Minimum thickness for a composite furnace wall

The wall of a furnace comprises three layers as shown in the figure. The
first layer is refractory (whose maximum allowable temperature is 1400oC)
while the second layer is insulation (whose maximum allowable
temperature is 1093oC). The third layer is a plate of 6.35 mm thickness of
steel [thermal conductivity = 45 W/(m K)]. Assume the layers to be in very
good thermal contact.

Figure. Layers in a composite furnace wall.

The temperature T0 on the inside of the refractory is 1370oC, while the

temperature T3 on the outside of the steel plate is 37.8oC. The heat loss
through the furnace wall is expected to be 15800 W/m2. Determine the
thickness of refractory and insulation that results in the minimum total
thickness of the wall.

Given thermal conductivities in W/(m K):

Layer k at 37.8oC k at 1093oC

Refractory 3.12 6.23
Insulation 1.56 3.12

Solution.
Click here for stepwise solution

Step. Thermal resistance representation for composite furnace wall

In general, the heat flow is given by Q = T/Rth and the thermal resistance

for a rectangular slab is Rth = x/(kA), where T is the temperature driving
force (thermal potential difference), x is the slab thickness, k is the
thermal conductivity, and A is the cross-sectional area of the slab.

The thermal resistances for the three layers are in series as shown in the
figure below.

Figure. Thermal resistance representation of composite furnace wall.

Based on the thermal resistance representation for the composite furnace

wall, the heat flux q is

(1)

In the refractory and insulation, the thermal conductivity k varies with

temperature. If a linear variation is assumed, then the arithmetic mean is to
be used for the thermal conductivity.

Step. Temperature at insulation - steel interface

The temperature T2 at the interface between the insulation and steel layers
is given by

(2)

The above expression can be used to calculate temperature T2 (as done

later).

Step. Thickness of refractory and insulation

The thickness of the refractory (x1 - x0) and insulation (x2 - x1) are

(3)

On adding the above two equations, we get

 (4)

Since q, T0 and T2 are known in the above expression, the first two terms

on the right-hand side are nearly fixed. The last term is negative as k12 is
less than k01 (i.e., thermal conductivity of insulation is less than that of
refractory). Since the aim is to minimize (x2 - x0), the temperature T1 must
be maximized.

Step. Substitution of numerical values

The temperature at the insulation - steel interface is

(5)

Next, the temperature T1 is set to 1093oC (i.e., the maximum allowable

temperature for the insulation). By linear extrapolation, the thermal
conductivity of the refractory at 1370oC is 7.05 W/(m K). Substitution of
numerical values gives the thickness of refractory as

(6)

and the thickness of insulation as

(7)

he wall of a furnace comprises three layers as shown in the figure. The first
layer is refractory (whose maximum allowable temperature is 1400oC) while
the second layer is insulation (whose maximum allowable temperature is
1093oC). The third layer is a plate of 6.35 mm thickness of steel [thermal
conductivity = 45 W/(m K)]. Assume the layers to be in very good thermal
contact.
 Figure. Layers in a composite furnace wall.

The temperature T0 on the inside of the refractory is 1370oC, while the

temperature T3 on the outside of the steel plate is 37.8oC. The heat loss
through the furnace wall is expected to be 15800 W/m2. Determine the
thickness of refractory and insulation that results in the minimum total
thickness of the wall.

Given thermal conductivities in W/(m K):

Layer k at 37.8oC k at 1093oC

Refractory 3.12 6.23
Insulation 1.56 3.12

Solution.
Click here for stepwise solution

Step. Thermal resistance representation for composite furnace wall

In general, the heat flow is given by Q = T/Rth and the thermal resistance

for a rectangular slab is Rth = x/(kA), where T is the temperature driving
force (thermal potential difference), x is the slab thickness, k is the
thermal conductivity, and A is the cross-sectional area of the slab.

The thermal resistances for the three layers are in series as shown in the
figure below.

