D. Bratcher, Super Systems Inc., Cincinnati, OH
There are numerous concerns related to the increasing costs in industry today. With globalization of manufacturing creating a hyper-competitive environment and with increasing costs from labor to energy, every process is being reviewed for potential efficiency improvements. As oil, gas and electric prices escalate, thermal process efficiency becomes more critical. Environmental concerns are compounding the effects of these inefficiencies. Optimizing operational efficiency, minimizing production costs and maximizing utilization, is a competitive advantage in good economic conditions. In leaner times, it is a basic necessity. Periodic checking and resetting of air-fuel ratios using modern sensors and technology is one of the simplest ways to get maximum efficiency out of fuel-fired process heating equipment. In heat treatment facilities, the customer would find potential efficiency improvements on generators, radiant tubes, furnaces, ovens, heaters, and boilers. The two main areas where heat treatment facilities benefit from combustion optimization are fuel savings and throughput improvements. Combustion optimization will be reviewed first. Next, the impact these improvements have on throughput and utilization will be explored.
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