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Summer Internship 2015 in Summer Internship 2015 in Piramal Glass LTDPiramal Glass LTD
KOSAMBA, SURAT GUJRATKOSAMBA, SURAT GUJRAT
Glass furnace Glass furnace Efficiency Efficiency Presentation from the
“MAHENDRA KUMAR BAIRWA”
Department of Ceramic Engineering
INDIAN INSTITUTE OF TECHNOLOGY
(BANARAS HINDU UNIVERSITY)
VARANASI (U.P.) 221005
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Training Agenda: Glass melting
Glass Manufacturing Processes Introduction of furnaceAssessment of furnaces
Energy efficiency opportunities
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Glass Manufacturing Processes:
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Mixed Raw MeltingFurnace
GlassForming
Annealing
Packing StorageFinishingOperations
Fig.- Schematic for glass manufacturing process
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Inspection and testing
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Training Agenda: Glass meltingGlass Manufacturing Processes
Introduction of furnace
Assessment of furnaces
Energy efficiency opportunities
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Introduction of furnaceFurnace Components
(The Carbon Trust)
Furnace chamber: constructed of
insulating materials
Hearth: support or carry the steel.
Consists of refractory materials
Burners: raise or maintain chamber
temperature
Chimney: remove
combustion gases
Charging & discharging doors for loading & unloading stockCharging & discharging doors for loading & unloading stock
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Introduction of furnace
Refractory lining of a furnace arc
Aluminium zirconium silica refractories used in the furnace
Refractory walls of a furnace interior with burner blocks
In the 55TPD Furnace
what are the RefractoriesUsed in the furnace?Used in the furnace?
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Training Agenda: Glass Training Agenda: Glass meltingmelting
Glass Manufacturing ProcessesIntroduction of furnaceAssessment of furnacesEnergy efficiency opportunities
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Assessment of FurnacesHeat Losses Affecting Furnace Performance
FURNACE
Flue gas
Moisture in fuel
Openings in furnace
Furnace surface/skin
Other losses
Heat inputHeat in stock
Hydrogen in fuel
FURNACE
Flue gas
Moisture in fuel
Openings in furnace
Furnace surface/skin
Other losses
Heat inputHeat in stock
Hydrogen in fuel
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Heat Losses in Industrial Heating Furnaces
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Assessment of Furnaces
Parameters to be measured
Location of measurement
Instrument required
Required Value
Furnace soaking zone temperature (reheating furnaces)
Soaking zone and side wall Pt/Pt-Rh thermocouple with indicator and recorder
1200-1300oC
Flue gas temperature In duct near the discharge end, and entry to recuperator
Chrome Alummel Thermocouple with indicator
700oC max.
Flue gas temperature After recuperator Hg in steel thermometer 300oC (max)
Furnace hearth pressure in the heating zone
Near charging end and side wall over the hearth
Low pressure ring gauge +0.1 mm of Wc
Oxygen in flue gas In duct near the discharge end Fuel efficiency monitor for oxygen and temperature
5% O2
Billet temperature Portable Infrared pyrometer or optical pyrometer
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Instruments to Assess Furnace Performance
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Assessment of Furnaces
Direct Method
Thermal efficiency of furnace = Heat in the stock / Heat in fuel consumed for heating the stock
Heat in the stock Q:
Q = m x Cp (t1 – t2)
Calculating Furnace Performance
Q = Quantity of heat of stock in kCal m = Weight of the stock in kg Cp= Mean specific heat of stock in kCal/kg oC t1 = Final temperature of stock in oC t2 = Initial temperature of the stock before it enters the furnace in oC
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Assessment of Furnaces
Direct Method - example
Heat in the stock Q = ◦ m x Cp (t1 – t2) ◦ 6000 kg X 0.12 X (1340 – 40)◦ 936000 kCal
Efficiency =◦ (heat input / heat output) x 100◦ [936000 / (368 x 10000) x 100 = 25.43%
Heat loss = 100% - 25% = 75%
Calculating Furnace Performancem = Weight of the stock = 6000 kg Cp= Mean specific heat of stock = 0.12 kCal/kg oC t1 = Final temperature of stock = 1340 oC t2 = Initial temperature of the stock = 40 oCCalorific value of oil = 10000 kCal/kgFuel consumption = 368 kg/hr
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Assessment of Furnaces
Indirect Method
Heat lossesa) Flue gas loss = 57.29 %
b) Loss due to moisture in fuel = 1.36 %
c) Loss due to H2 in fuel = 9.13 %
d) Loss due to openings in furnace = 5.56 %
