WORK SHOP WORK SHOP
ON ON
KILN FURNITURE AND ENERGY SAVINGS KILN FURNITURE AND ENERGY SAVINGS
ON 23RD FEBRUARY ‘2006 AT CGCRI — ON 23RD FEBRUARY ‘2006 AT CGCRI —
KHURJA CENTERKHURJA CENTER
AGENDA
WELCOME ADDRESS WELCOME ADDRESS
CORDIERITE AND ITS APPLICATION CORDIERITE AND ITS APPLICATION
LTM CONCEPT LTM CONCEPT
DO’S AND DONTS/CONVENTIONAL WARE — DO’S AND DONTS/CONVENTIONAL WARE —
CORDIERITE CORDIERITE
PAPER PRESENTATION BY CGCRI — KHURJA PAPER PRESENTATION BY CGCRI — KHURJA
VOTE OFTHANKSVOTE OFTHANKS
CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATION
CORDIERITE A MAGNESIUM ALUMINO SILICATE WITH A CORDIERITE A MAGNESIUM ALUMINO SILICATE WITH A MOLUCULAR FORMULA 2MgO 2A1203 5 SiO2. DUE TO MOLUCULAR FORMULA 2MgO 2A1203 5 SiO2. DUE TO ITS LOW THERMAL EXPANSION CHARACTER IT HAS GOT ITS LOW THERMAL EXPANSION CHARACTER IT HAS GOT VERY GOOD THERMAL SHOCK.VERY GOOD THERMAL SHOCK.
IT IS A SYNTHETIC MATERIAL AND NATURAL IT IS A SYNTHETIC MATERIAL AND NATURAL OCCURRENCES ARE VERY MINIMAL OCCURRENCES ARE VERY MINIMAL
THE FORMATION OF CORDIERITE IN A CERAMIC THE FORMATION OF CORDIERITE IN A CERAMIC PROCESS IS VERY SENSITIVE AND MINOR VARIATION IN PROCESS IS VERY SENSITIVE AND MINOR VARIATION IN THE MATURING ZONE AFFECT THE END PRODUCT THE MATURING ZONE AFFECT THE END PRODUCT PROPERTIES.PROPERTIES.
CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATIONDUE TO VERY COMPLEX PROCESS NATURE ONLY DUE TO VERY COMPLEX PROCESS NATURE ONLY COUNTABLE NUMBER OF INDUSTRIES ARE ENGAGED IN COUNTABLE NUMBER OF INDUSTRIES ARE ENGAGED IN THE MANUFACTURE OF CORDIERITE .THE MANUFACTURE OF CORDIERITE .
UTMOST CARE IS A MUST FROM SELECTION OF RAW UTMOST CARE IS A MUST FROM SELECTION OF RAW MATERIAL TO MATURING OF THE END PRODUCT MATERIAL TO MATURING OF THE END PRODUCT OTHERWISE LOSSESS WILL BE VERY HIGH .OTHERWISE LOSSESS WILL BE VERY HIGH .
FOR COMMERCIAL KILN FURNITURE MANUFACTURING FOR COMMERCIAL KILN FURNITURE MANUFACTURING CORDIERITE IS BONDED WITH A SECONDARY MULLITE CORDIERITE IS BONDED WITH A SECONDARY MULLITE TO ENHANCE THE KILN FURNITURE LOAD BEARING TO ENHANCE THE KILN FURNITURE LOAD BEARING PROPERTIES AT HIGH TEMPERATURE PROPERTIES AT HIGH TEMPERATURE
CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATION
THE MAIN FABRICATION PROCESS OF CORDIERITE KILN THE MAIN FABRICATION PROCESS OF CORDIERITE KILN
FURNITURE ARE DRY PRESSING, SLIP CASTING & FURNITURE ARE DRY PRESSING, SLIP CASTING &
EXTRUSION EXTRUSION
CORDIERITE IS THE ONLY CHEAPER AND BEST KILN CORDIERITE IS THE ONLY CHEAPER AND BEST KILN
FURNITURE UPTO 1300*C APPLICATION ALTERNATE TO FURNITURE UPTO 1300*C APPLICATION ALTERNATE TO
SILICON CARBIDE AND OTHER TYPE OF FURNITURES SILICON CARBIDE AND OTHER TYPE OF FURNITURES
ALMOST ALL THE CERAMIC MANUFACTURING UNIT ALMOST ALL THE CERAMIC MANUFACTURING UNIT
CHANGED OVER TO THE USAGE OF CORDIERITE KILN CHANGED OVER TO THE USAGE OF CORDIERITE KILN
FURNITURE THROUGOUT THE WORLDFURNITURE THROUGOUT THE WORLD
CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATION
DUE TO CONTINUOUS INCREASE OF RAW MATERIAL AND DUE TO CONTINUOUS INCREASE OF RAW MATERIAL AND FUEL PRICE, COST REDUCTION IS THE ONLY VIABLE FUEL PRICE, COST REDUCTION IS THE ONLY VIABLE ALTLERNATE TO COMPETE THE MARKET. THEREFORE ALTLERNATE TO COMPETE THE MARKET. THEREFORE CORDIERITE KILN FURNITURE SYSTEMS SCORE OVER CORDIERITE KILN FURNITURE SYSTEMS SCORE OVER OTHER REFRACTORIES. OTHER REFRACTORIES.
