FLOW, MIXING AND HEAT TRANSFER IN FURNACES
1 Introduction 11 What is a furnace? 3 12 Where are furnaces used? Brief review of current furnace applications and technology 7 13 Drivers for improved efficiency 28 14 Concluding remarks 29 References 30 2 The combustion process 21 Simple combustion chemistry 31 22 Combustion calculations 33 23 Chemical reaction kinetics 35 24 The physics of combustion 46 References 63 3 Fuels for furnaces 31 Manufactured gaseous fuels 67 32 Natural gas 74 33 Properties of gaseous fuels 74 34 Liquid fuels 81 35 Solid fuels 83 36 Biomass based fuels 86 37 Waste fuels 87 38 Choice of fuel 91 39 Safety 96 310 Emissions 96 References 97 4 An introduction to heat transfer in furnaces 41 Conduction 100 42 Convection 108 43 Radiation 121 44 Electrical heating 136 References 144 Appendix 4A table of emissivity data 144 5 Flames and burners for furnaces 51 Types of flame 151 52 Function of a burner and basics of burner design 160 53 Gas burners 166 54 Oil burners 181 55 Pulverised coal burners 191 56 Burners for biomass and waste-based fuels 193 57 Furnace aerodynamics 202 58 Combustion system scaling 212 59 Furnace noise 215 References 224 6 Combustion and heat transfer modelling 61 Physical modelling 228 62 Mathematical modelling 234 63 Application of modelling to furnace design 255 References 258 7 Fuel preparation and handling systems 71 Gas valve trains 262 72 Fuel oil handling systems 266 73 Pulverised coal handling and firing systems 271 74 Waste fuel handling 299 References 314 Applicable codes and standards 315 Appendix 7A Safety case 316 8 Furnace control and safety 81 Process control 320 82 Furnace instrumentation 321 83 Flue gas analysis 331 84 Combustion control 342 85 Ensuring furnace safety 343 86 Burner management systems 350 References 362 9 Furnace efficiency 91 Furnace performance charts 365 92 Mass and energy balances 368 93 Energy conversion 385 94 Heat recovery equipment 390 95 Identifying efficiency improvements 397 References 400 10 Emissions and environmental impact 101 Formation of carbon monoxide 403 102 Formation of nitrogen oxides 403 103 Formation of sulphur oxides 410 104 Formation of intermediate combustion products 411 105 Particulate emissions 416 106 Environmental control of emissions 422 References 436 11 Furnace construction and materials 111 Basic performance requirements of the furnace structure 440 112 Basic construction methods 441 113 Practical engineering considerations in the use of refractories 454 114 Ceramic refractory materials 457 115 Heat resisting and refractory metals 463 116 Practical engineering considerations in the use of high temperature metals 467 117 Concluding remarks 468 References 469 Appendix 11A Refractory materials 470 12 Furnace design methods 121 Introduction 481 122 Conceptual design 485 123 Furnace sizing 504 124 Burner selection 524 125 Detailed analysis and validation of the furnace design 528 126 Furnace instrumentation and controls 529 References 532 13 Economic evaluation 131 Cost accounting 533 132 Distinction between capital and revenue 535 133 Profit and profitability 536 134 Financial ratios 537 135 Project costing 538 136 Investment evaluation 542 137 Determining financial benefits 543 138 Post project analysis 564 References 565 14 Selected examples of real furnace applications 141 Design of a new burner for a lime sludge kiln 568 142 Optimising flash furnace design 576 143 Contribution to the design of a new reforming process for fuel cell applications 585 144 Resolving tube internal coking and premature tube failure in a refinery heater 600 145 Unsuccessful attempts to resolve severe problems with a preheater cement kiln 609 146 Investigation and elimination of coal firing system problems 624 147 Concluding remarks on implementation 633 References 633 15 Future trends and concluding remarks 151 Trends in new materials 636 152 Trends in furnace emissions and fuels for furnaces 636 153 Trends in carbon capture from furnaces 648 154 Trends in furnace controls 658 155 New applications for furnaces 658 156 Concluding remarks 659 References 660