Pusher slab furnace is an essential part of various industries, including ceramics, glass, and metallurgy. These furnaces are used for heating, cooling, and annealing different types of materials, including metals, glass, and ceramics. The pusher slab furnace is designed to move the material through the furnace by using a pusher plate. The pusher plate is moved by a hydraulic or electric pusher, which pushes the material through the furnace.

The design and operation of pusher slab furnaces vary depending on the type of material being processed and the specific requirements of the industry. Pusher slab furnaces can be designed to operate at high temperatures up to 2800°C or more, making them suitable for processing a wide range of materials. The furnaces can be designed to operate in a continuous or batch mode, depending on the specific requirements of the industry.

Key Takeaways

• Pusher slab furnaces are used for heating, cooling, and annealing different types of materials in various industries.
• The design and operation of pusher slab furnaces vary depending on the type of material being processed and the specific requirements of the industry.
• Pusher slab furnaces can be designed to operate at high temperatures and in a continuous or batch mode, depending on the specific requirements of the industry.

Design and Operation

Structural Components

The pusher slab furnace consists of a series of structural components that work together to heat and move the material through the furnace. The furnace is typically made of steel and features a pusher mechanism that moves the material through the furnace. The pusher mechanism is driven by a hydraulic or electric system that moves the material through the furnace at a controlled rate. The furnace also features a number of skids or rollers that support the material as it moves through the furnace. These skids or rollers are typically made of a high-temperature resistant material such as graphite or ceramic.

Heating Elements

The pusher slab furnace uses a variety of heating elements to heat the material as it moves through the furnace. These heating elements can include gas-fired burners, electric heating elements, or a combination of both. The heating elements are typically located above and below the material being heated to ensure even heating. The temperature of the furnace is monitored and controlled using a variety of sensors and control systems to ensure that the material is heated to the desired temperature.

Material Handling

The pusher slab furnace is designed to handle a variety of materials including slabs, billets, and blooms. The material is typically loaded onto skids or rollers and then pushed through the furnace using the pusher mechanism. Once the material has been heated to the desired temperature, it is typically removed from the furnace using a variety of material handling equipment such as cranes or forklifts. The furnace can be designed to handle a wide range of material sizes and weights, making it a versatile option for many different applications.

In summary, the pusher slab furnace is a highly efficient and effective method for heating and moving material through a high-temperature environment. The furnace is designed with a variety of structural components, heating elements, and material handling systems to ensure that the material is heated evenly and efficiently. Whether you are working with slabs, billets, or blooms, the pusher slab furnace is a reliable and versatile option for your heating needs.

Types of Pusher Slab Furnaces

Pusher slab furnaces are used for reheating slabs before they are rolled into sheets. There are different types of pusher slab furnaces, and each type has its unique features.

Single Pusher Furnace

A single pusher furnace has one pusher that pushes the slabs through the furnace. This type of furnace is suitable for smaller production rates.

Double Pusher Furnace

A double pusher furnace has two pushers that push the slabs through the furnace. This type of furnace is suitable for higher production rates than a single pusher furnace.

Triple Pusher Furnace

A triple pusher furnace has three pushers that push the slabs through the furnace. This type of furnace is suitable for even higher production rates than a double pusher furnace.

Walking Beam Furnace

A walking beam furnace has a conveyor system that moves the slabs through the furnace. The slabs are supported by a series of beams that move in a reciprocating motion. This type of furnace is suitable for high production rates and can handle slabs of different sizes.

Roller Hearth Furnace

A roller hearth furnace has a series of rollers that move the slabs through the furnace. This type of furnace is suitable for high production rates and can handle slabs of different sizes.

Overall, the type of pusher slab furnace you choose will depend on your production needs and the size of the slabs you are working with.

Applications and Industries

Pusher slab furnaces are widely used in various industries for their efficiency and cost-effectiveness. Here are some of the applications and industries where pusher slab furnaces are commonly used:

Metallurgy

Pusher slab furnaces are extensively used in the metallurgy industry for heat treatment of materials such as steel, aluminum, and copper. These furnaces are used for preheating and homogenizing milled slabs before the hot rolling process. The furnaces are designed to handle high temperatures and can accommodate large batches of materials. Pusher slab furnaces are energy-efficient and can reduce production costs significantly.

