This document discusses how coating refractory linings can increase furnace efficiency and reduce costs. It describes how refractory lining wear, carbon deposits, and other issues lead to increased downtime and costs. Coating refractory with ESPON-RCP can increase refractory life from 12 to 21 months, reduce fuel consumption by 2 liters per ton, and provide annual savings of over 15 lakh rupees in one case study. Testimonials from industrial users support that refractory coating is an effective way to lower costs and improve productivity in furnace operations.

1. INCREASING REFRACTORY
LINING 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.  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. MAJOR CAUSES OF
FURNACE DOWNTIME.
• Refractory Wear
• Carbon Deposits on Burner Blocks
• Choking of Burners
• Glossy Deposits on SQF lining.

4. MAJOR COSTS
IN FURNACE OPERATION.
1. Refractory
2. Fuel
(Furnace Oil, Pulverised Coal or Gas.)
REDUCED COST = IMPROVED PROFITABILITY

5. PROACTIVITY = PRODUCTIVITY
REACTIVITY = DOWNTIME

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. 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. REFRACTORY PROBLEMS
1. 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. 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. PROPERTIES OF ESPON-RCP
General:
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. PROPERTIES OF ESPON-RCP
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

12. FURNACE WALL BEFORE COATING.

13. FURNACE WALL AFTER COATING.

14. BURNER BLOCK BEFORE COATING.

15. BURNER BLOCK AFTER COATING.

16. What happened after coating
the Refractory Lining??

17. Without With
Coating ESPON-RCP Coating
Refractory 12 Months 21 Months
Lining Life
Fuel 40 ltrs per ton 38 ltrs per ton
Consumption
Annual Saving ---- 80,000 litres
Value of ---- Rs. 16,00,000/-
Annual Saving
Cost of Coating Rs. 80,000/-
Net Annual Saving Rs. 15,20,000/-

19. Case Study No. 2
At a leading Forge Shop in Rajkot,
savings reported in furnace oil
consumption = 3% per day.

20. 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.

21. TESTIMONIALS FROM
ESTEEMED USERS:

25. SUMMARY
Refractory coating can substantially
increase refractory lining life and
reduce fuel consumption.
The presented technique is a proven
method of cost reduction and
increased productivity.

26. • : Solving Problems Systematically
Through
• Innovative and customised products.

27. Thank you !
Tel. : 91-22-6797 8060 Fax : 91-22-2555 2459
Email : info@steelplantspecialities.com
Website : www.steelplantspecialities.com