Monthly Engineering Horizons

REDUCING HEAT LOSS THROUGH REFRACTORY DESIGN (PART-1)

REDUCING HEAT LOSS THROUGH REFRACTORY DESIGN (PART-1)

June 19
15:20 2019

By: P.L. Satre* and C. A. Essman** *Manger, Corporate Engineering, Allied Mineral Products, Inc.  Columbus, Ohio USA

Abstract

When considering the components of a refractory system for lining the equipment used in melting, holding, transferring, and pouring molten metal, several factors should be considered.  These factors include the durability of the lining material, the ease of installation, and the actual cost of the refractory.  The total cost should also include consideration of the heat loss, a measure of continual energy consumption.

While completely eliminating heat loss through the refractory lining from the melting process is impossible, the thoughtful consideration of material selection, lining dimensions, and most importantly the selection and placement of insulation materials within the refractory system can significantly impact heat loss.

This paper documents and compares the heat loss factors of common refractories and insulation materials available for foundry applications.

Case studies comparing the original and the modified heat loss results are shown to demonstrate the dramatic differences that proper lining design can have on reducing energy consumption.

Keywords:

Melting, energy, ladles, heat loss, process improvements

Introduction

Metal melting equipment must be lined with heat resistant refractory brick or monolithic refractory lining materials to protect the structural components from contact by the molten metal, to keep the vessel from being damaged by theheat of the process, and for protecting operating personnel from exposure to excessive temperatures.

Refractories are a necessary and essential component of metal melting and pouring that allows for the process of metal casting.

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Engineering Horizons

Engineering Horizons

“Engineering Horizons” is the first & leading technical magazine of Pakistan covering Process, Mechanical, Metallurgical, Mining, Electrical & Electronics field under a single cover. We also feel pleasure in saying that this is the only magazine of its own kind & style, which is widely circulated in all Engineering Sectors of Pakistan.

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As you know, monthly “Engineering Horizons” is the first & Leading Technical Magazine of Pakistan covering Process, Mechanical, Metallurgical, Mining, Electrical & Electronics fields under a single cover. We also feel pleasure in saying that this is the only magazine of its own kind & style, which is widely circulated in all Engineering Sectors of Pakistan.
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