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26-06-2024 | Ceramic Technology | Editor´s Pick | News

Lightweight Refractory Lining Saves Energy in the Production Process

Author: Holger Seybold

2 min reading time

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Like many other industrial sectors that use high-temperature processes, the brick industry faces major challenges when it comes to energy and environmental issues: Among other things, energy must be saved and the CO2 footprint reduced. The optimal refractory lining for high-temperature furnaces is a key factor in this respect.

The international refractory manufacturer Rath has developed such a lining for the tunnel kiln car of a European brick company. The result: A customized product with a lightweight refractory lining that makes a significant contribution to energy savings. “When it comes to saving energy, having the right refractory lining is crucial, especially for manufacturing processes in the brick industry. It’s been proven that the optimal refractory lining contributes significantly to energy savings. It's a topic that Rath has been working on intensively for some time now," says Alexander Jüttner, Head of Sales Ceramics & Special Furnaces, Rath Group.

High-temperature furnaces are increasingly being lined with lightweight or ultra-lightweight refractory linings. This has a number of important advantages: In addition to much lower heat losses, these linings offer greatly simplified repair procedures. As a result, downtimes are significantly reduced, and repair and maintenance work can be carried out more easily. In addition, energy consumption is also significantly reduced. This is demonstrated by the lightweight lining of a tunnel kiln car that Rath has developed for a company in the European brick industry. With this newly designed tunnel kiln car, which absorbs very little process heat, Rath has been able to show that equipping it with lighter refractory materials can lead to savings of up to 70 % in its specific energy consumption, without changing the process parameters or the dimensions of the furnace.

Analysis in five steps

Reduce energy consumption by customizing the refractory lining: That's where Rath Ecoref comes in. Using this analysis and concept approach, our engineering experts determine the best refractory lining for any given application – based on the corresponding technological, ecological and business objectives and depending on numerous distinct process and plant parameters. It takes five steps to determine the most suitable lining concept. This involves an extensive analysis of the system and operating parameters. What is particularly relevant is whether a system is operated periodically or continuously, how often the system is used and what its dimensions, operating temperature and temperature profile are. The operating process that is carried out with the system, which materials are heated and the atmosphere in which this takes place are also taken into account. The result of the analysis: concrete savings potentials, defined in kilowatt hours. "Energy savings are always due to an interaction of many factors. Rath Ecoref can make a significant contribution to achieving a good overall result here," summarizes Alexander Jüttner.

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Background information for this content

2018 | Book

High Performance Structural Materials

Proceedings of Chinese Materials Conference 2017

2020 | Book

Handbook of Advanced Ceramics and Composites

Defense, Security, Aerospace and Energy Applications

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