Developments in furnaces

By Prem Kumar Aurora Engg. Co. Mumbai

MAIN AREAS OF DEVELOPMENT

REFRACTORY MATERIALS INSULATION MATERIALS HEATING/COMBUSTION SYSTEMS CONTROL SYSTEMS MATERIALS FOR CHARGE CARRIERS & FIXTURES

CLASSIFICATION OF FURNACES
BROAD CLASSIFICATION ENERGY SOURCE DUTY CYCLE MODE OF HEAT TRANSFER ATMOSPHERE END USE

CLASSIFICATION BY ENERGY SOURCE FURNACE OIL L.D.O. OTHER GAS L.P.G./NATURAL GAS/COKE OVEN/OTHER ELECTRIC RESISTANCE/INDUCTION/ DIE ELECTRIC/ARC OIL

CLASSIFICATION BY DUTY CYCLE

BATCH MUFFLE PIT BOGIE SALT BATH CONTINOUS CONVEYOR PUSHER WALKING BEAM ROTARY HEARTH SHAKER HEARTH ROTARY TUBE TUNNEL PULL THROUGH ROLLER HEARTH

CLASSIFICATION BY HEAT TRANSFER

RADIATION CONVECTION CONDUCTION PLASMA

CLASSIFICATION BY ATMOSPHERE
AIR INERT REDUCING CARBURISING NITRIDING VACUMN

CLASSIFICATION BY END USE

HEAT TREATMENT DRYING BAKING CALCINING STRESS RELIEVING ANNEALING NORMALISING HARDENING CASE HARDENING MELTING CRUCIBLE ARC ROTARY OPEN HEARTH

ADVANTAGES OF HIGH EMMISIVITY COATINGS

RAPID HEAT UP INCREASED HEAT TRANSFER AT STEADY STATE IMPROVED REFRACTORY LIFE IMPROVED TEMPERATURE UNIFORMITY REDUCED REFRACTORY DUST

ADVANTAGES OF CERAMIC FIBRE LINING

GREATER THERMAL EFFICIENCY LOWER THERMAL CONDUCTIVITY LOWER HEAT STORAGE EASE OF INSTALLATION THERMAL SHOCK RESISTANCE NO DRY OUT OR CURING

A CASE STUDY OF A FURNACE RELINED WITH CERMAIC FIBRE

FURNACE SPEC. CONTINOUS TEMPERING CONVEYOR FURNACE DIMENSIONS 8Mx 1.9 M x 0.45M OP. TEMP. 450 600 0C OPERATION TO HEAT UP 10 T OF LEAF SPRING TO 500 AND SOAK FOR 5 HRS.

THE FURNACE WAS RELINED BY PROVIDING 75 MM BACK UP INSULATION AS UNDER 25 MM 128 KG/M3 BLANKET 25 MM 96 KG/M3 BLANKET 25 MM 64 KG/M3 BLANKET

BALANCE OF HEAT STORAGE LOSS/CYCLE KCAL BEFORE 10,08,310 AFTER 6,78,292 RADIATION LOSS KCAL/HR BEFORE 54,471 AFTER 34,615

 HEAT TO CHARGE KCAL BEFORE/AFTER 9,80,100 OPENING LOSS KCAL/HR BEFORE/AFTER 2,245 CONVEYOR LOSS KCAL BEFORE/AFTER 2,46,767 HEAT SAVING PER CYCLE 5,59,338 KCAL

FUEL SAVING PER CYCLE 56 KG FUEL SAVING/MONTH 855 KGS PER 15 DAYS OPERATION SAVING PER YEAR 10,260 KGS SAVINGS PER YEAR RS. 5.10 LAC INVESTMENT RS 18.56 LAC PAYBACK 38 MONTHS

HEAT SOURCE
% HEAT % HEAT

SUPPLIED FUEL 100 WASTE GASES ----LOSS THRO WALLS ---HEAT TO STOCK ----

RECIEVED -----61.4 11.7 26.9

HEAT CONTENT OF AIR BTU/CFT

TEMP
100 500 800 1000 1200 1400

HEAT CONTENT
BTU 0.5 7.8 13.5 17.4 21.4 25.4

ADVANTAGES OF VACUMN HEAT TREATMENT

FASTER HEATING NO OXIDATION NEAR NET SHAPE PROCESSING CLEAN OPERATION TEMPERATURE UNIFORMITY ENVOIRNMENTAL FREINDLY

ADVANTAGES OF PLASMA NITRIDING

ACCURATE CONTROL OF CASE DEPTH OPERATION AT LOWER TEMP. UNIFORM NITRIDING ENVOIRNMENTALLY FREINDLY

TO SUM UP PLASMA NITRIDING

PLASMA NITRIDING RETAINS CORE PROPERTIES OF THE WORK PIECE ALLOWS UNIFORM NITRIDING OF WORK PIECE OVERCOMES LIMITATIONS OF SHAPE GEOMETRY AND PRESENCE OF HOLES/SLOTS ETC ALLOWS TREATING MACHINED PARTS WTHOUT DIMENSIONAL CHANGES