Introduction to Furnace and its types

Furnace is a device use for heating or it is a equipment to heat materials to change their shapes like
rolling and forging or to change the properties of the material. Mostly furnace is used for melting metal
for casting .
Taking into account the system for creating heat, furnaces are comprehensively grouped into two sorts
specifically combustion sort (utilizing energizes) and electric sort. In the event of combustion sort
furnace, contingent on the sort of combustion, it can be comprehensively named oil terminated, coal let
go or gas let go.
Based on the method of charging of material furnaces can be delegated
(i)
(ii)

Irregular or Batch sort furnace or Periodical furnace and

Continuous furnace.

Based on method of waste heat recuperation as recuperative and regenerative furnaces.

Another sort of furnace order is made in light of method of heat exchange, mode of charging and
method of heat recovery .

Characteristics of an Efficient Furnace:

Furnace ought to be planned so that in a given time,
however much of material as could reasonably be
expected can be heated to a uniform temperature as
would be prudent with the slightest conceivable fuel
and work. To accomplish this end, the accompanying
parameters can be considered.
Determination of the amount of heat to be granted
to the material or charge.
Liberation of adequate heat inside of the furnace
to heat the stock and defeat all heat misfortunes.
Transfer of accessible piece of that heat from the
furnace gasses to the surface of the heating stock.

 Equalization of the temperature inside of the stock.

Reduction of heat misfortunes from the furnace to the base conceivable .

Furnace Energy Supply

Since the results of pipe gasses straight forwardly contact the stock, kind of fuel picked is of significance.
For instance, a few materials won't endure sulfur in the fuel. Likewise utilization of strong powers will
create particulate matter, which will meddle the stock spot inside the furnace. Thus, dominant part of
the furnaces use fluid fuel, vaporous fuel or electricity as vitality information. Melting furnaces for steel,
cast iron use electricity in induction and circular segment furnaces. Non-ferrous melting uses oil as fuel.

Oil Fired Furnace

Furnace oil is the significant fuel utilized as a part of oil terminated furnaces, particularly to reheat and
heat treatment of materials. LDO is utilized as a part of furnaces where vicinity of sulfur is undesirable.
The way to productive furnace operation lies
in complete combustion of fuel with least
overabundance air. Furnaces work with
efficiencies as low as 7% as against upto 90%
achievable in other combustion hardware,
for example, evaporator. This is a result of
the high temperature at which the furnaces
need to work to take care of the required
demand. For instance, a furnace heating the
stock to 1200oC will have its fumes gasses
leaving atleast at 1200oC coming about in a
gigantic heat misfortune through the stack.
In any case, upgrades in efficiencies have
been realized by systems, for example,
preheating of stock, preheating of
combustion air and other waste heat
recuperation frameworks.

Regular Furnace System

i)

Forging Furnaces

The manufacturing furnace is utilized for preheating billets and ingots to accomplish a "produce"
temperature. The furnace temperature is kept up at around 1200 to 1250oC. Manufacturing furnaces,
utilize an open chimney framework and the vast
majority of the heat is transmitted by radiation. The
run of the mill stacking in a manufacturing furnace
is 5 to 6 tons with the furnace working for 16 to 18
hours every day. The aggregate working cycle can
be isolated into
a)
heat-up time
b)
drenching time and
c)
Manufacturing time. Particular fuel
utilization relies on the sort of material and number
of "reheats" required.
ii) Rerolling Mill Furnace
a) Batch sort
A case sort furnace is utilized for clump sort rerolling factory. The furnace is essentially utilized for
heating up scrap, little ingots and billets measuring 2 to 20 kg. for rerolling. The charging and
releasing of the "material" is done physically and the last item is in the type of bars, strips and so on.
The working temperature is around 1200 oC. The aggregate process duration can be further sorted
into heat-up time and rerolling time. Amid heat-up time the material gets heated upto the required
temperature and is evacuated physically for rerolling. The normal yield from these furnaces changes
from 10 to 15 tons/day and the particular fuel utilization changes from 180 to 280 kg. of coal/ton of
heated material.

b) Continuous Pusher Type:

The procedure stream and working cycles of a ceaseless pusher sort is the same as that of the cluster
furnace. The working temperature is around 1250 oC. For the most part, these furnaces work 8 to 10
hours with a yield of 20 to 25 tons for every day. The material or stock recoups a piece of the heat in
pipe gasses as it moves down the length of the furnace. Heat retention by the material in the furnace is
moderate, enduring and uniform all through the cross-area contrasted and group sort.

iii) Continuous Steel Reheating Furnaces

The fundamental capacity of a reheating furnace is to raise the temperature of a bit of steel, regularly to
somewhere around 900C and 1250oC, until it is sufficiently plastic to be squeezed or rolled to the
fancied area, size or shape, The furnace should likewise meet particular necessities what's more, targets
as far as stock heating rates for metallurgical and profitability reasons. In nonstop reheating, the steel
stock structures a ceaseless stream of material and is heated to the fancied temperature as it goes
through the furnace.

