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ENERGY MANAGEMENT
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ENERGY MANAGEMENT
" #
% %$$
Forging
Re-rolling
Furnace
classification
According
to mode of
charging
Mode of
heat
recovery
Periodical
Continuous
Recuperative
Regenerative
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(Batch / continuous
pusher)
Pot
Glass tank
melting
(regenerative
/
recuperative)
ENERGY MANAGEMENT
%$
$
$
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ENERGY MANAGEMENT
&
!!#
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ENERGY MANAGEMENT
"
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ENERGY MANAGEMENT
'
%& &
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ENERGY MANAGEMENT
( %#
# &) #
#
Continuous
Pusher
Type:
The process flow and
operating cycles of a
continuous pusher type
is the same as that of
the batch furnace.
The material or stock
recovers a part of the
heat in flue gases as it
moves down the length
of the furnace.
Operating temperature
is 1250oC.
Heat absorption by the
material in the furnace
is slow, steady and
uniform
throughout
the
cross-section
compared with batch
type.
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ENERGY MANAGEMENT
Radiation
from
the
flame,
hot
combustion
products and
the
furnace
walls and roof
Convection
due to the
movement of
hot gases over
the
stock
surface.
PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV
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ENERGY MANAGEMENT
%$ %
&
&
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ENERGY MANAGEMENT
# % +%&
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ENERGY MANAGEMENT
$
%'
,#
% %$
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ENERGY MANAGEMENT
#
%
Material
handling loss
Cooling media
losses
Wall Loss:
Wall losses:
Radiation
(opening) loss
Radiation loss
Stack loss
(Waste-gas loss)
Air infiltration
wall losses
Page: 13
ENERGY MANAGEMENT
$
$
# # %
An oil-fired reheating furnace has an
operating temperature of around 1340oC.
Average fuel consumption is 400
litres/hour. The flue gas exit temperature
after air pre-heater is 750 oC. Air is
preheated from ambient temperature of
40 oC to 190 oC through an air pre-heater.
The furnace has 460 mm thick wall (x)
on the billet extraction outlet side, which
is 1 m high (D) and 1 m wide. The other
data are as given below. Find out the
efficiency of the furnace by both indirect
and direct method.
PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV
Page: 14
ENERGY MANAGEMENT
#-
! "
"
# $
" "
" % &
' # $ ( ) * + &
"
"
"
+ & +
,
$ -
Page: 15
ENERGY MANAGEMENT
$
$
.-
%"/
= 400 litres / hr
= 368 kg/hr
=368x10,000=3680000 kCal
= m x Cp x T
= 6000 kg x 0.12 x (1340 40)
= 936000 kCal
= Output x 100
Input
= 936000 x 100
3680000
= 25.43 % = 25% (app)
= 75% (app)
Page: 16
ENERGY MANAGEMENT
$
$
. "
%"/
=
=
=
=
=
=
=
=
=
=
14 kg
14 x 2.33 kg / kg of oil
32.62 kg / kg of oil
m x Cp x T
Weight of flue gas
32.62 + 1.0 = 33.62 kg / kg of oil.
Specific heat
33.62 x 0.24 x (750 40)
5729 kCal / kg of oil
5729 x 100
% Loss
10000
Page: 17
= 57.29%
ENERGY MANAGEMENT
$
$
. "
%"/
M { 5 8 4 + 0 .4 5 (T fg -T a m b )}
=
x1 0 0
G C V of Fuel
!
" #
!
$ %
$
& %
' ( ) * ) + ) ,
-
.
=1.36 %
10000
- / . 0 1 ' ( ) * ) + ) ,
. - / 1
Page: 18
ENERGY MANAGEMENT
$
$
*
0%
"
. "
% !
%"/
&1
" # $ % &
*
-
. ) / &
+
% #
# #
, ) / &
. / #
+ # #
2 #
$ %
!
' (
&
!
0
' $ ( # )
) , )
)
" # $ % &
,
,
' , , , 0
0 $ ( #
0 1
* $
* ' 0 ,
= 5.56 %
Page: 19
ENERGY MANAGEMENT
$
$
. "
%"/
Body
Page: 20
ENERGY MANAGEMENT
$
$
. "
%"/
at a Particular Temperature
Page: 21
ENERGY MANAGEMENT
$
$
2 *
0%
. "
% &
%"/
3 1
= a + b = 9.71 kg/hr
= 9.71 / 368 = 2.64%
Page: 22
ENERGY MANAGEMENT
%$*
'!
Page: 23
ENERGY MANAGEMENT
$
$
. "
%"/
2
#
- + 0 /
0 3 4 !
- 1 5
1 3 4 !
3 7
) 7 3 !
7
6
- / 1
- 5
- 0 5 )
Total losses
= 75.98 %
! "
# $
%
# # # &
' (
(
Page: 24
ENERGY MANAGEMENT
Theoretical Heat
Example of melting one tonne of steel from an ambient temperature of 20oC . Specific
heat of steel = 0.186 Wh/kg/0C, latent heat for melting of steel = 40 Wh/kg/0C. Melting
point of steel = 1600 oC.
Theoretical Total heat = Sensible heat + Latent heat
Sensible Heat = 1000 kg x 0.186 Wh /kg oC x (1600-20)oC = 294 kWh
Latent heat = 40 Wh/ kg x 1000 kg
= 40 kWh
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ENERGY MANAGEMENT
# % %'
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ENERGY MANAGEMENT
6/ %'!#
%'7
% 8
' '
Excess Air
25
48
50
55
75
63
100
71
Page: 27
ENERGY MANAGEMENT
Prevent flame
impingement.
To avoid high
flame
temperature,d
amage of
refractory and
for better
atomization
Align burner
properly to
avoid
touching the
material
To reduce
scale loss
Page: 28
ENERGY MANAGEMENT
Reheating furnaces
1200oC
CORRECT
TEMPERATURE
ENSURES
GOOD QUALITY
PRODUCTS.
TEMPERATURE
HIGHER THAN
REQUIRED
WOULD ONLY
USE UP MORE
FUEL
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ENERGY MANAGEMENT
Page: 30
be
ENERGY MANAGEMENT
2/)
& %
'%
%$$
"
&
Page: 31
ENERGY MANAGEMENT
:/ ! ' '
#;
Page: 32
ENERGY MANAGEMENT
</
%,
$%'
$
#
&
Stock preheating
Combustion air preheating
Using waste heat for other process
Page: 33
ENERGY MANAGEMENT
=/)
' ; &
#
#0%
Page: 34
ENERGY MANAGEMENT
>/
"
% *
0%
$%'
%$
Q = a x (t1 t2 )
5/4
+ 4.88 E x
t1 + 273
100
where.,
t2 + 273
100
Page: 35
ENERGY MANAGEMENT
Page: 36
ENERGY MANAGEMENT
11.
& %$
%,
#
,
%#
%
th
ta
Area
0.95
75
45
0.5
15.21
406
185390
With Al paint
0.65
75
45
0.5
12.65
406
154116
31274
26895
Particulars
Estimated
painting
investment
for
Rs. 0.60
4 months
Page: 37