Improving the energy efficiency in a walking hearth type reheating furnace by energy balance method and optimizing the resources

Most metal industries use reheating furnaces (RHF) for their finishing operations. This RHF is highly energyconsuming equipment that heats the material inside the chamber for rolling or shaping using the by-product gases, natural gas, or oil as fuel. It is necessary to minimize or optimize the fuel consumption to the extent possible. By analyzing the plant operating data, plant measurements, and energy balance calculation, this work aims to determine the potential for decreasing the fuel consumption of a billet reheating furnace. Predictions are made by modeling operating data to reveal the hidden problems and uncover underlying issues. The study results in increasing productivity by 11 % while oil consumption was reduced by 14 %. These actions significantly decreased carbon emissions considerably and generated significant cost savings.