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

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.

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

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.

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

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.