CERTAIN TABLE WARE UNIT OPERATES WITH A CERTAIN TABLE WARE UNIT OPERATES WITH A SUPPORT WARE(KILN CAR, SUPER STRUCTURE) :END SUPPORT WARE(KILN CAR, SUPER STRUCTURE) :END PRODUCT RATIO OF 6:1PRODUCT RATIO OF 6:1
LOW THERMAL MASS KILN CARS & SUPER STRUCTURE LOW THERMAL MASS KILN CARS & SUPER STRUCTURE WITH THE COMBINATION OF LIGHT WEIGHT CORDIERITE WITH THE COMBINATION OF LIGHT WEIGHT CORDIERITE WITH SILICON CARBIDE BEAMS ALONG WITH CERAMIC WITH SILICON CARBIDE BEAMS ALONG WITH CERAMIC FIBER RESULTED IN UNBELIEVABLE COST REDUCTION FIBER RESULTED IN UNBELIEVABLE COST REDUCTION ZN THE CERAMIC SECTOR. ZN THE CERAMIC SECTOR.
THE TREND SET GLOBALLY THREE DECADES AGO HAS THE TREND SET GLOBALLY THREE DECADES AGO HAS GOT MOMENTUM NOW IN INDIA GOT MOMENTUM NOW IN INDIA
CORDIERITE AND ITS APPLICATIONCORDIERITE AND ITS APPLICATION
THE MAJOR APPLICATION AREASTHE MAJOR APPLICATION AREAS SANITARY WARE SANITARY WARE
TABLE WARE TABLE WARE
FLOOR TILE/WALL TILE FLOOR TILE/WALL TILE
INSULATORS LT/HT INSULATORS LT/HT
GRINDING WHEEL GRINDING WHEEL
ELECTRO CERAMICS ELECTRO CERAMICS
ART WARE/STONE WARE ART WARE/STONE WARE
ROOFING TILE ROOFING TILE
FERRITE FERRITE
DYES/COLORS/PAINT DYES/COLORS/PAINT
VARIOUS PRODUCT SHAPES VARIOUS PRODUCT SHAPES
DECK SLABS DECK SLABS
PERFORATED SLABS PERFORATED SLABS
PROPS (PLAIN/STEPPED) PROPS (PLAIN/STEPPED)
BEAMS/SUPPORTS/CAPS BEAMS/SUPPORTS/CAPS
PROFILE SETTERS PROFILE SETTERS
MUG/CUP SETTERS MUG/CUP SETTERS
T-CRANK/TILE CRANK T-CRANK/TILE CRANK
FOOTREST FOOTREST
SAGGARS SAGGARS
SPECIAL SHAPES SPECIAL SHAPES
QUALITY PROBLEMQUALITY PROBLEM
DURING TRANSIT DURING TRANSIT
DURING STORAGE DURING STORAGE
ROUGH HANDLING ROUGH HANDLING
WRONG SELECTION WRONG SELECTION
WRONG LOADING WRONG LOADING
EXCEEDING THE TEMP LIMIT EXCEEDING THE TEMP LIMIT
FLAME/GLAZE/BEDDING MATERIAL ATTACK FLAME/GLAZE/BEDDING MATERIAL ATTACK
FURNITURE QUALITY PROBLEM FURNITURE QUALITY PROBLEM
LOW THERMAL MASSLOW THERMAL MASS ENERGY EFFICIENT CORDIERITE KILN ENERGY EFFICIENT CORDIERITE KILN
FURNITURE SYSTEM INTRODUCTIONFURNITURE SYSTEM INTRODUCTION
FUEL AND POWER COST IS THREATENING EVERY FUEL AND POWER COST IS THREATENING EVERY INDUSTRY IN CERAMIC SECTOR FUEL COST AMOUNTS INDUSTRY IN CERAMIC SECTOR FUEL COST AMOUNTS TO 35 TO 40% OF THE MANUFACTURING COST TO 35 TO 40% OF THE MANUFACTURING COST
ENERGY CONSERVATION IS A MUST TO STAY IN THE ENERGY CONSERVATION IS A MUST TO STAY IN THE GLOBALISED MARKETGLOBALISED MARKET
