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WORK SHOP ON KILN FURNITURE AND ENERGY SAVINGS ON 23RD FEBRUARY 2006 AT CGCRI KHURJA CENTER.

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Presentation on theme: "WORK SHOP ON KILN FURNITURE AND ENERGY SAVINGS ON 23RD FEBRUARY 2006 AT CGCRI KHURJA CENTER."— Presentation transcript:

1 WORK SHOP ON KILN FURNITURE AND ENERGY SAVINGS ON 23RD FEBRUARY 2006 AT CGCRI KHURJA CENTER

2 AGENDA WELCOME ADDRESS CORDIERITE AND ITS APPLICATION LTM CONCEPT DOS AND DONTS/CONVENTIONAL WARE CORDIERITE PAPER PRESENTATION BY CGCRI KHURJA VOTE OFTHANKS

3 CORDIERITE AND ITS APPLICATION CORDIERITE A MAGNESIUM ALUMINO SILICATE WITH A MOLUCULAR FORMULA 2MgO 2A SiO2. DUE TO ITS LOW THERMAL EXPANSION CHARACTER IT HAS GOT VERY GOOD THERMAL SHOCK. IT IS A SYNTHETIC MATERIAL AND NATURAL OCCURRENCES ARE VERY MINIMAL THE FORMATION OF CORDIERITE IN A CERAMIC PROCESS IS VERY SENSITIVE AND MINOR VARIATION IN THE MATURING ZONE AFFECT THE END PRODUCT PROPERTIES.

4 CORDIERITE AND ITS APPLICATION DUE TO VERY COMPLEX PROCESS NATURE ONLY COUNTABLE NUMBER OF INDUSTRIES ARE ENGAGED IN THE MANUFACTURE OF CORDIERITE. UTMOST CARE IS A MUST FROM SELECTION OF RAW MATERIAL TO MATURING OF THE END PRODUCT OTHERWISE LOSSESS WILL BE VERY HIGH. FOR COMMERCIAL KILN FURNITURE MANUFACTURING CORDIERITE IS BONDED WITH A SECONDARY MULLITE TO ENHANCE THE KILN FURNITURE LOAD BEARING PROPERTIES AT HIGH TEMPERATURE

5 CORDIERITE AND ITS APPLICATION THE MAIN FABRICATION PROCESS OF CORDIERITE KILN FURNITURE ARE DRY PRESSING, SLIP CASTING & EXTRUSION CORDIERITE IS THE ONLY CHEAPER AND BEST KILN FURNITURE UPTO 1300*C APPLICATION ALTERNATE TO SILICON CARBIDE AND OTHER TYPE OF FURNITURES ALMOST ALL THE CERAMIC MANUFACTURING UNIT CHANGED OVER TO THE USAGE OF CORDIERITE KILN FURNITURE THROUGOUT THE WORLD

6 CORDIERITE AND ITS APPLICATION DUE TO CONTINUOUS INCREASE OF RAW MATERIAL AND FUEL PRICE, COST REDUCTION IS THE ONLY VIABLE ALTLERNATE TO COMPETE THE MARKET. THEREFORE CORDIERITE KILN FURNITURE SYSTEMS SCORE OVER OTHER REFRACTORIES. CERTAIN TABLE WARE UNIT OPERATES WITH A SUPPORT WARE(KILN CAR, SUPER STRUCTURE) :END PRODUCT RATIO OF 6:1

7 LOW THERMAL MASS KILN CARS & SUPER STRUCTURE WITH THE COMBINATION OF LIGHT WEIGHT CORDIERITE WITH SILICON CARBIDE BEAMS ALONG WITH CERAMIC FIBER RESULTED IN UNBELIEVABLE COST REDUCTION ZN THE CERAMIC SECTOR. THE TREND SET GLOBALLY THREE DECADES AGO HAS GOT MOMENTUM NOW IN INDIA CORDIERITE AND ITS APPLICATION

8 THE MAJOR APPLICATION AREAS SANITARY WARE TABLE WARE FLOOR TILE/WALL TILE INSULATORS LT/HT GRINDING WHEEL ELECTRO CERAMICS ART WARE/STONE WARE ROOFING TILE FERRITEDYES/COLORS/PAINT

9 VARIOUS PRODUCT SHAPES DECK SLABS PERFORATED SLABS PROPS (PLAIN/STEPPED) BEAMS/SUPPORTS/CAPS PROFILE SETTERS MUG/CUP SETTERS T-CRANK/TILE CRANK FOOTREST SAGGARS SPECIAL SHAPES

10 QUALITY PROBLEM DURING TRANSIT DURING STORAGE ROUGH HANDLING WRONG SELECTION WRONG LOADING EXCEEDING THE TEMP LIMIT FLAME/GLAZE/BEDDING MATERIAL ATTACK FURNITURE QUALITY PROBLEM

