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Improving Refractory Lining Life & Energy Saving in Furnace Operations.
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IMPROVING REFRACTORY LINING LIFE AND ENERGY SAVING
IN FURNACE OPERATIONS.by by
S.P.SHENOYS.P.SHENOYC.E.O.,
211, RAIKAR CHAMBERS,
GOVANDI EAST,
MUMBAI–400 088. INDIA.
Tel. : 91-22-6797 8060 Fax : 91-22-2555 2459
Email : [email protected] 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
1. Thermal Shock Cracking.
2. 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 SO2 & V2O5.
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??
Without
Coating
With
ESPON-RC Coating
Refractory Lining Life
12 Months 21 Months
Fuel Consumption
40 ltrs per ton 38 ltrs per ton
Annual Saving ---- 80,000 litres
Value of
Annual Saving
---- Rs. 16,00,000/-
Cost of Coating Rs. 80,000/-
Net Annual Saving Rs. 15,20,000/-
Case Study No. 2
At a leading Forge Shop in Rajkot,savings reported in furnace oil
consumption = 3% per day.
Oil Saving per day 36 Litres (1200 x 3%)
No. of working days per month
25 Days
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/-
SUMMARY
1.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.