Furnace

1 Household furnaces

For other uses, see Furnace (disambiguation).

A furnace is a device used for high temperature heating.

Industrial Furnace from 1907

The name derives from Greek word fornax, which means

A condensing furnace
oven.
In American English and Canadian English usage, the
term furnace on its own refers to the household heating
systems based on a central furnace (known either as a
boiler, or a heater in British English), and sometimes as a
synonym for kiln, a device used in the production of ceramics. In British English, a furnace is an industrial furnace used for many things, such as the extraction of metal
from ore (smelting) or in oil reneries and other chemical plants, for example as the heat source for fractional
distillation columns.

A household furnace is a major appliance that is permanently installed to provide heat to an interior space
through intermediary uid movement, which may be air,
steam, or hot water. (Heating appliances that use steam
or hot water as the uid are normally referred to as a
residential steam boiler or residential hot water boiler.)
The most common fuel source for modern furnaces in the
United States is natural gas; other common fuel sources
include LPG (liqueed petroleum gas), fuel oil, coal or
The term furnace can also refer to a direct red heater, wood. In some cases electrical resistance heating is used
used in boiler applications in chemical industries or for as the source of heat, especially where the cost of elecproviding heat to chemical reactions for processes like tricity is low.
cracking, and is part of the standard English names for Modern high-eciency furnaces can be 98% ecient and
many metallurgical furnaces worldwide.
operate without a chimney. The small amount of waste
The heat energy to fuel a furnace may be supplied directly
by fuel combustion, by electricity such as the electric arc
furnace, or through induction heating in induction furnaces.

gas and heat are mechanically ventilated through PVC

pipes that can be vented through the side or roof of the
house. Fuel eciency in a gas furnace is measured in
AFUE (Annual Fuel Utilization Eciency).
1

1.1

1 HOUSEHOLD FURNACES

Categories

1.1.2 Forced-air

Residential furnaces can be classied into four general The second category of residential furnace is the forcedair, atmospheric burner style with a cast-iron or sectional
categories, based on eciency and design.
steel heat exchanger. This style furnace was used to
replace the big, natural draft systems, and was sometimes installed on the existing gravity duct work. The
1.1.1 Natural draft
heated air was moved by blowers which were belt driven
and designed for a wide range of speeds. These furnaces were still big and bulky compared to modern furnaces, and had heavy-steel exteriors with bolt-on removable panels. Energy eciency would range anywhere
from just over 50% to upward of 65% AFUE. This style
furnace still used large, masonry or brick chimneys for
ues and was eventually designed to accommodate airconditioning systems.
1.1.3 Forced draft
The third category of furnace is the forced draft, mideciency furnace with a steel heat exchanger and multispeed blower. These furnaces were physically much more
compact than the previous styles. They were equipped
with combustion air blowers that would pull air through
the heat exchanger which greatly increased fuel eciency
while allowing the heat exchangers to become smaller.
These furnace have multi-speed blowers and were designed to work with central air-conditioning systems.
1.1.4 Condensing
Diagram of natural draft gas furnace, early 20th century.

The rst category would be natural draft, atmospheric

burner furnaces. These furnaces consisted of cast-iron or
riveted-steel heat exchangers built within an outer shell
of brick, masonry, or steel. The heat exchangers were
vented through brick or masonry chimneys. Air circulation depended on large, upwardly pitched pipes constructed of wood or metal The pipes would channel the
warm air into oor or wall vents inside the home. This
method of heating worked because warm air rises. The
system was simple, had few controls, a single automatic
gas valve, and no blower. These furnaces could be made
to work with any fuel simply by adapting the burner
area. They have been operated with wood, coke, coal,
trash, paper, natural gas, and fuel oil. Furnaces that used
solid fuels required daily maintenance to remove ash and
clinkers that accumulated in the bottom of the burner
area. In later years, these furnaces were adapted with
electric blowers to aid air distribution and speed moving heat into the home. Gas and oil-red systems were
usually controlled by a thermostat inside the home, while
most wood and coal-red furnaces were controlled by the
amount of fuel in the burner and position of the fresh-air
damper on the burner access door.

