Question 1

Furnace operations — effect of air infiltration: In industrial furnaces, cold air can infiltrate through cracks, charging doors, peepholes, or other openings. Which combined effect does this unwanted ingress typically produce on furnace operation an…

Accepted Answer

Introduction / Context: Uncontrolled infiltration of cold ambient air into fuel-fired furnaces is a frequent operational problem. Leakage occurs through cracked refractories, poorly sealed charging doors, and expansion joints. Understanding its combined effects helps in energy auditing, combustion tuning, and emissions control. Given Data / Assumptions: Fuel-fired furnace exhausting hot flue gases through a stack. Ambient air entering unintentionally (not part of measured combustion air). Steady fuel input and set draft conditions before leakage. Concept / Approach: Infiltrated air is cool and oxygen-rich. Mixing with hot flue gas reduces overall gas temperature via sensible heat dilution. Extra oxygen shifts the atmosphere toward oxidizing conditions, increasing scale formation risk on steel. The additional gas volume must be moved by the draft system, increasing induced draft (ID) fan load while simultaneously upsetting pressure balance and decreasing effective furnace draft across the chamber. Step-by-Step Solution: Cold air mixes with hot products → lowers flue gas temperature (sensible heat loss).Oxygen from leakage makes atmosphere oxidizing → raises O2 and reduces CO, increasing oxidation potential.Greater total gas flow → higher flow resistance → more ID fan power demand and a reduction in available furnace draft. Verification / Alternative check: Stack O2 and CO trends during leakage typically show increased O2, reduced CO, and lowered stack temperature. Fan current rises due to higher volumetric flow. Why Other Options Are Wrong: (a), (b), and (c) each describe real effects; none alone captures the complete picture. Common Pitfalls: Confusing deliberate excess air with uncontrolled infiltration; the latter bypasses flow measurement, complicating control and heat balance calculations. Final Answer: all (a), (b) and (c)

Question 2

Specific heating capacity of a furnace: How is the capacity commonly expressed so that throughputs of different sized furnaces can be compared on a normalized basis?

Accepted Answer

Introduction / Context: When benchmarking furnaces, engineers need a size-independent metric to compare productivity. The specific heating capacity normalizes throughput by furnace internal volume to reflect how effectively space and heat are used. Given Data / Assumptions: Furnaces of different volumes handling similar materials. Steady continuous or averaged batch operation. Throughput expressed as mass per unit time. Concept / Approach: Simple throughput (weight heated per hour) does not account for furnace size. Dividing by the working volume gives a fair comparison across designs and scales. Thus, specific heating capacity = (weight heated per hour) / (furnace volume). Step-by-Step Solution: Define throughput basis: mass heated per hour.Normalize by furnace volume (m^3) for comparability.Obtain units: (kg/h)/m^3, i.e., kg·h^-1·m^-3. Verification / Alternative check: Plants with similar fuels but different sizes show closer performance alignment when using per-volume metrics rather than absolute throughput. Why Other Options Are Wrong: Weight heated/hr: lacks normalization by size.Weight heated/furnace volume: ignores time dimension.None of these: specific heating capacity is indeed weight heated/hr/furnace volume. Common Pitfalls: Comparing furnaces on absolute throughput can mislead decisions about efficiency and design quality; always include size normalization. Final Answer: weight heated/hr/furnace volume

Question 3

Mode of heat transfer with a surrounding liquid medium: Heating a part submerged in a high-temperature liquid bath occurs in which furnace type?

