Numerical investigation of an innovative furnace concept for industrial coil coating lines

In this work, the engineering performance of an innovative furnace concept developed for continuous drying and curing of paint-coated metal sheets (coil coating process) is investigated through advanced modeling and numerical simulation techniques. Unlike the traditional and wide-spread coil coating furnaces – which operate according to the so-called convective air-drying technology –, the present furnace concept relies on infrared radiative heating to drive solvent evaporation and curing reactions. Radiative heat is provided by the operation of radiant porous burners which are fed with evaporated solvents. The current furnace concept consists of two main chambers (the radiant burner section and the curing oven section) with different gas compositions (atmospheres) that are separated by a semi-transparent window. The window allows energy transfer and prevents gas mixing between the two sections. To utilize the solvent-loaded atmosphere available in the curing oven section as fuel – and to prevent the development of explosive conditions therein –, a novel inertization concept shielding the curing oven section from the external environment is considered. The current furnace concept aims at improving process intensification and promoting energy efficiency. For the current furnace concept, numerical simulation results support a suitable and competitive performance for drying the applied coatings in comparison with the traditional approach. Simultaneously, a safe operation is predicted, without (i) solvent leakage from the furnace and (ii) oxygen entrainment from the surrounding ambient into the furnace. These conditions are satisfied demonstrating a safe operation and a complete evaporation of solvents from applied liquid film coatings.