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|Enamel furnaces are typically the single biggest energy
consumer within an industrial porcelain enameling plant, because they
require considerable quantities of gas, oil and/or electricity during both daily
start-up and operation.
The lowest possible energy consumption of an enamel furnace is achieved by :
Specific energy consumption
This specific energy consumption is calculated by dividing the hourly energy consumption by the gross production. Click here to calculate the specific energy consumption of your furnace
The chart below show the relation between the absolute energy consumption, the specific energy consumption and the production. As expected the lowest possible specific energy of any furnace is achieved at maximum loading.
Influence of furnace design on the specific energy consumption.
The impact of the first & second aspect is clearly visible when comparing the specific energy of respectively a box, straight thru and U type furnace. See indicative chart below.
The impact of radiation losses becomes also visible when comparing the specific energy consumption of S-shaped furnaces with "double hooked" or L-shaped furnaces with the same size & productivity. (See chart of various furnace shapes below)
Significant differences in heating-up time & energy consumption due to radiation losses may be observed by removing the "anti-radiation shields" of a proper functioning enameling furnace.
For this reason some companies experimented in the past with movable anti-radiation shields, which were attached to the furnace conveyor.
Warm air are goes up and therefore air leakage is typically found at the furnace roof. Notorious sources for energy losses due to air leakage are deformed shoeplates and/or shoeplates, which are made from the wrong material, and vapour exhaust holes which are too far open.
Ditmer Trading & Consulting BV assist companies worldwide by providing knowledge and independent advice about porcelain enameling technology, plants & equipment.
We also support users of Ferro Holland, Smit Ovens and/or Smit Sinus enameling plants & furnaces by providing practical maintenance advice and/or by sourcing critical spare, wear and tear parts.