Improvement in thermal efficiency of industrial furnaces

The high exhaust gas temperature in industrial furnaces such as heating furnaces and heat treatment furnaces ensures that exhaust gas losses are high, despite good combustion management. To dramatically improve the thermal efficiency of such furnaces requires the recovery and efficient use of the sensible heat of exhaust gas. A number of methods are available for the use of exhaust gas sensible heat, however, a method providing large benefits and which can be applied in all cases is the regeneration of sensible heat, in other words, the use of sensible heat in the equipment itself. For example, heating of raw materials fed into the industrial furnace, and preheating of the combustion air. The following methods are the most common. (1) Preheating of raw materials: Raw materials are preheated with exhaust gas prior to feeding into a heating furnace to reduce the amount of heat added within the furnace, and save fuel. (2) Preheating of combustion air: Preheating of combustion air with the sensible heat of exhaust gas has historically been used in large boilers, metal heating furnaces, and high-temperature ceramic kilns, and is increasingly used in small boilers and small industrial furnaces. Types of air preheaters and range of application are shown in Figure 1.

Figure 1: Types of Air Preheaters and Range of Application (3) Use as other heat sources: With heating furnaces, exhaust gas temperature remains high at 400 600C despite recovery of heat with a regulator. When large amounts of steam and hot water are required in factories, a waste heat boiler is also installed to convert the sensible heat of the exhaust gas to steam and hot water. Furthermore, if the sensible heat of the exhaust gas matches the amount of heat, temperature range, and operating time of other equipment, a dramatic reduction in fuel consumption is possible. For example, use of the exhaust gas from a tempering furnace, as the heat source for an annealing furnace, and complete elimination of the need for fuel, is an example. Energy Saving Effects: Installation of an air preheater in the exhaust gas duct of a shuttle-baking furnace to preheat combustion air. Insulation is applied to combustion air piping.

Pressure control for industrial furnaces Heating furnaces are characterized by a large number of apertures, for example, raw material charging ports, extraction ports, and cracks in the furnace ceiling and side walls. Flame erupts through these apertures, and external air is sucked into the furnace, to a greater or lesser degree depending upon the pressure within the furnace.

Improving thermal insulation in industrial furnaces Sufficient thermal insulation in the walls of industrial furnaces such as heating furnaces and heat treatment furnaces is important in minimizing radiated heat. Sufficient thermal insulation in the walls of

industrial furnaces such as heating furnaces and heat treatment furnaces is important in minimizing radiated heat. As shown by the radiated heat (calculated value) relative to surface temperature of the furnace wall in Fig. 1, it is necessary to maintain the wall surface at a low temperature in order to reduce radiated heat. A material of low thermal conductivity is therefore used in the furnace walls. It should be noted that usable materials differ with temperature range, and that insulating material having a low thermal capacity is used in furnaces used at irregular intervals.

Figure 1: Amount of Heat Radiated From Furnace Wall

Lightweight thermal insulating ceramic fiber is replacing refractory brick and castable refractories as the insulating material in furnace walls in recent years. The characteristics of ceramic fiber are as follows. Light weight allows for a light weight structure (for example, the furnace frame) and foundation. Low thermal capacity, thus reducing the heat accumulation losses with irregular operation. Ease of installation, eliminating the need for drying and preheating, and thus reducing the construction period. When used at high temperature for long periods, crystallization occurs leading to embrittlement, shrinkage, and peeling due to the gas flow within the furnace.