Improving furnace energy efficiency through adjustment of damper angle

Lee, Chien-Li; Jou, Chih-Ju G.

doi:10.1016/j.ijhydene.2012.11.043

Cited by 10 publications

(4 citation statements)

References 21 publications

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“…The angle of the furnace flue damper impacts the amount of time that the hot gas flow spends in the radiation section of the furnace, which, in turn, affects the overall thermal efficiency and the amount of fuel consumed by the furnace. Lee et al [29] altered the angle of the furnace flue damper and their study showed that when the damper angle was decreased from 45 to 39 degrees, there was a decrease in pressure within the furnace of −5.1 mmH 2 O in the radiation area and −3.3 mmH 2 O in the convection area; the average temperatures rose by 40 • C in the convection area, and 42 • C in the radiation area with an increase in flue gas temperature of 28 • C and the potential to reduce the annual fuel consumption by 2.3 × 10 6 m 3 and carbon dioxide emissions by 2.6 × 10 3 tons. Hasanuzzaman et al [30] performed a complete overview of energy-saving methods and strategies for heating processes in industries that rely on combustion and reported that implementing a recuperator in the furnace could save up to 25% in energy, and using economizers in boilers could result in energy savings of 10% to 20%.…”

Section: Literature Reviewmentioning

confidence: 99%

Parametric Energy Efficiency Impact Analysis for Industrial Process Heating Furnaces Using the Manufacturing Energy Assessment Software for Utility Reduction

Bisht,

Gopalakrishnan,

Dahal

et al. 2024

Processes

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Industrial process heating furnace operations consume considerable energy in the U.S. manufacturing sector, making it crucial to identify energy efficient strategies due to the growing need to minimize energy usage and emissions. It is important to identify the potential impact of these factors to enable process engineers to operate process heating systems at the maximum possible efficiency. This study examines and identifies the key impact factors that influence the efficiency of process heating systems using MEASUR (v1.4.0), the DOE software tools such as the insulation effectiveness, the burner stoichiometry, cooling medium, thermal storage, and atmospheric gases. Data from a two-fuel-fired heat treatment furnace and an electric arc furnace (EAF) for steelmaking were employed to establish the baseline heat balance models in MEASUR. The fractional factorial design experiment was developed with two-level parameter values and energy efficiency strategies for the heat input into industrial furnaces. The three most significant parameters for the heat input for a fuel-fired industrial furnace, Industrial Furnace A, are excess air percentage or the oxygen percentage in flue gas (OF), average surface temperature (ST), and combustion air temperature (CT). Similarly, for an electric industrial furnace, Industrial Furnace B, the parameters are charge temperature (CHT), average surface temperature (ST), and time open (TO). A comparative analysis was carried out for the fuel-fired and equivalent electric resistance furnaces to identify the prospect of electrification of industrial furnaces relying upon fossil fuels. The study aims to assist industries and designers in making informed decisions regarding industrial furnace upgrades, process optimization, and maintenance investments, resulting in substantial energy and cost savings, and a reduced environmental impact.

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Section: Literature Reviewmentioning

confidence: 99%

Parametric Energy Efficiency Impact Analysis for Industrial Process Heating Furnaces Using the Manufacturing Energy Assessment Software for Utility Reduction

Bisht,

Gopalakrishnan,

Dahal

et al. 2024

Processes

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“…(18) and (19) denote the central and the average temperature ranges of a reheated slab, respectively. Constraint (20) provides the temperature range of segments in furnace hearth. In general, the first three constraints are applied to protect the reheated slabs from over-heated and the fourth one is particularly important for the furnace to keep a secure condition.…”

Section: Optimization Model For Oopsrpmentioning

confidence: 99%

“…From the analysis above, we consider an individual x i as a feasible solution in which each element x i,j is generated from the corresponding value range [L j , U j ], then the constraint expression (20) can be replaced with L j ≤ W(t j ) ≤ U j , and x i,j ≤ x i,j + 1 (j = 1,…,D). Therefore, the initial population is generated by (21).…”

