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1 Unit 1 Classification For Furnaces 2

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0% found this document useful (0 votes)
25 views30 pages

1 Unit 1 Classification For Furnaces 2

Uploaded by

shreyajagdale110
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Evaluation scheme

BLOOM TAXONOMY
• MSE – 30
• Assignment, Attendance,
Project based learning ,
Numericals– 20
• ESE- 50

• Subjective type
answers
• Design and Drawing
• Numericals Course Outcome:
At the end of course, students will be able to
CO 1: Relate selection of Furnace, Fuels, and Refractory with working conditions.
CO 2: Select Thermocouple and Atmosphere as per customer requirement.
CO 3. Utilize knowledge of various Furnaces used in industry as per applications
like Heat Treatment, Iron Making, Steel Making etc.
Furnaces
Solid state Transformation and Liquid State Transformation

Energy Efficiency
Heat transfer and Mass Transfer
Engineering Design
• Many design features of the furnace affects the energy efficiency.
Gas / Oil fired furnaces: These include

Reheating furnaces •

(i) type of burners,
(ii) furnace dimensions,
• (iii) number of furnace zones,
• (iv) type of wall and roof insulation,
• (v) skid design, and
• (vi) preheating of fuel and combustion air in recuperators by the
hot flue gases coming out from the furnace exit.

• The parameters important for furnace design include


• (i) the quantity of heat to be imparted to the charge,
• (ii) generation of sufficient heat which is available within the
furnace to heat the steel stock as well as to overcome all steel
losses,
• (iii) transfer of generated heat to the surface of the steel stock to
be heated,
• (iv) equalization of temperature within the steel stock, and
• (v) loss of heat from the furnace to the minimum.
Annealing is a heat treatment that
softens metals to allow for their
cold working to improve their
mechanical, electrical, and
other physical properties.
Annealing furnaces relieve the
internal stress of materials by
heating them to their
recrystallization temperature to
make them ductile for further
machining. After a workpiece
undergoes annealing, it is rolled,
drawn, forged, extruded,
headed, or welded—these are
processes that cause internal
stress.
Annealing
Types
• Conventional Annealing (Full Annealing)
• Bright Annealing
• Box Annealing
• Isothermal Annealing
• Spheroidise Annealing
• Subcritical Annealing
 Stress Relief Annealing
 Recrystallization Annealing
 Process Annealing

Annealing in Metallurgy and


Materials Science ,is a heat
treatment that alters a
material to increase its
ductility and to make it more
workable
Quenching Quenching is a process of rapidly cooling a
workpiece from a high temperature, and it is used

furnace to form martensite in steel. The cooling material


can be water or oil. Quenching furnaces are
normally paired with a batch furnace, roller
hearths, or pusher furnaces. Different quenching
furnaces are designed to meet the specific needs
of a given application. A necessity for quenching
furnaces is precision control of the temperature
to avoid uneven heating and overheating.

Vacuum Furnaces
When a product is processed in a vacuum furnace, it
is surrounded by a vacuum that prevents heat
transfer through convection and removes
contaminants. Normally, heating products to high
temperatures causes oxidation. This is not present
in a vacuum furnace since all oxygen has been
removed.
Vacuum furnaces are an ideal method for quenching
materials. They use an inert gas to quickly cool a
treated piece. A vacuum furnace includes a vacuum
unit, hydraulic system, and cooling system.
A tempering furnace is designed to
heat treat metal products to increase
their durability and hardness.
Increasing the toughness of a metal
product enhances the product's ability
to withstand deformation and energy
absorption before it cracks.

A tempering furnace brings out the


beneficial properties of a metal and
improves its mechanical
characteristics.

