seminar ficci

8/15/2019 Seminar FICCI

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Energy savings by selection ofadvanced insulation materials, low life

cycle cost

Presented by

Tapas Kumar Haldar

Murugappa Morgan Thermal Ceramics Ltd.


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Contents

• Introduction of Morgan Crucible & Thermal Ceramics

• Highlights of MMTCL

• Meeting End users Expectations• Design Considerations

• Advanced Insulation Products

• Features and benefits of advanced products• Conclusion

• Question & Answer session


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Introduction of Morgan Crucible

1856

,

1890,

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11500 140 40

, , ,

. 1


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Introduction of MMTCL

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End Users Expectations : combustion equipment

• Let us see from Furnace user’s perspective

– Lower cost per unit produced

– Faster throughput – Lower energy cost

– Lower downtime due to sudden breakdown

– Lower maintenance – Lower space utilisation by furnace

– Adherence to Environment norms

– Good Controls – Reduction in rejections


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New Age Business Drivers

• Hyper Competition - Quick & Aggressive

• Shrinking Business Cycle - Time to market, Cost• Comoditisation of Product & Services

• Products and Services - Differentiated by knowledge

• Rising external stakeholders power - Consumer,Investors, ….

• Increase of fuel/Energy price


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Customer Satisfaction: Past - Future

:

/

/


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Using Advanced InsulationMaterials will enable the

challenges


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Advanced insulation materials:

• BTU Block products

• Pyrobloc Modules

• JM range of Insulating firebricks

• Superwool PLUS blankets


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Design Considerations


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Basic design Aspects

Lining thickness- Heat

H e

Heat Storage=m*Cp*Av T

Lining thickness

t / T e m p

Ambient

Heat Loss

=Fn. of K


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Batch Type

Operations….

• moderate liningthickness

• Lower heat storage by

Continuos Operation..

•Higher liningthickness

•Higher heat storage

Typical Design Considerations

• Comparatively Higherheat loss throughsurface may be

considered

by lining•Lower heat loss

through surface is

desired


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Benefits of BTU Block Boards

– Reduced Energy Consumption

– Space Savings

• Increased Thermal Efficiency gives: – Increased Interior Space

– Increased Factory Floor Space

–

Improved Safety Conditions

– Solutions for Thermal Containment Problems• When Traditional Insulation Fails


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BTU Block Board/Flexible

• With 15 mm thk BTU back up, in place of anyback up (by Calsil, Ceramic Fibre board etc),

reduces cold face temp by 7 to 9 DegC(Operating temp 1200 deg C)

• .

Rs. 8000/annum/m2

• Pay back around a year


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PYROLOG& PYOBLOC

Classification Temp. - 1260 & 1425 Deg C,Density - 160, 190, 240 kg/Cub M


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K Value (W/mk) at mean temperatureTemperature Deg C

Pyrobloc 240 kg/m3 Folded module 160 kg/m3

200 0.0629 0.0713

400 0.0924 0.107

Thermal conductivity of Pyrobloc vs. Folded

module/Strip Module

. .

800 0.2004 0.2311


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• Pyro-Bloc, being

compressible in both

directions, easily adapts

to irregular spaces and

provides an easy on site

installation

• ower e ec o

shrinkage due to higher

density of 240 kg/m3

• Answer to high

temperature application• Lower heat loss over

folded module due to low

thermal conductivity


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By selecting Pyrobloc - 240 Kg/m3over normal folded module can save

10% depending upon OperatingConditions


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• JM & K range ofInsulation Fire Bricks

• Produced in Italy,USA & China

• Manufacturing

INSULATION FIRE BRICKS

capacity - 45 million

pces/annum

• Low K Value

• Good Hot Strength


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Temperature

Deg C

K-Value (W/mk) at mean temperature

JM23 HFI

(Mfr A) (Mfr B) (Mfr C)

Comparison of Thermal Conductivity of JM Insulation

Fire Bricks (IFB) vs. Other IFB

gC)

400 0.109 0.34 0.31 0.16 0.24

600 0.126 0.38 0.30 0.20 Not available

800 0.142 0.41 0.36 0.28 Not available

1000 0.157 0.44 0.37 0.31 Not available


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•The K value of JM 23 is just half of normal IFBs

available (Commercial quality)

• By using JM 23 as back up or hot face, in any

furnace/kiln the cold face temp will be at least 10 to

JM Insulation Fire Bricks

• This saves around heat loss by 500 w/m2 in hot zone

= 1.7 lit/m2 /day= Rs. 50/m2/day

• For back up or hot face application the pay back will

be within 1 to 2 years depending upon operatingconditions


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Bio-persistence

• Definition:

– The ability of fibres to resist removal from the

lungs by natural mechanisms (i.e., dissolutionand breakage)

• How Measured?: – It is measured by the time it takes for half of

the fibres induced to disappear from the lungs


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Features: Superwool PLUS

• Superwool PLUS products offer all of the features you arefamiliar with from standard Ceramic Fibre insulations:

– Excellent Thermal Conductivity

– Low Heat Storage

– Resistant to Thermal Cycling

– Hig trengt

– Ease of Fabrication

– Resistance to Molten Aluminum

– Extremely Low and Stable Shrinkage up to ServiceTemperature


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Linear Shrinkage – Superwool Products vs. RCF

6

8

10

s h r i n k a g e

6

8

10

s h r i n k a g e

Linear shrinkage (ENV1094Linear shrinkage (ENV1094--7):7):

0

2

1050 1100 1150 1200 1250 1300 1350

Temperature °C (oF)

L i n e a

SW 607 RCF SW607HT

Classification

Temperature:SW607HT

(2012) (2102) (2192) (2282) (2372) (2482)

0

2

1050 1100 1150 1200 1250 1300 1350

Temperature °C (oF)

L i n e a

SW 607 RCF SW607HT

Classification

Temperature:SW607HT

(2012) (2102) (2192) (2282) (2372) (2482)


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Benefits:

• By using Superwool PLUS blankets, the liningthickness can be reduced by ~ 15 to 20%compared to Ceramic fibre blankets

• If same thickness of Superwool PLUS used that ofCeramic Fibre, the energy savings will be ~ 10 to


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Mathematical Model of lifecycle cost -CGL

• Vertical CGL lined with Pyrobloc Module

Pyrobloc lining during commissioning Condition of lining after 4 years


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Pyrobloc Modulelining

Folded modulelining

Lining design 1425 grade/300 mm

thk/240 kg/m3

1425 grade/300 mm

thk/190 kg/m3

Price/m2 Rs 13000.00/m2 Rs 11000.00/m2

xpec e e ~ years ~ years

Heat loss (w/m2) 680 760

Energy savings

towards heat loss

Rs 100/m2/annum (Rs

700/m2 for lifecycle)

-

Maintenance cost (@5%/annum)

Rs 1300.00 for last 2years

Rs 3000.00 for 5 years


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Pyrobloc Modulelining

Folded modulelining

Total Cost of lining Rs 13000 + Rs 1300less Rs 700.00 = Rs13600.00

Rs 11000 + Rs 3000 =Rs 14000.00

Linin cost ear m2 Rs 1950.00 Rs 2800.00

• The lifecycle cost of Pyrobloc lining is 30% lesser than Foldedmodule

• For folded module, requires maintenance shutdown once in year,whereas there is no maintenance required for Pyrobloc for first 3 to 4years of operation


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