Optimization of parameters for an aluminum melting furnace using the Taguchi approach

To achieve high thermal efficiency, less pollutant emission and high quality products, a study on a regenerative aluminum melting furnace was carried out. The effects of the vertical angle of burner (A), height of burner (B), secondary flue (C), swirl number (D), horizontal angle between burners (E), air preheated temperature (F), natural gas mass flow (G) and air-fuel ratio (H) on the performance of aluminum melting furnaces were investigated. RSD (relative standard deviation) of aluminum temperature (Y1), melting time (Y2) and RSD of furnace temperature (Y3) were designed for evaluation criteria. An orthogonal array was used to arrange CFD experimental plan for above factors. CFD technique, in association with the Taguchi method and cross-table-based analysis of variance were employed for parameter optimization of melting process of the aluminum melting furnace. The optimum condition which may be used to reduce energy consumption and pollutant emission is A2B3C3D3E2F1G3H1. The obtained results were confirmed by statistical analysis method.