Computational Fluid Dynamics Investigation of Flow and Flame Behavior in Natural Gas Burners for Borax Pentahydrate Furnaces

The combustion behavior and thermal performance of industrial-scale borax pentahydrate (Na2B4O7·5H2O) melting furnaces remain underexplored despite their critical role in boric oxide (B2O3) production, a key input for high-performance manufacturing. This study addressed this gap by employing three-dimensional computational fluid dynamics (CFD) simulations to model two operational natural gas-fired furnaces with distinct burner configurations (four-burner and six-burner systems). The analysis focused on optimizing burner placement, specifically, the axial distance and inclination angle, to enhance thermal uniformity and reduce refractory wall damage caused by aggressive high-temperature borate corrosion. A comprehensive parametric study of twelve burner configurations revealed that tilting the burners at 5–10° significantly improved temperature uniformity while reducing peak wall temperatures and mitigating localized hot spots. The optimal design, incorporating a 10° burner angle and a staggered burner arrangement (Case 11), attained a melt pool temperature of 1831.3 K and a charging average wall temperature of 1812.0 K. These values represent essential benchmarks for maximizing furnace efficiency and operational stability. The modified designs for the four- and six-burner systems led to improved temperature distributions and a notable reduction in maximum wall temperatures, directly contributing to longer maintenance intervals and improved refractory durability. The findings of this study confirm that minor geometrical and angular adjustments in burner placement can yield significant performance gains. The validated CFD approach and proposed design modifications offer a scalable, low-cost strategy for improving combustion efficiency and furnace lifespan in borax processing facilities.