Compared to traditional refractory brick or castable linings, ceramic fiber module linings offer significant advantages in terms of maintenance convenience. This is primarily due to their "individual module, individual group" installation method-each module is secured by independent anchors and remains separate from others, facilitating localized replacement.
I. When to Demolish or Replace Modules?
During long-term operation, if a specific area of the furnace lining is subjected to prolonged overheating beyond the rated temperature tolerance of the modules, localized issues such as pulverization, reduced strength, or even detachment may occur. In such cases, a full furnace shutdown or major overhaul is unnecessary. The damaged module can be removed by loosening the fixing nuts with a wrench and replaced with a new module of the same grade.
II. Key Considerations During Replacement
1. Timely Action to Prevent Escalating Damage
Localized damage should be addressed immediately upon detection. Delaying replacement may allow high-temperature flames to penetrate the furnace shell, leading to widespread module detachment and greater economic losses. During removal, exercise caution to avoid excessive force that could damage adjacent intact modules.
2. Standardized Demolition for Thorough Restoration
When removing old modules, the corresponding compensation blankets and backing layers from both upper and lower sections must also be cleared. If the fixing studs are deformed due to overheating, they must be fully removed along with any surrounding flat-laid blankets. New studs should be welded in place, followed by re-laying backing blankets and compensation strips of the same grade. After installing the new module, inspect the surrounding gaps and tightly fill them with ceramic fiber blankets. Finally, apply a specialized surface hardener to the new module and allow it to dry completely before putting the furnace back into operation.
3. Assessing Lifespan for Batch Replacement When Needed
Under normal operating conditions, ceramic fiber linings can last up to 5 years. However, in environments with high-speed gas flow erosion or mechanical wear, their lifespan may be shortened. If widespread pulverization of modules is observed, it is advisable to schedule a furnace shutdown and conduct a systematic batch replacement to eliminate potential safety risks thoroughly.
4. Regular Maintenance for Extended Service Life
To prolong the overall lifespan of the furnace lining, periodic application of high-temperature surface hardeners to the modules is recommended. For example, SUNTHERM's high-temperature protective coating effectively enhances resistance to molten metal erosion and high-temperature gas flow impact, making it an ideal preventive maintenance solution.
