One UNIT of FuelSave equals 8Kg, supplied as ONE container of BASE (4Kgs) and ONE container of HARDENER (4Kgs). There are TWO units of FuelSave per standard box.
FuelSave can be used in any high temperature thermal processing vessel using a hot air or gas atmosphere to process or react a product. The maximum service temperature is 1650°C continuous, 1700°C intermittently. Once applied to a refractory substrate, FuelSave needs to be subjected to an initial sinter temperature of 850°C or above, for a period exceeding 30 minutes, to initiate polymerisation. Thereafter the properties of FuelSave become effective, even at lower temperatures.
Generally installations are completed using airless spray equipment, very small areas or remedial refractory repairs may be coated by brush or roller. Recommended spray equipment is available for purchase or hire.
Any substrate should be of sound and stable condition, free of soot, dust, ash, loose refractory particles, scale or other process contaminants. Depending on the furnace and lining type and surface area (and location), cleaning may involve the use of shot or ice blasting equipment, mechanical scrubbing, vacuuming or dressing with compressed air.
For the first installations FOUR layers of FuelSave are applied, which amounts to a total deposition of 30-40 microns, weighing approximately 500gm2 (250g per M2 after sinter).
At the installation rate mentioned above, 1Kg of FuelSave is sufficient to treat 1.5-2m2 of most refractory substrates. This is subject to the lining wear profile and the type of material being treated.
FuelSave is suitable for use on any refractory substrate, whether dense bricks and monolithic, insulation and castable or fibrous insulation (subject to appropriate preparations),old or new. FuelSave is compatible with all refractory chemical compositions and may be applied to freshly repaired “green” refractory mouldable or monolithics.
Assuming access in unrestricted or prohibitive, FuelSave installations are generally completed in one day irrespective of furnace size (excluding cleaning/preparations). For particularly large surface areas, we are able to increase the number of operatives to ensure turnaround time is kept to an absolute minimum.
FuelSave is solvent based and should therefore be left to air cure for a period of 24 hours once installation is complete. Exhaust/extraction fans should be running where possible and doors or wickets left open.
Furnace commissioning temperatures should not rise more than 100°C/hr for the first THREE hours, thereafter no specific recommendations apply for heating up rates of the FuelSave/ furnace.
FuelSave must be subjected to a temperature of 850°C for a period of 30 minutes to facilitate polymerisation.