e) Loss through furnace skin = 2.64 %
Total losses = 75.98 %
Furnace efficiency =◦ Heat supply minus total heat loss◦ 100% – 76% = 24%
Calculating Furnace Performance
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Training Agenda: Glass melting
Glass Manufacturing Processes
Introduction
Assessment of furnaces
Energy efficiency opportunities
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Energy Efficiency Opportunities:
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Energy Efficiency Opportunities:
Importance of excess air◦ Too much: reduced flame temp, furnace temp, heating rate◦ Too little: unburnt in flue gases, scale losses
Indication of excess air: actual air / theoretical combustion air Optimizing excess air
◦ Control air infiltration◦ Maintain pressure of combustion air◦ Ensure high fuel quality◦ Monitor excess air
1. Complete Combustion with Minimum Excess Air
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Energy Efficiency Opportunities:
When using burners
Flame should not touch or be obstructed No intersecting flames from different burners Burner in small furnace should face upwards but not hit roof
More burners with less capacity (not one big burner) in large furnaces
Burner with long flame to improve uniform heating in small furnace
2. Proper Heat Distribution
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Energy Efficiency Opportunities:
Operating at too high temperature: heat loss, oxidation, decarbonisation, refractory stress
Automatic controls eliminate human error
Slab Reheating furnaces 1200oC
Rolling Mill furnaces 1200oC
Bar furnace for Sheet Mill 800oC
Bogie type annealing furnaces 650oC –750oC
3. Operate at Optimum Furnace Temperature
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Energy Efficiency Opportunities:
Heat loss through openings◦ Direct radiation through openings◦ Combustion gases leaking through the openings◦ Biggest loss: air infiltration into the furnace
Energy saving measures◦ Keep opening small◦ Seal openings◦ Open furnace doors less frequent and shorter
4. Reduce Heat Loss from Furnace Openings
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Energy Efficiency Opportunities:
Negative pressure in furnace: air infiltration
Maintain slight positive pressure
Not too high pressure difference: air ex-filtration
Heat loss only about 1% if furnace pressure is controlled properly!
5. Correct Amount of Furnace Draft
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Energy Efficiency Opportunities
Optimum load◦ Under loading: lower efficiency◦ Overloading: load not heated to right temp
Optimum load arrangement◦ Load receives maximum radiation◦ Hot gases are efficiently circulated◦ Stock not placed in burner path, blocking flue system, close to openings
Optimum residence time◦ Coordination between personnel◦ Planning at design and installation stage
6. Optimum Capacity Utilization
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Energy Efficiency Opportunities:
Charge/Load pre-heating◦ Reduced fuel needed to heat them in furnace
Pre-heating of combustion air◦ Applied to compact industrial furnaces◦ Equipment used: recuperator, self-recuperative burner◦ Up to 30% energy savings
Heat source for other processes◦ Install waste heat boiler to produce steam◦ Heating in other equipment (with care!)
7. Waste Heat Recovery from Flue Gases
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Energy Efficiency Opportunities:
Choosing appropriate refractories
Increasing wall thickness
Installing insulation bricks (= lower conductivity)
Planning furnace operating times◦ 24 hrs in 3 days: 100% heat in refractories lost◦ 8 hrs/day for 3 days: 55% heat lost
8. Minimum Furnace Skin Loss
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Energy Efficiency Opportunities:
High emissivity coatings
Long life at temp up to 1350
Most important benefits◦ Rapid efficient heat transfer◦ Uniform heating and extended refractory life◦ Emissivity stays constant
Energy savings: 8 – 20%
9. Use of Ceramic Coatings
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Energy Efficiency Opportunities:
Selection criteria
Type of furnace Type of metal charge Presence of slag Area of application Working temperatures Extent of abrasion and impact
10. Selecting the Right Refractory
• Structural load of furnace
• Stress due to temp gradient & fluctuations
• Chemical compatibility
• Heat transfer & fuel conservation
• Costs
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Summer Internship in 2015 Summer Internship in 2015 Piramal Glass LTD Piramal Glass LTDKOSAMBA, SURAT GUJRATKOSAMBA, SURAT GUJRAT
Glass furnace Glass furnace Efficiency Efficiency
THANK YOUTHANK YOU
FOR YOUR ATTENTIONFOR YOUR ATTENTION
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