Energy losses from the furnace chamber walls during heating and heat treatment of heavy forgings

Hadała, B.; Malinowski, Z.; Rywotycki, M.

doi:10.1016/j.energy.2017.07.121

Cited by 28 publications

(11 citation statements)

References 14 publications

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“…Then, it is possible to propose alternatives to obtain better quality products, as well as to reduce processing the time and energy consumption. Several studies of thermal analysis in kilns can be found in the literature [32][33][34][35][36][37][38][39][40][41][42][43][44].Yu [32] developed a transient mathematical model for tunnel kilns. Using the model, the author was able to predict several parameters of the process, such as the temperature distribution in parts, energy consumption, heat losses, rate at which energy is accumulated, etc.…”

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confidence: 99%

“…The results were compared with the measured values, showing good agreement.Mezquita [34] and Soussi [35] quantified energy consumption when part of the gases from the tunnel kiln cooling zone are recovered in the firing chamber instead of being exhausted to the atmosphere. In both works, the authors found good agreement between the theoretical and experimental results and concluded that the recovery of gases provides energy savings for the process.Hadala [36] quantified heat losses by the sidewalls of an intermittent kiln during heating and heat treatment of metal parts. The temperature distribution in the kiln walls was determined by solving the heat conduction equation in each point using the finite element method.…”

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confidence: 99%

“…Hadala [36] quantified heat losses by the sidewalls of an intermittent kiln during heating and heat treatment of metal parts. The temperature distribution in the kiln walls was determined by solving the heat conduction equation in each point using the finite element method.…”

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confidence: 99%

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Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis

et al. 2019

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Drying and firing of ceramic products are processes that require high energy consumption. Making these processes more efficient can improve product quality, reduce processing time and energy consumption, and promote economic and environmental gains. In this sense, this work aims to quantify heat transfer in an intermittent ceramic kiln during the heating and cooling stages, with and without thermal insulation. All mathematical formulation is based on the first law of thermodynamics. From the results, we conclude that the greatest heat loss occurs by radiation in the sidewalls of the equipment, and that a considerable amount of energy is required to heat the sidewalls, base, and ceiling of the kiln. Further, with the use of thermal insulation, it was concluded that a high reduction in the heat lost through the sidewalls was achieved, thus providing a global energy gain of approximately 35% and a reduction in the maximum external surface temperature from 249.34 to 79.47 °C when compared to the kiln without thermal insulation, reducing the risks of work accidents and thermal discomfort when in operation.

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Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis

et al. 2019

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“…Simulations of a furnace chamber during heat treatment using natural gas combustion have been reported in the literature, where a boundary condition model for the estimation of heat flux through the walls was proposed and validated [11]. However, a finite-element method, rather than a finite-volume method, was used, and only the energy transport equation was solved.…”

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confidence: 99%

Numerical Simulation of the Flow and Heat Transfer in an Electric Steel Tempering Furnace

2020

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Heat treatments, such as steel tempering, are temperature-controlled processes. It allows ferrous steel to stabilize its structure after the heat treatment and quenching stages. The tempering temperature also determines the hardness of the steel, preferably to its optimum working strength. In a tempering furnace, a heat-resistant fan is commonly employed to generate moderate gas circulation to obtain adequate temperature homogeneity and heat transfer. Nevertheless, there is a tradeoff because the overall thermal efficiency is expected to reduce because of the high rotating speed of the fan. Therefore, this study numerically investigates the thermal efficiency changes of an electric tempering furnace due to changes in the rotating speed of the fan and the effects on temperature homogeneity and the heat transfer rate to the load. Heat losses through the walls were calculated from the external temperature measurement of the furnace. Four different speeds were simulated: 720, 990, 1350, and 1800 rpm. Thermal homogeneity was improved at higher rotating speeds; this is because the recirculation zone caused by the fan improved the flow mixing and the heat transfer. However, it was found that the thermal efficiency of the tempering furnace decreased as the rotating speed values increased. Therefore, these characteristics should be modulated to obtain a profit when controlling the rotating speed. For example, although thermal efficiency decreases by 20% when the rotating speed is doubled, the heat transfer rate to load is increased by up to 50%, which can be beneficial in decreasing the process of tempering times.

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“…The results of the authors for open furnaces, like induction and vacuum, is missing in the numerical study. Hadała et al [8] performed experiments and theoretical calculations to evaluate boundary conditions at the furnace wall and heat loss from furnace insulation. The results showed that heat loss is a function of furnace insulation.…”

Section: Introductionmentioning

confidence: 99%

Thermal Analysis of Vacuum Resistance Furnace

et al. 2019

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The current paper describes the effect of insulation thickness in a vacuum resistance furnace. An existing furnace was optimized for insulation thickness using analytical and numerical studies. Furnace heating efficiency was improved up to 64% by controlling the heat flow at the insulation face. The numerical results were validated experimentally and vice versa. The numerical results predicted a decrease in heat flow of 70%, while the experimentally achieved value was 64%. The percentage difference in numerical and experimental results was calculated to be 1.5–5% maximum in temperature value. The effect of mesh finesse was evaluated for thermal analysis and it was concluded that a very little difference of 5 °C occurs when element size is reduced 5 times. The study using numerical methods will help in designing better and upgraded furnaces with greater energy savings. Also, the application of numerical methods is proposed as an effective design and performance prediction tool during manufacturing and operational activities of vacuum furnaces, respectively.

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Energy losses from the furnace chamber walls during heating and heat treatment of heavy forgings

Cited by 28 publications

References 14 publications

Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis

Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis

Numerical Simulation of the Flow and Heat Transfer in an Electric Steel Tempering Furnace

Thermal Analysis of Vacuum Resistance Furnace

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