Exergy analysis and efficiency evaluation for an aluminium melting furnace in a die casting plant

10.32920/ryerson.14665482 ◽

2021 ◽

Author(s):

Dennis Lee

Keyword(s):

Natural Gas ◽

Die Casting ◽

Melting Furnace ◽

Exergy Efficiency ◽

Casting Plant ◽

Furnace Efficiency ◽

Stage Combustion ◽

Before And After ◽

Regenerative Burner ◽

Combustion Technique

An aluminium melting furnace efficiency in a die casting plant was investigated using energy and exergy methods. Energy efficiency and exergy efficiency values were evaluated for the natural gas-fired furnace, and the efficiency improvement was analyzed before and after two new regenerative burners were installed on the furnace. The research analyzed and compared the environmental impacts attributable to the melting furnace before and after the burner upgrading project, and also provided a financial analysis of the capital investment of the upgrading project. The study shows that the exergy method can be used beneficially to analyze the furnace efficiency and that exergy efficiency is a more practical measure in reality. Thus, it is believed that further applications of exergy methods are desirable to a wider range of industrial and engineering applications. From the results of comparisons, the study shows that the regenerative burner technology and stage-combustion technique can improve combustion performance, reduce fuel (natural gas) consumption and lower NOx and Co2 emissions. Adopting the regenerative burner and stage-combustion technique will be beneficial to the die casting plant on energy saving and cost reduction. Recommendations are also made for further efficiency improvements.

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Natural Gas Consumption Reducing in Aluminum Melting Furnaces by Heat Recovery of Flue

Scientific Bulletin of Valahia University - Materials and Mechanics ◽

10.1515/bsmm-2016-0003 ◽

2016 ◽

Vol 14 (11) ◽

pp. 17-22

Author(s):

Vasile Bratu ◽

Aurel Gaba ◽

Elena Valentina Stoian ◽

Florina Violeta Anghelina

Keyword(s):

Mathematical Model ◽

Natural Gas ◽

Computer Software ◽

Melting Furnace ◽

Gas Consumption ◽

Regenerative Burner ◽

Natural Gas Consumption ◽

Energy Balances ◽

The Mathematical Model ◽

Consumption Saving

Abstract This article presents different solutions to reduce natural gas consumptions of the aluminum melting furnaces, through recovery of the heat from flue gases. In order to be able to analyze the recovery solutions, a mathematical model for energy balance of these furnaces was adapted. This mathematical model allows drawing up energy balances together with the main working technique and economical parameters of these types of furnaces, in actual conditions, and the same, under optimizing conditions, by applying recovery solutions. The mathematical model which can elaborate energy balances for aluminum melting furnaces, was transposed in M. Excel based software, where the quantification of different solutions for natural gas consumption saving is possible. One of the applications of this computer software for an aluminum melting furnace, either for actual working conditions or per upgraded furnace by use an air pre-heater, materials pre-heater, or a regenerative burner system, is presented in this article.

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Flat-flame combustion of natural gas in a recuperative glass-melting furnace

Glass and Ceramics ◽

10.1007/bf00676749 ◽

1988 ◽

Vol 45 (3) ◽

pp. 121-123

Author(s):

V. I. Kirilenko ◽

I. S. Il'yashenko ◽

A. I. Es'kov ◽

I. B. Smulyanskii ◽

V. I. Basov

Keyword(s):

Natural Gas ◽

Glass Melting ◽

Melting Furnace ◽

Glass Melting Furnace ◽

Flame Combustion ◽

Flat Flame

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Process modelling and techno-economic analysis of natural gas combined cycle integrated with calcium looping

Thermal Science ◽

10.2298/tsci151001209e ◽

2016 ◽

Vol 20 (suppl. 1) ◽

pp. 59-67 ◽

Cited By ~ 8

Author(s):

María Erans ◽

Dawid Hanak ◽

Jordi Mir ◽

Edward Anthony ◽

Vasilije Manovic

Keyword(s):

Natural Gas ◽

Large Scale ◽

Combined Cycle ◽

Process Models ◽

Capital Costs ◽

Calcium Looping ◽

Industrial Sectors ◽

Natural Gas Combined Cycle ◽

Before And After ◽

Economic Analyses

Calcium looping (CaL) is promising for large-scale CO2 capture in the power generation and industrial sectors due to the cheap sorbent used and the relatively low energy penalties achieved with this process. Because of the high operating temperatures the heat utilisation is a major advantage of the process, since a significant amount of power can be generated from it. However, this increases its complexity and capital costs. Therefore, not only the energy efficiency performance is important for these cycles, but also the capital costs must be taken into account, i.e. techno-economic analyses are required in order to determine which parameters and configurations are optimal to enhance technology viability in different integration scenarios. In this study the integration scenarios of CaL cycles and natural gas combined cycles (NGCC) are explored. The process models of the NGCC and CaL capture plant are developed to explore the most promising scenarios for NGCC-CaL integration with regards to efficiency penalties. Two scenarios are analysed in detail, and show that the system with heat recovery steam generator (HRSG) before and after the capture plant exhibited better performance of 49.1% efficiency compared with that of 45.7% when only one HRSG is located after the capture plant. However, the techno-economic analyses showed that the more energy efficient case, with two HRSGs, implies relatively higher cost of electricity (COE), 44.1?/MWh, when compared to that of the reference plant system (33.1?/MWh). The predicted cost of CO2 avoided for the case with two HRSGS is 29.3 ?/ton CO2.

