The Thermal Analysis of Fuel Fired Crucible Furnace using Autodesk Inventor Simulation Software (original) (raw)
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Thermal Design of an Oil Fired Crucible Furnace using CFD Technique
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Heat Transfer-Asian Research, 2018
Technological development of furnaces over conventional melting methods of diesel or gas-fired furnaces is necessary. These furnaces have large amount of heat losses and hence their thermal efficiency is very low. Moreover, these furnaces do not produce good quality melt because of the chances of embedment of impurities from after-combustion gases and agitation. The time required for melting in such furnaces is more. Also, insulation is not provided and there are heat losses which increase the time of melting. An electric resistance heating furnace is developed which overcomes all the problems associated with the fuel-fired conventional furnace. The thermal efficiency of this developed furnace is found to increase quite drastically up to 85%, which is by about 33% more than conventional furnace; while reducing the operating cost of furnace. This benefits industry overall by profit of 70% and certainly can replace the existing conventional fuelfired furnaces.
Development of an Indigenously Made Diesel Fired Crucible Furnace
The technological advancement of any nation have been influenced and uplifted by the extent to which it can usefully harness and convert its mineral resources. The productions of metal in foundries and in all human lives have become a general practice. This work deals with the design, fabrication and performance evaluation of a diesel-fired crucible furnace suitable for use both in the rural and urban areas for casting of different types of metals using indigenously sourced materials and technology. The components of furnace were furnace casing, crucible, furnace cover, burner housing, furnace cover stand, base stand and burner. Mild steel sheet was used for the fabrication of the furnace, while the other components needed for the design were selected based on functionality, durability, cost and local availability. Experimental tests were performed to evaluate the performance of the furnace. The average heating rate of 19.54°C/min was recorded by the furnace and attained a temperature as high as 1420 °C. The furnace also had a melting rate of 454.55g/min for Aluminium. The thermal efficiency of the furnace was determined to be 10.80%. The low value was as result of the large energy wastage due to the type of insulator used in making the furnace wall. The furnace is environmental friendly without health hazards to the workers and can be moved from one place to another unlike the local one.
Design and Construction of an Oil Fired Crucible Furnace
https://www.ijrrjournal.com/IJRR\_Vol.5\_Issue.2\_Feb2018/Abstract\_IJRR0010.html, 2018
The study carried out a design and construction of an oil-fired crucible furnace. The study focused on ensuring a high efficiency in melting of aluminum, by effectively minimizing heat losses, and maximizing heat generation. To achieve this, a composite refractory material consisting of cement, asbestos, and clay in a ratio of 2:1:1 was used, and diesel fuel was atomized at the rate of 6.31x10-5 m 3 /min, using an Air compressor of 50kPa, volumetric air flow rate of 2 CFM, and power rating of 1hp. This generated a heat of 42.6 MJ at a working pressure of 0.4122 Mpa. 18.02% of the heat generated was lost due its interaction with the environment. Changes in the furnace geometry were negligible indicating a long service life potential. With a useful heat input of 34.92 MJ, the furnace is able to melt 56 kg of aluminum at a pouring temperature of 720 0 C, leaving its efficiency at 81.98%. The design is considered safe since the working pressure does not exceed the working stress of its casing which is made of mild steel.
Thermal Analysis of an Industrial Furnace
Sciprints, 2016
Industries, which are mainly responsible for high energy consumptions, need to invest in research projects in order to develop new managing systems for rational energy use and to tackle the devastating effects of climate change caused by human behavior. The study reported in this paper concerns the forging industry, where the production processes generally start with the heating of the steel in furnaces and continue with other processes, such as heat treatments and mechanical machining. One of the most critical operations, in terms of energy loss, is the opening of the furnace doors for the insertion and extraction operations. During this time, the temperature of the furnaces decreases by hundreds of degrees in a few minutes. Because the dispersed heat needs to be supplied again through the combustion of fuel, increasing the consumption of energy and the pollutant emissions, the evaluation of the amount of the lost energy is crucial for the development of operating or mechanical sys...
DESIGN OF A 50-KILOGRAM CAPACITY CAST IRON CRUCIBLE FURNACE USING LOCALLY AVAILABLE MATERIALS
This research work focuses on the design of a 50-kilogram capacity Cast-iron crucible furnace that is fired with diesel fuel. The furnace drum has an overall combustion capacity of 0.1404m 3. It is fitted with a chimney to allow for the easy escape of combustion gases. The air blower discharge air into the furnace at the rate of 0.3m 3 /s with an air/fuel ratio of 400:1. The cast-iron crucible furnace is designed to consume 4 gallons of diesel fuel with a rating of 139000kj/gallon which is required to completely melt 50-kilogram of cast iron over a period of 90min. The designed operation temperature range of the cast–iron crucible furnace is 1300 0 C to 1400 0 C. The cost of the cast-iron crucible furnace is three hundred and forty-eight thousand naira (N348, 000.00).
