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1 UNEP 2006
Introduction
Type of furnaces and refractory materials
Assessment of furnaces
Energy efficiency opportunities
2 UNEP 2006
Introduction
What is a Furnace?
Equipment to melt metals
Casting Change shape Change properties
Introduction
Furnace Components
Furnace chamber: constructed of insulating materials Hearth: support or carry the steel. Consists of refractory materials
4 UNEP 2006
Introduction
Introduction
Refractories
Refractory lining of a furnace arc
Introduction
Properties of Refractories
Melting point
Temperature at which a test pyramid (cone) fails to support its own weight
Size
Affects stability of furnace structure
Bulk density
Amount of refractory material within a volume (kg/m3) High bulk density = high volume stability, heat capacity and resistance
7 UNEP 2006
Introduction
Properties of Refractories
Porosity
Volume of open pores as % of total refractory volume Low porosity = less penetration of molten material
Introduction
Properties of Refractories
Pyrometric cones
Used in ceramic industries to test refractoriness of refractory bricks Each cone is mix of oxides that melt at specific temperatures
9 UNEP 2006
Introduction
Properties of Refractories
Volume stability, expansion & shrinkage
Permanent changes during refractory service life Occurs at high temperatures
10 UNEP 2006
Introduction
Properties of Refractories
Thermal conductivity
Depends on composition and silica content Increases with rising temperature
Introduction
Type of furnaces and refractory materials
Assessment of furnaces
Energy efficiency opportunities
12 UNEP 2006
Type of Furnaces
Forging furnaces Re-rolling mill furnaces Continuous reheating furnaces
13 UNEP 2006
Intermittent / Batch Periodical Forging Re-rolling (batch/pusher) Pot Continuous Pusher Walking beam Walking hearth Continuous recirculating bogie furnaces Rotary hearth furnaces
Recuperative Regenerative
14 UNEP 2006
Forging Furnace
Used to preheat billets/ingots Use open fireplace system with radiation heat transmission Temp 1200-1250 oC Operating cycle
Heat-up time Soaking time Forging time
Temp 1200 oC
Operating cycle: heat-up, re-rolling Output 10 - 15 tons/day Fuel use: 180-280 kg coal/ton material
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23 UNEP 2006
Classification of Refractories
Classification method Chemical composition
ACID, which readily combines with bases BASIC, which consists mainly of metallic oxides that resist the action of bases NEUTRAL, which does not combine with acids nor bases Special Silica, Semisilica, Aluminosilicate Magnesite, Chrome-magnesite, Magnesitechromite, Dolomite Fireclay bricks, Chrome, Pure Alumina Carbon, Silicon Carbide, Zirconia Blast furnace casting pit
Examples
End use
Method of manufacture
Dry press process, fused cast, hand moulded, formed normal, fired or chemically bonded, unformed (monolithics, plastics, ramming mass, gunning castable, spraying)
24 UNEP 2006
Fireclay Refractories
Common in industry: materials available and inexpensive Consist of aluminium silicates Decreasing melting point (PCE) with increasing impurity and decreasing AL2O3
Silica Brick
>93% SiO2 made from quality rocks Iron & steel, glass industry Advantages: no softening until fusion point is reached; high refractoriness; high resistance to spalling, flux and slag, volume stability
Magnesite
Chemically basic: >85% magnesium oxide
Chromite Refractories
Chrome-magnesite
15-35% Cr2O3 and 42-50% MgO Used for critical parts of high temp furnaces Withstand corrosive slags High refractories
Magnesite-chromite
>60% MgO and 8-18% Cr2O3 High temp resistance Basic slags in steel melting Better spalling resistance
27 UNEP 2006
Zirconia Refractories
Zirconium dioxide ZrO2
Monolithics
Single piece casts in equipment shape
29 UNEP 2006
Application
Monolithic linings of furnace sections Bases of tunnel kiln cars in ceramics industry
31 UNEP 2006
Ceramic Fibers
Thermal mass insulation materials
Ceramic Fibers
Remarkable properties and benefits
Low thermal conductivity Light weight Lower heat storage Thermal shock resistant Chemical resistance Mechanical resilience Low installation costs Ease of maintenance Ease of handling Thermal efficiency Lightweight furnace Simple steel fabrication work Low down time Increased productivity Additional capacity Low maintenance costs Longer service life High thermal efficiency Faster response
33 UNEP 2006
35 UNEP 2006
Introduction
Type of furnaces and refractory materials
Assessment of furnaces
Energy efficiency opportunities
36 UNEP 2006
Assessment of Furnaces
Flue gas
Moisture in fuel
Hydrogen in fuel
Openings in furnace
Furnace surface/skin
Other losses
37 UNEP 2006
Assessment of Furnaces
Location of measurement
Soaking zone and side wall
Instrument required
Pt/Pt-Rh thermocouple with indicator and recorder Chromel Alummel Thermocouple with indicator Hg in steel thermometer Low pressure ring gauge
Required Value
1200-1300oC
In duct near the discharge end, and entry to recuperator After recuperator Near charging end and side wall over the hearth
700oC max.
5% O2
Billet temperature
Portable
38 UNEP 2006
Assessment of Furnaces
Thermal efficiency of furnace = Heat in the stock / Heat in fuel consumed for heating the stock Heat in the stock Q:
Q = m x Cp (t1 t2)
Q = Quantity of heat of stock in kCal m = Weight of the stock in kg Cp= Mean specific heat of stock in kCal/kg oC t1 = Final temperature of stock in oC 39 t2 = Initial temperature of the stock before it enters the furnace in oC UNEP 2006
Assessment of Furnaces
Efficiency =
m = Weight of the stock = 6000 kg Cp= Mean specific heat of m x Cp (t1 t2) stock = 0.12 kCal/kg oC 6000 kg X 0.12 X (1340 40) t1 = Final temperature of 936000 kCal stock = 1340 oC t2 = Initial temperature of the stock = 40 oC (heat input / heat output) x 100 Calorific value of oil = 10000 [936000 / (368 x 10000) x 100 = 25.43% kCal/kg Fuel consumption = 368 kg/hr 40 UNEP 2006
Assessment of Furnaces
= 1.36 %
= 9.13 % = 5.56 % = 2.64 % = 75.98 %
Furnace efficiency =
Heat supply minus total heat loss
100% 76% = 24%
41 UNEP 2006
Assessment of Furnaces
3) Continuous Kiln
a. Hoffman b. Tunnel 25-90 20-80
4) Ovens
a. Indirect fired ovens (20 oC 370 oC) b. Direct fired ovens (20 oC 370 oC) 35-40 35-40
42 UNEP 2006
Introduction
Type of furnaces and refractory materials
Assessment of furnaces
Energy efficiency opportunities
43 UNEP 2006
1. Complete combustion with minimum excess air 2. Proper heat distribution 3. Operation at the optimum furnace temperature 4. Reducing heat losses from furnace openings 5. Maintaining correct amount of furnace draft
Indication of excess air: actual air / theoretical combustion air Optimizing excess air
Control air infiltration Maintain pressure of combustion air Ensure high fuel quality Monitor excess air
45 UNEP 2006
1200oC 800oC
650oC 750oC
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Area of application
Working temperatures Extent of abrasion and impact
55 UNEP 2006