Ceramics

Pusher slab furnaces are also used in the ceramics industry for firing ceramic materials. These furnaces can reach high temperatures and provide uniform heating, which is essential for producing high-quality ceramics. Pusher slab furnaces are used for both small-scale and large-scale manufacturing of ceramic products. The furnaces can accommodate a variety of shapes and sizes of ceramic products.

Glass Production

Pusher slab furnaces are used in the glass production industry for melting and refining glass. These furnaces are designed to handle high temperatures and can melt large batches of glass. Pusher slab furnaces are energy-efficient and can reduce production costs significantly. The furnaces can be used for both small-scale and large-scale glass production.

In summary, pusher slab furnaces are versatile and can be used in various industries for their efficiency and cost-effectiveness. These furnaces are designed to handle high temperatures and can accommodate large batches of materials. Pusher slab furnaces are energy-efficient and can reduce production costs significantly.

Thermal Efficiency and Energy Consumption

The thermal efficiency and energy consumption of a pusher slab furnace are crucial factors in the steel manufacturing process. The furnace’s thermal efficiency determines the amount of energy required to heat the steel and the amount of heat lost during the process. The energy consumption of a pusher slab furnace can be reduced by improving its thermal efficiency.

One way to increase the thermal efficiency of a pusher slab furnace is by using advanced combustion systems. These systems use oxygen enrichment to increase the combustion temperature, resulting in higher thermal efficiency and reduced energy consumption. Studies have shown that oxygen enrichment can reduce energy consumption by up to 30% [1].

Another way to improve thermal efficiency is by using regenerative burners. These burners recover waste heat from the exhaust gases and reuse it to preheat the incoming air. This reduces the amount of energy required to heat the air and improves the furnace’s thermal efficiency.

It is also important to properly insulate the furnace walls to reduce heat loss. Insulation materials such as ceramic fiber or refractory bricks can be used to prevent heat from escaping and improve thermal efficiency.

In addition to improving thermal efficiency, it is important to monitor and optimize energy consumption. This can be done by measuring the energy consumption per ton of steel produced and identifying areas where energy can be saved. For example, reducing the amount of time the furnace is idle or optimizing the charging pattern can reduce energy consumption [2].

Overall, improving the thermal efficiency and reducing energy consumption of a pusher slab furnace can result in significant cost savings and environmental benefits.

[1] Heat Transfer and Energy Analysis of a Pusher Type Reheating Furnace using Oxygen Enrichment, https://www.sciencedirect.com/science/article/pii/S1006706X10600799

[2] Bottleneck of slab thermal efficiency in reheating furnace based on energy apportionment model, https://www.sciencedirect.com/science/article/abs/pii/S0360544218303839

Control Systems and Automation

Pusher slab furnaces are highly automated systems that are controlled by advanced control systems. The control systems are responsible for maintaining the desired temperature and heating profile of the slabs as they move through the furnace. The control systems use a combination of sensors, actuators, and software to maintain the desired heating profile.

The control systems are typically implemented using PLCs (Programmable Logic Controllers) and SCADA (Supervisory Control and Data Acquisition) systems. The PLCs are responsible for controlling the various actuators and sensors in the furnace, while the SCADA system provides a graphical interface for monitoring and controlling the furnace.

The control systems use a variety of sensors to monitor the temperature and heating profile of the slabs as they move through the furnace. These sensors include thermocouples, pyrometers, and infrared cameras. The data from these sensors is used by the control system to adjust the heating profile of the furnace to maintain the desired temperature and heating profile.

The control systems also use advanced algorithms to optimize the heating profile of the furnace. These algorithms take into account factors such as the size and shape of the slabs, the desired heating profile, and the thermal characteristics of the furnace. The algorithms use this information to adjust the heating profile of the furnace to optimize the heating process.

In conclusion, the control systems and automation used in pusher slab furnaces are critical to the efficient and effective operation of these systems. The advanced control systems and algorithms used in these furnaces ensure that the slabs are heated to the desired temperature and heating profile, while minimizing energy consumption and processing costs.