Section: Initializationmentioning

confidence: 99%

Operation Optimization of Slab Reheating Process Based on Differential Evolution

2016

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In the slab reheating process, the temperature distribution of walking beam furnace is critical for the temperature of slab, as well as the subsequent hot rolling. Besides, this process is dynamic, nonlinear, and time varying due to coupling with complex physical and chemical reactions. In this paper, we focus on an operation optimization problem of tuning furnace temperature to optimize the slab reheating process, which considers the reheating quality and production cost. For this purpose, we develop a novel operation optimization method. Specifically, first, from the view of mechanism, a heat transmit model based on the heat-exchange of slab and furnace, an energy consumption function, and especially, an oxidation loss function are established. Therefore, incorporating the mechanism models, we build an optimization model to minimize temperature deviation of slab, energy consumption, and oxidation loss to describe our problem. Then, based on the features of the problem, we propose a modified differential evolution algorithm, which includes a space contraction scheme, a new self-adaptive parameter strategy, and a new mutation operator. Finally, to evaluate the performance of our method, extensive numerical experiments are implemented by comparing it with other well-known evolutionary algorithms based on practical data. The experimental results demonstrate the effectiveness of proposed operation optimization method on solving our problem.

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“…8,9 Undoubtedly, it is essential to improve furnace and kiln efficiency in China, therefore, to reduce energy consumption and to promote sustainable development of energy industry as a whole, a great deal of methods such as heat recovering have been undertaken. [10][11][12][13][14] With in-depth energy restructure and increasingly stringent environment regulations, a number of coal-fired and oil-fired furnaces (and kilns) in many industries were converted into natural gas in recent years. Unfortunately, many design concepts, structures, and operation remain unchanged, resulting in higher energy consumption and unimproved product quality.…”

mentioning

confidence: 99%

Energy efficiency evaluation of a shuttle kiln based on field test

Zhou

Qin

2017

Advances in Mechanical Engineering

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With intensified energy restructure in China, energy efficiency of various industrial furnaces and kilns fired by natural gas draws attentions of more and more researchers. In this article, a field test was performed for shuttle kiln popular in ceramics and refractory manufacture industry. The thermal efficiency, main heat loss, and the energy-saving potential were evaluated, and the defects of the existing kilns and improvement measure were clarified. The results show that the overall efficiency was only 13%-15%, if measured in terms of the entire heating period. The energy loss of flue gas accounted up to 50%; the effectiveness of air preheater was as low as only 30%; large amount of cold air infiltration was observed at the venting exit at the bottom of the kiln. The burner controls and gas flow within furnace remain to be optimized. KeywordsShuttle kiln, thermal behavior research, field test, energy-saving potential, cold air infiltration There are several hundred thousands of industrial furnaces and kilns in operation in China, accounting for 25% of national energy consumption, or equivalent to 60% of industrial energy consumption.1-4 Among fueldriven furnaces and kilns, solid fuel (coal) accounted for 70% while liquid fuel (oil) and gaseous fuel (gas) accounted for only 20% and 10%, respectively. Electricity-driven furnaces accounted up to 45% in terms of numbers of sets, but contributed only 8% of industrial furnace energy consumption. 5 The energy efficiency of industrial furnaces and kilns varies with their types and functions. It was estimated that the average efficiency was lower than 36%, 6,7 in comparison to the average efficiency above 50% in the developed countries. 8,9 Undoubtedly, it is essential to improve furnace and kiln efficiency in China, therefore, to reduce energy consumption and to promote sustainable development of energy industry as a whole, a great deal of methods such as heat recovering have been undertaken. [10][11][12][13][14] With in-depth energy restructure and increasingly stringent environment regulations, a number of coal-fired and oil-fired furnaces (and kilns) in many industries were converted into natural gas in recent years. Unfortunately, many design concepts, structures, and operation remain unchanged, resulting in higher energy consumption and unimproved product quality. Research on thermal behavior of gas-fired kiln can improve energy efficiency and provide guidelines for reasonable designs.Being a popular method to research thermal behavior of modern furnace (and kiln), field test is always difficult or even impossible to implement because of higher cost and long duration required. From 1960s to 1980s, some energy balance measurement and tests had been carried out in China, and related standards for measurement of some industrial furnaces (and kilns) were established.

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Improving furnace energy efficiency through adjustment of damper angle

Cited by 10 publications

References 21 publications

Parametric Energy Efficiency Impact Analysis for Industrial Process Heating Furnaces Using the Manufacturing Energy Assessment Software for Utility Reduction

Parametric Energy Efficiency Impact Analysis for Industrial Process Heating Furnaces Using the Manufacturing Energy Assessment Software for Utility Reduction

Operation Optimization of Slab Reheating Process Based on Differential Evolution

Energy efficiency evaluation of a shuttle kiln based on field test

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