CASE STUDIES

The following are case studies from various completed projects. Please have a look to see how they have benefited from the use of our products.

McConway & Torley, LLC - Austenitizing Furnace

FURNACE DETAILS

Lining Configuration: The austenitizing furnace operates at approximately 1750°F and is approximately 13’ L x 12’ W x 8’ H with a complete ceramic fiber lining. The sidewalls, door and roof are 8” thick fiber module construction.

Customer Need: Norheat Treatment Inc./ITC recommended a solution to address several major challenges including:

  • Excessive heat loss and shell temperatures on the roof and sidewalls
  • High fuel usage
  • Continual refractory maintenance within all zones

RECOMMENDATION

Engineered Approach: Norheat Treatment Inc./ITC recommended applying a proprietary high temperature, energy efficient ceramic coating on the hot face of the refractory insulation to eliminate shrinking and devitrification of the ceramic fiber and hot spots on the furnace shell. The project consisted of coating the entire furnace sidewalls, door and roof.

High Temperature Energy Efficient Ceramic Coatings: Norheat Treatment Inc. supplies a proprietary, high temperature, energy efficient ceramic coating to work in concert with the furnace conditions and all types of refractory design. Under ideal conditions, high temperature, energy efficient ceramic coatings absorb energy from the process and re-radiate it to the furnace load, imparting the following benefits:

  • Lower Heat Loss – Minimizes heat transfer through the furnace refractory walls
  • Lower Maintenance Costs – Protects the substrate refractory
  • Improved Furnace Operation – Improves the thermal efficiency of the process

IMPACT ON THE PROCESS

  • Lower Shell Temperatures – The high temperature energy efficient ceramic coatings that protect the fiber from shrinking and devitrification, have lowered shell temperatures and hot spots.
  • Improved BTU Savings – Due to the re-radiating properties of the coating, Btu savings are significantly better than uncoated fiber refractory. Temperature loss within the furnace has been reduced and temperature uniformity has become more consistent. Temperature uniformity before and after application of the coatings was +/- 400°F verses +/- 250°F respectively.
  • Reduced Fuel Consumption – Prior to coating application fuel consumption per load averaged 20.8 MCF. After coating application, fuel consumption dropped to an average of 18.7 MCF per load.
  • Reduced Refractory Maintenance – Protection from the coating helps eliminate ceramic fiber from shrinking and devitrification thus reducing the amount of time and material need to keep the furnace operational.
  • Increased Refractory Longevity – Once the coating is applied, refractory life is increased by 3 to 5 times its normal life expectancy.
  • Reduced Turnaround Times –After the application of the coating, turn around time was reduced by 20 minutes. This equates to one additional 5 ton load processed per week. Each 5 ton load adds an additional $10,000 in sellable product per week or a potential increase in yearly revenue of $480,000 plus. $10,000 x 4 weeks/month x 12 months/year = $480,000 per year.

IMPACT ON BOTTOM LINE COSTS

  • Fuel Savings = 20.8 MCF – 18.7 MCF = 2.1 MCF per load or 10% reduction
  • Increased ProductionPotential increase in yearly revenue of $480,000 per year plus = One additional 5 ton load per week (4 weeks/month) (12 months/year) ($10,000/week)
  • Heat Loss = Temperature uniformity improved with application of coatings, +/- 400°F verses +/- 250°F which equals approximately a 46% change.
Brampton Brick, Ontario, Canada - Brick Kiln #1 Pre-Heat and Furnace Zone

KILN DETAILS

Kiln: Kiln #1 is 400 feet long inside refractory and approx. 25 feet wide by 7 feet high.

Lining Configuration: The current roof lining consists of one layer of 2600˚F, 80% Alumina dog bone tile 18” thick and 3” of lightweight castable, with an air space between tile and roof shell. The sidewall lining consists of high duty firebrick 9” thick with a backup lining of 3” IFB and a 12” air space filled with vermiculite between the IFB and kiln shell.

Customer Need: Norheat Treatment Inc./ITC recommended a solution to address several major challenges including:

  • High fuel consumption.
  • Increase longevity of refractory lining and protection from thermal shock and spalling. 

RECOMMENDATION

Engineered Approach: Norheat Treatment Inc. recommended a ceramic coating to address the customers requirements. The coating design included a proprietary ceramic coating, ITC 100HT, applied to the pre-heat tile and brick lining of the furnace zone only per the customers request. This was done in addition to the hot zone coating which was completed previously.

