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The Design of a Radiation-Recuperative Heat Exchanger for a 200kg Capacity

Rotary Furnace

Article · January 2006

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AU J.T. 10(2): 101-108 (Oct. 2006)

The Design of a Radiation-Recuperative Heat Exchanger for a

200kg Capacity Rotary Furnace
A.T. Oyelami and S.B. Adejuyigbe*
Engineering Materials Development Institute
Akure, Ondo State, Nigeria

Abstract

The design of a radiation-recuperative heat exchanger for a 200kg capacity

rotary furnace has been undertaken in this study. It was discovered that an appreciable
percentage of the heat input into the furnace is being lost to the surrounding, most
especially through the waste gases produced from the fuel combustion. And also the
coefficient of heat utilization is greatly dependent on the temperature of the waste gases
leaving the furnace.
Therefore, the new design of recuperator, which is a heat exchanger,
incorporated into the rotary furnace is done in such a way that it returns substantial
part of the waste heat back into the furnace. A radiation type recuperator was designed
to achieve this objective. It was established that the design results in 34.78% increase
in the thermal efficiency of the furnace system and also leads to a 44.4% reduction in
the fuel consumption.
Keywords: Heat exchanger, rotary furnace, coefficient of heat utilization, clean
overall heat transfer coefficient, dirty overall heat transfer coefficient.

Introduction
The equipment used for heating can be
broadly termed a ‘furnace’. Because of the
diversity of manufacturing processes and raw
materials used, the types of furnace required
are numerous (Michael and David 1998).
Basically a furnace is a brick-lined chamber,
capable of holding/conveying the material to be
treated, to which heat is applied by one of
various means so as to achieve the required
final results (Krivadin and Markov 1980). In
fuel-fired furnaces, as the name implies, heat is
supplied by combustion of fuel and is
transmitted by a combination of heating
processes. Rotary furnace is a typical example
of a fuel-fired furnace. Rotary furnace is a
traditional method of recycling of aluminum
(Cottrell 1975). These furnaces are one of the
original methods for the production of
aluminum from
* Department of Mechanical Engineering,
Federal University of Technology Akure, Ondo
State, Nigeria
scraps. Today, besides their usage in
processing a wide variety of scraps materials,
from coated strip to used beverage cans and
furnace dross having different composition and
content of aluminum, rotary furnaces now play
a major role in the recycling of cast iron.
(Kazantsev 1997)
In general, fuel costs are a small fraction
of the total manufacturing cost, and in the past,
fuel economy has often been considered
unimportant in the design/manufacturing of a
rotary furnace (EMDI 2005). However, with
increasing costs and decreasing availability of
fuels, there is now a considerable financial and
a strong conservational incentive to watch fuel
economy aspects. Also, quite a large number of
rotary furnaces are found to perform below the
expected capacity, most especially in terms of
thermal efficiency, mainly because of non-
standardization of designs and more often than
not, non-inclusion of a heat exchanger (Stephen
2000). The reason being that the resultant
effect of the various units has a direct impact

