Journal articles on the topic 'Furnaces'
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1
Bacchetti, Andrea, Stefano Bonetti, Marco Perona, and Nicola Saccani. "Investment and Management Decisions in Aluminium Melting: A Total Cost of Ownership Model and Practical Applications." Sustainability 10, no. 9 (September 18, 2018): 3342. http://dx.doi.org/10.3390/su10093342.
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The well-established Total Cost of Ownership (TCO) concept has been applied to several durable goods industries, including machinery. However, none of the existing TCO models explicitly focus on such highly energy-intensive equipment as metal melting furnaces. In this paper, an application of the TCO concept to aluminium melting furnaces is explored. A TCO model is created and tested through seven case studies in the aluminium die casting industry. Results indicate that the capital expenditure (CAPEX) incurred by the sample companies accounts for only 3–5% of a furnace TCO. Moreover, the melting technology implemented in the furnace highly impacts its TCO, as both the furnace’s thermal efficiency and melting loss (i.e., the fraction of aluminium burnt during the melting process) significantly affect the costs incurred. Moreover, the sample furnaces’ cost effectiveness clearly relies on scale. This evaluation leads to identify technological and managerial levers to reduce a furnace TCO, e.g., by adopting energy-efficient furnaces and by installing centralized, large-sized furnaces to pursue scale economies.
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Wehrmeyer, Joseph A., David E. Boll, and Richard Smith. "Emission Spectroscopy for Coal-Fired Cyclone Furnace Diagnostics." Applied Spectroscopy 57, no. 8 (August 2003): 1020–26. http://dx.doi.org/10.1366/000370203322258995.
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Using a spectrograph and charge-coupled device (CCD) camera, ultraviolet and visible light emission spectra were obtained from a coal-burning electric utility's cyclone furnaces operating at either fuel-rich or fuel-lean conditions. The aim of this effort is to identify light emission signals that can be related to a cyclone furnace's operating condition in order to adjust its air/fuel ratio to minimize pollutant production. Emission spectra at the burner and outlet ends of cyclone furnaces were obtained. Spectra from all cyclone burners show emission lines for the trace elements Li, Na, K, and Rb, as well as the molecular species OH and CaOH. The Ca emission line is detected at the burner end of both the fuel-rich and fuel-lean cyclone furnaces but is not detected at the outlet ends of either furnace type. Along with the disappearance of Ca is a concomitant increase in the CaOH signal at the outlet end of both types of furnaces. The OH signal strength is in general stronger when viewing at the burner end rather than the exhaust end of both the fuel-rich and fuel-lean cyclone furnaces, probably due to high, non-equilibrium amounts of OH present inside the furnace. Only one molecular species was detected that could be used as a measure of air/fuel ratio: MgOH. It was detected at the burner end of fuel-rich cyclone furnaces but not detected in fuel-lean cyclone furnaces. More direct markers of air/fuel ratio, such as CO and O2 emission, were not detected, probably due to the generally weak nature of molecular emission relative to ambient blackbody emission present in the cyclone furnaces, even at ultraviolet wavelengths.
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Kryachko, G. Yu, and Ye M. Sigarev. "Assessment of changes in productivity and limitations in forcing movement when increasing the volume of blast furnaces." Metal and Casting of Ukraine 31, no. 2 (2023): 8–17. http://dx.doi.org/10.15407/steelcast2023.02.008.
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The selection of the useful volume of new or reconstructed blast furnaces is an urgent task for both manufacturers and designers; therefore, the assessment of the technological capabilities of furnaces of different volumes has always been of interest from both a practical and a theoretical point of view. The purpose of the presented work is the selection of the most representative indicators, with the help of which a comparative assessment of the operation of furnaces of different volumes is possible, the evaluation of the operation of furnaces in the conditions of planned and market economies, as well as an attempt to determine and classify the factors limiting the forced operation of furnaces of increased volume. It is shown that the use of indicators calculated per unit area furnace is not appropriate, since area furnace is not the main size furnace. The main size is full volume furnace, which determines design unit and amount of capital costs for its construction. Specific productivity indicators calculated per unit volume furnace similarly depend on the height furnace and adequately reflect performance of furnaces of different volumes. The indisputable advantage of compact blast furnaces with a useful volume < 1500 m3 in comparison with furnaces of larger volumes is shown, which indicates imperfection of a simplified approach to evaluating performance of furnaces based on the concepts of balance and gas dynamic components, since it is difficult to take into account all the components when determining these components influencing factors. Factors limiting process intensification in blast furnaces of medium and large volumes have been established and classified. The main external factors are the quality characteristics of coke, iron ore materials and blowing, more specifically, hot strength of coke, richness of raw materials in iron and the ability of air blowers to provide blowing with required degree of compression. The main structural solutions to overcome significant limitations in operation of furnaces with a useful volume > 1500 m3 are a rational profile, ratio of output cross-section of air nozzles and cross-section furnace, as well as the use of coneless loading devices.
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Qu, Na, and Wen You. "Design and fault diagnosis of DCS sintering furnace’s temperature control system for edge computing." PLOS ONE 16, no. 7 (July 6, 2021): e0253246. http://dx.doi.org/10.1371/journal.pone.0253246.
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Under the background of modern industrial processing and production, the sintering furnace’s temperature control system is researched to achieve intelligent smelting and reduce energy consumption. First, the specific application and implementation of edge computing in industrial processing and production are analyzed. The industrial processing and production intelligent equipment based on edge computing includes the equipment layer, the edge layer, and the cloud platform layer. This architecture improves the operating efficiency of the intelligent control system. Then, the sintering furnace in the metallurgical industry is taken as an example. The sintering furnace connects powder material particles at high temperatures; thus, the core temperature control system is investigated. Under the actual sintering furnace engineering design, the Distributed Control System (DCS) is used as the basis of sintering furnace temperature control, and the Programmable Logic Controller (PLC) is adopted to reduce the electrical wiring and switch contacts. The hardware circuit of DCS is designed; on this basis, an embedded operating system with excellent performance is transplanted according to functional requirements. The final DCS-based temperature control system is applied to actual monitoring. The real-time temperature of the upper, middle, and lower currents of 1# sintering furnace at a particular point is measured to be 56.95°C, 56.58°C, and 57.2°C, respectively. The real-time temperature of the upper, middle, and lower currents of 2# sintering furnaces at a particular point is measured to be 144.7°C, 143.8°C, and 144.0°C, respectively. Overall, the temperature control deviation of the three currents of the two sintering furnaces stays in the controllable range. An expert system based on fuzzy logic in the fault diagnosis system can comprehensively predict the situation of the sintering furnaces. The prediction results of the sintering furnace’s faults are closer to the actual situation compared with the fault diagnosis method based on the Backpropagation (BP) neural network. The designed system makes up for the shortcomings of the sintering furnace’s traditional temperature control systems and can control the temperature of the sintering furnace intelligently and scientifically. Besides, it can diagnose equipment faults timely and efficiently, thereby improving the sintering efficiency.
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Catur Ahadi, Yeyen, and Prantasi Harmi Tjahjanti. "Furnace Engine Modification to Lower Power." Jurnal Improsci 1, no. 2 (October 16, 2023): 99–109. http://dx.doi.org/10.62885/improsci.v1i2.69.
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Furnace machine or heating furnace is a tool used for heat treatment processes or usually called heat treatment, furnace machines have several types from the beginning found furnace machines, namely induction furnaces/conventional furnaces and then transformed into electric furnaces, electric furnaces are more often used for processes heat treatment because it is cleaner compared to the convection furnace.The furnace machine requires 5000 watts of power, 13.1A. to reach the temperature of 8000 takes 7296 seconds. Furnace machine testing is by quenching using ST-42 steel which is held at 6000 and varying time, the first test material is not treated with heat traetment, for the second test material with a variation of 15 minutes, third 30, fourth 60, fifth 90, sixth 120 minute. the results of the quenching process were tested using the Brinell and Vickers hardness test methods.
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Henninger, Matthias, Wolfgang Schlüter, Dominik Jeckle, and Jörg Schmidt. "Simulation Based Studies of Energy Saving Measures in the Aluminum Tool and Die Casting Industry." Applied Mechanics and Materials 856 (November 2016): 131–39. http://dx.doi.org/10.4028/www.scientific.net/amm.856.131.
