BENEFITS OF HOT REFRACTORY REPAIR
Hot repair – or hot face welding – is used to repair damaged refractories in a high-temperature operating environment. There are many benefits to conducting repairs when the furnace is hot, including minimizing interruption of production and minimizing the potential introduction of impurities to the production material. As the name implies, the hot face repair procedure takes place on the inside of the furnace refractory structure – this work can be conducted during furnace operation, eliminating the need for shut down.
With hot face welding, damaged areas can be welded together, holes and cracks filled and the mechanical stability of endangered areas restored. Hot face welding can be performed on all parts of the furnace refractory structure located above the glass bath surface. All refractory materials normally used in these areas can be welded by the employment of one of the ranges of materials available to Fuse Tech.
INSPECTING FURNACE DAMAGE WITH STATE-OF-THE-ART IMAGING EQUIPMENT
To determine the extent of any refractory damage or maintenance and repair needs, the Fuse Tech team uses a specialized furnace periscope to inspect the furnace interior and assess damage before the hot face welding repair process begins.
The furnace periscope can also be used during the welding process to provide views into difficult corners so that, if necessary, the work can be carried out with a video monitor. After the hot refractory repair work has been completed, the periscope can be used to review and present to repair results with your team. Images or videos taken with the periscope at regular intervals can provide your operations team with an appraisal of the furnace condition over its complete life to keep your furnace operating at its best.
HOT FACE WELDING WITH SPECIALIZED FUSE TECH LANCES
The Fuse Tech hot repair experts utilize many different welding lance designs and sizes to access and repair damaged areas in the furnace that can be difficult to reach. For example, the crown, port necks, burner arches, and doghouse arches are furnace areas that can be accessed with innovative welding lances. Additionally, state-of-the-art observation tools, such as periscopes, cameras, and monitors, are used to oversee the progress of hot face refractory repair work.
GAINING ACCESS TO THE FURNACE INTERIOR FOR HOT FACE WELDING
Hot face welding requires access to the furnace interior. Suitable access is not normally available and so must be created. Fuse Tech achieves this by the use of a water-cooled diamond tipped chainsaw to cut clean access openings in the refractory walls or crown at the most convenient location. After completion of the work the opening is either closed or modified to provide an additional peep hole. Openings that are to be closed are sealed by cold face welding.
SERVICING ALL INDUSTRIAL FURNACE TYPES
With years of hot face welding and hot refractory repair experience and expertise, Fuse Tech provides hot weld refractory repair services to the glass industry (float, containers, fibre, sodium silicate, special glasses) and other industries such as steel, coking, aluminum, copper, cast iron and cement. Fuse Tech hot refractory repair delivers long-lasting results to support the long term operation and efficiency of your furnace.
FUSE TECH IS THE LEADER IN FURNACE REPAIR AND CERAMIC SOLUTIONS
A range of ceramic solutions are available for hot face weld repairs and maintenance, depending on the location of the damaged area of the furnace. Learn about our full line of proprietary and patented ceramic weld materials available for applications such as the repair of cement kiln nose rings, repair of glass furnaces, repair of coke oven jambs, and the repair of glass furnaces and coke ovens.