Modeling heat flow across fuel-fired crucible furnace using ADINA
International Journal of Scientific and Engineering Research
The study simulated the heat flow across a fuel-fired crucible furnace using ADINA Software. Appropriate engineering materials were selected for the design and construction of the fuel fired crucible furnace. Among several parameters taken into consideration were strength/weight ratio, formability, cost and ability to fulfill specific service functions. Heat dissipation to the outside was minimal and this was clearly shown in the temperature gradient. Heat dissipation was uniform within the flame gap and inside the crucible pot. The Kaolin refractory material used showed very good insulation capacity significantly reduced heat losses. The modeled temperature distribution profile, heat flux and the temperature gradient were all in agreement with the validated results
Material Selection for Fuel Fired Crucible Furnace Using GRANTA
International Journal of Scientific and Engineering Research
The study investigated the material selection for a fuel fired crucible furnace using bubble charts. The results were generated using GRANTA software. Different properties were considered during the selection of the materials for the furnace. The appropriate engineering materials were sought locally for the design and construction of the fuel fired crucible furnace. Among several parameters taken into consideration are strength/weight ratio, formability, cost and ability to fulfill specific service functions. All these were taken into consideration during the material selection process for the fuel-fired crucible furnace. These properties were plotted against each other in bubble chart and the selection of the appropriate candidate material was done on the bubble chart. The software plotted the properties of each unit of the furnace in form of bubbles and the candidate material where selected from the bulk of materials suggested by the software. The functions, objectives and constra...
IJERT-Studies Of Parametric Analysis Of High Temperature Resistance Furnace
International Journal of Engineering Research and Technology (IJERT), 2013
https://www.ijert.org/studies-of-parametric-analysis-of-high-temperature-resistance-furnace https://www.ijert.org/research/studies-of-parametric-analysis-of-high-temperature-resistance-furnace-IJERTV2IS2355.pdf High temperature resistance furnace, so far in the conventional systems regarding manufacturing, temperature controlling and heating to the desired temperature, cause tremendous thermal losses, very bulky and costly affairs in resistance heating operating up to 1600 degree C. Though the concept of ‗high temperature resistance furnace' is quite old, but, recent development of material science has created a radical change in the aspects of manufacturing process, like, in the concept of insulation, concept of control systems and in the design of heating system astonishingly. Considering all the new-age developments, present proposed work is outlined specifically to meet the requirements of followings : " high and low temperature furnace with compound heating system (using two different types of heating elements up to 1600 degree C), to achieve optimum thermal efficiency (minimum thermal losses)". A new design of compound heating using two different elements, viz. silicon carbide (SiC) and molybdenum di sillicide (MoSi2) elements simultaneously to attain required temperature (1600 degree C), with minimum consumption of current, arresting thermal losses using improved insulation to improve thermal efficiency, and with latest control systems (PID programmable type). The goal of this experiments is to achieve optimum thermal efficiency with skin temperature equal to the room temperature, to achieve accurate results in terms of resolution and sensitivity, and for continuous operations in multiple programmable cycles etc set for various heating processes requiring temperature from ambient temperature up to 1600 degree C in multiple ranges to be programmed before to be followed continuously one after another, for wide range of applications as laboratory furnaces, testing the equipments within the temperature 1600 degree C (maximum), as high temperature ‗sintering production' furnaces etc. The present experiment will be a great mileage ushering new era for research, and tap so many untapped factors to achieve most satisfactory results in the field of-thermal engineering‖ in coming years. KEY WORDS: Resistance furnace, thermal efficiency, zirconium insulation, KANTHAL SUPER, programmable PID controller. INTRODUCTION Resistance heating furnace is a device where heat energy is available by electric arc to heat the charged materials, up to a temperature as high as 1600 C. Arc heating is one of the many ways of heating methods applied in an environment of air, inert gas, vacuum etc with no pollution. Thus the heating process is carried out using qualitative heating elements made up of Sic, MoSi2 etc meant for-higher temperature application‖ in multiple programmable cycles set before the operation and controlled by PID programmable controller to 100% resolution to achieve desired results. The heat transfer takes place by mode of conduction and radiation, with homogeneous heating inside the working chamber through out the cycles of operations continuously. High temperature resistance furnace with temperature range up to 1600C has large scope of applications, such as laboratory furnaces for testing the equipments within the temperature 1600C (max.), as high temperature ‗sintering production furnaces, many more.
EVALUATION OF HEAT TRANSFER AT THE REFERENCE TEMPERATURE POINTS IN A CRUCIBLE FURNACE
This paper deals with the study of heat transfer characteristics in a crucible furnace during steady state and oscillating combustion mode. The values of both the states of combustion were taken from the experiments carried out and analyzed the thermo physical properties at few different zones in the furnace. Heat transfer rate is an important factor for the enhancement in efficiency of a furnace by conduction, convection and radiation. From the results different Reynolds numbers, with respect to the time intervals were found out. The heat transfer coefficient and heat transfer is evaluated based on the heat supplied to load and heat carried away by the flue gases. The Nusselt numbers have been correlated through the empirical correlations involved with Reynolds numbers and Prandtl numbers with the different time intervals.