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This study, which focuses on analyzing aluminum melting and die casting procedures is part of the Smart Melting project in the research network Green Factory Bavaria (GFB). The aim of the present research project is to investigate these procedures and to suggest measures to increase the overall energy efficiency. The analysis starts with the capture of the operating structure, the relations between supply and consumption of liquid aluminum and an evaluation of aluminum furnaces themselves. The study concentrates on shaft furnaces whose specific energy consumption is 25 % higher than stated by the manufacturers. At the same time the melting capacity of the furnaces ranges at the lower end according to the manufacturer's data. The reason for this deviation is a discontinuous operation mode due to demand fluctuations. Consequently the flue gas has still a high temperature which means a high waste of energy. Based on these facts the furnace charge and operation mode have to be optimized and the high temperature flue gas can be used to preheat the pig aluminum.A numerical model of aluminum furnaces is applied to investigate this optimization potential. This model can simulate either a single aluminum furnace (case 1) or a furnace integrated in the entire manufacturing plant (case 2). The advantage of case 1 is the furnace's operation on its most efficient point because there is no influence of the die casting process. In case 1 an improvement of the furnace charge leads to a higher capacity utilization and therefore to a reduction of 30 % specific energy consumption and a 50 % increase of melting capacity. Whereas in case 2 the simulation of the entire manufacturing plant results in a rise of 25 % melting capacity and a 16 % decrease of specific energy consumption. The simulation proved increasing energy efficiency due to preheating the pig aluminum in both cases.
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Niu, Hongya, Wenjing Cheng, Wei Pian, and Wei Hu. "The physiochemical properties of submicron particles from emissions of industrial furnace." World Journal of Engineering 13, no. 3 (June 13, 2016): 218–24. http://dx.doi.org/10.1108/wje-06-2016-029.
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Purpose Smoke and dust emissions from industrial furnaces can do great harm to the environment and human health. This paper aims to analyze the morphology, diameter and elements of the submicron particles from the furnace flues and the nearby ambient air by using two typical industrial furnaces, the sintering furnace and the electric furnace. Design/Methodology/Approach Two typical industrial furnaces, the sintering furnace and the electric furnace, were chosen in this study, to analyze the morphology, diameter and elements of the submicron particles from the furnace flues and the near-by ambient air. Findings The results show that the particles from the two furnaces are mainly in the small sizes of 0.3-0.6 μm. Particles from sintering plant flue are mainly spherical and rich in K and Cl, whereas those from the electric plant flue are mainly particles rich in metal elements, such as Zn and Fe, and have different morphology. Originality/value The particles in the atmosphere nearby the two furnaces contain aged particles from the flue, lots of spherical particles, rectangle particles and various aggregations. The elements of those particles are complex.
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Korneev, S. V., and I. A. Trusova. "Efficiency of using alternative sources of heat in electric melting of metal." Litiyo i Metallurgiya (FOUNDRY PRODUCTION AND METALLURGY), no. 4 (December 16, 2020): 99–105. http://dx.doi.org/10.21122/1683-6065-2020-4-99-105.
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The paper considers ways to assess the efficiency of using alternative sources of heat when melting alloys in electric arc furnaces. The focus is on increasing furnace productivity and reducing production costs. The analysis of the use of various systems for intensifying melting in arc furnaces and their main indicators is carried out. An assessment of the efficiency of fuel use in electric arc furnaces has been carried out. The expected economic effect from the introduction of alternative energy sources in electric furnaces has been calculated. It is shown that the economic effect from the introduction of alternative energy sources on electric arc furnaces depends significantly on the increase in furnace productivity.
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Kornilov, B. V., O. L. Chaika, V. V. Lebid, Ye I. Shumelchyk, and A. O. Moskalina. "THE THERMAL WORK ANALYSIS OF THE FIREPLACES OF BLAST FURNACES OF UKRAINE OF VARIOUS DESIGNS." Fundamental and applied problems of ferrous metallurgy, no. 35 (2021): 55–68. http://dx.doi.org/10.52150/2522-9117-2021-35-55-68.
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The aim of the work is to study modern ways to increase the operational reliability of the furnace and hearth of blast furnaces, which largely determine the duration of the blast furnace campaign. The article analyzes the ways to increase the stability of the furnace and hearth, presents the results of the analysis of thermal work and ignition of the lining of metal receivers of blast furnaces of different designs. The modern directions of construction of the metal receiver of blast furnaces are determined. It is shown that the modern methodology of construction of blast furnace furnaces develops two main directions: the use of a coordinated combination of refractory materials with a cooling system; use of a combination of wear-resistant materials based on carbon and ceramics. However, even the improvement of the design and cooling system of the metal receiver does not allow to fully increase the duration of the campaign. To assess the service life of the furnace, it is necessary to provide regular automated control of the ignition of the furnace lining and hearth. In Ukraine, during the renovation of blast furnaces, the design of metal receivers with the use of "ceramic glass" was preferred. To date, the system of monitoring the thermal work and ignition of the furnace has been implemented in 10 blast furnaces using the automatic control system "Horn" developed by the HMI NASU. The implementation of continuous control over the ignition of the furnace in blast furnaces allowed us to assess the effect of the use of ceramic cups. The value of heat losses of the furnace and the cost of coke for their compensation are estimated. Methods and models for determining the thermal state and wear of the metal receiver lining based on a combination of calorimetric and thermometric control methods have been developed. Comparison of heat losses of the metal receiver in the cooling system of blast furnaces allows to quantify the thermal performance of controlled areas and the furnace as a whole. It is shown that the specific value of heat loss of the metal receiver per unit volume of the blast furnace can serve as an integral parameter. It is established that the value of specific heat losses per unit volume of the blast furnace with a ceramic cup is ~ 0.4-0.7 kW/m3, which is much less than blast furnaces without it (~ 0.9-1.1 kW/m3). Ceramic glass saves coke about 1 kg/t of cast iron.
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Shkirmontov, A. P., and S. A. Bishenov. "Comparison parameters for carbon ferrochrome smelting in AC and DC furnaces." Izvestiya. Ferrous Metallurgy 63, no. 2 (April 29, 2020): 163–65. http://dx.doi.org/10.17073/0368-0797-2020-2-163-165.
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One of the interesting technical solutions is technology of ferroalloys smelting using direct current (DC). In DC ferroalloy furnaces, apparently, it is possible to eliminate such a parameter as power factor in furnace circuit after current converter. Many researchers assume that melting at direct current allows intensification of the process of charge melting, increases reduction of leading elements of ferroalloy and reduces specific consumption of electricity. In this paper, brief analysis of carbon ferrochromium smelting in alternating current (AC) and in direct current (DC) furnaces is made based on energotechnological criterion of ferroalloy electric furnace performance. It is shown that with comparable active capacity in bath, AC furnaces have higher energotechnological criteria (0.2185 – 0.2381), compared to DC furnaces (0.1109 – 0.1320), at current level of technology used for carbonaceous ferrochrome smelting. Thus, in AC furnaces, specific electric power consumption in ferrochrome smelting is lower than in DC furnaces by 20 – 28 %.
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Spišák, Jan, Martin Truchlý, Ján Mikula, and Vratislav Šindler. "Caustic Magnesia Production in Microfluid Furnace." Advanced Materials Research 1119 (July 2015): 529–32. http://dx.doi.org/10.4028/www.scientific.net/amr.1119.529.
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During procedure and heat treatment of magnesite in shaft and rotary furnaces, a great number of fine fractions are generated. In terms of MgO content, the fractions comprises the highest quality raw material. However, the desired degrees of calcination or sintering have not been achieved. For direct heat treatment of fine particles the microfluidic furnace has been proposed. The microfluidic furnace consists of the fluidization chambers in which the technology operations are being carried out. The furnace operates on the counter-current principle. The experiments of dust magnesite and flue gas calcination from rotary and shaft furnaces were carried out in the furnaces.
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Whiteley, Peter. "A Historical Perspective of Aluminium Casthouse Furnace Developments." Materials Science Forum 693 (July 2011): 73–79. http://dx.doi.org/10.4028/www.scientific.net/msf.693.73.
