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.
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 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:
- 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