MAFTEC - A Case Study
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A CASE STUDY… Pre-Fabricated MAFTEC Roof Panels For a Furnace Roof
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Transcript of MAFTEC - A Case Study
A CASE STUDY…
Pre-Fabricated MAFTEC Roof Panels
For a Furnace Roof
Ceramic Fiber Modules being used in furnace roof and upper sidewalls
HTZ Blanket, 1” thick, 8 lb density“Service Limit” 2600 oF
Furnace Operating Temp = 2350 oF
THE SITUATION…
Excessive shrinkage, caused by thermal stress on the modulesLarge gaps appear between modules and surrounding refractoryEscaping heat causes hot spots on the furnace steelModule anchor system becomes affected by heat
THE PROBLEMS…
Vitrification (hardening) of module surface leads to crumbling and loss of materialModules lose their ability to contain the heatMore energy (fuel) required to maintain temperatures
THE PROBLEMS (cont’d)…
Hot spots occur on the outer steel, causing expensive damage to furnace structureOver time, more and more maintenance is required Open joints where shrinkage has occurred require re-packing with additional fiberShrinkage continuesModules become loose, due to shrinkage and anchor damage
THE PROBLEMS (cont’d)…
Hot spots continue to appear, becoming larger, doing more damageInjection of a pumpable servicing mix is tried, which might temporarily solve the problemFurnace reliability suffersModules are eventually replacedBurned, damaged steel is repairedCycle is repeated!
THE PROBLEMS (cont’d)…
SOUNDFAMILIAR
?
MAFTEC modules are madefrom polycrystalline alumina fiber blanketTemperature limit of 2950 oFShrinkage rate of MAFTEC at 2950 oF is only 1.5%, compared to 12-14% for ceramic fiberOpening of joints due to shrinkage is no longer an issueThermal efficiency is stable, reducing heat loss and fuel costs during the life of the lining
THE SOLUTION!
MAFTEC blanket is not affected by temperatures below 2950 oFRetains resiliency, no vitrification on surfaceNo maintenance required, no packing of joints, pumping, etc.Steel damage due to hot spots is avoidedFurnace reliability is improved
Cycle of Refractory Module Maintenance is Broken!
THE SOLUTION!
THE SOLUTION!
This MAFTEC roof has been in service for 5 years, with no maintenance to date.
Modules still tight, material still resilient
“Innovative Ways to Harness the Heat”
Contact TFL today for more information www.tflhouston.com