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This paper provides an historical perspective of aluminium casthouse furnace evolution over the past 30 years or so with a view towards explaining the reasons for those innovations, and the success or otherwise of some of the changes which were tried. The paper covers electrically energized furnaces such as channel and coreless induction furnaces as well as “glo-bar” heated furnaces. It goes on to discuss fuel fired furnaces including melters of many varieties including side charged, top charged, sidewell, and multichamber designs. Additionally it includes melter/holders and conventional holding (casting furnaces). The drivers for change have been many and varied, and have included the need to cope with capacity creep, reduced specific energy consumption, improved asset utilization, greatly enhanced process intensity, reduced melt loss, improved furnace reliability, acceptance of the benefits of automation, and always the concern for improved safety in all aspects of furnace operation. Accordingly the paper covers related matters such as major changes in burner choices; furnace charging and tending; refractory type and design; furnace enlargement; forced convection stirring; dealing with difficult scraps; the demise of stationary casting furnaces, recognition of the need for improved metal cleanliness; and the challenge to deal with a wider range of difficult alloys. Additionally there has been a much greater understanding of furnace functionality by computer modelling of heat transfer as well as modelling of furnace stress design by FEA as well as some physical modelling and full scale tests to validate computer model assumptions. One of the most significant aspects of improved science has been the manner in which furnaces are operated to maximize productivity, reduce energy cost and melt loss, and by the adoption of purpose built tending vehicles. Finally the paper discusses prospects for future technological development and other aspects of improved productivity through achieving target composition first time as well as by better production planning, together with the aid of dynamic simulation for optimisation of activities.
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Golikov, Alexander V., and Dmitry I. Subbotin. "Damage analysis and assessment of the impact of damage on the operation of supporting structures of oil refining tube furnaces." Structural Mechanics of Engineering Constructions and Buildings 16, no. 3 (December 15, 2020): 193–202. http://dx.doi.org/10.22363/1815-5235-2020-16-3-193-202.
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Relevance. Due to the widespread use in practice, tubular furnaces were chosen as the object of study of this work. The article provides an analysis of damage to the supporting structures of oil refining tubular furnaces. The causes of damage and the physical nature of the development of damage are established. According to the results of field surveys, it was found that about 10% of the furnaces are operated with damage in the form of significant curvature of the supporting structures that developed as a result of the explosion of the gas-air mixture and the technological product inside the furnace space. The aim of the work is to analyze the damage and assess the impact of damage on the operation of the supporting structures of furnaces. Methods. The main research results were obtained by static numerical analysis of spatial models of furnace frameworks in the LIRA-SAPR software package. This complex belongs to the class of software products that implement the finite element method. Results. According to the results of calculating a series of models of structures, the effect of damage on the operation of the supporting structures of the furnace is determined. Based on the analysis of calculation data for models of tube furnaces with damage and comparison of calculation results for furnace models with structural damage identified during the survey, ways to optimize the design decisions of an industrial furnace are determined. Studies have shown the need to improve the design of tube furnaces in the direction of improving technology and improving the structural form of the supporting frame of the furnace.
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Tapasa, Kanit, Ekarat Meechoowas, Usuma Naknikham, and Tepiwan Jitwatcharakomol. "Evaluation of Furnaces Performance of Glass Factories in Thailand." Key Engineering Materials 702 (July 2016): 135–38. http://dx.doi.org/10.4028/www.scientific.net/kem.702.135.
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The objective of this project is to evaluate the energy consumption and the efficiency of glass melting furnaces using a thermodynamic principle and heat (energy) balance analysis. The approach can carry out more accurate result of wall losses than the direct temperature measurement at the furnace walls. Six furnaces from different factories in Thailand were studied. To construct the heat balance of glass furnace, the amount of heat for melting raw materials batch to glass melt (Hex), input energy (Hin) and the heat of content of offgas had to be known. The heat (energy) balance indicated the performance of glass furnaces in term of energy consumption.Glass furnace, Efficiency, Heat balance
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Chandra Gupta, Yogesh, Kamal Bansal, and S. N.Sriniwas. "Secondary steel mill furnace performance." International Journal of Engineering & Technology 7, no. 2.6 (March 11, 2018): 102. http://dx.doi.org/10.14419/ijet.v7i2.6.10076.
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Energy in a steel re-rolling mill is mainly consumed in furnaces. Therefore, furnace performance is very important and its contribution in the cost of product is very high. Data has been collected for two different furnaces in Stackle mill and analyzed for performance of furnace. In this paper, effect of furnace performance on secondary steel sector is analyzed. These data about performance is collected on Walking beam furnace in Stackle mill and Re-heating furnace.
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Haubner, Roland, Irmgard Schatz, Franz Schatz, Wolfgang Scheiblechner, Wolf Dieter Schubert, and Susanne Strobl. "Archaeometallurgical Simulations of the Processes in Bloomery Furnaces from the Hallstatt and Medieval Period." Materials Science Forum 782 (April 2014): 641–44. http://dx.doi.org/10.4028/www.scientific.net/msf.782.641.
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Bloomery furnaces were the first units for iron smelting. In the Hallstatt period small bowl-type furnaces were used and until the medieval period the size of such furnaces was increasing continuously. Experimental archaeologists reconstruct bloomery furnaces to study the processes of bloom production. In a small bowl-type furnace (Hallstatt period) at Asparn and in a larger shaft-type furnace (medieval period) at Ybbsitz smelting experiments were performed, The samples contained metallic iron and slag. Various amounts of iron in different stages of conglomeration up to larger iron pieces were found. The slag belongs to a fayalitic-type, consisting of wustite (FeO), fayalite (Fe2SiO4) and glass-phase (amorphous Ca-, Al-silicates) in various concentrations. The yield of metallic iron was highly different for the various experiments. In general, more metallic iron was formed in the larger shaft-type furnaces. A large bloom was not obtained.
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M, Kuznetsov, Kryachko G, and Sigarev E. "Changes in the design and operation of the accumulatory part of domain furnaces in the process improving fuel technology." Theory and practice of metallurgy, no. 1, 2022 (January 5, 2022): 5–14. http://dx.doi.org/10.34185/tpm.1.2022.01.
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The purpose is the detection of changes in the design and operation of the storage part of blast furnaces, due to i mprovements in smelting technology, as well as increasing power and specific productivity of units. The methodology based on the use of a new approach to assessing the technological capabilities of the furnace and storage part of blast furnaces in the study of design and practical information on the profiling of furnaces over a period of time characterized by dynamic development of units and cast iron smelting technology. Findings The proposed characteristics of the technological capabilities of the furnace and the storage part of the furnace, as well as criteria for assessing these characteristics - the share of the storage part per air lance V_nch / n_f, the power of one air lance and the relative to the countercurrent part of the furnace / V_pr. It is shown that in the design and operation of blast furnaces it is desirable to maintain the criteria V_nch / n_f and V_nch / n_chl at the lowest possible level, and the criteria of air lance power and V_zum / V_pr at the maximum. There is a tendency to slow down the height of the furnace with increasing the useful volume of the furnaces. In modern furnaces, for every additional 1000 m3 of usable volume, the height of the furnace increased by an average of 9%. It is shown that the outstripping increase in the depth of the sump in comparison with other dimensions of the profile is due not only to its structural function, but also purely technological, namely the sump cast iron heat, which increases the inertia of the blast furnace process, and also participates in the cycle of accumulation and release of smelting products. Since the sump is part of the working space of the furnace, it is proposed to change the approach to determining the complete and useful height of the blast furnace. More specifically, the full height should be considered the distance from the ladder to the upper edge of the support ring (flange) of the grate cover, and useful - to the cone or tray of the backfill device in the lower working position. The study’s originality is to justify the new principles of the approach to assessing the technological capabilities of the furnace and storage part of blast furnaces, as well as to justify the need to consider the sump or dead layer as the sixth element of the profile. The practical value is to develop recommendations on the direction of changes in the design of the furnace and storage part of blast furnaces in the design of new and modernization of existing units, as well as a new approach to determining the useful and complete height of the furnace profile.
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Abdulin, Mykhailo, and Yurii Bietin. "Improving the Efficiency of the Furnace Process of Low-Temperature Low-Capacity Furnaces." NTU "KhPI" Bulletin: Power and heat engineering processes and equipment, no. 1-2 (August 7, 2023): 55–60. http://dx.doi.org/10.20998/2078-774x.2023.01.09.
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A review of studies of furnace processes in industrial furnaces has shown that there is a sufficient number of studies for high-temperature and medium-temperature furnaces. However, there is an insufficient understanding of furnace processes in low-temperature low-power furnaces. One of the most important factors in the working process of low-temperature ovens, in contrast to high-temperature and medium-temperature ovens, is a significantly lower level of temperature inhomogeneity. For example, in heating ovens in the machine-building industry, the temperature inhomogeneity is 30 °С…50 °C, while in baking ovens, temperature fluctuations of 5 °C…10 °C are permissible.The aim of this article is to analyze the efficiency of the organization of combustion processes in industrial baking ovens operating on natural gas, which are organized by two different combustion technologies: in a cupcake baking oven, the combustion process is organized using a vortex-type burner device operating in a pulse mode; in a wafer sheet baking oven, microflame gas combustion technology is implemented. Some disadvantages of using the above-mentioned technologies for the studied furnaces have been identified and ways to eliminate them by organizing furnace processes in these furnaces using jet-niche gas combustion technology have been proposed. Namely, the modernization of these furnaces with the replacement of standard burners with burners that implement the principles of jet-niche technology.