An unmanageable chamber built of protecting materials for holding heat at the high working
temperatures.
A hearth to bolster or convey the steel. This can comprise of unmanageable materials or an plan of
metallic backings that may be water-cooled.
Burners that utilization fluid or vaporous fills to raise and keep up the temperature in the chamber.
Coal or electricity can be utilized for reheating. A technique for evacuating the combustion debilitate
gasses from the chamber
A strategy for presenting and expelling the steel from the chamber.
These offices rely on upon the size and sort of furnace, the shape and size of the steel being prepared,
and the general design of the moving plant.
Common frameworks incorporate roller tables, transports, charging machines and furnace pushers.

Heat Transfer in Furnaces :

The fundamental routes in which heat is exchanged to the steel in a reheating furnace. In basic terms,
heat is exchanged to the stock by: 9 Radiation from the fire, hot combustion items and the furnace
dividers and rooftop; 9 Convection because of the development of hot gasses over the stock surface. At
the high temperatures utilized in reheating furnaces, the predominant method of heat exchange is
divider radiation. Heat exchange by gas radiation is reliant on the gas piece (mostly the carbon dioxide
and water vapor fixations), the temperature and the geometry of the furnace.

Types of Continuous Reheating Furnace:

Ceaseless reheating furnaces are essentially sorted by the system by which stock is transported through
the furnace. There are two essential systems:
Stock is butted together to frame a flood of material that is pushed through the furnace. Such furnaces
are called pusher sort furnaces.
Stock is put on a moving hearth or supporting structure which transports the steel through the
furnace. Such sorts incorporate strolling shaft, strolling hearth, revolving hearth what's more, nonstop
recycling bogie furnaces.
The significant thought as for furnace vitality use is that the bay and outlet openings ought to be
negligible in size and intended to maintain a strategic distance from air penetration.

i) Pusher Type Furnaces

The pusher sort furnace is famous in steel industry. It has moderately low establishment and upkeep
expenses contrasted with moving hearth furnaces. The furnace may have a strong hearth, yet it is
likewise conceivable to push the stock along slips with water-cooled underpins that permit both the top
and base countenances of the stock to heated.
Pusher sort furnaces, be
that as it may, do have a few
weaknesses, including:
Frequent
harm
of
headstrong hearth and slide
blemishes on material
Water
cooling
vitality
misfortunes from the slips and
stock supporting structure in top

furthermore, base let go furnaces detrimentally affect vitality use;

Discharge must be joined by charge:
Stock sizes and weights and furnace length are constrained by contact and the probability of
stock heap ups.
All round heating of the stock is unrealistic.

ii) Walking Hearth Furnaces

The strolling hearth furnace permits the stock to be transported through the furnace in discrete steps.
Such furnaces have a few alluring elements, including: effortlessness of outline, simplicity of
development, capacity to cook for distinctive stock sizes (inside limits), irrelevant water cooling vitality
misfortunes and negligible physical stamping of the stock.

The fundamental impediment of strolling hearth furnaces is that the base face of the stock can't be
heated. This would he be able to mitigated to some degree by keeping up expansive spaces between
bits of stock. Little spaces between the individual stock pieces restricts the heating of the side confronts
and expands the potential for unsuitable temperature contrasts inside of the stock at release. Hence,
the stock living arrangement time may be long, conceivably a few hours; this may adverse affect furnace
adaptability and the yield may be influenced by scaling.
iii) Rotary hearth furnace
The rotary hearth furnace has had a tendency to supersede the recycling bogie sort. The heating what's
more, cooling impacts presented by the intruders are dispensed with, so heat stockpiling misfortunes
are less. The rotational hearth has, however a more mind boggling outline with an annular shape and
rotating hearth.
iv) Continuous Recirculating Bogie type Furnaces
These sorts of moving hearth sort furnaces have a tendency to be utilized for minimized supply of
variable size and geometry. In bogie furnaces , the stock is put on a bogie with a unmanageable hearth,
which goes through the furnace with others as a train. The whole furnace length is constantly involved
by intruders. Bogie furnaces have a tendency to be long and limited and to experience the ill effects of

issues emerging from insufficient fixing of the hole between the intruders and furnace shell, challenges
in uprooting scale, and troubles in shooting over a limited hearth width.
v) Walking Beam Furnaces:
The strolling bar furnace overcomes numerous of the issues of pusher furnaces and licenses heating of
the base face of the stock. This permits shorter stock heating times and furnace lengths and along these
lines better control of heating rates, uniform stock release temperatures and operational adaptability. In
regular with top and base terminated pusher furnaces, be that as it may, a significant part of the furnace
is beneath the level of the factory : this may be a constraint in some applications.
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