common causes of refractory failure engineer liveinduction furnaces
Boiler Tube Failures
Short-term Overheat Failure results in a ductile rupture of the tube metal " " fracture surface is a thin edge. Causes Short-term overheat failures are most common during boiler start up. Failures result when the tube metal temperature is extremely elevated from a lack of cooling steam or water flow
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and MaintenanceRefractory Contractor F.S. Sperry
Choosing the Best Refractory Material for an Aluminum Furnace 19 Chapter 1—Refractory Material 5 Common Misconceptions About Refractories For many industrial plant engineers and managers selecting and installing a refractory can cause catastrophic failure.
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Analysis and Prediction of Corrosion of Refractory
As a kind of renewable resource biomass has been used more and more widely but the potassium contained in biomass can cause corrosion of the refractory. For a better understanding of corrosion thermodynamic mechanisms the five components of common refractory materials (magnesium chrome spinel MgO·Cr2O3 magnesium aluminum spinel MgO middotAl2O3 Al2O3 MgO and Cr2O3) with
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Refractory Materials April 2015
Apr 30 2015 · Any failure of refractory could result in a great loss of production time. The refractory material failure may caused by many different factors such as chemical reaction and corrosion spalling material selection plant operations material storage mixing installation curing and drying.
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Firetube Boiler Pressure Vessel And Refractory Cautions
Jun 13 2018 · Normally the causes for this type of failure are a damaged internal directional baffle and/or a damaged gasket or poor sealing due to improper tightening of the door after closing. Another cause of overheating and door failure can be combustion vibration (rumbling) causing the refractory to crack and break out.
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Everything You Need to Know on Rotary Kiln Refractory
The two primary causes of refractory failure are cycling and chemical incompatibility.
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USARegenerative soaking pit furnaceGoogle Patents
Such a condition is a continual hazard to the furnace structure due to the aillnity of the slag and the brick or refractory of the furnace which causes pitting of the latter and upon repeatedl heating and cooling of the furnace structure in its regenerative operation cracks are formed in the refractory through which the slag escapes in a downward and outward direction.
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Limitations and misuse of LOPAIChemE
failure frequencies are being multiplied by the hours used per day. This has in some cases become an almost standard practice and is often done without thinking through the logic. Common examples are flexible hose failure or pressure regulators. If a flexible hose or regulator is used for one hour a day the failure frequency is multiplied by 1/24.
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What are the causes of refractory failtures
Sep 05 2019 · Any failure of refractory could result in a great loss of production time. The refractory material failure may caused by many different factors such as chemical reaction and corrosion spalling
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Understand the Common Causes of Refractory Failure
Understand the Common Causes of Refractory Failure It is not uncommon for furnace lining material to fail resulting in loss of thermal energy reduced performance or even a complete outage. Informed collaboration with refractory material suppliers
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Understanding Refractory Failure—A New Perspective
Certain startup fuel (i.e. #6 oil) may contain vanadium which could react with the silica and lime in the cement found in a cement-bonded-type refractory. When vanadium is present it can cause a chemical attack and surface failure or cause a complete refractory failure (no refractory present). Step 5 Review of Installation Procedures
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Refractories HandbookGoogle Books
Aug 11 2004 · Refractories Handbook. Charles Schacht. CRC Press Aug 11 2004Science520 pages. 4 Reviews. This comprehensive reference details the technical chemical and mechanical aspects of high-temperature refractory composite materials for step-by-step guidance on the selection of the most appropriate system for specific manufacturing processes.
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Cupola furnacesSlideShare
May 10 2014 · The refractory becomes coated with solid slag which is much less corrosive than the liquid slag. Owning to the destruction of the refractory lining in cupola furnaces it operate for periods of 12 to 18 hours and then undergo routine repairs i.e. patching and gunning.
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4th Class Power Engineering Part B Unit 4Boiler Plant
Failure to _____ the furnace thoroughly before light-up can cause a furnace explosion Shut off the fuel to the burners and stop feed water flow If a tube fails on a gas-fired boiler and the level is falling the correct procedure is to
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Common causes of refractory failure Engineer Live
What are the seven of most common causes of refractory failure And what can engineers do to both fix a problem and avoid it in the future. Refractory materials and lining reliability are key to increasing the performance of fired heaters incinerators kilns and reactors across a range of industries.
