The effect of thermal camera and pyrometer usage in industrial tempering furnaces on optimum combustion performance

The decrease of energy sources, the increase of energy need and energy costs, competitive conditions in industry and environmental sensitivity require the effective usage of energy sources. In this study, optimum combustion study by using thermal camera and pyrometer in the correct heat furnace of an industry plant for the effective usage of energy in industry. For this reason, in tempering furnace of a milling roll workshop, in order to control the efficiency of tempering, detect the flame length and color and control the homogeneous tempering, 4 thermal cameras and 4 pyrometers have been assembled to the appropriate locations of the furnace. In the study, the tempering furnace has been observed and the results of observations have been evaluated. The contribution of the changes made to the production has been calculated by the information obtained from thermal camera and pyrometer and has been examined with the date of reimbursement. Possible spare part and production saving has been established as 364,460 $ annually and back-payment time as 3 months. Accident risk that is caused by the hot air and sometimes occurs during the controls has also been reduced so that the workers have been forced to work more safely according to WHS (workers’ health and security).

Variation Law of Temperature Field and Pressure Field in Synthesis of SiC by Carbothermal Reduction Method

Through numerical simulation of temperature field and pressure field in synthesis of SiC by carbothermal reduction method, the variation law of temperature and pressure with time in furnace was studied. Research results show that the high temperature isothernal face expands outside gradually with the prolong of the synthesis time, so the temperature field area compatible to the production of SiC increase gradually, but too long synthesis time not only increase energy consumption, but also generate SiC product yield decreased. Compared with single heat furnace, the pressure is comparatively more uniformity in three-heat-source and the pressure is 140~200kPa, which is useful for synthesis of SiC and can prevent furnace spewing. At the bottom of single heat furnace should pay attention to charge ration when charging, adding a little sawdust can increase the porosity and release pressure.

Optimal Control for Quality Indices of Heat Furnace

Heat furnace is one of the most important parts in iron and steel industry which is one of the basic industries. The control of furnace quality indices has a direct impact on iron and steel qualities and energy consumptions in an iron and steel manufacturing process. Due to dramatic changes of exhaust gas in combustion, this multi-variable process becomes time-varying, and also has inherent nonlinearities, couplings among the variables, large inertias and time delays.Therefore, manual operations are still being widely used in quality indices control. In this paper, an optimization control method is proposed for the control of furnace quality indices. The optimization consists of a materials temperature calculation model, an optimization objective, an ideal materials heating model and a furnace heating model. Optimization algorithm consists of the maximum principle, the simulated annealing algorithm，the iterative algorithm and sensitive analysis.Finally, quality indices were controlled by lower layer loop control on-line.The proposed optimization control method has been successfully applied to some steel plants. The industrial applications show the effectiveness of the proposed method.