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Hakan Caliskan
Assessment of Industrial
Department of Mechanical Engineering,
Faculty of Engineering,
Usak University,
Furnaces
Usak TR-64200, Turkey This study presents exergy analysis of a natural gas-fired radiant tube-heating furnace. In
e-mail: hakan.caliskan@usak.edu.tr the analysis, actual data over a test period of 3 h were used. Exergy efficiencies, destruc-
tions, losses, and entropy generation of the furnace were determined. For an average
Arif Hepbasli1 furnace temperature of 666.6 C, average exergy efficiency value was calculated to be
Department of Mechanical Engineering, 9.6%. The exergy destruction rate was obtained to be 5.34 kW while exergy rates of the
Faculty of Engineering, flue gases, exergy losses, and exergy steel were 12.53 kW, 44.28 kW, and 6.6 kW, respec-
Ege University, tively. On the other hand, the exergy rate of the product (steel) was found to be between
Bornova, Izmir TR-35100, Turkey 4.61 kW and 9.88 kW over the 15 min test periods, and it reached a maximum rate at the
e-mail: arif.hepbasli@ege.edu.tr end of the second hour. DOI: 10.1115/1.4001144
1 Introduction and lower CO2 and NOx emissions 7. Nogami et al. 8 applied
exergy analysis to a charcoal charged blast furnace and obtained
Energy resources of the world are limited. So, energy must be
enthalpy and exergy balances. It was found that exergy input was
used efficiently. Therefore, exergy analysis has to perform various
more needed for charcoal system than conventional iron making
parts of the science 1. Energy analysis only is not enough to system. Exergy analysis of a charcoal iron making system was
define the best efficiencies of the system. So, exergy analysis may also performed and compared with the conventional system. It
be successfully used to understand and improve the real efficien- was reported that the blast furnace produced slag less than the
cies of the whole system. Exergy analysis is based on the second conventional furnace. Total exergy input of the charcoal system
law of thermodynamics 2. Exergy is a potential or quality of was about 17.5 GJ/thm, and was 8.3% more than that of the con-
energy. It is possible to make sustainable quality assessment of ventional system. Exergy outflow from the charcoal system was
energy, and exergy is always evaluated with respect to a reference about 15.4 GJ/thm, and also larger than that of the conventional
environment 3. system. Exergy loss in the conventional system was about 55% of
Exergy concepts are practicable to all fields of engineering and one in the charcoal system 8.
science 4. These concepts are used especially for industrial pro- The present study differs from the previously conducted ones as
cesses to provide the best efficiency from international sectors 5. follows: i the fuel used was natural gas 13A, ii the analysis
It is necessary to use our resources effectively. To this end, exergy included a period of 3 h, and iii entropy production of the sys-
analysis was performed to an industrial furnace for determination tem was calculated. This paper was realized for determination of
loss, irreversibility, and efficiency of the system. The exergy the losses, irreversibilities, and efficiencies of the furnace, while
losses of the processes occur due to the irreversibility. Nonethe- the test time varied between 0 h and 3 h. It is imported to define
less, exergy losses seem, in process, to deliver semi-finished prod- the efficiency of the system for industrial sectors since they can
ucts 6. work 24 h in a day for the serial manufacture. So, exergy analysis
There are a few publications about exergy analysis of industrial was applied to a furnace, where a steel material was heat treated,
furnaces in the open literature to the best of the authors knowl- and which was fueled with natural gas 13A for obtaining the re-
edge. In this regard, Wall 5 applied exergy analysis to industrial sults about efficiencies and other exergetic parameters as well as
processes and discussed system boundaries and solutions of the for making suggestions toward possible improvements.
problems. Total exergy losses of pulp, rolling and paper mills, and
steel plant were reported to be 5809 MJ/tr, while exergy efficiency
was 54% 5. Lee 7 performed energy and exergy analyses of an 2 Analysis
aluminum melting furnace, which was fueled with natural gas in
die casting plant for determining the energy and exergy efficien- 2.1 Energy Analysis. Energy analysis was applied to a fur-
cies of the system. The furnace was compared with melting fur- nace first. General energy balance defines where and what form of
nace before and after the burner upgrading. Energy and exergy heat was given to the equipment, as can be expressed in the rate
efficiencies before upgrades were found to be 10% and 6%, while form below
energy and exergy efficiencies after upgrades were 16% and 9%,
respectively. Energy and exergy efficiencies would increase to m = m
in out 1
60% and 50%, respectively, if upgrading project could be applied.