The fourth category of furnace is the high-eciency, or

condensing furnace. High-eciency furnaces can achieve
from 89% to 98% fuel eciency. This style of furnace
includes a sealed combustion area, combustion draft inducer and a secondary heat exchanger. Because the heat
exchanger removes most of the heat from the exhaust
gas, it actually condenses water vapor and other chemicals
(which form a mild acid) as it operates. The vent pipes are
normally installed with PVC pipe versus metal vent pipe
to prevent corrosion. The draft inducer allows for the exhaust piping to be routed vertically or horizontally as it exits the structure. The most ecient arrangement for higheciency furnaces include PVC piping that brings fresh
combustion air from the outside of the home directly to
the furnace. Normally the combustion air (fresh air) PVC
is routed alongside the exhaust PVC during installation
and the pipes exit through a sidewall of the home in the
same location. High eciency furnaces typically deliver
a 25% to 35% fuel savings over a 60% AFUE furnace.

1.2 Heat distribution

The furnace transfers heat to the living space of the
building through an intermediary distribution system. If
the distribution is through hot water (or other uid) or

1.3

Furnace types

through steam, then the furnace is more commonly called

a boiler. One advantage of a boiler is that the furnace can
provide hot water for bathing and washing dishes, rather
than requiring a separate water heater. One disadvantage
to this type of application is when the boiler breaks down,
neither heating nor domestic hot water are available.

Octopus furnace with oil burner.

Air convection heating systems have been in use for over

a century, but the older systems relied on a passive air
circulation system where the greater density of cooler air
caused it to sink into the furnace, and the lesser density of Forced-air gas furnace, design circa 1991.
the warmed air caused it to rise in the ductwork, the two
forces acting together to drive air circulation in a system
termed gravity-feed the layout of the ducts and furnace 1.3.1 Single-stage
was optimized for short, large ducts. This caused the furnace to be referred to as an octopus furnace.
A single-stage furnace has only one stage of operation, it
By comparison, most modern warm air furnaces typi- is either on or o. This means that it is relatively noisy,
cally use a fan to circulate air to the rooms of house and always running at the highest speed, and always pumping
pull cooler air back to the furnace for reheating; this is out the hottest air at the highest velocity.
called forced-air heat. Because the fan easily overcomes
the resistance of the ductwork, the arrangement of ducts
can be far more exible than the octopus of old. In American practice, separate ducts collect cool air to be returned
to the furnace. At the furnace, cool air passes into the
furnace, usually through an air lter, through the blower,
then through the heat exchanger of the furnace, whence
it is blown throughout the building. One major advantage of this type of system is that it also enables easy installation of central air conditioning, simply by adding a
cooling coil at the outlet of the furnace.

One of the benets to a single-stage furnace is typically

the cost for installation. Single-stage furnaces are relatively inexpensive since the technology is rather simple.

Air is circulated through ductwork, which may be made

of sheet metal or plastic ex duct, and is insulated or
uninsulated. Unless the ducts and plenum have been
sealed using mastic or foil duct tape, the ductwork is likely
to have a high leakage of conditioned air, possibly into
unconditioned spaces. Another cause of wasted energy
is the installation of ductwork in unheated areas, such as
attics and crawl spaces; or ductwork of air conditioning
systems in attics in warm climates.

This type has two stages of operation, full speed and half
(or reduced) speed. Depending on the demanded heat, it
can run at a lower speed most of the time, and provide a
better comfort level. It is quieter, can move the air at less
velocity, and will better keep the desired temperature in
the house.

1.3

Furnace types

The downside to single-stage furnaces is that they only

have one stage of operation and therefore do not allow for
as good a comfort level as the newer, more controllable
furnaces.
1.3.2 Two-stage

1.3.3 Modulating
This type of furnace can modulate the heat output and air
velocity nearly continuously, depending on the demanded
heat and outside temperature. This means that it only

3 INDUSTRIAL PROCESS FURNACES

works as much as necessary and therefore saves energy.