101
AU J.T. 10(2): 101-108 (Oct. 2006)
on the flame length of the furnace, which is one
of the most important characteristics of the
furnace, that need to be accurately determined.
It is in this regard, among other reasons, which
this paper focuses on incorporating a radiation-
type recuperative heat exchanger into the
design of a 200kg capacity rotary furnace so as
to reduce considerably the operational/running
cost of the furnace in addition to increasing its
thermal efficiency appreciably.
Recuperative Heat Exchanger
A heat exchanger could be defined as a
device in which energy is transferred from one
fluid to another across a solid surface. (Edward
2000). Any recuperator is a heat exchanger
operating under steady state thermal
conditions, with heat being continuously
transferred, in this case, from cooled waste
gases to heated air through partition walls.
Recuperators ensure a constant temperature of
air preheating and require no reversing means;
this results in a smoother operation of furnaces
and provides greater possibilities for automatic
control. Recuperators have smaller dimensions
and mass than regenerators and their operation
involves no loss of gases to stack (Oyelami and
Ogunkoya 2002). The process of heat transfer
in recuperators comprises three stages:
a. Heat transfer from waste gases to
recuperator walls. This is transferred to the
wall by radiation as well as by convection.
b. Heat transfer by conduction through the
wall. This depends on the thermal state of the
wall and the state of its surface;
c. Heat transfer from the wall to the air being
heated. Heat is transferred from the wall to air
by convection only (Oyelami, et al. 2004)
Design Condition
The conditions to be created in a furnace
should be such that the heat flow to the surface
of material is at its maximum and that it can be
absorbed completely. This can be ensured by
the following measures:
ƒ The temperature difference between the
heating medium and heated surface
102
should be as high as feasible under the
given processed conditions
ƒ The furnace should be supplied with
heat extensively with the maximum
heat utilization within the furnace space
ƒ Gases in the furnace space should be
made to circulate vigorously, mainly
under the action of air fuel jets from
burners
ƒ Fuel should be burned completely and
combustion should occur within the
furnace space where possible
ƒ The design of a pressure conditions in it
should be such as to minimize the
contact of furnace atmosphere with the
surroundings (Dryden 1982)
Determination of the Furnace-Cylinder
Internal Diameter and Lining Thickness
The above-mentioned parameters are two
of the major parameters needed in the design of
the rotary furnace in addition to the flame
length desired (EMDI 2005). These parameters
are necessary to determining the internal
diameter of the recuperator. To effectively
calculate the parameters, it is highly essential
to do an analysis of the heat transfer in the
furnace.
Heat Transfer Analysis In Rotary
Furnace: In analyzing the heat transfer
process, basic assumptions made are:
1. The temperature and radiant
characteristics of the gases are taken to
be constant over the whole furnace
volume
2. The temperature in various points of
metal surface is assumed to be constant;
3. The heat flow transferred from the
gases to furnace lining by convection is
taken to be equal the heat flow given up
by the lining to the surrounding. This
last assumption makes it possible to
regard the lining as adiabatic relative to
the radiant flux falling onto it. (Krivadin
and Markov 1980)
Input Heat:
1. Chemical Heat of fuel combustion
Qch = B Qwl
AU J.T. 10(2): 101-108 (Oct. 2006)

Where Qwl = lower Calorific value of the fuel t = total time taken (h)
used in KJ/kg B = fuel flow rate in kg/h
B = fuel flow rate in kg/h vwg = quantity of the waste gases in
a unit mass of the fuel (m3/kg)
2. Physical Heat of preheated air
twg = temperature of the waste gases
Qph = Bcatanva
(oC)
Where
3. Heat of the chemical incompleteness of
ta = temperature of preheated air (0C)
fuel combustion
ca = specific heat capacity of air at Ta
Qci = B vwg a x 12142
(KJ/m3 0C)
Where a = proportion of unburnt CO in the
n = air excess factor
waste gases ≈ 0.015
va = quantity of air theoretically required
to burn a unit of fuel m3/kg 4. Heat from the mechanical incompleteness
3. Physical Heat of preheated fuel of combustion
Qf = BCfTf Qmi = 0.01 Qch
Where Cf = specific heat capacity of 5. Heat losses by conduction through the
preheated fuel (KJ/kgK) lining
Tf = temperature of preheated fuel (K)
4. Heat of exothermic reactions, which is πK L (r2 + r1 )(T1 − T2 )( L1 + L2 )
Qc =
basically the heat liberated through oxidation r2 − r1
of metal. Assuming the oxidation loss of iron Where KL = thermal conductivity of the lining
is 1% and its heating value is 5652KJ/kg (W/mK)
⇒ Qex =5652 M x 0.01 r2 = junction radius = internal radius of
= 56.52M the shell without the lining (m)
where M = mass of the charges (kg). r1 = internal radius of the shell with the
Total Heat input is lining (m)
Qi = Qch + Qa + Qf + Qex T1 = average temperature in the furnace
Since only the air is preheated (K)
Qi = Qch + Qex + Qa T2 = outside (surface) temperature of
(Oyelami et al 2003) the shell (K)
T0 = room temperature (K)
Output Heat: L1 = length of the shell (m)
L2 = slant length of the conical
1. Useful heat required to heat and melt the frustum (m)
materials:
6. Heat losses by radiation through open
Quh = MCm(Tm – T0) + MLm
doors of the furnace
= M[Cm(Tm – T0) + Lm]
Qr = C0(T1/100)4FФφ
where
Where C0 = emissivity of a black body =
M = mass of the charges (kg/h)
50768 W/m2K4
Cm = specific heat capacity of the
F = surface area of open door (m2)
charges (KJ/kgK)
Ф = diaphragming coefficient ≈ 0.67
Tm = melting point temperature of the
φ = time when the door is open (h)
charges (K)
T0 = initial temperature of the charges (K) 7. Heat lost with the cooling water (steam)
Lm = Specific latent heat of melting of in the furnace
the charges (KJ/kg) Qcw = 0.15(Heat input) = 0.15Qi
2. Heat lost with waste gases 8. Loss of the heat accumulated in the lining
Qwg = Bvwg twg Qha = 0.2Qi
Where
cwg = mean specific heat of waste 9. Unaccounted losses
gases (KJ/m3 0C)

