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BestPractices Technical Brief The ITP tip sheet on Preheated Combustion Air will offer guidance on how to estimate the efficiency and economic benefits of preheating combustion air.4 Energy reduction and recovery strategy A comprehensive program for reducing furnace energy consumption involves two types of activities. The first deals with achieving the best possible performance from the existing equipment. Equipment modifications, if required, are relatively modest. The second involves major equipment modifications and upgrades that can make substantial reductions in energy consumption. These techniques and their benefits are summarized in Table 1. Table 1. Areas of Potential Waste Heat Reduction and Recovery Improvement Energy Conservation Technique Heat Transfer to Load Reduction of Exhaust Gas Mass Temperature Uniformity Productivity Improving the Performance of Existing Equipment Reducing Heat Storage √ √ Reducing Wall Losses √ √ Reducing Material Handling Losses √ √ Reducing Cooling Media Losses √ √ √ √ Reducing Radiation Losses √ √ √ √ Optimizing Fuel-Air Ratio √ √ √ Reducing Air Infiltration √ √ √ √ Improving Scheduling & Loading √ √ Modifying and Upgrading Equipment Waste Heat Recovery - Air Preheating √ √ √ - Load Preheating √ √ √ - To External Processes* Oxygen-Enhanced Combustion √ √ √ Improving Heat Transfer with Advanced Burners and Controls √ √ √ √ * Process is not directly affected, but energy reduction can be achieved at the plant level. N Summary Obtaining the maximum efficiency and productivity from industrial furnaces and ovens is a two-step process. First, get the equipment up to its peak performance by reducing heat losses, improving production scheduling and closely controlling gas-air ratios. Once the equipment has reached this level of performance, additional significant improvements may come from recapturing waste heat through direct load preheating, combustion air preheating or steam generation. N Additional Process Heating Resources For additional information on topics referenced in this tech brief, please see tip sheets and case studies on the ITP BestPractices Web site at http://www.eere.energy.gov/industry/bestpractices. N Acknowledgements Special thanks to Richard Bennett of Janus Technologies and Arvind Thekdi of E3M, Inc., for their contributions to this Technical Brief. 4 The tip sheet on Preheated Combustion Air was in development at the time of this publication. The tip sheet will be available online on the ITP BestPractices Web site at www.eere.energy.gov/industry/bestpractices. 8 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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