The Secrets Of Industrial Furnaces
Furnaces are not, by any means, a recent invention: they have been used for production
since the very dawn of civilization, as archaeological traces tell us plainly. While at the beginning they were invented and used for the manufacture of ceramic, however, their main use today lies in heating, on an industrial level; usually, the generic name furnace applies to devices such as the
industrial furnaces which are used in oil refinery plants, and in general they are built to provide the powerful source of high-temperature heating that are necessary for any chemical plant's processes.
We must not think that an industrial furnace, thus, is simply a larger and more effective version of the household furnaces which we use to heat our homes on cold winter days: we are discussing a very distinct type of device, not only in size, as is clear, but in actual specifications. One of the main differences is in the fuel used: for household furnaces, this is most commonly some type of natural gas. On the other hand, for industrial furnaces, two main kinds of system are used: induction and electric arc. The latter work, clearly, by electricity, while the former use direct heaters and a process of induction to obtain the wanted level of heating.
One additional industrial field in which furnaces, specifically of the induction type, (which can more easily reach the very high boiling points needed for such work) are often used, is the metallurgical sector, for example to extract pure metal from the ore within which it is typically found and mined. Due to the many distinct needs, and vast range of metals handled in such plants, there are many different kinds of metallurgical furnace in use today: among these we can recognize blast furnaces, steel making ones, and reverberation type. In cases where unusually high temperatures are needed, we may also find vacuum type furnaces, for instance to remelt metals.
It can be useful, for better understanding, to have a brief look at the basic structure which furnaces of the most typical type - the so-called direct-heater type - share. Of course, more advanced models have a whole range of extra devices and structures for enhanced functioning, but these are the basic ones:
At the very bottom of the furnace building stand the burners, which are the core of the plant. Once provided, as we said, with their fuel, they alone generate the heat which will be employed to process materials in the chamber.
Second is the radiant section. What takes place here is that large coils receive heat from the radition of the burning flame, thus transferring that energy away from the fire and into the chamber we want to heat.
Above this, stands the convection section, which is significantly less hot than the former ones, since it is yet further away from the burners. The air in this part is heated by convection, and transfers heat to the overlying chamber. Meanwhile, soot - which could hamper the furnace's efficiency - is taken out by a soot blower.
Then we have the chamber, where the actual process happens. Since it is critical that the generated heat is not squandered here, insulation becomes a need, which is usually satisfied by coatings of fire-resistant materials such as ceramic bricks.
Finally, we have the stack. This is where all the harmful gases generated during the heating process are collected and finally discharged high in the air, to keep them away from the plant staff.
by: Rodolfo Peil
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