Improving Refractory Lining Life & Energy Saving in FO
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Improving Refractory Lining Life & Energy Saving in FO

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Improving Refractory Lining Life & Energy Saving in Furnace Operations.

Improving Refractory Lining Life & Energy Saving in Furnace Operations.

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Improving Refractory Lining Life & Energy Saving in FO Improving Refractory Lining Life & Energy Saving in FO Presentation Transcript

  • IMPROVING REFRACTORY LINING LIFE AND ENERGY SAVING IN FURNACE OPERATIONS. by S.P.SHENOY C.E.O., 211, RAIKAR CHAMBERS, GOVANDI EAST , MUMBAI–400 088. INDIA. Tel. : 91-22-6797 8060 Fax : 91-22-2555 2459 Email : espon@vsnl.net Website : www.esponcoating.com
  • MAJOR COSTS IN FURNACE OPERATION.
    • 1. Refractory
    • 2. Fuel
    • (Furnace Oil, Pulverised Coal or Gas.)
    REDUCED COST = IMPROVED PROFITABILITY
  • REFRACTORY PROBLEMS
    • Thermal Shock Cracking.
    • Carbon deposits on the Burner Blocks.
    • 3. Low Emissivity.
    • 4. Corrosive Action.
    • 5. Vicious Sand Blasting Effect.
    View slide
  •   View slide
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  • PROPERTIES OF ESPON-RC
    • General :
    • Odourless, Tasteless, Non toxic
    • Chemical Resistance:
    • After firing, ESPON-RC is unaffected by most acids and alkalies in liquid or gaseous form. Resistance to SO 2 & V 2 O 5.
    • Contd.. 2,
  • PROPERTIES OF ESPON-RC
    • Physical Properties :
    • Slightly plastic above 200 deg. C.
    • Thermal expansion: 1% over the range of
    • 0 to 1900 deg. C.
    • Shrinkage : 0.25% max.
    • Bulk Density: 2.42 gms/cc
    • Coverage: 1.5 kgs/sq.m
  • BENEFITS OF ESPON-RC
    • Energy Saving due to improved emissivity.
    • Prevention of carbon deposits on burner block.
    • Prevention of thermal shock cracking.
    • Resistance to high temperature corrosion by acidic gases.
    • Prevention of diffusion of hot gasses through refractory lining.
    • Prevention of energy leaks through cracks.
    • Prevention of slag adhesion.
    • Reduced maintenance downtime.
  • FURNACE WALL BEFORE COATING.
  • FURNACE WALL AFTER COATING.
  • BURNER BLOCK BEFORE COATING.
  • BURNER BLOCK AFTER COATING.
  • What happened after coating the Refractory Lining??
  • Rs. 80,000/- Cost of Coating Rs. 15,20,000/- Net Annual Saving Rs. 16,00,000/- ---- Value of Annual Saving 80,000 litres ---- Annual Saving 38 ltrs per ton 40 ltrs per ton Fuel Consumption 21 Months 12 Months Refractory Lining Life With ESPON-RC Coating Without Coating
  •  
  • Case Study No. 2 At a leading Forge Shop in Rajkot, savings reported in furnace oil consumption = 3% per day.
  • Rs. 8,600/- Cost of coating Rs. 1,21,000/- Savings in 6 months Rs. 21,600 (Rs.24 x 900 ltrs.) Monthly Saving Rs. 1,29,600/- 6 Monthly Saving Rs. 24/- Oil price per litre 900 Litres Oil saving per month 25 Days No. of working days per month 36 Litres (1200 x 3%) Oil Saving per day
  • SUMMARY
    • Use of a special refractory coating holds high promises to furnace operators who are interested in improving refractory lining life and energy saving.
    • 2. This technique is a sure way of cost reduction.
  • THANK YOU ! S.P.SHENOY 9820712387 [email_address]