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Industrial furnaces. Design guide
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Publisher: Editura Universitară
Author: Marin Gurgu
Edition: I
Pages: 284
Publisher year: 2025
ISBN: 978-606-28-1949-1
DOI: 10.5682/9786062819491
Product Code:
9786062819491
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Preface/9
1. Industrial furnaces equipped with natural gas combustion plant/13
1.1. Low-temperature furnaces/13
1.1.1. Low-temperature heat treatment furnaces used in the aluminum industry/13
1.1.2. Low-temperature heat treatment furnaces used in the machine-building industry/110
1.1.3. Furnaces without stirrers and muffle for low-temperature heat treatment/151
1.2. High-temperature furnaces/157
1.2.1. Forging furnaces/162
1.2.2. Rolling furnaces/170
1.2.3. Furnaces for melting aluminum scrap/171
2. Industrial furnaces equipped with electrical resistors/183
2.1. Choice of resistor material/185
2.1.1. Ferritic alloys (Fe Cr Al)/185
2.1.2. Austenitic alloys (Ni Cr, Ni Cr Fe)/186
2.1.3. Silicon carbide (SiC)/188
2.1.4. Molybdenum bisilicide (MoSi2)/190
2.1.5. Graphite/192
2.1.6. Other materials/193
2.2. Choice of resistor support type/196
2.2.1. Ceramic tubes/198
2.2.2. Profiled bricks/199
2.2.3. Ceramic bushings/201
2.2.4. Tubular resistors/203
2.3. Construction solutions/205
3. Calculation examples/226
3.1. Example no. 1 Stress relieving furnace/226
3.1.1. Calculation data/227
3.1.2. Calculation of thermal insulation/227
3.1.3. Calculation of the hourly amount of heat accumulated in the charge and its supports/234
3.1.4. Calculation of the amount of heat accumulated in the muffle, agitators, anchors/235
3.1.5. Calculation of the amount of heat accumulated in the thermal insulation/236
3.1.6. Calculation of the hourly amount of heat required for the furnace/239
3.1.7. Minimum furnace power/239
3.1.8. Calculation of the furnace power in the case of electrical heating, with resistors/240
3.1.9. Calculation of furnace power in case of methane gas heating/240
3.1.10. Calculation of necessary agitators/242
3.1.11. Calculation of the resistance structure of the hearth/246
3.1.12. Calculation of the running wheels/247
3.1.13. Calculation of the resistance structure of the vault/248
3.1.14. Calculation of the pillars of the furnace casing/249
3.1.15. Calculation of the drive mechanism of the hearth door version/251
3.1.16. Calculation of the controlled cooling system/256
3.2. Example No. 2 – Electric annealing furnace/261
3.2.1. Calculation data/261
3.2.2. Dimensions of the useful working space/262
3.2.3. Dimensions of the interior space of the furnace/262
3.2.4. Calculation of thermal insulation/262
3.2.5. Calculation of the amount of heat accumulated in the batch/266
3.2.6. Calculation of the amount of heat accumulated in the thermal insulation, muffle, anchors and stirrers/266
3.2.7. Calculation of the furnace power/269
3.2.8. Calculation of the furnace resistors/269
3.2.9. Calculation of the door drive mechanism/276
Bibliography/282
There is a very wide range of types and sizes of furnaces used in different industries: metallurgical industry, machine building industry, chemical industry, building materials industry, ceramic materials industry, food industry, etc.
In the specialized literature, there are several works, written in Romanian, which extensively deal with many basic problems related to the calculation and design of industrial furnaces: drawing up the heat balance, technical solutions for thermal insulation of these furnaces, constructive solutions for the construction of a furnace combustion plant equipped with burners, for recovering the heat of the flue gases and exhausting these gases to the chimney, calculation and design of resistors in an electric furnace, constructive solutions for the placement of resistors in an electric furnace, etc. Very important information can also be found in the brochures of the materials and equipment used in the execution of industrial furnaces. These brochures are made available by the manufacturers of the respective materials and equipment.
This paper does not aim to address in detail the issues already addressed in other specialized works. Those interested in these issues can easily find the appropriate works.
This paper aims to address only a few issues related to the design and execution of some types of relatively large industrial furnaces used in our country. These issues, although important, are not addressed or are insufficiently addressed in the specialized literature in Romania. The paper also presents concrete solutions for the realization of some types of furnaces as well as calculation examples. Although some solutions are described when presenting a certain type of furnace, they are applicable to many other types of furnaces.
For most industrial furnaces, a very important issue is that of temperature homogeneity in the useful working space. The concrete ways to solve this problem are very little covered in the Romanian literature, although it is essential for furnaces intended for heat treatments, but it is also important for other types of furnaces such as those intended for heating semi-finished products for plastic deformation, furnaces used in the ceramic, chemical, etc. industries.
The problem of temperature homogeneity in the useful working space of a furnace is a major one, especially in the case of low-temperature furnaces with high and very high heights, which have the volume of the useful working space from a few cubic meters to tens or hundreds of cubic meters.
The density of air decreases as its temperature increases. Therefore, naturally, the hot air rises in the furnace vault and causes temperature inhomogeneity in the useful working space. This inhomogeneity is all the more pronounced the higher the height of the internal space of the furnace is.