High Temperature Energy Efficient Ceramic Coatings: Norheat Treatment Inc. supplies several proprietary, high temperature, energy efficient ceramic coatings to work in concert with refractory or metal substrates. Under ideal conditions, these coatings absorb energy from the process and re-radiate it to the load, imparting the following benefits:

  • Lower Heat Loss – Minimizes heat transfer through the kiln tile and brick lining.
  • Reduced Fuel Consumption – Additional heat from above leads to 10% to 20% reductions in fuel  consumption thus improving thermal efficiency.
  • Refractory Longevity – Protects the substrate refractory from thermal shock and spalling.

IMPACT ON THE PROCESS

  • REFRACTORY LONGEVITY
    With the use of ITC Coatings, refractory life is extended on average 2 to 3 times longer
  • REDUCED PREHEAT TIME
    Start-up times have been reduced by 25% IMPROVED FUEL SAVINGS Due to the thermal efficiencies, fuel consumption was reduced by 7%+. They were also able to achieve a 4% production increase
  • REDUCED ENERGY CONSUMPTION
    Before ITC coating, average fuel consumption was 942,000 ft3/day After ITC coating, average fuel consumption is now 879,558 ft3/day

IMPACT ON BOTTOM LINE COSTS

FUEL SAVINGS OF APPROXIMATELY 10% Current average fuel costs – $3/1,000 ft3

Before: 942,000 ft3/day x 365 days/yr x $3/1,000 ft3 x = $1,031,490/yr

After: 879,558 ft3/day x 365 days/yr x $3/1,000 ft3 = $963,116/yr

Total Savings from Furnace Zone: $42,260/yr

Total Savings from Pre-Heat: $26,114/yr

TOTAL IMPACT/YEAR = $68,374 for Kiln #1

Brampton Brick, Ontario, Canada - Soak Furnace Zone of Kiln #1 and #2

KILN DETAILS

Kiln: Kiln #1 and #2 are 400 feet long inside refractory and approx. 25 feet wide by 7 feet high.

Lining Configuration: The current roof lining consists of one layer of 2600˚F, 80% Alumina dog bone tile 18” thick and 3” of lightweight castable, with an air space between tile and roof shell. The sidewall lining consists of high duty firebrick 9” thick with a backup lining of 3” IFB and a 12” air space filled with vermiculite between the IFB and kiln shell.

Customer Need: Norheat Treatment Inc./ITC recommended a solution to address several major challenges including:

  • High fuel consumption.
  • Increase longevity of refractory lining and protection from thermal shock and spalling.

RECOMMENDATION

Engineered Approach: Norheat Treatment Inc./ITC recommended a pre-heat coating to address the customers requirements. The coating design included a proprietary pre-heat coating, ITC 100HT, applied to the pre-heat tile and brick lining of the pre-heat zone only per the customers request. This was done in addition to the hot zone coating which was completed previously.

High Temperature Energy Efficient Ceramic Coatings: Norheat Treatment Inc. supplies several proprietary, high temperature, energy efficient ceramic coatings to work in concert with refractory or metal substrates. Under ideal conditions, these coatings absorb energy from the process and re-radiate it to the load, imparting the following benefits:

  • Lower Heat Loss – Minimizes heat transfer through the kiln tile and brick lining.
  • Reduced Fuel Consumption – Additional heat from above leads to 10% to 20% reductions in fuel  consumption thus improving thermal efficiency.
  • Refractory Longevity – Protects the substrate refractory from thermal shock and spalling.

IMPACT ON THE PROCESS

  • REFRACTORY LONGEVITY
    With the use of ITC Coatings, refractory life is extended on average 2 to 3 times longer
  • REDUCED PREHEAT TIME
    Start-up times have been reduced by 25% per kiln
  • IMPROVED FUEL SAVINGS
    Due to the thermal efficiencies, fuel consumption was reduced by 5% – 7% per kiln
  • REDUCED ENERGY CONSUMPTION
    Before ITC coating, average fuel consumption was 942,000 ft3/day per kiln After ITC coating, average fuel consumption is now 903,406 ft3/day per kiln

IMPACT ON BOTTOM LINE COSTS

Current average fuel costs – $3/1,000 ft3

Before: 942,000 ft3/day x 365 days/yr x $3/1,000 ft3 x = $1,031,490/yr per kiln

After: 903,406 ft3/day x 365 days/yr x $3/1,000 ft3 = $989,230/yr per kiln

TOTAL IMPACT/YEAR = $84,520 Combined for Kiln #1 and #2

Arcelor Mittal Harriman Steel - Pusher Reheat Furnace

FURNACE DETAILS

Furnace: The furnace is rated at 75 tons/hr. and utilizes Bloom high temperature burners designed for 750˚F combustion air with and utilizing a recuperator. The maximum Btu input is 89.9 MM Btu or 1.2 MM Btu/ton. The furnace controls are minimal with the system utilizing an air lead only instead of a more precise lead lag system, and the exhaust utilizes a forced evacuation fan with manually adjustable damper blades.