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Nicolle, Rémy. "History of the iron furnace using the physical-chemical blast furnace model." Metallurgical Research & Technology 120, no. 1 (2023): 108. http://dx.doi.org/10.1051/metal/2022098.
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The physical–chemical blast furnace model first built by Michard and Rist has proven to be a very efficient tool to predict and drive the present blast furnaces. It mostly describes the iron blast furnace as a counter current gas-solids dual heat and oxygen exchanger. The onset of coke gasification (orelse of iron oxide direct reduction), leads to a two-zones exchange model. This theory is used to look back at the operation of the earlier and smaller iron furnaces such as the early XIXth century charcoal blast furnace or the much older low shaft furnaces. It shows the interest of using physical-chemical models to better understand the operation of past production tools.
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Shustrov, N. N., V. G. Puzach, and S. A. Bezenkov. "The effect of the conductive walls of the cooking furnace of an electric furnace on the distribution of energy flows." NOVYE OGNEUPORY (NEW REFRACTORIES), no. 4 (September 16, 2020): 13–18. http://dx.doi.org/10.17073/1683-4518-2020-4-13-18.
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A method for modeling the electric glass melting process, which allows obtaining information about the unity of electric and thermal processes in the glass mass in an electric glass melting furnace has been developed. The furnace’s cooking pool is made of conductive chromoxide. The work was carried out using modeling on the EGDA integrator, as a result of which two versions of experimental electric furnaces with different directions of power lines and a pilot industrial furnace with a capacity of 7 tons per day for melting E glass, widely used in the manufacture of fiberglass, were built.
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Lubyanoi, D. A., S. A. Fomkin, A. V. Kukharenko, D. D. Lubyanoi, A. V. Markidonov, and Yu N. Soina-Kutishcheva. "Regarding a technology of Sulphur removal in acidic induction furnaces." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 75, no. 6 (July 26, 2019): 689–94. http://dx.doi.org/10.32339/0135-5910-2019-6-689-694.
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Sulphurremoval is a rather complicated metallurgical task, which require implementation of new energy-saving technologies, including metal desulphurization in induction furnaces. Results of analysis of different methods of metal desulphurization in the acidic induction furnaces. A technology of hot metal refining with Sulphurremoval by basic slags by extraction mechanism in the acidic induction furnaces proposed, tested and implemented at several plants. The essence of the xtraction mechanism applied to desulphurization method is as follows: particles of calcic slag involved by electromagnetic flows deep into an induction furnace. The surface layer of slag particles deoxidizes by carbon of the metal and silicon, resulting in the Sulphursolubility increases sharply due to its absorption by the metal surface layer of slag particles. Next, the metal flows deliver to the surface the slag particles saturated by Sulphur, the surface contacted with the furnace atmosphere, where the surface layer of slag particles is oxidized by oxygen of the atmosphere. It results in the Sulphursolubility decreasing sharply and after precipitating out of the slag; it oxidizes by oxygen to SO2 and removes into the furnace atmosphere. The process repeats multiply. The mechanism of theSulphur removal in the induction furnaces with acidic lining was studied at OJSC ZSMK foundry shop using IChT-10M furnaces when melting hot metal for melt bases and warmth-keeping jackets. To increase the proposed technology efficiency, the influence of different technological parameters on the rate and degree of metal desulphurization in the acidic induction furnaces of industrial frequency studied. Results of the study allowed to make a conclusion that induction furnaces, traditionally used for smelting of burden materials, convert into active refining melting facilities.
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Fuchs, Thomas, and Fritz Josef Ebner. "Furnace Technologies in Hot Stamping Concepts and Experience from Production." Advanced Materials Research 1063 (December 2014): 354–57. http://dx.doi.org/10.4028/www.scientific.net/amr.1063.354.
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Nowadays, a furnace designer has to meet the demands of the customer precisely to allow economical production at site. Repeatable high quality throughout millions of produced parts combined with high cost efficiency is needed to stay competitive. Thus the facility has to be changed from a black-box to a glassy furnace which records and controls all important process values that define the properties of the produced parts and the consumption of the facility. Current furnace designs offer a wide variety of layouts with unique advantages and disadvantages. Single type furnace designs are well known and need the lowest investments but they also take up a lot of space and do not offer a back-up solution during maintenance or in the event of malfunctions occurring. Twin type furnaces have a higher degree of flexibility as they still allow 50% production during downtime caused by maintenance or malfunctions, so availability is higher than with single type furnaces. Double layer furnaces, which are stacked versions of the twin type furnaces, only need half of the floor space but maintenance is more complicated on the upper level. An oxygen-free furnace atmosphere is essential for the production of components in process atmosphere in order to ensure high quality results with the minimum of scale and other surface defects. This is not possible in a multi-level furnace.
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Nicolle, Rémy. "The operation of charcoal blast furnaces in the XIXth century." Metallurgical Research & Technology 117, no. 1 (2020): 117. http://dx.doi.org/10.1051/metal/2019071.
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Processing conditions in charcoal blast furnaces and their related internal phenomena are described, with good precision in papers and books by Hassenfratz, Karsten, Dumas, and especially Ebelmen in 1841, using, for the first time, the newly developed techniques of chemical analyses of gases and solids. Reviewing their publications at the light of more recent physical chemistry data and further developed blast furnace models, brings about a more detailed evaluation of the internal phenomena occurring inside charcoal blast furnaces and about their operating point. As industrial measurements have been carried out on small size blast furnaces, it may also bring a contribution to the archeology of early blast furnace metallurgy.
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Nerubatskyi, Volodymyr Pavlovych, Edwin Spartakovych Gevorkyan, Olena Yevhenivna Zinchenko, Denys Anatoliiovych Hordiienko, and Oksana Mykolaivna Morozova. "FEATURE OF INCREASE IN ENERGY EFFICIENCY OF HIGH-TEMPERATURE INDUSTRIAL FURNACES WITH RESISTIVE HEATING." Collection of Scientific Works of the Ukrainian State University of Railway Transport, no. 203 (March 27, 2023): 6–18. http://dx.doi.org/10.18664/1994-7852.203.2023.277882.
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For the sintering of ceramic products, high-temperature electric furnaces are used, which work both in a protective environment and in air. In some technological processes, for example, for the production of ceramic carriers for afterburning car exhaust gases based on SiC and Al2O3, only air furnaces are used. Silicon carbide (SiC – silicate) heaters and molybdenum disilicide (MoSi2) are used as resistive heaters in such furnaces. Due to the relatively small resource of their work, it is energetically beneficial to use the residual heat when cooling the furnace. At the same time, there is a significant saving of electricity for heating. The residual heat is largely determined by the thermal insulation of the lining and the correct distribution of the heat balance of the furnace. The speed of temperature rise affects the thermal balance of the furnace in general, and even the speed of cooling of the furnace, which creates additional energy saving opportunities, which reduces the cost of ceramic products. The article examines the technological processes of sintering ceramic products in high-temperature electric furnaces. A calculation algorithm was selected for performing comparative assessments of energy intensity and possible implementation, which can be used in the analysis of specific situations regarding different types of ceramic parts, the sintering temperature of which exceeds 1400 °C. A factography of the dependences of the power distributed over the floor area on the floor area and the specific power on the internal volume for a range of models of Mobilotherm furnaces designed for firing ceramics with the maximum operating temperature was obtained. It was found that the additional reduction in energy consumption during sintering in electric furnaces for the production of one product and the increase in production productivity are associated with the balancing of the thermal balance of the furnace, the reduction of heat losses and the use of furnace designs in which residual heat can be used. The conducted studies make it possible to assume that the developed methods of calculating the heat balance allow choosing the most optimal furnace heating modes, recommending the most heat-resistant and heat-insulating lining materials.
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Nizhegorodov, A. I., and E. S. Kalyagina. "ENERGY AND ECOLOGICAL ASPECTS OF ROASTING OF BULK LIGHTWEIGHT MATERIALS IN ELECTRIC FURNACES." Spravochnik. Inzhenernyi zhurnal, no. 293 (August 2021): 25–29. http://dx.doi.org/10.14489/hb.2021.08.pp.025-029.
