Heating Furnace Research Articles

Effect of the sputtering gas temperature on the properties of indium tin oxide films

An external gas heating device is established, and a heat treatment technology of indium tin oxide (ITO) films prepared via sputtering gas (Argon) heating is developed. Six ITO films are prepared via magnetron sputtering at room temperature, 200 °C, 300 °C, 400 °C, 500 °C, and 600 °C using an external muffle furnace heating Ar. The effects of the Ar temperature on the structure, optical, and electrical properties of the ITO films are studied. It is found that with increasing sputtering gas temperature, the sputtering rate increases gradually, and the thickness of the ITO film increases slightly during the same sputtering time. For the same film thickness, the ITO films prepared at a higher sputtering gas temperature have better photoelectric performance. With increasing Ar temperature, the surface structure of ITO film becomes gradually dense.The crystallite sizes remain relatively uniform, the resistivity is gradually reduced, and the transmittance is gradually increased. The resistivity of the ITO films with the best performance in this experiment is 2.45 × 10−4 Ω·cm, and the average transmittance between 300 and 800 nm is 90.62%. The results indicate that the heat treatment process of the ITO films prepared via Ar heating is a convenient method, which can achieve uniform heating and simultaneous heating and vacuuming. Thus, it can significantly improve the production efficiency.

An Improved Technique for Trimethylamine Detection in Animal-Derived Medicine by Headspace Gas Chromatography-Tandem Quadrupole Mass Spectrometry.

Animal-derived medicines have distinctive characteristics and significant curative effects, but most of them have an obvious fishy odor, resulting in the poor compliance of clinical patients. Trimethylamine (TMA) is one of the key fishy odor components in animal-derived medicine. It is difficult to identify TMA accurately using the existing detection method due to the increased pressure in the headspace vial caused by the rapid acid-base reaction after the addition of lye, which causes TMA to escape from the headspace vial, stalling the research progress of the fishy odor of animal-derived medicine. In this study, we proposed a controlled detection method that introduced a paraffin layer as an isolation layer between acid and lye. The rate of TMA production could be effectively controlled by slowly liquefying the paraffin layer through thermostatic furnace heating. This method showed satisfactory linearity, precision experiments, and recoveries with good reproducibility and high sensitivity. It provided technical support for the deodorization of animal-derived medicine.

Influence of torrefaction with microwave and furnace heating on pyrolysis of poplar sawdust

Microwave heating is different from furnace heating in terms of heat transfer direction and heating mechanism. The torrefaction with microwave or furnace heating might further impact evolution of the pyrolytic products in further pyrolysis. This was investigated herein via thermal pretreatment of sawdust at 150 to 250 °C and the subsequent pyrolysis at 600 °C. The results showed that the microwave pretreatment led to more pronounced pyrolysis at 200/250 °C, which enhanced aromatic degree of semi-char and created difficulty for its further cracking in pyrolysis at 600 °C but not affected gasification. This led to the formation of more biochar and much more gases but less bio-oil with less heavy components than that from furnace heating plus pyrolysis. Additionally, the microwave pretreatment could enhance deoxygenation but the enhanced aromatic degree of the semi-char created difficulty for creating micropores and development of the pore structures (176.2 m2g−1 with 67.3% micropores from microwave pretreatment versus 441.1 m2g−1 with 78.5% micropores from furnace pretreatment). The characterization of the pyrolysis of semi-char with in-situ IR technique confirmed that the microwave pretreatment substantially removed the aliphatic structures and made the biochar with more fragmented morphology.

