With the continuous rise of energy costs and increasingly stringent environmental protection requirements, energy monitoring and energy-saving and consumption-reducing measures in heating furnace customization are becoming more and more critical.
First of all, the construction of the energy monitoring system is the foundation. By installing temperature sensors, pressure sensors, flow meters and other equipment at key parts of the heating furnace, real-time data such as temperature distribution in the furnace, gas or electricity consumption flow, and pressure changes in the furnace are collected. These data are transmitted to the central control system, and after processing and analysis, the energy usage of the heating furnace can be intuitively presented. For example, energy consumption curves for different time periods can be drawn to clearly reflect the peak and trough of energy consumption of the heating furnace in each production link, providing an accurate basis for the formulation of subsequent energy-saving measures.
Secondly, optimizing the thermal insulation design of the heating furnace can effectively reduce heat loss. Use high-quality thermal insulation materials, such as ceramic fiber wool, rock wool board, etc., to wrap the furnace body. An efficient thermal insulation layer is formed between the furnace and the furnace shell to reduce the heat dissipation to the surrounding environment. For parts such as the furnace door and observation port, special sealing and thermal insulation structures are used to prevent heat leakage. Taking an industrial heating furnace as an example, a good insulation design can reduce heat loss by 20% - 30%, significantly improving energy efficiency.
Furthermore, reasonable layout and power control of heating elements are important means of energy saving. According to the shape of the furnace, the characteristics of the heated object and the process requirements, the distribution position of the heating elements is carefully designed to ensure uniform heat transfer and avoid energy waste caused by local overheating or overcooling. At the same time, an intelligent power adjustment device is used to adjust the heating power in real time according to the temperature feedback in the furnace. Sufficient power is quickly provided during the heating stage, and the power is automatically reduced to maintain a stable temperature during the insulation stage, achieving accurate energy supply matching.
In addition, waste heat recovery is an energy-saving method that cannot be ignored. Install a waste heat recovery device, such as a heat exchanger, to transfer the heat in the discharged high-temperature exhaust gas to the combustion air or other media that need to be preheated. This not only reduces the exhaust gas emission temperature, but also reduces the heating furnace's demand for fresh energy. For example, the combustion air can be preheated to 200-300℃, which can effectively improve the combustion efficiency of the fuel and save 10%-15% of fuel consumption.
Then, improving the combustion system of the heating furnace can improve the energy utilization rate. For gas heating furnace, optimize the design of the burner so that it can achieve full and efficient combustion. Use advanced combustion control technologies, such as proportional regulation combustion and premixed combustion, to accurately control the ratio of gas and air, ensure complete combustion, reduce the emission of incomplete combustion products, and reduce energy consumption.
Finally, strengthening the training and management of operators is also crucial to energy conservation and consumption reduction. Operators should be familiar with the operating procedures and energy-saving points of the heating furnace, arrange production tasks reasonably, avoid unnecessary empty furnace operation and frequent heating and cooling operations. By formulating a complete operating specification and assessment system, operators are encouraged to actively take energy-saving measures, ensure the efficient operation of the heating furnace from the human factor, and achieve sustainable use of energy and effective control of costs.
