SaintGobain Ceramics LOMASS Kiln Furniture Systems

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Saint-Gobain CeramicsLO-MASS Kiln Furniture
Systems

• Omni William Penn
• Wednesday, May 23, 2007

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• Review Benefits and Evolution of LO-MASS Kiln
  Furniture Systems
• Discuss Material Developments
• Discuss Engineering Expertise Options

Agenda
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In the Beginning the Prior State of Art

• Before LO-MASS Kiln Systems

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Current State of Art in Sanitaryware

• LO-MASS Kiln Systems

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Benefits of LO-MASS

• Weight Savings of 70
• Cycle Times Reduced From 20 Hours to Less Than 10
  Hours
• BTUs Per Pound of Ware Reduced From 5,000 to
  2,500
• Fuel Savings of 50
• Delta T of Ware Reduced

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Evolution of LO-MASS

• Custom Assemblies More Complex Shapes
• Drop-In Lavy Cars
• Simple Lug-posts

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Evolution of LO-MASS

• Shuttle Kiln Cars
• Introduced Inter-locking Multi-Deck Designs
• Maximizing Loads
• Mimimizing Furniture Thermal Mass

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Evolution of LO-MASS

• Dinnerware
• Introduced Precision Defined Loading
• For Automated Systems

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Evolution of LO-MASS

• Residential Brick
• New Concept of Open Gas Firing
• Faster Cycles

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LO-MASS Design Concepts
Evolution of Thought
Lug-Post Systems
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LO-MASS Design Concepts

• Stackable Pallets
• Less Loading
• Increased Safety Efficiency

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Material Developments
Information Needed to Compare Oxidation
Resistance, Strength, Maximum Temperature,
Thermal Shock Resistance
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Saint-Gobain Design Expertise

• Basic Design Verifications
• Shape Optimization Calculations (load
  calculations)
• Environment Dependent Material Selection
• Advanced Design Verifications Via KilnWorks SM
• KilnWorksSM is a Process We Use to Analyze and
  Predict Product Behavior in a Variety of
  Environments.  We use a professional version of
  ANSYS to quantify our results
• Simulation of Current and Probable Environments
  (structural, thermal, both)
• Optimize Design/Material Compatibility
• Thermal Shock
• Designing to Prevent
• Analyzing to Validate/Recommend/Solve
• When Applicable, Simulated Product Behavior
  Verified With the Measured Product Behavior
  (thermocouple data)
• Single/Multi Component Thermal and Structural
  Analysis
• Geometry Adjustments
• Alternative Material
• Cycle Adjustments
• Assembly Adjustments
• FEA validation
• RD Developed and Experimentally Validated
  Process
• Northboro RD

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Thermal Model Results
Thermal Imaging Data
ANSYS Model
250x250 w/150 mm load after 60 seconds cooling
Tmin 627?C
Tmin 641?C
Tmax870?C
Tmax 879?C
The ANSYS Thermal Model is a Good Simulation of
the Actual Temperature Profile of the Part During
Cooling
Cross-section view
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KilnWorksSM
Check Address Compare Prevent
Prototype
Realize Critical Failure Components Prevent
Possible Product Failures
Existing Design
Address Recommend Compare
Validate Compare Recommend
Change in Environment