Design And Construction Of Dual–Powered Heat Treatment Furnace

Project and Seminar Material for Mechanical Engineering ME

Design And Construction Of Dual–Powered Heat Treatment Furnace


Abstract


This research is centered on the design and construction of dual-power heat treatment furnace using locally sourced materials. The design philosophy is to eliminate the use of heating elements requiring electric power which is poorly supplied in the country. Design drawings were produced and mild steel was used for the fabrication of the furnace casing, while the other components needed for the design were selected based on functionality, durability, cost and local availability. The furnace was assembled by lining the inner wall of the casing with refractory blocks made from heated mixture of kaolin, clay, sawdust and water after which the inner pot and electro technical devices (temperature controller, light indicator etc) were positioned. Testing was subsequently performed to evaluate the performance of the furnace. It was observed that the furnace has a fast heating rate (61.240C/min to attain a pre-set temperature of 9000C); and a fuel consumption rate less than 1.41litres/hr. It was also observed that the furnace has good heat retaining capacity; can be easily maintained and safe for use.


Chapter One


Introduction

1.1 Background of the Study

The modification of microstructures to achieve desired properties is a fundamental approach in metallic materials development. Heat-treatment which is one of the primary routes of developing microstructures requires the use of furnaces to be able to attain desired temperatures, heating and cooling rates; and holding environments required to induce phase transformations (Dossee and Boyer, 1997). Heat treatment furnaces with effective temperature sensing, heat retaining capacity and controlled environment are necessary for heat-treatment operations to be successfully performed. Some of the processes require heating cycles for durations spanning a few minutes to several hours depending of the material and the properties desired (George, 2002; Netsushori, 1998).


1.2 Statement of the Problem

The absence of constant power supply in the country has made it difficult for a wide range of heat-treatment operations to be effectively performed. In the Universities and research institutes this situation has affected research output for many research scholars who are interested in microstructure development through heat-treatment. This challenge is the motivation for this research aimed at the development of a portable heat-treating furnace that relies on diesel to fire and generate the heat needed to raise the temperature of the furnace to the desired level. The elimination of the use of heating elements which requires electric power to function is the fundamental design principle justifying the research work. A good number of research works have been reported on the design of furnaces to meet the needs of the Nigerian scientific and technological environment (Olanrewaju, 2000; Oyawale, 2007).; but very little literature is available on the design of diesel fired heat-treatment furnaces. The design on completion will significantly reduce the dependence on electric muffle furnaces and guarantee uninterrupted experimental heat-treatment research work.


1.3 Purpose of the Study

The aim of this study is to design and construct dual-power heat treatment furnace for the Department of Mechanical Engineering Laboratory, University of Ibadan.


1.4 Significance of the Study

It is believed that at the completion of the study, the findings will be beneficial to oil and gas industry in Nigeria. The study will also be of great benefit to the Department of Mechanical Engineering Laboratory, University of Ibadan as well as other Nigerian universities.

Finally the findings of this study will also be immense benefit to government, academia, scholars, researchers and the general public.


1.4 Scope of the Study

This study is limited to on the design and construction of dual-power heat treatment furnace using locally sourced materials.


1.5 Limitation of the Study

However the research has some limitations which are:

Availability Research Materials:

Materials that the researcher requires for the research work was unavailable for the research work.

Time Factor:

The time scheduled for the completion of this research project was too short. As a result, generating information/data was strenuous as it coincides with final year examination period, which needed attention.

Finance:

This is another barrier that limited the researcher’s work.


Chapter Four


Conclusion and Recommendations

4.1 Introduction

This chapter is basically on the conclusion and recommendations of the study. Heat treatment furnaces with effective temperature sensing, heat retaining capacity and controlled environment are necessary for heat-treatment operations to be successfully performed.


4.2 Conclusion

This research was centered on the design and construct dual-power heat treatment furnace using locally sourced materials. The design philosophy is to eliminate the use of heating elements requiring electric power which is poorly supplied in the country. On completion and testing, it was observed that the furnace has a fast heating rate (61.240C/min to attain a pre-set temperature of 9000C); and very good fuel economy – consuming less than 1.41litres/hr. It was also observed that the furnace has good heat retaining capacity; can be easily maintained and is safe for use.


