Steel is an indispensable material for the sustainable maintenance and progress of modern civilization. Its versatility in terms of mechanical and thermal characteristics, corrosion resistance, raw material availability, energy consumption and recyclability provides a clear advantage in a fast-changing technological landscape. In order to adapt to the changing needs, steel production methods have been evolving and improving over time. One such improvement opportunity in terms of energy efficient production is the ”heat pipe assisted annealing” concept. The cold rolling of steel is a process where the steel strip is cold-worked by means of rolls to achieve thickness reduction and better uniformity. This results in the strain hardening of steel. To reduce the hardness of steel and to render it more workable, it is thermally treated by heating it to a target soaking temperature and then cooling it down. This process is called annealing and it is an energy intensive process. Conventionally, heating is achieved with natural gas fired furnaces, whereas cooling is done using convective gas cooling. With this setting, the thermal energy extracted from the steel strip during the cooling stage is not used in any way. Moreover, none of the energy that is introduced during the heating stage is retained in the final product.An alternative technology for the annealing of steel was developed at Tata Steel IJmuiden R&D with the objective of recovering and using some of the heat removed during the cooling stage and thus, achieving more energy efficient annealing. With this technology called heat pipe assisted annealing, the cooling strip is thermally linked to the heating strip with multiple rotating heat pipes. In this way, each heat pipe transfers a certain amount of heat from the cooling strip to the heating strip. Only final heating and cooling of the steel strip is carried out in a conventional way. This concept is applicable to relatively low temperature (sub-critical) annealing where the cooling rate is not crucial. Therefore, packaging steel is a good candidate for the application of this technology.A rotating heat pipe is a highly efficient heat transfer device which is a wickless hollow cylindrical vessel rotating around its symmetric axis and containing a fixed amount of working fluid. The working fluid acts as a thermal energy carrier, transporting heat from one end of the heat pipe to the other. This basically occurs in four steps: (i) heat added to the evaporator part of the heat pipe causes the evaporation of the liquid, (ii) vapor travels to the condenser end of the heat pipe due to pressure difference, (iii) vapor condenses in the condenser section where heat is removed from the heat pipe, (iv) liquid returns to the evaporator with the help of the static pressure head and the centrifugal force induced by rotation. The heat pipe assisted annealing concept has been patented and subsequently further studied by Tata Steel Europe R&D. A water-filled rotating heat pipe test rig integrated with steel strips provided the bulk of the prior work. This test rig served as the proof-of-principle installation and it showed that heat can be transported from a hot strip to a cold one with a rotating heat pipe. In this context, several gaps have been identified to further acquire the knowledge on the system components, the concept performance and feasibility.This thesis focuses on four main aspects of the fundamentals and the feasibility of the heat pipe assisted annealing concept: (i) contact heat transfer between the steel strip and the rotating heat pipe, (ii) computationally efficient modelling of the interior dynamics of a rotating heat pipe, (iii) applicable working fluids for the high temperature range, (iv) behavior of the heat pipe assisted annealing system as a whole. These aspects are studied through a thermal engineering perspective. The heat pipe assisted annealing concept relies on the effective transfer of heat from the strip to the rotating heat pipe and vice versa. Therefore, it is important to understand the underlying physics governing this heat transfer and to be able to predict the heat transfer rate for possible configurations. In this context, in Chapter 2 of this thesis, the contact heat transfer between a steel strip and a rotating heat pipe is investigated both experimentally and numerically. The numerical model is based on first principles. It finds the thickness and the pressure of the gas layer between the strip and the heat pipe and subsequently considers different heat transfer mechanisms. The experimental work was carried out on the proof of- principle test rig. The model is validated with the experimental results. The contact heat transfer coefficient in the uniform region varied between 4,000 to 20,000 W/(m2.K). It showed an increase in the contact heat transfer with decreasing strip velocity and increasing radial stress. For the considered cases, conduction through the gas layer was the dominant heat transfer mechanism. Additionally, a simplified expression has been developed for the calculation of contact heat transfer through multiple regression analysis. The modelling of a rotating heat pipe is a crucial step for the detailed study of the heat pipe assisted annealing technology. Although modelling of rotating heat pipes has been the subject of many studies in the literature, these models are not computationally efficient enough to allow for the simultaneous modelling of multiple heat pipes linked to each other with strips. On this ground, in Chapter 3, a novel computationally efficient engineering model describing the transient behavior of the heat pipe is developed. In this model, the liquid and the vapor cells are allowed to change size radially in order to allow for the tracking of the liquid / vapor interface without the need for fine meshing or re-meshing. The model is also adapted to capillary-driven heat pipes. The model is validated with experimental and numerical studies from the literature. The deviation is computed to be around 2% with the numerical and analytical studies and around 6% with the experimental study.The heat pipe assisted annealing concept requires the operation of heat pipes within a temperature range of 25 °C to 700 °C. In order to operate within this range, different working fluids need to be used for different temperature ranges due to constraints of vapor pressure, life time, performance and safety. These working fluids are studied in Chapter 4. First, a selection of the working fluids is made based on a literature review. This selection yielded water, Dowtherm A, phenanthrene and cesium. Then, a life time test has been carried out with thermosyphons to test the stability of phenanthrene. At the end of a 3 months long test at 460 °C, thermal decomposition of phenanthrene was observed. However, these tests should be repeated with better initial vacuum and at multiple temperatures. Finally, Dowtherm A has been used in a rotating heat pipe setup to test its applicability and performance. It has been shown that Dowtherm A is suitable to be used in a rotating heat pipe at the designated temperature range in terms of performance, provided that annular flow is avoided. With the knowledge gathered from the previous chapters of this thesis, a model of the heat pipe assisted annealing line has been developed in Chapter 5. The aim of this model is to quantify the energy efficiency advantage brought by the concept for different number of heat pipes and to understand the behavior of the system as a whole. The simulations were run for a fixed plant layout with varying number of heat pipes and an average wrap angle of 104°. The energy recoveries for the simulations run for a strip of 0.25 mm and a line speed of 6.133 m/s were 76.5%, 73.4%, 69.4% and 63.9% for a total number of 90, 75, 60 and 45 heat pipes, respectively. From the simulation results it follows that cesium heat pipes are more efficient than organic heat pipes. Finally, the simulation results showed that the thermal cycle requirements can be satisfied with this new technology. ... Read more