LOW THERMAL MASS CONCEPT IS PROVEN EXAMPLE OF LOW THERMAL MASS CONCEPT IS PROVEN EXAMPLE OF FUEL REDUCTION TECHNIQUEFUEL REDUCTION TECHNIQUE
LOW THERMAL MASSLOW THERMAL MASS
LTM CONCEPT WILL REDUCE THE FUEL BY A MINIMUM LTM CONCEPT WILL REDUCE THE FUEL BY A MINIMUM OF 10 to 15 % AND INCREASE IN PRODUCTION OF 10 % OF 10 to 15 % AND INCREASE IN PRODUCTION OF 10 % MIN MIN
LOW MASS/LOW THERMAL EXPANSION CORDIERITE LOW MASS/LOW THERMAL EXPANSION CORDIERITE KILN FURNITURE — CERAMIC FIBER AND KILN FURNITURE — CERAMIC FIBER AND RECRYSTALLIZED BEAMS ARE THE MAIN COMPONENTS RECRYSTALLIZED BEAMS ARE THE MAIN COMPONENTS USED IN THE LTM CARS FOR ENERGY CONSERVATRION USED IN THE LTM CARS FOR ENERGY CONSERVATRION
ABREF HAS TAKEN THE TASK OF PRODUCING READY ABREF HAS TAKEN THE TASK OF PRODUCING READY MADE LTM KILN CAR OR INSTALLATION OF LTM AT MADE LTM KILN CAR OR INSTALLATION OF LTM AT CUSTOMER ENDCUSTOMER END
LOW THERMAL MASSLOW THERMAL MASS
RECENTLY ABREF HAS ISTALLED TWO LTM CARS RECENTLY ABREF HAS ISTALLED TWO LTM CARS SUCCESSFULLY IN A SANITARY WARE IN MORBI AND SUCCESSFULLY IN A SANITARY WARE IN MORBI AND AWAITING ONE EXPORT ORDER FROM A TILE INDUSTRY AWAITING ONE EXPORT ORDER FROM A TILE INDUSTRY
ALSO CONVERTED OUR OWN SHUTTLE KILNS CARS AS ALSO CONVERTED OUR OWN SHUTTLE KILNS CARS AS LTM AND ALSO PROVIDED RECUPERATION SYSTEM IN LTM AND ALSO PROVIDED RECUPERATION SYSTEM IN THE FLUE PATH AND USED THE WASTE HEAT AGAIN AS THE FLUE PATH AND USED THE WASTE HEAT AGAIN AS SECONDARY AIR SECONDARY AIR
BENEFITSBENEFITS FUEL SAVING OF 10% IS CLEARLY ACHIEVABLE FUEL SAVING OF 10% IS CLEARLY ACHIEVABLE
THE TIME TAKEN TO HEAT THE CAR AND THE LOADED THE TIME TAKEN TO HEAT THE CAR AND THE LOADED WARE IS — REDUCED, RESULTING IN INCREASED WARE IS — REDUCED, RESULTING IN INCREASED CAPACITY : LTM DESIGN ALLOWS MORE FLEXIBILITY CAPACITY : LTM DESIGN ALLOWS MORE FLEXIBILITY IN LOADING IN LOADING
PRODUCT CONTAMINATION IS ELIMINATEDPRODUCT CONTAMINATION IS ELIMINATED
BONDING CEMENT IS NOT USED IN THE ASSEMBLY BONDING CEMENT IS NOT USED IN THE ASSEMBLY HENCE VERY LESS TIME TO ASSEMBLE AND HENCE VERY LESS TIME TO ASSEMBLE AND
DISMANTLINGDISMANTLING
BENEFITSBENEFITS
LTM MATERIAL IS SUITABLE FOR ANY TYPE OF FAST LTM MATERIAL IS SUITABLE FOR ANY TYPE OF FAST OR SLOW FIRING SYSTEM — DUE TO VERY GOOD OR SLOW FIRING SYSTEM — DUE TO VERY GOOD THERMAL SHOCK & MECHANICAL STRENGTH — VERY THERMAL SHOCK & MECHANICAL STRENGTH — VERY GOOD INTERLOCKING OF BASE AND SUPER GOOD INTERLOCKING OF BASE AND SUPER STRUCTURE. STRUCTURE.
