2.4 Furnaces PDF

ENERGY MANAGEMENT
PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV
Page: 1
ENERGY MANAGEMENT
A furnace is an equipment to melt

metals
for casting or
for heating materials or
for change of shape (rolling,
forging etc) or for change of
properties (heat treatment).
Page: 2
ENERGY MANAGEMENT
" #
% %$$
Based on the method of generating heat: combustion type

(using fuels) and electric type
According
to mode
of heat
transfer
Open fire place furnace
Heated through liquid medium
Forging
Re-rolling
Furnace
classification
According
to mode of
charging
Mode of
heat
recovery
Periodical
Continuous
Recuperative
Regenerative
Page: 3
(Batch / continuous
pusher)
Pot
Glass tank
melting
(regenerative
/
recuperative)
ENERGY MANAGEMENT
%$
$
$
Furnace should be designed

so that in a given time, as
much of material as possible
can be heated to an
uniform temperature as
possible with the least
possible fuel and labour.
Page: 4
ENERGY MANAGEMENT
&
!!#
Since flue gases directly contact the

stock, the type of fuel chosen is very
important.
For example, some stock will not
tolerate sulphur in the fuel. Also use
of solid fuels will release particulate
matter (dust), which will interfere
with the stock placed inside the
furnace.
Hence, majority of the furnaces use
liquid fuel, gaseous fuel or electricity
as energy input.
Ferrous (steel, cast iron) melting
furnaces such as induction and arc
furnaces use electricity
Non-ferrous melting furnaces use oil.
Page: 5
ENERGY MANAGEMENT
"
Furnace oil is the major fuel used in

reheating and heat treatment furnaces
LDO is used in furnaces where
presence of sulphur is undesirable.
Furnaces operate with efficiencies as
low as 7% as against upto 90%
achievable in other combustion
equipment such as boiler.
This is because of the high temperature
at which the furnaces operate to meet
the required demand. For example, a
furnace heating the stock to 1200oC
will have its exhaust gases leaving
atleast at 1200oC resulting in a high
heat loss through the stack.
Page: 6
ENERGY MANAGEMENT
'
%& &
Used for preheating billets and ingots

to attain a forge temperature.
The
furnace
temperature
is
maintained at 1200 to 1250oC.
Forging furnaces, use an open
fireplace system and most of the heat
is transmitted by radiation.
The typical loading in a forging
furnace is 5 to 6 tones with the furnace
operating for 16 to 18 hours daily.
The total operating cycle can be
divided into (i) heat-up time (ii)
soaking time and (iii) forging time.
Specific fuel consumption depends
upon the type of material and number
of reheats required.
Page: 7
ENERGY MANAGEMENT
( %#
# &) #
#
Batch type furnace:

Used for heating up
scrap, small ingots
and billets weighing
2 to 20 kg. for batch
type re-rolling.
Charging
and
discharging of the
material is done
manually and the
final product is in
the form of rods and
strips.
Operating
temperature is 1200
oC.
Total cycle time can
be categorized into
heat-up time and rerolling time.
Continuous
Pusher
Type:
The process flow and
operating cycles of a
continuous pusher type
is the same as that of
the batch furnace.
The material or stock
recovers a part of the
heat in flue gases as it
moves down the length
of the furnace.
Operating temperature
is 1250oC.
Heat absorption by the
material in the furnace
is slow, steady and
uniform
throughout
the
cross-section
compared with batch
type.
Page: 8
ENERGY MANAGEMENT
Radiation
from
the
flame,
hot
combustion
products and
the
furnace
walls and roof
Convection
due to the
movement of
hot gases over
the
stock
surface.
Heat Transfer in furnace
Page: 9
ENERGY MANAGEMENT
%$ %
&
Based on method by which stock

moves through the furnace
Stocks placed side by side to form
stream of material which is moved
through the furnace
Stocks placed on hearth or supporting
structure which moves the stock
%
&
Page: 10
ENERGY MANAGEMENT
Rotary hearth type furnace

%
# % +%&
Page: 11
ENERGY MANAGEMENT
$
%'
,#
% %$
Heat losses in industrial heating Furnaces
Page: 12
ENERGY MANAGEMENT
#
%
Material
handling loss
Cooling media
losses
Wall Loss:
Wall losses:
Radiation
(opening) loss
Radiation loss
Stack loss
(Waste-gas loss)
Air infiltration
wall losses
Air infiltration from furnace opening.
Stored Heat Loss:

Page: 13
ENERGY MANAGEMENT
$
$
# # %

An oil-fired reheating furnace has an
operating temperature of around 1340oC.
Average fuel consumption is 400
litres/hour. The flue gas exit temperature
after air pre-heater is 750 oC. Air is
preheated from ambient temperature of
40 oC to 190 oC through an air pre-heater.
The furnace has 460 mm thick wall (x)
on the billet extraction outlet side, which
is 1 m high (D) and 1 m wide. The other
data are as given below. Find out the
efficiency of the furnace by both indirect
and direct method.
Page: 14
ENERGY MANAGEMENT
#-

! " "
# $
" "
" % &
' # $ ( ) * + &
" " "
+ & +

,

$ -
. " " +

) + &
" /
# $ + & + &

" " " 0 $ $

" " +
1 " * $
Page: 15
ENERGY MANAGEMENT
$
$
.-
%"/
Furnace Efficiency (Direct Method)

Fuel input
Heat Input
Heat output
Efficiency
Efficiency
Losses
= 400 litres / hr
= 368 kg/hr
=368x10,000=3680000 kCal
= m x Cp x T
= 6000 kg x 0.12 x (1340 40)
= 936000 kCal
= Output x 100
Input
= 936000 x 100
3680000
= 25.43 % = 25% (app)
= 75% (app)
Page: 16
ENERGY MANAGEMENT
$
$
. "
%"/
1. Sensible Heat Loss in Flue Gas:

Corresponding excess air
=
=
(O2 x 100) / (21 O2)

133% excess air
Theoretical air required to burn 1 kg of oil

Total air supplied
=
=
=
=
=
=
=

=
14 kg
14 x 2.33 kg / kg of oil
32.62 kg / kg of oil
m x Cp x T
Weight of flue gas
32.62 + 1.0 = 33.62 kg / kg of oil.
Specific heat

33.62 x 0.24 x (750 40)
5729 kCal / kg of oil
5729 x 100
Sensible heat loss

m
Cp
T

Heat loss

% Loss
10000
Page: 17
= 57.29%
ENERGY MANAGEMENT
$
$
. "
%"/

M { 5 8 4 + 0 .4 5 (T fg -T a m b )}
=
x1 0 0

G C V of Fuel

!

" # !
$ %
$ & %

' ( ) * ) + ) ,
-
.
=1.36 %
10000
3. Loss Due to Evaporation of Water Formed due to Hydrogen in Fuel

% Loss
= 9 x H2 {584 + 0.45 (Tfg-Tamb)}

---------------------------------------- x 100
GCV of Fuel

- / . 0 1 ' ( ) * ) + ) ,
. - / 1

Page: 18
ENERGY MANAGEMENT
$
$
*
0%
"
. "
% !
%"/
&1
Heat loss due to openings can be calculated by computing

black body radiation at furnace temperature, and
multiplying these values with emissivity
and the factor of radiation through openings.
Use fig. for black body radiation loss and Factor of
radiation through openings

" # $ % &
*
-
. ) / &

+ % #

# #
, ) / &

. / # + # #
2 #

$ %

!

' (
& !

0

' $ ( # )
) , )
)
" # $ % & ,
,
' , , , 0
0 $ ( #
0 1
* $
* ' 0 ,
= 5.56 %
Page: 19
ENERGY MANAGEMENT
$
$
. "
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Body

Page: 20
ENERGY MANAGEMENT
$
$
. "
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at a Particular Temperature
Page: 21
ENERGY MANAGEMENT
$
$
2 *
0%
. "
% &
%"/
3 1
5a). Heat loss through roof and sidewalls:

Total average surface temperature
= 122oC
Heat loss at 122 oC
= 1252 kCal / m2 / hr
Total area of heating + soaking zone
= 70.18 m2
Heat loss
= 1252 kCal / m2 / hr x 70.18 m2
= 87865 kCal/hr
Equivalent oil loss (a)
= 8.78 kg / hr
5b). Total average surface temperature of
area other than heating and soaking zone= 85oC
Heat loss at 85oC
= 740 kCal / m2 / hr
Total area
= 12.6 m2
Heat loss
= 740 kCal / m2 / hr x 12.6 m2
= 9324 kCal/hr
Equivalent oil loss (b)
= 0.93 kg / hr
Total loss of fuel oil
Total percentage loss
= a + b = 9.71 kg/hr
= 9.71 / 368 = 2.64%
Page: 22
ENERGY MANAGEMENT
%$*
'!
Page: 23
ENERGY MANAGEMENT
$
$
. "
%"/

2 #
- + 0 /
0 3 4 ! - 1 5
1 3 4 !
3 7
) 7 3 !
7
6

- / 1
- 5

- 0 5 )
Total losses
= 75.98 %

! "
# $ %

# # # & ' ( (

Page: 24
ENERGY MANAGEMENT
Theoretical Heat
Example of melting one tonne of steel from an ambient temperature of 20oC . Specific
heat of steel = 0.186 Wh/kg/0C, latent heat for melting of steel = 40 Wh/kg/0C. Melting
point of steel = 1600 oC.
Theoretical Total heat = Sensible heat + Latent heat
Sensible Heat = 1000 kg x 0.186 Wh /kg oC x (1600-20)oC = 294 kWh
Latent heat = 40 Wh/ kg x 1000 kg
= 40 kWh
Total Heat = 294 + 40 = 334 kWh.

So the theoretical energy needed to melt one tonne of steel from 20o C = 334 kWh.
Actual Energy used to melt to 1600o C is 700 kWh
Efficiency = 334 kWh x 100 = 48%
700 kwh
Page: 25
ENERGY MANAGEMENT
# % %'
1) Complete combustion with minimum

excess air
2) Correct heat distribution
3) Operating at the desired temperature
4) Reducing heat losses from furnace
openings
5) Maintaining correct amount of
furnace draught
6) Optimum capacity utilization
7) Waste heat recovery from the flue
gases
8) Minimum refractory losses
9) Use of Ceramic Coatings
Page: 26
ENERGY MANAGEMENT
6/ %'!#
%'7
% 8
' '
The amount of heat lost in the flue gases

depends upon amount of excess air. In the
case of a furnace carrying away flue gases
at 900oC, % heat lost is shown in table :
Table Heat Loss in Flue Gas Based on Excess Air Level
Excess Air
% of total heat in the fuel

carried away by waste gases
(flue gas temp. 900oC)
25
48
50
55
75
63
100
71
Page: 27
ENERGY MANAGEMENT
2) Correct Heat Distribution
Heat distribution in furnace
Prevent flame
impingement.
To avoid high
flame
temperature,d
amage of
refractory and
for better
atomization
Align burner
properly to
avoid
touching the
material
To reduce
scale loss
Alignment of burners in furnace

Page: 28
ENERGY MANAGEMENT
3) Operating at Desired Temperature
Temperature for Different Furnaces

Slab
Reheating furnaces
1200oC
Rolling Mill furnaces

1200oC
Bar furnace for Sheet Mill
800oC
Bogey type annealing
furnaces- 650oC -750oC
CORRECT
TEMPERATURE
ENSURES
GOOD QUALITY
PRODUCTS.
TEMPERATURE
HIGHER THAN
REQUIRED
WOULD ONLY
USE UP MORE
FUEL
For maintaining temperature, do not leave

it to operator judgment, Use ON/OFF
controls
Page: 29
ENERGY MANAGEMENT
4) Reducing Heat Loss from Furnace Openings
Heat loss through openings consists of direct

radiation and combustion gas that leaks
through openings.
Keeping the doors unnecessarily open leads to
wastage of fuel
Inspection doors should not kept open during
operation
Broken and damaged doors should be
repaired
The heat loss from an opening can
calculated using the formula:
Q=4.88 x T 4 x a x A x H k.Cal/hr
100
T: absolute temperature (K),
a: factor for total radiation
A: area of opening,
H: time (Hr)
Page: 30
be
ENERGY MANAGEMENT
2/)
& %
'%
%$$
"
&
Negative pressures : air infiltration- affecting air-fuel ratio

control, problems of cold metal and non-uniform metal
temperatures,
Positive Pressure: Ex-filtration -Problems of leaping out of
flames, overheating of refractories, burning out of ducts etc.
Page: 31
ENERGY MANAGEMENT
:/ ! ' '
#;
There is a particular loading at which the