Consequently, regenerative burner and staged-combustion tech- Ein = Eout 2
nique could improve combustion, reduce natural gas consumption,
where the subscripts in and out represent the inlet and exit
is mass flow rate and E is the
output states, respectively, while m
1
Corresponding author. Visiting Professor, King Saud University, Saudi Arabia. energy rate.
Contributed by the Advanced Energy Systems Division of ASME for publication
in the JOURNAL OF ENERGY RESOURCES TECHNOLOGY. Manuscript received April 14, Ein + Eg Eout = Est 3
2009; final manuscript received January 26, 2010; published online March 26, 2010.
Assoc. Editor: Muhammad M. Rahman. where Ein is the inlet energy, Eg is the generated energy, Eout is the
Journal of Energy Resources Technology Copyright 2010 by ASME MARCH 2010, Vol. 132 / 012001-1
where Exin, Exout, and Exdest are the exergy input, output, and
q2 = 50 TsC 9 destruction rates, respectively. If the general exergy balance is
where q1 is the heat content of the steel from 50 C to the final performed for the experimental industrial furnace, the exergy bal-
temperature of the steel T f = 725 C, ms is the mass of steel, Ts is ance of the furnace process can be explained by
the standard temperature Ts = 12.7 C, and C is the mean specific
Exin = Exdest + Exsteel + Exflue gas + Exloss 22
heat of the steel 10.
The heat loss of the exhaust gas Q2 is expressed as follows: where Exdest is the exergy destruction rate, Exsteel is the exergy
Q2 = V1 C p T 10 changing rate of the steel, Exflue gas is the exergy rate of flue gas,
with and Exloss is the exergy loss rate of the system.
Exergy input rate must be determined first. Because of the fuel
V1 = Vg,n v2 input of the process, there is only the chemical exergy of the fuel
11 natural gas 13A to be the exergy input, and it can be expressed
T = Tex Ts as follows:
where V1 is the total wet exhaust gas rate, C p is the mean specific Exin = Exfuel = Exfuel,ch = nfuelfuel,ch 23
heat of exhaust gas, v is the specific wet exhaust gas rate v2
= 16.2 N m3 / N m3, and Tex is the exhaust temperature Tex where Exfuel is the exergy rate of fuel natural gas, Exfuel,ch is the
= 523.6 C obtained from Ref. 10. chemical exergy rate of fuel, fuel,ch is the specific chemical ex-
Heat diffusion from the furnace wall Q3 can be calculated as ergy rate of fuel, and nfuel is the molar flow fuel consumption
follows 10: rate of the fuel.
The specific chemical exergy rate of the fuel fuel,ch can be
Q3 = hc + hrTAt 12
calculated by
with
hr = 5.67e
Tfw 4
Ts 4
1
13
fuel,ch = gfuel + nO2gO2 nCO2gCO2 + nH2OgH2O
100 100 Tfw,oa
n
and hc for the furnace wall can be expressed as follows 10: y OO2
24
2
+ RT0 ln
hc = 3.26T
n CO2 H2O n
4
horizontal and facing upward 14 y CO yH O
2 2
Hakan Caliskan received his B.Sc and M.Sc. degrees with a first class honor in Department of Mechanical
Engineering at Pamukkale University, Denizli, Turkey in 2007, and Department of Mechanical Engineering
at Eskisehir Osmangazi University, Eskisehir, Turkey, in 2009 (Autumn term), respectively. He is a doctorate
student under the supervision of Dr. Hepbasli, while he also works as a Research Assistant in the Depart-
ment of Mechanical Engineering at Usak University, Usak, Turkey. His research interest is concerned
primarily with energy, exergy and exergoeconomic analyses of various types of energy systems.
