Retrofit Panel Kits
ELECTRIC RETROFIT KITS
MORGANMMS element panels are affordable and work longer and harder.- Designed to last a minimum of 2 years.
- Element wire is embedded in the panel to minimize effects of radiation.
- Wired to isolate damage to a single panel.
- Longer lasting element panels and crucibles mean more uptime on the furnace and better productivity.
The element wire diameter commonly used in fiber backed panels is large, typically 5mm in diameter. Larger diameter wire is more susceptible to creep forces and stresses caused by expansion differential between element wire and the fiber substrate on which it is mounted. The combination of creep forces and expansion stresses causes fiber panels to fracture and break up which in turn cause the element wire to slump, contact adjacent elements and eventually short out the panel.
MorganMMS element wire is much smaller and embedded in the panel to maximize the effects of radiation.
In a typical panel, if one element fails, 3 others lose power. The remaining 8 panels must increase power to maintain the furnace set point, putting additional stress on the remaining active panels which accelerates effects as mentioned in the first reason. In addition to overheating the remaining 8 element panels beyond their use limit, a cool zone is created on 33% of the furnace chamber. The resulting temperature differential in the furnace causes the crucible to oxidize more rapidly along the cool zone reducing the service life of the crucible.
MorganMMS panels are wired to isolate damage to a single panel. This has minimal impact on the rest of the panels. Reduces cool zones and minimizes the effects of oxidation on the crucible and increases service life.
In a typical panel, element wires are placed on a fiber substrate. Besides having no strength at temperatures above 1200°F, fiber panels are thermal insulators. This has the effect of increasing the temperature at the contact point of the element wire and insulation beyond the use limit of the element wire. Burnt out element wires increase maintenance costs and effects casting cell productivity numbers.
The MorganMMS panel substrate is a dense refractory which will not break down at higher temperatures. Elements remain secure at temperatures over 2000°F. Our panel substrate has a high thermal conductivity effectively acting as a heat sink, allowing temperature to escape to the back of the panel and not overheat the element wire.
In addition, our panels are designed to last a minimum of 2 years. Longer lasting element panels and crucibles mean more uptime on the furnace and better productivity.
To view and print information on our Retrofit Kits and to read Testimonials on the Payback from Client and an Energy Audit please visit our Library.
GAS-FIRED RETROFIT KITS
Ask most people how heat is transferred in a gas fired crucible furnace and they will likely key on two modes, convection and conduction. Overpowered burners, brick or dense castable refractory linings, no thermal couple readings and open tops are all features of the convection and conduction design. Furnaces that incorporate this design ignore the most important mode of heat transfer, Radiation. Over 60% of heat energy is transferred in the crucible furnace by radiation. Proper furnace design should highlight radiant energy transmission.
Morgan Molten Melting Systems has a solution: Retrofit Kits. Our kits combine dense, high alumina element panels that distribute radiant energy evenly throughout the furnace chamber with low thermal mass insulation back up material. The result is an easy to install lining that more efficiently transfers heat into the metal.
MMMS’ Element Panels incorporate a series of raised nodules on a dense refractory panel. The design creates a high surface area that promotes radiant energy transfer to the outer surface of the crucible. Radiant energy is distributed more effectively and requires less energy input to melt metal.
Backing up the non insulating radiant panel with Thermal Ceramics insulation products such as SF607 fiber means the outside surface of the furnace stays cooler, reducing heat loss through the sides and increasing the efficiency of the furnace.
Installation is simple. The prefired Element Panels require no mixing but do require curing prior to installation. There are no forms to place and remove. Morgan MMS‘ Retrofit Kits can be installed and ready for start up in less time than it takes to install, cure and start up a typical brick or castable lining.
Morgan MMS‘ Retrofit Kits can improve your furnace efficiency by 30%, and improve melt rates.
To view and print information on our Retrofit Kits, please visit our Library.