Design and Construction of Heat Treatment Furnace Using Ant Hill

A heat treatment furnace using anthill has been designed and fabricated. Developing our local content in the production of heat treatment furnaces will be a major boost in the bid to take a prominent position in foundry and metallurgical engineering. It will contribute to checking the excess waste on the foreign scarce resources spent on the importation of heat treatment and crucible furnaces. Growing our technology is very important to promoting us into global recognition as producers instead of our unfortunate consuming nature which our nation is known for. The developed furnace has volume and height of 0.037m 3 and 0.188m respectively. It worked well when tested for about five hours.. It had an efficiency of 91.3% Keywords: Furnace, Design, heat treatment, foundry and Anthill DOI: 10.7176/ISDE/13-1-03 Publication date: March 31 st 2023

Development of an Electric Furnace for Heat Treatment of Vermiculite with Firing Module Curved Surfaces

Development of an Electric Furnace for Heat Treatment of Vermiculite with Firing Module Curved Surfaces

Heating Rate Control in Electric Furnace with SSR and K-Type Thermocouple Using Arduino Uno Atmega 328P

Electric furnace is a tool that can be used to melt, heat, and change the physical shape of a substance. Electric furnaces sold in the market are still relatively expensive, therefore it is necessary to make an electric furnace at a low cost. This research designed an electric furnace using a K-type thermocouple sensor as a temperature reader and SSR relay as an ON/OFF heater  control .  Keypad serves to enter the temperature value in the heating furnace. The heating element used is 1 mm in diameter and 1.86 ohm resistance with a load of 21 Ampere, capable of heating a C1 type refractory brick furnace that has been tested to a temperature of 1000 OC. The results of temperature reading sensitivity tests against the type-K thermocouple sensor get a coefficient value of 0.99893, this indicates that the thermocouple sensor is worth using. From the electric furnace test thermocouple sensor has an average accuracy rate of 92.07%, as well as errors worth 7.93%. While there is a precision value of 98.786% which shows the system works optimally.

Pelatihan Perancangan dan Pengaplikasian Alat INTENSOR

Technological developments have a role in the competition for metal processing in the home industry, namely the development of metal heating devices. However, the home industry needs to consider environmentally friendly metal heaters. One of the environmentally friendly metal heaters is an induction heater. Induction heater has a metal heating technique by utilizing electromagnetic induction which is more efficient than using a conventional metal heating furnace. Induction heaters have advantages in terms of easier use, efficient in terms of energy, time and temperature regulation. Induction heating is a metal heating technique by utilizing electromagnetic induction from high frequency AC waves, which is more efficient than using conventional metal heating furnaces. This problem is the basis for holding training on the design and application of the INTENSOR tool. This community service activity has had quite a good impact in: 1) increasing the knowledge and skills of metal processing business actors in designing INTENSOR tools; 2) increase the knowledge of metal processing business actors in making and applying INTENSOR tools. Community service activities are carried out for 6 months and are intended for metal processing business actors.

Mismatch problem of the model and topology of oil pumping facilities

The mismatch of the model and the topology of real objects is important in modeling technological processes, which is the purpose of this paper. The problem is considered when modeling hot oil pumping in the "Kasymov–Bolshoy Chagan" oil pipeline. In this problem, the topology of objects consists of the linear part of the pipeline and technological equipment (pumps and heating furnaces) of the stations. The accuracy of the simulation results is determined by the calculations of pressure and temperature in the oil pipeline. The pressure in the pipeline is created by pumps at the stations and is determined by the dependence of the pressure and efficiency of the pump on the oil flow rate. These characteristics change depending on the service life of the pump. The identification of the actual dependences of the pressure and efficiency of the pump on the oil flow rate was carried out by the regression analysis of experimental data. The pressure in the linear part is determined by the hydraulic resistance of the pipeline. The actual dependence of the hydraulic resistance coefficient on the Reynolds number and wall roughness was obtained by regression analysis of experimental data. The temperature in the oil pipeline is created at the stations by heating furnaces. The identification of the actual characteristics of the heating furnace was also found by regression analysis of the experimental data. The temperature distribution in the linear part is determined by the heat transfer of oil with the surrounding environment. An undefined parameter for calculating heat transfer is the soil thermal conductivity, which depends on the type of rock and the degree of soil moisture. The soil thermal conductivity is determined in such a way that at a given oil flow rate, oil temperatures at the beginning of the section and soil at the section, the calculated oil temperature at the end of the section has the smallest discrepancy with the actual one. Thus, the determination of the actual dependencies of the objects makes it possible to increase the accuracy of the results of hot pumping modeling and eliminates the mismatches of the model and the topology of the objects.

