Specifications, furnace

Prebaked carbon electrodes are manufactured in all diameters up through 1500 mm. Some prebakes are produced as quadriforms to suit specific furnaces. Self-baking electrodes are in service through 2134 mm diameter. Electrode lengths are as needed for particular appHcations. Rounds are available in lengths up to 2794 mm and quadriforms as long as 3556 mm. Self-baked electrodes are continuous. 

The calorimeter method is considered highly accurate. However, many hours (days) are required at a specific furnace temperature in order to establish steady state conditions, hence, establishing a k versus T relationship may take weeks to complete. 

Data for each of the specific furnace types will be discussed and detailed in the subsequent sections. 

The application of this specific cupola t)q)e is only possible for new installations, since it has a specific furnace layout. Injection systems for solid or fluffy fuels may be applied on existing cupola furnaces. 

A general overview of the inputs and outputs of the foundry process is given in the figure below. The Casting step mentioned in the centre of the picture covers also all necessary moulding operations. The major input streams are metal, energy, binders and water. The key emissions are dust, amines and VOCs, and for specific furnace types also SO2, dioxins and NOx. 

Figure 2.16 compares magnitudes of gas-to-load radiation and gas-to-refractory-to-load radiation for a specific furnace/flame configuration. 

This category comprises conventional LPG (commercial propane and butane), home-heating oil and heavy fuels. All these materials are used to produce thermal energy in equipment whose size varies widely from small heaters or gas stoves to refinery furnaces. Without describing the requirements in detail for each combustion system, we will give the main specifications for each of the different petroleum fuels. 

Frequency Selection. When estabhshing the specifications for a coreless induction furnace, the material to be melted, the quantity of metal to be poured for each batch, and the quantity to be produced per hour must be considered simultaneously. Graphs have been developed that combine these factors with practical experience to indicate possible solutions for a specific requirement. 

Hearth. The hearth of a channel induction furnace must be designed to satisfy restraints that are imposed by the operating inductor, ie, the inductor channels must be full of metal when power is required, and it is also necessary to provide a sufficient level of metal above the channels to overcome the inward electromagnetic pressure on the metal in the channel when power is appHed. Once these requirements are satisfied, the hearth can then be tailored to the specific appHcation (13). Sizes range from stationary furnaces hoi ding a few hundred kilograms of aluminum to rotating dmm furnaces with a useful capacity of 1500 t of Hquid iron. 

Another design, shown ia Figure 5, functions similarly but all components are iaside the furnace. An internal fan moves air (or a protective atmosphere) down past the heating elements located between the sidewalls and baffle, under the hearth, up past the work and back iato the fan suction. Depending on the specific application, the flow direction may be reversed if a propeUer-type fan is used. This design eliminates floorspace requirements and eliminates added heat losses of the external system but requires careful design to prevent radiant heat transfer to the work. 

Fire-Resistant Hydraulic Fluids. Fire-resistant hydrauhc fluids are used where the fluid could spray or drip from a break or leak onto a source of ignition, eg, a pot of molten metal or a gas flame (17). Conditions such as these exist in die-casting machines or in presses located near furnaces. Specific tests for fire resistance are conducted by Factory Mutual in the United States. 

Copper is frequently a main impurity ia blast-furnace charges, and its limited solubiUty ia molten lead as copper sulfide requires that the excess be removed by chemical reaction with components of the charge. For this reason enough sulfur is left ia the siater to form a copper sulfide matte layer having a specific gravity of 5.2. 

Heat Recovery and Seed Recovery System. Although much technology developed for conventional steam plants is appHcable to heat recovery and seed recovery (HRSR) design, the HRSRhas several differences arising from MHD-specific requirements (135,136). First, the MHD diffuser, which has no counterpart ia a conventional steam plant, is iacluded as part of the steam generation system. The diffuser experiences high 30 50 W/cm heat transfer rates. Thus, it is necessary to allow for thermal expansion of the order of 10 cm (137) ia both the horizontal and vertical directions at the connection between the diffuser and the radiant furnace section of the HRSR. 

Domestic fuel oils are those used primarily in the home and include kerosene, stove oil, and furnace fuel oil. Diesel fuel oils are also distillate fuel oils, but residual oils have been successhjlly used to power marine diesel engines, and mixtures of distillates and residuals have been used on locomotive diesels. Heavy fuel oils include a variety of oils, ranging from distillates to residual oils, that must be heated to 260°C or higher before they can be used. In general, heavy fuel oil consists of residual oil blended with distillate to suit specific needs. Heavy fuel oil includes various industrial oils and, when used to fuel ships, is called bunker oil. 

Heavy fuel oil usually contains residuum that is mixed (cut back) to a specified viscosity with gas oils and fractionator bottoms. For some industrial purposes in which flames or flue gases contact the product (eg, ceramics, glass, heat treating, and open hearth furnaces), fuel oils must be blended to low sulfur specifications low sulfur residues are preferable for these fuels. 

Specific Heat. In some appHcations refractories are used for heat-exchange purposes on the regenerative principle, for instance, in blast-furnace stoves. High heat capacity is requited in such appHcations (Table 8). 

---