Case Study on Round-Top Fire Rates

Abstract

Energy makes up a major portion of the controllable costs involved in melting aluminum. While technology such as regenerative burners and multi-chamber furnaces improve energy efficiency, these technologies are expensive and difficult to cost justify given current U.S. natural gas prices. Low cost methods to improve energy efficiency without high capital outlays include process optimization, better maintenance, and furnace settings. The burners on many furnaces are over-fired and poorly controlled. This case study shows the results from a trial made with different fire rates and control schemes on a round-top aluminum melting furnace.