IMPROVING REFRACTORY LINING LIFE

AND
ENERGY SAVING IN FURNACE OPERATION
By
S. P. Shenoy
M.Tech, (MET. ENGG.), M.I.I.M.

C.E.O., Steel Plant Specialities, 211, Raikar Chambers,

Govandi East, Mumbai – 400 088
Tel. : 6797 8060, Fax : 91-22-2555 2459
E-mail : espon@vsnl.net
Website : www.esponcoating.com

Hot rolling involves plastic deformation of heated metals and alloys into flat
products (slabs, plates) or long products (wire rods, angles, channels, I sections,
TMT bars, etc.). In this important metal forming operation, refractory and fuel
for the reheating furnace (such as furnace oil, pulverized coal or gas) are the
major costs. Any process or technique to reduce these costs will automatically
improve the profitability of the rolling mill. The following problems are
encountered in the case of refractories
1) Thermal shock cracking.
Thermal shock is unavoidable in furnace operation, however much care may
be taken. Due to thermal shock, cracks are initiated in the refractory lining.
Energy leaks through these cracks. This loss may be as high as 33% of the
total energy consumption. This is the reason why fuel consumption is
observed to be more after a time gap of say, six months from the date of
relining the furnace, for the same level of production.

2) Low Emissivity.
Refractory lining has a low emissivity of 0.2 and hence hampers furnace
efficiency.
Improving this value to 0.5 or more will lead to fuel saving

3) Corrosive Action.
Furnace oil contains sulphur dioxide and vanadium pent oxide. These
compounds corrode the refractory lining.

4) Vicious sand blasting effect.

The flame impinging on the refractory lining has a vicious effect of sand
blasting.

5) Carbon deposit on the burner blocks.

This problem is more pronounced when the fuel used is furnace oil.
Unburned carbon deposits on the burner blocks, and over a period of time,
sufficient carbon build up takes place. Due to this build up, the flame
geometry is impaired and heating efficiency is lowered.
Steel Plant Specialties, a Mumbai based firm, has come out with a unique
solution to overcome all the above problems. The entire refractory lining of
the reheating furnace is coated with a special coating, ESPON-RC.

A hot rolling mill producing 40,000 tons per annum of TMT bars has
reported the following results:

1. Refractory lining life

Without coating : 12 months

With ESPON-RC coat : 21 months

2. Fuel Consumption:

Without coating : 40 liters per ton

With ESPON-RC coat : 38 liters per ton

Annual saving : 80,000 liters

Value of annual saving : U.S. $ 35,555
Cost of Refractory coating : U.S. $ 1,555
Net annual saving : U.S. $ 34,000
Fig.1 and 2 show the condition of the refractory lining and burner blocks
before coating and fig. 3 and 4 show their condition after coating with
ESPON-RC.

SUMMARY

1. Use of a special refractory coating holds high

promises to any rolling mill which is interested in
improving refractory lining life and energy saving.

2. This technique is a sure way of cost reduction.

Fig.1

Fig 2.
Fig.3.

Fig.4.