Lining Configuration: Most of the existing refractory was in reasonably good shape except for the billet charge, discharge peel bar and billet discharge openings, which were badly damaged. The soak zone burner wall was also badly damaged.

Customer Need: A solution was recommended to address several major challenges:

  • Excessive heat loss and shell temperatures on the roof and sidewalls
  • High fuel usage
  • Continual refractory maintenance with charge and discharge openings

RECOMMENDATION

Engineered Approach: ITC recommended a hot face veneer to address the customers’ requirements. The veneer design included:

  • 1” thick 12”x12” ceramic fiber squares (2300˚F temperature use limit)
  • A proprietary, high emissivity hot face coating

High Emissivity Coatings: ITC manufactures a proprietary, high emissivity coating to work in concert with the furnace conditions and veneer design. Under ideal conditions, high emissivity coatings absorb energy from the process and re-radiate it to the furnace load, imparting the following benefits:

  • Lower Heat Loss – Minimizes heat transfer through the furnace refractory walls
  • Lower Maintenance Costs – Protects the substrate refractory
  • Improved Furnace Operation – Improves the thermal efficiency of the process
  • Reduction in Scale Generation – Less Fe2O3 available due to more efficient burning
  • Increased Thru Put – Additional energy (Btu’s) available to heat product at an increased rate

ITC-Arcelor-Mittal-Harriman-Reheat-Furnace-Impact--9

IMPACT ON THE PROCESS

  • Lower Shell Temperatures – The combination of veneer and the coating significantly lowered shell temperatures
  • Improved BTU Savings – Due to the thermal efficiencies, Btu/gas savings was reduced by 20%
  • Lower Operating Temperatures – The thermal efficiencies of the new design enabled the operators to drop normal furnace operating temperatures (as indicated by thermocouples) from 2150˚F to 1840˚F.
  • Increased Throughput – By reflecting the energy back to the colder steel load in the furnace, the furnace throughput increased from 65 tons to the rated 75 tons per hour.
  • Reduced Scale/More Product – Decreased operating temperatures and increased throughput have allowed an increase in yield of approximately 2 ½ % due to a significant decrease in scale generation. At full production this amounts to 6,150 additional tons of saleable product per year.
  • Reduced Amount of Energy Required – Combining all efficiencies, the amount of energy required dropped from 1.2 MM Btu/ton to 0.96 MM Btu/ton. If the flue exhaust is restricted as is recommended and the burner control system updated, this furnace could attain 0.88 MM Btu/ton or a reduction in fuel usage of 33%

IMPACT ON BOTTOM LINE COSTS

  • Fuel Savings = $833,000 per year (at $8.00 per MM Btu)
    Previous: (65 tons/hr.)(1.2 MM Btu/ton) = 1,872 MM Btu/day
    New: (75 tons)(.8 MM Btu/ton) = 1,440 MM Btu/day
  • Increased Production = $2,929,500 per year
    = (6,510 additional tons/year)($450 ton)
  • ROI = 1.33 weeks (at full production of 6,000 hours/yr. or 15 turns/wk.)
  • TOTAL IMPACT/YEAR = $3,762,500
Nucor Steel Birmingham - Pusher Reheat Furnace

FURNACE DETAILS

Furnace: Three (3) zone, 115 tons/hr pusher type reheat furnace operating at 2350˚F, processing rebar and merchant bar products.

Customer Need: To minimize/reduce excessive BTU loss in roof, sidewalls and skid pipe.