Accepted Answer

Introduction / Context: Some heat-treatment operations require rapid, uniform heating with excellent surface contact. Salt bath furnaces use molten salt as a heat-transfer medium, immersing the workpiece to achieve fast and controllable heat penetration. Given Data / Assumptions: Workpiece is fully or partly submerged in a liquid bath. Liquid is typically molten salt at elevated temperature. Objective is efficient, uniform heating. Concept / Approach: Heat transfer by forced contact with a liquid (molten salt) greatly increases the convective coefficient versus air or flue gas. This reduces temperature gradients within the part and minimizes oxidation compared to direct flame environments. Step-by-Step Solution: Identify heating medium: a liquid (molten salt).Relate process to common equipment: salt bath furnace.Select the corresponding option. Verification / Alternative check: Salt baths are standard for austempering, martempering, and some carburizing steps; the liquid fully envelops the workpiece for uniform heating. Why Other Options Are Wrong: Blast furnace: countercurrent solid-gas reactor for ironmaking, not liquid bath heating.Steam boiler: produces steam; not a workpiece heat-treatment bath.Annealing furnace: typically a gaseous atmosphere or vacuum, not a liquid immersion. Common Pitfalls: Confusing quench tanks (cooling) with salt baths (heating). Salt baths heat first; quench tanks cool later. Final Answer: salt bath furnace.

Question 4

Applications of shaft furnaces: Shaft-type furnaces (vertical reactors with descending burden and rising gases) are typically used for which thermal processes?

Accepted Answer

Introduction / Context: Shaft furnaces are vertical, countercurrent thermal reactors in which solids descend by gravity while hot gases flow upward. Their design supports a wide range of high-temperature processes in minerals and metals industries. Given Data / Assumptions: Generic shaft furnace geometry and operation. Appropriate refractory and gas-handling systems. Feedstocks include ores, fluxes, and limestone. Concept / Approach: Because solids and gases move countercurrently in a compact vertical path, shaft furnaces enable efficient heat and mass transfer, making them suitable for: (a) smelting (e.g., iron blast furnace), (b) calcining (e.g., lime kilns), and (c) roasting (sulfide ores), depending on gas composition and temperature profile. Step-by-Step Solution: Identify process mechanisms: reduction/smelting, decomposition (calcination), oxidation (roasting).Confirm compatibility with shaft geometry and gas-solid contact.Conclude broad applicability across all three processes. Verification / Alternative check: Industrial examples include blast furnaces (smelting), shaft lime kilns (calcining CaCO3 to CaO), and roasting furnaces for sulfides to oxides with SO2 evolution. Why Other Options Are Wrong: Single selections omit other valid processes; shaft furnaces commonly cover all (a), (b), and (c). Common Pitfalls: Assuming “shaft furnace” implies only ironmaking; the geometry suits many chemistries when gas composition and temperature are tuned. Final Answer: all (a), (b) and (c)

Question 5

Stack (chimney) heat loss comparison at 600°C flue gas temperature: For complete combustion, which fuel–oxidant combination typically gives the highest percentage stack loss?

Accepted Answer

Introduction / Context: Stack loss (sensible heat carried out by flue gases) depends on flue gas temperature, specific heat, and mass of dry gas per unit heat released. Low-calorific fuels requiring large combustion air volumes yield higher stack loss percentages for the same exit temperature. Given Data / Assumptions: All cases at 600°C flue gas temperature and complete combustion. Air contains substantial nitrogen diluent; oxygen firing avoids nitrogen ballast. Blast furnace gas (BFG) has low calorific value and high inert content (notably CO2 and N2). Concept / Approach: Percent stack loss increases with the amount of inert gas heated per unit of fuel energy. BFG burned with air generates large flue gas volumes (fuel inerts + air nitrogen), so the sensible heat fraction lost is large relative to the small heat input. Furnace oil has high calorific value and requires less air per unit energy; oxygen firing further reduces flue gas volume by eliminating nitrogen ballast. Step-by-Step Solution: Rank gas volume per unit heat: BFG+air ≫ furnace oil+air.Oxygen firing removes N2 → lowers flue gas mass → lowers stack loss %.Thus, the maximum percent stack loss occurs with BFG combusted with air. Verification / Alternative check: Heat balance calculations using typical ultimate analyses confirm that BFG has higher kg of flue gas per MJ; oxygen enrichment reduces losses markedly. Why Other Options Are Wrong: Furnace oil with air: higher CV and lower gas volume per MJ → lower stack loss %.Furnace oil with oxygen / BFG with oxygen: oxygen firing minimizes stack losses via reduced N2. Common Pitfalls: Confusing absolute heat loss with percentage. Although hotter gas increases absolute loss, the percentage depends strongly on gas mass per heat input. Final Answer: blast furnace gas with air.

