Furnace: Temper shot furnace #1 is 17 feet long inside refractory and approximately 48 inches in diameter. There are nine (9) burners total each rated at 450,000 Btu.
Lining Configuration: The current ling consists of two layers of IFB, the hot face is 9” of 2300˚ IFB and the backup lining is 3” of 2000˚ IFB.
Customer Need: A solution was recommended to address several major challenges:
Engineered Approach: A hot face coating was recommended to address the customers’ requirements. The coating design included a proprietary high emissivity hot face coating, ITC 100HT, applied to the hot face of the IFB.
High Emissivity Coatings: ITC manufactures several proprietary, high emissivity coatings to work in concert with refractory or metal substrates. Under ideal conditions, high emissivity coatings absorb energy from the process and re-radiate it to the load, imparting the following benefits:
Refractory Longevity – Current refractory maintenance costs are estimated at $10,000.00 per year. With the use of ITC Coatings refractory life is extended on average 2 to 3 times longer.
Reduced Preheat Time
Lower Operating Temperatures – Due to the thermal efficiencies, kWh savings was reduced by 7% – 10%.
Reduced Amount of Energy Required – Before ITC coating, average fuel consumption was 325kWh/ton – After ITC coating, average fuel consumption is now 300 kWh/ton.
Reduced Amount of CO2 and NOx Emitted – By increasing the thermal efficiency of the furnace and lowering the gas consumption, more oxygen is burned thus lowering the amount of pollutants emitted.
Fuel Savings of 7% – 10%
Before: 16,000 ton/yr x 325 kWh/ton x $0.20/m3 x m3/10.44 kWh = $99,617.00/yr
After: 16,000 ton/yr x 300 kWh/ton x $0.20/m3 x m3/10.44 kWh = $91,954.00/yr
CO2 REDUCTION OF 8%
Before: 16,000ton/yr x 325 kWh/ton x therm/29.3 kWh x 0.005302 ton CO2/therm = 940 ton CO2/yr
After: 16,000ton/yr x 300 kWh/ton x therm/29.3 kWh x 0.005302 ton CO2/therm = 869 ton CO2/yr
ROI = 2.4 months
TOTAL IMPACT/YEAR = $17,633