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Refractory, furnace and anti-corrosion guides
Practical advice from our sites and 20+ years of experience: cut fuel costs, make linings last longer and choose the right materials.
How to improve furnace and HAG efficiency and cut coal and briquette consumption
Fuel is the biggest running cost of a coal or briquette fired furnace or hot air generator. These practical steps reduce it without new equipment.
How to calculate refractory brick and castable quantity
A simple method to estimate how many bricks, or how many tonnes of castable, your lining needs, with a worked example.
What decides the cost of a refractory relining job?
Two quotations for the same furnace can differ widely. Here is what actually drives relining cost, and how to compare quotes fairly.
Why rotary kiln refractory fails early: common causes and fixes
Hot spots, falling bricks and short campaigns usually trace back to a few causes. Here is what to look for in your kiln.
Why castable keeps falling off in CFBC and AFBC boilers
Repeated castable failure in boiler cyclones and bed areas usually points to anchors, water, dry-out or erosion. Here is how to break the cycle.
Thermic fluid heater refractory and insulation: a maintenance checklist
A simple weekly and shutdown checklist for process houses to keep thermic fluid heaters efficient and avoid breakdowns.
Hot air generator lining: what to check before and after startup
A new or relined hot air generator is only as good as its first heat-up. Use this checklist before you light up.
Induction furnace lining: how to get more heats from your ramming mass
Lining life in an induction furnace depends as much on ramming, sintering and melting practice as on the mass itself.
Supply only, or supply with installation: which is better for your plant?
Buying material and hiring a contractor separately can look cheaper. Here is when it works, and when one accountable party saves money.
Why acid-proof lining fails: 6 common reasons
Leaks, loose tiles and attacked concrete usually trace back to the joint, the mortar choice or the curing. Here is what goes wrong.
Annual rate contracts for refractories: how they cut cost and downtime
Buying refractory job by job means urgent prices and waiting for material. An annual rate contract turns it into a planned cost.
7 signs your kiln or furnace lining needs relining
A refractory lining rarely fails without warning. Here are the signs to watch on the shell, in the fuel bill and during every shutdown inspection.
Why controlled dry-out decides the life of a new lining
A new lining can be installed perfectly and still fail on its first heat-up. The usual cause is moisture leaving too fast.
K-silicate, furane, phenolic or epoxy: choosing an acid-resistant mortar
In acid-resistant lining the brick usually survives; the joint is where leaks begin. That makes the mortar the most important choice.
Fire bricks or high alumina bricks: which one does your lining need?
Both are dense hot-face bricks. The difference is alumina content, and with it how much heat, slag and wear the brick can take.
Ceramic fibre or calcium silicate: choosing the right insulation
Both cut heat loss, but they work very differently. Here is how to decide which belongs in your furnace, duct or pipeline.
How to read a refractory test certificate
Alumina, porosity, CCS, PCE, RUL, PLC: what each value on a refractory test certificate means, and why it matters to your lining.
Acid-resistant tile flooring: what to check before you build
Chemical-resistant floors fail at joints, slopes and drains. Here is what to settle before the first tile is laid.
Planning refractory work for a shutdown: a practical checklist
Most shutdown overruns are decided weeks before the plant stops. Use this checklist to keep refractory work on schedule.
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