Energy Efficiency Estimate in Complex and Large Equipments

A billets reheating furnace simulator was used to identify the variables that must be measured with more accurate devices and methods to estimate the furnace's energy efficiency when real energy audits are performed. For this purpose, experiments were statistically designed, and easy-to-implement data analysis methods were employed. The results analysis shows that the variables with practical and statistically significant effect on energy efficiency are the percentage of O2in the combustion gases, the fuel flow in the burners, and the combustion air temperature. A confirmatory experiment validated the results analysis and points out that Design of Experiments is a tool that cannot be ignored by those who perform energy audits or have the responsibility to combat energy waste in energy-intensive manufacturing industries.