furnace will operate at maximum thermal
efficiency.
Best method of loading is generally obtained
by trial-noting the weight of material put in at
each charge, the time it takes to reach
temperature and the amount of fuel used.
Mismatching of furnace dimension with respect
to charge and production schedule.
Coordination between the furnace operator,
production and planning personnel is needed.
Page: 32
ENERGY MANAGEMENT
</
%,
$%'
$
#
&
Stock preheating
Combustion air preheating
Using waste heat for other process
Page: 33
ENERGY MANAGEMENT
=/)
' ; &
#
#0%
About 30% of the fuel input to the furnace

generally goes to make up for heat losses in
intermittent or continuous furnaces. The
appropriate choice of refractory and insulation
materials is needed for high fuel savings in
industrial furnaces.
The extent of wall losses depend on:
Emissivity of wall
Thermal conductivity of refractories
Wall thickness
Whether furnace is operated continuously
or intermittently
Page: 34
ENERGY MANAGEMENT
>/
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% *
0%
$%'
%$
The quantity (Q) of heat release from a reheating

furnace is calculated with the following formula:
Q = a x (t1 t2 )
5/4
+ 4.88 E x
t1 + 273
100
where.,
t2 + 273
100
a : factor regarding direction of the surface of natural

convection ceiling = 2.8, side walls = 2.2, hearth = 1.5
tl : temperature of external wall surface of the furnace (C)
t2 : temperature of air around the furnace (C)
E: emissivity of external wall surface of the furnace
Page: 35
ENERGY MANAGEMENT
10. Use of Ceramic Coatings
The benefits of applying a highemissivity ceramic coating:Rapid heat-up

Increased heat transfer at steady
state
Improved temperature uniformity
Increased refractory life
Elimination of refractory dust.
Page: 36
ENERGY MANAGEMENT
11.
& %$
%,
#
,
%#
%
The emissivity of the surface depends on the colour of the

paint. Silver paint with metallic base is radiating the
minimum heat. Hence it is recommended to repaint the oven
with silver paint. Energy saving potential is calculated as
follows;
e
th
ta
Area
Heat loss (Watt)
With cream paint
0.95
75
45
0.5
15.21
406
185390
With Al paint
0.65
75
45
0.5
12.65
406
154116
Energy Saving in Watt
31274
Energy Saving in Kcal/hr
26895
Annual energy savings
26895 x8640/(0.8 x 11000) x (13.5/0.8)

Rs. 2.28 Lakhs
Particulars
Estimated
painting
investment
Simple payback period
for
Rs. 0.60
4 months
Page: 37

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ENERGY MANAGEMENT

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

A furnace is an equipment to melt

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Based on the method of generating heat: combustion type

Open fire place furnace

Heated through liquid medium

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Furnace should be designed

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Since flue gases directly contact the

Furnace oil is the major fuel used in

Used for preheating billets and ingots

Batch type furnace:

Heat Transfer in furnace

Based on method by which stock

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Rotary hearth type furnace

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Heat losses in industrial heating Furnaces

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Air infiltration from furnace opening.

Stored Heat Loss:

.  "  "  +

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Furnace Efficiency (Direct Method)

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

1. Sensible Heat Loss in Flue Gas:

(O2 x 100) / (21 O2)

Theoretical air required to burn 1 kg of oil

Sensible heat loss

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

3. Loss Due to Evaporation of Water Formed due to Hydrogen in Fuel

= 9 x H2 {584 + 0.45 (Tfg-Tamb)}

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Heat loss due to openings can be calculated by computing

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

5a). Heat loss through roof and sidewalls:

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Total Heat = 294 + 40 = 334 kWh.

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

1) Complete combustion with minimum

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

The amount of heat lost in the flue gases

% of total heat in the fuel

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

2) Correct Heat Distribution

Heat distribution in furnace

Alignment of burners in furnace

3) Operating at Desired Temperature

Temperature for Different Furnaces

Rolling Mill furnaces

For maintaining temperature, do not leave

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

4) Reducing Heat Loss from Furnace Openings

Heat loss through openings consists of direct

PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV

Negative pressures : air infiltration- affecting air-fuel ratio

. " " +