Anchor Support Welding Through Residual Refractory Lining
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Solution Overview
Problem
Existing methods for maintaining refractory linings in industrial plants require the complete removal and reconstruction of protective linings, which is time-consuming, costly, and environmentally detrimental, as they cannot effectively weld new anchor supports onto existing refractory material without removing the residual lining.
Innovation Solution
A method involving drilling holes in the residual refractory lining to insert and arc-weld anchor supports using a ceramic ferrule, allowing new refractory concrete to be applied directly over the existing lining, ensuring a stable and uniform protective layer without full demolition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complete removal and reconstruction of protective lining is performed, then adequate protection level is restored, but maintenance time and cost increase significantly
Solution Approach 1:
The invention segments the refractory lining restoration process by creating localized access points (holes) through the existing lining to weld individual anchor supports, rather than removing and reconstructing the entire lining system. This allows selective reinforcement at critical areas while preserving the overall structure.
Solution Approach 2:
The method performs preliminary cleaning and preparation of the metal structure surface through the holes before welding the anchor supports. This preliminary action ensures proper adhesion and welding quality without requiring complete lining removal, enabling faster maintenance while maintaining protection reliability.
2Reliability
If complete removal and reconstruction of protective lining is performed, then adequate protection level is restored, but labor and material costs increase
Solution Approach 1:
The invention applies local quality by reinforcing only the specific areas where anchor supports are welded through the holes in the existing lining. New refractory material is applied locally at these reinforced points rather than covering the entire structure, reducing material consumption while maintaining adequate protection levels.
Solution Approach 2:
The method recovers and preserves the existing refractory lining by welding anchor supports through it rather than removing it completely. The existing lining is retained and reused where possible, discarding only the minimal amount necessary to create access holes, thereby reducing overall material consumption.
3Strength
If arc welding with ceramic ferrule is performed through holes in residual lining, then anchor supports are securely attached, but welding precision and alignment become more difficult
Solution Approach 1:
The ceramic ferrule acts as an intermediary element in the welding process. It is inserted through the holes in the residual lining to reach the metal structure surface, providing a stable platform for arc welding. This intermediary component facilitates proper anchor support attachment while compensating for the limitations of working through confined hole access.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the need for extensive refractory material and labor, minimizes environmental impact, and significantly shortens maintenance downtime by allowing in-situ restoration of the protective lining with improved adhesion and structural integrity.
Implementation Method 1
making a plurality of holes in a residual refractory lining, which covers the metal structure by means of a core drill machine
Implementation Method 2
cleaning the surface of the metal structure at the bottom of the holes from sludge and oxidation by means of a cleaner in order to obtain electrical continuity
Implementation Method 3
arc welding with ceramic ferrule an anchor or clamp for refractory concretes on the metal structure of the industrial plant through each hole made in the residual refractory lining
Implementation Method 4
the anchor is removed so as to trigger an electric arc between the surface of the sheet and the small aluminum trigger, the electric arc being able to melt the two parts
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5c
AI summary
A method for welding anchor supports for refractory linings of a metal structure of an industrial plant comprises the steps of making a plurality of holes (f) in a residual refractory lining (cu) until the metal structure (s) is uncovered, each hole (f ) having a diameter greater than that of a ceramic ferrule (8) for stud-welding, cleaning the bottom of the holes (f), arc welding the anchor (Z) on the metal structure (s) of the industrial plant through each hole (f) made in the residual refractory liner (cu) so that the anchor protrudes from the residual refractory lining (cu), and overlapping new refractory concrete (cn) in order to restore the protective lining for the metal structure (s) of the industrial plant. A stud-welding device is also described for practicing the method.