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Refractory Wear Monitoring System Betters Lining Life, Reduces Furnace Damage.

The refractory lining in furnaces is consumable A material that is used up and needs continuous replenishment, such as paper and toner. "The low-tech end of the high-tech field!" . Hidden wear and uncontrolled penetration of the melt into the refractory can cause damage to the furnace, create production stoppages and produce safety hazards for employees. One solution presented by Saveway Corp., Wyomissing, Pennsylvania Wyomissing is a borough in Berks County, Pennsylvania, United States, established on July 2, 1906. The population was 8,587 at the 2000 census, but after the 2001 merger with neighboring Wyomissing Hills, the combined 2000 Census estimate was 11,155 making it the most populous , is the Saveway Lining Wear Monitoring System, which incorporates sensor electrodes Electrodes
Tiny wires in adhesive pads that are applied to the body for ECG measurement.

Mentioned in: Electrocardiography
 into the furnace refractory system to perform analysis.

As the melt penetrates the refractory lining, there is an increase in temperature, which results in a reduction of the electrical resistance Electrical resistance

Opposition of a circuit to the flow of electric current. Ohm's law states that the current I flowing in a circuit is proportional to the applied potential difference V.
 of the refractory material. The lining monitoring system relates the measured resistance as a function of temperature to determine residual wall thickness and monitor lining life.

For installation in an induction crucible crucible, vessel in which a substance is heated to a high temperature, as for fusing or calcining. The necessary properties of a crucible are that it maintain its mechanical strength and rigidity at high temperatures and that it not react in an undesirable way with  furnace, the measuring electrodes are integrated into a sensor mat (electrode plate) as two engaging comb-shaped electrodes. The standard design of the electrode plate consists of two flexible mica materials, with the material facing the melt possessing the same resistive resistive /re·sis·tive/ (re-zis´tiv) pertaining to or characterized by resistance.  properties as the refractory material. The electrode plates for crucible induction furnaces are 500 mm wide and are adapted to the height of the coil.

The electrode plate is placed on the coil grouting grout  
a. A thin mortar used to fill cracks and crevices in masonry.

b. A thin plaster for finishing walls and ceilings.

2. Chiefly British Sediment; lees. Often used in the plural.
 instead of the conventional slip plane or insulating layer. Since the electrode plate is a consumable, it has to be changed during relining as the wear is indicated on a matrix display or computer. The shortest distance between the melt and the electrode wires always is indicated for the area of the whole sensor mat.

The result from the lining monitoring system is: an increased service life of the refractory because hidden wear is made apparent and it can be fully utilized without any risk. Also, determining the causes of abnormal lining wear becomes easier due to the transparency of refractory with the monitoring system. The system is able to monitor several furnaces running together or separately using one control unit.

The monitoring system runs on WindowsNT software and has the ability to compile data from various furnaces and perform analysis.

According to according to
1. As stated or indicated by; on the authority of: according to historians.

2. In keeping with: according to instructions.

 the manufacturer, the furnaces monitored by the system have not exhibited undetected melt penetration in its 6 years of field experience. In addition, for induction furnaces of less than 20 tons, testing thus far has proven that the monitoring system increases lining life by at least 20%.

Up to now, the monitoring systems have been installed on induction crucible furnaces, however new applications include holding, channel induction and arc furnaces.
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Title Annotation:Saveway Corp.
Comment:Refractory Wear Monitoring System Betters Lining Life, Reduces Furnace Damage.(Saveway Corp.)
Publication:Modern Casting
Article Type:Brief Article
Geographic Code:1USA
Date:Nov 1, 2000
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