Increasing refractory lining life and energy saving in furnace operations.

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This presentation introduces a unique technique to substantially increase refractory lining life and save fuel. A number of successful industrial case studies are presented. The technique holds promise of savings for any billet re-heating or sealed quench furnace user by applying this technique.

Increasing refractory lining life and energy saving in furnace operations.

  1. 1. INCREASING REFRACTORYLINING LIFE AND ENERGY SAVING IN FURNACE OPERATIONS. by S.P. SHENOY - C.E.O. and SRIKAR SHENOY – G.M. 211, RAIKAR CHAMBERS, GOVANDI EAST, MUMBAI–400 088. INDIA. Tel. : 6797 8060 Fax : 2555 2459 Email : info@steelplantspecialities.com Website : www.steelplantspecialities.com
  2. 2.  Introduction. Major Causes of Furnace Downtime. Major Costs in Furnace Operation. Pre-Requisites of Optimum Furnace Productivity. Refractory Problems. Benefits of Coating Refractory Lining. Case Studies. Summary.
  3. 3. MAJOR CAUSES OF FURNACE DOWNTIME.• Refractory Wear• Carbon Deposits on Burner Blocks• Choking of Burners• Glossy Deposits on SQF lining.
  4. 4. MAJOR COSTS IN FURNACE OPERATION. 1. Refractory 2. Fuel (Furnace Oil, Pulverised Coal or Gas.)REDUCED COST = IMPROVED PROFITABILITY
  5. 5. PROACTIVITY = PRODUCTIVITY REACTIVITY = DOWNTIME
  6. 6. PRE-REQUISITES OF OPTIMUM FURNACE EFFICIENCY.• Design of refractory lining and furnace to ensure proper heat distribution in furnace.• Pre-heating furnace oil up to 100°C.• Use of recuperator and recovery of heat from flue gases.• Frequent burner cleaning and tuning.• Control of heat loss from furnace openings.
  7. 7. PRE-REQUISITES OF OPTIMUM FURNACE EFFICIENCY.• Complete Combustion with Minimum Excess Air.• 45% Alumina Refractory Bricks. TESTED. -Fe2O3 test : not more than 2%.• Fortified Refractory Lining by use of Refractory Coating.
  8. 8. REFRACTORY PROBLEMS1. Thermal Shock Cracking.2. Carbon deposits on the Burner Blocks.3. Low Emissivity.4. Corrosive Action.5. Vicious Sand Blasting Effect.6. Linear Expansion of Bricks Lead to Increased Furnace Skin Temperature.
  9. 9. BENEFITS OF ESPON-RCP• 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.• Reduced maintenance downtime.
  10. 10. PROPERTIES OF ESPON-RCPGeneral:Non Toxic, Odourless, Tasteless.Chemical Resistance: After firing, ESPON-RCP is unaffected by most acids and alkalies in liquid or gaseous form. Resistance to SO2 & V2O5. Contd.. 2,
  11. 11. PROPERTIES OF ESPON-RCPPhysical 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/ccCoverage: 1.5 kgs/sq.m
  12. 12. FURNACE WALL BEFORE COATING.
  13. 13. FURNACE WALL AFTER COATING.
  14. 14. BURNER BLOCK BEFORE COATING.
  15. 15. BURNER BLOCK AFTER COATING.
  16. 16. What happened after coating the Refractory Lining??
  17. 17. Without With Coating ESPON-RCP CoatingRefractory 12 Months 21 MonthsLining LifeFuel 40 ltrs per ton 38 ltrs per tonConsumptionAnnual Saving ---- 80,000 litresValue of ---- Rs. 16,00,000/-Annual SavingCost of Coating Rs. 80,000/-Net Annual Saving Rs. 15,20,000/-
  18. 18. Case Study No. 2At a leading Forge Shop in Rajkot, savings reported in furnace oil consumption = 3% per day.
  19. 19. Oil Saving per day 36 Litres (1200 x 3%) No. of working days 25 Days per month Oil saving per month 900 Litres Oil price per litre Rs. 24/- Monthly Saving Rs. 21,600 (Rs.24 x 900 ltrs.) 6 Monthly Saving Rs. 1,29,600/- Cost of coating Rs. 8,600/- Savings in 6 months Rs. 1,21,000/-Information as provided by M/s. Forge & Forge Pvt. Ltd., Rajkot, in year 2008.
  20. 20. TESTIMONIALS FROM ESTEEMED USERS:
  21. 21. SUMMARYRefractory coating can substantiallyincrease refractory lining life andreduce fuel consumption.The presented technique is a provenmethod of cost reduction andincreased productivity.
  22. 22. • : Solving Problems Systematically Through• Innovative and customised products.
  23. 23. Thank you ! Tel. : 91-22-6797 8060 Fax : 91-22-2555 2459 Email : info@steelplantspecialities.comWebsite : www.steelplantspecialities.com

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