 |
|
|
|
| Report
on fuel savings and kiln loading in intermittent and
tunnel kilns |
RE: TUNNEL & INTERMITTENT KILNS
1. Tunnel kiln (1240°c) Brick lining
Approximate fuel savings after application of
coating: 5%.
We have been unable at this time to reproduce an
identical kiln loading: before and after, but on a
pro-rata calculation we would estimate that it
should be possible to achieve 6-7%.
2. Intermittent kiln (1380°c) IFB lining
As with the tunnel kiln we have not had a like for
like, before and after kiln loading.
However, on the last firing it looked like we could
achieve better than 7%. We will put in additional
monitoring equipment.
Trust this information is helpful; we will keep you
informed.
Kind Regards,
Douglas Wright
MANAGING DIRECTOR
NORTON ADVANCED CERAMICS
KING STREET FENTON
STOKE-ON-TRENT
ST4 3LY, ENGLAND
TELEPHONE 0782 744821
TELEFAX 0782 747200
TELEX 36231
www.refractories.saint-gobain.com
Back to top
|
| Report
on the use of Omega 1 to seal ceramic board kiln
lining |
6th November 1997
Attention Mr. Soren Kierkegaard
Dear Sir,
As a regular user of your Omega refractory coatings
for just over 2.5 years now, we feel that perhaps
you would like some feedback on just how the
coatings have been performing.
As you will be aware, we began using these coatings
because we wanted to seal the vacuum formed ceramic
fibre board linings of our kilns and eliminate fibre
dust.
Initially the kilns were coated with your "Omega 1"
coating. In this regard the coating has raised the
level of acceptance of our kilns beyond all
expectations.
A long lasting totally dust free lining is now a
reality. We have now coated more than 230 kilns and
only in the heaviest production based glaze firing
kilns have we experienced any alkali attack, and
even then, only ceilings have been affected after
two years of continual use.
More recently we have employed "Omega 2" to improve
resistance to alkali attack from glaze products.
We are extremely confident that Omega 2 will provide
the solution to our needs. We will keep you
informed.
Once again thank you for your continued support.
Yours faithfully,
Peter Geddes
MANAGER
WOODROW KILNS
www.kilns.com.au
Back to top
|
|
| Report
on use of Omega 2 at New Zealand refinery company
transition duct |
1 August 1997
Our refer: L239/TT
REPORT ON USE OF OMEGA 2 AT NEW ZEALAND REFINERY
COMPANY TRANSITION DUCT
During the annual maintenance shut down in 1994 the
ceramic fibre blanket in the transition duct from
the KTI Reformer 7101 to the convention unit
downstream was coated with Omega 2 and a coating of
Omega 1 over the top of that coating.
The ceramic fibre in this section of duct was
exhibiting fibre break down and in some of the
higher velocity areas there was some delamination of
the blanket.
Some localised small repairs were undertaken and the
blanket then coated with the Omega products.
The objective was to forestall the need to replace
the top layer of blanket.
During a recent shutdown, February 1997, the unit
was open for inspection and the following was
observed.
The coating on the blanket look stable and in
excellent condition.
The blanket was still intact and there was no
evidence of further delamination which indicated
that the break down of the blanket fibre structure
seems to have been halted.
It seems certain that the objectives that were
saught from the Omega coatings have been achieved
and we would expect the operational life of the
ceramic fibre blanket to be extended appreciably.
Subsequent to the encouraging results thus far, NZRC
have specified Omega 2 for use in other refractory
applications in their plant.
Kevin McColl
Operations Manager
CROW REFRACTORY
www.tbsgroup.co.nz/Refractory/Activities/activities.html
Back to top
|
|
| Report
on the use of Omega 2 at BHP NZsteel walking beam
furnace |
31 July 1997
Our refer: L238/TT
During the annual maintenance shut down undertaken
during the 94/95 Christmas period for refractory
repairs to BHP NZSteel’s IHI designed Walking Beam
Furnace, Omega 2 was applied to the East Waste Gas
Duct.
This furnace has two Waste Gas Ducts, a East and a
West duct from which waste gas from the furnace
passes through to recuperators. After the
recuperators the ducts connect into a common header
duct and the waste gas passes to the stack.
The waste gas ducts are lined with 225mm thickness
of ceramic fibre blanket installed in a ship lapped
installation.