High temperature inhomogeneity in a furnace can cause major damage in operation: batch rejection, damage to equipment intended for plastic deformation, increased specific energy consumption, large material losses due to overoxidation of semi-finished products heated to too high temperatures, etc.
Other issues addressed in this paper are:
- precision of temperature regulation in the useful working space of the furnaces
improving the thermal insulation of industrial furnaces
- improving the thermal insulation and sealing of furnace doors
improving the sealing of the hearths of industrial furnaces with a mobile hearth
designing methane gas combustion installations that equip industrial furnaces
- designing resistors and electrical and automation installations for electric furnaces, etc.
In this paper, some theoretical considerations regarding the issues addressed are briefly presented, but concrete, practical solutions are presented in more detail, which can be adopted when designing or modernizing a furnace to prevent problems in operation. Most of the solutions mentioned have been verified in practice, on several furnaces.
When preparing the work, several types of furnaces frequently encountered in the Romanian industry were taken into account:
furnaces equipped with a natural gas combustion plant
furnaces equipped with electric resistors
From a constructive point of view, the most used industrial furnaces, which are addressed in this work, are:
- chamber-type furnaces, with a fixed hearth, with a guillotine door, intended for heat treatments or heating for plastic deformation
chamber-type furnaces, with a movable hearth, with a guillotine door or a door suspended on the hearth, intended for heat treatments or heating for plastic deformation.
tunnel-type furnaces, with continuous or discontinuous operation (without doors or with doors at both ends).
This work is addressed to students from faculties and specializations that have a thermotechnical and metallurgical profile as well as to young engineers who design new industrial furnaces or design the modernization of old furnaces. The work is also useful for those involved in the execution, assembly, commissioning and operation of industrial furnaces.
In the specialized literature, there are several works, written in Romanian, which extensively deal with many basic problems related to the calculation and design of industrial furnaces: drawing up the heat balance, technical solutions for thermal insulation of these furnaces, constructive solutions for the construction of a furnace combustion plant equipped with burners, for recovering the heat of the flue gases and exhausting these gases to the chimney, calculation and design of resistors in an electric furnace, constructive solutions for the placement of resistors in an electric furnace, etc. Very important information can also be found in the brochures of the materials and equipment used in the execution of industrial furnaces. These brochures are made available by the manufacturers of the respective materials and equipment.
This paper does not aim to address in detail the issues already addressed in other specialized works. Those interested in these issues can easily find the appropriate works.
This paper aims to address only a few issues related to the design and execution of some types of relatively large industrial furnaces used in our country. These issues, although important, are not addressed or are insufficiently addressed in the specialized literature in Romania. The paper also presents concrete solutions for the realization of some types of furnaces as well as calculation examples. Although some solutions are described when presenting a certain type of furnace, they are applicable to many other types of furnaces.
For most industrial furnaces, a very important issue is that of temperature homogeneity in the useful working space. The concrete ways to solve this problem are very little covered in the Romanian literature, although it is essential for furnaces intended for heat treatments, but it is also important for other types of furnaces such as those intended for heating semi-finished products for plastic deformation, furnaces used in the ceramic, chemical, etc. industries.
The problem of temperature homogeneity in the useful working space of a furnace is a major one, especially in the case of low-temperature furnaces with high and very high heights, which have the volume of the useful working space from a few cubic meters to tens or hundreds of cubic meters.
The density of air decreases as its temperature increases. Therefore, naturally, the hot air rises in the furnace vault and causes temperature inhomogeneity in the useful working space. This inhomogeneity is all the more pronounced the higher the height of the internal space of the furnace is.
High temperature inhomogeneity in a furnace can cause major damage in operation: batch rejection, damage to equipment intended for plastic deformation, increased specific energy consumption, large material losses due to overoxidation of semi-finished products heated to too high temperatures, etc.
Other issues addressed in this paper are:
- precision of temperature regulation in the useful working space of the furnaces
improving the thermal insulation of industrial furnaces
- improving the thermal insulation and sealing of furnace doors
improving the sealing of the hearths of industrial furnaces with a mobile hearth
designing methane gas combustion installations that equip industrial furnaces
- designing resistors and electrical and automation installations for electric furnaces, etc.
In this paper, some theoretical considerations regarding the issues addressed are briefly presented, but concrete, practical solutions are presented in more detail, which can be adopted when designing or modernizing a furnace to prevent problems in operation. Most of the solutions mentioned have been verified in practice, on several furnaces.
When preparing the work, several types of furnaces frequently encountered in the Romanian industry were taken into account:
furnaces equipped with a natural gas combustion plant
furnaces equipped with electric resistors
From a constructive point of view, the most used industrial furnaces, which are addressed in this work, are:
- chamber-type furnaces, with a fixed hearth, with a guillotine door, intended for heat treatments or heating for plastic deformation
chamber-type furnaces, with a movable hearth, with a guillotine door or a door suspended on the hearth, intended for heat treatments or heating for plastic deformation.
tunnel-type furnaces, with continuous or discontinuous operation (without doors or with doors at both ends).
This work is addressed to students from faculties and specializations that have a thermotechnical and metallurgical profile as well as to young engineers who design new industrial furnaces or design the modernization of old furnaces. The work is also useful for those involved in the execution, assembly, commissioning and operation of industrial furnaces.
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