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3(/. Fbrging-Stamping- Heat Treatii^ October, 1925 F a c t o r s A f f e c t i n g t h e S e l e c t i o n o f F u e l ' The Ultimate Choice Should Be Based on Cost per Unit of Goods Manufactured, and the Various Secondary Advan PROBaA.BLY no problem of equal practical importance to a manufacturer is more difficult to solve than the selection of the most suitable fuel and furnace and the prediction of the results obtainable. Yet, the industrial gas man is continually being called on to do ju^t that thing for it is his purpose to convince the manufacturer that gas is the fuel he should use. The basic principles of combustion are common to all fuels but the many differences in the details of their application dependent on manufacturing requirements render choice difficult, the more so. because there has always been a lack of experienced men who understand these fundamentals and can exercise judgment and discretion in making their decisions. The very complexity that a close study of fuels reveals is also the reason for their varied usefulness. For example, each different use requires certain special properties in the fuel so that it shall be suitable for the installation at hand. Gaseous fuels have the widest range of adaptability- without doubt, but their generally high cost has made adoption slow even where the local gas company has been progressive in furthering their use. However, it is most important to emphasize that bare fuel costs are not and should not be determining factors in influencing fuel selection. The ultimate choice should be based, first, on the cost per unit of goods manufactured, and second on the various secondary advantages of convenience and cleanliness to which it is often difficult to assign a direct value but which nevertheless are most important. In general it is the use to which a fuel is to be put that dictates the choice. But. in heating operations where more than one fuel can be used, due consideration should be given to all the factors just mentioned. Furthermore, it is to be noted that while natural fuels exist in great variety, it is both good engineering and in the interests of conservation of our natural resources to manufacture other fuels from them, thus besides securing two heating fuels, gas and coke, we save most valuable by-products. These facts indicate that the relative merits of the various fuels should be studied quite closely and the first step towards this end is a classification of fuels as shown in Fig. 2. Fuels, as indicated, can be solid, powdered, liquid. gaseous or delivered in the form of electrical energy directly available for use. The efficiency of their utilization on a Btu. basis is not a constant but varies with temperature of operation, design of furnace, actual operation conditions as well as other lesser factors. It is important in this connection to avoid the unfair but common practice of crediting a fuel for improvements resulting when a cheap, ttnsuited, inefficiently run furnace is replaced by an efficient, speciallydesigned apparatus expertly operated on another fuel. This procedure has frequently resulted in the selection •From a book prepared by tin. Industrial Gas Section of the American Gas Association. tages of Convenience and Cleanliness of very expensive fuels, particularly electricity, to perform heating operations more efficiently, comparing the results as found in practice and neglecting the fact that the same result could be accomplished with the cheaper fuel if the same care and thought were given to the design of its furnace as is given, for example, to electrical equipment. As one prominent furnace maker has aptly stated, "There is no one type of furnace or form of heat energy (combustible or electric) that has a monopoly on uniformity of heating or economy of operation." Even though, from the viewpoint of thermal efficiency, much depends on the furnace, yet one fuel can be inherently better than another because of its physical properties. Of all the fuels gas possesses the most advantages, some of which are reiterated below. 1. Combustion is easily controlled, the atmosphere can be kept oxidizing, reducing or neutral, as desired. It is free from sulphur compounds (traces only, allowed by legal standards) rendering it very suitable for direct fired metallurgical operations. 2. Flexibility of gas as a fuel is evident, turn of a valve and an unlimited supply of heat is available. In event of coal shortage, public utilities get priority orders. 3. Temperature control can be affected through pyrometers or for low temperatures by direct acting thermostats. 4. Gas requires no storage space. Coal yards occupy costly space; oil storage requires costly tanks and generally increases the fire risk. 5. Gas burns clean, no smoke, no soot, no ashes. In the selection of fuels, not only the fuel but also the furnace merits special attention and study. Consider then some of the outstanding features of good furnace design so that an intelligent selection can be made from the great number of types available. The chief points to consider in good furnace design include the following: a. Wherever possible continuous furnaces with counter-current flow of heat and materials should be installed because these not only have the greatest capacity for a given space but also the best fuel economies. The choice is influenced by the size, shape and weight of materials being heated; by the quantity and rate of movement through the heating chamber. b. Automatic temperature control not only insures uniform results but will yield better operating efficiencies than are possible with manual control. c. Greater attention paid to the methods of utilizing the available heat will repay itself many times. Perfect combustion, good insulation, no leakage losses are all elements of great importance. In continuous ovens considerable heat is often carried away by the conveying mechanism. d. Structurally, the design of gas furnaces has not always been as satisfactory as could be desired. First cost is not so important in furnace design as permanency and freedom from repairs. Special attention
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January, 1925 BEAUDRY UTILITY HAMME
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