Our current challenge involves the rapid deterioration of the refractory lining in a Thermal Oxidizer (Enclosed furnace). I am interested in learning about methods for online monitoring refractory thickness to address this issue. Any assistance in this area would be greatly appreciated for ensuring optimal furnace performance and longevity.
What are the different types of refractory materials used in furnace linings? Are fire-insulating bricks commonly used in the innermost layer? How many layers typically make up a refractory lining - are they in brick form or casted? What is the peak temperature reached inside the furnace and what type of furnace is it? Are thermocouples inserted into the furnace walls for temperature monitoring? What is the operating temperature range for the outer furnace walls? Is there a noticeable temperature increase after the refractory lining wears down? Can thermographic imaging detect any temperature spikes or hotspots on the furnace skin?
What type of refractory material is used in the innermost layer of the furnace? Yes, it is fire-insulating bricks. How many layers make up the refractory linings - in brick form or castable? There are 2 layers of bricks and 1 layer of castable. What is the maximum temperature reached inside the waste thermal oxidizer furnace? The temperature can reach up to 1600 degrees Celsius. Have thermocouples been inserted into the furnace walls? Yes, we have installed 3 thermocouples at each interface as part of the upcoming repairs. What is the designated temperature for the outer furnace skin? The alarm temperature is set at 350 degrees Celsius, although the exact design temperature is currently unknown. Have there been any temperature increases noticed after the thinning of the refractory lining? Yes, hot spots have been observed approximately 3 months afterward, prompting discussions with the OEM for alternative refractory materials. Can thermography be used to detect any temperature increases or hotspots on the furnace skin? Yes, it can.
How many layers make up the refractory linings? Are they in brick form or castable? The furnace reaches temperatures of up to 1600 degrees Celsius. It is a waste thermal oxidizer, similar to an autothermal reactor. Does it have a burner? If so, is the burner centered with a flame that does not infringe on any side? Thermocouples are inserted into the furnace walls for measuring purposes. As we approach the repair stage, three thermocouples have been installed at each interface. Can the remaining refractory thickness be calculated by measuring the exposed length of the thermocouple and subtracting it from the total length inside the refractory linings and furnace wall? What is the original thickness of the fire-insulating bricks? Thermal transfer across the refractory linings can be estimated by working from the skin temperature inwards to identify any potential thinning of the fire-insulating brick thickness. Are there any broken pieces expected, or have any bricks become glassified, glassy, or melted?
A centrally located single fuel burner with side-by-side aqueous and organic feeds is essential for optimal operation. The burner should have an exposed length of approximately 100 mm. The original thickness of 110 mm is crucial, as it dictates the placement of thermocouples for monitoring purposes. A glassy surface has been noted, prompting the need for a continuous or intermittent in-house inspection system for refractory thickness. Unfortunately, laser-based methods commonly used in ladles may not be suitable for this particular application.
It is crucial for the exposed length of the refractory lining to be approximately 100 mm. This measurement becomes significant after any erosion or thinning of the lining, rather than focusing on the length of the thermocouple extending into the furnace. The original thickness of 110 mm necessitated the installation of the thermocouples, as a glassy surface has been noticed over time. There is interest in implementing a system for regular in-house monitoring of refractory thickness, possibly through thermal calculations to track changes in skin temperature. A spreadsheet can be utilized for simplified calculations by inputting relevant data. It is uncertain whether laser technology used in ladles would be effective in this scenario, as it may not penetrate the furnace's metal shell and refractory linings, which are 110mm thick. Could gamma rays, as taught in physics, be a viable option for measuring refractory lining thickness? The continuous measurement of refractory thickness serves the purpose of preventing potential explosions in the future.
An interesting challenge. Have you considered implementing an acoustic pyrometer? This technology uses sound waves to measure temperature profiles which can indirectly provide information about refractory wear. It is a non-destructive testing method and can be used while the furnace is in operation, preventing unnecessary downtime. In addition, understanding how different materials and operating conditions affect your refractory lining can guide you in choosing the appropriate refractory to enhance the lining's lifespan. Make sure to work with refractory suppliers who have profound knowledge and experience in dealing with thermal oxidizers. This could significantly improve your situation.
Have you considered using ultrasonic testing for online monitoring of the refractory thickness? It's a non-destructive method that can give you real-time data on wear and help you make timely decisions on maintenance. Additionally, integrating sensors with data analytics could provide insights into wear patterns based on operation conditions. This might help you optimize performance and extend the lifespan of your thermal oxidizer!
✅ Work Order Management
✅ Asset Tracking
✅ Preventive Maintenance
✅ Inspection Report
We have received your information. We will share Schedule Demo details on your Mail Id.
Answer: 1. Why is monitoring refractory thickness important in a Thermal Oxidizer? - Monitoring refractory thickness is crucial in a Thermal Oxidizer as it helps in assessing the condition of the lining, detecting deterioration, and ensuring optimal performance of the furnace. It also contributes to extending the longevity of the equipment.
Answer: - Some common methods for online monitoring of refractory thickness include using ultrasonic testing, infrared thermography, and visual inspections. These methods can help in identifying areas of thinning or damage in the refractory lining.
Answer: - By regularly monitoring the refractory thickness, operators can detect early signs of deterioration and take proactive maintenance measures to prevent rapid degradation. This can include timely repairs or replacements to ensure the furnace operates at optimal performance levels.
Answer: - Maintaining optimal refractory thickness in a Thermal Oxidizer can lead to improved thermal efficiency, reduced energy consumption, lower emissions, and increased equipment lifespan. It also helps in avoiding costly downtime due to unexpected failures or repairs.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.