Question 6

Identifying regenerative furnaces: Which of the following industrial furnaces employ regenerators to store and periodically return heat to the process?

Accepted Answer

Introduction / Context: Regeneration is a classic waste heat recovery method in heavy industry. Brickwork checker chambers alternately store heat from hot flue gases and preheat incoming combustion air or fuel, improving overall thermal efficiency. Given Data / Assumptions: Typical vintage and modern designs of open hearth and by-product coke oven heating systems. Alternating flow through checkers on timed cycles. Concept / Approach: In both open hearth furnaces and coke oven heating chambers, regenerators with checkerwork are integral. Flow direction is reversed periodically so that the hot checker bricks preheat the next incoming cold stream, recovering sensible heat that would otherwise be lost. Step-by-Step Solution: Identify equipment known for checker regenerators.Confirm periodic flow reversal and heat storage-release cycle.Conclude that both listed furnaces are regenerative. Verification / Alternative check: Process schematics show pairs of regenerator chambers with reversing valves, standard in these furnace types. Why Other Options Are Wrong: Selecting only one omits the other well-known regenerative application.“Neither” conflicts with established furnace design practice. Common Pitfalls: Confusing regenerators with recuperators; regenerators reverse flow in packed checkers while recuperators use continuous heat exchange across walls. Final Answer: Both (a) and (b).

Question 7

Waste heat recovery equipment with periodic flow reversal: In which device are the flows of flue gas and air alternately reversed after fixed time intervals to store and release heat?

Accepted Answer

Introduction / Context: High-temperature furnaces often recover waste heat to improve efficiency. Two principal devices are used: recuperators and regenerators. Understanding their operating principles is key to proper selection and design. Given Data / Assumptions: Fixed-interval flow reversal is mentioned. Checker brick mass is commonly used for heat storage. Concept / Approach: A regenerator stores heat from hot exhaust in a solid matrix (checkers). After a set period, valves reverse the flow so cold combustion air passes through the hot matrix, picking up the stored heat. A recuperator, in contrast, is a continuous exchanger with separate, non-reversing passages. Step-by-Step Solution: Identify the hallmark: alternate flow direction through a heat-storing matrix.Match this to “regenerator.”Exclude continuous devices without reversal (recuperators, boilers). Verification / Alternative check: Industrial drawings of open hearth/coke oven systems show reversing valves feeding regenerator checkers. Why Other Options Are Wrong: Recuperator: continuous countercurrent/cocurrent exchange; no reversal.Waste heat boiler: generates steam; no flow reversal in the sense described.None of these: incorrect because regenerator fits. Common Pitfalls: Assuming both devices behave the same; only regenerators rely on thermal storage with timed reversals. Final Answer: Regenerator

Question 8

Identifying non-electric furnace types: Which one of the following listed furnaces does not use electric power as the primary heating source?

Accepted Answer

Introduction / Context: Electric furnaces heat via electrical energy: arcs, induced currents, or resistive elements. Some furnace names refer to geometry or use-case rather than power source; recognizing which are inherently electric avoids design confusion. Given Data / Assumptions: Arc furnace: electric arc between electrodes and bath/charge. Induction furnace: eddy currents induced electrically in the charge. Resistance furnace: resistive elements convert electricity to heat. Pot furnace: traditionally a small refractory-lined vessel heated by fuel flames. Concept / Approach: Arc, induction, and resistance are electric by definition. “Pot furnace” is a generic term associated historically with fuel firing (oil/gas) under or around the pot. While an electric pot is possible in modern practice, the conventional classification denotes a fuel-fired unit. Step-by-Step Solution: Classify each option by principal energy input.Arc/induction/resistance → electric; pot → typically fuel-fired.Select “Pot.” Verification / Alternative check: Standard furnace catalogs separate electric furnace categories from fuel-fired crucible/pot furnaces. Why Other Options Are Wrong: Arc/Induction/Resistance: all inherently electrical heating methods. Common Pitfalls: Assuming “pot” refers to any small furnace; the heating method matters more than geometry. Final Answer: Pot

Question 9

Where are regenerators commonly installed? Select the furnace applications that routinely include checkerwork regenerators for high-efficiency combustion air preheating.