Droplet evaporation characteristics of hydrogenated biodiesel-ethanol-diesel ternary fuel

ABSTRACT A multi-component blend of highly volatile ethanol with low volatile hydrogenated biodiesel and diesel is the subject of study. The internal vapor bubble dynamics and evaporation characteristics of individual droplets at high temperatures were investigated. The evaporation characteristics of droplet normalized square diameter and droplet lifetime of the blends of hydrogenated biodiesel, ethanol, and diesel were captured by means of the hanging droplet method and high-speed microscopic imaging in a constant temperature heating furnace. It is revealed that the rise in ambient temperature contributes to increasing the evaporation rate of fuel droplets and intensifies the micro explosion during evaporation and shortens the evaporation of droplets to a certain extent; Compared to diesel, the inhibition effect of evaporation is stronger with the increase of hydrogenated biodiesel in binary fuels and compared with binary fuels, ethanol in ternary fuels promotes micro explosions and shortens droplet evaporation; The droplet evaporation of binary fuels shows three typical phases of ethanol domination, ethanol, and diesel co-domination and co-evaporation of all three in sequence.

Changes in the structure and properties of the thick sheets of bainitic/martensitic steel at a cross-section

To expand the grade of rolled low-carbon low-alloy steels chrome-nickel-molybdenum composition. The analysis of changes the mechanical properties and structure in the thickness of rolled sheets of 15, 50 and 60 mm produced using quenching with furnace heating and high tempering was performed.

Study on the Exergy Transfer Characteristics of the Heat Transfer Process of the Tube Heating Furnace

Abstract Aiming to describe the heat transfer process of tubular heating furnace from the angle of energy quality, an exergy transfer model of tubular heating furnace was established to evaluate the energy consumption level of heat furnace. The model is based on the 1-N heat exchange chain theory, innovatively combined with the transfer evaluation index. The temperature distribution in the furnace chamber is calculated by the mathematical model of the zonal method, and then the reduction rate of the heat transfer density and the resistance rate of the heat transfer are calculated. The results show that the exergy potential of the radiant furnace tubes during the heat transfer of the heat furnace is large, and the influences of both the blackness of the furnace wall and the coefficient of convective heat transfer of the exergy transfer of the radiant furnace tubes under steady-state conditions are discussed in detail. With the increase in the blackness of the furnace wall, the exergy density of the flue gas side of the pipe wall increases significantly. With the decrease in the coefficient of convective heat transfer, the exergy density of the working medium side of the tube wall decreases significantly. The energy efficiency of the heat furnace can be improved by adjusting the two parameters in engineering.

An insight into dynamic properties of SAC305 lead-free solder under high strain rates and high temperatures

The development of high density and high integration of electronic chips puts forward stricter requirements on electronic packaging structures. Under the premise of lead-free rules, Sn-3.0Ag-0.5Cu (SAC305) has developed into a competitive solder material. However, the reliability of its mechanical properties has been attracting much attentions especially under extreme conditions. In this paper, the high-strain rate experiments are performed by a split-Hopkinson pressure bar (SHPB) to realize different plastic strain rate, while the high temperature environment is achieved by incorporating a heating furnace. By combining these two devices, the dynamic responses of solder specimens can be measured in the strain rate range from 833 s−1 to 1961 s−1 and the temperature conditions of 70 °C and 120 °C. It is worth noting that as a typical strain-rate hardening process, the maximum stress undergoes an initial ascending stage as the applied strain rate increases. Nevertheless, the hardening process is followed by a descending stage to indicate a softening process of maximum stress due to a further temperature increase during the rapid material deformation at higher strain rates. To gain a further insight into this maximum stress transition, the microstructure characterizations of the impacted solder specimens are carried out by a scanning electron microscope (SEM). It is found that the β-Sn phases and eutectic phases appear to experience refinement and then coarsen as the plastic strain rate continues to increase. A finite element (FE) model is created in the commercial nonlinear FE software ABAQUS/Explicit by considering all the experimental details. Since none of the existing material models in the material library is available for such a maximum stress transition with different ranges of strain rate, the mechanical properties of solder material are emphasized by proposing an improved Johnson-Cook model which can be readily utilized in the numerical evaluations of packaging structures under extremely high strain-rate conditions.

