Energy & Cost Saving SolutionsBy High Emissivity Technology, Emisshield

(Hanwha Chemical Yeosu Plant)

TFS Global Co, Ltd.POSCO 1ST Spin-off Company

Dec. 13. 2013

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Current problem

Operators of chemical manufacturing furnaces are facing significant operating cost increases due to constantly-increasing fuel costs and short decoking cycle.

Besides the high cost of fuel, capital expenditures to furnace maintenance expenses represent significant costs that negatively affect profitability.

“fuel is one of the largest operational cost components and

downtime by short decoking cycle is the one of the largest loss”

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VCM-1 Furnace(F-200)

Chance to save the cost

NASA

Extend Decoking cycle &Energy Cost Saving Solutions

By Emisshield(NASA Technology)

C4Raffinate-III : 195억 원/년 Decoking cycle : 9~11 months

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Parts Material Size Area RemarksSide wall Ceramic brick - 397.8 m2

468 m2End wall & Ceiling Ceramic Fibber - 70.2 m2

Tube Incoloy 800H8” O.D×20m(2열 16라인)

408 m2 -

Emisshield Application for VCM Furnace

Applied parts of Emisshield

Side wall (Ceramic

Brick)

U-curved Tube (lncoloy 800H)

End Wall & ceiling(Ceramic Fiber)

Straight Tube (Incoloy 800H)

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What is Emisshield

High Emissive Nano Technology developed by NASA

Products for Ceramic and Metal substrates Operation Temperature: Max.1650℃ Emissivity: 0.85-0.95 Thin Film Water –based with no VOC’S Super Adhesion Unique Binder

HIGH EMISSIVITY

HIGHTEMPERTURE

STRONGADHESION

Improve productivity & reduces energy consumption Green Technology Reduces maintenance and downtime

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When EMISSHIELD is applied to the hot face of the furnace wall and tube surface.

How does Emisshield work: Wall

Emisshield applied to wall

More thermal energy go to the tube

(TC)

Ceramic Bricks(Side wall)

Radiant and convective energy from the burners and hot furnace gases are absorbed at the surface of the coating and reradiated to the cooler tube.(TC>TL)

TubeLoad(TL)

* Ceramic Fiber(End wall & celling) More ThermalEnergy

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When EMISSHIELD is applied to the hot face of the tube surface.

How does Emisshield work: reduce the coaking

Prevent the hot spot outside/inside tube

Emisshield applied to outside of Tube

Burner Flame(Burner Side)

The coating reduces the coking by preventing hot spots due to thermal energy from hot burner flame. (TS > TF)

More thermal energy is transferred into the tube

TubeLoad(TL)

TubeSurface Temp.

(TS)

The coating absorbs more of the radiant heat emitted from the coated furnace lining. (TL<TC) Heat flux (W/m2) across the tube to the product is increased.

(TS > TF)

More uniform heat to products

Furnace Inside Temp.(TF)

(TC)

wall

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Where: Q = re-radiated energy absorbed by the furnace load E = emissivity

- Without Emisshield 0.3-0.5- With Emisshield 0.9

σ = Stefan-Boltzmann constant TC = coating temperature TL = load temperature

“Turning down the burners to maintain the same Q achieved without the coating”

How does Emisshield work and heat balance The amount of heat reradiated from EMISSHIELD® is predicted

by the following equation:

Q = E . σ . (TC4-TL4)

This means that the furnace will be hotter at the same fuel usage after EMISSHIELD® is applied to the box & tube, resulting in shorter cycle time and higher productivity.

After Emisshield,consuming less fuel

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LoadLoad

Step 1: Uneven heating across the tube creates hot spots

Step 1: No hot spots are formed

Process Tube- Reduced Coking

With EmisshieldNo Emisshield

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With EmisshieldNo Emisshield

LoadLoad

Step 2: Reduce metal oxide formationStep 2: Metal oxide formation, nucleation site

Process Tube- Reduced Coking

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LoadLoad

Step 3: Double or Triple the time between decokingStep 3: Coking Initiated

Process Tube- Reduced Coking

With EmisshieldNo Emisshield

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LoadLoad

Step 4: Decoking Required Step 4: Double or Triple the time between decoking

Process Tube- Reduced Coking

With EmisshieldNo Emisshield

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Work procedure

Main work- Emisshiled coating

Preparation work- Tube Shot Blast

- Surface Cleaning(Side Wall & Tube)

Finish

Dry

Start Background Data:Measure fuel usage and productivity before coating with Emisshield for background data: production rate / cracking depth or efficiency / decoke cycle.

Final Data: Measure fuel usage and productivity after coating with Emisshield for final data. (same as above)

Heat Balance Control

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Example: Emisshield coating work for VCM

Before Coating After Coating

Tube(U-curved)

Tube(Straight)

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Before Coating After Coating

SideWall

Floor

Example: Emisshield coating work for VCM

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Increase fuel savings, production or both

- Fuel cost saving: more than 3 % (Formosa Average 5%)

- Production Increase : more than 3%(Formosa Average 6%)

- Uniform temperature of tube - Strong ROI

Longer life time & maintenance cost savings- Reduce decoking cycle time : more than double time between decoking

-Ceramic life extension- Tube oxidation reduce

Green Technology- Emission/Environment Enhancement

123

Benefits of Emisshield project

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Worldwide Applications

FORMOSA Licensed plant