Morgan Thermal Ceramics Furnace Repair Process Expends Furnace Life and Reduces Downtime

Morgan Thermal Ceramics, global leaders in high temperature thermal insulation, has announced that its Superwool Plus insulation is now available as part of its infrared (IR) thermography service, which reduces downtime, extends furnace operation and enables process managers to increase efficiencies and make associated cost savings.

The IR thermography service identifies and repairs weakened furnace linings quickly. Morgan Thermal Ceramics' specially trained applications engineers conduct IR imaging and analyse the IR scans to identify hot spots on furnace casings and provide recommendations on the most appropriate repair options.

The company's high temperature Superwool Plus insulation, or high performance Superwool 607 HT and Kaowool mastic can then be injected immediately. As a result, furnace operation is extended for several months up to as long as a year.

A major benefit of using mastic insulation is that the material is pumped from outside of the furnace, and so the furnace can be idled to a lower temperature without completely cooling. Consequently, wet fibre such as Superclad or Kaoclad insulation can be used to make furnace repairs within hours. Repairing furnace lining with fibre blankets or monolithics would typically require furnaces to be shut down or idled until the temperature cools and it is safe for maintenance personnel to enter. However, this process can take a few days or even up to a few weeks in some cases.

Where IR scans indicate that mastic repairs are viable, Superwool Plus, Superwool 607 HT or Kaowool mastic insulations can be injected from outside the furnace or boiler, filling cracks and voids caused by deteriorated insulation and gaps. Morgan Thermal Ceramics' mastic products are ideal for providing re-insulation behind boiler tubes in sidewalls, seals and floors as well as repairs of ovens, furnaces and process equipment. These products are quick and easy to install with specially designed extrusion or diaphragm pumps.

"Our applications engineers are highly skilled and offer expert advice for industrial furnace lining repairs," says Ron Wainwright, Technical Director, Morgan Thermal Ceramics "In many cases, IR scans show that mastic and other wet fibre technologies are cost effective alternatives to get customers back online in hours rather than days or weeks."

As energy costs continue to rise, using high performance insulations such as Superwool Plus, together with regular furnace maintenance in heat-intensive industries is crucial to sustaining high furnace efficiency.

For more information about Morgan Thermal Ceramics' Superwool Plus insulation and its IR thermography service visit www.morganthermalceramics.com.

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