Accepted Answer

Introduction / Context: Regeneration with checker brick structures is prominent wherever very hot flue gases are available and high preheat of combustion air or fuel delivers large fuel savings. Three iconic applications are glass melting tanks, open hearth steel furnaces, and by-product coke ovens. Given Data / Assumptions: High-temperature continuous firing with substantial waste heat potential. Periodic flow reversal to alternate between storage and release phases. Concept / Approach: Regenerators capture sensible heat from exhaust and return it via preheated air/fuel during the next cycle. All three listed furnace types utilize checker chambers because the thermal duty and temperature levels justify the added complexity and capital cost. Step-by-Step Solution: Identify common high-temperature furnaces with long residence times and steady flue gas streams.Confirm the presence of regenerators in glass tanks, open hearth, and coke oven heating systems.Hence, all three are correct. Verification / Alternative check: Process flow diagrams and historical furnace literature consistently depict dual regenerator chambers with reversing valves. Why Other Options Are Wrong: Any single selection ignores the standard use in the other applications; “all” is accurate. Common Pitfalls: Interchanging regenerators with recuperators; remember regenerators require periodic flow reversal and storage mass. Final Answer: all (a), (b) and (c).

Question 10

Reducing furnace-scale formation: Which gas condition in the flue or furnace atmosphere helps suppress oxide scale growth on hot steel surfaces?

Accepted Answer

Introduction / Context: Scale forms on steel when an oxidizing atmosphere reacts with hot metal surfaces to form iron oxides. Controlling the furnace atmosphere to be slightly reducing minimizes oxidation and scale pickup, improving product quality and reducing material loss. Given Data / Assumptions: Hot steel stock in a reheating or heat-treatment furnace. Atmosphere composition affects oxidation-reduction reactions. Target is to lower the oxidation potential. Concept / Approach: Carbon monoxide (CO) and hydrogen (H2) are reducing agents at high temperature. A high CO/CO2 ratio indicates a more reducing carbon potential, which favors reduction of iron oxides and suppresses further oxidation. Balancing safety and emissions, industries tune excess air and, when applicable, inject controlled amounts of reducing species. Step-by-Step Solution: Recognize that scaling increases with oxygen potential in the gas phase.Identify reducing components: CO and H2 consume oxygen/oxides.High CO/CO2 ratio corresponds to lower oxygen potential → less scale growth. Verification / Alternative check: Ellingham-type considerations and practical furnace trials show scale thickness decreases as the atmosphere becomes more reducing (within metallurgical limits). Why Other Options Are Wrong: Selecting only one misses that CO, H2, and the CO/CO2 ratio together characterize a reducing environment. Common Pitfalls: Driving the atmosphere too reducing can cause soot or carbon pick-up; control must be precise to avoid surface defects. Final Answer: all (a), (b) & (c)

Question 11

Waste-heat boiler design for furnace gas recovery In industrial furnace technology, the design of a waste-heat boiler used to recover heat from furnace exhaust gases primarily depends on which set of gas characteristics?

