Improving energy efficiency in furnaces
Developments in refractory materials and design can contribute to reduced heat
waste and higher energy savings
STEVE CHERNACK
Morgan Advanced Materials
M
any companies in the hydro-
carbon processing industry
are making the transition to
new generation designs of insula-
tion for furnace linings to increase
reliability, lower operating costs,
prepare for expected future energy
price increases, and position them-
selves to compete globally.
The main energy units in refiner-
ies and petrochemical plants,
furnaces often consume more
energy than any other single piece
of equipment in the plant. So
companies are focusing more
closely on the efficiency of their
fired heaters and looking for more
efficient and reliable insulation
linings for them, from the flooring
to the stack, and all areas in
between.
Fortunately, fibre and refractory
manufacturers are developing light-
weight, energy saving products
with unique refractory designs to
significantly minimise heat loss in
these units.
Before launching in to specific
floor to ceiling tips, here are a few
general refractory options for
reducing energy consumption in
fired heaters:
1. Use insulating firebrick (IFB) – it
is generally about 25-50% more
thermally efficient than castable
options and actually has better
thermal conductivity than fibre in
temperatures over 2000°F.
2. Consider the use of pliable
(compressible yet robust) mono-
lithic ceramic fibre logs and
modules made with a lubricant to
allow compressibility in all four
directions for easy installation.
Then harden at moderate
temperatures.
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Figure 1 Furnace areas benefiting from
energy efficient solutions
3. Take a look at using thin, light-
weight, microporous insulations
that offer the lowest thermal
conductivity of any material availa-
ble. This is an especially good
choice for areas where tough geom-
etries or older style linings make
cold face temperatures higher than
normal.
4. Use high density monolithic
ceramic fibre modules manufac-
tured specifically for flat flame
burner block areas.
5. Monolithic ceramic fibre modules
can be especially good choices,
including those prefabricated in
L-shapes to fit around corners such
as radiant to transition, transition
to convection sections, and on
columns.
The following guidelines are for
bottom to top insulating products
and engineered design solutions
which out-perform traditional
refractory materials in fired heaters.
Figure 1 is a simplified diagram of a
fired heater, like those used in
process heaters, reformers and
pyrolysis.
Floors
Use insulating firebrick or
monolithic ceramic fibre logs
Floors in fired heaters have tradi-
tionally been lined with
hydraulically bonded refractory
castables. Consider one of the
following two more energy saving
alternatives, known as dry
solutions:
• A combination of high duty fire-
brick (HDFB) backed by insulating
firebrick (IFB) augmented with
back-up block type insulation
• A newer, more thermally efficient
dry floor solution that starts with
HDFB, backed by a levelling layer
of high strength vacuum formed
fibre board and efficient monolithic
ceramic fibre log floors.
Floor linings made of IFB and
ceramic fibre materials offer
improved thermal efficiency and
lower heat storage than those insu-
lated with castables, allowing for a
thinner lining.
Lightweight, economical IFB
offers excellent thermal efficiency,
low heat loss and good structural
strength properties. When used to
line floors, IFB is generally
augmented with back-up stable
block insulation like TR-19.
However, if end users are still
concerned about perceived floor
strength, a thin layer (1.5-2.5in) of
firebrick can be placed on the hot
face.
The other cost effective alterna-
tive to hard refractories uses the
newer monolithic ceramic fibre log
PTQ Q2 2015 43
 floor design, for example Pyro-Log
fibre produced by Morgan
Advanced Materials.
Lower walls
Consider microporous materials
with low thermal conductivity
The lower walls of floor-fired units
have traditionally been lined with
insulating firebrick backed up by
mineral wool block. These low
temperature insulation blocks can
be a suitable option; however,
mineral wool-based blocks deterio-
rate over time, causing long term
hot spots. Instead, opt for a combi-
nation of a stable back-up block
(TR-19) and new microporous
materials, which offer the lowest
thermal conductivity around, deliv-
ering considerable insulation
benefits. For instance, just one inch
of microporous insulation, such as
BTU-Block Board from Morgan
Advanced Materials, delivers the
same thermal efficiency as several
inches of standard ceramic fibre
blanket.
