DESIGN AND CONSTRUCTION AN ELECTRIC MUFFLE FURNACE
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TITLE PAGE
DESIGN AND CONSTRUCTION AN ELECTRIC MUFFLE FURNACE
BY
---
EE/H2013/01430
DEPARTMENT OF ----
SCHOOL OF ---
INSTITUTE OF ---
DECEMBER,2018
APPROVAL PAGE
This is to certify that the research work, "design and construction an electric muffle furnace" by ---, Reg. No. EE/H2007/01430 submitted in partial fulfillment of the requirement award of a Higher National Diploma on --- has been approved.
By
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Supervisor Head of Department.
Signature………………. Signature……………….
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External Invigilator
DEDICATION
This project is dedicated to Almighty God for his protection, kindness, strength over my life throughout the period and also to my --- for his financial support and moral care towards me.Also to my mentor --- for her academic advice she often gives to me. May Almighty God shield them from the peril of this world and bless their entire endeavour Amen.
ACKNOWLEDGEMENT
The successful completion of this project work could not have been a reality without the encouragement of my --- and other people. My immensely appreciation goes to my humble and able supervisor mr. --- for his kindness in supervising this project.
My warmest gratitude goes to my parents for their moral, spiritual and financial support throughout my study in this institution.
My appreciation goes to some of my lecturers among whom are Mr. ---, and Dr. ---. I also recognize the support of some of the staff of --- among whom are: The General Manager, Deputy General manager, the internal Auditor Mr. --- and the ---. Finally, my appreciation goes to my elder sister ---, my lovely friends mercy ---, ---, --- and many others who were quite helpful.
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This wok is on the muffle furnace using locally sourced materials. The design philosophy is to eliminate the use of heating elements requiring electric power which is poorly supplied in the country. In the design, mild steel was used for the fabrication of the furnace casing, while the other components needed for the design were selected based on functionality, durability, cost and local availability. The furnace was assembled by lining the inner wall of the casing with refractory blocks made from heated mixture of kaolin, clay, sawdust and water after which the inner pot and electro technical devices (temperature controller, light indicator etc) were positioned. Testing was subsequently performed to evaluate the performance of the furnace. It was observed that the furnace has a fast heating rate (61.240C/min to attain a pre-set temperature of 9000C); and a fuel consumption rate less than 1.41litres/hr. It was also observed that the furnace has good heat retaining capacity; can be easily maintained and safe for use.
CHAPTER ONE: INTRODUCTION
- background of study
- aim and objectives
- statement of problem
- relevance / significance
- scope and limitation
- methodology
CHAPTER TWO: LITERATURE REVIEW
2.1 Historical Background (trend) types of furnace; sources of energy etc.
2.2 review of related works
2.3 related mathematical formulae
2.4 basic application principle
2.4.1 heat transfer mode
2.4.2 Heat resistant Material
2.4.2.1 Retractories (types)
2.4.2.2 TYPES OF REFRACTORIES
- Fireclay
- High alumina
- Chromites
- Silica bricks
- Zirconia
- Oxide
- Monolithic
2.4.4 heat losses and furnace lagging
2.4.4.1 insulating materials
- Ceramic fibre
- Natural fibre
- Locally available insulating material e.g kaolin, sawdust, ash charcoal dust, sodium silicate, fire cement, etc.
Thermal properties of an insulating materials, e.g.
- Thermal conductivity
- Specific heat capacity
- Thermal diffusivity
CHAPTER THREE
METHODOLOGY AND MATERIALS SELECTION
- Design considerations and calculations
- Materials used
- Design
- Fabrication procedure
- Design constants and calculation
CHAPTER FOUR
- Result analysis
- Performance evaluation
- Safety and maintenance
- Cost analysis
CHAPTER FIVE
- Conclusion
- References
1.0 INTRODUCTION
1.1 BACKGROUND OF THE PROJECT
This work is on an electric muffle furnace which is a furnace in which the subject material is isolated from the fuel and all of the products of combustion, including gases and flying ash. [C.A. Crowley, 1937]. After the development of high-temperature heating elements and widespread electrification in developed countries, new muffle furnaces quickly moved to electric designs. [C.A. Crowley, 1937]
Historically, small muffle ovens were often used for a second firing of porcelain at a relatively low temperature to fix overglaze enamels; these tend to be called muffle kilns. The pigments for most enamel colours discoloured at the high temperatures required for the body and glaze of the porcelain. They were used for painted enamels on metal for the same reason.
