•INTRODUCTION.

•GAS SAVING AREAS

1. Gate Opening and closing
2. Furnace valve control
3. Gate repairing
4. Repairing furnace damage
5. Material build-up inside furnace
6. Controlled charging
7. Flame setting (Air & Gas)
8. Reducing furnace wall temperature
9. Auto Temperature controlling.
•SUGGESTION
1 . Flue Gas Usage.
2. Increase Productivity.
3. Charging Trolley.
4. Furnace Damper.
5. Oxygen Enrichment.
6. Charging from Flue gas exhaust area.
7. Extension in Furnace charging area & using Flue Gas.
•Aluminium melting furnaces are the greatest consumers of natural gas and
they represent over 75% from the total energy consumed in the secondary
aluminium industry.
• For most aluminium melting furnaces their thermal efficiency is around 23%
(26.3%-27.5%).
•Because of its low thermal efficiency extra focus is given on reducing the
losses, main losses are;
 1. GATE OPENING & CLOSING
COUNTER
PICTURE PROBLEM
MEASURE

Two possible
Door remain solutions;
open after 1. Installing a
charging the Siren and
material into Limit Switch.
the furnace or 2. Connecting a
after fluxing. timer with
door hoist.
 2. Flame Valve Control
COUNTER
PICTURE PROBLEM
MEASURE

1. Once adjust
1. After the flame
excessive and take off
charging the valve
operator handle.
increases the 2. Routine
main flame inspection
valve. for flame
condition.
 3. Gate Repairing
COUNTER
PICTURE PROBLEM
MEASURE
1. Should be
properly
fixed to
avoid
1. Improper
leakage.
fixing of
2. Using of
furnace door.
Glass wool
for extra
heat
protection.
 4. Repairing Furnace Damages
COUNTER
PICTURE PROBLEM
MEASURE

1. Weekly
1. There are
maintenance
furnace which plan will be
have broken made and
wall and followed to
leakages prevent this
type of issues.
resulting in
2. Any leakages
extra loss of will be dealt
heat/gas. immediately.
5. Removing of Build up Material inside Furnace.
COUNTER
PICTURE PROBLEM
MEASURE
1. Excessive
1. Periodic
build up
cleaning of
materials on
furnace by
furnace wall
making
prevents
furnace
heating up of
cleaning plan.
aluminium
2. Furnace wall
metal.
should and
2. Extra gas &
must be
time required
straight.
of melting.
 6. Controlled Charging
COUNTER
PICTURE PROBLEM
MEASURE
1. Charging SOP
will be made.
2. Charging will
1. Excessive only be done
material is when
charged temperature is
resulting in at max.
dropping of 3. Charged
Materials will
temperature. not be put
directly into
the furnace.
 7. Flame Setting (Air and Gas)
COUNTER
PICTURE PROBLEM
MEASURE
1. Routine
inspection of
flame colour
1. Flames are prevent extra
not properly burning of gas.
set it must be
roaring blue in
colour.
 8. Reducing Furnace wall Temperature
COUNTER
PICTURE PROBLEM
MEASURE
1. Furnace wall
temperature
should be like
1. Furnace wall you can place
temperature is your hand on
100’C result in it.
extra loss of
heat.
 9. Auto Temperature Controlling
COUNTER
PICTURE PROBLEM
MEASURE
1. Need to
check every
furnace
1. Thermocontroller
issue. daily.
2. Problem in 2. Any
thermocontroller problematic
will make flame
burn excessively. controller
need to
addressed
promptly.
 1. Flue Gas Usage
Recovery of heat contented in flue gases, from the aluminum melting furnace using
radiation and convection pre-heaters, lead to saving energy (natural gas) up to 30%.
The Scientific Bulletin of VALAHIA University MATERIALS and MECHANICS –Vol. 14, No. 11
 1. Flue Gas Usage

