How pre-fabricated MAFTEC modules can break the cycle of continuous module maintenance

1. A CASE STUDY…
Pre-Fabricated MAFTEC Roof Panels
For a Furnace Roof

2. Ceramic Fiber Modules being used in
furnace roof and upper sidewalls
HTZ Blanket, 1” thick, 8 lb density
“Service Limit” 2600 o
F
Furnace Operating Temp = 2350 o
F
THE SITUATION…

3. Excessive shrinkage, caused
by thermal stress on the
modules
Large gaps appear between
modules and surrounding
refractory
Escaping heat causes hot
spots on the furnace steel
Module anchor system
becomes affected by heat
THE PROBLEMS…

4. Vitrification (hardening) of
module surface leads to
crumbling and loss of
material
Modules lose their ability to
contain the heat
More energy (fuel) required
to maintain temperatures
THE PROBLEMS (cont’d)…

5. Hot spots occur on the outer steel, causing
expensive damage to furnace structure
Over time, more and more maintenance is
required
Open joints where shrinkage has occurred
require re-packing with additional fiber
Shrinkage continues
Modules become loose, due to shrinkage
and anchor damage
THE PROBLEMS (cont’d)…

6. Hot spots continue to appear, becoming
larger, doing more damage
Injection of a pumpable servicing mix is
tried, which might temporarily solve the
problem
Furnace reliability suffers
Modules are eventually replaced
Burned, damaged steel is repaired
Cycle is repeated!
THE PROBLEMS (cont’d)…

7. SOUND
FAMILIAR?

8. MAFTEC modules are made
from polycrystalline alumina fiber blanket
Temperature limit of 2950 o
F
Shrinkage rate of MAFTEC at 2950 o
F is only
1.5%, compared to 12-14% for ceramic fiber
Opening of joints due to shrinkage is no
longer an issue
Thermal efficiency is stable, reducing heat
loss and fuel costs during the life of the
lining
THE SOLUTION!

9. MAFTEC blanket is not affected by
temperatures below 2950 o
F
Retains resiliency, no vitrification on surface
No maintenance required, no packing of
joints, pumping, etc.
Steel damage due to hot spots is avoided
Furnace reliability is improved
Cycle of Refractory Module
Maintenance is Broken!
THE SOLUTION!

10. THE SOLUTION!
This MAFTEC roof has been in service for 5
years, with no maintenance to date.
Modules still tight, material still resilient

11. “Innovative Ways to Harness the Heat”
Contact TFL today for more information
www.tflhouston.com