Design and Development of an Energy-Efficient Oil-Fired Tilting Furnace with an Innovative Recuperator

In this paper, design and development of an energy-efficient oil-fired tilting furnace with an innovative recuperator are reported. During the melting of metals, it is reported that around 50% of the total energy is lost in flue gases. Therefore, there is always a need to improve upon the efficiency of the furnaces. The design of the recuperator is based upon the application of all the three basic modes of heat transfer to preheat the incoming air. Financial and environmental aspects were also evaluated after upgradation with the recuperator. The internal hollow pipe of the proposed recuperator is so designed that at its exterior cylindrical surface, multiple turns of a guide way are welded in a spiral fashion. This increases the heat transfer between the flue gas and ambient air to the burner. The study shows that the efficiency of the oil-fired tilting furnace got enhanced by 50% after implementing the proposed recuperator. Specific fuel consumption without the recuperator was 0.166 kg/kWh, which was reduced to 0.138 kg /kWh with the recuperator. The principle of increasing thermal efficiency and limiting fuel consumption was based on heat recovery from the combustion products to preheat the cold incoming fuel mixture. Therefore, this study focuses on the relations between combustion and heat exchanges on a large scale. The exergy evaluation technique was used constructively to estimate the furnace’s efficiency since the exergy efficiency is an additional sustainable appraisal in real situations. A channel for flue gases is provided in the developed furnace, which helps to divert hazardous gases away from the working environment.