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R. V. APSHANKAR info@energysystech ENERGY SYSTECH PUNE

CASE STUDIES ON FURNACE INSULATION. R. V. APSHANKAR info@energysystech.com ENERGY SYSTECH PUNE. INTRODUCTION TO ENERGY SYSTECH. SERVICE TO THE ALUMINIUM CASTING INDUSTRY. MELTING & HOLDING FURNACES – ELECTRICAL AND FUEL-FIRED

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R. V. APSHANKAR info@energysystech ENERGY SYSTECH PUNE

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  1. CASE STUDIES ON FURNACE INSULATION R. V. APSHANKAR info@energysystech.com ENERGY SYSTECH PUNE

  2. INTRODUCTION TO ENERGY SYSTECH • SERVICE TO THE ALUMINIUM CASTING INDUSTRY • 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

  3. 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!!

  4. 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

  5. DESIGN ASPECTS • CERAMIC FIBRE BLANKETS & BOARDS • INSULATION MOUNTING - ANCHORING, ETC • SEALING OF THE FURNACE • MECHANICAL WARPING-PROOF DESIGN • LOAD SUPPORT (BOTTOM BRICKS) • MOUNTING OF HEATERS • LIMITATIONS ON FUEL-FIRING

  6. ELECTRICALLY-HEATED CRUCIBLE FURNACE

  7. ENERGY SOURCES FUEL-FIRED ELECTRICAL INDUCTION RESISTANCE HEATED SOLID LIQUID GAS

  8. EFFICIENCY OF FURNACES RELATED TO LOSSES Heat Balance of a Furnace

  9. LIGHT OIL FIRED CRUCIBLE FURNACE

  10. 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

  11. THANK YOU

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