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N What Determines Waste-Gas Losses? To answer this, the flow of heat in a furnace, boiler, or oven must be understood. The purpose of a heating process is to introduce a certain amount of thermal energy into a product, raising it to a certain temperature to prepare it for additional processing, change its properties, or some other purpose. To carry this out, the product is heated in a furnace or oven. As shown in Figure 1, this results in energy losses in different areas and forms. First, the metal structure and insu- lation of the furnace must be heated so their interior surfaces are about the same temperature as the product they contain. This stored heat is held in the structure until the fur- nace shuts down, then it leaks out into the surrounding area. The more frequently the furnace is cycled from cold to hot and back to cold again, the more frequently this stored heat must be replaced. In addition, because the furnace cannot run production until it has reached the proper operating tem- perature, the process of storing heat in it causes lost production time. Fuel is consumed with no useful output. Wall losses. Additional heat losses take place while the furnace is in produc- tion. Wall or transmission losses are caused by the conduction of heat through the walls, roof, and floor of the heating device, as shown in Figure 2. Once that heat reaches the outer skin of the furnace and radiates to the surrounding area or is carried away by air currents, it must be replaced by an equal amount taken from the combustion gases. This process continues as long as the furnace is at an elevated temperature. Material handling losses. Many furnaces use equipment to convey the work into and out of the heating chamber, and this can also lead to heat losses. Con- veyor belts or product hangers that enter the heating chamber cold and leave it at higher temperatures drain energy from the combustion gases. In car bottom furnaces, the hot car structure gives off heat to the room each time it rolls out of the furnace to load or remove work. This lost energy must be replaced when the car is returned to the fur- nace. Cooling media losses. Water or air cooling protects rolls, bearings, and doors in hot furnace environments, but at the cost of lost energy. These components and their cooling media (water, air, etc.) become the conduit for additional heat losses from the furnace. Maintaining an adequate flow of cooling media is essential, but it might be possible to insulate the furnace and load from some of these losses. Radiation (opening) losses. Furnaces and ovens operating at temperatures above 1,000°F might have significant radiation losses, as shown in Figure 3. Hot surfaces radiate energy to nearby colder surfaces, and the rate of heat transfer increases with the fourth power of the surface's absolute temperature. Anyone who has ever stood in front of the open door of a Figure 1. Heat losses in industrial heating processes. Gross Net Flue losses Stored heat Wall loss Opening loss Useful output (heat to load) Cooling water loss and/or conveyor fuel input input fuel Available heat Figure 2. Wall loss. HEAT Insulation Outside Skin 2 BestPractices Technical Brief Waste Heat Reduction and Recovery for Improving Furnace Efficiency, Productivity, and Emissions PerformancePDF Image | Waste Heat Reduction and Recovery for Improving Furnace Efficiency, Productivity and Emissions Performance
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