CO2 Reduction Tips
There are various methods for CO2 reduction, ranging from simple introduction and modifications to existing furnaces to large-scale furnace renewals. Please feel free to contact us for the best solution for your needs by utilizing our know-how as a top teir innovative industrial furnace manufacturer.
- What are next-generation fuels that do not emit CO2?
- What is an industrial furnace heated by electricity?
- How do you use fuel efficiently?
- Energy saving by controlling the furnace pressure!
- What are the different types of waste heat recovery methods?
- What is direct use of exhaust gas?
- Power saving by inverter control of blower!
- Is cooling water necessary?
- Energy saving by improving thermal insulation!
- Energy saving & space saving by reviewing the process!
What are next-generation fuels that do not emit CO2?
Ammonia (NH3) and hydrogen (H2) do not contain carbon (C), so they are attracting attention as next-generation fuels, which do not produce CO2 when burned.
We are participating in the Green Innovation Fund Project*, which plays a major role in the government’s goal of becoming carbon neutral by 2050, and are conducting research on low NOx combustion technology for ammonia and hydrogen and its effects on heated metals and refractory materials. We have also set up an experimental hydrogen combustion furnace in our own plant to conduct basic research on the combustion characteristics.
(※)Details are available from the “Topics” page.
Related Information
What is an industrial furnace heated by electricity?
We have experience and installation references in delivering all-electric or hybrid (combined use of electricity and gas) equipment in the fields of aluminum, steel, galvanizing/plating, etc., instead of conventional gas-fueled equipment. The following table is an example. Please contact us in regards to electrification of facilities other than those listed above.
| Aluminum | All-electric Aluminum Melting and Holding Furnace (S-MIC)* World’s first Hybrid type rapid melting furnace (Hybrid Melter), etc. |
|---|---|
| Steel | Mobile furnace body type heat treatment furnaces, two-part vertical heat treatment furnaces, etc. |
| Galvanizing/Plating | Ceramic bath furnaces（CERARO), etc. |
We also offer high output immersion heaters (SA heaters) that can be used as auxiliary heat sources for aluminum holding furnaces, galvanizing furnaces, etc.
Related Information
How do you use fuel efficiently?
Combustion requires air (oxygen), and insufficient air results in incomplete combustion and too much air requires extra energy to heat the excess air. In other words, combustion efficiency can be improved by properly controlling the air/gas ratio during combustion.
Conventionally, multiple burners are controlled by an equalization valve in a single loop, but equalization valve control has a limited combustion range with a stable air ratio. Therefore, we have adopted an individual burner flow control system to maintain a constant efficient air ratio over the entire combustion range.
In addition, for facilities using regenerative burners, we propose the “Individual Combustion Control by Integral Precision Flow Control System” (patented), which can control the air ratio more precisely using the totalized combustion data (patented ICC System).
This system is compatible with all combustion furnaces and can be installed in existing furnaces.
Energy saving by controlling the furnace pressure!
The pressure inside the furnace changes according to the furnace temperature and combustion control. When the furnace pressure is low, outside air is sucked into the furnace, and when the furnace pressure is high, the hot furnace atmosphere is released out of the furnace through the gap (seal), which increases fuel consumption in both cases.
In other words, optimal control of the furnace pressure reduces fuel consumption.
We recommend control by dampers, which are relatively an easy way to save energy.
What are the different types of waste heat recovery methods?
There are various types of waste heat recovery methods that use waste heat for efficient heating, each with different temperature ranges and energy-saving effects.
Regenerative System
Normally, two burners with a built-in heat exchangers are used as a set, alternating between combustion and exhaust for short periods of time. While one burner is burning, the other burner flues the hot exhaust gases through the heat exchanger to store heat in the heat exchanger. Conversely, when that burner is burning, combustion air is preheated by passing it through the high-temperature heat exchanger.
Example: Regenerative burner, Self-regenerative burner, etc.
Recuperator System
Exhaust gases from equipment are passed through a heat exchanger to exchange heat with combustion air.
Examples: Centralized recuperator (concentrating furnace exhaust heat in one place) + hot air burner, self heat recovery type (= recu-burner: burner with built-in recuperator)
What is direct use of exhaust gas?
Thermal energy contained in exhaust gases emitted from a facilities/furnaces can be effectively used to preheat combustion air or for other heating processes.
In the T6 (solution annealing/aging) heat treatment furnace for aluminum products, we have developed a system (patented) to reuse exhaust gas from the solution furnace as a heat source for the aging furnace, and have achieved energy savings of 60,000 kWh per year.
Power saving by inverter control of blower!
Conventionally, the amount of combustion air is controlled by a damper without changing the blower speed, but we propose to install a pressure transmitter in the air piping of the burner to control the blower motor by an inverter and only supply the necessary amount combustion air at an optimum speed.
This reduces the power consumption of the blower.
Is cooling water necessary?
In the past, equipment with furnace temperatures of 1200°C or higher required water cooling to prevent heat distortion of “furnace body hardware (frontage),” “furnace interior partition wall hardware,” and “furnace interior rollers”.
We propose to eliminate this need and reduce the total heat loss due to water cooling by adopting highly heat-insulating refractory materials and increasing the heat tolorances various parts’ materials.
Energy saving by improving thermal insulation!
In order to reduce the amount of heat dissipated from the furnace walls, we propose to improve thermal insulation by reviewing the refractory composition and adopting heat-insulating plates and paints.
As shown in the left figure, there is a case in which the furnace wall surface temperature was reduced from 84°C to 41°C by revising the refractory material composition.
Energy saving & space saving by reviewing the process!
Significant energy and space savings can be achieved by reviewing the process itself.
In the re-melting process of aluminum chips generated in the manufacturing process of aluminum products, we have converted the chips into briquettes and revised the structure of the melting furnace in order that drying and melting can be performed at the same time (patented). This has resulted in a 75% improvement in fuel consumption rate and a 60% reduction in facility space.