Refractory products and installation techniques used in linings are key to preventing the failure of fired heaters, incinerators, kilns and reactors across a range of industries, a recent article claims.
According to Engineer Live, there are a number of common reasons refractors fail, many of which relate to installation. If fibres have fallen from the roof and the modules or support anchoring are missing, poor installation may be at fault, for example. If the anchorage is intact, however, the problem may be mechanical.
Poorly maintained brick walls in the lining of the refractor may also result in a failure, as may walls that are leaning or deformed. This can be caused by increased temperatures or a bad choice of firebrick.
Floors may also crack under extreme temperatures, while cracks may additionally be observed in convection castables or corbels, which are typically caused in construction or during shipping.
Another common cause of refractor failure is the mating of dissimilar refractory products. Two different types of material side by side may result in hotspots, which – especially when close to door opening or peep sight – may cause a refractory failure.
Where possible, the same or similar refractory materials should be used around peep openings to create the tightest seal, the article states. Tube seals can also be useful when used with a high temperature fibre expansion joint.
Meanwhile, castable linings, which aren’t finished until installation, may crack if the dry-out procedure is rushed or completed unprofessionally. Cracking from shrinkage is common but excessive cracking may result from overuse of water, according to the article.
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