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Teide presentation clemson 2013 Presentation Transcript

  • 1. CLEMSON ' 13 TEIDE REFRACTORY SOLUTIONS 1954 - 2013 59 years working for the ceramic industry Carlos Mazorra Sales Director cm@teide.es Barcelona , SPAIN 1
  • 2. CLEMSON ' 13 INDEX 1. INTRODUCTION 2. R + D WORKS 2.1.- TESTS 2.2.- 3D PROTOTYPES PRINTER 2.3.- VIRTUAL SIMULATOR SOFTWARE 1. KILN CARS 3.1.- PRESSED MATERIAL VS EXTRUDED 3.2.- VTP: FULLY PRESSED KILN CAR. 3.3.- VMX: MIXED PLATFORM KILN CAR. 3.4.- VEX: EXTRUDED PLATFORM KILN CAR. 3.5.- VNT2 AND VNA: NEW TECHNOLOGY KILN CAR. 3.6- COMPARATIVE CHART 3.7- PRE-ASSEMBLY OF THE LINING AT TEIDE’S WORKS. 4. CEILING ROOFS 4.1.- PRESSED SUSPENDED DOME 4.2.- INSULATING FLAT DOME 4.3.- CONCRETE DOME 5. WALLS. 5.1.- COMPARATIVE CHART 5.2.- WAL TYPE MDF 6. WORLDWIDE REFERENCES 2
  • 3. CLEMSON ' 13 1.- INTRODUCTION. - TEIDE REFRACTORY SOLUTIONS is a SPANISH leader company in the refractory field. Through our policy of innovation, TEIDE offer its high quality materials, accredited by international standards. TUV 9001:2008 German Accreditation. - More than 30.000 tons/year - 2 production sites, more than 25.000 sqm of works. - 20 presses, 2 extruders and 4 kilns(2 tunnel),work up-to 3.000 ºF. - More than 1.400 formulations adapted to our customers. - 25 years designing kiln cars for the ceramic industry. - Teide designs you can find them on the five continents 3
  • 4. 4 CLEMSON ' 13 2.- R + D WORKS. 2.1.- TESTS Our laboratory’s people together with our research and development department ( R&D) is continuously performing several tests , in our facilities , not only to control the consolidated products but also the ones that are still under study to be developed.: - MECHANICAL RESISTANCE POROSITY RESISTANCE TO THERMAL SHOCK ABRASION RESISTANCE OXIDATION OF THE MATERIAL DENSITY REVERSIBLE LINEAR VARIATION PERMANENT LINEAR VARIATION VICAT TEST GRANULOMETRY TEST - CORROSION IMPACT RESISTANCE PERMEABILITY YOUNG’s MODULUS FLUENCE. (∆ dimension at constant Temperature ) - CREEP (∆ dimension at increased Temperature ) - MIXING EQUIPMENT - WORKABILITY TEST
  • 5. CLEMSON ' 13 2.- R + D WORKS. 2.1.- TESTS RESISTANCE TO THERMAL SHOCK: UNE EN 993-11 5
  • 6. KELLER 0907 6
  • 7. KELLER 0907 7
  • 8. KELLER 0907 8
  • 9. 4. KELLER 0907 9
  • 10. KELLER 0907 R-COR-PI :Reversible linear dilatation 10
  • 11. CLEMSON ' 13 2.- R + D WORKS. 2.1.- TESTS IMPACT RESISTANCE TEST 11
  • 12. CLEMSON ' 13 2.- R + D WORKS. 2.1.- TESTS MECHANICAL RESISTANCE TEST: UNE EN 993-5 12
  • 13. 13 CLEMSON ' 13 2.- R + D WORKS. 2.2.- 3D PRINT Our Engineering department has a 3D printer that allows show the customer the proposed design before being manufactured (scale 1:5). On the other hand, this print let us check one new technology or design before that we recommend it, to our costumers. WE CAN DO ANY COSTUMER’S PROTOTIPE IN DAYS!! Printer working video 3D Printer