Figure. Thermal resistance representation of composite furnace wall.

Based on the thermal resistance representation for the composite furnace

wall, the heat flux q is
 (1)

In the refractory and insulation, the thermal conductivity k varies with

temperature. If a linear variation is assumed, then the arithmetic mean is to
be used for the thermal conductivity.

Step. Temperature at insulation - steel interface

The temperature T2 at the interface between the insulation and steel layers
is given by

(2)

The above expression can be used to calculate temperature T2 (as done

later).

Step. Thickness of refractory and insulation

The thickness of the refractory (x1 - x0) and insulation (x2 - x1) are

(3)

On adding the above two equations, we get

(4)

Since q, T0 and T2 are known in the above expression, the first two terms

on the right-hand side are nearly fixed. The last term is negative as k12 is
less than k01 (i.e., thermal conductivity of insulation is less than that of
refractory). Since the aim is to minimize (x2 - x0), the temperature T1 must
be maximized.

Step. Substitution of numerical values

The temperature at the insulation - steel interface is

(5)

Next, the temperature T1 is set to 1093oC (i.e., the maximum allowable

temperature for the insulation). By linear extrapolation, the thermal
conductivity of the refractory at 1370oC is 7.05 W/(m K). Substitution of
numerical values gives the thickness of refractory as

(6)

and the thickness of insulation as

(7)

Heat transfer

The wall of a furnace comprises three layers as shown in the figure. The
first layer is refractory (whose maximum allowable temperature is 1400oC)
while the second layer is insulation (whose maximum allowable
temperature is 1093oC). The third layer is a plate of 6.35 mm thickness of
steel [thermal conductivity = 45 W/(m K)]. Assume the layers to be in very
good thermal contact.

Figure. Layers in a composite furnace wall.

The temperature T0 on the inside of the refractory is 1370oC, while the

temperature T3 on the outside of the steel plate is 37.8oC. The heat loss
through the furnace wall is expected to be 15800 W/m2. Determine the
thickness of refractory and insulation that results in the minimum total
thickness of the wall.

Given thermal conductivities in W/(m K):

Layer k at 37.8oC k at 1093oC

Refractory 3.12 6.23
Insulation 1.56 3.12

Solution.
Click here for stepwise solution

Step. Thermal resistance representation for composite furnace wall

In general, the heat flow is given by Q = T/Rth and the thermal resistance

for a rectangular slab is Rth = x/(kA), where T is the temperature driving
force (thermal potential difference), x is the slab thickness, k is the
thermal conductivity, and A is the cross-sectional area of the slab.

The thermal resistances for the three layers are in series as shown in the
figure below.

Figure. Thermal resistance representation of composite furnace wall.

Based on the thermal resistance representation for the composite furnace

wall, the heat flux q is

(1)

In the refractory and insulation, the thermal conductivity k varies with

temperature. If a linear variation is assumed, then the arithmetic mean is to
be used for the thermal conductivity.

Step. Temperature at insulation - steel interface

The temperature T2 at the interface between the insulation and steel layers
is given by
 (2)

The above expression can be used to calculate temperature T2 (as done

later).

Step. Thickness of refractory and insulation

The thickness of the refractory (x1 - x0) and insulation (x2 - x1) are

(3)

On adding the above two equations, we get

(4)

Since q, T0 and T2 are known in the above expression, the first two terms

on the right-hand side are nearly fixed. The last term is negative as k12 is
less than k01 (i.e., thermal conductivity of insulation is less than that of
refractory). Since the aim is to minimize (x2 - x0), the temperature T1 must
be maximized.

Step. Substitution of numerical values

The temperature at the insulation - steel interface is

(5)

Next, the temperature T1 is set to 1093oC (i.e., the maximum allowable

temperature for the insulation). By linear extrapolation, the thermal
conductivity of the refractory at 1370oC is 7.05 W/(m K). Substitution of
numerical values gives the thickness of refractory as

(6)
and the thickness of insulation as

(7)