4.3 Recommendations

Based on the findings of this study, it is recommended that:

  1. Fluctuating power voltage to the burner should be avoided as it can cause damage to the blower motor.
  2. Also, servicing of the blower/pump should be carried out at least twice a year to guarantee optimum performance of the furnace.
  3. The operator should always put on personal protection equipment (safety gadgets) such as hand gloves, heat protectors; and after the days work ensure that beverage rich in milk is taken to compensate for the effects of heat radiation from the furnace.

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Frequently Asked Questions


What is a heat treatment furnace?

Current furnace model During the heating process of heat treatment, the workpieces are heated in the furnace. The mixed fuel gases are fired in the burner, and the cold workpieces, furnace walls, furnace accessories etc. will absorb heat from the hot burner. Furnaces which are equipped with a water cooling system also absorb part of the heat.

What is the best furnace design and operation program?

FurnXpert program is developed to optimize furnace design and operation. The program mainly focuses on the heat balance of the furnace. The load pattern is just aligned load pattern with one layer and it cannot deal with the condition of workpieces loaded in the fixtures.

What is the heat transfer model of a furnace?

Heat transfer model The temperature history of the loaded furnace in the heat treating cycle is a hybrid convection/radiation heat transfer process. According to the heat transfer theory and energy balance equation, the heat exchange of loaded furnace can be mathematically presented in the following model: N i i storage i i T q cp V

What is the process of heat treatment?

During the heating process of heat treatment, the workpieces are heated in the furnace. The mixed fuel gases are fired in the burner, and the cold workpieces, furnace walls, furnace accessories etc. will absorb heat from the hot burner.

Should I get a new heat pump, or a furnace?

Where you live plays a large part in whether or not a heat pump vs. furnace is right for your home. If you live in an area with mild winters, a heat pump is a great option. Southeastern climates are ideal for heat pump use.

What is the most energy efficient furnace brand?

The Better Business Bureau has given Trane a B rating and its customers have reviewed how truly efficient this furnace is. 2 Lennox. The Better Business Bureau has given Lennox an A+ rating and Lennox furnace reviews have given this system 4.5/5 stars. 3 Goodman. … 4 Rheem. … 5 Bryant. …

How do I choose the best furnace?

Find reviewers who live in a home of a similar size and in a similar climate to yours. Reviews can help you understand a furnace’s heat output, how quickly the furnace heats the home and how the furnace performs in various temperatures. Reviews may also provide information about the furnace’s reliability, common problems and typical repair costs.

What is the art of furnace design?

The art of furnace design involves achieving the best combination of these five objectives over the entire life of the furnace, in other words to produce a high quality product at the lowest achievable cost. Although these five objectives may seem self-evident, in our experience they are not always achieved.

What is the best furnace to buy in 2020?

The 5 best furnaces of 2020 1 Trane. The Better Business Bureau has given Trane a B rating and its customers have reviewed how truly efficient this furnace is. 2 Lennox. The Better Business Bureau has given Lennox an A+ rating and Lennox furnace reviews have given this system 4.5/5 stars. 3 Goodman. … 4 Rheem. … 5 Bryant. …

What is the heat transfer model used for?

In particular, the heat transfer model is used to infer the distribution of the latent heat of austenitization by heating boron nitride coated samples in the muffle furnace.

What is heat transfer model of the muffle furnace?

Heat transfer model of the muffle furnace. Additionally, it can also be observed that the temperature at the center of the furnace is approximately 10°C higher than the temperature at the front and back of the furnace. This indicates that there is a noticeable variation in the temperature of the furnace from

What is the initial heat transfer model of blank heating?

The initial heat transfer model was developed for unpatched blanks heated in a muffle furnace according to the experimental setup presented in the previous chapter. The model is based on the following assumptions: (1) radiation and convection are the dominant mode of blank heating, so

What is the heat transfer in a furnace?

The radiative heat transfer of the flame is transferred to to average flame temperature T g. The emissivity equals the radiative emissivity from the flame to the furnace surface a F. Then, the heat transfer between between two parallel infinite planes. According to the heat transfer principle,

What happens during heat treatment?

The temperature at which this happens in a specific metal is known as its Curie temperature. Heat treatment is the process of heating and cooling metals to change their microstructure and to bring out the physical and mechanical characteristics that make metals more desirable. 

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