How to Repair Refractory Installation Failures
Refractory installation failures can happen when you are least expecting it.
Although refractory is essential for heat-generating industries, refractory installation lacks the attention it deserves.
That is why you need a certified and experienced refractory contractor. Because they can properly design and install refractory engineering. Hence, you can save up to 5-7% of fuel costs.
But, it is difficult to detect why refractory materials fail. This is due to the complex process only refractory installers can figure out.
What causes Refractory Installation Failure?
- Chosen refractory material does not fit the environment
- The burned fuel damages the refractory monolithic
- Improper handling of refractory materials (mix, install, dry out and store)
- The selected refractory product does not fit the environment after the burning process
- Refractory shield won’t stay in place
So, as one of the top engineering contractors for refractory in Malaysia, SLP has a tried and tested guide to fix refractory installation failures.
How to Repair Refractory Installation Failures
1. Analyze the Refractory Materials
Before refractory rebuilds are in order, the refractory installation contractor will collect important details. This is done by conducting refractory failure analysis.
Refer: API 936 Refractory Quality Management Control
List of inspection data for refractory damage repairs:
- Datasheets of current refractory brick or refractory lining
- Samples of heated materials
- Location of refractory materials storage
- Refractory products date of manufacture
- Conditions during previous refractory installation
- Quantity of installed refractory insulation
- Previous installation and dry out process
2. Check the Current Materials
Any experienced engineer will always find the main cause of refractory installation failure.
Once identified, the refractory contractor can find other options of refractory lining solution that last longer.
Questions when inspecting damaged refractory materials:
- Was the material damaged due to thermal shock?
- Did excessive shrinkage due to high temperature cause the rupture?
- Was the refractory material installed improperly?
- Did the equipment operation damage the material?
- Are there any mechanical injuries?
After answering these questions, the refractory engineer will collect material samples to test.
First, it will go through a cold crush test. Then, the strength of the refractory material will be analyzed. Afterward, compare the results with the datasheets. Lastly, the results will show whether the refractory mix was too wet or too dry.
Suggested read: How to Choose the Right Refractory Material
3. Ratio Calculation of Materials
Based on the analyses in steps 1 & 2, the refractory contractor will measure the moisture content of the heated material.
As a matter of fact, the level of moisture combined with atmospheric moisture will separate the silicon carbide-based materials.
This will happen if the moisture percentage of the heated material passes 15%. Thus, it will react with the cement-based refractory such as high alumina refractory cement.
If the refractory breach repair procedure is the same, it will cause a chemical attack and surface failure of the refractory. Hence, more costs to take care of.
4. Review Refractory Installation Process
Finally, the refractory contractor will install the proper refractory repairs and conduce refractory inspection.
Equally important, the refractory installation contractor must handle the refractory material. As a result, it reaches its desired strength for a more durable refractory repair.
How to Handle Refractory Materials Properly
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- Use fresh materials and follow proper storage methods.
- Refractory material manufacturers suggest using drinkable water for mixing.
- Use the right type of mixer, follow the set mixing process, and take note of the material’s pot life.
- Ensure the final mix temperature is in a specific range.
- A proper curing process allows proper chemical action to happen and helps the refractory reach its maximum strength when dried.
- Remove all mechanical and chemical water to reach its desired strength by drying out the cured refractory.
- Know the exact quantity of materials to ensure the refractory is not too thick or too sparse
The Right Refractory Installer for Proper Refractory Installation
All in all, various factors may cause the failure of a refractory installation.
That is why it is important to take care of the basics as thoroughly as possible. Factors such as refractory material selection, plant operations, mixing, installation, curing, and drying should be managed properly.
By following the correct procedures, you can effectively prevent any future refractory failures. Or at least still have time to fix the damage done.
All in all, refractory experts agree that properly designed and installed refractory not only saves money but is essential for productive plant operation.
Suggested read: 6 Services that a Refractory Contractor Should Provide
Need to repair your refractory linings? Get in touch with our attentive support team for more information.