Tempering furnaces have ceramic


and quartz heating elements that
are lined with electrical coils to
provide uniform heating of the
chamber. There are different heating
ranges depending on the material to
be processed. Tempering takes place
at temperatures between (300 °C and
750 °C).
Heat treatment cycle used for M2 and M35
Pit furnaces are located at floor level and are

Pit Furnace
top loading. Workpieces to be treated are held
in fixtures or baskets or can be placed at the
base of the furnace. Pit furnaces are best
suited for heating long shafts, tubes, and rods.
The main purpose of a pit furnace is to melt
small amounts of metals for casting. Pit
furnaces are fueled by coke.
Rotary Tube Furnace

A rotary tube furnace is a heat treatment


circular furnace that rotates during heat
treating. Materials travel a circular path
through the furnace as they are treated. Rotary
tube furnaces use a continuous processing
method to apply heat in thermal zones where
the heat source supplies heat to a rotating
tube.
Walking beam furnaces are
Walking Beam furnaces efficient methods for
processing large, heavy parts.
The main uses of walking
beam furnaces are annealing,
forging, heating, stress
relieving, quenching, and
tempering at a maximum
temperature of 2012 °F (1100
°C). The material to be
processed is gradually fed
through the furnace by water-
cooled beams that lift and
move materials in short steps.
The drive system of the
furnace is protected from
scales by sealing materials
and an arrester. The cooling of
the beams is to ensure a long
life of usefulness. The door to
the furnace opens as the
beam enters and closes
Furnace Design
Sintering is a heat treatment
process designed to transform
Sintering furnace
loose, fragmented material into a
solid mass. The amount of heat
provided during sintering varies in
accordance with the type of
material, but it is always slightly
below the material’s melting point.
During sintering, the porous spaces
in a workpiece are minimized as the
material is squeezed and shaped at
high temperatures and pressures.
The purpose is to heighten the
material’s properties, such as
thermal and electrical conductivity,
strength, and translucency.
Powder Metallurgy products
Industrial Sintering Furnace
in out

preheat zone cooling zone


Temp hot zone
Job temp.

Furnace
temp.

Time/Position
16
Parameters in Sintering

Powder Distribution of
 Particle size  Dopants
 Shape  Second phases
Size distribution

Process parameters Powder Consolidation


Heating rate  Density
Temperature  Pore size
Applied pressure distribution
Atmosphere
Mechanism of Sintering Driving forces are
The curvature of the
particle surfaces
An externally applied
pressure
A chemical reaction

 Atomic diffusion takes place and


the welded areas formed during
compaction grow until eventually
they may be lost completely .
Diffusion.
Spark Plasma Sintering

Laser Sintering 19
Microwave
sintering

20
Blast furance
A blast furnace is a cylindrical furnace that is used
for smelting, which is the process of extracting
metals from their ores. The furnace is loaded from
the top with ore, fuel, and limestone. As the
components move down the cylinder, a reaction
takes place between them that produces molten
metal and slag. At the bottom of the furnace are
parallel pipes that push hot blast air up the
cylinder to create the reaction between the
materials.
The parts of a blast furnace are the hopper,
adjustable gates, rotating chute that blends the
materials, fire brick, combustion chamber, gas
burner, carbon brick, tap hole, and tuyere to
supply air. The raw materials are loaded in the
stack zone and progress to the barrel zone or
reduction zone where the chemical reaction takes
place.
Fired Process Furance
Fired process furnaces have the same function as
electric process heaters, which is to heat a fluid to
a desired working temperature. The fluid flows
through tubes that are heated by a combusting
fuel. Fired process furnaces are widely used by
refineries, petrochemical plants, the chemical
industry, gas processing, ammonia plants, olefin
plants, and the fertilizer industry.
Several names are given to fired process furnaces,
including feed preheaters, cracking furnaces,
fractionator heaters, steam reforming heaters, and
crude heaters. Fired process furnaces can reach
temperatures of 3500 °F (1926 °C). The created
heat is released into an open space, where it is
transferred to tubes containing the fluid. The tubes
are placed along the walls and roof of the open
space. Then, the heat is transferred by direct
radiation convection or from refractory wall linings
in the open chamber.
Induction Furnace
Electric Arc Furnace
• Electric Arc Furnaces
• Electric arc furnaces are used to
produce steel by recycling ferrous
scrap. Scrap is melted and converted
to steel by high-powered electric arcs
that are formed by a cathode and one
or more anodes. The scrap is loaded
into a basket with limestone for slag
formation, then charged in the
furnace. The energy required to melt
the scrap and heat is approximately
350 kWh to 370 kWh. The amount
of energy necessary to power the arc
depends on the mix of scrap and its
composition.
Electric High Frequency Induction Furnaces
• Electric induction furnaces work on the same
principles used to design transformers. The primary
winding of an induction furnace is wound around the
furnace and connected to an AC electrical supply. The
charge inside the furnace acts as the secondary
winding and uses induced current to heat up the
charge. The primary coils are made of hollow tubes
through which water circulates to keep the coils
cooled to the appropriate temperature limits.

