3D Multiphysics model of the effect of flue-wall deformation on the anode baking homogeneity in horizontal flue carbon furnace

In horizontal flue wall carbon baking furnaces, the flue walls consist of bricks which are usually linked together by mortar. During service, the thermal expansion of flue walls is restrained due the presence of headwalls. This, as well as the load of the packing cokes and the anodes, promotes the deflection of the flue walls limits their life. The development of a 3D computational model able to take into account a large number of phenomena that play a role in the baking process and affect the flue wall aging process is then justified. This model will take into account the Thermo-Hydro-Mechanical coupling due to coupled fluid flow and transient heat transfer, packing coke load and the thermal expansion, and enable us to analyze the influence of these parameters on the resistance to deflection of the flues walls. The mechanical aspect is coupled indirectly by considering a deformed flue wall. The Thermo-Hydro-Mechanical coupling simulations were done by the commercial CFD code for Multiphysics Finite Element Analysis COMSOL. This model can be used as a powerful tool in the development of new furnaces and flue wall design and retrofitting existing ones.