CR-5206: Industrial Furnaces, Instrumentation and Control

Saturday: 5/1/13
Time: 10:15 am to 12:15 pm

Furnaces and Ceramic furnaces

Construction

Syllabus:

These are constructed with ceramic fibers.

Classification of furnace Detailed study of

industrial furnace used in refractorys glass,
ceramics, and cement, ferrous and nonferrous industries with respect to their
design calculations keeping process
parameters in view. Role of multilayer
lining, combustion, gas flow and heat
transfer in furnaces. Physico-chemical
considerations in designing of furnaces;
Measurement of temperature, pressure, draft
etc. in furnace system and their control;
Efficiency and fuel conservation; Use of top
electrode for electric melting; Pollution
control option for furnace noise, flaring and
disposal.

Have low thermal mass and heat loss with

high thermal efficiency.

Text books:
1. Furnace Operation by Robert
Reed
2. Fuel furnaces and Refractories
Gilchrist
3. Heating design and Practices
Robert Henderson
4. Steel plant & Refractories
Chaster
5. Glass tank furnaces by Gusitres
6. Industrial furnaces by Trink

Problem:
Shuffle Kiln:
To Design a low thermal mass Shuffle
Kiln:
The Kiln will be used to fire 6.57 tons of
standard brick at a maximum temperature of
1100C. Firing Schedule graph is given.
Natural gas will be used as a fuel in high
velocity burner with pre heated combustion
layers.
1200C
1100

by
by
by

Difference between Kiln and Furnaces:

Kilns deals with solid materials

Furnaces deals with molten
materials
Discussion about thermal mass

Ex: Stands for thermal NOx

740

740
20.5

10

15 hrs

20

30

40

hrs

To simplify the calculation, certain

simplifying assumption have been made

a. The heating schedule has been

converted to two step functions at
740C and 1100C as shown in
figure.
b. The heat transmission through walls,
roof and door is under study state
for the step period of 20.5 and 15
hrs respectively instead of 40 hrs.
c. The outside surface of walls roof and
door are subjected to natural
convection.
The
car
bottom
temperature is constant at 150C
through-out heating period and
ambient temperature is at 30C.
d. Total moisture (free and chemically
bound) content of green brick is
10%. Green brick standard size

16

91.2

220.8 Or 221
Or 229

15.2

In each horizontal flow of the hack there are

8 lines of bricks and each line has 4 bricks
length wise as shown in figure. A space of
15.2cm is kept between wall facing size of 4
hacks and kiln wall for adequate gas recirculated around the hack for preventing
the burners flame to touch the bricks.
Saturday: 5/1/13
Time: 10:15 am to 12:15 pm
Construction:

9 4 {1} over {2} 3 right )

91.2

the width and 16cm along the length of the

deck. The brick in each hack are also placed
that both sides of each brick are in contact
with high velocity flowing gas inside the
hack.

B
B

The main structure of the kiln is made of

6mm mild steel sheet pre forced with flat
angles, tees etc. to ensure sufficient
mechanical strength and rigidity. The roof is
made of 30cm thick ceramic fiber bolts and
modules which are held tight to the
horizontal metal sheet with in-cornel heat
resistant clamps bolted to the sheet.
ms
30 cm

CFB

15.2
228.8 Or 229
Or 229

Brick settling:

3 side walls are made of 23 cm insulation

brick wall internally lined with 23 cm
ceramic fiber bolts, and modules anchored
in a similar way.

The
brick
of
standard
size
( 7.6 cm 11.4 cm 22.8 cm ) arranged in 4
hacks on car deck, symmetrically leaving an
8cm space between each of two bricks along

IB
23

CFB

23

The gate is made of 5cm CFB back by 25cm

ceramic fiber module both anchored with incornel clamps on a 3mm mild vertical sheet
which is mechanically strengthened angles
flats and tees etc. The gate is moved
vertically through pulleys and tees.

area A =25 38 38=3.61m

Below `A` there are 36 fire brick columns of

( 11.4 cm22.8 cm 15.2 cm(height ) )

to

support all the corner and ages of the slabs

of A.