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Refractory Materials April 2015
Apr 30 2015 · Any failure of refractory could result in a great loss of production time. The refractory material failure may caused by many different factors such as chemical reaction and corrosion spalling material selection plant operations material storage mixing installation curing and drying.
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Engineering resilience with precast monolithic refractory
2 COMMON FAILURE MODES OF PRECAST MONOLITHICS The same modes of failure would be found in precast mono-lithic shapes as most other refractory materials used in indus-trial applications. While failure modes vary widely two of the most prevalent causes for end of service have been found to be corrosion and/or mechanical failure. 2.1 Corrosion
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INVESTIGATION OF REFRACTORY CONCRETE FAILURE IN
Conventional castables which contain a high amount of calcium alumininate cement typically exhibit deficiencies of high porosity and low refractoriness as the result of a high water content
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REFRACTORIES - CHARACTERISTICS OF A GOOD
Mar 05 2014 · The efficiency of the refractory product mainly depends on its constituents processing and final curing. (i) The most common cause for failure of refractory is chemical reaction with the environment in which it is operating. For example an acidic refractory should not be used in furnaces using basic fluxes slag etc. and vice-versa.
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There s a Crack in My Refractory F.S. Sperry F.S
Dec 18 2015 · If the crack can cause the refractory to loosen or fall out then heavy cycling can cause cracks to propagate as the slags/product get into the cracks and make them worse (ex the crack contracts when cool debris trickles into crack then on heat up the crack cannot fully close).
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Industrial Heating Thermal processing technical journal
Industrial Heating thermal processing technical journal covering heat treating ferrous nonferrous thermal processes in excess of 1000 degrees F.
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Metropolitan Engineering Consulting and ForensicsCAUSES
A direct blast of high pressure condensate can quickly cut through the thin tube surfaces resulting in tube failure. The most common cause of wet steam is inadequate warm-up and draining of the
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Modes of Material failure Fracture Creep Fatigue And More
The loads may be well below that which would be. expected to cause failure but over a period of time failure can occur due to metal fatigue. Some of these failure modes will now be described. Materials can fail due to metal fatigue creep and brittle fracture at stress
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Steam ReformingCommon Problems
• Mainly affects Top Fired furnaces • Two types #1direct impingement of flame on tube This is the worst since tube wall temperatures will be raised the most Can lead to rapid tube failure #2impingement of hot flue gas on tube Normally observed as shimmering on tube surface Will lead to premature failure in long term • Both
Get PriceRefractory Liningan overview ScienceDirect Topics
Most holding furnaces which I see appear designed to maximise the dangers of failure. Cracks in the refractory lining of the furnace filled with liquid metal give a high conductivity path for leakage of heat from the furnace with the result that if the leak reaches the outer steel shell that portion of the shell becomes extremely hot and
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Engineering resilience with precast monolithic refractory
Sep 12 2019 · 2 COMMON FAILURE MODES OF PRECAST MONOLITHICS. The same modes of failure would be found in precast monolithic shapes as most other refractory materials used in industrial applications. While failure modes vary widely two of the most prevalent causes for end of service have been found to be corrosion and/or mechanical failure. 2.1 Corrosion
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A typical refractory will be capable of maintaining a temperature drop of 1000 °C or more between its hot and cold faces. The shell temperature needs to be maintained below around 350 °C to protect the steel from damage and continuous infrared scanners are used to give early warning of "hot-spots" indicative of refractory failure.
Get PriceCommon Boiler Problems Part 4 Improper Warm-up
Also as the air inside the furnace and refractory cool moisture is absorbed from the air in the refractory. A gradual warm-up is required to prevent refractory from cracking this allows adequate time for the moisture to be driven from the refractory. Trapped moisture quickly becomes steam and causes the refractory to spall as the steam escapes.
Get PriceModes of Material failure Fracture Creep Fatigue And More
The loads may be well below that which would be. expected to cause failure but over a period of time failure can occur due to metal fatigue. Some of these failure modes will now be described. Materials can fail due to metal fatigue creep and brittle fracture at stress
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