Inspection of Missing Corners and Edges of Refractory Products
Refractory materials are of great importance in the industrial production and energy consumption as they are used to line both non-ferrous and ferrous melting furnaces, electric arc and resistance furnaces, and combustion chambers. The success of any refractory application depends on how well it is designed and installed and how it performs in service. Although refractories may seem strong at first, the combination of changing temperatures, thermal stress, chemical attack, abrasion, and erosion continually leads to deterioration. Therefore, it is essential to inspect refractory materials for missing corners and edges.
Missing corners and edges are regions of refractory materials that are thin or nonexistent. They are usually caused by inadequate precast shapes, cracking when heated, or misadvised installation of the refractory material. In severe cases, the entire refractory brick may be defective, causing a weak link in the refractory lining. The following inspection parameters should be used to properly and accurately inspect for missing corners or edges on refractory products:
1. Visual Inspection - The area should be visually inspected to confirm that there is an issue with any of the corners or edges. Visual inspection is also used to detect any cracking or expansion of the material. The severity of any issues should be noted to provide an accurate assessment of the state of the refractory material.
2. Thickness Measurement - The thickness of the material should be measured to determine if any of the corners or edges are too thin. This is done to determine if additional material needs to be added to reinforce the region.
3. Temperature Measurement - The temperature of the area should be measured to determine if any additional heat may be causing the material to expand and crack.
4. Stress Measurement - Stress measurements should be taken of the region to determine if any of the corners or edges are undergoing excessive stress. This is especially important for high-temperature applications.
5. Porosity Measurement - The porosity of the material should be measured to determine if the region has become porous due to the erosive effects of slag or molten metal.
6. Sulphur Content Measurement - The sulphur content of the material should be measured to determine if the region has become compromised due to the corrosive effects of sulphur.
The above parameters should be used in combination to determine the condition of the refractory material. The measurements should be taken in order to determine the working environment that the material is exposed to, as well as the physical condition of the refractory material. If any of the parameters indicate an issue, additional material may need to be added to the region in order to reinforce it.
In conclusion, it is important to inspect for missing corners and edges of refractory products, as these can cause weak links in the refractory lining. Using the above inspection parameters can help to accurately diagnose the condition of the refractory material and take the necessary steps to reinforce it.
