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FURNACE HOTWORK SERVICES

DGC has more than 90 years’ experience in providing multidisciplinary services to large industrial furnaces across the complete range of metals smelting, mineral processing, chemical, refining and thermal power industries.

 

Dickinson Hotwork Services; a subsidiary of DGC was initially established in 1994 and has for more than 25 years been providing services to various industries worldwide. The company specializes in on-site heat treatment; utilizing mobile gas or diesel fired equipment.

 

The company has a large number of High Velocity Burner sets, with the capacity to undertake numerous furnace refractory drying-out and heat-up projects simultaneously, ensuring that our customers receive the highest quality service and expertise.

 

All our technicians are trained in-house according to the OEM manuals to operate all the equipment optimally and safely. Our technicians are graded annually to ensure that they are well qualified to undertake our furnace hotwork services in accordance with our safety and quality standards

INDUSTRIES

  • Glass Furnaces

  • Steel & Coke Making

  • Cement & Minerals

  • Non-Ferrous Metals

  • CFB Boilers

  • Incinerators & Biomass

  • Aluminium Furnaces

  • Copper & PGM Furnaces 

SERVICES

  • Refractory Dry Out

  • Furnace Heat Up

  • Furnace Cooldown

  • Furnace Expansion Control

  • Regenerator Cleaning

  • Insulation Coating of Regenerators

  • Furnace Hot Repairs

  • Temperature Monitoring

  • Post-weld heat treatment (stress relieving).

  • Internal firings or temporary furnaces, utilizing diesel or gas burners.

FURNACE REFRACTORY DRY-OUT

Residual moisture in refractories during furnace dry-out operations may be converted into steam too quickly, resulting in explosions, which may adversely impact the efficiency and life of the refractory linings. This is because most conventional process heat sources are not suitable for carrying out the initial dry out as they do not afford close temperature control in the lower ranges. Our Refractory Dry-Out Services involve controlled heating and ventilation of a furnace to remove all the moisture in refractory mortars and monolithic materials.

 

DGC’s technology is based on the use of gas or diesel fuelled High Velocity Burners that are portable and can be positioned in the most appropriate manner to provide uniform temperature distribution throughout the entire volume of the furnace. By passing large volumes of hot gases over the refractory surface, the system provides an even temperature distribution that removes all moisture from refractory. This will not only save time and money from fuel consumption; it also protects the initial investment in the expensive refractory and enhances the furnace refractory life time.

FURNACE HEAT-UP

Our company’s specialised heat-up technology and equipment is suitable for the heat up of all types and sizes of furnaces. The systems make use of High Velocity Burners operating on excess air, producing a positive furnace pressure that assures uniform temperatures throughout the designated areas of the furnace.

 

The systems ensure precise temperature control and can be regulated at all stages between 60°C and 1200°C; simultaneously eliminating hot-spots and stagnant areas within the furnace.

FURNACE EXPANSION / CONTRACTION CONTROL

The correct and timely adjustment of the furnace steel work during the refractory expansion, or contraction, is a very important aspect of every furnace start-up or shutdown as it has a bearing on a furnace’ stability and lifespan. DGC’s Refractory Dry Out & Heat Up Services Technicians have successfully completed numerous furnace expansion control projects with different requirements and procedures giving them the flexibility to respond to any challenges.

GLASS FURNACE CULLET FILL IN:

In the case of Glass Furnaces, the company provides services for Cullet Fill In; the process of gradually feeding of raw material into the system while carefully controlling the temperatures until a constant flow of glass throughout the furnace is achieved. The glass flow then gradually increases resulting in the molten glass passing through the furnace process allowing the furnace to trickle and commence production.

FURNACE ON-LINE REPAIRS

Dickinson Hotwork Services provides world-class services to the metals smelting and mineral processing industries. Our company has the ability to execute hot flux line- and throat over coating with no downtime and with little to no production losses.

 

Our personnel are experienced in working under hot conditions and production parameters, with the understanding that the customer needs to achieve minimal production losses and time delays.

 

DGC also has the capability and experience to execute hot crown or furnace roof repairs, including the installation of refractory materials for the extension of its lifespan, as well as the hot repairs of ‘rat holes’, and the crown/roof expansion joint sealing.

ON-SITE HEAT TREATMENT SERVICES

  • Pre / Concurrent heat minimizing the heat difference between the heat affected zone (HAZ) / welding area and the surrounding work piece during welding operations. The technique is used to reduce moisture and thermal strains and helps prevent cracking during welding and can prolong the life of the welded area. Applications include pipe work, fabrication or repairs to pressure vessels or high strain areas.

 

  • Post Weld Heat Treatment (PWHT) processes heat, soak and cool the material at calculated rates to return the molecular compound to its initial state (before welding). Thereby eliminating stresses caused by welding, which can lead to the cracking or complete failure of welds. This is done by utilizing calculated processes according to the material, material thickness and as well as the relevant welding technique. PWHT can be used on any fabrication and is most commonly used on pressure vessels, high pressure pipe work and high strain areas.

 

  • Expansion fitting or removal involves the accurate and even heating of gears, bearings or bushes for expansion, allowing them to be fitted or removed on/from a shaft or where ever it may need to be fitted or removed.

 

  • De-Gassing is the process in which heat is applied to expand the molecules of a metal releasing hydrogen gasses, allowing the material to be welded and re-used.

 

  • Annealing, Hardening or Normalizing is the process of heating and cooling at calculated rates in order to harden, soften or normalize metals. This is commonly done on castings, materials needing machining and cold formed metals.

DICKINSON HOTWORK SERVICES ADVANTAGES

  • Even temperature distribution throughout the furnace.

  • Extend Refractory life due to proper refractory dry-out and settling.

  • Reduced risk of steam explosions during start-up.

  • Cost effective solution incorporating variables being at the clients’ disposal.

  • 365 days / year availability for any repairs / emergencies.

WHERE YOU CAN BENEFIT

FROM OUR SERVICE:

  • Where installed equipment cannot be moved.

  • Where the client wishes to survey the heat treatment task closely, on his own premises.

  • To save transport costs to and from fixed heat treatment plant(s).

  • To eliminate the time wasted when items are sent away for off-site heat treatment.

  • Where your furnace burners cannot maintain the low temperature rise, while you require a more even heat up to the take-over temperature.

  • DGC’s Refractory Dry Out & Heat Up Services provides an unbeatable level of service

  A WELL RESPECTED ENTERPRISE  

  DICKINSON HOTWORK SERVICES IS 

  THE VALUE OF:  

  THAT FULLY UNDERSTANDS 

  • The sense of urgency to support a breakdown or repair and maintenance operation.

  • The need and requirement of our clients to meet the high-quality levels required for sophisticated projects and day to day engineering.

  • A 24-hour availability, 365 days per year.

ASSET INTEGRITY MANAGEMENT & INDUSTRIAL SOLUTIONS

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