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Thermal Analysis of an Industrial Furnace

Author

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  • Mirko Filipponi

    (CIRIAF (Centro Interuniversitario di Ricerca sull’Inquinamento e sull’Ambiente), Università degli Studi di Perugia, Via G. Duranti 67, 06125 Perugia, Italy)

  • Federico Rossi

    (CIRIAF (Centro Interuniversitario di Ricerca sull’Inquinamento e sull’Ambiente), Università degli Studi di Perugia, Via G. Duranti 67, 06125 Perugia, Italy)

  • Andrea Presciutti

    (CIRIAF (Centro Interuniversitario di Ricerca sull’Inquinamento e sull’Ambiente), Università degli Studi di Perugia, Via G. Duranti 67, 06125 Perugia, Italy)

  • Stefania De Ciantis

    (CIRIAF (Centro Interuniversitario di Ricerca sull’Inquinamento e sull’Ambiente), Università degli Studi di Perugia, Via G. Duranti 67, 06125 Perugia, Italy)

  • Beatrice Castellani

    (CIRIAF (Centro Interuniversitario di Ricerca sull’Inquinamento e sull’Ambiente), Università degli Studi di Perugia, Via G. Duranti 67, 06125 Perugia, Italy)

  • Ambro Carpinelli

    (Divisione Fucine di Acciai Speciali Terni, V.le B.Brin 218, 05100 Terni, Italy)

Abstract

Industries, which are mainly responsible for high energy consumption, need to invest in research projects in order to develop new managing systems for rational energy use, and to tackle the devastating effects of climate change caused by human behavior. The study described in this paper concerns the forging industry, where the production processes generally start with the heating of steel in furnaces, and continue with other processes, such as heat treatments and different forms of machining. One of the most critical operations, in terms of energy loss, is the opening of the furnace doors for insertion and extraction operations. During this time, the temperature of the furnaces decreases by hundreds of degrees in a few minutes. Because the dispersed heat needs to be supplied again through the combustion of fuel, increasing the consumption of energy and the pollutant emissions, the evaluation of the amount of lost energy is crucial for the development of systems which can contain this loss. To perform this study, CFD simulation software was used. Results show that when the door opens, because of temperature and pressure differences between the furnace and the ambient air, turbulence is created. Results also show that the amount of energy lost for an opening of 10 min for radiation, convection and conduction is equal to 5606 MJ where convection is the main contributor, with 5020 MJ. The model created, after being validated, has been applied to perform other simulations, in order to improve the energy performance of the furnace. Results show that reducing the opening time of the door saves energy and limits pollutant emissions.

Suggested Citation

  • Mirko Filipponi & Federico Rossi & Andrea Presciutti & Stefania De Ciantis & Beatrice Castellani & Ambro Carpinelli, 2016. "Thermal Analysis of an Industrial Furnace," Energies, MDPI, vol. 9(10), pages 1-13, October.
    • Handle: RePEc:gam:jeners:v:9:y:2016:i:10:p:833-:d:80728
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    References listed on IDEAS

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    Cited by:

    1. Sajad Mirzaei & Nima Bohlooli Arkhazloo & Farzad Bazdidi-Tehrani & Jean-Benoit Morin & Abdelhalim Loucif & Mohammad Jahazi, 2023. "Influence of Spacers and Skid Sizes on Heat Treatment of Large Forgings within an Industrial Electric Furnace," Energies, MDPI, vol. 16(7), pages 1-18, March.
    2. Mersedeh Ghadamgahi & Patrik Ölund & Nils Å. I. Andersson & Pär Jönsson, 2017. "Numerical Study on the Effect of Lambda Value (Oxygen/Fuel Ratio) on Temperature Distribution and Efficiency of a Flameless Oxyfuel Combustion System," Energies, MDPI, vol. 10(3), pages 1-16, March.
    3. Jiming Lin & Haozhen Li & Yong Zhang & Jianhong Yang, 2022. "Experimental and Numerical Study of a Two-Stage Swirl Burner," Energies, MDPI, vol. 15(3), pages 1-19, February.
    4. L. Schoina & R. Jones & S. Burgess & D. Vaughan & L. Andrews & A. Foley & A. Valera Medina, 2023. "Numerical and Techno-Economic Analysis of Batch Annealing Performance Improvements in Tinplate Manufacturing," Energies, MDPI, vol. 16(20), pages 1-28, October.
    5. Bo Gao & Chunsheng Wang & Yukun Hu & C. K. Tan & Paul Alun Roach & Liz Varga, 2018. "Function Value-Based Multi-Objective Optimisation of Reheating Furnace Operations Using Hooke-Jeeves Algorithm," Energies, MDPI, vol. 11(9), pages 1-18, September.
    6. Hadała, Beata & Malinowski, Zbigniew & Rywotycki, Marcin, 2017. "Energy losses from the furnace chamber walls during heating and heat treatment of heavy forgings," Energy, Elsevier, vol. 139(C), pages 298-314.

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