3mm
203 cm
25cm cm

5mm

211 cm
15

11.4

Car deck:

22.8

The
top
(A)
having
an
area
( 203 cm 211 cm ) , is made of 25 no of

( 38 cm 38 cm3.8 cm )
slabs

with 3.2 cm and

thick fire brick

5.2 cm

gap

along the width and length among each

other respectively.
3.2
38
5.2

27

203 cm

areaB =36 11.4 22.8=0.9357 m2

Below

there

are

25

( 38 cm 38 cm3.8 cm(thick ) )

no

of

fire brick

slabs placed in the same way as A to cover

entire A.

38

areaC =25 38 38=3.61 m 2

211 cm

L 226cm
A

181 X 11.4

W
218

B
C
Sand

D
E
23.8 cm
Below C there are 4 brick channels of

( 11.4 cm181 cm 15.2 cm(h) )

along

length and 22.8 (wide) 15.2 cm (height)

insulation brick loader constructed with
external dimension of ( 218 cm 226 cm )
internal dimension as ( 173 cm181 cm ) .
These channels and borders are made of
insulation brick and support to the slab of
C. The insulation brick at the border serve
as brick rubbing seal at the sides, this
construction D rest on the insulation brick
( 203 cm 211 cm ) and
phase of area
height 7.6 cm . The base E rest on a car
frame through made of 6mm mild steel
shield F with 7.6 cm height and two side
blades to pass through sand shields. The car
frame rests on 2 sets of mild steel wheel on
the rail.

area D=( 226 218 )( 173 181 ) + ( 4 11 181 )

area D=2.621 m2
Heat loss from car deck bottom:
q=KA

t
x

Q= heat loss; R= Resistance offered;

RA=

XA
KA AA

RA=

3.8
=0.0234
4.5 10 3.61 104
3

KA = thermal conductivity
A=area in cm
3

K A , K B , K C =4.5 10

cal

gm sec

RB =

XB
K B AB

RB =

15.2
=0.361
3
4.5 10 9357.32

RB =

XC
K C AC

q=

74030
=326 cal /sec
1.811
4

Q=326 20.5 3600=2.4 10 Kcal

15.2
RB =
=0.361
3
4.5 10 9357.32
XD
R D=
KD AD
K D , K E=0.54 103

cal

gm sec

R D=1.074

R E=

XE
KE AE

R E=

7.6
3
0.54 10 203 211

q=KA

t t
=
x
R

R=R A + RB +R C +R D + RE

732

614

606

256

149

t A=q R A =326 0.0234=8

15.2
R D=
3
0.54 10 2.621 104

R E=0.329

Similarly
t B =118
t C =8
t D =350
t E =107
Heat stored at

Ct

m C =25( No of Fb s) 38 38 3.8 2.05(bulk density)t

mC =285 kg
t A=73630=706
Heat stored in B
m=36 11.4 22.8 15.2 2.05

 t B =67330=643

hr =heat transfer coefficient due radiation

Saturday: 2/2/13

( T w 4 T a4 )
hr =
T w T a

Time: 10:15 am to 12:15 pm

hr =

Heat loss from side valves:

Ti calculate Qc the convective and
radioactive Heat transfer coefficient at
outside valves have to estimated the
temperature of valve is taken as 80C the
ambient temperature as 30C for vertical
value Heat transfer coefficient is due to
natural convection.
4

hnc =1.03 10

1
4

(( ) )
t
L

Where L is the outside height in cm

4

hnc =1.03 10

((

8030
221

1
4

))

hr =1.766 104

cal

2
gmcm

Radiant heat loss:

ht =2.476 104
Back wall is constructed of 23cm thick
ceramic fiber board fitted on insulation
brick. The fiber is facing high temperature.
Total heat loss is taken 740 inside
temperature.
qc=

=stefen boltzmanconstant

t
X
X
+
KA CF KA

( ) ( ) + h1A
IB

Total heat loss per sec.