103
AU J.T. 10(2): 101-108 (Oct. 2006)

Qul = 0.2(Qci + Qmi + Qc + Qr + and pressure drop are met. (Robert and Don
Qcw + Qha) 1984)
Let Qu = Qci + Qmi + Qr + Qcw + Qha
⇒ Qul = 0.2(Qu + Qc) Analysis of Stream Compositions: The
analysis is done to obtain not only the
Compressive Strength of the Lining: Let percentage compositions of the combustion
the Compressive strength be σ products (the waste gases), but also to evaluate
δΔt c Ec Δt c Ec some important parameters that are needed for
Then σ= {1 + } the analysis of heat transfer. Those parameters
r2 (r2 − r1 ) (r2 − r1 ) E L
include among others the total quantity of
(Dryden 1982) waste gases formed through combustion of unit
Where mass of fuel and the quantity of air
δ = lining shrinkage allowance (m) theoretically required to burn a unit of fuel.
∆tc = thickness of the cylindrical shell Due to its availability, diesel is chosen as the
without the lining (m) working fuel.
Ec = Young’s modulus of cylinder (Pa) Diesel contains 98.5% C12H26 (1%S,
EL = Young’s modulus of lining (Pa) 0.5%N & O) (Kazantsev 1997) and has a
combustion equation
Manipulation of all the equations gives
C12H26 + 372 O2 → 12CO2 + 13H2O
4δt c E c E L Qc − 0.69πLtK L T1 (12x12+26x1)kg C12H26 + (37/2 x32)kg O2 →
− t c E c + {t c2 E c2 + [EL − EL ( )]}
σ Qc + 0.69πLtK L T 12(12+32)kg CO2 + 13(2+16)kg H2O
r2 =
Q − 0.69πLtK L T1 170kg C12H26 + 592kg O2 →
2[ E L − E L ( c )]
Qc + 0.69πLtK L T 528kg CO2 + 234kg H2O
----------------- (*) (Oyelami et al, 2003) 1kg C12H26 + 592/170 kg O2 →
528/170kg CO2 + 234/170 kg H2O
r1 = ur2 1kg of C12H26 + 3.482kg O2 produces →
lining thickness = ∆tL = r2 – r1 -----(**) 3.106kg CO2 + 1.376kg H2O

(but 1kg of fuel contains 98.5% C12H26)