Arif Hepbasli is a Full Professor of Mechanical Engineering at Ege University, Izmir, Turkey. Before
joining the university in 1996, he worked for ten years in various Turkish energy companies. Some of his
research covers energy, exergy and exergoeconomic analyses of thermal systems, energy efficiency and
management and ground-source heat pumps. Dr. Hepbasli, who is also a Certified Industrial Energy Man-
ager, is author and co-author of over 395 papers on a national and international basis. He has served as a
consultant in cases involving his research area and is also a board member in five prestigious international
journals.
Item Value
haust gas and other heat losses were calculated to be 28% and
48%. The results of the energy analysis of the furnace are given in
Fig. 3 Control volume of the furnace
Table 5, and the energy flow Sankey diagram of the furnace is
shown in Fig. 4.
Later, exergy analysis of the furnace for various test times was
is increased until 800 C for 2 h, and then, this temperature is kept
performed. In the exergy analysis, the exergetic efficiency of the
constant for 1 h.
system was calculated for the average temperature T f,1
For the analysis, the standard temperature was taken to be the
room temperature, while the heating value of the fuel was taken to = 666.6 C = 939.6 K, T f,2 = 725.2 C = 998.2 K, and Ti = 12.7 C
be 41,660 kJ/ N m3. The control volume of the furnace is given in = 285.7 K, and the efficiency value was found to be 9.6%. The
Fig. 3. results of the exergy analysis of the furnace for an average tem-
In the analysis, the values obtained from the measurements perature of T f,1 = 666.6 C are given in Table 6, while the exergy
were utilized, as listed in Tables 24 10. For the analysis, the loss and flow Grassmann diagram of the system is indicated in
real combustion equation of the system, in which natural gas 13A Fig. 5.
was used as fuel, is given as follows: If we consider the analysis for every 15 min, the exergy rates of
the steel were found to be between 4.61 kW and 9.88 kW for
0.85Fuel + 2.66 O2 + 10.03 N2 0.97 CO2 + 0.77 O2 various test times. The exergy rates of the steel for various times
are given in Table 7, and a comparison of the various types of
+ 10.03 N2 + 1.82 H2O 37
furnaces in terms of efficiencies is listed in Table 8.
where fuel was 0.9CH4 + 0.0463C2H6 + 0.0391C3H8 The exergy variation rate of the steel with process duration is
+ 0.0098C4H10 + 0.0008C5H12. shown in Fig. 6. The maximum exergy rate of the steel was 9.88
kW at the second hour of the test.
4 Results and Discussion When the regenerative burner system would be used for up-
grading, based on the calculations done, combustion air could be
First, energy analysis applied to the industrial furnace fueled preheated from 0 C to 46 C. The exergy change rate of the steel
with natural gas 13A by Hepbasli 10. As a result of the energy could increase due to the new preheated air temperature, increas-
analysis, it was found that the heat loss was because of the ex- ing the exergetic efficiency of the furnace from 9.6% to nearly
12.6%.
Table 2 Data used in the calculations 10
5 Conclusions
Symbol Value Exergy analysis is applied to a furnace fueled with natural gas
13A. The performance and characteristics of the furnace are
A f = Ar m
2
2.67 evaluated. Considering the results of the exergy analysis, it is
Aff m2 0.27 possible to draw the following conclusions:
Ah m2 1.59
Ari = Al m2 3.27 The exergy efficiency is calculated to be 9.6%, while the
At m2 2.63 energy efficiency is 13%.
