Total engineering solution dramatically improves kiln efficiency at Morgan Technical Ceramics
Morgan Technical Ceramics, Southampton has seen significant improvements in the operation of four of its sinter fire kilns following a rebuild using a complete engineering solution to deliver high temperature insulation, supplied by sister company Morgan Thermal Ceramics. The rebuild project has resulted in dramatically reduced energy costs for each of the four kilns, while delivering assured production efficiency, durability and increasing the total lifespan of the kilns.
Due to the processing of high volumes of lead zirconium titanate (PZT) ceramic – a piezo electric material used in ultrasonic sensors and transducers that are sintered in the four kilns – the brick linings in the kilns previously needed to be replaced every 12 to 18 months. The sintering temperatures of up to 1290°C and the high lead content of the products was causing parts of the roof and walls in the kilns to quickly corrode. This increased the time taken for the kilns to reach their operating temperature and resulted in a significant reduction in productivity and increase in energy usage.
Tony Beswick, general manager of the Morgan Technical Ceramics site in Southampton, explains: “Typically, the heat within these kilns increases by 100°C every hour. The impact of corrosion within the roof and walls means the kiln struggles to reach the required temperature during the desired time frame. For example, on average it should take 12 hours for a kiln to heat to 1200°C, but we were experiencing delays of up to 10 hours.
“The lead-rich atmosphere was also damaging the brick face within the kiln, causing ‘puddling’ in the roof – drips caused by lead attack. In severe cases, these would drip over the saggars (alumina-based content firing trays) housed in the kiln, causing them to stick to each other and to the sides of the kiln. This exposes the system to an increased risk of damage when lifting the saggars from the kiln, potentially causing the items inside to break.”
Morgan Thermal Ceramics proposed an integrated engineered solution based on a range of products to enhance the efficiency of the kilns. One of the Superwool® Plus fibre products, Superwool Plus Blok wasJMTM 30 insulating fire brick (IFB) proposed for the hot face insulation.
Superwool® Plus insulating fibre is a high temperature insulating wool that achieves increased energy savings by maximising the number of fibres available in the insulation layer. Additionally, it has low bio-persistence which provides a key health and safety benefit during installation and removal.
The roofs of the kilns are now constructed from Tri-Mor® Morflo, a low castable cement incorporating fine fillers and dispersants that significantly reduce water demand, while the rest of hot face lining of the kiln continues to use Morgan Thermal Ceramics’ JM™ 30 IFB, 76mm in depth and capable of withstanding temperatures up to 1650°C. The structural integrity of the company’s JM™ IFB range makes them capable of tolerating erosive and abrasive environments.
Tony Beswick commented: “While we used to see ‘puddling’ in our previous systems after only a few weeks, the new insulation system has ensured that the kilns have been operating efficiently for eight months now. To date, the maximum time to bring the kilns up to temperature has been no more than two hours, resulting in lower energy costs, increased production and reduced total cost of ownership.
“Using Tri-Mor® Morflo castable and the JM™ 30 IFB for the hot face lining, backed up by Superwool® Plus Blok, means we can rely on the systems to provide a consistently high level of output. The products have delivered a superior all-round performance to our operations in Southampton and we are delighted with the results.”
