1. Presentation of HASLE Refractories A/S Insulation and Heat Loss

2. Insulation 
High-temperature processes require a considerable amount of energy. Often the energy consumption for high-temperature processes is used only partially for the actual technical process and 30 to 40% energy escapes through the walls into the atmosphere. To optimize the energy used and to prevent its escape into the ambience, special materials called insulating refractories are necessary.
The function of insulating refractory is to reduce the rate of heat flow (heat loss) through the walls of kiln/furnaces. Insulation is effected by providing a layer of material having low heat conductivity, which means heat does not readily pass through them.
The choice of an insulating material must be based on its ability to resist heat conductivity, on the highest temperature it will withstand and method to install it.
Insulating materials may be classified into the following groups:
Insulation Castable/Gunning
Insulation Bricks
Calcium Silicate Board
4. Ceramic Fiber

3. Insualation Type of Insulation Insulating Castables
Insulating castables are different from other castables in the way that the main component of the castable is made from products with high porosity, or through the heating up/curing forming highly porous structures.

4. Insualation Type of Insulation Insulating Castables Advantages:
An insulating castable is very suitable to fill up the space between a strong hot face refractory lining and a fibre insulation. The castable flows into all corners and cracks, and leaves no cavity. Besides, it is easy and uncomplicated to handle.
Disadvantages:
Insulating castables usually have low refractoriness, low temperature application limits and low mechanical strength, and they are therefore rarely applied as primary lining. In addition, they are not resistant to slag and other chemical attack.

5. Insualation Type of Insulation 2. Insulating Bricks
Insulating bricks differ from other bricks by greater porosity and thereby lower crushing strengths. The advantage of an insulating brick is that it can be used both as primary lining and back lining.
3. Calcium Silicate
Calcium Silicate is an insulation material molded by reacting calcium silicate powder with high pressure heat, and mixing it with inorganic fiber. It is easy and fast for installation.

6. Insualation Type of Insulation 4. Ceramic Fibre
It can be spun or blown into bulk, air-laid into a blanket, folded into modules, converted into papers, boards, and shapes, die-cut into gaskets, twisted into yarns, woven into rope and cloth, and blended into liquid binders for mastics and cements.
They are used in areas where good insulating properties are needed - for packing and for expansion joints. If there is no mechanical wear, ceramic fibre can be used as the only refractory material in contact with the process - e.g. in kilns for heat treatment of metal, glass etc.

7. Heat Transfer Sample: Shape: Square
Shape: Square
Hot Face Temperature: 1,000 Degree C.
Ambient Temperature: 30 Degree C.
Type of Out Side Surface: Absolute Black Surface.
Convektion Cold Face: Natural
They install Castable+Insulating Castable+Calciumsilicate Board and would like to know approximated temperature outside?

8. Estimate for temperature and energy potential.
Heat Transfer
Sample:
Estimate for temperature and energy potential.
Thickness (mm). Energy (MJ/m2) Temp (Degree C)
  ,000
Castable D59A
Insulating Castable BS
Calciumsilicate Board  
Heat transfer 1,123 W/m2
1,000 C
932 C
760 C
109 C
30 C
D59A
BS1200
Cal
D59A 95mm. + BS mm. + Cal 50mm.
Heat transfer 1,123 W/m2

9. Heat Transfer
We fix total lining thickness 254mm. and we can design refractories lining:
Heat transfer 1,218 W/m2
1,000 C
926 C
738 C
115 C
30 C
D59A
BS1200
Fiber
95mm.
109mm.
50mm.
932 C
760 C
109 C
Cal
Heat transfer 1,123 W/m2
Heat transfer 779 W/m2
951 C
614 C
91 C
BHI1200
Heat transfer 2,648 W/m2
837 C
177 C
Heat transfer 1,235 W/m2
925 C
116 C
159mm.

10. Heat Transfer Sample: Shape: Square
Shape: Square
Hot Face Temperature: 1,300 Degree C.
Ambient Temperature: 30 Degree C.
Type of Out Side Surface: Absolute Black Surface.
Convektion Cold Face: Natural
They install Castable+Insulating Castable+Calciumsilicate Board and total thickness is 250mm.

11. Heat Transfer
We fix total lining thickness 250mm. and we can design refractories lining:
1,300 C
1,197 C
981 C
136 C
30 C
D59A
BS1200
Cal
Heat transfer 1,674 W/m2
100mm.
50mm.
1,000 C
1,067 C
146 C
Heat transfer 1,889 W/m2
200mm.
1,250 C
93 C
Heat transfer 809 W/m2
150mm.

12. QUESTIONS?

13. THANK YOU

14. Acid Dew Point:
Waste containing acidic components form combustion products which are corrosive when combined with water. Methyl Chloride contains chlorine, which forms HCl. When cooled to oF, the water vapor / HCl mixture in the flue gas condenses. Corrosion of refractory or vessel shell material results. Sulfur compounds burn to form SO2 and SO3 (usually 3 to 10% ends up as SO3). The SO3 combines with water vapor when flue gas cools to the dew point temperature - often between 200 and 400o F, condensing to form H2SO4. Dewpoint problems often occur at the furnace shell when the refractory/rainshield system allow a low shell temperature.
Refractory linings are relatively porous. Flue gas components penetrate to the steel shell. If the shell temperature is below the acid dewpoint of the gas, condensation will occur