The hot gas exiting the furnace is at sufficiently
high temperature that it results in the structure of
the ceramic fibre breaking down. It also contains a
quantity of mill scale that clings to the blanket
and we speculate that this build up combined with
the break down of the fibre structure is the
mechanism causes failure of the blanket lining.
The quality of the top layer of the lining has been
improved to 1400°C x 160 kg/m3 from the original
installation which was 1260°C x 130 kg/m3 material.
The blanket was originally secured with "Insultwist"
washers on 316 s/s pins with wet felt covers however
this system was replaced upstream of the
recuperators with threaded 310 s/s 6mm diameter pins
and 75mm ceramic cuplocks secured to the pins with
M6 310 s/s nuts.
These pins were stud welded through the blanket by a
special method developed locally.
In the past the vertical sections of the Waste Gas
Ducts had required extensive blanket repairs
annually and sometimes this repair was not limited
to the top layer of the blanket.
It was suggested to BHP NZSTEEL that the need for
annual repair could be eliminated by coating the new
blanket with Omega 2 and it was decided that the
East vertical section of duct would be lined and the
performance evaluated.
For the record, the West duct was also re-veneered
(that is, the top layer of blanket replaced) and
sprayed with a rigidiser solution.
During the next annual shut down during the
Christmas 95/96 period no work was necessary to the
East duct vertical section.
The West duct however required extensive repair and
after the repair was completed the duct was sprayed
with a product "SCF 1400", a ceramic fibre and
refractory cement product applied using a fibre
spray machine.
There was no annual shut down for the Walking Beam
furnace Christmas 96/97.
The opportunity to inspect the furnace arose mid
1997 and the following observations were made.
The East waste gas duct has some areas where the
blanket will require localised repair. It is almost
as if the armouring of the Omega 2 has worn off.
This is 2.5 years after application.
The West waste gas duct is in worse condition and
will require more extensive repairs.
The furnace is to be down for repair in September of
1997.
Kevin McColl
Operations Manager.
CROW REFRACTORY
www.tbsgroup.co.nz/Refractory/Activities/activities.html
Back to top
|
|
| Report
on the use of Omega 2 on Expansion Joints at New
Zealand Refinery Company |
3 April 1996
Refer: L089
During a shut down in April 1995 it was decided to
coat expansion joints in different ducts with Omega
2 coating.
The expansion joint on the duct from furnace F7602
to the Waste Heat Boiler F7651, has an internal
diameter of 1460 mm with a width of 500 mm (due to
seismic requirements) and was relined using ceramic
fibre modules manufactured from 1400oC blanket. This
expansion joint does not suffer from very much
chemical attack however it was decided to coat the
joint anyway.
The expansion joint on the duct from furnace F7601
to the Waste Heat Boiler F7651, has an internal
diameter of 1720 mm with a width of 500 mm (due to
seismic requirements) and was relined using ceramic
fibre modules manufactured from 1400°C blanket. This
expansion joint suffers severe chemical attack,
Furnace F7601 being fired on bitumen. This expansion
joint required regular replacement to guarantee the
integrity of the plant between shutdowns. The joint
was likewise coated with Omega 2.
In March 1996 a unplanned Catalyst changed provided
the opportunity to undertake some maintenance work
on this part of the plant and we were able to
inspect the two expansion joints referred to above.
The first mention joint was in a as new condition in
appearance. No chemical attack had occurred and this
was as expected. The physical condition of the joint
was excellent. The expansion joint was prepared for
return to service by packing the gap left/caused by
residue compression with new blanket.
It should be noted that the compression in service
had not caused the Omega 2 to crack.
The more interesting case was the joint from F7601
to the Waste Heat Boiler. This expansion joint had
the expected heavy deposit of black "clinker"
material adhered to it but the usual heavy yellow
staining and broken down fibre structure, which had
occurred in the past was not present.
Where the gap was from compression in service we
could see that the ceramic fibre blanket was in
excellent condition. This gap was packed with new
blanket and the expansion joint returned into
service.
The New Zealand Refinery Companies Officer Mr. Rod
Bronlund can be contacted on this matter. His
telephone number is New Zealand, area code 9 432
6875.
Kevin McColl
Operations Manager
CROW REFRACTORY
www.tbsgroup.co.nz/Refractory/Activities/activities.html
Back to top
|
|
|
|
|
|
|
|
|