Cs kJ/ kg C 0.46
d m 0.15
D m 1.03 Table 5 Results of the energy analysis of the furnace 10
H1 kJ/ N m3 41,600
K W/m C 1.043 Item Value
S 4.5
t h 3 Heat loss
Vth,a N m3 / N m3 11 Total amount of wet exhaust gas, V1 N m3 341.2
Vth,g N m3 / N m3 10 Mean specific heat of exhaust gas, C p kJ/ N m3 C 1.416
ms kg 250 Heat loss of exhaust flue gas, Q2 kJ 246,835
Table 3 Data collections of the fuel related to the furnace 10 Heat balance
Heat input
Item Value Combustion heat of fuel, Qg kJ 877,360
Heat output
Net heating value, H1 kJ/ N m3 41,660 Heat capacity of steel, Q1 kJ 113,275
Supply pressure, Pg kPa 1.9064 Heat loss of exhaust flue gas, Q2 kJ 246,835
Temperature, Tg C 12.7 Heat diffusion from furnace wall, Q3 kJ 93,270
Consumption, Vg m3 21.63 Other heat losses, Q4 kJ 423,980
Consumption after correction, Vg,n N m3 21.06 Thermal efficiency of the furnace % 13
Combustion heat, Qg kJ 877,360 Specific energy consumption rate, SEC kJ/kg 3509.4
The entropy generation rate of the furnace is 0.0179 kW/K. The exergy variation rates of the steel are found to be be-
In order to reduce it, the reference temperature must be over tween 4.61 kW and 9.88 kW under test conditions for every
than 0 C. 15 min. This rate decreases after the second hour due to the
The exergy destruction rate of the furnace is calculated to be constant temperature between the second and third hours
5.34 kW, followed by the fuel with 68.75 kW, the steel with while the time increases regularly.
6.6 kW, the flue gases with 12.53 kW, and other losses with For future work, an exergoeconomic analysis, which is a
44.28 kW. combination of exergy and economics, is recommended.
Table 6 Results of the exergy analysis of the furnace for the average temperature Tf,1
= 666.6 C
Fig. 5 Exergy loss and flow Grassmann diagram of the system average
SEC a SExC b
Investigator Type of furnace Type of fuel Product kJ/kg MJ/kg ELFc ExLF d
%
Wall 5 Electric steel furnace - Steel - 6.456.84 1462 MJ/tr 1859 MJ/tr 54
Lee 7 Furnace with regenerator Natural gas Aluminum 507.09 - 7.23 TJ 2.1 TJ 9
Nogami et al. 8 Blast furnace Charcoal Iron - 11.99 - 4.53 GJ/thm -
Present study Radiant tube heating furnace Natural gas Steel 3509 0.99 423.98MJ 159.40MJ 9.6
a
SEC: Specific energy consumption rate
b
SExC: Specific exergy consumption rate
c
ELF: Energy loss of the furnace
d
ExLF: Exergy loss of the furnace
Acknowledgment Indices
a air
The authors are very grateful to the reviewers and the editor for AV average
their valuable and constructive comments, have been utilized in c convection
improving the quality of the paper. The corresponding author also ch chemical
would like to thank the Electrical Power Resources Survey and cv control volume
Development Administration EIE in Turkey for the support in d dry
attending the Energy Conservation and Management Training dest destruction
given by the Japan International Cooperation Agency JICA, and ex exhaust gas
is grateful to JICA & Kitakyushu International Techno- f front, final
cooperative Association KITA for the excellent course delivered ff flue
and their kind support. fw furnace wall
g gas, generated
Nomenclature h hearth
A surface area m2
i inlet
C
mean specific heat kJ/ kg C in input
d
flue diameter m l left
D
width between inside the walls of the furnace n nominal
m o outlet
E total energy kJ out output
ELF energy loss of the furnace kJ oa outlet air
Hakan Caliskan received his B.Sc and M.Sc. degrees with a first class honor in Department of Mechanical
Engineering at Pamukkale University, Denizli, Turkey in 2007, and Department of Mechanical Engineering
at Eskisehir Osmangazi University, Eskisehir, Turkey, in 2009 (Autumn term), respectively. He is a doctorate
student under the supervision of Dr. Hepbasli, while he also works as a Research Assistant in the Depart-
ment of Mechanical Engineering at Usak University, Usak, Turkey. His research interest is concerned
primarily with energy, exergy and exergoeconomic analyses of various types of energy systems.
Arif Hepbasli is a Full Professor of Mechanical Engineering at Ege University, Izmir, Turkey. Before
joining the university in 1996, he worked for ten years in various Turkish energy companies. Some of his
research covers energy, exergy and exergoeconomic analyses of thermal systems, energy efficiency and
management and ground-source heat pumps. Dr. Hepbasli, who is also a Certified Industrial Energy Man-
ager, is author and co-author of over 395 papers on a national and international basis. He has served as a
consultant in cases involving his research area and is also a board member in five prestigious international
journals.