Recuperator Specific Design Calcu- ⇒ 0.985kg of C12H26 + 3.43kg O2
lations (for a 200 kg Rotary Furnace) produces 3.06kg CO2 + 1.355kg H2O
Amount of O2 needed = 3.43/32 x 22.4 =
The first step taken in the design of the 2.401m3/kg of fuel
recuperator is to determine the process Amount of N2 that accompanies the air
conditions. This includes the analysis of the needed to produce 3.43kg O2 is
fluid (waste gases) compositions, determination 76.8/23.2 x 3.43 = 11.35kg/kg
of the temperatures of operation and the = 11.35/28 x 22.4 = 9.08m3/kg
pressures drop. The second step was to obtain Air needed per unit mass of fuel (va) is
all the required physical properties over the
temperature and pressure ranges of interest. va = 2.401 + 9.08 = 11.481m3/kg
The third stage involved choosing the type of CO2 : 3.06x22.4/44 = 1.558m3/kg
recuperator needed while the fourth and the last H2O : 1.355x22.4/18 = 1.686m3/kg
stage was the real design and re-design
(whenever necessary) to get the necessary Waste gases produced:
dimensions and ensure that the process vwg = 1.558 + 1.686 + 9.08
specifications with respect to both heat transfer = 12.324m3/kg

104
AU J.T. 10(2): 101-108 (Oct. 2006)

at 7000C

Table 1. Volumetric analysis of the combustion products per 100m3 of fuel

Fuel Air, m3 Combustion products, m3
Component Content, O2 N2 Total CO2 SO2 H2O O2 N2 Total
m3

C12H26 98.5 1822.25 1823.75x 1823.75+ 1182 - 1280.5 - 0.25+ 2462.5

3.76 6860.77 6860.77
= 6860.77 = 8684.52 = 6861.02
S 1 1 - 1 - - 1
O2 0.25 - - - - 0.25 0.25
N2 0.25 0.5 - - - - 6861.02
∑ m3 (%) 100 1823.75 6860.77 8684.52 1182 1 1280.5 0.25 6861.02 9324.77
at n = 1 (21.0) (79.0) (100) (12.676) (0.011) (13.732) (0.003) (73.578) (100)

at n = 1.2 100 2188.5 8232.92 10421.42 1182 1 1280.5 365 8233.17 11061.67
(21.0) (79.0) (100) (10.686) (0.009) (11.576) (3.3) (74.429) (100)

Qa cCO2 = 0.127 x 2.1077 = 0.2677 KJ/m3

where = Q lph = 7905× 10 3 J/kg; n = 1.2; ca
B c N 2 = 0.736 x 1.3553 = 0.9975 KJ/m3
(at 4000C) = 1.3302 x 103 J/m3 0C;
c H 2O = 0.137 x 1.6338 = 0.2279 KJ/m3
va = 11.481m3/kg
f
c wg =c= 1.4931 KJ/m3
∑
1 The specific heat capacity of air is
t a = 7905 × 10 3.
1.2 × 1.3302 × 10 3 × 11.481 at 270C
= 431.340C 27 − 0
Thus the final temperature of air t af used for c ain = 1.3009 + (0.3051 − 1.3009) =
100 − 0
the design is 4500C 1.03203KJ/m3 oC
at 4500C
ƒ Calculation of Final Temperature of 450 − 400
Waste Gases Expected from the Recuperator c af = 1.3302 + (1.3440 − 1.3302)
500 − 400
This is done through the analysis of the heat =1.3371KJ/m3 0C
balance in the recuperator. On the assumption 1
that the recuperator is perfectly gas-tight, the Using 1 hrs as the standard cycle period,
2
heat balance is analyzed based on further
from table 1.0
assumption that 10% of the heat supplied is
Vwg =9324.72/1.5 = 6217m3/h
lost to the surroundings.
Va = 8684.52/1.5 = 5790m3/h
0.9Vwg (c wg t wg − c wg
in in f f
t wg ) = Va (c af t af − c ain t ain )
0.9 × 6217(1.5516 × 1050 − 1.4931t wg
f
)
(Krivadin and Markov 1980)
= 5790 (1.3371 × 450 − 1.03203 × 27 )
t in
= 1050 0 C , t af = 450 0 C , t ain = 27 0 C
5595.3(1629.18 – 1.4931 t fwg ) = 3322476.8
wg
o
at 1050 C
1050 − 1000 3322476.8 1
(2.2593 − 2.2266)]t wg = (1629.18 − 5595.3 ) × 1.4931 =
f
cCO2 = 0.127 × [2.2266 +
1100 − 1000
= 0.2849 KJ/m3 oC 693.440C
1050 − 1000
c N 2 = 0.736 × [1.3938 + (1.4056 − 1.3938)] ƒ Average Temperature Difference in the
1100 − 1000 Recuperator
= 1.0302 KJ/m3
1050 − 1000 Using the logarithmic mean
c H 2O = 0.137 × [1.7133 + (1.7397 − 1.7133)]
1100 − 1000 temperature difference (LMTD) approach
= 0.2365 KJ/m3 (Kern 1984)
3
c wg = c = 1.5516 KJ/m
in
∑