Heat Transfer Analysis Using Thermofluid Network Models for Industrial Biomass and Utility Scale Coal-Fired Boilers

Integrated whole-boiler process models are useful in the design of biomass and coal-fired boilers, and they can also be used to analyse different scenarios such as low load operation and alternate fuel firing. Whereas CFD models are typically applied to analyse the detail heat transfer phenomena in furnaces, analysis of the integrated whole-boiler performance requires one-dimensional thermofluid network models. These incorporate zero-dimensional furnace models combined with the solution of the fundamental mass, energy, and momentum balance equations for the different heat exchangers and fluid streams. This approach is not new, and there is a large amount of information available in textbooks and technical papers. However, the information is fragmented and incomplete and therefore difficult to follow and apply. The aim of this review paper is therefore to: (i) provide a review of recent literature to show how the different approaches to boiler modelling have been applied; (ii) to provide a review and clear description of the thermofluid network modelling methodology, including the simplifying assumptions and its implications; and (iii) to demonstrate the methodology by applying it to two case study boilers with different geometries, firing systems and fuels at various loads, and comparing the results to site measurements, which highlight important aspects of the methodology. The model results compare well with values obtained from site measurements and detail CFD models for full load and part load operation. The results show the importance of utilising the high particle load model for the effective emissivity and absorptivity of the flue gas and particle suspension rather than the standard model, especially in the case of a high ash fuel. It also shows that the projected method provides better results than the direct method for the furnace water wall heat transfer.

Infrared thermography method to detect cracking of nuclear fuels in real-time

The efficiency and performance of nuclear fuels are essential to the safety, reliability, and economics of nuclear energy. Crack formation occurs relatively early in the fuel operation cycle and lowers its life and efficiency; accordingly, understanding crack formation and propagation in fuels is key to evaluating and improving fuel performance. The harsh environment inside a nuclear reactor is the primary challenge for real-time fuel monitoring. A coherent fiber optic bundle (CFOB) based infrared thermography (IRT) method may be a viable method for real-time fuel monitoring. A radiation hardened, temperature resistant CFOB can be used to transmit a real-time image from inside the harsh reactor environment to the near infrared (NIR) camera outside the reactor. In this paper, the feasibility of the method was tested and confirmed on oxide nuclear fuel surrogates in a laboratory setting. Two different fuel surrogate materials are showcased with and without the CFOB using furnace heating, laser heating, and reflected illumination from an incandescent bulb. The behavior of common features, such as cracks, mounds and pits, were all compared in detail for the different heating/illumination techniques and samples for temperatures ranging from 23–500°C. The effects of five different image processing techniques were also studied. Cracks down to ≈300nm wide with a field of view of ≈6.4×5.12mm were easily detected with the IRT system with and without the CFOB.

Effect of multi-pass cooling compression and subsequent heat treatment on microstructural and mechanical evolution of TC4 alloys

