General

• Establish a management information system on loading, efficiency, and specific fuel consumption.
• Prevent infiltration of air, using doors or air curtains.
• Monitor O2/CO2/CO ratios and control excess air level.
• Improve burner design, combustion control, and instrumentation.
• Ensure that the furnace combustion chamber is under slight positive pressure.
• Use ceramic fiber linings in the case of batch operations.
• Match the load to the furnace capacity.
• Retrofit with heat recovery devices.
• Investigate cycle times and avoid extended hours of runtime and excess heating.
• Provide temperature controllers.
• Ensure that the flame does not touch the stock.

Insulation

• Repair damaged insulation.
• Use an infrared gun to check for hot wall areas during hot weather.
• Ensure that all insulated surfaces are clad with aluminum lining.
• Insulate all flanges, valves, and couplings.

Waste Heat Recovery

• Recover maximum heat from flue gases.
• Ensure upkeep of heat transfer surfaces by regular cleaning.
• Using waste heat for other process