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CFD-Based Evaluation of Waste Heat Recovery and Pressure Drop in Rotary Sinter Coolers Under Varying Bed Properties and Inlet Conditions

Author

Listed:
  • İbrahim Zengin

    (Department of Mechanical Engineering, Zonguldak Bülent Ecevit University, İncivez 67100, Türkiye)

  • Kubilay Bayramoğlu

    (Department of Mechanical Engineering, Zonguldak Bülent Ecevit University, İncivez 67100, Türkiye)

  • Nuri Özgür Aydın

    (Department of Mechanical Engineering, Zonguldak Bülent Ecevit University, İncivez 67100, Türkiye)

  • Halil İbrahim Topal

    (Department of Aerospace Engineering, Zonguldak Bülent Ecevit University, İncivez 67100, Türkiye)

  • Beytullah Erdoğan

    (Department of Mechanical Engineering, Zonguldak Bülent Ecevit University, İncivez 67100, Türkiye)

  • Şeyma Ulukaya

    (Department of R&D, Karabük Iron Steel Industry Trade & Co. Inc., Karabük 78000, Türkiye)

Abstract

Demonstrating the waste heat recovery potential of rotary sinter coolers in iron production facilities is critical for improving energy efficiency and reducing environmental impacts. In this study, numerical analyses were performed for the rotary cooler, and the system’s waste heat recovery capacity was optimized. The effects of particle size, porosity ratio, and inlet air temperature on system performance were examined in detail. Considering two different air outlet regions, the relationships between temperature profiles, cooling efficiency, and pressure loss were evaluated. The findings indicate that there is significant waste heat potential in high-temperature regions and that the system’s energy performance can be improved by recovering this energy. Furthermore, it was found that porosity and particle diameter have decisive effects on both heat transfer and pressure loss. For example, increasing the porosity ratio from 0.3 to 0.5 resulted in a 26% decrease in outlet air temperature and an 82.5% decrease in pressure drop. Similarly, increasing the particle diameter from 0.04 m to 0.08 m reduced the outlet temperature in one region by 11.2 K and the pressure loss by approximately 45%.

Suggested Citation

  • İbrahim Zengin & Kubilay Bayramoğlu & Nuri Özgür Aydın & Halil İbrahim Topal & Beytullah Erdoğan & Şeyma Ulukaya, 2025. "CFD-Based Evaluation of Waste Heat Recovery and Pressure Drop in Rotary Sinter Coolers Under Varying Bed Properties and Inlet Conditions," Sustainability, MDPI, vol. 17(17), pages 1-17, September.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:17:p:8066-:d:1744350
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    References listed on IDEAS

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    1. Zheng, Ying & Cai, Jiu-ju & Dong, Hui & Feng, Jun-sheng & Liu, Jing-yu, 2019. "Experimental investigation of volumetric exergy transfer coefficient in vertical moving bed for sinter waste heat recovery," Energy, Elsevier, vol. 167(C), pages 428-439.
    2. Zude Cheng & Haitao Wang & Junsheng Feng & Yongfang Xia & Hui Dong, 2021. "Energy and Exergy Efficiency Analysis of Fluid Flow and Heat Transfer in Sinter Vertical Cooler," Energies, MDPI, vol. 14(15), pages 1-18, July.
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    4. Salmon, F. & Ghadim, H. Benisi & Godin, A. & Haillot, D. & Veillere, A. & Lacanette, D. & Duquesne, M., 2024. "Optimizing performance for cooling electronic components using innovative heterogeneous materials," Applied Energy, Elsevier, vol. 362(C).
    5. Liu, Yan & Yang, Jian & Wang, Jin & Cheng, Zhi-long & Wang, Qiu-wang, 2014. "Energy and exergy analysis for waste heat cascade utilization in sinter cooling bed," Energy, Elsevier, vol. 67(C), pages 370-380.
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