Industrial and Process Furnaces

Industrial and Process Furnaces

Principles, Design and Operation

2nd Edition - October 23, 2013

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  • Authors: Barrie Jenkins, Peter Mullinger
  • eBook ISBN: 9780080993782
  • Hardcover ISBN: 9780080993775

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Furnaces sit at the core of all branches of manufacture and industry, so it is vital that these are designed and operated safely and effi-ciently. This reference provides all of the furnace theory needed to ensure that this can be executed successfully on an industrial scale. Industrial and Process Furnaces: Principles, 2nd Edition provides comprehensive coverage of all aspects of furnace operation and design, including topics essential for process engineers and operators to better understand furnaces. This includes: the combustion process and its control, furnace fuels, efficiency, burner design and selection, aerodynamics, heat release profiles, furnace atmosphere, safety and emissions. These elements and more are brought together to illustrate how to achieve optimum design and operation, with real-world case studies to showcase their application.

Key Features

  • Up-to-date and comprehensive reference encompassing not only best practice of operation but the essential elements of furnace theory and design, essential to anyone working with furnaces, ovens and combustion-based systems.
  • More case studies, more worked examples.
  • New material in this second edition includes further application of Computational Fluid Dynamics (CFD), with additional content on flames and burners, costs, efficiencies and future trends.


Professional engineers (chemical, mechanical, power, process, HVAC, environmental), designers, production staff who use heat and combustion as part of a process. Advanced students of Chemical, Mechanical and Powever Engineering (as a reference) dealing with energy conversion/thermal engineering

Table of Contents

  • Dedication

    Foreword to Second Edition

    Foreword to First Edition

    Preface to the Second Edition

    Preface to First Edition


    List of Figures

    List of Tables

    Chapter 1. Introduction


    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

    1.4 Concluding Remarks


    Chapter 2. The Combustion Process


    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


    3.1 Gaseous Fuels

    3.2 Liquid Fuels

    3.3 Solid Fuels

    3.4 Waste Fuels

    3.5 Choice of Fuel

    3.6 Safety

    3.7 Emissions



    Solid Fuel Bibliography

    Chapter 4. An Introduction to Heat Transfer in Furnaces


    4.1 Conduction

    4.2 Convection

    4.3 Radiation

    4.4 Electrical Heating



    Chapter 5. Flames and Burners for Furnaces


    5.1 Types of Flame

    5.2 Function of a Burner and Basics of Burner Design

    5.3 Gas Burners

    5.4 Oil Burners

    5.5 Pulverised Coal Burners

    5.6 Furnace Aerodynamics

    5.7 Combustion System Scaling

    5.8 Furnace Noise

    Nomenclature for Chapter 5

    References for Chapter 5

    Chapter 6. Combustion and Heat Transfer Modelling


    6.1 Physical Modelling

    6.2 Mathematical Modelling

    6.3 Application of Modelling to Furnace Design



    Chapter 7. Fuel Handling Systems


    7.1 Gas Valve Trains

    7.2 Fuel Oil Handling Systems

    7.3 Pulverised Coal Handling and Firing Systems

    7.4 Waste Fuel Handling


    References for Chapter 7

    Applicable Codes and Standards

    Chapter 8. Furnace Control and Safety


    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



    Certification and Testing Organisations

    Chapter 9. Furnace Efficiency


    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


    Chapter 10. Emissions and Environmental Impact


    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


    Chapter 11. Furnace Construction and Materials


    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


    Selection of Relevant Standards

    Advisory Organisations

    Appendix 11A

    Chapter 12. Furnace Design Methods


    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


    Chapter 13. Economic Evaluation


    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


    Chapter 14. Selected Examples of Real Furnace Applications


    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


    Chapter 15. Future Trends and Concluding Remarks


    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 Trends in Furnace Controls

    15.5 New Applications for Furnaces

    15.6 Concluding Remarks



Product details

  • No. of pages: 676
  • Language: English
  • Copyright: © Butterworth-Heinemann 2013
  • Published: October 23, 2013
  • Imprint: Butterworth-Heinemann
  • eBook ISBN: 9780080993782
  • Hardcover ISBN: 9780080993775

About the Authors

Barrie Jenkins

Barrie Jenkins
Barrie Jenkins has held senior technical management roles in industry and academia. He currently advises major energy users and continues to lecture at a number of Universities. He is currently Engineering Director at Origen Power Ltd.

Affiliations and Expertise

Engineering Director, Origen Powers Ltd., London, and Consulting Engineers, High Wycombe, UK

Peter Mullinger

Peter Mullinger
Peter Mullinger held senior management roles with both equipment suppliers and end users before joining the University of Adelaide as Associate Professor in 1999. Now semi-retired, he continues to teach process design and process safety.

Affiliations and Expertise

Visiting Research Fellow, School of Chemical Engineering, University of Adelaide, North Adelaide, SA, Australia

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