105
AU J.T. 10(2): 101-108 (Oct. 2006)

(t wg
in
− t ain ) − (t wg
f
− t af ) Thickness of the lining = 0.1329m =
Δt av = 132.9mm
in
t wg − t ain Inner shell diameter (after lining) =
ln[ ]
f
t wg − t af 582.536-132.9x2 = 316.736mm
(1050 − 27) − (693.44 − 450) The recuperator inner diameter is then
= = 5430 C chosen as 320mm
1050 − 27
ln[ ] Recuperator sprout base diameter =
693.44 − 450 582.536-132.9 = 449.636
The recuperator’s sprout base diameter
Determination of the Basic Design is then chosen as 450mm and its slant length
Parameters as 440mm.
From A = 2πrl = πdl,
A typical radiant recuperator has an A 1.247
l= = = 1.2403m 2
appreciable thermal load of the heating surface πd 3.142 × 0.32
ranging from 250 to 335 MJ/(m2.h) (Alan
1984). Taking the average of the two, the ƒ ANNULUS SPACE
expected thermal load is The equivalent diameter
4 × FlowArea 4π (D02 − Di2 ) D02 − Di2
(250+335)/2 = 292.5MJ/(m2.h) = 292.5 x De = = =
WettedPerimeter 4πDi Di
106/3600 = 81250W/m2
Heat transfer coefficient is the thermal load per Using 44%Di as De
unit temperature. D 2 − Di2
0.44 Di = 0 ,
Therefore, heat transfer of the heating surface Di
is
D0 = 1.44Di = 1.44 × 0.32 = 0.384m = 384mm
ThermalLaod
Kc = in
, Kc = 81250/1050
t wg Determination of the Recuperator’s Wall
2o
= 77.38 W/m C Thickness
This is the clean overall heat transfer
coefficient, which shows that dirt has not been Thickness of the recuperator’s wall is
taken into account. The design overall determined from the equation expressing the
coefficient is the dirty overall coefficient Kd. overall heat transfer coefficient in terms of
1 1 the wall thickness,
= + Rd or
Kd Kc 2π
Kc = W/(m2.0
Kc 1 α 1 r1 + (1 λ ) ln r2 r1 + 1 α 2 r2
Kd = (Orlov 1980)
1 + Rd K c C) (Kern 1984)
For diesel combustion products, Rd = Re-arranging the equation gives
0.00175 m2 0C/W λ λ 2πλ
ln r2 + + − − ln r1 = 0
77.38 α 2 r2 α 1 r1 K c
Kd = = 68.15 W/m2 oC.
1 + 0.00175 × 77.38 r2 = 0.128m satisfies the equation. The
The heating surface covered by the waste thickness of the recuperator is then chosen as
Q 0.003m = 3mm thick.
gases before reaching t wg f
is A =
K d Δt av
From which Increase in Coefficient of Heat
Q 46145.43 Utilization
A= = = 1.247 m 2
K d Δt av 68.15 × 543
There are two forms of coefficient of
The heating surface area is 2πrl.
heat utilization. They are the coefficient of
Using equations (*) and (**), diameter of the
useful heat utilization (ηuhu) and coefficient
cylindrical shell = 0.582536m = 582.536mm
of total heat utilization (ηhu)

