The Insulcon Group’s Hot Spot Repair service is a real trouble-shooting speciality service for problems with refractory linings in thermal units. In the last forty years, Insulcon has successfully repaired many large hot spots throughout the world, while business processes continue to run. This unique system consists of a custom developed pumping mix (Injection Mould), a controlled pumping system, and Insulcon its experienced engineers.
Since the start of our Hot Spot Repair technique, Insulcon has been able to exercise their craftsmanship at various locations around the globe. Repairs have been carried out on the refractory lining (castables, brick linings, fibre) of many thermal units such as cracking furnaces, reformers, crude units, rotary kilns, boilers, combustors and flue gas ducts.
The unique Hot Spot Repair technique is very successful due to the development of a wide range of high-temperature injection mixes, a fully controlled pneumatic injection system and qualified personnel who are always on standby and have lots of experience and knowledge in repairing hot spots.
When the furnace is in continuous operation, the LTM (low thermal mass) or the hard refractory lining is subject to wear over the years. This could result in damage, so that the hot gasses can bypass behind the lining and damage the steel casing, which causes the steel casing (or even the main carrying structure) to overheat. Therefore, the steel structure might start to deform as well.
A hot spot brings many dangers. When damage occurs in the refractory lining, it will quickly become bigger and bigger. The steelwork (casing plate and load-bearing construction) around the unit can become so hot that the strength of the structure is affected. This results in reduced strength of the supporting parts. The total unit will become unpredictably unstable and this is a safety risk. What follows is an (unscheduled) emergency shutdown.
We provide a temporary repair of the hot spots with our Hot Spot Repair service, which enables the thermal unit to remain online. When the first scheduled maintenance stop is reached, the affected area can be restored as per the refractory lining. In some cases the repaired hot spot remains in place due to the difficult accessibility in the thermal unit.
For a visual impression, please watch the video about the biggest hot spot refractory repair in the history of the Insulcon Group on our YouTube channel.