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A Comparative Exploration of Enhancing Thermal Characteristics of Natural Gas Flame by Synchronous Combustion Technique

Heat Transfer-Asian Research ◽

10.1002/htj.21209 ◽

2015 ◽

Vol 46 (3) ◽

pp. 237-250

Author(s):

S. H. Pourhoseini

Keyword(s):

Natural Gas ◽

Thermal Characteristics ◽

Gas Flame ◽

Combustion Technique

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Measuring the Benefits of Greater Spatial Granularity in Short-Term Pricing in Wholesale Electricity Markets

The American Economic Review ◽

10.1257/aer.101.3.247 ◽

2011 ◽

Vol 101 (3) ◽

pp. 247-252 ◽

Cited By ~ 14

Author(s):

Frank A Wolak

Keyword(s):

Natural Gas ◽

Electricity Markets ◽

Electricity Market ◽

Short Term ◽

Locational Marginal Pricing ◽

Marginal Pricing ◽

Before And After ◽

Natural Gas Prices ◽

The Impact ◽

Generation Unit

Hourly generation unit-level output levels, detailed information on the technological characteristics of generation units, and daily delivered natural gas prices to all generation units for the California wholesale electricity market before and after the implementation of locational marginal pricing are used to measure the impact of introducing greater spatial granularity in short-term energy pricing. The average hourly number of generation unit starts increases, but both the total hourly energy consumed and total hourly operating costs for all natural gas-fired generation units fall by more than 2 percent after the implementation of locational marginal pricing.

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Development of two-stage combustion technique for woody biomass

The Proceedings of Conference of Chugoku-Shikoku Branch ◽

10.1299/jsmecs.2018.56.prize1 ◽

2018 ◽

Vol 2018.56 (0) ◽

pp. Prize1

Author(s):

Fumiaki ABE ◽

Masaya NAKAHARA ◽

Kenichi TOKUNAGA

Keyword(s):

Woody Biomass ◽

Two Stage ◽

Stage Combustion ◽

Combustion Technique

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600 MW Direct Air-Cooling Unit Back-Pressure Optimization and Theoretical Analysis

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.875-877.1739 ◽

2014 ◽

Vol 875-877 ◽

pp. 1739-1743

Author(s):

Hong Bin Zhao ◽

Yong Hui Yan ◽

Meng Li

Keyword(s):

Efficiency Analysis ◽

Exergy Efficiency ◽

Back Pressure ◽

Exergy Loss ◽

Air Cooling ◽

Power Gain ◽

Cooling Unit ◽

Before And After ◽

Actual Operation ◽

Fan Speed

In recent years, direct air cooling units have developed rapidly in China, but in the actual operation, the back-pressure often deviate from the optimal back-pressure, which affect the economy of the unit. The paper has figured out the optimum back-pressure, fan speed and power gain with the method of equivalent enthalpy drop; the paper also worked out the exergy loss of each device before and after the optimization. Through the exergy efficiency analysis of the devices before and after the optimization, we find out that after optimization, exergy loss of the turbine reduces by 0.954MW and the net amount of the generated power increases 130.5kW, the net exergy efficiency of units improves about 0.018 percent points.

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Power and Emission Evaluation of Natural Gas Engines Converted From Gasoline

Volume 4: Fatigue and Fracture, Heat Transfer, Internal Combustion Engines, Manufacturing, and Technology and Society ◽

10.1115/esda2006-95017 ◽

2006 ◽

Cited By ~ 1

Author(s):

Bashir Samsam Shariat

Keyword(s):

Natural Gas ◽

Power Loss ◽

Experimental Tests ◽

Open Loop ◽

Spark Ignition Engine ◽

Natural Gas Engines ◽

Before And After ◽

Mixer Design ◽

Base Engine ◽

Engine Power

In the present article, the performance analysis of a bi-fuel spark ignition engine is investigated. An originally gasoline-fuelled car is used for experimental tests. It is converted to a bifuel vehicle which may run both on natural gas and gasoline. The wheel and motor power of the car are measured before and after conversion together with exhaust emissions. It is observed that the engine power reduces not only in gas but also in gasoline state after the conversion in comparison with the base engine power. The effect of gas/air mixer design is fully explained. The results of closed-loop and open-loop gas supplying systems are compared. The influence of ignition timing on the power loss is discussed. The optimum timing advance for natural gas is obtained through laboratory experiments. The power and emissions of the converted vehicle are compared with the base power and emission values for a series of engine speeds. The reasons for the power loss are discussed and some useful methods are recommended to decrease the amount of power loss.

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