RECOMMENDATION

Engineered Approach: Using thermography and heat flow calculations, a hot face veneer was recommended to address BTU loss. The veneering design included:

  • 1” thick 12”x12” ceramic fiber squares on sidewalls, doors & skid pipes
  • ½’ thick 12”x12” ceramic fiber squares on the roof
  • A proprietary, high temperature, energy efficient ceramic hot face coating

High Temperature Energy Efficient Ceramic Coatings: ITC manufactures a proprietary, high temperature energy efficient ceramic (HTEEC) coating to work in concert with the furnace conditions and veneer design.  Under ideal conditions, HTEEC coatings absorb energy from the process and reradiate it to the furnace load, imparting the following benefits:

  • Lower Heat Loss – Minimizes heat transfer through the furnace refractory walls
  • Lower Maintenance Costs – Protects and prolongs the substrate refractory life
  • Improved Furnace Operation – Improves the thermal efficiency of the process
  • Reduction in Scale Generation – Less Fe2O3 available due to more efficient burning
  • Increase Thru Put – Additional energy (Btu’s) available to heat product at an increased rate

IMPACT ON THE PROCESS

  • Lower Shell Temperatures – The combination of veneer and the coating significantly lowered shell temperatures.
  • Improved BTU Savings – Due to the thermal efficiencies, Btu savings were significantly better than the estimates.
  • Lower Operating Temperatures -The thermal efficiencies of the new design enabled the operators to drop normal furnace operating temperatures in the discharge zone.

ROOF, SIDEWALL & SKID PIPE THERMAL CALCULATIONS
Original Lining: 300˚ – 400˚F (calculated) – 330˚ – 430˚F (actual)
After Veneer/Coating: 250˚ – 350˚F (calculated) – 228˚ – 342˚F (actual)
BTU Savings: 50 MM BTU/hr (calculated) – 54.7 MM BTU/hr (actual)

nucor-beforenucor-after

IMPACT ON BOTTOM LINE COSTS

  • BTU Savings Per Year = 54.77 MM Btu/hr x 24 hr/day x 208 days/yr x $4.05/MM Btu)
  • TOTAL IMPACT/YEAR = $1,230,000
Arcelor Mittal Georgetown Steel - Pusher Reheat Furnace

FURNACE DETAILS

Lining Configuration: Lining Configuration: After years of service at 2150˚F, the refractory plastic roof and walls (9” Super Duty/3”Lt wt castable) were in need of repairs, along with the hearth, discharge wall and skid pipes.

Customer Need: A recommendation was made to address two (2) major challenges:

  • Excessive heat loss and shell temperatures on the roof and sidewalls
  • Minimal time and financial resources to completely reline the entire furnace

RECOMMENDATION

Engineered Approach: Using thermography and heat flow calculations,a hot face veneer was recommended to address both customer requirements. The veneer design included:

  • 1” thick 12”x12” ceramic fiber squares (2300˚F temperature use limit)
  • A proprietary, high emissivity hot face coating

High Emissivity Coatings: ITC manufactures a proprietary, high emissivity coating to work in concert with the furnace conditions and veneer design. Under ideal conditions, high emissivity coatings absorb energy from the process and re-radiate it to the furnace load, imparting the following benefits:

  • Lower Heat Loss – Minimizes heat transfer through the furnace refractory walls
  • Lower Maintenance Costs – Protects the substrate refractory
  • Improved Furnace Operation – Improves the thermal efficiency of the process

IMPACT ON THE PROCESS

  • Lower Shell Temperatures – The combination of veneer and the coating significantly lowered shell temperatures.
  • Improved Btu Savings – Due to the thermal efficiencies, Btu savings were significantly better than the estimates.
  • Lower Operating Temperatures – The thermal efficiencies of the new design enabled the operators to drop normal furnace operating temperatures (as indicated by thermocouples) from 2150˚F to 1840˚F.
  • Increased Throughput – By reflecting the energy back to the colder steel load in the furnace, the furnace throughput increased from 88 tons to as much as 120 tons per hour.
  • Reduced Scale/More Product – Decreased operating temperatures and increased throughput have allowed an increase in yield of approximately 2% due to a significant decrease in scale generation (scale boxes previously emptied daily are now emptied on weekends). This amounts to 9000 additional tons of saleable product per year.
  • Reduced Amount of Energy Required – Combining all efficiencies, the amount of energy required dropped from 1,500,000 Btu/ton to 800,000 Btu/ton.