Accepted Answer

Introduction / Context: Waste-heat boilers (WHBs) recover sensible heat from hot furnace off-gases and convert it to useful steam or hot water. Proper design must consider several gas-side parameters to ensure high efficiency, reliability, and safe operation in real plant conditions. Given Data / Assumptions: The WHB serves a furnace exhaust stream. We compare the importance of gas quantity and temperature, dust loading and dust character, and corrosivity. Only one option should best capture the full design dependency. Concept / Approach: Gas-side design governs heat-transfer area, tube geometry, fouling allowances, cleaning provisions, metallurgy, and allowable gas velocities. These choices hinge on thermal load (flow and temperature), particulate nature (erosion, deposition, and plugging risks), and chemistry (acid dew points and high-temperature corrosion). Step-by-Step Solution: Recognize that thermal duty = gas mass flow * specific heat * temperature drop; this fixes heat-transfer surface scale.Abrasive or sticky particulates set velocity limits, tube pitch, soot-blowing/rap systems, and orientation (horizontal vs vertical passes).Corrosive species (e.g., SO3, HCl, alkali vapors) dictate materials selection, tube metal temperatures, and gas exit temperature to avoid acid condensation.Therefore the comprehensive answer must include all three aspects. Verification / Alternative check: Field practice shows WHBs frequently fail due to fouling/erosion (dust) or cold-end corrosion (chemistry) rather than pure thermal sizing, confirming that multi-parameter design is essential. Why Other Options Are Wrong: Quantity & temperature only — ignores fouling/corrosion risks that dominate lifecycle performance.Dust factors only — ignores duty sizing and metallurgy for corrosive gases.Corrosivity only — ignores capacity and fouling control. Common Pitfalls: Designing solely on thermal load, underestimating dust stickiness, and setting gas exit temperature below acid dew point causing rapid corrosion. Final Answer: all (a), (b) and (c).

Question 12

Directly fired intermittent furnace — identify the correct example Among common industrial furnaces, which one is a directly fired, intermittent (batch) type unit?

Accepted Answer

Introduction / Context: Industrial furnaces are categorized by how heat is delivered (direct vs indirect firing) and by operating mode (intermittent/batch vs continuous). Recognizing furnace types is crucial for selecting burners, controls, and heat recovery systems. Given Data / Assumptions: We compare common furnace names. “Directly fired” means the flame and hot products of combustion heat the work or the furnace chamber directly. “Intermittent” means cyclic charging, heating/soaking, and discharging (batch operation). Concept / Approach: A reverberatory furnace is directly fired: the flame and hot gases reflect (reverberate) off the roof into the hearth, heating the charge. Many reverberatories operate in batch mode (intermittent) for non-ferrous melting, holding, or reheating. In contrast, walking beam furnaces and tunnel kilns are typically continuous, with the stock moving through heating zones in a steady flow. Step-by-Step Solution: Classify each option by firing and operating mode.Reverberatory furnaces: direct-fired; often batch ⇒ matches.Walking beam furnaces: continuous reheating in steel mills ⇒ not intermittent.Tunnel kilns: continuous firing of ceramics; stock moves through a long tunnel ⇒ not intermittent.“Tower furnace” is less standard in this context and is not the best match. Verification / Alternative check: Process flow descriptions for reverberatory units emphasize batch charging and tapping, consistent with intermittent direct firing. Why Other Options Are Wrong: Walking beam reheating furnace — continuous steel reheating.Tunnel kiln — continuous firing of bricks/ceramics.Tower furnace — ambiguous term; not the textbook example of direct-fired intermittent mode. Common Pitfalls: Confusing “directly fired” with “indirectly fired muffle” and mixing up operating modes when only the firing method is recognized. Final Answer: Reverberatory furnace

Question 13

Burner turndown ratio in furnace operation What is correctly meant by the “turndown ratio” of an industrial burner used on furnaces and boilers?

