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Industrial Furnace Mastery

The document discusses a training course on furnace design and operation over three days. It will cover topics like combustion processes, furnace fuels, burner selection, aerodynamics, safety, and optimization. The goal is to enable attendees to develop and operate industrial furnaces effectively. Furnaces are classified into different types based on their design and examples are given. Design objectives are outlined like producing a quality product using minimum energy and costs while achieving a long service life. Common industrial furnace types are then briefly described like pottery kilns, cement kilns, glass furnaces, and those used in steel, copper, and oil refining.

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436 views22 pages

Industrial Furnace Mastery

The document discusses a training course on furnace design and operation over three days. It will cover topics like combustion processes, furnace fuels, burner selection, aerodynamics, safety, and optimization. The goal is to enable attendees to develop and operate industrial furnaces effectively. Furnaces are classified into different types based on their design and examples are given. Design objectives are outlined like producing a quality product using minimum energy and costs while achieving a long service life. Common industrial furnace types are then briefly described like pottery kilns, cement kilns, glass furnaces, and those used in steel, copper, and oil refining.

Uploaded by

kING
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Furnace design and

operation

Presented by
Prof. Barrie Jenkins
Kuala Lumpur, Malaysia, 18 - 20th July 2011
Introduction

 The course is designed to enable


attendees to develop and operate
industrial process furnaces to maximise
their potential
 Over the next three days comprehensive
training in all aspects of furnace design
and operation will be covered
Introduction

 Topics that will be covered include


 the combustion process and its control
 furnace fuels
 combustion and process efficiency
 burner design and selection
 aerodynamics
 safety and control
 optimisation
Introduction

 Each of the lectures is designed to


develop the subject from its engineering
basics to their specific application to
furnaces, concentrating only on those
aspects that are relevant and important,
and using practical examples to
demonstrate their use
What is a furnace
What is a furnace
Classification Example of type of furnace
number
1 watertube boiler
2 water or thermal fluid heater
3 rotary kiln, moving or rotary hearth
4 open hearth furnace
5 fixed or moving grate with steam tubes
6 tubestill cabin heater
7 fluidised bed, multi-hearth furnace
8 refinery cracking furnace
9 tubestill heater, firetube boiler
10 rotary kiln, fluidised bed, flash heating furnace, shaft kiln, moving or rotary hearth
11 open hearth furnace, glass tank, metal reheating furnace
12 refinery cracking furnace, reformer furnace, air heater
13 firetube boiler, tubestill heater metal reheating furnace
14 rotary kiln, fluidised bed, flash heating furnace, shaft kiln, moving or rotary hearth
15 open hearth furnace, glass tank, metal reheating furnace
16 plasma furnace
17 molten metal arc furnace
18 metal melting arc and induction furnaces
19 molten metal immersion heaters, glass tank bed heating
20 muffle furnace
21 batch heater, annealing furnace
What is a furnace

 Heat is liberated by burning fuel with air (or oxygen), or


from electrical energy, and some of this heat is
transferred to the product. The remaining heat leaves in
the flue gas and through openings such as charging
doors, or is lost from the external surface
Design objectives
 1. Obtain a satisfactory product
 2. Use minimum fuel and energy to achieve that product
 3. Construct the furnace for the lowest capital cost
 4. Operate with the lowest possible manning levels
 5. Achieve a satisfactorily long life with low maintenance costs
 Objective 1 overrides all others because, if the product is
unsatisfactory, then it cannot be sold or must be sold for an inferior
price
 While safety has not been included in the above objectives, it can
be taken as “a given” in today’s environment
 The art of furnace design involves achieving the best combination
of these five objectives over the entire life of the furnace, in other
words to produce a high quality product at the lowest achievable
cost
Ceramics, bricks & pottery

Downdraft batch pottery kiln


Lime

Shaft lime kilns


Lime

Twin regenerative lime kilns


Cement

Rotary cement kilns


Glass

Regenerative glass kiln


Metals - steel

Blast furnace - steelmaking


Metals - copper

Reverbatory furnace - copper smelting


Metals - nickel

Hydrogen atmosphere furnace - nickel briquettes


Alumina

Flash calciner
Steel

Reheating furnaces
Incineration

Liquid waste heat recovery unit


Ore treatment

Herreschoff multiple hearth roaster


Oil refining

Petrochemical heaters
Steam raising

Power station boilers

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