Three Reasons Refractories Fail

Refractory failures can be dangerous and costly, causing inefficiencies, and potentially forcing plant shut-downs.  At Kingston Refractory, we work closely with our customers to ensure a quality installation, on time and on budget and we are proud when our work performs beyond expectations.

However, over the years, we have established a reputation of remediating refractory failures and we thought we would share with you some of the reasons for those failures so that they can be avoided.  Here are three: 

 1.       Material Selection

Selecting the type of material to suit the specific industrial application is important when conducting repairs or annual scheduled maintenance. There are a wide range of materials available that can meet temperature and application requirements. When the wrong material is installed, it can lead to severe refractory failure, overheating of the unit, unnecessary energy consumption and decreased production.

2.       Anchors

There are a wide range of anchor types, shapes, placement orientation and material composition to suit the application. Understanding the process temperature is a key starting point to selecting the proper alloy composition. The refractory thickness will determine the length and style of anchor. Most importantly, the fusion between the anchor and the shell structure, whether it’s arc welding or stud welding, is vital to a secure refractory lining. Failure can occur if the fusion between the anchor and the shell is inadequate, causing the refractory lining to fail.

3.       Dry-out process

The dry-out process is the last step during the installation of refractory. This is a time and temperature-controlled event which is required to release moisture from the refractory prior to reaching operating temperatures. If the dry-out process is not diligently followed, the water content in the refractory creates steam which, if released too quickly, could cause an explosion.

These failures are avoidable. It is important for plants to work closely with installers and material suppliers to get the best product available along with any technical specifications to meet the proper industry requirements.