Accepted Answer

Introduction / Context: Burner turndown describes how widely a burner can modulate heat input while maintaining stable combustion, good mixing, and proper flame shape. It is central to part-load efficiency and temperature control in furnaces. Given Data / Assumptions: We focus on the standard definition. Permissible heat input includes safe, stable firing without flame-out or excessive CO/soot. Concept / Approach: Turndown ratio = Q_max / Q_min at which the burner operates within acceptable limits. Higher turndown allows deeper load-following without cycling. It is not a prescriptive value (like 1:2 or 1:1) but a burner capability metric; typical values may be 8:1, 10:1, or higher for modern systems. Step-by-Step Solution: Identify definition-based option.Confirm that options prescribing fixed values are not definitions.Select the ratio of maximum to minimum permissible heat input rates. Verification / Alternative check: Burner datasheets list turndown as a ratio (e.g., 10:1), referring to stable low-fire and rated high-fire conditions. Why Other Options Are Wrong: “As low as possible 1:2” — low turndown reduces controllability; modern goals are higher turndown.“1:1 for batch furnace” — meaningless; 1:1 implies no modulation.“Normally much more for continuous furnaces” — operating needs vary; not a definition and not universally true. Common Pitfalls: Confusing a burner’s definition with rules of thumb and believing one-size-fits-all values independent of fuel, mixing, and control method. Final Answer: is the ratio of maximum to minimum permissible heat input rates.

Question 14

Improving furnace thermal efficiency — select the comprehensive strategy Which measures collectively raise the thermal efficiency of industrial furnaces during routine operation?

Accepted Answer

Introduction / Context: Furnace thermal efficiency is the fraction of fuel energy delivered to the stock. Operators improve efficiency by enhancing heat recovery, limiting losses, and maintaining stable combustion with correct air flow (draught). Given Data / Assumptions: We compare three common efficiency levers. Goal: higher useful heat to the load per unit fuel. Concept / Approach: Flue gas heat is a major loss; recuperators/regenerators reclaim it to preheat combustion air or load. Wall and opening losses are reduced via insulation, tight doors, and sealing. Proper draught ensures the intended air-to-fuel ratio, reduces infiltration, and stabilizes flames for high radiant heat transfer. Step-by-Step Solution: Waste heat recovery cuts stack losses.Better refractories and minimized leaks cut wall/opening losses.Correct draught maintains near-stoichiometric firing and avoids excess air penalties.Therefore the combined choice is best. Verification / Alternative check: Energy balances routinely show stack losses and wall losses as leading terms; draught control affects both excess air and infiltration, validating the combined improvements. Why Other Options Are Wrong: Each single action helps but is incomplete. Common Pitfalls: Over-relying on one measure (e.g., only insulation) while running with high excess air; the best gains are holistic. Final Answer: all (a), (b) and (c).

Question 15

Purpose of the muffle in a muffle furnace What is the principal function of the muffle (separating wall/box) in a muffle furnace used for heat treatment and materials processing?

Accepted Answer

Introduction / Context: A muffle furnace separates the charge from direct flame contact by interposing a refractory “muffle” chamber. This enables clean, controlled heating where contamination or direct oxidation must be avoided. Given Data / Assumptions: Muffle wall isolates the work from combustion products. Muffle geometry and thermal mass also influence temperature uniformity. Concept / Approach: By preventing contact between the flame and the charge, the muffle eliminates flame impingement, soot, and combustion byproducts on sensitive loads. Simultaneously, the muffle acts as a radiative/convective buffer, evening out local fluctuations on the burner side and fostering uniform heat flux to the load. Step-by-Step Solution: Identify direct protection function: separation from combustion gases.Identify uniformity function: thermal smoothing and radiative re-emission from a hot, relatively uniform muffle wall.Conclude that both functions apply. Verification / Alternative check: Operating manuals for muffle furnaces emphasize contamination control and temperature uniformity, matching both listed roles. Why Other Options Are Wrong: (a) or (b) alone — incomplete; muffles serve both purposes.Neither — contradicts the fundamental design of a muffle furnace. Common Pitfalls: Calling a muffle furnace “indirectly fired” and assuming only cleanliness matters; uniformity is equally critical for heat treatment quality. Final Answer: both (a) & (b)

Question 16

Induction electric furnaces — effect of induced currents and skin effect The electric furnace that develops heat by both induced currents and the skin effect is best described as which type?