Upper walls
Switch to high density monolithic
ceramic fibre modules
In floor-fired units, the upper walls
are less prone to flame impinge-
ment, and traditional linings
include ceramic fibre blanket or
insulating firebrick with vacuum
formed fibre peep sites. Another
option is monolithic ceramic fibre
modules, with temperature grades
up to 1427°C (2600°F) and densities
up to 15 pcf (240 kg/m3). Because
of their high density, these fibre
modules can also be cut and used
as peep sites. They offer equal or
better thermal conductivity and
users can experience reduced heat
flow and substantial energy
savings.
Side walls and burner blocks/peep
sites
Move away from castables to high
density monolithic ceramic fibres
The side walls in side fired units
have traditionally been lined with
IFB with refractory castable burner
blocks, but HPI companies have
begun transitioning to ceramic fibre
module linings to achieve improved
energy efficiency. For example,
44 PTQ Q2 2015
Pyro-Bloc modules are the only
monolithic ceramic fibre modules
made specifically for burner blocks.
Another option is robust vacuum
formed boards and shapes made of
Superwool fibre, which feature
good hardness properties and ther-
mal shock resistance, resistance to
molten iron and steel, and are easy
to machine into shapes for burner
blocks and peepholes.
Arch linings
Use material that compresses in all
four directions, and add a textile
tube seal for penetration points
These areas are commonly insu-
lated with folded ceramic fibre
modules that only compress on two
sides, which can cause issues where
the corners are difficult to seal or
the material falls out under vibra-
tion conditions. Consider using
high density monolithic products
which compress in all four direc-
tions. These modules are simple to
install, do not require batten strips,
seal well around adjacent modules,
and reduce heat loss.
In areas where there are penetra-
tions from pipework or valves
outside the furnace, consider the
addition of a textile tube seal,
which is basically a removable,
flexible thermal insulation designed
to stop the influx of ambient air
and remain a good seal even if the
tube moves.
Corner blocks
Move away from material wasting
options and consider solid pieces of
monolithic fibre prefabricated to fit
effectively
The areas around the external
corners of fired heaters can be
particularly difficult to insulate
because they are subject to high
velocity and mechanical abuse.
Butt-jointed modules can easily
slump and cause hot spots. Other
options include compressing layers
of L-shaped blanket together or
using folded layers and cutting
them to fit. However, these meth-
ods waste considerable material,
and the layers can separate, result-
ing in inconsistent insulation, hot
spots and heat loss.
Consider using products designed
specifically for this application, like
solid pieces of monolithic fibre
prefabricated into L-shapes to fit
more snugly around corners.
Convection sections
Use high density monolithic fibre
and consider the use of structural
insulation to replace the back-up
layer
Convection sections experience
considerable velocity and difficult
service conditions with relatively
high and turbulent velocities. This
area has traditionally been lined
with castables, but more recently
many users are opting for more
energy efficient high density mono-
lithic fibre modules, like Pyro-Bloc.
This option is not appropriate for
areas with tubes designed to be
steam cleaned, but it is fine for
clean gas-fired units.
Another cost effective option
includes using structural insulation,
such as TR-19, as a replacement for
a back-up layer to reduce thickness
and achieve improved insulation.
This has the added benefit of facili-
tating any work that has to be done
in the area; with castables, it is not
practical to do required mainte-
nance or repair work while still
operating the furnace. In addition,
it eliminates the typical high water
content of super-insulating castable
(typically 150% water by weight),
helping to make refractory dry-out
much easier.
Conclusion
Engineers who want to upgrade the
insulation design in fired heaters
should consider all options before
proceeding, not just the standard
ones that have been used for
decades. Think about reducing
energy waste, heat loss and hot face
temperature to find a cost-effective
insulation system that will improve
reliability, cut heat loss, reduce
energy waste and offer long term
savings.
Steve Chernack is Manager, Engineered
Accounts, Morgan Advanced Materials Thermal
Ceramics Business.
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