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Applications Analysis: Increasing the Capacity of a Tile Curing Furnace
Tile Curing Furnace
Proposition:
A company that operates a series of 10 specialty tile curing is looking to increase the carrying capacity of each furnace by reducing the amount of insulation necessary in the hearth, while at the same time maintaining the current cold face temperature of the metal shell upon which the furnace sits at its current 200°F.
• The hearth is 5’ wide x 20’ long, and operates continuously at 2,100°F.
• Currently, the composite lining of the hearth is comprised of 4.5” of Super Duty Firebrick, 4.5” of 2300 Insulating Firebrick, and 3” of Calcium Silicate material.
• Each tile is 12”w x 12”l x 1” thk, and is processed in stacked layers of 100 SF and separated by .5” thick blocks to ensure that the tiles do not come in contact with one another during curing. The furnace is 4’ high, and there are 30 layers of 100 tiles per run.
• Each curing run lasts for 3 hours, and yields approximately 3,000 tiles per run
• Each curing run lasts for 3 hours, and yields approximately 3,000 tiles per run.
Given that each furnace runs continually, the estimated annual production rate for the furnace is approximately 8.76 million tiles (or 87.6 million tiles for all 10 furnaces).
Primary Goals:
Due to increasing pressures for production efficiency and increased productivity with minimal capital expenditures, the company is looking to achieve the following goals by decreasing the insulation lining of the hearth:
• Reduce the thickness of the hearth insulation lining by as much as 15% to allow more room within the furnace for materials processing.
• Increase the amount of production of specialty tiles by between 3 – 5%, if possible, by creating more useable space for the material to be processed.
• A steady state cold face temperature no higher than the current 200°F for the metal shell upon which the insulation composite rests on the floor of the hearth.
Proposal:
By substituting a 1” thickness of microporous DynaGuard Board 18# material for the 3” of Calcium Silicate material being utilized in the current composite, the company would reduce the amount of insulation necessary in the hearth by up to 17% without sacrificing their desired cold face temperatures, while simultaneously raising their estimated annual production from 8.76 million tiles/furnace to 9.05 million tiles/furnace (i.e. a 3% increase in production).
Thermal Analysis & Comparison:
Thermal Analysis and Comparison chart
Results:
• The composite with the DynaGuard] Board 18# material requires a thickness 2” less than that of the composite with the Calcium Silicate material, yielding a 17% decrease in the hearth insulation lining from its current system.
The composite with the DynaGuard™ Board 18# material yields a cold face temperature one degree lower than the composite with the Calcium silicate material, even though less material is being utilized for the goal at hand.
Production Analysis & Comparison:
Given the differences in estimated production volume/quantity for the two composites, the following can be estimated for the number of tiles produced for each:
Production Analysis and Comparison chart
Results
The composites utilizing DynaGuard™ Board 18# material yield an estimated 2.9 million more tiles/year than the composites without.
• The initial cost of DynaGuard™ Board 18# material can be easily justified on the basis of gained production efficiencies alone.
Conclusion:
The composite with the DynaGuard Board 18# material is the best one to accomplish all the objectives that the company set forth as their primary goals. It provides the greatest thermal management and financial gains within minimal space, and performs at the given temperature levels as efficiently or better than the other materials currently being utilized.
For more information about how ThermoDyne’s DynaGuard]Flexible, Ladle Liner, Board or Panel materials may be of use in your particular application, please contact ThermoDyne’s team of Application Engineers at toll-free: 866.741.5458.
Assumptions:
- Calculations assume ambient air temperature to be = 80°F, with natural convection consistent with an indoor environment.
- Calculations assume steady state.
- Calculations and information provided are for comparison purposes only, and are not intended for design specifications as individual scenarios for material use may vary.
- Photo used courtesy of Armil CFS
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