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 thirty years, Insulcon has successfully repaired many large hot spots throughout the world, while business processes continued to run. This unique system consists of a specially developed pumping mix (Injection Mould), a controlled pumping system, and Insulcon's experienced engineers.
Over the years, Insulcon has been able to exercise their craftsmanship at various locations in the world by repairs carried out on refractory lining (concrete, stone, fibre) of many thermal units such as various types of stoves (crackers, reformers, crude units, and rotary kilns), boilers, combustors and flue gas ducts.
The unique Hot Spot Repair technique is very successful because of 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 may start to deteriorate. This could result in damage to the backup insulation, which causes the steel casing (or even the main carrying structure) to get overheated and therefore the steel structure can start to deform.
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 'first aid' 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 lining can be replaced if necessary. But most of the time the repaired hot spot is a permanent hot face repair.
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.