Effects of Mesh Generation on Modelling Aluminium Anode Baking Furnaces

Anode baking is critical in carbon anode production for aluminium extraction. Operational and geometrical parameters have a direct impact on the performance of anode baking furnaces (ABF), and hence on the resulting anode quality. Gas flow patterns, velocity field, pressure drop, shear stress and turbulent dissipation rate are the main operational parameters to be optimised, considering a specific geometry that is discretised as a mesh. Therefore, this paper aims to establish the need to generate an appropriate mesh to perform accurate numerical simulations of three-dimensional turbulent flow in a single section of an ABF. Two geometries are considered for generating three meshes, using COMSOL and cfMesh, with different refinement zones. The three meshes are used for creating nine incompressible isothermal turbulent flow models, with varying operational parameters. Velocity field, convergence and turbulent viscosity ratio in the outlet of fuel inlet pipes are the quantification criteria. Quantification criteria have shown that a better physical representation is obtained by refining in the whole combustion zone. COMSOL Multiphysics’ built-in mesh generator allows quadrilateral, tetrahedron and hexahedron shapes. Adaptive cell sizes and shapes have a place within modelling, since refining a mesh in appropriate zones brings the Peclet number down when the incompressible isothermal turbulent flow is simulated.