LONGER SERVICE LIFE LONGER SERVICE LIFE
CONCLUSIONCONCLUSION
CERAMIC INDUSTRIES ARE IMPORTANT SEGMENT CERAMIC INDUSTRIES ARE IMPORTANT SEGMENT CONTRIBUTING TO THE NATIONS’S ECONOMYCONTRIBUTING TO THE NATIONS’S ECONOMY
COMPETITIVNESS IN THE CERAMIC INDUSTRY CAN BE COMPETITIVNESS IN THE CERAMIC INDUSTRY CAN BE TREMENDOUSLY IMPROVED BY REDUCTION IN ENERGY TREMENDOUSLY IMPROVED BY REDUCTION IN ENERGY COST COST
THE LTM CARS AND SUPER STRUCTURE WILL HAVE A THE LTM CARS AND SUPER STRUCTURE WILL HAVE A MAJOR ROLE IN ENERGY COST REDUCTION IN THE MAJOR ROLE IN ENERGY COST REDUCTION IN THE CERAMIC INDUSTRY CERAMIC INDUSTRY
BOTH SMALL & LARGE CERAMIC PRODUCT BOTH SMALL & LARGE CERAMIC PRODUCT MANUFACTURERS SHOULD CAPITALISE ON THE MANUFACTURERS SHOULD CAPITALISE ON THE LATEST DEVELOPMENTS IN LTM MATERIALS FOR LATEST DEVELOPMENTS IN LTM MATERIALS FOR BOTH BASE AND SUPER STRUCTURE AND REAP BOTH BASE AND SUPER STRUCTURE AND REAP THE BENEFIT OF ENERGY CONSERVATION THE BENEFIT OF ENERGY CONSERVATION
CONCLUSIONCONCLUSION
CONVENTIONAL WARE/CORDIERITECONVENTIONAL WARE/CORDIERITE
Conventional wares are made of fire clay grog, Conventional wares are made of fire clay grog, aluminosilicate grog or recycled material grog with aluminosilicate grog or recycled material grog with unknown chemistry unknown chemistry
The above mentioned grogs are mixed with enormous The above mentioned grogs are mixed with enormous amount of clay and temporary binders to make it a plastic amount of clay and temporary binders to make it a plastic mass. mass.
Pressed manually in the mould and fired at a very low Pressed manually in the mould and fired at a very low temperature temperature
Introducing all sorts of flaws and end up with a product Introducing all sorts of flaws and end up with a product having all undesirable quality having all undesirable quality
CONVENTIONAL WARE/CORDIERITECONVENTIONAL WARE/CORDIERITE
These type of products are heavy and do not withstand These type of products are heavy and do not withstand load at higher temperature and also due to higher thermal load at higher temperature and also due to higher thermal expansion, wares breaks off within a few cycle expansion, wares breaks off within a few cycle
The situation is now becoming too worse due to The situation is now becoming too worse due to introduction of shorter firing cycle being introduced in the introduction of shorter firing cycle being introduced in the ceramic industry ceramic industry
Totally the above practice is too bad and no one bother to Totally the above practice is too bad and no one bother to estimate the cost of money/manpower/time involved estimate the cost of money/manpower/time involved
Almost 90% of the ceramic manufacturers have switched Almost 90% of the ceramic manufacturers have switched over to usage of cordierite over to usage of cordierite
Conventional waresConventional wares Cordierite waresCordierite waresMature at a lower Mature at a lower temperature with temperature with undesirable silica phaseundesirable silica phase
Mature at high temp with Mature at high temp with controlled cordierite/mullitecontrolled cordierite/mullite
Profile mismatch of setter Profile mismatch of setter affects the end product affects the end product qualityquality
Product density is high Product density is high B.D.2.lto 2.5g/ccB.D.2.lto 2.5g/cc
Product density is low 8.0.1.8 Product density is low 8.0.1.8 to24g/ccto24g/cc
Conventional waresConventional wares Cordierite waresCordierite waresHigh TE& poor TSHigh TE& poor TS
Cracks within 4 or 5 cyclesCracks within 4 or 5 cycles
Reaction with end ware is Reaction with end ware is moremore
Actual cost is moreActual cost is more