forging…. foward · 2020. 10. 22. · houston, texas 77039 usa e-mail address -...
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3000° F Polycrystalline Alumina Fibers
Forging…. Foward
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Ceramic fibers are Silica based and….
Start shrinking at temperatures below 2000°F, continue to shrink losing their
thermal insulation properties through a of function of time & temperature
Provide inconsistant Thermal Performance of the furnace impacting heating
Uniformity of forgings, their meteligical Quality and potentially higher scaling
.
Unfortunately create costly Down time & Production losses, increased
Maintenance cost, Energy loss and offten the need for structural repairs
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Ceramic fiber linings….
Offten opperate at or above their continous service temperature limits
allowing for no additional temperature capicity when burners are at full capicity
Service temperature limits are offten reduced additionaly by fluxes and compounds used
in the ingot manufactring process, resulting in increased deieratation / melting of the lining
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MAFTEC® ALUMINA FIBERS ARE 3000°F MULLITE BASED….
Provides very low shrinkage rates of 1% @ 2600°and 1.5% @ 2912° F a melting
temperature above 3370° F allowing MAFTEC to maintain its thermal insulating properties
throughout the function of time & temperature, providing a long service life lining
Provide consistant thermal performance of the furnace lining positivly impacting
heating uniformity of forgings, their meteligical quality and potentially lower scaling
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MAFTEC® ALUMINA FIBERS ARE MULLITE BASED….
Have no free silica; it’s contained within the mullite alumina structure, providing improved Safety benefits
through its raw material base and Controlled Fiber Diameter through the manufacturing process
Can provide these Operating cost improvements & benefits…..
Safer lining
Improved heating uniformity of forging
Reduced scaling on product
Improved lining thermal effectiveness – increased capacity
Improve combustion system control
Substantial reduction in downtime for lining repair & replacement cost
Increase lining service life
Reduction in annual fuel & emissions cost
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MAFTEC® ALUMINA FIBER LININGS…..
Required no frequent outages for lining repair/replacement…..
Favorably impacting downtime cost & productivity
MAFTEC after 5 years in service…. MAFTEC after 10 years in service….
No signs of shrinkage, thermal shock, velocity or chemical damage…No repairs required.
Are not severely impacted by 2400°F -2600°F operating temperature…
contributing to improved furnace reliability- productivity and cost to operate
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MAFTEC® Lintel
Previous Dense castable lasted 6 months, caused damage to the door lining
and provided a poor sealing surface for the door
MAFTEC® Lintel in service for over 17 months, no repair or downtime
Customer reduce energy cost by 13% annually, eliminated maintenance downtime to
repair and replace the lintel, increasing capacity and reduced operating cost
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MAFTEC® Flue
Previous Dense castable after 6 months service life
MAFTEC® flue after 1 year in service performing very well
MAFTEC’s high temperature capabilities and fiber resiliency
have created another long term cost savings solution.
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MAFTEC® & StelBolt® system…
The system is a easy as packing shrunken area in the furnace lining and StelBolting MAFTEC to the existing lining
MAFTEC® & StelBolt® Veneering System
Existing Lining Pack shrinkage joints Pin 1” layer of MAFTEC®
2nd layer of MAFTEC Auger style StelBolt® Installed until snug Over 1st layer joint Hi-Alumina retaining washer Installation complete
Instead of continously re-pack & replacing ceramic fiber linings, overlay them
with MAFTEC to protect the exsisting lining from high temperature and chemical attack
MAFTEC & StelBolt system has been installed Shrinkage gap now has a
protective barrier to eliminate shrinkage, hot spots and most importantly… Downtime
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MAFTEC® & StelBolt® system Thermal performance….
Burner flame impact was causing the ceramic fiber lining to need repacking every 2 to 3 weeks & replacement 4 times
a year. The MAFTEC & StelBolt system was installed. No repair replacement or downtime after 16 months
Before & After Thermal imaging below shows the Thermal performance of the MAFTEC & StelBolt system, providing temperature& heating uniformity to the product
Before After
Have a new ceramic fiber lining…let MAFTEC protect it from the start!
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MAFTEC® Applications
Roof
Door
Hanging wall – zone dividing wall / baffle wall
Flue & Damper
Lintels
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MAFTEC® Operational Benefits
Improve Safety
Improve Your Product Quality
Save Energy
Reduce Fuel Emissions
Reduce lining repair shut downs
Increase furnace reliability
Raise production capability
Increase lining service life
Reduce cost to operate
TFL, INCORPORATED14626 Chrisman
Houston, Texas 77039 USAe-mail address - TFL@TFLHouston.com
Web Site www.TFLHouston.com
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