Applications
PROBLEMS OF THE EXTRACTION PROCESS OF MELTING FURNACES AND CUPOLAS
Flue gas extraction from melting furnaces is one of the most important extraction systems in foundries, smelters and ironworks. The melting of metal produces large quantities of flue gases, which must be extracted by a performance-stable extraction and filtration system. Flue gas extraction from melting furnaces is divided into hot and cold applications according to the temperature of the exhausted flue gas. Hot flue gases are generated in gas melting furnaces, cupolas and rotary kilns. The temperature at the furnace outlet is around 350 to 500°C.
For the extraction and filtration of the flue gases, it is necessary to use either filter units of special construction, equipped with ceramic filter media with a heat resistance of up to 900 °C, or to cool the flue gases before filtration with a textile filter. Industrial tube coolers or recuperators are used to cool the exhaust gases to a temperature suitable for filtration with a textile filter. Cold flue gases are extracted from electric induction furnaces. In electric induction furnaces, the flue gases are not produced by the combustion of gas or other fuel, but the molten material is gradually heated by electric induction.
Gas furnace extraction is most often applied in aluminium smelting. Modern furnaces are equipped with flue gas regenerators or heat exchangers. These heat exchangers reduce the temperature of the exhausted flue gas and transfer the extracted energy to the flue air. Despite the flue gas regenerators, the flue gas temperature is around 350 °C. The filter system is designed with its own flue gas cooling system using a tubular flue gas-air exchanger. Before the cooled flue gas enters the filter unit, we add a sorbent to the flue gas to reduce the HF and HCl content. We design the filter unit with textile filter elements with temperature resistance up to 200°C. The filters are equipped with automatic regeneration of the filter medium by means of pressurized air. The filter is divided into individual chambers for off-line regeneration. The entire exhaust system must be thermally insulated to prevent condensation of wet flue gases.
Modern exhaust systems use the temperature of the flue gases to generate electricity. This method of flue gas extraction differs from others in the return on investment. It is applicable to continuous kilns such as rotary cement kilns or contilite plants. The extraction system works in such a way that the flue gases are not cooled before filtration, but are filtered at high temperature. For the filtration of hot flue gases, flue gas filters with ceramic filter media are used, which can withstand the effects of high temperatures up to 900°C. The flue gases exiting the ceramic filters are fed into the heat exchanger of the CHP unit. Filtration is carried out upstream of the CHP unit to prevent fouling of the CHP unit heat exchanger. The outlet flue gas after the cogeneration unit reaches a temperature of approximately 120 °C to prevent condensation of the flue gases throughout the pipework up to the chimney head. The entire system requires continuity of process parameters such as flue gas quantity and temperature.
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