11 LOW THERMAL MASS ENERGY EFFICIENT CORDIERITE KILN FURNITURE SYSTEM INTRODUCTION ENERGY EFFICIENT CORDIERITE KILN FURNITURE SYSTEM INTRODUCTION FUEL AND POWER COST IS THREATENING EVERY INDUSTRY IN CERAMIC SECTOR FUEL COST AMOUNTS TO 35 TO 40% OF THE MANUFACTURING COST ENERGY CONSERVATION IS A MUST TO STAY IN THE GLOBALISED MARKET ENERGY CONSERVATION IS A MUST TO STAY IN THE GLOBALISED MARKET LOW THERMAL MASS CONCEPT IS PROVEN EXAMPLE OF FUEL REDUCTION TECHNIQUE

12 LOW THERMAL MASS LTM CONCEPT WILL REDUCE THE FUEL BY A MINIMUM OF 10 to 15 % AND INCREASE IN PRODUCTION OF 10 % MIN LOW MASS/LOW THERMAL EXPANSION CORDIERITE KILN FURNITURE CERAMIC FIBER AND RECRYSTALLIZED BEAMS ARE THE MAIN COMPONENTS USED IN THE LTM CARS FOR ENERGY CONSERVATRION ABREF HAS TAKEN THE TASK OF PRODUCING READY MADE LTM KILN CAR OR INSTALLATION OF LTM AT CUSTOMER END

13 LOW THERMAL MASS RECENTLY ABREF HAS ISTALLED TWO LTM CARS SUCCESSFULLY IN A SANITARY WARE IN MORBI AND AWAITING ONE EXPORT ORDER FROM A TILE INDUSTRY ALSO CONVERTED OUR OWN SHUTTLE KILNS CARS AS LTM AND ALSO PROVIDED RECUPERATION SYSTEM IN THE FLUE PATH AND USED THE WASTE HEAT AGAIN AS SECONDARY AIR ALSO CONVERTED OUR OWN SHUTTLE KILNS CARS AS LTM AND ALSO PROVIDED RECUPERATION SYSTEM IN THE FLUE PATH AND USED THE WASTE HEAT AGAIN AS SECONDARY AIR

14 BENEFITS FUEL SAVING OF 10% IS CLEARLY ACHIEVABLE THE TIME TAKEN TO HEAT THE CAR AND THE LOADED WARE IS REDUCED, RESULTING IN INCREASED CAPACITY : LTM DESIGN ALLOWS MORE FLEXIBILITY IN LOADING PRODUCT CONTAMINATION IS ELIMINATED PRODUCT CONTAMINATION IS ELIMINATED BONDING CEMENT IS NOT USED IN THE ASSEMBLY HENCE VERY LESS TIME TO ASSEMBLE AND DISMANTLING

15 BENEFITS LTM MATERIAL IS SUITABLE FOR ANY TYPE OF FAST OR SLOW FIRING SYSTEM DUE TO VERY GOOD THERMAL SHOCK & MECHANICAL STRENGTH VERY GOOD INTERLOCKING OF BASE AND SUPER STRUCTURE. LONGER SERVICE LIFE

16 CONCLUSION CERAMIC INDUSTRIES ARE IMPORTANT SEGMENT CONTRIBUTING TO THE NATIONSS ECONOMY COMPETITIVNESS IN THE CERAMIC INDUSTRY CAN BE TREMENDOUSLY IMPROVED BY REDUCTION IN ENERGY COST THE LTM CARS AND SUPER STRUCTURE WILL HAVE A MAJOR ROLE IN ENERGY COST REDUCTION IN THE CERAMIC INDUSTRY

17 BOTH SMALL & LARGE CERAMIC PRODUCT MANUFACTURERS SHOULD CAPITALISE ON THE LATEST DEVELOPMENTS IN LTM MATERIALS FOR BOTH BASE AND SUPER STRUCTURE AND REAP THE BENEFIT OF ENERGY CONSERVATION CONCLUSION

18 CONVENTIONAL WARE/CORDIERITE Conventional wares are made of fire clay grog, aluminosilicate grog or recycled material grog with unknown chemistry The above mentioned grogs are mixed with enormous amount of clay and temporary binders to make it a plastic mass. Pressed manually in the mould and fired at a very low temperature Introducing all sorts of flaws and end up with a product having all undesirable quality

19 CONVENTIONAL WARE/CORDIERITE These type of products are heavy and do not withstand load at higher temperature and also due to higher thermal expansion, wares breaks off within a few cycle The situation is now becoming too worse due to introduction of shorter firing cycle being introduced in the ceramic industry Totally the above practice is too bad and no one bother to estimate the cost of money/manpower/time involved Almost 90% of the ceramic manufacturers have switched over to usage of cordierite

20 Conventional wares Cordierite wares Mature at a lower temperature with undesirable silica phase Mature at high temp with controlled cordierite/mullite Profile mismatch of setter affects the end product quality Product density is high B.D.2.lto 2.5g/cc Product density is low to24g/cc

21 Conventional wares Cordierite wares High TE& poor TS Cracks within 4 or 5 cycles Reaction with end ware is more Actual cost is more


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