Today, a muffle furnace is a front-loading box-type oven or kiln for high-temperature applications such as fusing glass, creating enamel coatings, ceramics and soldering and brazing articles. In ceramics muffle kilns were typically used for relatively low temperatures, for overglaze decoration. They are also used in many research facilities, for example by chemists in order to determine what proportion of a sample is non-combustible and non-volatile (i.e., ash). Some models incorporate programmable digital controllers, allowing automatic execution of ramping, soaking, and sintering steps[C.A. Crowley, 1937]. Also, advances in materials for heating elements, such as molybdenum disilicide, can now produce working temperatures up to 1,800 degrees Celsius (3,272 degrees Fahrenheit), which facilitate more sophisticated metallurgical applications.
An electric muffle furnace is usually heated to desired temperatures by conduction, convection, or blackbody radiation from electrical resistance heater elements. Therefore, there is no combustion involved in the temperature control of the system, which allows for much greater control of temperature uniformity and assures isolation of the material being heated from the byproducts of fuel combustion.
1.2 PROBLEM STATEMENT
The heating means of conventional furnace is only done thermally which becomes a problem when the means of generating the heat is not available. In other to overcome this challenge a muffle furnace was invented, which is an enclosure in which energy in a non-thermal form is converted to heat, especially such an enclosure in which heat is generated by the combustion of a suitable fuel. The furnace is usually heated to desired temperatures by conduction, convection or blackbody radiation from electrical resistance heating elements
1.3 AIM AND OBJECTIVES THE PROJECT
The main aim of this work is to build a piece of oven-type equipment that can reach high temperatures. It usually works by putting a high-temperature heating coil in an insulated material. The insulating material effectively acts as a muffle, preventing heat from escaping.
1.4 APPLICATION OF THE PROJECT
Today, an electric muffle furnace is usually a front-loading box or tube design used for high-temperature applications such as melting glass, creating enamel coatings, technical ceramics or soldering and brazing. They are also used in many research facilities to determine what proportion of a sample is non-combustible and non-volatile (i.e. ash).
1.5 SIGNIFICANCE OF THE PROJECT
An electric muffle furnace is made of standard quality materials which make it durable, reliable and perfect for long time use. The outer case or cabinet of this muffle furnace is made of thick PCRC sheet. The case is painted with stove enable that keeps the unit rust free. Electric muffle furnace provides accuracy and reliability, set point and actual temperature dual display.
1.6 SCOPE OF THE PROJECT
An electric muffle furnace has an externally heated chamber, the walls of which radiantly heat the contents of the chamber, so that the material being heated has no contact with the flame. Muffle furnaces are most often utilized in laboratories as a compact means of creating extremely high-temperature atmospheres. They are employed to test the characteristics of materials at extremely high and accurate temperatures. A muffle furnace is also known as a retort furnace.
1.7 METHODOLOGY
To achieve the aim and objectives of this work, the following are the steps involved:
- Study of the previous work on the project so as to improve it efficiency.
- Draw a block diagram.
- Test for continuity of components and devices,
- programming of microcontroller
- Design and calculation for the work was carried out.
- Studying of various component used in circuit.
- Construct the whole circuit.
- Finally, the whole device was cased and final test was carried out.
The work is organized as follows: chapter one discuses the introductory part of the work, chapter two presents the literature review of the study, chapter three describes the methods applied, chapter four discusses the results of the work, chapter five summarizes the research outcomes and the recommendations
CHAPTER TWO: The chapter one of this work has been displayed above. The complete chapter two of "design and construction an electric muffle furnace" is also available. Order full work to download. Chapter two of "design and construction an electric muffle furnace" consists of the literature review. In this chapter all the related work on "design and construction an electric muffle furnace" was reviewed.
CHAPTER THREE: The complete chapter three of "design and construction an electric muffle furnace" is available. Order full work to download. Chapter three of "design and construction an electric muffle furnace" consists of the methodology. In this chapter all the method used in carrying out this work was discussed.
CHAPTER FOUR: The complete chapter four of "design and construction an electric muffle furnace" is available. Order full work to download. Chapter four of "design and construction an electric muffle furnace" consists of all the test conducted during the work and the result gotten after the whole work
CHAPTER FIVE: The complete chapter five of design and construction of a "design and construction an electric muffle furnace" is available. Order full work to download. Chapter five of "design and construction an electric muffle furnace" consist of conclusion, recommendation and references.
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