• Heat is generated by eddy currents flowing


concentrically, producing a high frequency supply of
500 Hz to 1000 Hz. A laminated core is used to
protect the furnace's structure. Energy is transferred
to the heated object through electromagnetic
induction.

• The benefits of high frequency induction furnaces are:


• Decreased melting time
• Precision temperature control
• Simple design of crucible and container
Environmental laws

The Agra may be cited as an example where cupola melting practice by


foundries is not allowed due to emission problems that damage the world
heritage monument—The Taj Mahal. The foundries in Agra have to
install gas fired melting furnaces or electricity based melting units.
Furnace Regulations

• The major concern with industrial furnaces is their emissions, which are regulated by the Environmental

Protection Agency (EPA). The federal New Source Performance Standards (NSPS) have stipulations

regarding the size, function, and construction of industrial furnaces. The emissions of greatest concern are

listed as Hazardous Air Pollutants (HAP).

• Furnace operations are differentiated by furnaces designed for processing new products and those for

heating. In 2011, the EPA published a list of pollutants and limits for each type. The publication was in

compliance with part 60 of the Clean Air Act.

• The International Organization for Standardization (ISO) has developed a set of specific regulations

regarding industrial furnaces, which are found in ISO 13574, 13577, 13578, 13579, and 23459. They were

first introduced in 2008 as ISO/TC 244 and have been progressively adjusted to include arc furnaces with

ISO 13578: 2017.

• ISO 13574: 2017 – outlines the vocabulary associated with industrial furnaces

• ISO 13577 – has stipulations regarding safety standards for combustion and the handling of fuel, use of

gasses, and required protective systems

• ISO 13579 – outlines energy measurement and efficiency

• ISO 23495 – was enacted in 2021 regarding the requirements for converters and similar equipment
Furnace Regulations
• The American National Standards Institute (ANSI) has standards and codes regarding the

safety, reliability, quality, and performance of industrial heating equipment.

• The American Society of Mechanical Engineers (ASME) inspects and approves of industrial

furnaces that are in compliance with their standards. The main concerns of the organization

are safety and quality.

• The United States Department of Energy (DOE) has established energy efficiency standards

regarding industrial manufacturing equipment.


National Fire Prevention
Association (NFPA)
• The NFPA works to prevent injury and property and economic loss from fire and electrical
hazards. The organization has specific guidelines in reference to furnaces under NFPA 86.
• NFPA 86 – The purpose of the NFPA 86 is to minimize explosions or fire hazard risks by
outlining safeguards in the event of an explosion. The idea is to avoid cases where explosive
limits of fuels exist, whether they are from the fuel being used or from products being heated.
Included in the guidelines are pre-startup sequences since most accidents occur during
startup. Although the standards are very broad and all-inclusive, the many concepts can be
categorized as:
• Location
• Construction
• Heating systems
• Electrical management
• Operation
• Maintenance
• Inspection
• Testing
• The main focus of NFPA 86 is the avoidance and control of risk and harm caused by poor
management of furnace operations. The basic principle is that risk leads to injury, damage,
and endangerment.
Conclusion

• A furnace is a device used to provide heat for industrial


processes .
• Through the combustion of fuels and gases, raw materials
and products are heated by direct or indirect contact.
• The wide selection of furnaces have different methods of
performing their functions and use different fuels.
• Regardless of the differences in operation, all furnaces serve
the primary purpose of providing heat.
• Industrial uses of furnaces tend to center around the
annealing, melting, tempering, and carburizing of
metals.

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