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IMPROVING REFRACTORY LINING LIFE AND ENERGY SAVING
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.