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BestPractices Technical Brief Waste Heat Reduction and Recovery for Improving Furnace Efficiency, Productivity, and Emissions Performance N Introduction Thermal efficiency of process heating equipment, such as furnaces, ovens, melters, heaters, and kilns is the ratio of heat delivered to a material and heat supplied to the heating equipment. For most heating equipment, a large amount of the heat supplied is wasted in the form of exhaust or flue gases. These losses depend on vari- ous factors associated with the design and operation of the heating equipment. This technical brief is a guide to help plant operators reduce waste heat losses associated with the heating equipment. This technical brief supports or complements the software tool Process Heating Assessment and Survey Tool (PHAST) developed jointly by the Industrial Heating Equipment Association (IHEA) and the U.S. Department of Energy’s (DOE) Industrial Technologies Program. N Heat Losses from Fuel-Fired Heating Equipment. Waste-gas heat losses are unavoidable in the operation of all fuel-fired furnaces, kilns, boilers, ovens, and dry- ers. Air and fuel are mixed and burned to generate heat, and a portion of this heat is transferred to the heating device and its load. When the energy transfer reaches its practical limit, the spent combustion gases are removed (exhausted) from the furnace via a flue or stack to make room for a fresh charge of combustion gases. At this point, the exhaust flue gases still hold considerable thermal energy, often more than what was left behind in the process. In many fuel-fired heating systems, this waste heat is the greatest source of heat loss in the process, often greater than all the other losses combined. Reducing these losses should be a high priority for anyone interested in improving the energy efficiency of furnaces and other process heating equipment. The first step in reducing waste heat in flue gases requires close attention and proper measures to reduce all heat losses associated with the furnace. Any reduction in furnace heat losses will be multiplied by the overall available heat factor. This could result in much higher energy savings. The multiplier effect and available heat factor are explained in greater detail in the following sections. These furnace losses include: • Heat storage in the furnace structure • Losses from the furnace outside walls or structure • Heat transported out of the furnace by the load conveyors, fixtures, trays, etc. • Radiation losses from openings, hot exposed parts, etc. • Heat carried by the cold air infiltration into the furnace • Heat carried by the excess air used in the burners. All of these losses can be estimated by using the PHAST software tool or the ITP’s Process Heating Tip Sheets, available on the DOE’s BestPractices Web site at www.eere.energy.doe.gov/industry/bestpractices. Reducing waste heat losses brings additional benefits, among them: • Lower energy component of product costs • Improved furnace productivity • Lower emissions of carbon monoxide (CO), nitrogen oxides (NOx) and unburned hydrocarbons (UHCs) • May contribute to more consistent product quality and better equipment reliability. Waste Heat Reduction and Recovery for Improving Furnace Efficiency, Productivity, and Emissions Performance 1PDF Image | Waste Heat Reduction and Recovery for Improving Furnace Efficiency, Productivity and Emissions Performance
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