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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 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:
- 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 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 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.
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