How refractory products are reducing the maintenance cost of your manufacturing plants



Fig. 1 The Refractory unit will conduct a detailed

condition assessment throughout the inspection

procedure to assist in determining the requirement

for repairs.



Fig.2. Based on the conclusions of the assessment, the plant manager should do a detailed cost-benefit analysis to determine which option is the right fit: maintenance or entire lining substitution.



Identifiers form an important interface between the technical units of the heating process and the items to be heated. Their performance influences the quality of the product and the cost of heating processes. The reference materials should comply with the highest standards in the areas of critical application, such as metal, glass and ceramic production. Refractory materials must withstand very different heat, chemical and mechanical loads. This leads to a large number of identified products: stubborn and suspicious bricks, dense products such as basic bricks, fire bricks or silk bricks, tile furniture, fiber building materials, and a large number of unstructured people to join, repair or cover. Without the pressure of solid prices, the successive costs of quality material resistance issues are very high. Therefore, the highest standards must be followed.


As the old saying goes, “An ounce of prevention is worth a pound of cure.” This is especially true when it comes to your refractories.


Manufacturers around the world rely on Refractories to protect their boilers, incinerators and ovens from heat and rust brought on by temperatures up to 3000 ° F (1650 ° C).


Without refractories – an unauthorized champion of the production process – it would not have been possible to process inputs for cars, chemicals, power plants, buildings, roads and much more. Therefore, it makes sense to have a financial and business idea to provide basic repairs to your equipment. By protecting your sensitive heat processing equipment, you can reduce costly downtime, reduce energy loss, prevent employee injuries and, most importantly, prevent catastrophic equipment failure.


Given the importance of refractories in performance, it is important to remember that they are practical and will wear out. This is important because without proper nutrition your processing equipment can fail at the wrong time, and the rest of the furnace or dryer – even for one day – can cost hundreds or thousands of dollars. The rewards of proper nutrition far outweigh the costs.


It’s also worth remembering that refractors aren’t assets. Chemical composition varies greatly even within the generic group of refractories. As an outcome, refractories will need to follow distinct repairs and maintenance procedures.


Refractory repairs are costly. This is why maintenance requirements should be included when assessing what issues will be included in your application. For example, the previous cost of built structures can be 20-30% higher than monolithic refractories. However, they require less drying, are easier to apply and in some cases last longer than others traditionally. Also, if there are over-dressed areas that may be difficult to access due to location or geometry, it is financially advisable to go through pre-existing conditions to reduce future maintenance costs.


Dress code

What causes Refractors to wear? Time, temperature, destructive gases, slag and operating habits will all affect them, just as thermal engineering will do it all. Other offenders that lead to damage to the light line can be improper fire controls, improper flame setting, anchor failure or heat shock resulting from extreme temperature fluctuations. More often than not it is a combination of these or other factors that lead to opposing injury – not a single cause.


Failure to follow the manufacturer’s recommended recommendation and drying process can also lead to damage. If the end user wants to speed up the process due to production requirements, quick-standing products can be a good option.


Some manufacturers offer building materials that offer reduction during the dry season and can offer almost the same features as their traditional, non-fast counterparts. The advantage of these quick / dry treatment products is that the dry periods are cut in half, which can represent savings of up to 40-50 hours. While they offer a simple, time-saving solution, however, there are limitations to their material and thirst warnings.


It is a good idea to use the drying time to check for factors such as ship pressure, ventilation system, temperature monitoring, thermocouple position and humidity connection.


How Can You Assist Refractory Durability?

The purpose of periodic testing, maintenance and repair is to ensure longevity and function of refractories (Fig. 1). During maintenance, worn-out parts and over-dressing areas are repaired before they become major problems.


Depending on job creation, skills and budget, hiring permanent staff to perform these services may be financially unreasonable. Instead, working with a professional external contractor with extensive experience in the field that can provide maintenance services, emergency response and repair work can be very costly for the end user.


Under any application of the app, there are precautionary measures that can be taken internally to extend the opposing performance and extend the longevity.

1.Heating the furnace and cooling down: Follow the procedures established by the furnace maker. Proper heating creates a positive pressure in the furnace, ensuring an equitable distribution of temperature. Extension or weight control is important to avoid back injuries.

2. Removal of Dustl: Keep dust off metal on roofs with exposed adhesion structure. This simple step keeps stainless steel parts from getting too hot and tired.

3.Cracking “good” compared to “bad” cracks: Understand the important difference between good and bad cracks. A good crack in Refractory is made and seen as part of a cool natural process. These should be left alone as they will disappear during the heating process. If the end user fills the “good” cracks, they will have problems down the road with the bulge shell because the refractory will increase naturally during heating and production.

