Energy Savings for Ovens and Furnaces

Let's continue our discussion on Energy Savings. This time the focus is ovens and furnaces:

In multi-zone oven applications where solvents and solvent levels change depending upon the product produced, LFL/LEL Analyzers are necessary for monitoring in order to stay safe. These analyzers need to be consistent and reliable amongst this constantly changing atmosphere.

So ... is there a way to save money and reduce energy without compromising this safety?

So Many Ways to Save Energy

In a large facility, like the one a specialty chemical company operates, there are often many opportunities for energy savings. Particularly, on the different types of process heating units.

Reduce, Reuse, Recycle

Aluminum is infinitely recyclable, in fact 75% of all aluminum ever produced is still in use today. 

Progressive Energy, Environment and Sustainability Summit: May 29-31

On May 29th - 31st we will be presenting at the FMA Annual Progressive Energy, Environment and Sustainability Summit. This summits target owners, managers and operators of commercial, industrial, and retail facilities so that they may learn and understand how to better achieve and surpass their strategic goals of energy efficiency, usage, cost & environmental footprint reduction within their facilities.

Process Monitoring vs Leak Detection

Sensors that detect leaks spend most of their lives exposed to little or no flammable gas. Only rarely are they needed to detect the leak, and in these moments they are useful if they can indicate the presence of a significant or unusual concentration of flammable gas. The precise concentration of the vapor cloud emanating from the leak is less important than reliable detection that such a leak has occurred.

Monitoring Combustible Gases in Kilns

Firing ceramics that contain organic binders poses a unique safety consideration. When heated, organic binders release combustible vapors. Under some conditions, concentrations may reach flammable or explosive levels during binder burn-out.

LFL Monitoring in Coil Coating Ovens

Coil coating ovens typically operate at high temperatures, with some zones at over 800°F. This temperature range is needed to cure organic polymer coatings to their substrate materials.

What's Damper Control and how can it help my application?

According to NFPA-86, additional Solvent Vapor Analyzers can be installed onto a process to specifically control damper positions. By adding additional LFL Analyzers to safely automate the dampers, the amount of ventilation air needed to maintain a safe LFL level in an oven would be minimized...and what does this mean? You can save money. In fact often times, by automating damper controls on ovens, as much as a 50% reduction in fuel costs can be realized. So the cost of adding solvent vapor analyzers would be quickly recouped.

Being Safe and Responsible

Responsible Care® is the Chemical Industry’s program that enables worldwide chemical companies to achieve high standards of performance and generate great value for their businesses. 

The program pertains to some of these key areas of safety:

Is your Flare Stack Compliant?

The US EPA is targeting improvement of Flare Operation Practices. This includes better control and monitoring of supplemental gas, steam and air for better combustion efficiency, less emissions and reduced operating costs.

For more information read the EPA Article

So what can be done to assure compliance with these requirements? Effectively monitor and control the supplemental gas of the flare.

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