Batch Furnace Gas Flow Control for Energy Recovery
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Solution Overview
Problem
Batch ovens require more heating energy than continuously operated ovens, making them less energy-efficient and typically used only for producing high-quality goods. This limits their application in processes requiring special properties.
Innovation Solution
The proposed solution involves operating batch ovens in an energy-efficient manner by utilizing lines at different temperature levels and optimizing gas flows within these lines. This reduces the energy needed to heat and burn Formlings, allowing batch ovens to be operated as efficiently as continuously operated ovens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch furnaces are used for thermal treatment of goods, then high-quality goods can be produced with special properties, but more heating energy is required compared to continuously operated furnaces
Solution Approach 1:
The patent recovers waste heat from the exhaust gas of batch furnaces by directing it through heat exchangers to preheat incoming air and fuel gases, and to generate steam. This heat recovery system reduces the primary heating energy requirement, allowing batch furnaces to achieve energy efficiency levels comparable to continuous furnaces while maintaining the quality production advantages of batch processing.
Solution Approach 2:
The patent implements preliminary heating of air and fuel gases using waste heat from the furnace exhaust before they enter the furnace chamber. This preheating action reduces the energy burden on the furnace during the heating phase, thereby reducing total energy consumption while maintaining the batch processing quality advantages.
2Ease of operation
If batch furnaces are operated traditionally, then simple operation is maintained, but energy efficiency is low
Solution Approach 1:
The waste heat recovery system is designed to operate automatically using the natural temperature differential between the hot exhaust gas and the cold incoming gases. The heat exchangers are positioned to utilize the existing gas flows, requiring minimal additional energy input and maintaining ease of operation while significantly improving energy efficiency through passive heat recovery.
Solution Approach 2:
The system incorporates temperature sensors and control mechanisms that monitor the exhaust gas temperature and adjust the heat recovery process accordingly. This feedback control ensures optimal heat extraction while maintaining simple operation, as the system automatically adapts to varying operating conditions without requiring complex manual intervention.
3Manufacturing precision
If multiple batch furnaces are operated separately, then individual quality control is maintained, but energy cannot be efficiently recovered and utilized
Solution Approach 1:
The patent connects multiple batch furnaces through a shared waste heat recovery system where exhaust gases from one furnace can preheat incoming gases for another furnace. This merging of thermal energy sources across multiple units enables efficient energy recovery while maintaining the independent quality control capabilities of each furnace, as each unit can still operate with its own process parameters.
Solution Approach 2:
The waste heat recovery system serves multiple functions simultaneously: it preheats incoming air, preheats fuel gases, and generates steam for various process needs. This multi-functionality allows multiple batch furnaces to operate efficiently with recovered energy, maintaining quality control while reducing overall energy consumption through versatile heat utilization.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables batch ovens to be operated energy-efficiently, allowing for the efficient recovery of energy released during operation, particularly when burning Formlings. The method reduces the energy required for heating and burning, making it possible to operate multiple interacting batch ovens with improved energy efficiency.
Implementation Method 1
the operating gas stream is heated to the target gas temperature by means of a heating device (8) for the batch furnace (1) before being fed into the charging space (29)
Implementation Method 2
the operating gas stream (32) flows through the stack of blanks (33) arranged in the loading chamber (29)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A method for operating at least one batch furnace (1) with a loading chamber (29) is proposed, wherein a gas inlet (30) is connected to a supply line (2) and a gas outlet (31) is connected to an outlet line (3), wherein the supply line (2) is connected to a hot line (4), to a cold line (5) and via a return line (6) to the outlet line (3), wherein an operating gas flow (32) is set in the supply line (2) according to a target gas temperature curve (7) by means of a control device, wherein the operating gas flow (32) comprises a part of a gas flow from the hot line (4) or a part of a gas flow from the cold line (5) and a part of a gas flow from the outlet line (3), wherein the excess gas flow in the outlet line (3) is fed to the hot line (4) when the temperature of the gas flow in the outlet line (3) is within a predefinable return value range.