[...]... What is a furnace? 1.2 Where are furnaces used? Brief review of current furnace applications and technology 1.3 Drivers for improved efficiency 1.4 Concluding remarks References 3 7 28 29 29 2 Industrial and Process Furnaces Combustion and furnaces are the very heart of our society Furnaces and kilns are used to produce virtually everything we use and many of our food and drink items, either directly... woeful sketches into artistic masterpieces and Dave Crawley of DCDesign Services, who produced the process and instrument drawings and flow diagrams Grateful thanks are also due to Dr Christine Bertrand, Mr Dennis Butcher and Dr John Smart for their invaluable contribution to the sections on ‘CFD modelling’, ‘Furnace control and safety’ and ‘NOx formation and control’ respectively xxii Acknowledgements... throughput and emissions related issues with alumina calciners Fortunately I met the authors of this book, Peter Mullinger and Barrie Jenkins, and was delighted to discover that a scientific approach to furnace design is possible and methods are available to investigate and optimise many aspects of the combustion and associated processes It was highlighted through physical modelling of the flow patterns and. .. downstream separation Combining and separation furnace system 12.2.2 Defining the physical and chemical changes 12.2.3 Preliminary mass and energy balances 455 456 458 459 459 460 464 464 464 464 464 466 443 444 445 445 446 447 Contents 12.2.4 xv Reliability of available process knowledge Existing processes New processes and pilot plants 12.2.5 Effect of upstream and downstream processes 12.2.6 Fuel choice... thousands of years and yet, beyond the basic chemical reactions and heat release calculations, engineers rarely have any formal training in relation to furnace design, combustion and their integration into industrial processes It is therefore not surprising that the solution to issues of emissions, throughput and performance related problems have relied heavily on trial and error and experience Within... charcoal burners and the weather, Darby triggered an industrial revolution that is continuing to this day The vast majority of the materials we use, and the food and drink we consume, have been heated at some stage during the production process Combustion processes are conveniently divided into high and low temperature process Although there is no strict dividing line between the two, processes with... high temperature High temperature processes include cement and lime manufacture, brick and ceramic manufacture, most metal processing, glass making, etc., while low temperature processes include drying processes, food processing and sterilisation, steam raising, oil refining, etc It is much more difficult to ensure efficient use of the fuel’s energy in high temperature processes than their low temperature... illustration of how a passive oxide layer protects the metal Figure 12.1 Design constraints Figure 12.2 Evolutionary development of the rotary kiln cement-making process Figure 12.3 The design process Figure 12.4 Furnace process functions within the overall manufacturing process Figure 12.5 Schematics of cross-flow and counter-flow recuperators and regenerative heat wheel for preheating combustion air Figure... for a deep understanding of the science of combustion and furnace heat transfer processes as there are many traps for the unwary and the uninformed Whether you are engaged in modelling, design of original equipment or equipment upgrades or operation of combustion and furnace heat transfer processes, this book provides much of the essential understanding required for success Greg Mills Senior Consultant... 7 Fuel handling systems 7.1 Gas valve trains 7.1.1 Safety shutoff systems Double block and bleed Leak testing and proving 7.2 Fuel oil handling systems 7.2.1 Storage, pumping and heating 7.2.2 Oil valve trains 7.3 Pulverised coal handling and firing systems 7.3.1 Raw coal bunkers and feeders 7.3.2 Coal grinding and drying Coal drying characteristics 7.3.3 Coal mills Ball mills Vertical spindle mills . class="bi x0 y0 w0 h0" alt="" Industrial and Process Furnaces This page intentionally left blank Industrial and Process Furnaces Principles, Design and Operation Peter Mullinger Associate. Flash and fluid bed furnaces 18 1.2.7 Metal physical processing 20 1.2.8 Incinerators and resource recovery furnaces 24 1.2.9 Furnaces with reducing atmospheres 24 1.2.10 Oil refining and petrochemical. furnace designers and operators 5 1.2 Where are furnaces used? Brief review of current furnace applications and technology 7 1.2.1 Ceramics, brick making and pottery 7 1.2.2 Cement and lime