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The article studies the energy and ecological aspects of the process of roasting of vermiculite and other lightweight materials in electric modular-firing furnaces which are alternatives to fired furnaces using hydrocarbon fuel. A double industrial electric furnace with a series-parallel interface of modules having auxiliary equipment is described. It forms a technological system for processing vermiculite concentrates and conglomerates. Energy and environmental performance indicators (efficiency, heat losses, and specific energy intensity) are assessed for these types of furnaces. The methods for collecting and accumulating useful resources – finely dispersed materials formed when vermiculite swells in new electric furnaces – are described.
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Guillon, Rodrigue, Christophe Petit, Jean Louis Rajot, Amadou Abdourhamane Touré, Oumarou A. Idé, and Zibo Garba. "Classification et chronologie de bas fourneaux de réduction du fer à usage unique au sud-ouest du Niger." Journal of African Archaeology 14, no. 1 (November 1, 2016): 55–82. http://dx.doi.org/10.3213/2191-5784-10283.
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In southwestern Niger, near Niamey, several thousand singleuse bloomery furnaces have been mapped and identified. The archaeological study of approximately 30 furnaces and their slag reveals the existence of four methods for iron smelting: three types of pit furnace and one slag-tapping type. The slag pit furnaces are clearly differentiated by the form and volume of their pits. All slag-tapping furnaces drain off slag through small openings. The slag is tapped either vertically or laterally. According to radiocarbon dates, the smelting activity developed in the 2nd century AD and intensified through to the 14th century. It continued to evolve until the middle of the 20th century. The low intensity of iron production for these furnaces indicates the products were intended mainly for the local market.
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Olczykowski, Zbigniew. "Arc Voltage Distortion as a Source of Higher Harmonics Generated by Electric Arc Furnaces." Energies 15, no. 10 (May 16, 2022): 3628. http://dx.doi.org/10.3390/en15103628.
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Due to high unit capacities, electric arc furnaces are among the receivers that significantly affect the power system from which they are supplied. Arc furnaces generate a number of disturbances to the power grid, including fast-changing voltage fluctuations causing the phenomenon of flickering light, asymmetry, and deformation of the voltage curve. The main issues discussed in the article are problems related to the distortion of current and voltage waveforms, resulting from the operation of electric arc furnaces. An analysis of the indices characterizing the voltage distortion recorded in the supply network of the arc furnaces is presented. The changes in the range of current and voltage waveform deformation in individual smelting phases in the arc furnace are also presented. Furthermore, the changes in the degree of deformation of the current and voltage waveforms in the individual smelting phases in an arc furnace are presented. A multi-voltage electric arc model used in computer simulations is proposed.
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Bratu, Vasile, Aurel Gaba, Elena Valentina Stoian, and Florina Violeta Anghelina. "Natural Gas Consumption Reducing in Aluminum Melting Furnaces by Heat Recovery of Flue." Scientific Bulletin of Valahia University - Materials and Mechanics 14, no. 11 (October 1, 2016): 17–22. http://dx.doi.org/10.1515/bsmm-2016-0003.
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Abstract This article presents different solutions to reduce natural gas consumptions of the aluminum melting furnaces, through recovery of the heat from flue gases. In order to be able to analyze the recovery solutions, a mathematical model for energy balance of these furnaces was adapted. This mathematical model allows drawing up energy balances together with the main working technique and economical parameters of these types of furnaces, in actual conditions, and the same, under optimizing conditions, by applying recovery solutions. The mathematical model which can elaborate energy balances for aluminum melting furnaces, was transposed in M. Excel based software, where the quantification of different solutions for natural gas consumption saving is possible. One of the applications of this computer software for an aluminum melting furnace, either for actual working conditions or per upgraded furnace by use an air pre-heater, materials pre-heater, or a regenerative burner system, is presented in this article.
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Bonechi, L., F. Ambrosino, P. Andreetto, G. Bonomi, D. Borselli, S. Bottai, T. Buhles, et al. "BLEMAB European project: muon imaging technique applied to blast furnaces." Journal of Instrumentation 17, no. 04 (April 1, 2022): C04031. http://dx.doi.org/10.1088/1748-0221/17/04/c04031.
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Abstract The BLEMAB European project (BLast furnace stack density Estimation through on-line Muon ABsorption measurements), evolution of the previous Mu-Blast European project, is designed to investigate in detail the capability of muon radiography techniques applied to the imaging of a blast furnace’s inner zone. In particular, the geometry and size of the so called “cohesive zone”, i.e. the spatial zone where the slowly downward moving material begins to soften and melt, that plays an important role in the performance of the blast furnace itself. Thanks to the high penetration power of the natural cosmic ray muon radiation, muon transmission radiography represents an appropriate non-invasive methodology for imaging large high-density structures such as blast furnaces, whose linear size can be up to a few tens of meters. A state-of-the-art muon tracking system, whose design profits from the long experience of our collaboration in this field, is currently under development and will be installed in 2022 at a blast furnace on the ArcelorMittal site in Bremen (Germany) for many months. Collected data will be exploited to monitor temporal variations of the average density distribution inside the furnace. Muon radiography results will also be compared with measurements obtained through an enhanced multipoint probe and standard blast furnace models.
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Kuvaldin, A. B., Maxim A. Fedin, A. O. Kuleshov, and I. Y. Zhmurko. "Development of Relay Control Systems of Power and Temperature Mode of Induction Crucible Furnaces with Use of Physical Modeling." Materials Science Forum 906 (September 2017): 8–15. http://dx.doi.org/10.4028/www.scientific.net/msf.906.8.
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The physical models of the induction crucible furnaces with nonconducting crucible and conducting crucible were developed. Experimental study of the parameters of an induction crucible furnace for melting of ferromagnetic lumpy charge in ferromagnetic nonconducting crucible was made. Experimental study of the parameters of the furnace for melting copper and magnesium in conducting crucible was made. Three-position control system of active power of induction crucible furnace for melting of ferromagnetic lumpy charge and two-position control system for temperature regime of induction crucible furnaces with conductive crucible were developed.
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Gao, Zhu, Xiao Min Ji, and Chun Qiang Zhang. "Dynamic Display of Industrial Furnace Products Based on the Technology of Virtual Reality." Advanced Materials Research 381 (November 2011): 99–103. http://dx.doi.org/10.4028/www.scientific.net/amr.381.99.
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Taking some type of steelmaking electric arc furnace for example, this paper, by using 3DS MAX, conducts a dynamic simulation of such industrial furnaces based on 3D modeling of SolidWorks and realizes the virtual, dynamic and interactive demonstration of industrial furnaces combining with the virtual reality technology of WebMax.
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Nikolaev, A. A., P. G. Tulupov, O. S. Malakhov, and S. S. Ryzhevol. "IMPROVING THE EFFICIENCY OF ELECTRIC MODES CONTROL SYSTEMS OF ELECTRIC ARC FURNACES THROUGH THE USE OF AN ADAPTIVE IMPEDANCE REGULATOR." Bulletin of the South Ural State University series "Power Engineering" 21, no. 4 (2021): 82–93. http://dx.doi.org/10.14529/power210410.
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The article discusses an improved automatic electrodes movement control system for electric arc furnaces (arc steel-making furnaces and ladle-furnace installations), which improves the dynamic parameters of the quality of secondary electrical circuit impedance (s) control due to the use of a new structure of a nonlinear adaptive impedance controller. The use of an improved control system stabilizes the metal charge melting process in arc steel-making furnaces as well as the liquid steel heating process in ladle-furnace installations with intensive bottom blowing. This allows for the technical effect of reduced operating time under current and reduced specific power consumption in electric arc furnaces. The non-linear adaptive impedance controller provides full linearization of control loops, including a proportional directional control valve (servo valve) with a non-linear control characteristic and a secondary electrical circuit with a non-linear dependence of impedance on the arc length. The research used a complex mathematical model of the electric circuit of an electric arc furnace, hydraulic drives for moving electrodes and an automatic control system for moving electrodes, implemented in the MATLAB Simulink mathematical package. The effectiveness of the improved control system in the conditions of the existing metallurgical production was evaluated against the example of the “RADUGA NPA PK” control system, developed at the Federal State Budgetary Educational Institution of Higher Education “MSTU im. Nosov” and a ladle-furnace operating at the installation in the electric steel-smelting shop of PJSC “Magnitogorsk Metallurgical Plant”. The developed improved control system can be used in other modern electric arc furnaces of various capacities operating at metallurgical enterprises in Russia and abroad.
