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

1. Refractory

2. Fuel

(Furnace Oil, Pulverised Coal or Gas.)

REFRACTORY PROBLEMS Thermal Shock Cracking. Carbon deposits on the Burner Blocks. 3. Low Emissivity. 4. Corrosive Action. 5. Vicious Sand Blasting Effect.

Thermal Shock Cracking.

Carbon deposits on the Burner Blocks.

3. Low Emissivity.

4. Corrosive Action.

5. Vicious Sand Blasting Effect.

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,

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

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.

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.

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]