Energy & Cost Saving Solutions By High Emissivity Technology, … Chemi Yeosu... · 2014. 3....
Transcript of Energy & Cost Saving Solutions By High Emissivity Technology, … Chemi Yeosu... · 2014. 3....
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