1. CASE STUDIES ON FURNACE INSULATION
R. V. APSHANKAR
ENERGY SYSTECH
PUNE

2. SERVICE TO THE ALUMINIUM CASTING INDUSTRY
INTRODUCTION TO ENERGY SYSTECH
SERVICE TO THE ALUMINIUM CASTING INDUSTRY
MELTING & HOLDING FURNACES – ELECTRICAL AND FUEL-FIRED
HEAT TREATMENT FURNACES FOR ALUMINIUM CASTINGS (DROP QUENCH SOLUTION ANNEALING)
DEGASSING MACHINES FOR ALUMINIUM MELT
DENSITY TESTING MACHINES FOR GAS DETERMINATION

3. CASE STUDY ON ALUMINIUM HOLDING FURNACE
ALUMINIUM HOLDING FURNACE IN A LEADING FOUNDRY IN PUNE
CRUCIBLE-TYPE: CAPACITY 300 kg AL
PREVIOUS INSULATION: INSULATION BRICK
PREVIOUS CONSUMPTION: kWh / DAY
NEW INSULATION: CERAMIC FIBRE BOARD
NEW CONSUMPTION: kWh / DAY
ANNUAL SAVING : RS 1,60,000 (YEAR )
PAYBACK PERIOD: LESS THAN 6 MONTHS
22 FURNACES!!

4. BENEFITS LOWER ENERGY BILLS
LOWER AMBIENT TEMPERATURES -> BETTER WORK ENVIRONMENT
BETTER TEMPERATURE CONTROL
LOWER CONNECTED LOAD (MAX DEMAND CHARGES)
POSSIBILITY OF CAPACITY EXPANSION
LONG LIFE OF INSULATION

5. CERAMIC FIBRE BLANKETS & BOARDS
DESIGN ASPECTS
CERAMIC FIBRE BLANKETS & BOARDS
INSULATION MOUNTING - ANCHORING, ETC
SEALING OF THE FURNACE
MECHANICAL WARPING-PROOF DESIGN
LOAD SUPPORT (BOTTOM BRICKS)
MOUNTING OF HEATERS
LIMITATIONS ON FUEL-FIRING

6. ELECTRICALLY-HEATED CRUCIBLE FURNACE

7. ENERGY SOURCES FUEL-FIRED ELECTRICAL INDUCTION RESISTANCE HEATED SOLID
LIQUID
GAS

8. EFFICIENCY OF FURNACES RELATED TO LOSSES Heat Balance of a Furnace

9. LIGHT OIL FIRED CRUCIBLE FURNACE

10. DIESEL-FIRED ALUMINIUM MELTING-CUM-HOLDING FURNACE
HEAT RECUPERATION FROM FLUE GASES
AUTOMATIC BURNER => ON-OFF TEMP. CONTROL
LOW THERMAL MASS => QUICK START UP
ADVTGS OF INGOT PREHEATING

11. THANK
YOU