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BURTONBURTONPartner of Partner of thethe ceramicsceramics industryindustry

forfor longlong--lastinglasting-- + + energyenergy savingsaving refractoryrefractory systemssystems

-- worldwideworldwide ––IndiaIndia MarchMarch 2011 2011 –– Mr. J. Mr. J. BoekeBoeke

1. Introduction of Burton

2. Durability / long lasting products (short extract)

3. Energy saving systems3.1. Where do energy losses arise that can be influenced by BURTON?3.2. BURTON‘s influence on energy consumption (up to BurcoLight material +

design)

4. Conclusion

Contents

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1. Introduction of Burton- Production site in Germany and Hungarywith- Products and systems- Developments and patents- Facts and figures

The production site in Germany

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Berlin

Hamburg

München

BURTON issituated in thewestern part of North Germany

BURTON - refractories -For over 60 years BURTON has developedsystems for ceramics kiln construction and is market leader in the field of completerefractory systems for theceramics industry:

- Wall systems

- Suspended/arched roof systems

- Tunnel kiln car systems- for top-fired and - side + bottom-fired kilns

- Kiln furnitures

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New developements in the BURTON group(inclusive several patents):

Tunnel kiln car systems 1960Suspended roof systems 1970BURTON kiln car lightweight system 1974U-cassettes, dry-pressed 1978U-ribbed cassettes, dry pressed 1980Viaduct blocks 1984H-cassettes, cast 1987H-cassettes, dry-pressed 1992SIC production 1998BurcoLight for energy-saving for kiln cars 2003H-cassettes, dry pressed BURTON 2004H-cassettes, cast NEW BURTON KF 2006H-cassettes, cast BurcoLight custom-made 2009

Tunnel kiln car systems for theclinker and facing brick industry

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Tunnel kiln car systems for thewall brick industry

-> Wienerberger ZI – Bilder fehlen

Tunnel kiln car systems for theclay roofing tile industry

U-Cassettes for roofing tiles

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Tunnel kiln car systems for theclay roofing tile industry

H-Cassettes for high quality firing of roofing tiles (Hungary)

Tunnel kiln car systems forstructural ceramics

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Facts & Facts & FiguresFigures

Total capacity

75.000 tons of fired ware per year= 250 tons of fired ware per calendar day.

Of this capacity approx.:

75 % part for the ceramics industry

25 % for the aluminium, iron/steel,glas-industry, general kilnconstruction

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Regular staff of approx.: 200 people

Staff

This includesas many as 10 peopleworking in the research and developement departement !

For the dry-pressed BURTON systems BURTON makes use of:

14 hydraulic presses

with pressure capacity

of up to 1.600 tons

applied pressure

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For the dry-pressed BURTON systems BURTON makes use of:

4 setting robots

placed next to thehydraulic presses

of 800 and 1.000 tons

applied pressure

Firing capacity

- 1 Tunnel kiln for firing temperatures ofup to 1560 °C / 2840 °F

- 1 Tunnel kiln for firing temperatures ofup to 1650 °C / 3000 °F

- 1 Shuttle kiln for firing temperatures ofup to 1850 °C / 3360 °F

- 1 Shuttle kiln for firing temperatures ofup to 1500 °C / 2735 °F

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Automatic cutting machine5 cuts per process possible

100 % testing of hanger blocks.

Certifiedsince 1994

DIN ISO 9001

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BURTON Kiln Furniture in Hungary, Europe: Production site for cast products

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Cast H-cassettes

Capacity BURTON Kiln Furniture in Hungary:approx. 800.000 – 1.000.000 H-Cassettes per yearand others, like U-Cassettes, accessories etc.

Regular staff of approx.: 20 people

Staff

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Production at BURTON Kiln Furniture

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Production and Quality control at BURTON Kiln Furniture

Laboratory

2. Durability / long lasting products(short extract)

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• BURTON delivers worldwide refractory products and complete systems for over 60 years

• Wall- / roof- and car-sytems are installed as well as kilnfurnitures

• Depending on the special production processrequirements and conditions from BURTON´s clients eachdelivery will be evaluated by means of material quality, design, durability (possible production cycles) and others

• BURTON uses HIGH END Information Technology to examine the products before manufacturing to secure a maximum of safety for quality

RESULTS

• All over the world there are lots of factories which arerunning for more than 30 (and more) years on minimizedmaintenance status with BURTON´s systems/products, for example such as BURCOTOP and BURCOLIGHT

• More than 3.000 customers trust in Burtons Know How

• Far more than 100.000 orders show the reliability and safety of BURTON´s deliveries

• Reference lists are available

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3. Energy saving systems

3.1. Where do energy losses arise that can be influenced by BURTON?

3.2. BURTON‘s influence on energy consumption (BurcoLight material + design)

3.1. Where do energy losses arise thatcan be influenced by BURTON?

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Energy loss through the ceiling

Energy lossthrough the wall

Energy lossthrough the wall

Energy loss through the car Energy lossafter the kiln furniture left the

kilnEnergy loss

after the car left the kiln

What are the proportions?- The following page shows the proportions as an

example for a quite new system for the roofingtile industry - with kiln furniture and heatcompound

- Depending on the age and the type of thesystem/kiln, these proportions can vary and canalso be larger than the proportions shown

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Proportions in the energy balance (sample)