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Azad Agayev, Ayyam Abbasov, Azad Agayev, Ayyam Abbasov. "RELIABILITY OF COIL TUBES DURING OPERATION OF PYROLYSIS FURNACES OF PETROCHEMICAL INDUSTRIES." PAHTEI-Procedings of Azerbaijan High Technical Educational Institutions 147, no. 01 (February 26, 2024): 45–50. http://dx.doi.org/10.36962/pahtei147012024-45.
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Technologies of processing of crude oil, hydrocarbons, are necessary to obtain products used in the national economy and industry. In the article, taking into account this fact, the conditions of operation of pyrolysis furnaces, their general principle of operation are considered. It also describes what parts (compartments) and elements make up the pyrolysis furnace. It is noted that in the radiant section of the pyrolysis furnace are installed tubular pyrolysis reactors or coil tubes. They are the main working element of pyrolysis furnaces, through which hydrocarbon feedstock passes and the pyrolysis process takes place. The processes affecting the reliability index in the operation of coil pipes are indicated. Also in the article it is indicated that reliability of operation of coil tubes (reaction tubes) depends on the quality of their manufacturing technology. The article notes that the processing of hydrocarbon raw materials in pyrolysis furnaces, occurs at operation of coil tubes at high temperatures. From the facts and processes described in the article, it follows that the indicator of reliability of coil tubes is achieved in compliance with the technical conditions of operation of pyrolysis furnaces in petrochemical production. Keywords: pyrolysis furnace, coil tubes, petrochemical production, hydrocarbon raw materials (crude oil), operation, reliability.
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Machulec, B., S. Gil, and W. Bialik. "Similarity of Ferrosilicon Submerged Arc Furnaces With Different Geometrical Parameters." Archives of Metallurgy and Materials 62, no. 4 (December 1, 2017): 2343–47. http://dx.doi.org/10.1515/amm-2017-0344.
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Abstract In order to determine reasons of unsatisfactory production output regarding one of the 12 MVA furnaces, a comparative analysis with a furnace of higher power that showed a markedly better production output was performed. For comparison of ferrosilicon furnaces with different geometrical parameters and transformer powers, the theory of physical similarity was applied. Geometrical, electrical and thermal parameters of the reaction zones are included in the comparative analysis. For furnaces with different geometrical parameters, it is important to ensure the same temperature conditions of the reaction zones. Due to diverse mechanisms of heat generation, different criteria for determination of thermal and electrical similarity for the upper and lower reaction zones were assumed contrary to other publications. The parameter c3 (Westly) was assumed the similarity criterion for the upper furnace zones where heat is generated as a result of resistive heating while the parameter J1 (Jaccard) was assumed the similarity criterion for the lower furnace zones where heat is generated due to arc radiation.
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Aranburu, Iñigo, Bakartxo Egilegor, Iñigo Bonilla, Jaio Manzanedo, and Haizea Gaztañaga. "Modelica model of industrial gas furnaces." E3S Web of Conferences 116 (2019): 00003. http://dx.doi.org/10.1051/e3sconf/201911600003.
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Modelica models for the prediction of the temperature of the load inside a walking basket type reheat furnace of the aluminium industry have been developed. The loads move through the furnace with discrete movements. Several library components have been developed using the Modelica Standard Fluid Library. In order to validate them a full 1D furnace simulation model has been built. It allows calculating the heat transfer through walls, the temperature and the composition of combustion gases, the temperature of the aluminium products, as well as the fumes flow and the pressure drops. The library provides the necessary resources for modelling this type of furnaces flexibly and quickly. The objective of the work is to validate Modelica as analyse tool for evaluating the different possibilities of heat recovery in this kind on furnaces.
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Ganin, D. R., V. G. Druzhkov, A. A. Panychev, and A. Yu Fuks. "Analysis of indices and operation improvement conditions of JSC “Ural Steel” blast furnace shop." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information, no. 12 (December 19, 2018): 46–54. http://dx.doi.org/10.32339/0135-5910-2018-12-46-54.
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For elaborating of measures to improve the blast furnace technology, it is necessary to analyze production data related to blast furnaces operation. Estimation of technical level of blast furnace production in conditions of JSC “Ural Steel” was the aim of the study. Data on chemical composition of casted iron produced and burden materials quoted, as well as data on iron ore materials consumption, sinter grain-size distribution, pellets chemical composition and strength characteristics, coke mechanical strength and grain-size distribution. Results of analysis presented of production operation indices of Nos 1–4 blast furnaces within a five years period, the furnaces having net volumes 1007, 1033, 1513 and 2002 m3 correspondently. Periods of non-stable furnaces operation with long stops and repairs were excluded from the analyzed data. It was determined that iron and manganese oxide contents in the sinter are presented at lower level comparing with most of sintering plants of European Communities and Japan. Fine fraction less 5 mm content is considerably higher than the index for sinter, produced at other sintering plants of Russia, as well as of developed nations. Laboratory study and experimental-industrial tests at JSC “Ural Steel” confirm reasonability of the following mineral additives utilization in sintering process, delivered into the sintering burden by sludge: brown iron ore, bentonite clay, serpentinite-magnesites, that enables to increase suitable sinter yield, productivity of sintering machines, sinter impact strength. A necessity to optimize blast furnace slags chemical composition by relation SiO2/Al2O3 and CaO/MgO determined to improve scull formation conditions and elimination of coolers mass burning-through. To improve the technical and economic indices of JSC “Ural Steel blast furnaces operation some measures on the plant blast furnace technology modification proposed.
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Alkatsev, V. M., A. L. Rutkovsky, and A. K. Makoeva. "Mathematical modeling of zinc concentrate roasting in a fluidized bed." iPolytech Journal 26, no. 4 (January 2, 2023): 669–76. http://dx.doi.org/10.21285/1814-3520-2022-4-669-676.
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The paper aims to stabilize the roasting of zinc sulfide concentrates in fluidized-bed furnaces using oxygen- enriched air. The balance between the given excess air blast (on average 20%) and the amount of loaded charge is achieved by selecting an appropriate number of evaporative cooling elements in the fluidized-bed furnace. Through the evaluation of scientific and technical information, as well as literature sources on the research topic, data were collected on the effects produced by an oxygen excess in the blast on the quality of sulfide concentrate roasting and by a blast volume on the state of the fluidized bed. In addition, statistical data for the study were obtained by analyzing the operation of fluidized-bed furnaces at Electrozinc. As part of the study, the heat balance in roasting was determined, taking into account the following technical characteristics of fluidized-bed furnaces used for roasting zinc sulfide concentrates: fluidized- bed level, number of nozzles, furnace diameter, diameter in the bed zone, hearth thickness, and the total weight of the furnace. Relying on the operation analysis of fluidized-bed furnaces, a method was proposed to regulate the oxygen supply depending on the amount of loaded charge. The oxygen supply is regulated in order to ensure a stable excess of oxygen in the blast without causing any significant changes in the blast volume and, consequently, to maximize the sulfur removal from the charge. A decrease in the excess air blast below 15% was found to significantly degrade the quality of the resulting cinder and dust, while an increase of over 20% reduced the SO2 content in the exhaust gases with no noticeable improvement in the quality of cinder. Therefore, the proposed method for regulating the oxygen supply to the furnace can improve the techno-economic performance of zinc sulfide concentrate roasting in fluidized-bed furnaces.
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Nizhegorodov, A. I. "Energy analysis of an electric furnace with a vibration hearth for roasting vermiculite concentrates." NOVYE OGNEUPORY (NEW REFRACTORIES), no. 2 (April 26, 2019): 7–12. http://dx.doi.org/10.17073/1683-4518-2019-2-7-12.
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An energy analysis of an electric furnace with a vibration hearth using previously obtained analytical absorption models and a new, refined model of vermiculite heat assimilation is presented. The temperature-time equation, the formulas of the productivity of the furnace unit and the specific energy intensity of the calcination of vermiculite concentrates are obtained. It is shown that the new concept furnaces have a specific energy intensity of not more than 77.8 mJ/m3, which is more than three times lower than the energy intensity of fiery furnaces for roasting vermiculite. Ill. 4. Ref. 14.
