Industrial and Process Furnaces

Chapter 1: Introduction

• • Abstracts
• • 1.1 What is a Furnace?
• • 1.2 Where are Furnaces Used? Brief Review of Current Furnace Applications and Technology
• • 1.3 Drivers for Improved Efficiency and reduced emissions
• • 1.4 Concluding Remarks
• • References

Chapter 2: The Combustion Process

• • Abstracts
• • 2.1 Simple Combustion Chemistry
• • 2.2 Combustion Calculations
• • 2.3 Chemical Reaction Kinetics
• • 2.4 The Physics of Combustion
• • Nomenclature for Chapter 2
• • References for Chapter 2

Chapter 3: Fuels for Furnaces

• • Abstract
• • 3.1 Gaseous Fuels including the gasification of biomass, manufacture and application of hydrogen with types and applications of fuel cells
• • 3.2 Liquid Fuels
• • 3.3 Solid Fuels
• • 3.4 Biomass derived fuels
• • 3.5 Waste Fuels
• • 3.6 Choice of Fuel
• • 3.7 Safety
• • 3.8 Emissions
• • Nomenclature
• • References
• • Fuels Bibliography

Chapter 4: An Introduction to Heat Transfer in Furnaces

• • Abstract
• • 4.1 Conduction
• • 4.2 Convection
• • 4.3 Radiation
• • 4.4 Electrical Heating
• • Nomenclature
• • References

Chapter 5: Flames and Burners for Furnaces

• • Abstract
• • 5.1 Types of Flame
• • 5.2 Function of a Burner and Basics of Burner Design
• • 5.3 Gas Burners, including burners for hydrogen and mild combustion
• • 5.4 Oil Burners
• • 5.5 Pulverised Coal Burners
• • 5.6 Burners for waste based fuels
• • 5.7 Furnace Aerodynamics
• • 5.8 Combustion System Scaling
• • 5.9 Furnace Noise
• • Nomenclature for Chapter 5
• • References for Chapter 5

Chapter 6: Process, Combustion and Heat Transfer Modelling

• • Abstract
• • 6.1 Physical Modelling
• • 6.2 Mathematical Modelling including process modelling using ASPEN, Matlab, etc including advantages and limitations CFD modelling including latest developments
• • 6.3 Application of Modelling to Furnace Design
• • Nomenclature
• • References

Chapter 7: Fuel Handling Systems

• • Abstract
• • 7.1 Gas Valve Trains
• • 7.2 Fuel Oil Handling Systems
• • 7.3 Pulverised Coal Handling and Firing Systems
• • 7.4 Waste Fuel Handling
• • Nomenclature
• • References for Chapter 7
• • Applicable Codes and Standards

Chapter 8: Furnace Control and Safety

• • Abstract
• • 8.1 Process Control
• • 8.2 Furnace Instrumentation
• • 8.3 Flue Gas Analysis
• • 8.4 Combustion Control
• • 8.5 Ensuring Furnace Safety
• • 8.6 Burner Management Systems
• • Nomenclature
• • References
• • Certification and Testing Organisations

Chapter 9: Furnace Efficiency

• • Abstract
• • 9.1 Furnace Performance Charts
• • 9.2 Mass and Energy Balances
• • 9.3 Energy Conversion
• • 9.4 Heat Recovery Equipment
• • 9.5 Identifying Efficiency Improvements
• • Nomenclature for Chapter 9
• • References

Chapter 10: Emissions and Environmental Impact

• • Summary
• • 10.1 Formation of Carbon Monoxide
• • 10.2 Formation of Nitrogen Oxides
• • 10.3 Formation of Sulphur Oxides
• • 10.4 Formation of Intermediate Combustion Products
• • 10.5 Particulate Emissions
• • 10.6 Environmental Control of Emissions including CO2 mitigation and removal
• • References

Chapter 11: Furnace Construction and Materials

• • Abstract
• • 11.1 Basic Performance Requirements of the Furnace Structure
• • 11.2 Basic Construction Methods
• • 11.3 Practical Engineering Considerations in the Use of Refractories
• • 11.4 Ceramic Refractory Materials
• • 11.5 Heat Resisting and Refractory metals
• • 11.6 Practical Engineering Considerations in the Use of High Temperature Metals
• • 11.7 Concluding Remarks
• • References
• • Selection of Relevant Standards
• • Advisory Organisations
• • Appendix 11A

Chapter 12: Furnace Design Methods

• • Abstract
• • 12.1 Introduction
• • 12.2 Conceptual Design
• • 12.3 Furnace Sizing
• • 12.4 Burner Selection
• • 12.5 Detailed Analysis and Validation of the Furnace Design
• • 12.6 Furnace Instrumentation and Controls
• • Nomenclature for Chapter 12
• • References

Chapter 13: Economic Evaluation

• • Abstract
• • 13.1 Cost Accounting
• • 13.2 Distinction Between Capital and Revenue
• • 13.3 Profit and Profitability
• • 13.4 Financial Ratios
• • 13.5 Project Costing
• • 13.6 Investment Evaluation
• • 13.7 Determining Financial Benefits
• • 13.8 Post Project Analysis
• • References

Chapter 14: Selected Examples of Real Furnace Applications

• • Abstract
• • 14.1 Design of a New Burner for a Lime Sludge Kiln
• • 14.2 Optimising Flash Furnace Design
• • 14.3 Contribution to the Design of a New Reforming Process for Fuel Cell Applications
• • 14.4 Resolving Tube Internal Coking and Premature Tube Failure in a Refinery Heater
• • 14.5 Unsuccessful Attempts to Resolve Severe Problems with a Preheater Cement Kiln
• • 14.6 Investigation and Elimination of Coal Firing System Problems
• • 14.7 Concluding Remarks on Implementation
• • References

Chapter 15: Future Trends and Concluding Remarks

• • Abstract
• • 15.1 Trends in New Materials
• • 15.2 Trends in Furnace Emissions and Fuels for Furnaces
• • 15.3 Prospects for Alternative Electrical Energy as a Power Source
• • 15.4 Potential role of solar and other renewable forms of energy
• • 15.5 The potential role of hydrogen as a “clean fuel” storing and transporting hydrogen, limitations of hydrogen supply owing to fresh water supply constraints
• • 15.6 The Whyalla Steelworks approach to harnessing solar energy for sustainable steelmaking
• • 15.7 Trends in Furnace Controls
• • 15.8 New Applications for Furnaces
• • 15.9 Concluding Remarks
• • References