How does a vertical furnace achieve energy-saving sintering? Harness Internal Energy for Efficient Pellet Treatment

Vertical furnaces achieve energy efficiency primarily by leveraging the inherent chemical energy within the composite pellets themselves. Instead of relying solely on continuous external fuel, the system uses natural gas only to reach the initial ignition temperature. Once active, the combustion of carbon components inside the pellets—derived from coal mine waste rock—generates the heat necessary to sustain the sintering process naturally.

The core innovation lies in shifting from external heating to internal, self-sustaining combustion. By utilizing forced ventilation to oxidize carbon within the pellets, the furnace minimizes natural gas consumption and relies on the waste material's own energy to drive the thermal treatment.

The Mechanism of Self-Sustaining Sintering

Harnessing Internal Chemical Energy

The primary driver of energy savings is the composition of the composite pellets. These pellets are formulated to contain carbon components, specifically derived from coal mine waste rock.

The Role of Auxiliary Heating

Unlike traditional furnaces that require fuel throughout the entire cycle, the vertical furnace uses natural gas only for the initial phase. The gas is used solely as an auxiliary heat source to raise the temperature to the ignition point of the carbon within the pellets.

Forced Ventilation and Oxidation

To unlock the energy stored in the pellets, the furnace employs forced ventilation. This provides the oxidizing environment necessary for the carbon to burn.

Transition to Internal Heating

Once the ignition temperature is reached, the internal carbon begins to combust. The heat released from this internal reaction becomes the primary thermal source, allowing the system to maintain sintering temperatures without heavy reliance on external fuel.

Structural Contributions to Efficiency

Advanced Refractory Insulation

Beyond the combustion process, the physical structure of the furnace plays a critical role. The furnace utilizes an advanced refractory structure designed to provide superior insulation performance.

Minimizing Heat Loss

The materials used in the furnace lining are selected to absorb less heat and prevent thermal escape.

Quantifiable Energy Gains

The combination of improved insulation and low-heat-absorption materials contributes significantly to overall efficiency. This structural design alone can result in energy savings of more than 20% compared to previous furnace designs.

Operational Dependencies and Trade-offs

Reliance on Feedstock Composition

The energy-saving model is heavily dependent on the quality of the pellets. The system is most effective when pellets contain sufficient carbon components (from waste rock) to fuel the internal combustion process.

Criticality of Airflow Control

Because the system relies on oxidation to generate heat, the forced ventilation system must be precise. Inadequate airflow could stifle combustion, while excessive airflow might cool the system inefficiently.

Optimizing Thermal Treatment Efficiency

To maximize the benefits of a vertical furnace for composite pellets, consider your specific operational constraints:

• If your primary focus is reducing fuel costs: Ensure your composite pellets consist of coal mine waste rock with consistent carbon content to maintain self-sustaining combustion.
• If your primary focus is thermal retention: Prioritize the installation of advanced refractory linings to capture the documented >20% energy savings from insulation alone.

By treating the pellet not just as a product to be heated, but as a fuel source itself, the vertical furnace turns a material processing step into an energy-efficient cycle.

Summary Table:

Feature	Energy-Saving Mechanism	Impact on Efficiency
Fuel Source	Internal carbon combustion (coal mine waste rock)	Minimal external natural gas consumption
Airflow Control	Precision forced ventilation	Sustains oxidation and internal heat generation
Insulation	Advanced refractory lining structures	>20% reduction in thermal loss
Heating Mode	Transition from external to internal thermal sources	Self-sustaining sintering process

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References

1. Bakhriddin Turakulov, Yury Liseitsev. Research on the Production of Pigments Based on Composite Pellets in the Recycling of Industrial Waste. DOI: 10.3390/jcs7070289

This article is also based on technical information from Kintek Solution Knowledge Base .