1.4

Possible failures

The following rare but dicult-to-diagnose failure can

occur. If the temperature inside the furnace exceeds
a maximum threshold, a safety mechanism with a
thermostat will shut the furnace down. A symptom of this
failure is that the furnace repeatedly shuts down before
the house reaches the desired temperature; this is commonly referred to as the furnace riding the high limit
switch. This condition commonly occurs if the temperature setting of the high limit thermostat is set too close
to the normal operating temperature of the furnace. Another situation may occur if a humidier is incorrectly installed on the furnace and the duct which directs a portion
of the humidied air back into the furnace is too large.
The solution is to reduce the diameter of the cross-feed
tube, or install a bae that reduces the volume of re-fed
air.

Electric induction furnace

Reheating furnace
Furnaces used to remelt metal in foundries.
Furnaces used to reheat and heat treat metal for use
in:
Rolling mills, including tinplate works and
slitting mills.
Forges.
Vacuum furnaces

3 Industrial process furnaces

Stack

Damper

Metallurgical furnaces

Breeching
Convection
section
Shield section

Radiant
section

HTF in
HTF out

Coil

Air blower
Burner

The Manufacture of Iron -- Filling the Furnace, an 1873 wood

engraving

In metallurgy, several specialized furnaces are used.

These include:
Furnaces used in smelters, including:

Schematic diagram of an industrial process furnace

An industrial furnace or direct red heater, is an equipment used to provide heat for a process or can serve as
reactor which provides heats of reaction. Furnace designs vary as to its function, heating duty, type of fuel and
method of introducing combustion air. However, most
process furnaces have some common features.

The blast furnace, used to reduce iron ore to

Fuel ows into the burner and is burnt with air provided
pig iron
from an air blower. There can be more than one burner in
Steelmaking furnaces, including:
a particular furnace which can be arranged in cells which
heat a particular set of tubes. Burners can also be oor
Puddling furnace
mounted, wall mounted or roof mounted depending on
Reverberatory furnace
design. The ames heat up the tubes, which in turn heat
Bessemer converter
the uid inside in the rst part of the furnace known as
Open hearth furnace
the radiant section or rebox. In this chamber where
Basic oxygen furnace
combustion takes place, the heat is transferred mainly by
Electric arc furnace
radiation to tubes around the re in the chamber. The

3.3

Radiant coil

heating uid passes through the tubes and is thus heated

to the desired temperature. The gases from the combustion are known as ue gas. After the ue gas leaves
the rebox, most furnace designs include a convection
section where more heat is recovered before venting to
the atmosphere through the ue gas stack. (HTF=Heat
Transfer Fluid. Industries commonly use their furnaces
to heat a secondary uid with special additives like antirust and high heat transfer eciency. This heated uid
is then circulated round the whole plant to heat exchangers to be used wherever heat is needed instead of directly
heating the product line as the product or material may be
volatile or prone to cracking at the furnace temperature.)

3.1

Radiant section

Middle of radiant section

The radiant section is where the tubes receive almost all

its heat by radiation from the ame. In a vertical, cylindrical furnace, the tubes are vertical. Tubes can be vertical
or horizontal, placed along the refractory wall, in the middle, etc., or arranged in cells. Studs are used to hold the
insulation together and on the wall of the furnace. They
are placed about 1 ft (300 mm) apart in this picture of
the inside of a furnace. The tubes, shown below, which
are reddish brown from corrosion, are carbon steel tubes
and run the height of the radiant section. The tubes are
a distance away from the insulation so radiation can be
reected to the back of the tubes to maintain a uniform
tube wall temperature. Tube guides at the top, middle
and bottom hold the tubes in place.

3.2

Convection section

The convection section is located above the radiant section where it is cooler to recover additional heat. Heat
transfer takes place by convection here, and the tubes are
nned to increase heat transfer. The rst two tube rows
in the bottom of the convection section and at the top of
the radiant section is an area of bare tubes (without ns)
and are known as the shield section (shock tubes), so

Convection section

named because they are still exposed to plenty of radiation from the rebox and they also act to shield the convection section tubes, which are normally of less resistant
material from the high temperatures in the rebox. The
area of the radiant section just before ue gas enters the
shield section and into the convection section called the
bridgezone. A crossover is the tube that connects from
the convection section outlet to the radiant section inlet.
The crossover piping is normally located outside so that
the temperature can be monitored and the eciency of
the convection section can be calculated. The sightglass
at the top allows personnel to see the ame shape and
pattern from above and visually inspect if ame impingement is occurring. Flame impingement happens when the
ame touches the tubes and causes small isolated spots of
very high temperature.

