Refractory linings are constantly exposed to the most extreme conditions that are characterised by heat, physical stress and chemical attack.
Consequently, in order to maintain optimal levels of plant performance; repairs of different magnitudes will be necessitated at various intervals throughout the lifespan of a facility. Given the high costs refractory materials and unplanned stoppages; high quality refractory materials have to be properly installed during refractory relining campaigns. This article briefly discusses some critical refractory installation issues that need to always be carefully addressed:
Refractory relining campaigns should be sufficiently resourced with skilled refractory technicians and well experienced supervisors to ensure the highest quality outcomes
Comprehensive pre-shutdown inspections and scope identification have to be carried out with the involvement of all relevant personnel prior to the commencement of the works.
Advanced project and construction management techniques should be employed to ensure timeous completion of the works within budgets
Effective refractory material management procedures have to be applied throughout the process; right from material selection, procurement, transportation, quality analysis through to stock management
The correct refractory material installation techniques have to be used at all times, some of installation techniques are listed at the end of the article
An appropriate commissioning criteria has to be developed to ensure that the life of the refractory lining is maximised; this involves correctly scheduling heat-up phases and dry-out periods
Once in operation, various condition monitoring techniques can be continuously used to establish a holistic overview of the state of the refractories production facilities as well as the respective efficiencies
POPULAR REFRACTORY INSTALLATION TECHNIQUES
Refractory masonry products
Specialized refractory bricklaying
Rigging of refractory blocks
Monolithic refractories
Vibrocasting
Shotcreting
High density and pneumatic gunning
Ramming installations
Grouting installations
Dense pneumatically applied castable
Ceramic fibre
Installation of various types of ceramic fibre