Three passes of hot compression tests of hot isostatic pressed Ti-6Al-4V alloys are carried out on a Gleeble-1500D thermo-mechanical simulator with a temperature-drop of 950–900-850 °C, constant strain rate of 0.01∼1 s−1, and the height reduction from 20% to 70%. Then, the subsequent solution and aging treatments are conducted on a heat treatment furnace. The corresponding results of microstructures and mechanical properties show: In the process of multi-pass deformation, dynamic recrystallization with spheroidization of lamellar α phases are the main characteristics affecting flow behaviors. With the increasing strain, lamellar α phases gradually transform from a bimodal distribution to a single peak state perpendicular to the compression direction. The decreasing length and rising thickness of lamellar α phases in the transformation process facilitate the formation of spheroidized α phases. During the heat treatment, the proportion of spheroidized α phases increases, and the spheroidization phenomenon promotes the reduction of lamellar α phases in length and increment in thickness. Lamellar α phases mainly dominate the contribution of microhardness in the hot compression process, and the equiaxed α phases and β transformation structures are combined to influence the mechanical properties of heat-treated Ti-6Al-4V alloys. Notably, β transformation structures contribute primarily at a higher solution temperature.

Application of microwave in manufacturing technology: A review

In todays world due to wide experimentation of materials and wider application in various field and with introduction of reduced production or manufacturing costs, and processing lead times, newly developed processing technology is what is required with these advantages. The newly developed processing techniques should be such that it should be widely acceptable for all types of materials including metals, non-ferrous metals, non-metals etc. Such processing methods are many but microwave processing is one of the fastest and latest emerging manufacturing technology that has found new application in material joining, casting, heat treatment, cladding, sintering, machining and drilling. In comparison to other conventional processes, microwave processing of materials not only enhances the mechanical properties but also redues the defects and has certain economical advantage in power and time savings. In comparison to conventional processes, microwave processing due to hybrid and selective heating, the parts produced has more uniform, axial, cellular and homogeneous type of structure is obtained. It has found application in not only in food processing industry but wide application has been found in manufacturing industry. Though other processes are available in the industries like electric furnace and ohmic resistance heating but the microwave due to its properties like penetration radiation, controllable electric field distribution, rapid heating, selective heat, self limit reactions with advantage of lower environmental impact has been extensively used for industrial and material processing applications. This work describes the review focusses on technological advancement of microwave processing of materials and their application in manufacturing applications in industries.

Near-infrared normal spectral emissivity of molten Fe-Ni alloys by electromagnetic heating

The spectral emissivity of molten Fe-Ni alloys is especially critical to analysis the performance and quality of alloy. The near-infrared normal spectral emissivity of molten Fe-Ni alloys was measured at 1000–1600 nm in the temperature range of 1690–1845 K by a self-built measurement apparatus using the electromagnetic heating technology. The measurement apparatus mainly consists of the electromagnetic heating furnace, blackbody, optical fiber spectrometer and colorimetric thermometer. The dependence of near-infrared normal spectral emissivity of Fe-Ni alloys (Ni, Fe10Ni90, Fe30Ni70, Fe50Ni50, Fe70Ni30, Fe90Ni10 and Fe) on wavelength, temperature and composition were systematically investigated. The results show that the emissivity of Fe70Ni30 is higher in the iron-rich area, while the emissivity of Fe30Ni70 is the lowest in the nickel-rich area. Comparison of the measured and simulated results show that the emissivity of molten Fe-Ni alloys is reliable. The emissivity of Fe-Ni alloys provides reliable data for the research of alloys properties.

Development of situation models for duration of production cycles of manufacturing finished rolled products. Message 1