3.3 Radiant coil

This is a series of tubes horizontal/ vertical hairpin type
connected at ends (with 180 bends) or helical in construction. The radiant coil absorbs heat through radiation.
They can be single pass or multi pass depending upon the
process-side pressure drop allowed. The radiant coils and
bends are housed in the radiant box. Radiant coil materials vary from carbon steel for low temperature services
to high alloy steels for high temperature services. These
are supported from the radiant side walls or hanging from
the radiant roof. Material of these supports is generally
high alloy steel. While designing the radiant coil, care is
taken so that provision for expansion (in hot conditions)
is kept.

3.4 Burner
The burner in the vertical, cylindrical furnace as above,
is located in the oor and res upward. Some furnaces
have side red burners, such as in train locomotives. The
burner tile is made of high temperature refractory and is
where the ame is contained. Air registers located below

3 INDUSTRIAL PROCESS FURNACES

cally done during maintenance with the air blower turned
on. There are several dierent types of sootblowers used.
Wall blowers of the rotary type are mounted on furnace walls protruding between the convection tubes. The
lances are connected to a steam source with holes drilled
into it at intervals along its length. When it is turned on,
it rotates and blows the soot o the tubes and out through
the stack.

3.6 Stack

Overhead view to stack:

Furnace burner
Stack

the burner and at the outlet of the air blower are devices
with movable aps or vanes that control the shape and
pattern of the ame, whether it spreads out or even swirls
around. Flames should not spread out too much, as this
will cause ame impingement. Air registers can be classied as primary, secondary and if applicable, tertiary,
depending on when their air is introduced. The primary
air register supplies primary air, which is the rst to be
introduced in the burner. Secondary air is added to supplement primary air. Burners may include a pre-mixer
to mix the air and fuel for better combustion before introducing into the burner. Some burners even use steam
as premix to preheat the air and create better mixing of
the fuel and heated air. The oor of the furnace is mostly
made of a dierent material from that of the wall, typi- Stack damper
cally hard castable refractory to allow technicians to walk
The ue gas stack is a cylindrical structure at the top of
on its oor during maintenance.
all the heat transfer chambers. The breeching directly beA furnace can be lit by a small pilot ame or in some older low it collects the ue gas and brings it up high into the
models, by hand. Most pilot ames nowadays are lit by atmosphere where it will not endanger personnel.
an ignition transformer (much like a cars spark plugs).
The pilot ame in turn lights up the main ame. The pi- The stack damper contained within works like a buttery
lot ame uses natural gas while the main ame can use valve and regulates draft (pressure dierence between air
both diesel and natural gas. When using liquid fuels, an intake and air exit) in the furnace, which is what pulls
atomizer is used, otherwise, the liquid fuel will simply the ue gas through the convection section. The stack
pour onto the furnace oor and become a hazard. Using damper also regulates the heat lost through the stack. As
a pilot ame for lighting the furnace increases safety and the damper closes, the amount of heat escaping the furease compared to using a manual ignition method (like a nace through the stack decreases, but the pressure or draft
in the furnace increases which poses risks to those workmatch).
ing around it if there are air leakages in the furnace, the
ames can then escape out of the rebox or even explode
if the pressure is too great.
3.5 Sootblower
Damper blade

Damper closed

Position indicator

Bushing

Control cables

Breeching

Damper partially open

Sootblowers are found in the convection section. As this

section is above the radiant section and air movement is
slower because of the ns, soot tends to accumulate here.
Sootblowing is normally done when the eciency of the
convection section is decreased. This can be calculated
by looking at the temperature change from the crossover
piping and at the convection section exit.

3.7 Insulation

Insulation is an important part of the furnace because it

improves eciency by minimizing heat escape from the
heated chamber. Refractory materials such as rebrick,
castable refractories and ceramic bre, are used for insulation. The oor of the furnace are normally castable type
Sootblowers utilize owing media such as water, air or refractories while those on the walls are nailed or glued in
steam to remove deposits from the tubes. This is typi- place. Ceramic bre is commonly used for the roof and

7
wall of the furnace and is graded by its density and then
its maximum temperature rating. For example, 8# 2,300
F means 8 lb/ft3 density with a maximum temperature
rating of 2,300 F. The actual service temperature rating
for ceramic ber is a bit lower than the maximum rated
temperature. (i.e. 2300 F is only good to 2145 F before
permanent linear shrinkage).

