Energy Analysis of the Tilting Crucible Furnace at IUPB in Relation to Thermal Efficiency for Aluminium Melting

EasyChair Preprint 15869

Abstract

Introduction

This study evaluated the energy efficiency of a mechanical-tilting crucible furnace powered by natural gas (NG) at the Pascual Bravo University Institution. An integrated methodology was used, considering variables such as fuel consumption, material load, combustion gas temperature and composition, furnace dimensions, and construction materials. The objective was to determine energy losses and calculate the furnace’s real efficiency in order to propose technological improvements for its operation.

Methodology

Tools such as a Flir® E4 thermal camera, a type K thermocouple connected to a data acquisition system with Arduino and LabVIEW, and a Kigaz 310 gas analyser were used to measure temperature and gas composition. Sampling times were 5 minutes, and for the crucible temperature, every 0.5 seconds. The useful energy for melting 80 kg of aluminium was estimated, and energy losses were calculated using specific equations.

Results

The energy released from NG combustion was 986,923 kJ, with 65% lost through exhaust gases. 15% of this energy was used to melt the aluminium, and 20% was allocated to heating the furnace mass. The burner operated at 7.15 kg/h of NG, with a power of 83.86 kW. Efficiency and emission indices revealed that the furnace has disadvantages compared to other market equipment.

Conclusions

Useful energy was calculated both theoretically and experimentally, with a 25% correction due to the progressive input of the aluminium. The most significant losses came from exhaust gases (65%). The furnace consumes 15.04 m³ of natural gas in 3.35 hours, with an operational cost of 39,000 COP per test. Areas for improvement were identified to optimise energy efficiency and reduce operational costs.

Keyphrases: Aluminium melting, Combustion, Energy, energy efficiency

@booklet{EasyChair:15869,
  author    = {Oscar M. Carmona Agudelo and Juan D. Ortega Mesa and Jorge I. Cortes Pérez and Andrés D. Morales Rojas},
  title     = {Energy Analysis of the Tilting Crucible Furnace at IUPB in Relation to Thermal Efficiency for Aluminium Melting},
  howpublished = {EasyChair Preprint 15869},
  year      = {EasyChair, 2025}}