We like to keep your furnace hot
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1 We like to keep your furnace hot Hot repairs and hot repair materials SERVICES FOR THE GLASS INDUSTRY
2 IGT - Technology Services Glass 2 Why does a furnace fail? There are many reasons!!! A furnace fails due to: just as time goes by due to normal wear wrong choice of refractory material (wrong material for the application) bad construction or wrong design mistakes during heat-up (joints open or not closing) wrong insulation (too much, too little) changes in operation (pull, temperature, firing) problems during operations (loss of power, overheating, loss of cooling)
3 IGT - Technology Services Glass 3 What does it need to keep a furnace alive 1. identify 5. prevent problem 2. assess 4. repair 3. plan
4 IGT - Technology Services Glass 4 Hot repairs vs. Cold repairs + fast + long term fix + cheaper than cold repair + easy access + little or no loss of production + limited danger + furnace stays hot + moderate working conditions - experienced staff necessary - expensive - sometimes dangerous - slow - difficult working conditions - loss of production - Most of the time no long term fix -cool down/heat-up necessary
5 IGT - Technology Services Glass 5 Hot repairs: Crown Damage: Rat holes, stingers Cause: hot gases work in open joints till fire is visible on the outside
6 IGT - Technology Services Glass 6 Hot repairs: Crown Repair: small spots or even larger areas repair with suspended bricks small joints by ramming, patching or overcoating Material choice: fused Silica bricks (e.g. Fondal SCW) fused silica mixes (e.g. Fondit K) Option: Overcoating of larger areas after closing of rat holes with shotcast mix (e.g. Compacshot FS 99SB) or patch (e.g. Zircon patch Resistit ZS 150P)
7 IGT - Technology Services Glass 7 Hot repairs: Crown
8 IGT - Technology Services Glass 8 Hot repairs: Crown Damage: Melt down of crown Cause: overheating of the crown
9 IGT - Technology Services Glass 9 Hot repairs: Crown Repair: removal of the insulation shotcast of the full ring till self sustaining structure is reached Material choice: fused Silica Shotcast mix (e.g. Compacshot FS 99SB)
10 IGT - Technology Services Glass 10 Hot repairs: Superstructure Damage: Corrosion of the of superstructure/tuckstones, loss of superstructure support Cause: contact with batch, corrosion by run down of Silica, corrosion by dust
11 IGT - Technology Services Glass 11 Hot repairs: Superstructure Repair: Cutting of the area and insertion of tiles Material choice: Bonded AZS (e.g. Durital AZ58P) or Chrome Alumina (e.g. Durital RK30NP) Option: ceramic welding on top of the inserted tiles
12 IGT - Technology Services Glass 12 Hot repairs: tank Damage: Metal line corrosion, horizontal cracks Cause: corrosion by glass melt, loss of cooling, thermal shock
13 IGT - Technology Services Glass 13 Hot repairs: tank Repair: overcoating of metal line or even whole sidewall Material choice: Chrome Alumina Tiles (e.g. Durital RK30NP) bonded AZS tiles (e.g. Durital AZ58P) fc AZS tiles (e.g. Refel 1532 FVP)
14 IGT - Technology Services Glass 14 Hot repairs: throat/doghouse Damage: corrosion, cracks, open joints Cause: high wear area corrosion by glass melt, loss of cooling, abrasion
15 IGT - Technology Services Glass 15 Hot repairs: throat / doghouse Repair: freezing of the glass melt in front of the throat/dog house by inserting watercooled lances replacement of the throat blocks/doghouse careful de-freezing of the throat/doghouse Material choice: fc AZS blocks (e.g. Refel 1240 FVB) or Chrome Alumina (e.g. Supral RK50)
16 IGT - Technology Services Glass 16 RHI Glas GmbH in cooperation with Glass Design Inc & Franke IndustrieofenService supports you with keeping your furnace hot!
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