3.8

Foundations

Concrete pillars are foundation on which the heater is

mounted. They can be four nos. for smaller heaters and
may be up to 24 nos. for large size heaters. Design of
pillars and entire foundation is done based on the load
bearing capacity of soil and seismic conditions prevailing
in the area. Foundation bolts are grouted in foundation
after installation of the heater.

3.9

Access doors

The heater body is provided with access doors at various

locations. Access doors are to be used only during shutdown of heater. The normal size of the access door is
600x400 mm, which is sucient for movement of men/
material into and out of the heater. During operation the
access doors are properly bolted using leak proof high
temperature gaskets.

See also
Blast furnace
Electric arc furnace
Basic oxygen steelmaking
Open hearth furnace
Masonry heater
Russian oven
Shell boiler
Jetstream furnace
HVAC

5 Notes
6 References
Gray, W.A. and Muller, R (1974). Engineering calculations in radiative heat transfer (1st ed.). Pergamon Press Ltd. ISBN 0-08-017786-7.
Fiveland, W.A., Crosbie, A.L., Smith A.M. and
Smith, T.F. (Editors) (1991). Fundamentals of radiation heat transfer. American Society of Mechanical Engineers. ISBN 0-7918-0729-0.
Warring, R. H (1982). Handbook of valves, piping
and pipelines (1st ed.). Gulf Publishing Company.
ISBN 0-87201-885-7.
Dukelow, Samuel G (1985). Improving boiler eciency (2nd ed.). Instrument Society of America.
ISBN 0-87664-852-9.
Whitehouse, R.C. (Editor) (1993). The valve and
actuator users manual. Mechanical Engineering
Publications. ISBN 0-85298-805-2.
Davies, Clive (1970). Calculations in furnace technology (1st ed.). Pergamon Press. ISBN 0-08013366-5.
Goldstick, R. and Thumann, A (1986). Principles
of waste heat recovery. Fairmont Press. ISBN 088173-015-7.
ASHRAE (1992). ASHRAE Handbook. Heating,
ventilating and air-conditioning systems and equipment. ASHRAE. ISBN 0-910110-80-8. ISSN
1078-6066.
Perry, R.H. and Green, D.W. (Editors) (1997).
Perrys Chemical Engineers Handbook (7th ed.).
McGraw-Hill. ISBN 0-07-049841-5.
Lieberman, P. and Lieberman, Elizabeth T (2003).
Working Guide to Process Equipment (2nd ed.).
McGraw-Hill. ISBN 0-07-139087-1.

7 External links

Solar power

Furnaces, Incinerators, Kilns at DMOZ

Cremation

http://www.youtube.com/ How It Works: Furnace

Fan heater
Geothermal systems
Fire test furnaces
Batch oven
Forced-air gas

8 TEXT AND IMAGE SOURCES, CONTRIBUTORS, AND LICENSES

Text and image sources, contributors, and licenses

8.1

Text

Furnace Source: http://en.wikipedia.org/wiki/Furnace?oldid=652766572 Contributors: Magnus Manske, DavidLevinson, Maury