106
AU J.T. 10(2): 101-108 (Oct. 2006)

Using fuel consumption rate of 25L/h

25 × 10 −3
(= = 2.395 × 10-3 kg/h)
10.44
Qch = BQ wl = 2.395 × 10 −3 × 44000 × 10 3
=105.38 × 103J/h
Qwg = Bvwg c wg t wg = 2.395 × 10 −3 × 12.324 × 1493.1 × 1050
= 46.27 × 103 J/h
105.38 × 10 3 − 46.27 × 10 3
η hu/ = = 0.5609
105.38 × 10 3
With recuperator incorporation,
Qch + Q ph − Qwg
η hu =
Qch + Q ph
Fig 1(a). Orthographic Views

Qch = BQ wl = 2.395 × 10 −3 × 44000 × 10 3

= 105.38 × 103 J/h
Qwg = Bv wg c wg t wg
= 2.395 × 10 −3 × 12.324 × 1493 .1 × 693.44
= 30.56 × 103 J/h
Q ph = Bc a t a nv a
= 2.395 × 10 −3 × 1337 .15 × 450 × 1.2 × 11.481
=19.86 × 103 J/h

105.38 × 10 3 + 19.86 × 10 3 − 30.56 × 10 3

η hu =
105.38 × 10 3 + 19.86 × 10 3
= 0.7560
The percentage increase in the coefficient of
heat utilization is
η −η /
Fig 1(b): 3D View % Increaseη hu = hu / hu × 100%
η hu
Fig.1. Overall Recuperator-Incorporated Rotary 0.7560 − 0.5609
Furnace = × 100% = 34.78%
0.5609
Source: Oyelami 2006 This signifies a significant
improvement on the thermal efficiency of
Qch + Q ph − Qwg − Qlos the rotary furnace system as a result of the
η uhu =
Qch + Q ph recuperator incorporation.
Qch + Q ph − Qwg
η hu = Reduction in Fuel Consumption
Qch + Q ph
(Krivadin and Markov 1980) Qch + Q ph − Qwg
For the purpose of finding the effect of From η hu =
Qch + Q ph
recuperator incorporation on the coefficient of
heat utilization in the rotary furnace, the 44 × 10 B / + 8.29 × 10 6 B / − 30.56 × 10 3
6
0.5609 =
coefficient of total heat utilization is used. 44 × 10 6 B / + 8.29 × 10 6 B /
Without recuperator incorporation, 52.29 × 10 6 B / − 30.56 × 10 3
Qch − Qwg =
Qph is zero; η hu/ = 52.29 × 10 6 B /
Qch From where

107
 AU J.T. 10(2): 101-108 (Oct. 2006)
30.56 × 10 3
B/ = = 1.331 × 10-3kg/h
22.96 × 10 6
=1.331 × 10-3 × 10.44 × 103 = 13.90litres/h
B − B/
% FuelConsumption Re duction = × 100%
B Kern, D.Q 1984. Process Heat Transfer.
25 − 13.9
= × 100% = 44.4%
25
This also signifies a significant reduction
on the fuel consumption rate of the rotary
furnace system as a result of the recuperator
incorporation, thereby reducing the operational
cost.
Conclusions
Incorporation of recuperative heat
exchanger into the design of a rotary furnace is
very essential. A major reason being that a unit
of physical heat recovered from waste gases
and returned back into the furnace with air is
much more useful than a corresponding unit of
chemical heat produced in the furnace through
combustion of fuel. Advantages of
incorporation of recuperator into the design are
ƒ Appreciable increase in the furnace
thermal efficiency, in this case by
34.78%
ƒ Considerable increase in the
temperature of combustion, by 33.33%
ƒ Significant reduction in the fuel
consumption (by 44.4%) thereby
reducing operating cost and
ƒ Aiding complete combustion.
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