Industrial Furnace Optimization by Robust Design for Efficiency Upgradation and Adaptability to Different Loads

Abstract

This research work focuses on the robust design and optimization of a 16 ton MS capacity of Bogie Hearth Furnace used for forging application of dish ends used for pressure vessels. By applying robust design methodology, the furnace firing done earlier by oil only may run with Oil/PNG/LPG as dual fuel. Different loads’ adaptability by robust design principle saves on replacement of furnace or capital equipment and efficiency. The objective is to maintain the temperature uniformity inside the furnace as well as maintaining the rise in temperature by 50 °C per hour after 300–1050 °C (+/10 °C) uniformly to achieve 0% rejection. Independent burner temperature control system and parameters control helped to achieve the target. Validation of the work is done by NABL (National Accreditation Board for Laboratory testing and calibration). Another task of adaptability to different loads without replacement of a furnace or any capital equipment of existing furnace saves on additional cost for different demands from the market. Fuel-saving about 25% while operating on full load is achieved with the help of an independent burner control automation system over a manual system. The furnace project is practically implemented and is in use at M/s ICEM Engineering Pvt. Ltd., Maharashtra, India.