In a conventional continuous annealing line, the energy supplied to steel strip during heating is not recovered while cooling it. Therefore, an alternative heat transfer technology for energy efficient continuous annealing of steel was developed. This technology enables reusing the heat extracted during cooling of the strip in the heating part of the process. This is achieved by thermally linking the cooling strip to the heating strip via multiple rotating heat pipes. In this context, the dynamic simulation of a full heat pipe assisted annealing line is performed. The dynamic simulation consists of the interaction of computational building blocks, each comprising of a rotating heat pipe and strip parts wrapped around the heat pipe. The simulations are run for different installation configurations and operational settings, with the heat pipe number varying between 50 and 100 and with varying strip line speed and dimensions. The heat pipes are sized to be 0.5 m in diameter and 3 m in length. The simulation results show that the equipment is capable of satisfying the thermal cycle requirements of annealing both at steady-state and during transition between steady-states following changes in boundary conditions. With this concept, energy savings of up to 70% are feasible. ... Read more

Rotating wickless and stationary capillary cylindrical heat pipes are widely used heat transfer devices. Transient behavior of such heat pipes has been investigated numerically with computational fluid dynamics and lumped parameter models. In this paper, the advantages of both methods are combined into a novel engineering model that is low in computational cost but still accurate and rich in the details it provides. The model describes the interior dynamics of the heat pipe with a 2D representation of a cylindrical heat pipe. Liquid and vapor volumes are coarsely meshed in the axial direction. The cells are allowed to change in size in the radial direction during simulation. This allows for tracking the liquid/vapor interface without having to implement fine meshing. The model includes the equations for mass, momentum and energy and is applicable to both rotating and stationary heat pipes. The predictions of the model are validated with other experimental, numerical, and analytical works having an average deviation of less than 4%. The effects of various parameters on the system are explored. The presented model is suitable for the simulation of heat pipe systems in which both the level of detail and the computational cost are crucial factors. ... Read more

A new concept for energy efficient annealing of steel strip comprises of multiple rotating heat pipes. Each heat pipe extracts heat from the cooling strip which is reused to increase the temperature of the heating strip. In this context, the heat transfer between the steel strip and the rotating heat pipe is investigated. When the strip is transported over the heat pipe, gas entrains in the gap. The gas compresses into a uniform gas layer. The contact heat transfer deteriorates due to this phenomenon. A numerical model to quantify the heat transfer between the surfaces is developed. Since there is no direct way to quantify the heat transfer between two moving surfaces, the problem is divided into a gas entrainment and a heat transfer part. The model is validated with experiments executed on a rotating heat pipe test rig. The validation was made varying the strip thickness, specific tension and strip velocity. The results show a uniform gas layer forming within the first 1° of the 180° wrap angle in all cases. The heat transfer is dominated by gas conduction. Results for the uniform gas layer region yield heat transfer coefficients in the range between 4000 and 20,000 W/m2·K. ... Read more