Accepted Answer

Introduction / Context: Induction furnaces heat conductive charges via eddy (induced) currents generated by a time-varying magnetic field. At higher frequencies, current crowds near the surface (skin effect), intensifying surface heating and stirring (in coreless types). Given Data / Assumptions: We compare heating mechanisms across furnace types. Skin depth decreases with frequency, heightening skin effect at high frequency. Concept / Approach: Arc furnaces use arc radiation/resistance of the arc column; resistance furnaces heat via Joule heating in elements or the charge. Induction furnaces exploit induced currents; at high frequency, skin effect becomes pronounced, raising surface power density and enabling rapid melting/heating of metals. Step-by-Step Solution: Identify which furnace relies on induced currents: induction types.Recognize skin effect prominence: increases with frequency.Thus “high frequency induction” is the specific furnace where both induced currents and skin effect notably produce heat. Verification / Alternative check: Skin depth δ ∝ 1/√f; therefore, higher frequency reduces δ, intensifying surface current density and heating, matching high-frequency induction furnaces. Why Other Options Are Wrong: Arc — not induction-based.Resistance — Joule heating in elements/charge, not by induced eddies.Low frequency induction — reduced skin effect; heating is less concentrated at the surface. Common Pitfalls: Assuming all induction furnaces behave identically regardless of frequency; frequency selection is central to heating profile and penetration. Final Answer: high frequency induction

Question 17

What governs the heating capacity of a muffle furnace? For a given firing condition, the practical heating capacity of a muffle furnace depends primarily on which set of factors?

Accepted Answer

Introduction / Context: In muffle furnaces, the load (stock) is heated primarily by radiation from the hot muffle walls and by convection within the enclosed chamber. The rate at which energy reaches the stock determines the effective heating capacity. Given Data / Assumptions: Radiative heat transfer dominates at high temperatures. Emissivity and area govern radiative exchange. Concept / Approach: Net radiative exchange between a hot wall and the stock depends on both the wall’s radiative properties and the stock’s absorptivity/emissivity and view factors. Larger area and higher emissivity support greater radiative heat flux; higher wall temperature increases driving potential strongly. Step-by-Step Solution: Identify stock-side factors: surface area and emissivity affect how much incident radiation is absorbed.Identify wall-side factors: wall temperature, area, and emissivity set emission power and uniformity.Conclude that both groups of factors control the furnace’s practical heating capacity. Verification / Alternative check: Standard furnace design notes highlight that blackened or high-emissivity stock surfaces heat faster, and high-emissivity, large-area hot walls deliver greater radiant energy. Why Other Options Are Wrong: Only (a) or only (b) — incomplete because radiative exchange requires both emitter and receiver properties.Neither — contradicts basic heat-transfer principles. Common Pitfalls: Ignoring emissivity; bright or oxidized surfaces can change heating rates markedly even at the same gas or wall temperature. Final Answer: both (a) & (b)

Question 18

Effect of air infiltration on furnace performance Considering real-world leakage around doors, joints, and flues, what is the typical impact of cold air infiltration on furnace operation and efficiency?

Accepted Answer

Introduction / Context: (Note: “Air filtration” in many texts is a typographical variant for “air infiltration.”) Infiltration is the unwanted ingress of ambient air into the furnace. It alters combustion conditions and increases stack losses, undermining fuel efficiency. Given Data / Assumptions: Cold outside air leaks into a hot furnace chamber or flue. We assess its effect on thermal efficiency and indicative symptoms. Concept / Approach: Infiltration introduces extra nitrogen and oxygen not accounted for in combustion control. This cools the combustion products and increases total flue-gas mass, thereby raising sensible heat carried to the stack per unit of useful heat delivered to the load. Net result: lower thermal efficiency. Step-by-Step Solution: Recognize that added cold air absorbs heat and departs up the stack, increasing losses.Note that excess oxygen readings at the stack may rise, and flame shape may destabilize, but the primary effect is efficiency reduction.Select the option that captures the overall performance impact: reduced thermal efficiency. Verification / Alternative check: Energy balances show higher flue-gas flow and lower average gas temperature in the furnace region; overall efficiency drops even if stack temperature may or may not increase depending on control settings. Why Other Options Are Wrong: “Flame sting out” — imprecise term; flame instability can occur, but it is not the standard diagnostic phrase.“Increases the flue gas temperature” — infiltration often cools furnace gases; stack temperature behavior is not universally higher.“None of these” — incorrect because efficiency reduction is well known. Common Pitfalls: Confusing controlled excess air with uncontrolled infiltration; the former can be optimized, the latter should be minimized via sealing and pressure balance. Final Answer: reduces its thermal efficiency.

