Even the most advanced refractory systems are prone to failure if not selected, installed, or maintained correctly. Understanding the causes can help industries prevent unplanned downtime and expensive repairs.
1. Spalling
Spalling is the cracking or flaking of the refractory surface due to rapid temperature changes. It’s particularly common in castables and poorly dried linings.
2. Chemical Attack
Acidic or basic slags, molten metals, and gases can corrode refractory linings. Using basic refractories like magnesia in basic environments reduces corrosion risk.
3. Erosion
High-velocity particles or liquids erode the surface of refractories. Found in blast furnaces and fluidized beds, erosion is mitigated with denser, abrasion-resistant materials.
4. Thermal Fatigue
Repeated heating and cooling cycles lead to micro-cracks that grow over time. This issue is solved by selecting materials with high thermal shock resistance and flexible structural design.
5. Installation Errors
Poor anchoring, uneven drying, or incorrect gunning techniques can all cause premature failure. Having experienced professionals or external audits ensures quality and long-term stability.
Prevention Through Expertise
Failure prevention starts with a strategic selection of materials and ends with continuous maintenance. Companies like MXS Refractories provide audits and diagnostic services to prevent these issues and optimize plant performance.