Car deck bottom thermal conduction
qc=

q A =A ( T w 4T a 4 )
=emissivity of side wall=0.91

cal

gmcm2

ht =hnc +hr =( 0.71+1.766 ) 104

(Heat transfer coefficient in surface since it

was due natural convection)
hnc =0.71 104

0.91 4.92 108 ( 3534 3034 ) 10 3 104

3600 ( 8030 )

t
23
23
+
4
0.35 10 59000 CF 0.54 104 59000

) (

R1=1.181 ; R2=0.0722 ; R3=0.068

qc=

t
t
=
( R ) ( R1 + R2 + R 3 )

) + 2.4
IB

q c=

t
( 1.181+0.722+0.068 )

m=2.28 2.21 23 0.16=185

q c =360 cal/sec

30

q SF=185 0.25(52830)

23

23

IB

CB

Specific heat of CFB = 0.25

740C

t=52830=498
QSIB =m s t

QC20,5 hrs =2.66 10 4 cal/sec

m=mass of ceramic fiber bolt

t=q R1=360 181=425

m=2.28 2.25 23 0.6=695 kg

q SIB=695 2.25 ( 18530 )

23

30

23

740
4

IB

CB

185

528

55

315

Avg temp

t=q R2=360 0.762=260

As the value of Tw is less than assumed
value of 80C the estimated Qc is higher and
therefore same for design purpose.
Heat stored:
q SF=m s t
m=mass of ceramic fiber bolt

q SIB=2.693 10 K cal
Specific heat of CFB = 2.25
t=18530=155
QS =q SIB +q SF=4.9963 104 K cal
QS =6.25 104 K cal if vol=2.67 m 2.21m 23
QS average =5.623 104 K cal
Similarly while calculating Qc and Qs at
1100C the value of Tw will become 84C,
which is very closed to assumed value 80C.
Qc and Qs for all the walls, roof and gate
can be calculated by this way.

1500
For Exhaust gas

QS =m s t
S=0.26 whenunburn=0.25 when fired

740

300

Q S =6.675 0.26 (74030)

1500
For Exhaust gas

QS =123 104 K c al
1100

400

QS =m s t
QS =6.675 0.26 (110030)
4

Saturday: 9/2/13

QS =185.7 10 K cal
Heat losses due to evaporation of 10%
moisture from load
Q evap =6.675 0.1 (539+70)
QS =40.65 10 4 K cal
Where 539 is heat of evaporation and 70 is
raised temperature from room to 1000C.

Time: 10:15 am to 12:15 pm

The amount of flue gas generated at 740C
& 1100C
Net CalorificValue of fuel (NCV )=8149 kcal /m3
molecular weight of gas=18.26
Density of gas=

18.26
=0.8152kg /m3
22.4

Heat in pre-heated air exit gas:

When the high velocity burners are used, the
temp difference between hot gas, kiln and
load is small due to high heat transfer
coefficient of forced convection. The
temperatures of hot gases at 740C &
1100C are 800C & 1500C respectively.
The pre heated air temperatures are 300C
& 400C.

