The Thermo Furnace: Design, Build and Validation
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Date
2014
Authors
Ali Jaber
Mahmoud Abu Al rob
Obaid Atieh
Sanad Obaid
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Abstract
A furnace is equipment used to melt metals for casting or to heat materials to change their shape or properties. Furnace ideally should heat as much of material as possible to a uniform temperature with the least possible fuel and labor.(7)All furnaces have the following components: Refractory chamber constructed of insulating materials to retain heat at high operating temperatures. Hearth to support or carry the steel. Burners that use liquid or gaseous fuels to raise and maintain the temperature in the chamber. Chimneys to remove combustion exhaust gases from the chamber. Charging and discharging doors. Three methods of forming oxide film on metal, electrochemical formation, thermal formation in an electric furnace, and thermal formation by simple heating, were studied as possible means of producing titanium dioxide electrodes. The maximum photocurrents produced by potentiostatically or galvanically formed oxide film electrodes under anodic polarization were 1/10 that of single crystal rutile electrodes, and similar results were obtained using electrodes formed in an electric furnace to which oxygen was supplied. Those produced in a reducing atmosphere produced slightly greater photocurrents. The oxide film layers formed by heating in a gas burner were thicker than those obtained by other methods, and produce anodic photocurrents comparable to those produced by a single crystal rutile electrode. A photocell containing titanium dioxide film anodes was developed on the basis of these results and collected hydrogen at the rate of 6.6l of H2/sq mm of titanium dioxid Insulating materials greatly reduce the heat losses through walls. Insulation is achieved by providing a layer of material with low heat conductivity between the internal hot surface of a furnace and the external surface, thus keeping the temperature of the external surface low. The Insulating materials can be classified into the following groups, such as insulating bricks, insulating, Insulating castables, Ceramic fiber, Calcium silicate, Ceramic coating. The temperature control technology of the thermal reserve zone is examined as a technology which drastically improves reaction efficiency in the blast furnace, and the usage technology of high reactivity coke is proposed. The adaibatic blast furnace simulator which is able to simulate the temperature transition and the gas volume change according to the coke reaction under ore and coke coexistence is developed. Following findings are obtained. The starting temperature of coke reaction corresponds to the temperature of the thermal reserve zone (Ttrz). Ttrz has decreased along with the rise of the coke reactivity. The blast furnace reaction efficiency improves by using high reactivity coke voluminously and by mixing using the small-size high reactivity coke and sinter. The decrease of the fuel ratio of about 25-35 kg/t can be expected by using the high reactivity coke. The factors of reaction efficiency improvement by using the high reactivity coke are shown as follows. Transition of FeO-Fe reduction equilibrium point (W point), that is, decrease of thermal reserve zone temperature, Improvement of the gas reduction ability by the coke reaction, Increase of micro-pore volume according to reduction from wustite to iron, Decrease of melt generation and control of pore decrease by reduction of CW (calcio-wustite), Gas reduction promotion by increase of porosity. A basically new mechanism of the thermal decomposition of solids is proposed to explain the mass spectral observations of gaseous molecules of CoO, CuO, Cu2O, NiO, PbO and Mg(OH)2 during the low-temperature decomposition of the anhydrous and hydrated nitrates of these metals. The mechanism consists of two stages: congruent gasification of all reaction products irrespective of their saturated vapor pressure and subsequent condensation of the low-volatility species (oxides and hydroxides). The partial pressures of these species at the appearance temperatures calculated from this theory for the first stage of the process (150 mPa) are in agreement with the detection limits of the quadrupole mass spectrometers used in these experiments. The proposed mechanism is supported by other available data obtained by thermal analysis. The completion of the project and setting the required parameters for the project, for example; furnace diameter, dimensions and material selection for building up the furnace. In addition, the type of the metal that will be casting. The required calculations necessary related to the suitable material thickness for the insulation for the furnace are calculated. After that the final stage of the furnace was manufacturing at the workshop at An-Najah National University