This study investigates nozzle diameter and fuel type effects on combustion characteristics and NOx emissions in radiant tube heating systems through numerical simulation. Four fuels were analyzed: LPG, natural gas, coke oven gas, and hydrogen under varying nozzle conditions using computational fluid dynamics with energy conservation, species transport, and thermal NOx formation models. Results show that nozzle diameter optimization significantly enhances internal recirculation, improving fuel-air mixing and reducing NOx formation. Hydrogen exhibits higher flame temperatures, potentially increasing thermal NOx generation, but optimal nozzle design controls this effect through enhanced mixing patterns. The optimized configuration achieved substantial NOx reduction while maintaining combustion stability across all tested fuels.

In this study used Computational Fluid Dynamic analysis to examine NOx reduction in hydrogen combustion, analyzing six conditions with varying air/fuel ratios, temperatures, and concentrations. Results were compared between two combustor shapes and previous experimental data. Findings showed increased air/fuel ratios decreased flame temperature and increased post-combustion O2. NOx emissions peaked at high temperatures and low O2. Numerical results aligned with previous experimental trends, validating the approach. Combustor shape differences, reflecting variations in fuel and air pipes, significantly affected flow rates and combustion positions. This reduced NOx emissions up to a certain air/fuel ratio, but excessive increases diminished this effect. The study highlights the complex relationship between combustor design, operating conditions, and NOx emissions. Further research is needed to optimize NOx reduction by considering pipe numbers and combustion locations. Future studies should explore various combustor geometries, fine-tune air/fuel ratios, and investigate additional parameters influencing NOx formation and reduction in hydrogen combustion systems.

Radiant tubes heat exchangers are critical components that facilitate the heat transfer process to steel in an annealing furnace, and it addresses several engineering problems, such as thermal stress and mechanical failure due to long-term thermal cycling, which can significantly affect the longevity of the tubes and maintenance requirements. In this study, we used commercial software (ANSYS) to simulate the thermal stress and deformation of radiant tubes subjected to extreme thermal conditions and pressure loads. We evaluated both thermally induced deformation and creep deformation, which is a time-dependent deformation under constant stress over the long term. The results showed that uneven temperature conditions and pressure loads lead to significant deformation and potential failures. To mitigate these engineering challenges, we also tested several designs that include supporting brackets. This study provides valuable insights for designing radiant tube heat exchangers in annealing furnaces to extend their lifespan and ensure system safety.