  • 14. CLEMSON ' 13 2.- R + D WORKS. 2.3.- VIRTUAL SIMULATOR TEIDE has an own software which allows simulate the work conditions that one piece or a group of it will have in the real application. Also permit us to study a problem that could have any costumer, simulating the work of this piece and trying to find the solution. - Heat Transfer. - Thermal Stress. - Fluid Dynamics WE CAN SIMULATE YOUR THERMAL BALANCE KILN TO ACHIEVE ANY PERFORMANCE YOUR REQUIRED!! 14
  • 15. 2.- R + D WORKS. 2.3.1- HEAT TRANSFER EXAMPLE
  • 16. 2.- R + D WORKS. 2.3.2- MECHANICAL STRESS EXAMPLE LOAD = 1.100 lb / piece
  • 17. CLEMSON ' 13 3.- KILN CARS TEIDE IS MAYBE THE MOST VERSATILE KILN CAR DESIGNER, WITH AROUND 10 DIFFERENT TECHNOLOGIES. SOME OF THEM ARE IN THE FOLLOWING PAGES 17
  • 18. 18 CLEMSON ' 13 3.- KILN CARS 3.1.- PRESSED MATERIAL VS EXTRUDED PRESSED EXTRUDED 900 - 1500 750 – 1.000 Mechanical strength. + - Durability. + - Dimensional tolerance. - + Porosity. - + Thermal shock resistance + - Manufactured pressure psi 7.000 700 Price USD/Tn
  • 19. 19 CLEMSON ' 13 3.- KILN CARS 3.1.- PRESSED MATERIAL VS EXTRUDED Press with 1.000 tons of pressure working: Video Cordierite Press slabs versus extruded ones for brick kiln car. Test video
  • 20. CLEMSON ' 13 3.- KILN CARS 3.2.- VTP: FULLY PRESSED KILN CAR • Made on cordierithic materials, all parts are 100% by pressed, being a solution with excellent mechanical resistance. Pressed pieces can offer a Cold crushing strenght over 6.500 psi. 20
  • 21. CLEMSON ' 13 3.- KILN CARS 3.3.- VMX: MIXED PLATFORM KILN CAR • Made on cordierithic materials, pressed parts to most vulnerable zones and lighter extruded parts to the rest. • This technology offers the best average on quality / price. • REALLY RECOMENDED BY TEIDE to almost all cases. 21
  • 22. CLEMSON ' 13 3.- KILN CARS 3.4.- VEX: EXTRUDED PLATFORM KILN CAR • Made on cordierithic materials. All parts produced by extrussion, except the corners, which are by pressed to support the dilatation of the rest. 22
  • 23. CLEMSON ' 13 3.- KILN CARS 3.5.- VNT2: A NEW TECHNOLOGY OF KILN CARS • Made on cordierithic materials, do not considers any kind of platform. Flue blocks stand directly above the inner support tubes. Insulation core on two layers. A really low cost option, with low heat storage but higher maintenance. 23
  • 24. CLEMSON ' 13 3.- KILN CARS 3.5.- VNA: A NEW TECHNOLOGY OF KILN CARS • Made on cordierithic materials, do not considers any kind of platform. Flue blocks stand over transversal plots. Insulation core on two layers; low temperature calcium silicate and lightweight insulating concrete.. 24
  • 25. 25 CLEMSON ' 13 3.- KILN CARS 3.6.- COMPARATIVE CHART Type of kiln car Kiln car density Price (lb/cuft) average CONDITIONS: - 2.000 ºF - Thickness 12,5” + 4,9” Max payload Weight Tª cold face Heat loss Heat storage admited average (ºF) (Btu/ft2hr) (Btu/ft2) (lb/ft2) 1.- VTP 67 100 % 100% 183 220 18.007 512 2.- VMX 64 81 % 94% 181 213 17.830 410 3.- VEX 60 75 % 90% 180 207 17.654 328 4.- VNT2 57 58 % 89% 181 209 14.917 266/307 5.- VNA 64 68 % 99% 181 206 18.095 287
