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ENERGY MANAGEMENT
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Inorganic
insulation
are
Siliceous/Aluminous/Calcium materials in
fibrous, granular or powder forms.
Example: Mineral wool, Calcium silicate etc
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The heat flow from the pipe surface and the ambient can be
expressed as follows
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Uninsulated
275 Kcal/m
50 mm insulation
25 Kcal/m
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100 mm insulation
15 Kcal/m
275 - 25 = 250 Kcal/m
10 Kcal/m
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Cost of fuel
Annual hours of operation
Heat content of fuel
Boiler efficiency
Operating surface temperature
Pipe diameter/thickness of surface
Estimated cost of insulation.
Average exposure ambient still air
temperature
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=SxA
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Ts 65oC
Ta 25oC
Modified System
S = [10+(65-25)/20] x
(65-20)
= 480 K.cal/hrM2
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Melting point
Base materials must have melting point above the
products (eg. Steel) to be produced
Pyrometric cone equivalent (PCE) is the Temperature
at which refractory will deform under its own weight is
known as softening temperature which is indicated by
PCE
Bulk density
Increase in bulk density increases its volume stability,
heat capacity and resistance to slag penetration
PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV
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Porosity
Low porosity is desirable as it would prevent easy
penetration of refractory and also larger number of small
pores are preferred over small number of large pores
Thermal conductivity
PREPARED BY K. MANOKARAN, LEAD AUDITOR, DNV
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Examples
Silica, Semisilica,
Aluminosilicate.
Magnesite, chromemagnesite,
Dolomite.
Chrome, Pure Alumina
Carbon, Silicon Carbide,
Zirconia.
Blast furnace Casting Pit
- Dry Press Process
- Fused Cast
- Hand Moulded
- Formed Normal, fired or
Chemically bonded.)
- Unformed (Monolithicsplastics, Ramming Mass,
Gunning Castable, Spraying.)
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Main advantages
No Joints required
Faster application and no skill required
Transportation and handling are simple
Reduced downtime for repairs
Reduce inventory and eliminate special shapes
Heat saver
Better spalling resistance
Greater volume stability
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Insulating bricks
Insulating Castables
Ceramic fibre
Calcium silicate
Ceramic coating
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Type
Diatomite
Solid
Grade
Diatomite
Porous
Grade
Clay
High
Aluminia
Silica
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Thermal
Max. safe
conductivity at temperature0C
4000C
.025
1000
Cold Crushing
Strength
Kg/cm2
270
Porosity
%
Bulk density
Kg/m3
52
1090
.014
800
110
77
540
.030
.028
1500
1500-1600
260
300
68
66
560
910
.040
1400
400
65
830
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Area of application
Working temperatures
Extent of abrasion and impact
Structural load of the furnace
Stress due to temperature gradient in the
structures and temperature fluctuations
Chemical compatibility to the furnace
environment
Heat transfer and fuel conservation
Cost considerations
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Establish the
measurement.
bare
2.
3.
4.
5.
6.
pipe
surface
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temperature,
by
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