenge both for industrial furnace construction and for operators of high-temperature processes. Networked computer models and precise measurement data are indispensable as a basis for model calculations in order to be able to guarantee optimum energy efficiency and consistently high product quality, not only in the design of new furnace systems but also in the control and monitoring of production processes in furnaces. The project aims to develop appropriate digital tools for the future needs of furnace manufacturers and users.
Objective
Schematic representation of the multiscale concept for the simulation of thermal processes in industrial kilns: kiln segment - firing stack 2-stage - product with coupling to material model
The aim of this sub-project was to develop concepts and methods that enable the virtual development of thermal process plants with the aid of digital furnace twins. In the field of furnace simulation, this includes in particular the selection and validation of submodels for the efficient modeling of large industrial furnaces and the coupling of material and thermal models on the various scales under consideration. Equally important are methods for the procurement and quality-assured internal provision of precise material data from databases, literature and our own measurements.
Results
Examples of kiln simulations: Model of a bogie hearth with load (wash basin) in the tunnel kiln (left), corresponding cross-section with temperature distribution (right).
- Selection and procurement of suitable databases
- Scripts for material data search and parameterization
- Development of methods for topology optimization of furnace components:
- App for the design of kiln insulation
- Methods for the topology-optimized design of kiln furniture
- Development of a submodel concept for large industrial kilns
- Selection, testing and experimental validation of important simulation methods (FE, CFD)
- Networking, further development and supplementation of the simulation methods available at the HTL in the sense of ICME (Integrated Computational Materials Engineering)