  • 26. CLEMSON ' 13 3.- KILN CARS 3.7.- PREASSEMBLY OF THE LINING AT TEIDE’S WORKS - At the end of the production and before the delivery, our technicians make a set-up simulation to test and verify a correct production. - This set-up is a real test to validate the drawings of the project. - The test would allow us to detect any deviation on the dimensions or defaults on the production, being able to correct them quickly. 26
  • 27. CLEMSON ' 13 3.- KILN CARS 3.7.- PREASSEMBLY OF THE LINING AT TEIDE’S WORKS 27
  • 28. CLEMSON ' 13 3.- KILN CARS 3.7.- PREASSEMBLY OF THE LINING AT TEIDE’S WORKS 28
  • 29. CLEMSON ' 13 3.- KILN CARS 3.7.- PREASSEMBLY OF THE LINING AT TEIDE’S WORKS 29
  • 30. CLEMSON ' 13 4.- CEILING ROOFS 4.1.- PRESSED SUSPENDED DOME - Best cost/quality ratio. - Better traction/flexion than concrete dome. - Density average 62 lb/cu ft. - Slow shut down and start firing required (1-2 weeks). 30
  • 31. CLEMSON ' 13 4.- CEILING ROOFS 4.2.- INSULATING FLAT DOME - Start/Stop of firing in 48-72 hours. - Average density 40 lb/cu ft. - Energy savings. 31
  • 32. CLEMSON ' 13 4.- CEILING ROOFS 4.3.- CONCRETE DOME - For quick installations or repairs in 2-3 weeks. - Ceramic anchors on stock. - Average density 93 lb/cu ft. 32
  • 33. CLEMSON ' 13 5.- WALLS Our R+D people have developed several alternatives to common brick walls and pre-shaped blocks walls. We have studied and compared the different wall conceptions too, in order to state which is the better option. Basically we can tell up-to 5 different types: 1 – Wall type MF: Pre-shaped and hollow blocks. 2 – Wall type MDF: Pre-shaped and dense blocks. 3 – Wall type MTD: on a basis of dense firebricks. 4 – Wall type MTA: on a basis of insulating brick. 5 – Wall type MTH: on a basis of castable Refractory 33
  • 34. CLEMSON ' 13 5.- WALLS 5.1.- COMPARATIVE CHART 34
  • 35. CLEMSON ' 13 5.- WALLS 5.2.- WALL TYPE MDF THE MDF TECHNOLOGY, IS THE FASTER ERECTION ONE AND GOOD INSULATION. 35
  • 36. CLEMSON ' 13 6.- WORLDWIDE REFERENCES • More than 300 projects around the world … Goal: Equilibrium between: - Insulation, Energy saving. - Decreasing waste material. - Maintenance cost. - Adquisition cost. 36
  • 37. CLEMSON ' 13 6.- WORLDWIDE REFERENCES Wienerberger Terca Beerse, is the biggest kiln car ever supplied by TEIDE, 30,2 ft x 21,7 ft) which works at 2.280ºF for facing bricks. 37
  • 38. CLEMSON ' 13 6.- WORLDWIDE REFERENCES Wienerberger Terca Beerse 38
  • 39. CLEMSON ' 13 6.- WORLDWIDE REFERENCES Heluz-Hevlin, Czech Republic, the most efficient plant in Europe. Fully automatic with minimal staff per shift to produce 16Milion bricks, 10 hours cicle. 39
  • 40. CLEMSON ' 13 6.- WORLDWIDE REFERENCES BORAL Midwest, Terre Haute IN, USA. 27 ft x 18,2 ft More than 100 cars were supplied in our biggest installation done in USA. 40
  • 41. CLEMSON ' 13 6.- WORLDWIDE REFERENCES Kiln car for sanitary ware, 2.375ºF SURIA TOTO, Indonesia. 41
  • 42. CLEMSON ' 13 6.- WORLDWIDE REFERENCES TOPTELHA, Brazil. Tile firing kiln car. 42
  • 43. KELLER 0907 43
  • 44. KELLER 0907 44
  • 45. 45 CLEMSON ' 13 ... Sometimes fire doesn’t burn... cm@teide.es www.teide.es