What are refractory materials?
Refractory bricks are used in industrial regenerative furnaces, and are composed of materials capable of withstanding extreme heat of 3000º F or greater. Often called fire bricks, they have greater energy efficiency due to having low thermal conductivity. Refractory bricks are typically composed of alumina, silica, zirconia and chrome, which are capable of preventing the corrosive effect of the heat. Over time, refractory materials can break down or become cracked, causing the need for repair or maintenance to retain long-term commercial tank furnace efficiencies.
What is the typical lifetime for regenerative furnace (refractory) materials?
Industrial refractory materials have a limited lifetime depending on the specific material composition, temperature and conditions they are exposed to and preventative maintenance schedule. Proper installation and maintenance is vital to extending the lifespan of industrial pot furnaces and preventing refractory degradation. Typically, the lifespan of refractory materials should be approximately ten years, but with proper predictive and preventative maintenance, commercial tank furnace life could extend to twenty years or more.
How often should I have my regenerative furnace and refractory inspected?
Different types of refractory equipment and materials will require different maintenance and inspection schedules. A qualified refractory engineer should always be on site to perform any type of heat processing equipment inspection to ensure quality and provide long-term solutions. While some industrial melting furnace equipment can be scheduled for inspection or calibration on set intervals, it is best to contact a professional furnace engineer to design a plan specific to your factory conditions and environment. At a minimum, refractory linings and associated equipment should receive yearly inspections to ensure proper efficiency and prevent the potential for catastrophic repair needs.
How does Fuse Tech repair refractory materials?
Fuse Tech utilizes proprietary equipment and processes designed for the specific needs of each customer. Patented ceramic welding equipment, used in the repair of refractory materials are placed into the regenerative melting furnace, delivering a mixture of refractory aggregate via water-cooled lances. The hot refractory repair process is preferred by most customers to prevent the stoppage of operations, keep commercial tank furnace equipment running and avoid costly downtime. In severe cases, cold refractory repair is preferred due the need for a controlled cool down or shutdown to make necessary commercial furnace repair, service or maintenance.
What industries can Fuse Tech service? And what types of industrial furnace repair and service can Fuse Tech do?
A wide variety of refractory furnace types and associated industries are serviced through the Fuse Tech solution process. Glass (including fiberglass), coke, cement and other minerals are a handful of refractory industries that we service. Modern industrial kilns comprising all tank furnace linings, overcoatings, fire brick materials and large scale float glass industrial furnace equipment are serviced by our skilled technicians.
How often should checker and port cleaning and maintenance be conducted?
Checker and port cleaning should be conducted as soon as debris and/or plugins are detected to prevent the impairment of optimal high temperature furnace operations and avoid checker problems. Debris or a clogged furnace can have a significant detrimental impact on furnace efficiency, resulting in increased energy and production costs. Additionally, to help ensure the safety of workers at your facility it is important to take the necessary steps to keep your industrial furnace well-maintained and clean on a regular basis. Learn More