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ENERGY SAVING OPPORTUNITY ANDPOLLUTION CONTROL IN FURNANCES
ABSTRACT
In the present era of fastly growing technology, Engineers are looking towards the Non-Conventional energy sources. This is because of deplication level of conventional energy sources. Humans are consuming the conventional resources witha rapid acceleration. He uses land, wind, water, mineral, etc. in every task. Moreover,on other hand the rate of pollution is also rising due to these reasons. Controllingwastage in daily life can control this.In industries there are several applications in which there is huge amount of wastageof energy. Wastage of energy means wastage of resources and increase in pollution.Thermal systems have working efficiency of not more than 20% to 30%. This is because of wastages taking place in systems in form of heat. This waste heat can berecovered by different methods. For example the waste heat recovery unit installed infurnaces can be used to preheat the combustion air thus increases the efficiency of furnacesThus the heat wasting out in the form of flue gases from the furnances gases will becaptured to increase the thermal efficiency of furnances and thus controlling theenviormental pollution through energy efficient operation of furnances
INTRODUCTION
Waste heat is heat, which is generated in a process by way of fuel combustion or chemical reaction,and then “dumped” into the environment even though it could still be reused for some useful andeconomic purpose. The essential quality of heat is not the amount but rather its “value”. The strategyof how to recover this heat depends in part on the temperature of the waste heat gases and theeconomics involved. Large quantity of hot flue gases is generated from Boilers, Kilns, Ovens andFurnaces. If some of this waste heat could be recovered, a considerable amount of primary fuel could be saved. The energy lost in waste gases cannot be fully recovered.
Here we are trying to minimize the energy losses by reusing thewaste heat in industrial furnaces. Depending upon the type ofprocess, waste heat can be rejected at virtually any temperaturefrom that of chilled cooling water to high temperature waste gasesfrom an industrial furnace or kiln. Usually higher the temperature,higher the quality and more cost effective is the heat recovery. Inany study of waste heat recovery, it is absolutely necessary thatthere should be some use for the recovered heat.
Typical examples of usewould be preheating of combustion air, space heating, or pre-heating boiler feed water or processwater. With high temperature heat recovery, a cascade system of waste heat recovery may be practiced to ensure that the maximum amount of heat is recovered at the highest potential.
Thus
 
will serve the nature by reducing the wastage of conventionalenergy sources.
FUEL CONSUMPTION AND HEAT ECONOMY
The performance of a furnace installation can be expressed in various ways, the ultimate aim beingthe determination of the total quantity of fuel required to perform the required operation. The term‘efficiency’ in an industrial furnace, when used in the true sense, has reference to heat cost per unitweight of finished saleable product. Or as the quantity of fuel expended to heat a unit weight of stock. While the efficiency in a furnances ranges from 7 to 10 % with very high temperature range.The effiency of furnances are sometimes low as 5%. One reason for the difference in the effiency of industrial furnances is in the final temperature of the material being heated .Gases can give up heatto the charge only as long as they are hotter than the charge. Consequently flue gases leave industrialfurnances at a very high temperature .This factor is responsible for low furnance effiency andincrease in pollution as per Enviorment.So this case study of industrial furnances after theimplementation of the heat recovery unit as sown in figure .The effiency of furnance is increased byapproximately 2% and the percentage of carbon is also reduces as the exhaust temp. reduces.
FACTORS AFFECTING FUEL ECONOMY
Various factors which affect fuel economy in industrial furnaces are :
1)COMPLETE COMBUSTION WITH MINIMUM EXCESS AIR 
A certain amount of excess air is needed to complete combustion and ensure that release of the entireheat contained in fuel oil. If too much air than what is required for completing combustion wereallowed to enter, additional heat would be lost in heating the surplus air to the chimney temperature.This would result in increased stack losses. Less air would lead to the incomplete combustion andsmoke. Which will results in environment pollution.
By measuring carbon dioxide (CO
2
) or oxygen (O
2
) in flue gases bycontinuous recording instruments or Orsat apparatus or portablefyrite, the excess air level as well as stack losses can beestimated with the graph as shown in Figure 1.2 and Figure 1.3. Foroptimum combustion of fuel oil, the CO
2
, or O
2
in flue gases shouldbe maintained at 14-15 % in case of CO
2
and 2-3 % case of O2. Thusoptimizing the excess air we can achieve efficient combustion offuel and at the same time environmental pollution on thecontrolled.
2) PROPER HEAT DISTRIBUTION
The flame should not touch the stock and should propagate clear of any solid object. Any obstructionwhat so ever, deatomises the fuel particles thus affecting combustion and creating black smoke. If the flame touches the stock, the scale losses increase manifold. The flames from various burners inthe combustion space should also stay clear of each other. If the flames intersect, inefficientcombustion would occur. Which will cause environmental pollution. The inefficient combustion thiscan be controlled by staggering the burners of the opposite walls.
 
Operating at too high a temperature will not only mean unnecessarywaste of fuel in terms of heat, but will also cause overheating ofthe stock, its spoilage of excessive oxidation and decarburizationas over-stressing the refectories. The furnaces are often runwithout any temperature controls, often with ‘on-off control’,which is extremely harmful to the optimum performance of thefurnace. In the ‘off’ condition, only the atomizing air enters thefurnace bringing down its temperature rapidly so that when the oilfiring process is recommended., the amount of oil supplied to thefurnace to bring up the temperature, is much more than would benecessary had the furnace been operated on a ‘proportionalcontrol’.
3) REDUCING HEAT LOSSES FROM FURNACE OPENINGS :
In oil fired furnaces, substantial heat losses occur throughfurnace openings.In order to stop this wasteful practice. An experiment wasconducted on two identical furnaces; gun metal to be melted wasweighed and charged to both furnaces at the same time. One furnacewas operated as it was normally done by the operators, and theother furnace was operated openings with refractory bricks. In bothcases, the time taken and fuel consumed noted again.Hence it is imperative that all unnecessary openings of thefurnaces be sealed and the flame be contained within the furnace.Doors should be tightly shut and made of light material that isdurable and heat roof. Door that are hinged or swinging type may beprovided. The minimize heat losses, the refractory lining should besufficiently thick and of good insulation quality.
MINIMISING WALL LOSSES
About 30-40% of the fuel input to the furnace generally goes to make up to heat losses inintermittent or continuous. Furnaces. The appropriate choice of refractory and insulation materialsgoes a long way in achieving fairly high fuel savings in industrial furnaces.
Insulation of furnaces :- The use of insulating refectories ofappropriate quality and thickness can cut down heat storagecapacity of walls, and time required to bring the furnace tooperating temperature by as much as 60-70 per cent in intermittentfurnaces.Insulating Materials :- Insulating materials owe their lowerconductivity to the pores, while their thermal inertia depends onthe weight per unit volume of solids and its specific heat. Thereare, in general three types of insulating bricks;
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