Industrial and Process Furnaces
Principles, Design and Operation
- 3rd Edition - December 2, 2022
- Latest edition
- Authors: Peter Mullinger, Barrie Jenkins
- Language: English
- Paperback ISBN:9 7 8 - 0 - 3 2 3 - 9 1 6 2 9 - 5
- eBook ISBN:9 7 8 - 0 - 3 2 3 - 9 8 4 9 1 - 1
Industrial and Process Furnaces: Principles, Design and Operation, Third Edition continues to provide comprehensive coverage on all aspects of furnace operation and design, i… Read more
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.
- 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
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
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
- Edition: 3
- Latest edition
- Published: December 2, 2022
- Language: English
PM
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, AustraliaBJ
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, UKRead Industrial and Process Furnaces on ScienceDirect