net Calorific Value=

8149
=10.033m m3 of gas
0.8152
3

Theoritcal Air required=10.04 m /m of gas

with 20 excess air , required gas=10.04 1.2=12.048 m3 /m

A mount of flue gas=19+1=20 kg

At 740

Qevap =0 104 K cal

Qc =17.89 104 K cal
Qs=164.8 104 K cal

Qevap =40.5 10 4 K cal

Total heat required=114.34 10 4 K cal

Total heat=

114.34 104
K cal=7.26 10 4 K cal/hr
20.5 hrs

Gas required for first cycle

Total heat required=223 104 K cal

Total heat=

223 104
K cal=10.9 10 4 K cal /hr
20.5 hrs

mng+ ( CV of Natural gas 1.033 10 4 K cal ) + { + ( s 0.26

Gas required for first cycle

mng=12.47

kg
m kg /20.5 hrs
187
hr( ng +19)

air
heatatrequired
for1100C
kiln
So the burning rate
740C &
are
4
{

0.26
) + { &t (30030)
mng+ ( CV of Natural gas 1.033 10 K cal ) + + ( s14.5
=[ (flue gasesThe
mng 20) ( s
kg/hr
12.47 kg/hr }respectively.

burners must have the maximum total

capacity of 14.5 kg/hr to ensure uniform
kg
recirculation of gas. Four burners are to be
mng=14.5 297 kg/ 20.5 hrs
hr
installed. With 20% excess air capacity of
each
burner
should
be
about
4
Similarly for 1100 cycle at 1000C
4.5 10 K cal/hr . The data from
At 1000

Qc =17.89 104 K ca l

burners manufacturer may also consider.

Heat balances:

Total gas burned ={ ( At 740 297.1 )+( At 1100 187

Qs=(249.55164.8) 10 4 K cal
Total gas burned =500.210 4 K cal
Because it have to neglect from first cycle so
it will minimized from total heat required

Energy preheat ed air=[ 14.495 20.5 ( air 19 ) 0.26 ( 30030 ) ]+ [ 12.47 15 ( air 19 ) 0.26 (400

Energy output:
1.

Useful heatheating brick 1100 withmoisture evaporation=( 185.7 104 + 185.7 104 ) K cal=226.3 10
2.
Convectionheat loss roof , gatecar=( 17.89 104 +29.63 10 4 ) K cal=226.3 10 4 K cal
Heat storageroof , gatecar at 1100 =63.85 104 K cal

3.
4.

Heat wastehot flue gas exit is=[ 14.495 20.5 ( air 19 ) 0.27 ( 80030 ) ] + [ 12.47 15 ( air 19 ) 0.2
5.

Unaccounted heat loss ( 5 )=0.05 501.47 104 K cal=25.07 104 K cal

Thermal efficiency of the designed shuffle Kiln is 43.1%

S. NO.
1.

S.
NO.
1.

Type of heat loss

Gas burning

%
100

Value
525.16 104 K cal

2.

Pre heated air

14

73.84 10 4 K cal

3.

Useful heat in brick

43.1

226.3 104 K cal

4.

Convection wall

9.0

47.5 10 4 K cal

5.

Storage loss

12.1

63.79 10 K cal

6.

Waste gas loss

45

236.35 104 K cal

7.

Un accounted loss

4.8

25.04 10 K cal

Wall

Back
wall
2. Side
walls
(two)
3. Roof
4.

Gate
(door)

Area 10 cm Qc at 740 10 K cal

QS at 740 10 K cal
QC at 1100 10 K cal
QS at 1100 10 K cal
5.9

2.66

5.76

4.35

9.47

12.16

5.49

11.88

8.97

19.52

7.34

4.07

3.51

6.99

5.50

5.9

3.26

2.72

5.58

4.21

5.

Car

2.41

17.75

3.74

25.15

6.

Load
(brick)

123.22

185.7

. Heat transfer in regenerators:

GMTF Glass melting tank furnaces

Velocity of the flue gas for that we need

total quantity of flue gases
Flue gases at 60 =42000 11.1=466200

B Blowers
Check-line delivers heat in combustion air
GMTF
Flue gas

11.1 = quantity of the flue gas

For combustion of 1 ft3 of NG requires
10.04 ft3 of combustion air.
Excess of air (15 )=42000 ( 10.04 0.015 )=63252
Total=529452 ft 3

