Taylor Rector, Peter Komrowski, Steve Palin, Phil Saucier

November 7, 2023

Maximizing furnace efficiency: innovative solutions for sustainable industrial operations

With climate action a clear global imperative, businesses around the world are seeking solutions for sustainable operations and decarbonization. This is driving a rapid shift to renewable energy, improved efficiency, advancing low-carbon technologies and energy systems, and decarbonizing key sectors such as energy and manufacturing. In response, industrial companies are exploring innovative solutions to reduce their carbon footprint and achieve their sustainability goals.

Heavy forgings plant. Metal work, melt metal work
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Improvements to furnace efficiency and burner technology offer sustainable solutions that not only reduce emissions and fuel consumption but also improve overall process efficiency.

Improving furnace efficiency

While industrial furnaces are critical components in many manufacturing processes, they also consume significant energy and generate emissions that contribute to climate change. To improve furnace efficiency and reduce fuel consumption, industrial companies are exploring a variety of solutions, including:

  • High-efficiency burners: Using high-efficiency burners, such as recuperative or regenerative burners, can significantly reduce fuel consumption and emissions while maintaining the necessary process temperatures.
  • Pulse firing combustion: Unlike traditional combustion systems, pulse firing combustion uses an algorithm that cycles burners through a high fire/low fire/off firing sequence, which delivers the necessary heat that the application requires and prevents the heating up of additional air that is wasted. This approach allows for greater control over the combustion process and reduces fuel consumption and emissions while maintaining the necessary process temperatures.
  • Waste heat recovery: Capturing waste heat from industrial processes and reusing it in other parts of the manufacturing process can significantly improve energy efficiency and reduce fuel consumption.
  • Combustion air preheating: Preheating combustion air using waste heat from the process or other sources can significantly reduce fuel consumption and emissions.
Benefits of furnace efficiency improvements

Improvements to furnace efficiency offer several key benefits to industrial companies, including:

  • Lower emissions: By reducing fuel consumption and improving combustion efficiency, improvements to furnace efficiency can significantly reduce emissions of harmful pollutants, such as nitrogen oxides (NOx) and carbon monoxide (CO).
  • Fuel savings: The ability to cycle burners on and off, use high-efficiency burners, and capture waste heat results in significant fuel savings, reducing operational costs for industrial companies.
  • Improved energy efficiency: By optimizing the combustion process and capturing waste heat, furnace efficiency improvements can reduce the amount of wasted heat and improve overall process efficiency.
Case study: 27% natural gas savings with pulse firing

A recent installation of pulse firing combustion on a box style furnace at a manufacturing plant resulted in approximately 27% savings in natural gas consumption. The installation included an algorithm that cycled the burners through a high fire/low fire sequence based on the required process temperatures, resulting in improved energy efficiency and significant fuel savings.

glühende Stahlträger Hochofen / steel mill factory
Natural gas consumption statistics
  1. When 1,000 cubic feet of natural gas (one dekatherm) is burned, it releases approximately 120 pounds of carbon dioxide (CO2) into the atmosphere.
  2. In the US, the industrial sector is responsible for approximately 29% of total energy-related CO2 emissions. Within the industrial sector, approximately 34% of emissions come from combustion of natural gas.
  3. In 2020 the industrial sector was responsible for the combustion of 10.3 trillion cubic feet of natural gas, resulting in the release of approximately 1.4 billion metric tons of CO2 emissions, according to the US Energy Information Administration.
  4. The combustion of natural gas also results in the emission of other pollutants, including nitrogen oxides (NOx), sulfur dioxide (SO2), and particulate matter (PM).
  5. The use of pulse firing combustion technology in industrial applications has been shown to result in significant reductions in natural gas consumption, ranging from 10-40%. This can translate into significant reductions in CO2 and NOx emissions as well.
Ramboll can help

Ramboll is at the forefront of the green transition, with an unmatched position in renewable energy, and with cutting-edge sector and consulting expertise. Our scientists and engineers have decades of experience assisting industrial clients with updates that better align business objectives with Environmental, Social, and Governance (ESG) commitments and reduce their operational expenditures. We provide a range of services, including pulse firing combustion, to help clients improve energy efficiency, reduce emissions, and contribute to a more sustainable future.

Want to know more?

  • Taylor Rector

    Business Development Manager 1

    +1 315-243-1334

    Taylor Rector

  • Steve Palin

    Sr. Vice President - Advanced Manufacturing

    +1 315-439-2343

    Steve Palin

  • Peter Komrowski

    Director, Energy Intensive Industries

    +1 315-440-6688

    Peter Komrowski

  • Phil Saucier

    Thermal Process Manager

    +1 315-447-0976

    Phil Saucier