Today, furnace design still proceeds mainly by extrapolation from existing furnaces. Investigating existing furnaces shows the dangers of underestimating the impact of apparently small modifications: e.g., larger pits to accommodate higher anodes can result in furnaces with substandard performance. Side effects such as soot creation have then to be accepted. This paper presents an approach to bake furnace design which completely eliminates extrapolation from existing furnaces. The same approach can be used to estimate the optimization potential for existing furnaces.

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