Energy inflow100 %

Tunnel kiln

12 %

kilns carscoming out of the kiln

Energy outflow

7 %

energy loss in the insulationarea of wall +

ceiling

5 %

kiln furniture(cassettes) coming out of the kiln

3 %

fired warecoming out of the kiln

4 %

outblowthrough kiln

buildingjoints

25 %

losses in exhaustgases

44 %

air suction, (undercar airsuction 2 %)

=> BURTON‘s influence on energy consumption: at least 20 to 30 %

• a newly implemented plant and therefore itscontinuous energy saving during its operation(from the beginning)

• a subsequent optimization of a plant made stepby step: an optimized continuous energy savingis only achieved when all tunnel kiln cars and cassettes have been replaced

…there are differences between:

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3.2. BURTON‘s influence on energyconsumption(up to BurcoLight material + design)

Influencing factors on energy consumption of kiln cars

Refractory material Insulation

Design Firing curve

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Influencing factors on energy consumption of H-Cassettes

Design

Refractory material

Firing curve

• Every plant and every thermal processis different – static, dynamic and thermal conditions require theselection of the appropriate design + material

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SelectionSelection of of thethe refractoryrefractorymaterialmaterial

• BURTON developed new qualities up to BurcoLight for drypressed products

• BURTON developed 5 new qualities of BurcoLight - fromBurcoLight KFL 1,4 to 1,8 as well as the standard quality BurcoritKF 1 and Burcorit KF 2 quality with a very high density for castedproducts

• Depending on the quality, it is possible to minimize the weight bymore than 30%

this results in a much higher energy efficiency, as 30% lessmass has not to be heated up and cooled down!

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Development of lightweight refractory materials up to dry pressed BurcoLight

1,20

1,40

1,60

1,80

2,00

2,20

Concrete Fireclay Burcotop125 H

Burcotop17/25 H

BurcoLightH

BurcoLight14/25 H

BurcoLight13/25 H

[kg/

dm³]

Thermal conductivityComparison Burcotop / BurcoLight

0,5000,6000,7000,8000,9001,0001,1001,2001,3001,4001,5001,600

200 300 400 500 600 700 800 900 1000 1100 1200

Temperature [°C]

Ther

mal

co

nd

uct

ivit

y [W

/m K

]

Burcotop 125 H Burcotop 17/25 H BurcoLight H

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Decisive factors of casted BurcoLight KFL H-Cassettes are:

saving in weightabrasion dataas well as the open porosity

SelectionSelection of of designdesign

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“Lightweight“ border blocks

T-border blockNumber 2442Wall thickness 50 mm

Universal borderblock

Number 2445Wall thickness 85 mm

Tunnel kiln car systems for facing bricksand backing bricks

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Example: U-cassette TDK 55

Result:A saving in weight of 6,6 Kg (= 20%) (Mass, that doesn‘t haveto be heated up and cooled down)

33,5 kg

26,9 kg

BURTON Study carried out by the Institute for

Brick Research, Germany at a roofing tile plant

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Results

AZ/BZ KZ Ausfahrt

TOW neu-leicht

TOW neu-schwer

TOW alt

1451

510

941993

455538625

202

423

0

200

400

600

800

1000

1200

1400

1600

stor

ed h

eat

[kW

h/TO

W]

BURTON GmbH + Co. KG

Bild 44

Old tunnel kiln car; 9 to

New tunnel kiln car –heavyweight, 4 to

New tunnel kiln car –lightweight, 3,5 to

Preheatingzone/Firing zone Cooling zone Exit

SCHIEDEL, Zliv plant/ CZ

Re-equipment of 180 tunnel kilncars

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Schiedel, Zliv plant / CZ

Results:

- Reduction of the car weight from 3,120 kg to 2,282 kg (-23.5%)

- Reduction of the undercar temperature from 240°C to 108°C

- Specific energy consumption reduced from 1.25 KWh/kg of goods to 1.14 KWh/kg of goods (-9%)

- Carbon dioxide production reduced by ~390 to/year

- Gas consumption reduced by 200,000m³

- Saving of approx. 50.000 € (=3.137.400 INR) in energycosts/year

Roof tile factory example: H-Cassette TMA01

• Weight of H-Cassette in Burcorit KF 1 with a bulkdensity of 1,92: 5,61 Kg

• Weight of H-Cassette in BurcoLight KFL 1,5 with a bulk density of 1,52: 4,48 Kg

• Saving in weight per H-Cassette:1,13 Kg = 20%(Mass, that doesn‘t need to be heated up and cooleddown)

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This means for a tunnel kiln car loaded with2.592 H-cassettes asaving in weight of 2,93 to per kiln car

a mass of 2,93 to per kiln car that doesn‘thave to be heated up and cooled down higher energy efficiency!

4. Conclusion

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• Material and Design have a deep impact on durability and energy consumption

• Energy costs can be reduced

• Durability + higher energy efficiency = Continuous cost reduction

• Durability + energy saving from BURTON by

– optimized BURTON design

and/or

– BURTON material

4. Conclusions

• Less CO2-Emmission rights have to be purchased• Lower maintenance costs

• The energy consumption of plants that have been in longtermoperation without any changes is much higher than in modern systems!

Additional advantages + comments

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For For furtherfurther detailsdetails, , pleaseplease visitvisit usus atat

www.burton.dewww.burton.de

Thank youfor yourattention!