The problems of system analysis and development of a complex set of models necessary for constructing an algorithm for situational (multivariant) estimation of the duration of production of different batches of rolled products in the conditions of a modern automated medium-sized shop (object of study), including rigidly connected production sections with continuous and cyclic technological processes (feeding blanks, heating in method furnaces, rolling, cutting the rolled stock into strips, cooling, trimming the ends of the bundles of rolled stock, cutting to cut lengths, forming and tying bundles of finished rolled products, loading bundles into railway cars). The study of the functioning of the rolling shop was carried out in the following order: the study of technological processes; technical characteristics of the main and auxiliary equipment; analysis of technical and economic indicators; performance of chronometric and monitoring observations of the metal flow, the operation of units and equipment; decomposition of the production process into operations, elements and trace elements; analysis of the influence of the human factor in the organization of production and operational management of processes; analysis of expert assessments of real and possible production situations related to the fulfillment of orders for finished products. The duration of production cycles is proposed to be classified as follows: piece (corresponding to a workpiece, a pack of workpieces, a package of finished rolled products); batch (corresponding to the shipment of products); subsystem and system (related to sections, departments, workshop as a whole); technically possible, normative, planned, predictive and actual. Based on the preliminary development of situational batch models of the duration of production cycles of the departments of the shop, a situational system model of the duration of the production cycle for manufacturing a batch of finished rolled products is determined by selecting the models of the unit with the maximum cycle duration. To bring the duration of the production cycles of subsystems and the system as a whole into a comparable form, the quantitative characteristics of rolled products batches are determined. Mathematical models of the duration of the production cycle of the warehouse of blanks are built; technological line. The clock models of work of the warehouse of blanks, the production line, the warehouse of finished products have been formed.

Effect of peripheral nonuniform distribution of furnace heat flux on thermo-hydraulic characteristics and design of riser downcomer circuit of natural circulation boiler

The usual practice of design of riser tubes of natural circulation boilers is with an assumption of uniform furnace heat flux. Using the uniform diameter of riser tubes inside the furnace zone is also very common. The effect of peripheral nonuniform distribution of furnace heat flux on thermo-hydraulic characteristics and design of the riser downcomer circuit of a natural circulation boiler is presented here for the first time. As the riser tubes are exposed under substantially high heat flux, the tubes containing water-steam mixture are vulnerable and susceptible to overheating, particularly at high flux zone. From systematic analysis, it is proposed that using different diameters and the number of riser tubes at various sections can overcome the early occurrence of tube dry-out. An appropriate two-phase flow model is developed with flow regime mapping, tube wall temperature calculation, and identification of possible dry-out. The peripheral nonuniform distribution of furnace heat flux is implemented analytically in the model by introducing a distribution parameter estimated from the actual furnace data. Results reveal that with an average heat flux of 150 kW/m2, the dry-out occurs near a riser tube height of 44 m for a typical 210 MW capacity boiler. However, considering the nonuniform heat flux variation, the dry-out appears near a height of 32 m and 73 m for higher and lower heat flux zone, respectively. The present analysis shows that the implementation of larger size and lower size diameter of riser tubes, respectively, in higher and lower heat flux regions has a 9.45 % cost-benefit compared to the usual design practice with a consideration of uniform diameter tube and heat flux. The present work concludes that instead of using uniform tube diameter with average heat flux assumption, the use of different diameter of tubes in different heat flux zone not only avoid the early onset of possible dry-out but also has a cost-benefit.

EVALUATION OF FURNACE-02 EFFICIENCY USING THE HEAT LOSS METHOD IN REFINERY UNITS AT PUSAT PENGEMBANGAN SUMBER DAYA MANUSIA MINYAK DAN GAS BUMI CEPU - JAVA

The production or processing of crude oil at PPSDM Migas Cepu using an atmospheric distillation system, which is a method of separating petroleum fractions based on differences in the boiling points of each fraction under atmospheric conditions. Oil processing at PPSDM Migas Cepu first raises the temperature by using a Heat Exchanger and Furnace to obtain the desired feed temperature or temperature. Furnace is heating equipment for processing petroleum which requires the largest operational costs in its processing business. Furnace-02 at the Refinery Unit at PPSDM Migas Cepu is more than 100 years old, and is still operating today. In petroleum processing, the furnace is very important because the furnace is a heat exchanger, which functions to raise the temperature of the petroleum before it is separated in the fractionation column. This study aims to evaluate the efficiency value of furnace-02 from calculations using the heat loss method. Furnace efficiency calculations must be carried out periodically in order to determine furnace performance so as to avoid long-term damage that can lead to maintenance. If the feed that enters the furnace is not in accordance with the specifications, it can burden the furnace's performance. From the results of calculations using the heat loss method, the performance of the furnace-02 at PPSDM Migas Cepu is 86.16%.