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MAFTEC - A Case Study

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How pre-fabricated MAFTEC modules can break the cycle of continuous module maintenance

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MAFTEC - A Case Study

  1. 1. A CASE STUDY… Pre-Fabricated MAFTEC Roof Panels For a Furnace Roof
  2. 2. Ceramic Fiber Modules being used in furnace roof and upper sidewalls HTZ Blanket, 1” thick, 8 lb density “Service Limit” 2600 o F Furnace Operating Temp = 2350 o F THE SITUATION…
  3. 3. Excessive shrinkage, caused by thermal stress on the modules Large gaps appear between modules and surrounding refractory Escaping heat causes hot spots on the furnace steel Module anchor system becomes affected by heat THE PROBLEMS…
  4. 4. Vitrification (hardening) of module surface leads to crumbling and loss of material Modules lose their ability to contain the heat More energy (fuel) required to maintain temperatures THE PROBLEMS (cont’d)…
  5. 5. Hot spots occur on the outer steel, causing expensive damage to furnace structure Over time, more and more maintenance is required Open joints where shrinkage has occurred require re-packing with additional fiber Shrinkage continues Modules become loose, due to shrinkage and anchor damage THE PROBLEMS (cont’d)…
  6. 6. Hot spots continue to appear, becoming larger, doing more damage Injection of a pumpable servicing mix is tried, which might temporarily solve the problem Furnace reliability suffers Modules are eventually replaced Burned, damaged steel is repaired Cycle is repeated! THE PROBLEMS (cont’d)…
  7. 7. SOUND FAMILIAR?
  8. 8. MAFTEC modules are made from polycrystalline alumina fiber blanket Temperature limit of 2950 o F Shrinkage rate of MAFTEC at 2950 o F is only 1.5%, compared to 12-14% for ceramic fiber Opening of joints due to shrinkage is no longer an issue Thermal efficiency is stable, reducing heat loss and fuel costs during the life of the lining THE SOLUTION!
  9. 9. MAFTEC blanket is not affected by temperatures below 2950 o F Retains resiliency, no vitrification on surface No maintenance required, no packing of joints, pumping, etc. Steel damage due to hot spots is avoided Furnace reliability is improved Cycle of Refractory Module Maintenance is Broken! THE SOLUTION!
  10. 10. THE SOLUTION! This MAFTEC roof has been in service for 5 years, with no maintenance to date. Modules still tight, material still resilient
  11. 11. “Innovative Ways to Harness the Heat” Contact TFL today for more information www.tflhouston.com

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