Authors: T. Ireland-Hay, A. Sadri, J. Vandervielt, P.Lauzon, M.Spreij
Abstract
Refractory materials represent a major component of the capital and operating costs of any plant. The initial refractory material cost is significant, but the "full life value" including loss of production, loss of product quality and unexpected failures, can be even more significant. Understanding when repairs or replacement is required and controlling all the costs, direct and indirect, is key to maximising refractory value.
To achieve the best "full life value" requires a fully integrated refractory management system that incorporates: good refractory design, appropriate refractory materials selection for the operating conditions, well understood materials property and quality control specifications, detailed quality installation and dry-out practices, the development of appropriate refractory maintenance techniques, and excellent monitoring during operation.
This paper looks at the advances made in refractory monitoring and discusses the benefits and drawbacks of a number of refractory condition monitoring techniques including; visual inspections, thermography, surveying and ultrasonic testing. We outline how these can be used to maximise the “full life value” of the refractory and how this benefit can be calculated back against a plant’s bottom line.
