Industrial and Process Furnaces

Industrial and Process Furnaces

Principles, Design and Operation

3rd Edition - August 1, 2022

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  • Authors: Barrie Jenkins, Peter Mullinger
  • Paperback ISBN: 9780323916295

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Description

Industrial and Process Furnaces: Principles, Design and Operation, Third Edition continues to provide comprehensive coverage on all aspects of furnace operation and design, including topics essential for process engineers and operators to better understand furnaces. New to this edition are sections on production, handling and utilization of alternative fuels such as biomass, hydrogen and various wastes, modeling of the process, combustion and heat transfer, their benefits, advantages and limitations, mitigation and removal of CO2 , the role of solar and other renewable energy, recent research, and the practical approach of the Whyalla steelworks for harnessing solar energy for sustainable steelmaking, hydrogen and as a "clean fuel". The book also includes a discussion on the limitations of hydrogen supply owing to fresh water supply constraints, the difficulty of storing and transporting hydrogen, and the current sociopolitical impetus of CO2.

Key Features

  • Covers the manufacture and utilization of hydrogen as a clean fuel
  • Includes process modeling and expands on computational fluid dynamics (CFD), with a special focus on flames and burners, costs, efficiencies and future trends
  • Expands on future trends, including sociopolitical impacts on CO2 emissions and control

Readership

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 Power Engineering (as a reference) dealing with energy conversion/thermal engineering. Environmental (air quality) inspectors and policy makers

Table of Contents

  • Chapter 1. Introduction 

    Abstracts 

    1.1 What is a Furnace? 

    1.2 Where are Furnaces Used? Brief Review of Current Furnace Applications and Technology 

    1.3 Drivers for Improved Efficiency and reduced emissions 

    1.4 Concluding Remarks 

    References 

     

    Chapter 2. The Combustion Process 

    Abstracts 

    2.1 Simple Combustion Chemistry 

    2.2 Combustion Calculations 

    2.3 Chemical Reaction Kinetics 

    2.4 The Physics of Combustion 

    Nomenclature for Chapter 2 

    References for Chapter 2 

     

    Chapter 3. Fuels for Furnaces 

    Abstract 

    3.1 Gaseous Fuels including the gasification of biomass, manufacture and application of hydrogen with types and applications of fuel cells  

    3.2 Liquid Fuels 

    3.3 Solid Fuels  

    3.4 Biomass derived fuels 

    3.5 Waste Fuels 

    3.6 Choice of Fuel 

    3.7 Safety 

    3.8 Emissions 

    Nomenclature 

    References 

    Fuels Bibliography 

     

    Chapter 4. An Introduction to Heat Transfer in Furnaces 

    Abstract 

    4.1 Conduction 

    4.2 Convection 

    4.3 Radiation 

    4.4 Electrical Heating 

    Nomenclature 

    References 

     

    Chapter 5. Flames and Burners for Furnaces 

    Abstract 

    5.1 Types of Flame 

    5.2 Function of a Burner and Basics of Burner Design 

    5.3 Gas Burners, including burners for hydrogen and mild combustion 

    5.4 Oil Burners 

    5.5 Pulverised Coal Burners 

    5.6 Burners for waste based fuels 

    5.7 Furnace Aerodynamics 

    5.8 Combustion System Scaling 

    5.9 Furnace Noise 

    Nomenclature for Chapter 5 

    References for Chapter 5 

     

    Chapter 6. Process, Combustion and Heat Transfer Modelling 

    Abstract 

    6.1 Physical Modelling 

    6.2 Mathematical Modelling including process modelling using ASPEN, Matlab, etc including advantages and limitations CFD modelling including latest developments 

    6.3 Application of Modelling to Furnace Design 

    Nomenclature 

    References 

     

    Chapter 7. Fuel Handling Systems 

    Abstract 

    7.1 Gas Valve Trains 

    7.2 Fuel Oil Handling Systems 

    7.3 Pulverised Coal Handling and Firing Systems 

    7.4 Waste Fuel Handling 

    Nomenclature 

    References for Chapter 7 

    Applicable Codes and Standards 

     

