The use of Advanced Refractory Ceramic Materials to Address Industrial Energy Efficiency Challenges

Novel refractory ceramic systems and application techniques have been used to improve the energy efficiency of traditional industrial processes through increased furnace efficiency. Examples of advances in refractory materials for furnace applications related to the aluminum industry, biomass and coal gasification, the glass industry, and lime kilns will be highlighted, along with how these advances can be applied to other processes. The energy savings strategies discussed focus on the reduction of chemical reactions, the elimination of mechanical degradation caused by these service environments, the reduction of temperature limitations for applied materials, and the elimination of costs or loss of productivity due to installation and repair issues. Key results of several case studies resulting from US Department of Energy (DOE) funded research programs will be discussed with emphasis on applicability of these results to high temperature furnace applications and needed research directions for the future.