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Hai, Zhenyin, Zhixuan Su, Kaibo Zhu, Yue Pan, and Suying Luo. "Printed Thick Film Resistance Temperature Detector for Real-Time Tube Furnace Temperature Monitoring." Sensors 24, no. 10 (May 9, 2024): 2999. http://dx.doi.org/10.3390/s24102999.
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Accurately acquiring crucial data on tube furnaces and real-time temperature monitoring of different temperature zones is vital for material synthesis technology in production. However, it is difficult to achieve real-time monitoring of the temperature field of tube furnaces with existing technology. Here, we proposed a method to fabricate silver (Ag) resistance temperature detectors (RTDs) based on a blade-coating process directly on the surface of a quartz ring, which enables precise positioning and real-time temperature monitoring of tube furnaces within 100–600 °C range. The Ag RTDs exhibited outstanding electrical properties, featuring a temperature coefficient of resistance (TCR) of 2854 ppm/°C, an accuracy of 1.8% FS (full scale), and a resistance drift rate of 0.05%/h over 6 h at 600 °C. These features ensured accurate and stable temperature measurement at high temperatures. For demonstration purposes, an array comprising four Ag RTDs was installed in a tube furnace. The measured average temperature gradient in the central region of the tube furnace was 5.7 °C/mm. Furthermore, successful real-time monitoring of temperature during the alloy sintering process revealed approximately a 20-fold difference in resistivity for silver-palladium alloys sintered at various positions within the tubular furnace. The proposed strategy offers a promising approach for real-time temperature monitoring of tube furnaces.
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LYAKH, A. P., A. G. KOLESNIKOV, and A. A. FILATOV. "ANALYSIS OF DESIGN OF THE ROLLERS OF THROUGH FURNACES OF ROLLING MILLS." Ferrous Metallurgy. Bulletin of Scientific , Technical and Economic Information 78, no. 6 (July 29, 2022): 516–21. http://dx.doi.org/10.32339/0135-5910-2022-6-516-521.
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Furnace rollers are the most expensive part of the through-type furnaces, which determine the efficiency of the whole furnace unit. The features of design of rollers that are used at different temperatures of the working space of the furnace were considered. At temperature up to 1000 °C the rollers are used without water cooling (“dry”) or with cooling only of trunnions. With increase in temperature in the furnace up to 1250 °C the rollers with cooled shaft are used. It is shown that the operating costs of the through-type furnaces of rolling mills depend on the durability of the rollers and the costs associated with their cooling. Application of modern heat-resistant materials for manufacturing of furnace rollers enable to eliminate the necessity of their cooling in the furnaces with the temperature of working space up to 1250 °С and to reduce operating costs at the expense of saving of technological fuel for furnace heating. It is noted that the use of “dry” furnace rollers at furnace temperatures up to 1250 °C would require more expensive refractory materials, which will increase their cost. Therefore, it is important to select the correct material strength criteria for the barrel rollers in the design, taking into account the demanding operating conditions of the rollers. Based on the analysis of the process loads on the furnace rollers, the strength criterion is the conditional yield strength of the barrel material at the operating temperature and a safety margin of 3.5.
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Nikolaev, Alexander, Gennady Kornilov, and Evgeniy Povelitsa. "Developing and Testing of Improved Control System of Electric Arc Furnace Electrical Regimes." Applied Mechanics and Materials 792 (September 2015): 488–94. http://dx.doi.org/10.4028/www.scientific.net/amm.792.488.
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The article deals with the description of an improved automatic control system for steel-making furnaces (electric arc furnaces and ladle furnaces) electrode positioning and the results of its production testing. The control performance of electrode positioning of the developed automatic control system was studied using a mathematical model, which included the main components of the system: the hydraulic drive of electrode positioning with a servo valve, electric circuit of the furnace described by Cassie nonlinear differential equation, impedance nonlinear controller. It was proved that a more accurate positioning makes it possible to significantly reduce electric power consumption per tap-to-tap cycle.
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Kukartsev, Viktor A., Vladislav V. Kukartsev, and Vadim S. Tynchenko. "The Peculiarities of Smelting of Wear-Resistant Cast Iron IChH28N2 in the Induction Crucible Furnace IChT10." Solid State Phenomena 299 (January 2020): 397–402. http://dx.doi.org/10.4028/www.scientific.net/ssp.299.397.
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Wear-resistant cast iron smelting is produced in electric arc furnaces, due to the use of steel scrap in metal charge, ferrochrome and refund if there is one. Scrap of cast iron with the necessary chemical composition is not present because the proportion of manufacturing parts from wear-resistant cast iron is very small. Thus, there is no opportunity to form castings of wear-resistant cast iron using foundries equipped only with induction crucible furnaces of industrial frequency (IChT), since the furnace is designed for melting temperatures not above 1500 °C. In addition, the lining of induction furnaces of industrial frequency is made of quartzite, which provides the necessary durability when operating at temperatures not above 1500 °C. The ability to manufacture blanks from wear-resistant cast iron gives an additional opportunity to expand the range of orders and prevent a reduction in production in factories equipped only with the smelting furnaces of the IChT. The article describes the peculiarities of smelting cast iron IChH28N2 in the furnace IChT10 with acid lining. The technology of conducting melting on pure charge materials without use of cast iron scrap and return is briefly described.
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Vytiaganets, Valentin, Valeriy Shaporev, Inna Pitak, and Antonina Baranova. "CONSTRUCTIVE DESIGN AND FEATURES OF THE PROCESSES IN THE ROASTING SHAFT FURNACES BY USING GASEOUS FUEL." Bulletin of the National Technical University «KhPI» Series: New solutions in modern technologies, no. 2(8) (June 15, 2021): 96–100. http://dx.doi.org/10.20998/2413-4295.2021.02.14.
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The article analyzes shaft furnaces for lime production. According to the method of firing, shaft furnaces are of bulk type, semi-gas type, gaseous and liquid fuels. The disadvantages of the operation of the main modern kilns during lime burning have been established. The main aggregates for high-tonnage lime production are mine lime kilns, in which blast furnace coke or anthracite, or high-quality coals are used as fuel. Generally, lean fuels are used in industries where, together with the technological cycle, carbon dioxide is used, which are contained in flue gases with a concentration of 36−40%mass. The data on the operation of six furnaces on the territory of Ukraine at the enterprises showed that gas shaft furnaces of cylindrical and slotted type with a straight-lining profile were widely used. The parameters of such furnaces are productivity from 100 to 250 tons per day, shaft diameter from 3.2 to 5.4 m, and height 6−8 furnace diameters. Most often, they use heating systems with central and two rows of peripheral injection burners without protrusion. The most critical part of all furnaces is the distribution of gas flow rates over the cross-section of the furnace shaft and the depth of radial penetration of the gas flow into the material layer. Calculations of τ1 and τП were carried out in the following way: for τ1, the temperature range of the medium was chosen from 1300 to 250−300 °С, τox − the temperature range for the material was chosen from 1000 to 100 °С and the density of the product was taken into account at the degree of decomposition of limestone 98% (=1700 kg/m3). In the preheating zone, the limiting stage is the supply of heat from the gas to the lump material, and at the same time can be taken equal to ⁓400−450 kJ/(m2∙h∙К) and τ1 is estimated as 0.8÷1 hour. The total residence time of the material in the furnace (in the heating zone and in the firing zone) is estimated at 1.4÷1.5 hours. The average speed of material movement in the cylindrical part of the furnace is estimated as 0.004 m/s, which makes it possible to consider the filtering layer conditionally stationary. These characteristics affect the quality of limestone and the uniformity of limestone firing that was the basis for the design of roasting shaft kilns using gaseous fuel.
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Song, Kezhou, and Ari Jokilaakso. "CFD Modeling of Multiphase Flow in an SKS Furnace with New Tuyere Arrangements." Metallurgical and Materials Transactions B 53, no. 1 (December 27, 2021): 253–72. http://dx.doi.org/10.1007/s11663-021-02362-9.
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AbstractThere has been a great deal of focus on the optimization of tuyere arrangements in SKS bottom blown copper smelting furnaces since the last decade, as the improved furnace operation efficiency of SKS technology has potential that cannot be ignored. New –x + 0 + x deg tuyere arrangements with 14 tuyeres are proposed in this research paper. Using a previously verified numerical model, CFD tests on the velocity distribution and wall shear stress for scaled-down SKS furnace models were conducted, with a constant total volumetric gas flow rate, and different operating parameters and furnace cross-section geometries. The results indicate that, at a relatively low gas injection speed compared with the previously optimized tuyere arrangement, although the –x +0 +x deg tuyere arrangements are unable to supply enhanced agitation in the typical round furnaces, they achieve better performance in elliptical furnaces. At a comparatively higher gas injection speed, the – x + 0 + x deg tuyere arrangements can improve the agitation performance in a round furnace while maintaining an acceptable wall shear stress on the bottom and side wall. The agitation enhancement with the − x +0 +x deg tuyere arrangements can essentially be attributed to stronger interactions between bubble plumes and furnace side walls. To further exploit the advantages of the new tuyere arrangements, an optimized tuyere angle was confirmed by a full-scale furnace model simulation.
