Designing a new drying furnace utilizing fluidized bed annealing furnace and waste energy from zinc furnaces in Galvanized wire production line

The aim of this thesis is to design a system that recovers waste energy generated during the production process of galvanized wire and reduces production costs by decreasing natural gas consumption. In the galvanized wire production process, operations such as normalization annealing, surface cleaning, coating, and protective treatments are performed starting from the drawn wire. In the existing system, the waste flue gases from the furnace are released into the atmosphere at temperatures of approximately 300-500 °C. In this study, a new drying furnace design was developed to efficiently recover the waste energy from the furnace and use it in the drying process. By implementing this design, natural gas consumption has been reduced and energy efficiency in the production process has increased. Additionally, the environmental impact has decreased, and a sustainable production system has been achieved. The master's thesis, supported by process simulations, data analyses, and design optimizations, evaluated the performance of the new furnace design. With this design, the annual energy cost of the drying furnace was reduced from 889,972.08 TL to 407,671.2 TL. The results obtained have made significant contributions to increasing energy efficiency in the galvanized wire production sector.