BURTON. Contents. 2. Durability / long lasting products (short extract)

Transcription

1 BURTON Partner of the ceramics industry for long-lasting lasting- + energy saving refractory systems - worldwide India March 2011 Mr. J. Boeke Contents 1. Introduction of Burton 2. Durability / long lasting products (short extract) 3. Energy saving systems 3.1. Where do energy losses arise that can be influenced by BURTON? 3.2. BURTON s influence on energy consumption (up to BurcoLight material + design) 4. Conclusion 1

2 1. Introduction of Burton - Production site in Germany and Hungary with - Products and systems - Developments and patents - Facts and figures The production site in Germany 2

3 Hamburg Berlin BURTON is situated in the western part of North Germany München BURTON - refractories - For over 60 years BURTON has developed systems for ceramics kiln construction and is market leader in the field of complete refractory systems for the ceramics industry: - Wall systems - Suspended/arched roof systems - Tunnel kiln car systems - for top-fired and - side + bottom-fired kilns - Kiln furnitures 3

4 New developements in the BURTON group (inclusive several patents): Tunnel kiln car systems 1960 Suspended roof systems 1970 BURTON kiln car lightweight system 1974 U-cassettes, dry-pressed 1978 U-ribbed cassettes, dry pressed 1980 Viaduct blocks 1984 H-cassettes, cast 1987 H-cassettes, dry-pressed 1992 SIC production 1998 BurcoLight for energy-saving for kiln cars 2003 H-cassettes, dry pressed BURTON 2004 H-cassettes, cast NEW BURTON KF 2006 H-cassettes, cast BurcoLight custom-made 2009 Tunnel kiln car systems for the clinker and facing brick industry 4

5 Tunnel kiln car systems for the wall brick industry -> Wienerberger ZI Bilder fehlen Tunnel kiln car systems for the clay roofing tile industry U-Cassettes for roofing tiles 5

6 Tunnel kiln car systems for the clay roofing tile industry H-Cassettes for high quality firing of roofing tiles (Hungary) Tunnel kiln car systems for structural ceramics 6

7 Facts & Figures Total capacity tons of fired ware per year = 250 tons of fired ware per calendar day. Of this capacity approx.: 75 % part for the ceramics industry 25 % for the aluminium, iron/steel, glas-industry, general kiln construction 7

8 Staff Regular staff of approx.: 200 people This includes as many as 10 people working in the research and developement departement! For the dry-pressed BURTON systems BURTON makes use of: 14 hydraulic presses with pressure capacity of up to tons applied pressure 8

9 For the dry-pressed BURTON systems BURTON makes use of: 4 setting robots placed next to the hydraulic presses of 800 and tons applied pressure Firing capacity - 1 Tunnel kiln for firing temperatures of up to 1560 C / 2840 F - 1 Tunnel kiln for firing temperatures of up to 1650 C / 3000 F - 1 Shuttle kiln for firing temperatures of up to 1850 C / 3360 F - 1 Shuttle kiln for firing temperatures of up to 1500 C / 2735 F 9

10 Automatic cutting machine 5 cuts per process possible 100 % testing of hanger blocks. Certified since 1994 DIN ISO

11 BURTON Kiln Furniture in Hungary, Europe: Production site for cast products 11

12 Cast H-cassettes Capacity BURTON Kiln Furniture in Hungary: approx H-Cassettes per year and others, like U-Cassettes, accessories etc. Staff Regular staff of approx.: 20 people 12

13 Production at BURTON Kiln Furniture 13

14 Production and Quality control at BURTON Kiln Furniture Laboratory 2. Durability / long lasting products (short extract) 14

15 BURTON delivers worldwide refractory products and complete systems for over 60 years Wall- / roof- and car-sytems are installed as well as kiln furnitures Depending on the special production process requirements and conditions from BURTON s clients each delivery will be evaluated by means of material quality, design, durability (possible production cycles) and others BURTON uses HIGH END Information Technology to examine the products before manufacturing to secure a maximum of safety for quality RESULTS All over the world there are lots of factories which are running for more than 30 (and more) years on minimized maintenance status with BURTON s systems/products, for example such as BURCOTOP and BURCOLIGHT More than customers trust in Burtons Know How Far more than orders show the reliability and safety of BURTON s deliveries Referencelistsareavailable 15

16 3. Energy saving systems 3.1. Where do energy losses arise that can be influenced by BURTON? 3.2. BURTON s influence on energy consumption (BurcoLight material + design) 3.1. Where do energy losses arise that can be influenced by BURTON? 16

17 Energy loss through the ceiling Energy loss through the wall Energy loss through the wall Energy loss through the car Energy loss after the kiln furniture left the kiln Energy loss afterthecarleftthekiln What are the proportions? - The following page shows the proportions as an example for a quite new system for the roofing tile industry - with kiln furniture and heat compound - Depending on the age and the type of the system/kiln, these proportions can vary and can also be larger than the proportions shown 17

