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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,
( )
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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Mathematical Model of lifecycle cost -CGL
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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Mathematical Model of lifecycle cost -CGL
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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