Use of Emisshield in a Technical Ceramics Afterburner to Reduce Fuel Consumption and Cycle Times

Emisshield ST-2 (US Patent 6,921,431) has been effectively used in an afterburner of a batch kiln that cures technical ceramics at an operating temperature of 1400°F.

The Problem

Customers demand considerable decrease in fuel use and shorter ramp-up time to reach 1400°F in the afterburner. The afterburner is used to heat exhaust gases to completely burn organic binders, which are discharged from the fired ceramics. During the 48 hours kiln cycle, 25% of the total fuel was actually used in the afterburner to ramp-up and maintain the temperature at 1400°F.

The Solution

The firebricks lined in the afterburner chamber were first prepared for the application of coating. The area to be coated was cleaned of all debris, and dust was removed using an air compressor system. Using a spray gun, a coating of Emisshield ST-2 was applied. Fifteen gallons of the material were used to cover the afterburner chamber, which was 6 feet tall, 80 feet long and 42 inches across. The entire chamber was coated at a coverage density of nearly 150 ft²/ gallon.

The Benefits

Initially, natural gas burners in the afterburner had to be set to a rate setting of 35% to maintain the afterburner at 1400°F. After the application of Emisshield, however, these burners could be set to rates between 25% and 29%. By effective utilization of heat re-radiated into the chamber of the afterburner, the use of Emisshield ST-2 reduced the total amount of fuel required. Over a one-year period, the customer saved 23% on fuel costs. Use of Emisshield thus allows customers to achieve a significant reduction in fuel costs within a span as short as three months.

This information has been sourced, reviewed and adapted from materials provided by ANH Refractories Europe.

For more information on this source please visit ANH Refractories Europe.

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