Question 19

Why use pulverised coal firing in boilers? In steam-generating boiler furnaces, what is the principal advantage achieved by firing pulverised coal instead of lump coal?

Accepted Answer

Introduction / Context: Pulverised coal (PC) firing grinds coal into fine particles and pneumatically conveys it to burners. This increases surface area for rapid devolatilization and char burnout, enabling high heat release rates in compact boilers. Given Data / Assumptions: Comparing PC firing to lump/stocker firing. Single best advantage must be selected. Concept / Approach: Finely divided coal dramatically improves mixing with combustion air and shortens burnout time, producing high, controllable flame temperatures and complete combustion (lower CO and unburnt carbon losses). Calorific value is an inherent fuel property and does not increase by pulverizing. Smoke opacity can be reduced with proper burners and staging, but “smokeless” is not inherent. Wall erosion can worsen if ash-laden high-velocity jets impinge surfaces. Step-by-Step Solution: Identify the fundamental mechanism: increased surface area and mixing.Relate mechanism to outcome: faster, more complete combustion.Choose “better combustion” as the single most correct, general advantage. Verification / Alternative check: Boiler performance tests show higher combustion efficiency and lower unburnt losses with well-designed PC burners compared to lump coal grates. Why Other Options Are Wrong: Higher calorific value — pulverizing does not change intrinsic heating value.Smokeless burning — achievable but not guaranteed; depends on burner design and operation.Less erosion — PC systems can increase erosion without proper burner and shielding design. Common Pitfalls: Assuming PC always reduces emissions; NOx and particulate controls still need optimized air staging and capture systems. Final Answer: better combustion

Question 20

Which furnace typically exhibits the highest thermal efficiency? Considering common industrial units, select the furnace type that generally achieves the greatest thermal efficiency in practice.

Accepted Answer

Introduction / Context: “Thermal efficiency” here refers to the ratio of useful energy captured (e.g., in steam) to fuel energy input. Different furnace classes serve different purposes—metallurgical heating vs steam generation—so their efficiencies vary by design and duty. Given Data / Assumptions: Compare typical efficiencies for common units. Assume modern, well-operated equipment of each type. Concept / Approach: Boiler furnaces are optimized to transfer heat to water/steam circuits with extensive radiant and convective surfaces and effective heat recovery (economizers, air preheaters). As a result, modern boilers can achieve very high thermal efficiencies compared with metallurgical furnaces whose objective is heating massive workpieces, often with larger wall and opening losses and limited heat recovery. Step-by-Step Solution: Recognize boiler furnace purpose: efficient steam generation with strong heat recovery.Contrast with soaking pits/reheating furnaces/rotary kilns: large wall losses, frequent door openings, variable loads, and limited recovery.Select boiler furnace as typically the most thermally efficient among the options. Verification / Alternative check: Plant benchmarks: well-tuned packaged boilers can exceed 85–90% fuel-to-steam efficiency (HHV basis) with economizers, while many high-temperature metallurgical furnaces operate at significantly lower thermal efficiencies. Why Other Options Are Wrong: Soaking pits — heavy wall/door losses; low recovery.Walking beam reheating furnace — improved over older designs but generally less efficient than boilers.Rotary kilns — long, refractory-lined with notable shell and exhaust losses. Common Pitfalls: Equating high flame temperature with high efficiency; efficiency depends on how much energy is captured as useful output, not the flame temperature itself. Final Answer: Boiler furnace

Furnace Technology Questions