Improved Productivity & Reduced Emissions
By utilizing more of the heat energy available in the exhaust leg of the tube, furnace owners can increase their production output per MBTU (mcf) of natural gas while reducing emissions. Improved productivity can be realized in one of two ways; increased production rates or reduced gas consumption.
1) Increase in Production - Providing more energy to the load will allow line speeds to be increased (continuous furnace) or heat up cycle times to be reduced (batch furnace) while consuming the same amount of fuel.
2) Fuel Savings with Reduced Emissions - Providing more energy to the load while maintaining the same production rate will result in reduced gas consumption. Using less fuel for the same production output not only saves on the fuel bill, but also results in fewer emissions!
By combining radiant tube inserts with our combustion tuning and furnace diagnostic services, additional productivity benefits can be obtained. Learn more about PSNergy's professional services.
Figure 1 - Empty radiant tube exhaust leg. Hot core flue gas flowing uninterrupted down the center. Minimal heat transfer taking place along the tube wall. High exhaust temperature at tube exit.
Improved Quality & Reduced Operations Costs
PSNergy's radiant tube inserts increase overall exhaust leg temperature, creating a more balanced temperature profile between the burner and exhaust leg. A more uniform temperature profile improves product consistency and reduces stresses between the burner and exhaust legs of the radiant tube caused by differences in thermal expansion. Reduced thermal stresses will result in longer tube life, less downtime, & less maintenance costs.
Typically, a significant amount of unused energy escapes out of the exhaust stack of radiant tube furnaces. This major loss of energy is a result of minimal heat transfer taking place between uninterrupted hot flue gas flow and the inside wall of the radiant tube, as shown in Figure 1.
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PSNergy's radiant tube inserts increase the convective and radiant heat transfer in the exhaust leg of radiant tubes resulting in more energy delivered to the load. Our directional wing and shell design concentrates the heat energy exactly where it needs to be; towards the load. Figure 2 depicts computational fluid dynamic results of PSNergy's radiant tube inserts directing, absorbing and emitting flue gas energy towards the load.
Patent-Pending Directional Design
PSNergy’s patent pending, directional radiant tube inserts (RTI's) positively impact emissions, productivity, quality, and operation costs of industrial radiant tube furnaces.
Figure 2 - Radiant tube exhaust leg with PSNergy radiant tube inserts. Hot flue gas energy being directed, absorbed, and emitted towards the load. Low exhaust temperature at tube exit.
Metal processing companies utilizing gas fired, radiant tube furnaces continue to face the problems of increased environmental regulations regarding furnace emissions, increasing quality requirements from customers, and the ever present need to continuously improve productivity.