Velocity of flue gases

Air

V
529452
=
=124 ft /sec
hr . area 3600 118

Where free area =118

C
Fee area =118
Problem:
Flue gas quantity 4200 ft3/hr flue gases will
be 11.1 ft3/ ft3 NG. Excess air = 15% Free
area = 118 ft 2 open size =

Total number o f openings=

(7 12 7 {1} over {2} )

Vertical surface =15660 ft2
Horizontal surface = 12970 ft2

118
1
7 7 {1} over {2}
2

Heat transfer taken place by radiation &

convection

hc =1+2.71 v

Where = density at 60C

GMTF

( ))

lb
hc =1+2.71 0.0664 3 + 1.24=1.223
ft

Flue gas

375 + 1341 1716 F

2470
2470 1354 1116F

Assuming t here is 130F

Surface area = 15660 ft2

horizontal=12970 0.2

1116 F

Air

Total area=18254 ft 3
Heat transfer=hc A t=1.223 18254 130 =2902207
Heat transfer by radiation:
Assuming a in cm thickness of gas layer and
average gas temperature 1800C the coefficient
of heat transfer by gases radiation is 5.5
btu/ft2.h.F.
Assuming a waste gas to bring differential of
130 F

To calculate the temperature of waste gases

leaving the checker:

Total Heat transfer by waste gases=H r + H c =1203843

Absorption of heat by checker brick is 81%

Heat transfer by waste gas=0.87 529452 0.0943 t

btu
1203843
Heat transfer by radiation=hr A t body coeff( 0.70
t= )=5.5 18254 134 0.7=913627
=1354 hr
0.87 529452 0.0943
t=24701354=1116
Temperature of pre heated checkered:
It is assumed that air entering at a
temperature of 375C In it travels to the
checker.

Total combustion air=( combustion air+15 excess air )=420

hc =1+ ( 2.71 0.07642 1.14 )=1.236

ustion checker flue side valves . ure Assume

20 Extra for electro pass layout=2039400 0.2=407880 k

a brick to air differential is 530F

1.6 Extra for 9 months holding furnace= ( H . H +20 t )

Heat transfer brick air =h c A t=1.236 18254 530=195730

( 1.6
10

Heat absorbed by air=V air S t=484952 0.0184

Melting
1341
temperature is 1460C
Heat leaving the chekered=375+ 1341=1716
Saturday: 16/2/13
Time: 10:15 am to 12:15 pm
Determine the amount of natural gas required to
melt 30 metric tons of glass/24 hr in continuous
end port regenerative container glass melting
furnace i.e. 9 months old. Furnace is line with
Electrostatic blocks. The melting end of the
furnace is 3.6m wide and 5.5 m long.
S NO.
1.

Material
A

2.
3.

Z
S

Notation
Aluminu
m
ZrO2
SiO2

Energy required for heation glass batch 30 1460=( 20,000

2
batch1
10000= of glass
of glass collected
3
3

Energy required for melting=m Endothermic energy=20

Total energy required for raising
temperature of batch + cullet and
endothermic reaction in 24 hrs

Temperature
2050C

Endothermic reaction24 hr =904000 ( glass batch ) +96382

2700C
1730C

Net energy reqired 1 hr =

To increase the life of the metal lines will

operated from material. The holding heat will
20% excess from outside holding, furnace
temperature will all regenerators in regulators
will kept slight positive.

1. Area of the furnance=3.6 5.5=19.8 m2

Holding heat of the furnace having 19.8 m 2
areas is 10300 k cal/hr m2 for 1 hr

Total holding heat=19.8 103000=20394000 kcal

10542200
=439258 kcal/hr
24

Total energy required for raising

temperature of batch + cullet and
endothermic reaction in 24 hrs

Total energy required for 1hr =holding heat+ losses due co

V Natural gas NCV =3238946 k cal/hr
V Natural gas =

3238946 cal 3238946

k
=
=384.6 m3 /h
NCV
hr
8420