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Active Contributor

Join Date: Jul 2009
Posts: 10

Refractory Bricks Life Cycle

04/25/2011 5:02 AM

With a period of almost 2 and 8 months operation, the refractory bricks installed at the front panel of our pusher type reheating furnace was collapsed (fell down). We suspect the problem was started at the arch bricks on the burner block. The thickness of the wall is 545mm, (230mm -70%Alumina Bricks, 115mm-50%Alumina Bricks, 115mm-Insulation Bricks and 75mm siliminite blocks/ceramic blanket). Our operation is only 5 days a week but we keep furnace temperature at 700degC during nonworking day. What is the probable cause of this problem.

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Guru

Join Date: Aug 2010
Posts: 687
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#1

Re: refractory bricks life cycle

04/25/2011 7:07 AM

Bentonite mortar was probably used between the bricks. Over time this material will degrade. Even though you have keep the furnace at some temp. A couple of questions on the unit. Where was the failure and do you have pictures of same. I have rebuilt many of these units over the years with brick and with plastic ram materials. The last few years I have gone to compressed fiber blocks. Longevity of the later is much improved over the old brick systems.

From your description I would say it was a burner block failure which over heated mortar. But, without seeing it, it's hard to tell. Contact a refractory manufacture and have them inspect. They can give you the cause of failure. But 2 plus years on a brick lined unit is pretty good.

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Power-User

Join Date: Aug 2009
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#2

Re: refractory bricks life cycle

04/25/2011 8:40 AM

More than likely failure of the Mortar

Can You Post Pics?

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Anonymous Poster #1
#3

Re: Refractory Bricks Life Cycle

04/27/2011 8:57 AM

I have a strong doubt about the quality of your burner blocks. Once your burner block starts spalling, then expect the arch bricks above it will follow soon.

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Guru
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#4

Re: Refractory Bricks Life Cycle

02/27/2017 3:23 PM

I know this is old post,... but the other possibility is that there was not any tempering of the brick and mortar after installation. And after install, without the tempering, instead it was ramped it up to operating temperature.

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