Every Terajoule ERS implementation has resulted in the untapped potential furnace performance dramatically improved
Our fuel savings estimates are taken from recorded data measured before and after ERS implementation at Terajoule customers.
Several factors unique to your furnace system are accounted for including fuel, diameter and ore size/type and we can predict fuel savings percentages with a high degree of accuracy.
If you prefer to estimate potential savings yourself, please access the US Department of Energy’s Process Heating Assessment and Survey Tool (PHAST) here:
https://measur.ornl.gov/landing-screen
The tool works best with an accurate temperature measurement from the flue gas exhaust of your furnace. But it is possible to very accurately predict percentage fuel savings using a range of possible exhaust temperatures. We can assist with this modelling through our customized Engineering Study.
Enhanced Furnace Lifetime: Avoiding extreme temperature differentials within the furnace helps to minimize wear and tear on furnace components, prolonging the equipment's operational life.
Faster Processing Times: A balanced temperature distribution can accelerate the processing time as all parts of the material receive adequate heat simultaneously.
Consistent Product Quality: Even temperature gradients ensure uniform heat distribution, leading to consistent and predictable product quality. This is especially crucial in industries where product specifications and properties must meet tight tolerances.
Reduced Material Stress: Uneven temperature gradients can cause thermal stress on the Perlite particles or the material being processed. A more even temperature profile reduces the risk of material distortion, cracking, or other forms of structural damage.
Improved Energy Efficiency: An even temperature distribution reduces the need for excessive heat input, leading to better energy efficiency and lower operating costs.
Minimizing Air Waste: An excessive air supply (lean mixture) can lead to wasted energy, as additional energy is required to heat the excess air. Operating close to the stoichiometric ratio reduces this waste.
Minimizing Fuel Waste: On the other hand, insufficient air supply (rich mixture) leaves unburned fuel, reducing combustion efficiency and potentially leading to the production of harmful byproducts.
Environmental Impact: Combustion processes operating at or close to stoichiometry produce fewer greenhouse gases and air pollutants, leading to a reduced environmental impact.
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