18 Proportions in the energy balance (sample) Energy inflow 100 % Tunnel kiln Energy outflow 12 % 7 % 5 % 3 % 4 % 25 % 44 % kilns cars coming out of the kiln energy loss in the insulation area of wall + ceiling kiln furniture (cassettes) coming out of the kiln fired ware coming out of the kiln outblow through kiln building joints losses in exhaust gases air suction, (undercar air suction 2 %) => BURTON s influence on energy consumption: at least 20 to 30 % there are differences between: a newly implemented plant and therefore its continuous energy saving during its operation (from the beginning) a subsequent optimization of a plant made step by step: an optimized continuous energy saving is only achieved when all tunnel kiln cars and cassettes have been replaced 18

19 3.2. BURTON s influence on energy consumption (up to BurcoLight material + design) Influencing factors on energy consumption of kiln cars Refractory material Insulation Design Firing curve 19

20 Influencing factors on energy consumption of H-Cassettes Refractory material Design Firing curve Every plant and every thermal process is different static, dynamic and thermal conditions require the selection of the appropriate design + material 20

21 Selection of the refractory material BURTON developed new qualities up to BurcoLight for dry pressed products BURTON developed 5 new qualities of BurcoLight - from BurcoLight KFL 1,4 to 1,8 as well as the standard quality Burcorit KF 1 and Burcorit KF 2 quality with a very high density for casted products Depending on the quality, it is possible to minimize the weight by more than 30% this results in a much higher energy efficiency, as 30% less mass has not to be heated up and cooled down! 21

22 Development of lightweight refractory materials up to dry pressed BurcoLight 2,20 2,00 [kg/dm³] 1,80 1,60 1,40 1,20 Concrete Fireclay Burcotop 125 H Burcotop 17/25 H BurcoLight H BurcoLight 14/25 H BurcoLight 13/25 H Thermal conductivity Comparison Burcotop / BurcoLight Thermal conductivity [W/m K] 1,600 1,500 1,400 1,300 1,200 1,100 1,000 0,900 0,800 0,700 0,600 0,500 Burcotop 125 H Burcotop 17/25 H BurcoLight H Temperature [ C] 22

23 Decisive factors of casted BurcoLight KFL H-Cassettes are: saving in weight abrasion data as well as the open porosity Selection of design 23

24 Lightweight border blocks T-border block Number 2442 Wall thickness 50 mm Universal border block Number 2445 Wall thickness 85 mm Tunnel kiln car systems for facing bricks and backing bricks 24

25 Example: U-cassette TDK 55 33,5 kg Result: A saving in weight of 6,6 Kg (= 20%) (Mass, that doesn t have to be heated up and cooled down) 26,9 kg BURTON Study carried out by the Institute for Brick Research, Germany at a roofing tile plant 25

26 Results BURTON GmbH + Co. KG stored heat [kwh/tow] Old tunnel kiln car; 9 to New tunnel kiln car heavyweight, 4 to TOW alt TOW neu-schwer Preheating zone/firing zone 0 AZ/BZ KZ Cooling zone Ausfahrt Exit TOW neu-leicht New tunnel Bild kiln 44 car lightweight, 3,5 to SCHIEDEL, Zliv plant/ CZ Re-equipment of 180 tunnel kiln cars 26

27 Schiedel, Zliv plant / CZ Results: - Reduction of the car weight from 3,120 kg to 2,282 kg (-23.5%) - Reduction of the undercar temperature from 240 C to 108 C - Specific energy consumption reduced from 1.25 KWh/kg of goods to 1.14 KWh/kg of goods (-9%) - Carbon dioxide production reduced by ~390 to/year - Gas consumption reduced by 200,000m³ - Saving of approx (= INR) in energy costs/year Roof tile factory example: H-Cassette TMA01 Weight of H-Cassette in Burcorit KF 1 with a bulk density of 1,92: 5,61 Kg Weight of H-Cassette in BurcoLight KFL 1,5 with a bulk density of 1,52: 4,48 Kg Saving in weight per H- Cassette: 1,13 Kg = 20% (Mass, that doesn t need to be heated up and cooled down) 27

28 This means for a tunnel kiln car loaded with H-cassettes a saving in weight of 2,93 to per kiln car a mass of 2,93 to per kiln car that doesn t have to be heated up and cooled down higher energy efficiency! 4. Conclusion 28

29 4. Conclusions Material and Design have a deep impact on durability and energy consumption Energy costs can be reduced Durability + higher energy efficiency = Continuous cost reduction Durability + energy saving from BURTON by optimized BURTON design and/or BURTON material Additional advantages + comments Less CO2-Emmission rights have to be purchased Lower maintenance costs The energy consumption of plants that have been in longterm operation without any changes is much higher than in modern systems! 29

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