Markowitz, Jaknouse, Hfastedge, Danhicks, Josie, Darkwind, Andrewa, Glenn, Tristanb, Samw, Pizza Puzzle, Dcoetzee, Katana0182, Finlay McWalter, Seglea, Lupo, Rjkaes, Fabiform, Rchandra, Khalid hassani, Bobblewik, Zeimusu, Quadell, Ouro, Noisy, Rich Farmbrough,
Adam850, GPoss, Mwanner, Harris000, NetBot, Takis, Billymac00, Reinyday, Dolce850, Kjkolb, Haham hanuka, Anthony Appleyard,
MrB, Atlant, Romary, Sourcer66, Riana, Velella, Wtshymanski, RJFJR, Zntrip, Mindmatrix, Commander Keane, Tabletop, BD2412,
Saperaud, Rjwilmsi, Eptalon, Dbrook, Sprezzatura, Enon, Wongm, DVdm, YurikBot, Peterkingiron, Stephenb, Shaddack, T.E. Goodwin, Aeusoes1, NickBush24, Hugh Manatee, Avalon, Sandstein, Yonidebest, Closedmouth, Aranymalinko, GrinBot, Tom Morris, Anthony717, SmackBot, Commander Keane bot, BirdValiant, Chris the speller, Bluebot, Saint Midge, Droll, Deli nk, Smoken Flames, Jwillbur, COMPFUNK2, Radagast83, Suttonpubcrawl, DMacks, Mbeychok, JHunterJ, Makyen, Beetstra, Ahering@cogeco.ca, P199, Hu12,
Wizard191, Ollie, Gogo Dodo, Teratornis, Barticus88, WhaleyTim, Dawnseeker2000, Mentisto, Gioto, Fayenatic london, Saxophobia,
Afaz, Barek, MER-C, Amvakar, Connormah, Endeneon, Ekotkie, Enaidmawr, Gun Powder Ma, Marktj, R'n'B, J.delanoy, FactsAndFigures,
Jorourke92, Pthareja, TreasuryTag, Philip Trueman, Nw-srjones, Una Smith, Dudenarmo, Venny85, Andy Dingley, Mikez302, Bottlecapninja, Fleela, DimiKosta, MCTales, Michael Frind, PericlesofAthens, WereSpielChequers, Jack Merridew, Northlanddistrib, Alexfusco5,
Lightmouse, Roland Goossens, Xnatedawgx, ClueBot, Elegie, Blanchardb, Immrnicegy, Thingg, Scalziand, Helixweb, Badgernet, Sharafy,
Addbot, Anchorage48, Captain-tucker, Mr. Wheely Guy, Cst17, Morning277, Smokingunholdingape, Tide rolls, JSR, TaBOT-zerem,
Pdery, Mmclean9150, Foolo, Aboalbiss, Kostan1, Kellimuzzy, Ceramres, AnomieBOT, Jim1138, Materialscientist, SecretAgentCat, Citation bot, BritishWatcher, JayJay, Vijay1403, Furnace123, FrescoBot, Riventree, Expansionvalve,
, SoftwareSimian, Citation bot 1,
Pinethicket, Metricmike, Pikiwyn, Lorenzson, Susan Homann, Jenday, , JeepdaySock, Salvio giuliano, K6ka, Gertdam, OnePt618,
Hudson Stern, Noggo, Gillian Aird, GrayFullbuster, CraigERama, ClueBot NG, Bped1985, Kayostar, Cntras, Lrkleine, Widr, Reify-tech,
Briandda, Dougmcdonell, MerlIwBot, Nareto, Helpful Pixie Bot, Choqa zanbil, RudolfRed, Mogism, Snipekiller1000, Vgeek15, Aladdin
Ali Baba, AnandGirish, GuruvayurappanG, Eks9, Tentinator, Robert.Buye, Gus Scorchio, Monugeni, Nick heckford, Vieque, Bonner62,
Johnchapin1, Smartypants717, Utkarsh53 and Anonymous: 161

8.2

Images

File:Burner1.jpg Source: http://upload.wikimedia.org/wikipedia/en/2/27/Burner1.jpg License: PD Contributors:

self-made
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Anchorage48 (talk)
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artist: ?
File:Condensing_furnace_diagram.png Source: http://upload.wikimedia.org/wikipedia/commons/2/2a/Condensing_furnace_diagram.
png License: Public domain Contributors: http://hem.dis.anl.gov/eehem/picts/94110818_8.gif Original artist: ?
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File:Lamneck-central-heating-gas-furnace-cutaway-diagram.png Source: http://upload.wikimedia.org/wikipedia/commons/0/01/
Lamneck-central-heating-gas-furnace-cutaway-diagram.png License: Public domain Contributors: <a data-x-rel='nofollow' class='external
text' href='http://books.google.com/books?id=TysyAQAAMAAJ'>Report of the Househeating Committee</a>, American Gas Institute,
1917, pg. 15 on Google Books Original artist: American Gas Institute
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Author
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