r. v. apshankar [email protected] energy systech pune case studies on furnace insulation
TRANSCRIPT
INTRODUCTION TO
ENERGY SYSTECH
• MELTING & HOLDING FURNACES – ELECTRICAL AND FUEL-FIRED
• HEAT TREATMENT FURNACES FOR ALUMINIUM CASTINGS (DROP QUENCH SOLUTION ANNEALING)
• DEGASSING MACHINES FOR ALUMINIUM MELT• DENSITY TESTING MACHINES FOR GAS
DETERMINATION
SERVICE TO THE ALUMINIUM CASTING INDUSTRY
CASE STUDY ON ALUMINIUM HOLDING
FURNACE• ALUMINIUM HOLDING FURNACE IN A
LEADING FOUNDRY IN PUNE• CRUCIBLE-TYPE: CAPACITY 300 kg AL• PREVIOUS INSULATION: INSULATION
BRICK• PREVIOUS CONSUMPTION: 350 kWh /
DAY• NEW INSULATION: CERAMIC FIBRE
BOARD• NEW CONSUMPTION: 240 kWh / DAY• ANNUAL SAVING : RS 1,60,000 (YEAR
1999-2000)
• PAYBACK PERIOD: LESS THAN 6 MONTHS
• 22 FURNACES!!
BENEFITS
• LOWER ENERGY BILLS• LOWER AMBIENT TEMPERATURES ->
BETTER WORK ENVIRONMENT• BETTER TEMPERATURE CONTROL• LOWER CONNECTED LOAD (MAX
DEMAND CHARGES)• POSSIBILITY OF CAPACITY EXPANSION• LONG LIFE OF INSULATION
DESIGN ASPECTS
• INSULATION MOUNTING - ANCHORING, ETC
• SEALING OF THE FURNACE• MECHANICAL WARPING-PROOF
DESIGN• LOAD SUPPORT (BOTTOM BRICKS)• MOUNTING OF HEATERS• LIMITATIONS ON FUEL-FIRING
CERAMIC FIBRE BLANKETS & BOARDS
ELECTRICALLY-HEATED CRUCIBLE FURNACE
RESISTANCE HEATED
INDUCTION
ENERGY SOURCES
SOLID LIQUID GAS
ELECTRICAL FUEL-FIRED
EFFICIENCY OF FURNACES RELATED TO
LOSSES
Heat Balance of a Furnace
LIGHT OIL FIRED CRUCIBLE FURNACE
DIESEL-FIRED ALUMINIUM MELTING-CUM-HOLDING
FURNACE
• HEAT RECUPERATION FROM FLUE GASES• AUTOMATIC BURNER => ON-OFF TEMP.
CONTROL• LOW THERMAL MASS => QUICK START UP• ADVTGS OF INGOT PREHEATING
THANKYOU
