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Furnace Design and Operation: Heat Transfer Fundamentals

This document summarizes key concepts related to furnace design and heat transfer, including: 1) Heat must be transferred from a source (e.g. flame gases) to a sink (e.g. product or furnace walls) for efficient thermal transfer, requiring a temperature difference between source and sink. 2) Heat transfer occurs via conduction, convection, and radiation. Conduction involves molecular vibration transfer in solids and fluids, convection involves fluid motion, and radiation involves electromagnetic wave transfer from all materials. 3) Equations govern the various heat transfer modes, and correlations using dimensionless numbers can provide generalized convective heat transfer relationships depending on conditions.

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kING
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© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
113 views

Furnace Design and Operation: Heat Transfer Fundamentals

This document summarizes key concepts related to furnace design and heat transfer, including: 1) Heat must be transferred from a source (e.g. flame gases) to a sink (e.g. product or furnace walls) for efficient thermal transfer, requiring a temperature difference between source and sink. 2) Heat transfer occurs via conduction, convection, and radiation. Conduction involves molecular vibration transfer in solids and fluids, convection involves fluid motion, and radiation involves electromagnetic wave transfer from all materials. 3) Equations govern the various heat transfer modes, and correlations using dimensionless numbers can provide generalized convective heat transfer relationships depending on conditions.

Uploaded by

kING
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Furnace design and

operation

Heat transfer fundamentals


Heat transfer fundamentals

 The reason we burn fuel in industrial furnaces and


boilers is to provide heat to process materials or raise
steam
 Thus we must transfer heat from the source (i.e. the
flame gases) to the sink (i.e. the product or furnace
walls).
 The degree of success in achieving this defines the
thermal efficiency of the system.
 There must be a temperature difference between the
source and the sink
Conduction
 In a solid, the flow of heat by conduction is the result of the
transfer of vibrational energy from one molecule to the next, and in
fluids it occurs in addition as a result of the transfer of kinetic
energy. Conduction may also be created from the movement of
free electrons (viz. metals).

Flow of heat through rod


Convection
 Heat transfer by convection is attributable to macroscopic motion of
a fluid and is thus confined to liquids and gases. Natural convection
arises from density differences caused by temperature gradients in
the system. Forced convection occurs due to eddy currents in a
fluid in turbulent motion.
Warm lower Forced air
density air rises flow out
Cold
dense
air Hot surface Hot surface
replaces slow fast
warm Forced air
air flow in
Radiation
 All materials radiate thermal energy in the form of electro-magnetic
waves. When radiation falls on a surface it may be reflected,
transmitted, or absorbed. The fraction of energy that is absorbed is
manifest as heat.
Governing equations for
heat transfer


Q
=

t) n

 n
C
o
n
d
uc
t
i
on k
A
/
x 1
C
o
n
v
ec
t
i
on h
A 1
R
a
d
i
at
i
on 


A 4
Conduction problems
 Fourier equation is the differential form of general equation i.e.

Q t
 kA
q x

 There are two modes


 steady state - t independent of q
x
t
 transient - x depends on q
Steady state conduction
problems
 Heat loss through a wall - effect of refractory and insulation
selection
25oC T2oC (=25.2) T1oC (=1404) 1500oC

Q Q Q
Insulation Firebrick
Steel k=0.12 k=2.5
Shell
k=43.3
5mm 90 mm 130 mm

 Heat loss with insulation 1.84 kW/m2


 Heat loss with no insulation 28.37 kW/m2
Transient conduction
problems
 A typical example would be billet heating

Ingot heating curve after Gurnie-Lurie

2600

2400

2200
temperature F

2000

1800

1600

1400

1200

1000
0 5 10 15 20 25 30 35
time hours

centre mid point


Convection problems
 Convection usually contributes <10% of the total heat transfer
from a flame, but is of primary importance in heat recovery
equipment.
 Selection of the correct convective heat transfer value is critical.
 These are experimentally determined and depend on
 the surface condition and geometry
 the fluid velocity and physical properties
Convective heat transfer
coefficient correlations
 Dimensionless groups are used to provide generalised relationships

hD
Nu 
k
vD
Re

Cp
Pr 
k
tD 3  2 g
Gr 
2
Common correlations
General equation is of the form Nu a = C Reb Prc Grd
System a C b c d Limitations
Air to single cylinder, forced 1 0.891 0.330 - - 1<Re<4
Air to single cylinder, forced 1 0.821 0.385 - - 4<Re<40
Air to single cylinder, forced 1 0.615 0.466 - - 40<Re<4000
Air to single cylinder, forced 1 0.174 0.618 - - 4000<Re<40000
Air to single cylinder, forced 1 0.024 0.805 - - 40000<Re<250000
Flow inside tube, forced gas 1 0.023 0.800 0.33 - Re>10000 D>60diameters
Flow over sphere, forced gas 1 0.370 0.600 0.30 - 25<Re<105
Flow over flat plate , forced gas 1 0.037 0.800 0.33 -
Flow over tubes, forced gas, in-line 1 0.300 0.600 0.33 -
Flow over tubes, forced gas, staggered 1 0.380 0.600 0.33 -
Flow over tubes, forced gas, coflowing 1 0.037 0.800 0.33 -
Flow over vertical plate, natural laminar 1 0.555 - 0.25 0.25 Gr<109
Flow over vertical plate, natural turbulent 1 0.100 - 0.33 0.33 Gr>109
Flow over horizontal cylinder, natural 1 0.530 - 0.25 0.25 Pr>0.5 103 <Gr<109
Flow over sphere, natural 1 2+0.450 - 0.25 0.25
Flow over hot plate, face up, or cold plate,
face down, natural 1 0.540 - 0.25 0.25 105 <Gr<2x107
Flow over hot plate, face up, or cold plate,
face down, natural 1 0.140 - 0.33 0.33 2x107 <Gr<3x1010
Flow over hot plate, face down, or cold
plate, face up, natural 1 0.270 - 0.25 0.25 3x105 <Gr<3x1010
Radiation problems
 Radiation accounts for >90% of the heat transfer from most
industrial flames
 Energy radiates equally in all directions from a point source, and
depending on what it meets along its path it may be absorbed,
reflected or transmitted
 All solid materials are affected by radiation.
 Some gases are also radiative emitters and absorbers, significantly
these include the products of combustion i.e CO2,CO and H2O
Emissivity, absorptivity
and transmissivity
 The emissivity (), absorptivity (a)and transmissivity () are
temperature and wavelength dependent
 Only a few materials transmit radiation (e.g.glass), most reflect (r)
the balance of incident radiation that is not absorbed

1  r  a
 The absorptivity and emissivity are equal at the same temperature
Gas emissivity
Typical radiative transfer
in a furnace
Flux geometry

s
u
r
fa
c
e1S
1S
3 s
u
r
fa
c
e3

S
S
3
2
S
S
1
2

s
u
r
fa
c
e2
T
o
t
a
le
xc
h
a
ng
ea
r
e
a=
a
.
1.
S
2S
1+
2

1.
(a
1
-)
.
S
3S
1a
.
3.
S
2S
32

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