    Chapter 8. Furnace Control and Safety 

    Abstract 

    8.1 Process Control 

    8.2 Furnace Instrumentation 

    8.3 Flue Gas Analysis 

    8.4 Combustion Control 

    8.5 Ensuring Furnace Safety 

    8.6 Burner Management Systems 

    Nomenclature 

    References 

    Certification and Testing Organisations 

     

    Chapter 9. Furnace Efficiency 

    Abstract 

    9.1 Furnace Performance Charts 

    9.2 Mass and Energy Balances 

    9.3 Energy Conversion 

    9.4 Heat Recovery Equipment 

    9.5 Identifying Efficiency Improvements 

    Nomenclature for Chapter 9 

    References 

     

    Chapter 10. Emissions and Environmental Impact 

    Summary 

    10.1 Formation of Carbon Monoxide 

    10.2 Formation of Nitrogen Oxides 

    10.3 Formation of Sulphur Oxides 

    10.4 Formation of Intermediate Combustion Products 

    10.5 Particulate Emissions 

    10.6 Environmental Control of Emissions including CO2 mitigation and removal 

    References 

     

    Chapter 11. Furnace Construction and Materials 

    Abstract 

    11.1 Basic Performance Requirements of the Furnace Structure 

    11.2 Basic Construction Methods 

    11.3 Practical Engineering Considerations in the Use of Refractories 

    11.4 Ceramic Refractory Materials 

    11.5 Heat Resisting and Refractory metals 

    11.6 Practical Engineering Considerations in the Use of High Temperature Metals 

    11.7 Concluding Remarks 

    References 

    Selection of Relevant Standards 

    Advisory Organisations 

    Appendix 11A 

     

    Chapter 12. Furnace Design Methods 

    Abstract 

    12.1 Introduction 

    12.2 Conceptual Design 

    12.3 Furnace Sizing 

    12.4 Burner Selection 

    12.5 Detailed Analysis and Validation of the Furnace Design 

    12.6 Furnace Instrumentation and Controls 

    Nomenclature for Chapter 12 

    References 

     

    Chapter 13. Economic Evaluation 

    Abstract 

    13.1 Cost Accounting 

    13.2 Distinction Between Capital and Revenue 

    13.3 Profit and Profitability 

    13.4 Financial Ratios 

    13.5 Project Costing 

    13.6 Investment Evaluation 

    13.7 Determining Financial Benefits 

    13.8 Post Project Analysis 

    References 

     

    Chapter 14. Selected Examples of Real Furnace Applications 

    Abstract 

    14.1 Design of a New Burner for a Lime Sludge Kiln 

    14.2 Optimising Flash Furnace Design 

    14.3 Contribution to the Design of a New Reforming Process for Fuel Cell Applications 

    14.4 Resolving Tube Internal Coking and Premature Tube Failure in a Refinery Heater 

    14.5 Unsuccessful Attempts to Resolve Severe Problems with a Preheater Cement Kiln 

    14.6 Investigation and Elimination of Coal Firing System Problems 

    14.7 Concluding Remarks on Implementation 

    References 

     

    Chapter 15. Future Trends and Concluding Remarks 

    Abstract 

    15.1 Trends in New Materials 

    15.2 Trends in Furnace Emissions and Fuels for Furnaces 

    15.3 Prospects for Alternative Electrical Energy as a Power Source 

    15.4 Potential role of solar and other renewable forms of energy 

    15.5 The potential role of hydrogen as a “clean fuel” storing and transporting hydrogen, limitations of hydrogen supply owing to fresh water supply constraints 

    15.6 The Whyalla Steelworks approach to harnessing solar energy for sustainable steelmaking  

    15.7 Trends in Furnace Controls 

    15.8 New Applications for Furnaces 

    15.9 Concluding Remarks 

    References

Product details

  • No. of pages: 762
  • Language: English
  • Copyright: © Butterworth-Heinemann 2022
  • Published: August 1, 2022
  • Imprint: Butterworth-Heinemann
  • Paperback ISBN: 9780323916295

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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