Maintenance and Safety

Routine Procedures

To ensure the safe and efficient operation of your pusher slab furnace, it is important to follow routine maintenance procedures. Regular inspections of the combustion systems, fans, conveyors, and all safety systems should be scheduled and performed. This will help to identify any potential issues before they become major problems.

In addition to inspections, routine cleaning of the furnace and its components is also necessary. This includes cleaning the burners, heat exchangers, and combustion chambers. Accumulated debris can cause blockages and affect the furnace’s performance.

Lubrication of the furnace’s moving parts is also important to prevent wear and tear. Regular lubrication of the pusher mechanism, bearings, and chains will ensure smooth operation and extend the life of these components.

Emergency Protocols

While routine maintenance is essential, it is also important to have emergency protocols in place in case of unexpected breakdowns. These protocols should include procedures for shutting down the furnace and addressing any safety concerns.

It is important to have a clear understanding of the furnace’s emergency shutdown procedures and to ensure that all personnel are trained in these procedures. This will help to prevent injuries and damage to the furnace.

Regular training of personnel on safety procedures is also crucial. This includes training on the use of personal protective equipment and proper handling of hazardous materials.

By following routine maintenance procedures and having emergency protocols in place, you can ensure the safe and efficient operation of your pusher slab furnace.

Innovations and Technological Advancements

Pusher slab furnaces have come a long way since their inception in the early 20th century. Today, these furnaces are equipped with advanced technologies that make them more efficient, cost-effective, and environmentally friendly.

One of the most significant innovations in pusher slab furnace technology is the use of hot riders for skids. This solution was pioneered by Tenova and has been developed over the last 30 years. Hot riders for skids provide a more uniform heating of the slabs, which reduces the risk of distortion and improves the quality of the final product.

Another technological advancement is the use of digital solutions, new algorithms, and innovative AI models to control the furnace’s operations. This allows for better control of the heating process, resulting in higher productivity, better temperature uniformity, and reduced pollutant emissions. Tenova’s Walking Beam Furnaces, for example, are equipped with these advanced technologies, making them the most compact solution for slab reheating.

In addition to these technological advancements, pusher slab furnaces have also become more cost-effective. For example, the Dillinger rolling mill recently completed an upgrade of its slab pusher furnace, which resulted in a 750 MWh reduction in electrical energy consumption per year. This is a significant cost savings that can be passed on to customers.

Overall, pusher slab furnaces continue to evolve and improve, thanks to ongoing innovations and technological advancements. With these advancements, pusher slab furnaces will continue to play a vital role in the steel industry for years to come.

Environmental Impact and Regulations

Pusher slab furnaces are known to have a significant environmental impact due to their high energy consumption. The combustion of fossil fuels to generate heat for the furnace releases greenhouse gases, which contribute to climate change. To mitigate this impact, regulations have been put in place to ensure that pusher slab furnaces meet certain environmental standards.

In many countries, emissions from industrial processes are regulated by government agencies. For example, in the United States, the Environmental Protection Agency (EPA) regulates emissions of air pollutants, including those from industrial furnaces. The EPA requires that pusher slab furnaces meet certain emissions standards, such as limits on the amount of nitrogen oxides (NOx) and sulfur dioxide (SO2) that can be released into the atmosphere.

To comply with these regulations, pusher slab furnace operators may need to install pollution control equipment, such as scrubbers or baghouses, to capture and remove pollutants before they are released into the environment. These systems can be expensive to install and maintain, but they are necessary to ensure that the furnace meets environmental standards.

In addition to emissions regulations, pusher slab furnace operators may also need to comply with regulations related to energy efficiency and resource conservation. For example, in some countries, energy efficiency standards are in place to ensure that industrial equipment, including furnaces, operate at maximum efficiency. Operators may also need to comply with regulations related to the use of water, such as limits on the amount of water that can be used for cooling purposes.

Overall, pusher slab furnaces can have a significant environmental impact, but regulations and standards are in place to help mitigate this impact. By complying with these regulations and implementing pollution control equipment and energy-efficient practices, pusher slab furnace operators can reduce their environmental footprint and contribute to a more sustainable future.