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 : 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

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.

THANK YOU !

S.P.SHENOYS.P.SHENOY98207123879820712387

espon@vsnl.netespon@vsnl.net