Exergy-based Analysis and Efficiency Evaluation for an Aluminium Melting Furnace

Abstract : The efficiency of a natural gas-fired aluminium melting furnace in a caster plant is examined using energy and exergy methods, to improve understanding of the burner system in the furnace and so that potential improvements can be identified. Such improvements not only reduce fuel consumtion, but also mitigate environmental emissions and impacts such as climate change. In this study, the energy efficiency of the Aluminum melting furnace obtained 10% and its exergy efficiency 6%. The results confirm that exergy analysis can be used beneficially to analyze and improve the furnace efficiency and that exergy efficiency is a more practical measure in reality. The insights gained through the assessments into the melting furnace are described and potential improvements indicated are discussed. By reviewing of results, It was suggested the solutions to optimize energy consumption include adding regenerative burners and regenerators, preheating ingots, using compressed natural gas, reclaiming heat from cooling water, and replacing combustion air. It is anticipated that the results will be of interest and benefit to designers of new and retrofit systems.