Flue Gas Transfer Pipe

Furnace#2 Furnace#1
 2. Increase Productivity
Since so much of the heat loss is relatively fixed, regardless of throughput, factors, it
becomes clear that increasing the throughput or production on any particular furnace
will increase overall unit efficiency --- BTUs or Kilocalories per pound or kilogram. Data
and experience confirm this conclusion.
 2. Increase Productivity
Gas Consumption (m3/Ton)= Gas Used (m3)/ Input Material (Ton)
Assume we are using 300m3 Assume we are using 300m3
gas in a day and charged gas in a day and charged
material is around .850Ton material is around 1.1Ton
= 300/.85cal Now if productivity increases the
input material is also increases
= 352.9 m3/ton
with same amount of gas used.
= 300/1.1Ton
= 272.72 m3/ton
Just for trial we can do the opposite as we know the Standard Production along with
shot weight and part weight we can limit the gas consumption so that we can not
use the gas above that limit.
Assume Product A has an input of around 0.85Ton and we know that we wanted the
gas consumption 280m3/Ton
 2. Increase Productivity
Just for trial we can do the opposite as we know the Standard Production along with
shot weight and part weight we can limit the gas consumption so that we can not
use the gas above that limit.
Assume Product A has an input of around 0.85Ton and we know that we wanted the
gas consumption around 280m3/Ton so now equation becomes;

280 (m3/Ton)= Gas unit (m3)/.85Ton

= 238 m3

So if we can limit the gas unit by placing any regulator we can have the idea how
long it will take to reach the designated gas limit.
 3. Charging Trolley
By introducing a charging trolley and proper SOP for charging the furnace we can also
save the gas consumption, as most of the time material is charged directly into the
furnace resulting in temperature down and consuming extra gas.
*Material should not be charged directly into thee furnace rather it should be placed in
the preheating area in order to save the gas consumption.

•To use it at its full extent it should be connected

with operators table.
•Runner Riser and biscuit should fall into this trolley.
•Size should be small that is can carry just half an
hour production.
•Must have lifting option so that is can directly
charge material inside the furnace.
•Should have an attached pushing rod to transfer the
scrap inside the furnace.
 4. Furnace Damper
Pressure inside the furnace must be kept as close as possible to absolute zero. If there is
negative pressure, cold air will be sucked in and efficiency is reduced. If there is
positive pressure, flame will come out of the doors and other openings, damaging the
structure.
A simple test of furnace pressure is to take a small tissue paper and hold it near a door
edge, and its movement in or out will indicate the pressure.
Pressure control may be made using a damper on the exhaust chimney.
 5. Oxygen Enrichment
•When natural gas is burned, oxygen in the combustion air chemically combines with
hydrogen and carbon in the fuel to form water and carbon dioxide, releasing heat in the
process.
•Air is composed of approximately 21% oxygen, 78% nitrogen, and 1% various other gases.
•During air-fuel combustion, the chemically inert nitrogen dilutes the reactive oxygen and
carries away some of the energy in the hot combustion exhaust gas.
•An increase in oxygen in the combustion air can reduce the energy loss in the exhaust
gases and increase heating system efficiency.
 6. Charging From Flue Gas Exhaust Area
Preheated Material/Scraps requires less heating to melt thus resulting is lower gas
consumption.
If we modify the furnace in such away that there is charging opening from the point
where the flue gas exhaust then we might be able to save gas consumption.

Flue Exhaust Area Charged area

modification such that
scraps slide down from
the flue gas exhaust
area.
 7. Extension in Furnace Preheating Area and
Exhaust Chimney
Another modification can be done to utilize the Flue gas.
By utilizing the flue gas we can heat the ingots/scraps to a point from where it takes less
gas to melt the aluminum completely.
Old Exhaust New Exhaust
Closed Open

Extending
Preheating
Area.
Southern California Gas Company conducted the study and developed a calculator
for six different losses heads.
•Oxygen Enrichment
•Moisture Reduction
•Wall Losses
•Aluminum Charge Preheat
•Steel Charge Preheat.
•Furnace Fixture Replacement

Among these 6 heads 3 can be directly related.

THANKS!!!!