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INDUSTRIAL HEATINGPROCESSES

1.1. INDUSTRIAL PROCESS HEATING FURNACES

Industrial process heating furnaces are insulated enclosures designed to deliver heatto loads for many forms of heat processing.

Melting

ferrous metals and glasses re-quires

very high temperatures,

and may involve erosive and corrosive conditions.

Shaping

operations use

high temperatures

to soften many materials for processessuch as forging, swedging, rolling, pressing, bending, and extruding.

Treating

mayuse

midrange temperatures

to physically change crystalline structures or chemically(metallurgically) alter surface compounds, including hardening or relieving strainsin metals, or modifying their ductility. These include aging, annealing, austenitizing,carburizing, hardening, malleablizing, martinizing, nitriding, sintering, spheroidiz-ing, stress-relieving, and tempering. Industrial processes that use

low temperatures

include drying, polymerizing, and other chemical changes.Although Professor Trinks’ early editions related mostly to metal heating, partic-ularly steel heating, his later editions (and especially this sixth edition) broaden thescope to heating other materials. Though the text may not specifically mention othermaterials, readers will find much of the content of this edition applicable to a varietyof industrial processes.Industrial furnaces that do not “show color,” that is, in which the temperature isbelow 1200 F (650 C), are commonly called “ovens” in North America. However, thedividing line between ovens and furnaces is not sharp, for example, coke ovens oper-ate at temperatures above 2200 F (1478 C). In Europe, many “furnaces” are termed“ovens.” In the ceramic industry, furnaces are called “kilns.” In the petrochem andCPI (chemical process industries), furnaces may be termed “heaters,” “kilns,” “after-burners,” “incinerators,” or “destructors.” The “furnace” of a boiler is its ‘firebox’ or‘combustion chamber,’ or a fire-tube boiler’s ‘Morrison tube.’

In this book, “very high temperatures” usually mean

2300 F (

1260 C), “high temperatures”

1900–2300 F (1038–1260 C), “midrange temperatures” = 1100–1900 F (593–1038 C), and “low temperatures”= < 1100 F (<593 C).

INDUSTRIAL HEATING PROCESSES

TABLE 1.1 Temperature ranges of industrial heating processes

Material Operation Temperature, F/KAluminum Melting 1200–1400/920–1030Aluminum alloy Aging 250–460/395–510Aluminum alloy Annealing 450–775/505–685Aluminum alloy Forging 650–970/616–794Aluminum alloy Heating for rolling 850/728Aluminum alloy Homogenizing 850–1175/720–900Aluminum alloy Solution h.t. 820–1080/708–800Aluminum alloy Stress relieving 650–1200/615–920Antimony Melting point 1166/903Asphalt Melting 350–450/450–505Babbitt Melting

600–800/590–700Brass Annealing 600–1000/590–811Brass Extruding 1400–1450/1030–1060Brass Forging 1050–1400/840–1030Brass Rolling 1450/1011Brass Sintering 1550–1600/1116–1144Brass, red Melting

1830/1270Brass, yellow Melting 1705/1200Bread Baking 300–500/420–530Brick Burning 1800–2600/1255–1700Brick, refractory Burning 2400–3000/1589–1920Bronze Sintering 1400–1600/1033–1144Bronze, 5% aluminum Melting

1940/1330Bronze, manganese Melting 1645/1170Bronze, phosphor Melting 1920/1320Bronze, Tobin Melting 1625/1160Cadmium Melting point 610/595Cake (food) Baking 300–350/420–450Calcium Melting point 1562/1123Calender rolls Heating 300/420Candy Cooking 225–300/380–420Cement Calcining kiln firing 2600–3000/1700–1922China, porcelain Bisque firing 2250/1505China, porcelain Decorating 1400/1033China, porcelain Glazing, glost firing 1500–2050/1088–1394Clay, refractory Burning 2200–2600/1480–1700Cobalt Melting point 2714/1763Coffee Roasting 600–800/590–700Cookies Baking 375–450/460–505Copper Annealing 800–1200/700–920Copper Forging 1800/1255Copper Melting

2100–2300/1420–1530Copper Reﬁning 2100–2600/1420–1700Copper Rolling 1600/1144Copper Sintering 1550–1650/1116–1172Copper Smelting 2100–2600/1420–1700

INDUSTRIAL PROCESS HEATING FURNACES

TABLE 1.1 (

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Material Operation Temperature, F/KCores, sand Baking 250–550/395–560Cupronickel, 15% Melting 2150/1450Cupronickel, 30% Melting 2240/1500Electrotype Melting 740/665Enamel, organic Baking 250–450/395–505Enamel, vitreous Enameling 1200–1800/922–1255Everdur 1010 Melting 1865/1290Ferrites 2200–2700/1478–1755Frit Smelting 2000–2400/1365–1590German silver Annealing 1200/922Glass Annealing 800–1200/700–920Glass Melting, pot furnace 2300–2500/1530–1645Glass, bottle Melting, tank furnace 2500–2900/1645–1865Glass, ﬂat Melting, tank furnace 2500–3000/1645–1920Gold Melting 1950–2150/1340–1450Iron Melting, blast furnace tap 2500–2800/1645–1810Iron Melting, cupola

2600–2800/1700–1810Iron, cast

Annealing 1300–1750/978–1228Iron, cast Austenitizing 1450–1700/1060–1200Iron, cast Malleablizing 1650–1800/1170–1255Iron, cast Melting, cupola

2600–2800/1700–1800Iron, cast Normalizing 1600–1725/1145–1210Iron, cast Stress relieving 800–1250/700–945Iron, cast Tempering 300–1300/420–975Iron, cast Vitreous enameling 1200–1300/920–975Iron, malleable Melting

2400–3100/1590–1980Iron, malleable Annealing, long cycle 1500–1700/1090–1200Iron, malleable Annealing, short cycle 1800/1255Iron Sintering 1283–1422/1850–2100Japan Baking 180–450/355–505Lacquer Drying 150–300/340–422Lead Melting

620–750/600–670Lead Blast furnace 1650–2200/1170–1480Lead Reﬁning 1800–2000/1255–1365Lead Smelting 2200/1477Lime Burning, roasting 2100/1477Limestone Calcining 2500/1644Magnesium Aging 350–400/450–480Magnesium Annealing 550–850/156–728Magnesium Homogenizing 700–800/644–700Magnesium Solution h.t 665–1050/625–839Magnesium Stress relieving 300–1200/422–922Magnesium Superheating 1450–1650/1060–1170Meat Smoking 100–150/310–340Mercury Melting point 38/234Molybdenum Melting point 2898/47(

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