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Yushkevych, P. O. "Generic concept of typing of the set and constructive features of the vaults for reflective types furnaces." Fundamental and applied problems of ferrous metallurgy 36 (2022): 182–93. http://dx.doi.org/10.52150/2522-9117-2022-36-182-193.
Full textAbstract:
Reflective types furnace: Martin furnace; Siemens–Martin furnace (double-bath unit for steel making), still have taking an important place among the total quantity of all industrial steel-smelting units in Ukraine. Due to the fact that they are cane to correctly work in the raw material base that is currently available for domestic metallurgical enterprises. The рrocessing done of information, data and literature made it possible to confirm that in the production of steel, the generic term of one company for the operation on the reflective furnaces, under other normal conditions, is determined by the using term of the refractory lining. Due to the fact that, it is very difficult to carry out hot repair work at the during the operation of the furnaces and capital works are almost impossible. According to the evidence of a number of scientific works and industrial experience of recent years, of all the main structural elements of the furnace protected by refractory lining materials, most often, the vault itself limits the overall operational resource of one use refractory lining cicle. At the work achieved the purposed and formed a general concept of typification the structure and structural features of the vaults on the reflective types furnaces, which were used in recent years in the working conditions of Ukrainian metallurgical enterprises, and to characterizeted of the main types materials, for their refractory lining. Defined the factors that significantly affect the stability of the vault of reflective types furnaces and limit the operational resource of their lining. It was established that due to a series of imperfections, it is advisable to: creation and use of more advanced modern refractory lining materials for vaults; the development of new structures or the modernization of the existing vaults for furnaces the reflective type, which will contribute to the improvement of their explantation conditions, increase the resource of refractory lining use, and improve the environmental indicators of the process.
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Narzullayev, Bobur Sh, and Mirzokhid A. Eshmirzaev. "Causes of the appearance of current waves in high voltage electric arc furnaces, and methods of their reduction." E3S Web of Conferences 417 (2023): 03003. http://dx.doi.org/10.1051/e3sconf/202341703003.
Full textAbstract:
This article presents a method of generation and reduction of current waves in high-voltage electric arc furnaces in industrial and mining enterprises, in contrast to existing methods. The developed method is currently relevant for the solution of problems related to the generation of current waves during the operation of high-voltage electrics are furnaces with a power of 3 MWt used in the melting and pouring of metals of different densities at the Navoi mechanical engineering plant. The main goal of implementing the developed method is to reduce the electric energy consumption of high-voltage electrics arc furnaces and to increase the efficiency of electric energy consumption of the furnace.
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Bernasowski, M., A. Klimczyk, and R. Stachura. "Support algorithm for blast furnace operation with optimal fuel consumption." Journal of Mining and Metallurgy, Section B: Metallurgy 55, no. 1 (2019): 31–38. http://dx.doi.org/10.2298/jmmb180206010b.
Full textAbstract:
Fuel consumption in blast furnaces depends on many factors that are mainly conditioned by the technological level of a given blast furnace, the steel mill in which it operates, and the type and quality of ferrous feed, coke, and additional reducing agents. These are global factors which a furnace crew cannot control during operation. On the other hand, using their own experience and decision-making software, a crew can run a blast furnace with minimal fuel consumption under current batch and process conditions. The paper presents a model-based algorithm for optimizing the operation of blast furnaces to achieve the lowest fuel consumption. The algorithm allows the heat demands to be continuously calculated and highlights any wastage that could be reduced without affecting the stable operation of the blast furnace.
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Kukartsev, Viktor A., Vladislav V. Kukartsev, and Vadim S. Tynchenko. "Cast Iron and Steel Smelting in Induction Crucible Furnaces of Industrial Frequency." Solid State Phenomena 299 (January 2020): 530–34. http://dx.doi.org/10.4028/www.scientific.net/ssp.299.530.
Full textAbstract:
A brief analysis of the cast iron and steel smelting in induction furnaces of industrial and medium frequency has been carried out. The analysis of the used metal scrap for the smelting of synthetic iron in induction melting furnaces with a padded lining of a lining mixture, based on quartzite, is carried out. The requirements for temperature melting modes, which are regulated by this type of melting furnaces developers, are reflected. The advantages and disadvantages of using induction crucible furnaces of industrial and medium frequency are considered. The features of smelting synthetic pig iron in Russia are noted, the main of which are the following: the absence of cast iron scrap, which makes it necessary to use a metal scrap from a single steel scrap, and use temperature melting conditions above 1450 ° C; use a lining based on quartzite, as the cheapest, but sharply reducing its resistance to the operation of the furnace at such melting temperatures (from 300-350 to 200-250 smelts). The actuality of the possibility of steel smelting in induction crucible furnaces of industrial frequency with the use of acid lining, based on the Pervouralsk quartzite, is substantiated. It is explained by the fact that existing foundries are equipped mainly with induction melting furnaces of industrial frequency, and the use of induction melting furnaces of medium frequency requires considerable material costs.
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Chen, Xinxi. "Temperature control in electric furnaces: Methods, applications, and challenges." Journal of Physics: Conference Series 2649, no. 1 (November 1, 2023): 012032. http://dx.doi.org/10.1088/1742-6596/2649/1/012032.
Full textAbstract:
Abstract Temperature control of electric heating furnaces, a common piece of equipment in industrial production, is essential for assuring product quality and enhancing production effectiveness. In order to better understand the similarities and differences in temperature management between various types of electric heating furnaces, this paper first discusses the fundamental concepts and classifications of electric heating furnaces. Following that, it systematically describes the applications of the various temperature control techniques now used for electric heating furnaces, such as PID control, fuzzy logic control, genetic algorithm control, and model predictive control. This paper further analyzes the difficulties in controlling the temperature of electric heating furnaces and identifies potential future development trends in light of the issues that currently used control methods must deal with in practical applications, such as insufficient control accuracy, slow response speed, and poor stability. Finally, it summarizes the information in the entire paper and considers the direction of temperature control research for electric heating furnaces. This research will focus on new control theories and algorithms, furnace body design optimization, control system integration, and intelligent adaptive temperature control. In order to advance the development and advancement of technology in this area, the goal of this article is to provide a thorough theoretical reference and practical advice for the temperature management of electric heating furnaces.
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Varga, Augustín, Ján Kizek, Miroslav Rimár, Marcel Fedák, Ivan Čorný, and Ladislav Lukáč. "Modeling of Heat Flux in a Heating Furnace." Computation 11, no. 7 (July 17, 2023): 144. http://dx.doi.org/10.3390/computation11070144.
Full textAbstract:
Modern heating furnaces use combined modes of heating the charge. At high heating temperatures, more radiation heating is used; at lower temperatures, more convection heating is used. In large heating furnaces, such as pusher furnaces, it is necessary to monitor the heating of the material zonally. Zonal heating allows the appropriate thermal regime to be set in each zone, according to the desired parameters for heating the charge. The problem for each heating furnace is to set the optimum thermal regime so that at the end of the heating, after the material has been cross-sectioned, there is a uniform temperature field with a minimum temperature differential. In order to evaluate the heating of the charge, a mathematical model was developed to calculate the heat fluxes of the moving charge (slabs) along the length of the pusher furnace. The obtained results are based on experimental measurements on a test slab on which thermocouples were installed, and data acquisition was provided by a TERMOPHIL-stor data logger placed directly on the slab. Most of the developed models focus only on energy balance assessment or external heat exchange. The results from the model created showed reserves for changing the thermal regimes in the different zones. The developed model was used to compare the heating evaluation of the slabs after the rebuilding of the pusher furnace. Changing the furnace parameters and altering the heat fluxes or heating regimes in each zone contributed to more uniform heating and a reduction in specific heat consumption. The developed mathematical heat flux model is applicable as part of the powerful tools for monitoring and controlling the thermal condition of the charge inside the furnace as well as evaluating the operating condition of such furnaces.