The transition to low-carbon energy is crucial for energy-intensive sectors like ceramics and metallurgy. Hydrogen (H₂), either as a pure fuel or blended with methane (CH₄), offers significant potential to reduce CO₂ emissions. Blending up to 30% H₂ into existing CH₄ systems has already shown improved combustion efficiency with minimal infrastructure changes. However, full-scale hydrogen adoption faces challenges, including storage, transport, and safety concerns. This study presents a two-stage modeling approach to evaluate hydrogen integration in a sanitary ware kiln. First, a one-dimensional (1D) model analyzes general thermal trends. Then, a detailed computational fluid dynamics (CFD) simulation using the RANS k-omega model captures spatial variations in gas flow and heat distribution. Based on a validated reference configuration, the model explores critical kiln zones—pre-heating, firing, and rapid cooling—under varying CH₄-H₂ fuel blends. Results provide insight into the thermal behavior of hydrogen-enhanced combustion for different levels of fuel blending, and inform future kiln design and operational strategies for low-carbon transition.

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RANS Simulations of Gas Flow Within an Industrial Kiln for Sanitary Ware Manufacture

  • Eugenio Schillaci,
  • Jesus Ruano,
  • Joaquim Rigola,
  • Jiannan Liu,
  • Carlos D. Perez-Segarra

摘要

The transition to low-carbon energy is crucial for energy-intensive sectors like ceramics and metallurgy. Hydrogen (H₂), either as a pure fuel or blended with methane (CH₄), offers significant potential to reduce CO₂ emissions. Blending up to 30% H₂ into existing CH₄ systems has already shown improved combustion efficiency with minimal infrastructure changes. However, full-scale hydrogen adoption faces challenges, including storage, transport, and safety concerns. This study presents a two-stage modeling approach to evaluate hydrogen integration in a sanitary ware kiln. First, a one-dimensional (1D) model analyzes general thermal trends. Then, a detailed computational fluid dynamics (CFD) simulation using the RANS k-omega model captures spatial variations in gas flow and heat distribution. Based on a validated reference configuration, the model explores critical kiln zones—pre-heating, firing, and rapid cooling—under varying CH₄-H₂ fuel blends. Results provide insight into the thermal behavior of hydrogen-enhanced combustion for different levels of fuel blending, and inform future kiln design and operational strategies for low-carbon transition.