ROOF, SIDEWALL THERMAL CALCULATIONS
Original Lining: 350˚ – 400˚F (calculated) – 350˚ – 400˚F (actual)
After Veneer/Coating: 310˚ – 350˚F (calculated) – 250˚ – 300˚F (actual)
Btu Savings: 1.9 MM Btu/hr (calculated) – 2.2 MM BTU/hr (actual)

Georgetown-beforeGeorgetown-after

IMPACT ON BOTTOM LINE COSTS

  • Fuel Savings = $1,950,000 per year (at $10 per MM Btu)
    Previous: (88 tons)(1.5 MM Btu/ton) = 3168 MM Btu/day
    New: (120 tons)(.8 MM Btu/ton) = 2304 MM Btu/day
  • Increased Production = $3,600,000 per year
    (9000 additional tons/year) ($400 ton)
  • TOTAL IMPACT/YEAR = $5,500,000
W Abrasives, Ontario Canada – Retort Furnace

FURNACE DETAILS

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 ConfigurationThe 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:

  • High fuel consumption.
  • Continual refractory maintenance and repair.

RECOMMENDATION

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 CoatingsITC 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:

  • Lower heat loss – Minimizes heat transfer through the ladle preheat lid refractory.
  • Lower Maintenance costs – Protects the substrate refractory.
  • Reduced preheating time – Improves the thermal efficiency of the process thus allowing quicker furnace start-up after downturns.

IMPACT ON THE PROCESS

  • 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.

w-abrasive-before    w-abrasive-after

IMPACT ON BOTTOM LINE COSTS

  • 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
Salt River Materials Group, AZ – Cement Kiln Burner Pipe

BURNER PIPE DETAILS

Burner Pipe: Burner pipe is 26 feet long and approximately 30 inches in diameter.

Lining Configuration: The current ling consists of 1/4” layer of ceramic fiber blanket, with 3” of RESCO’s R-Max CZ high performance castable.

Customer Need: A solution was recommended to address the customers main challenge:

  • Continual refractory maintenance and repair due to thermal shock from cycling the kiln. On average, current refractory life is approximately 4 months.

RECOMMENDATION

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 R-Max CZ.

High Temperature Energy Efficient Ceramic CoatingsITC 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:

  • Lower Maintenance costs – Protects the substrate refractory from thermal shock due to cyclical operation.
  • Lower Heat Loss – Minimizes heat transfer through the refractory and reduces oxidation of the burner pipe and premature failure of burner internal parts.

IMPACT ON THE PROCESS

  • Refractory Longevity – Current refractory maintenance costs are estimated at $35,000.00 to $50,000.00 per year. With the use of ITC Coatings refractory life is extended on average 2 to 3 times longer

    

IMPACT ON BOTTOM LINE COSTS

  • BTU Savings Per Year
    Before: Complete burner reline, 3 times per year at a total yearly cost $50,000.00
    After: Coating applied to hot face of burner refractory once per year at a total cost of $16,262.00
  • ROI = 3.1 months
  • TOTAL IMPACT/YEAR = $33,374
TXI Cement, TX – Cement Kiln Bag House

BAG HOUSE DETAILS

Bag House: Each bag house compartment is 20’ x 25’ x 60’h with a total of 12 compartments. The bag house shell and tube sheet are constructed of plain carbon steel.

Customer Need: A recommended solution to address the customers main challenge:

  • Corrosion of the steel shell and build-up of fly ash agglomeration from condensing flue gases that develop as internal temperatures drop allowing the formation of an acid dew point.

tx-bag-house-layout

RECOMMENDATION

Engineered Approach: A proprietary high temperature, energy efficient ceramic coating system on the internal steel shell consisting of ITC 213 specifically formulated for metal, ITC 100HT thermal barrier coating and ITC 296A high purity, low porosity top coat.

High Temperature Energy Efficient Ceramic CoatingsThere are several proprietary, high temperature, energy efficient ceramic coatings to work in concert with refractory or metal substrates. Under ideal conditions, high temperature coatings absorb energy from the process and re-radiate it to the process, imparting the following benefits:

  • Lower Maintenance Costs – Protects the metal substrate from condensing acidic flue gases thus reducing downtime needed for costly maintenance repairs.
  • Lower Heat Loss – Minimizes heat transfer through the steel shell thus eliminating the formation of an acid dew point.

IMPACT ON THE PROCESS

  • Bag House Longevity – Current metal loss is estimated between 0.5 mm to 1 mm per year. With the use of ITC Coatings steel shell life is extended on average 4 to 5 times longer.
  • Increase in Efficiency – Reduction in condensing flue gases and corrosion leads to a reduction in bag and cartridge corrosion as well.
  • Reduction in Downtime/Reduced Maintenance Costs