Preventative Tactics

Develop a relationship with a trustworthy, knowledgeable and knowledgeable professional who has a good interest in your heart. During the evaluation process, your specialist and their explanatory team should provide you with a complete condition assessment to help determine the need for correction. The test allows the opposing contractor to analyze the refractory status and select the appropriate solution to ensure long-term adjustment.


Often, the first sign that there may be a problem with the fabric is to resist the appearance of “hot spot” in the shell. The hot spot is where the shell surface works at a higher temperature than the surrounding area. This can be caused by cracks, cracks or other problems that lead to damage to the opposing membrane.


When hot spots are found, a refractory specialist will pack, cover, hold or “insert” the area if it is located outside. They may also “burn the gun” inside.


The number and size of hot spots, which are usually obtained using an infrared camera and thermal analysis, can help the opposing experts or engineer to determine the integrity of the opposing fabric. Depending on the results, the supervisor / engineer should perform a full profit analysis to help determine which option is best – to repair or replace the complete line area (Figure 2).


When faced with any kind of refractory adjustment, the best practice will be to reduce the size and timing process. Quick fixes can be targeted using gunning (cold / hot) or a shotcrete resistance process. Another option is a plastic printer to fill a hole / isolar or raise the membrane.


A time-consuming and sometimes better option would be a complete membrane repair. This adjustment is made to a complete degree, allowing for appropriate treatment, thirst and ancholinin


Premature Failure – An Ounce of Remedy

Without proper maintenance of the opposition, you run the risk of premature failure of the opposition line. The funny thing, or not so funny about the failure of the opposition is that you will usually not get a notice on that day telling you that one of your critical plans will fail. And if a failure occurs, it’s all in the hands of the problem-solving and restoring your online performance very quickly.


During the process, you or your opposing expert must collect samples of the available material to help determine the causes of the failure. For example, gloss and thinning indicate exposure to extreme temperatures. Shaving away with high resistance service can be evidence of a hot shock.


In addition, calculating the base-to-acid ratio will indicate whether the Refractory type included should have been selected in the first place. Built-in materials are made to work in a variety of places. A well-chosen and well-installed Refractory lasts longer, helps reduce blockage and leads to better fuel efficiency.


Finally, fuel should be considered to determine whether it contributes to the deterioration of refractories. For example, gasoline moisture can be very high or contain chemicals that damage the lining.


Refractory Substitution and Disposal with Minimal Fuss

In some cases, the maintenance required for thermal equipment is more than repair. This leaves a complete line of insertion as the only option. This is a special job that requires the skills of a stubborn experienced installer.

To ensure the removal of non-drama opposition and replacement, follow these five important tips.

1. Ask for the support of experienced and professional contractors. Not all contractors are experts in opposition work. Make sure the contractor has immediate access to objections.

2. Get a complete job (SOW) and a solid system. Some of the things that should appear in a good SOW include:

Ø Amount of goods required and in hand

Ø List of equipment provided

Ø The plan and details of the tears plan

Ø Proper treatment / drying program

3. Prepare for the unexpected. Usually, problems do not arise until the unit cools down and starts to cry. This fact requires that there be an emergency plan in place. In addition, it emphasizes the importance of working with a full-time contractor who demonstrates a contract that is accessible to an opposing manufacturer that uses timely production standards.

4. Where applicable, enter and apply precast status. These conditions are ready for installation and require minimal drying.

5. Talk to your opposition specialist if a quick dryer may be your preferred option. Installing fast dryers such as Plibrico’s FastTrack® can reduce the traditional drying time.

When working with your counter installer, it is important to focus on your specific plan in order to drive the material needs. It is easy to get caught up in songs and new bright features. The app should determine the target object, not the other way around.


Suitable for Your Equipment, Suitable for Your Wallet

Proper refractory storage is not only good for your thermal processing equipment, it is good for your wallet. The fact is that your Refractory life can be reduced by up to 50% (or more) without proper nutrition. In fact, failing to provide basic aluminum storage in the furnace, for example, could leave the end user with an unspecified and unexpected bill of $ 150,000 or more to install the roof completely. This is a cost that could have been postponed for many years with a well-maintained refractory. At that time it was unplanned, budgeted and unplayable.


Worse, in the event of a catastrophic failure of the opposition when an anchor tile system or a full wall is cut off, the repair bill could easily exceed $ 200,000. Remember that these statistics only correct addresses. Add to the huge cost of lost product and high skirt prices instantly!


As Benjamin Franklin would admit, he took care of the opponent – the infamous hero of the production process –

It will also provide you with a safe and efficient work environment, reduced downtime, reduced energy loss and, most importantly, avoided catastrophic failure of thermal processing equipment.