Analysis of the Causes of Cracking in Refractory Bricks of Chemical Furnaces: How to Identify Thermal Stress Damage and Prevent Unscheduled Furnace Shutdowns?

Sunrise

2025-10-15

Technical knowledge

This article delves deep into the main causes of cracking in refractory bricks used in chemical furnaces, with a particular focus on the impact of thermal stress on the structural stability of refractory bricks. Through a scientific analysis of the mechanisms by which sudden temperature changes, uneven heating, and material defects contribute to cracking, and in combination with the hollow - sphere structure and high - grade clay formula of high - strength refractory clay insulation bricks, it explains the advantages of their thermal shock resistance. The content includes key points for daily inspections, methods for early identification of thermal stress damage, and maintenance suggestions, aiming to assist equipment maintenance personnel and technical teams in the chemical industry to effectively prevent unscheduled furnace shutdowns and improve the safety and economic operation efficiency of the furnace. The article is equipped with charts and case studies, presented in a professional yet accessible manner, providing users with practical technical guidance and scientific maintenance ideas.

Analysis of the Causes of Cracking in Refractory Bricks for Chemical Furnaces: How to Identify Thermal Stress Damage and Prevent Unplanned Furnace Shutdowns?

In the chemical industry, the cracking of refractory bricks in chemical furnaces is a common yet critical issue. This phenomenon not only poses a threat to the safety of the furnace operation but also has a significant impact on the economic efficiency of the production process.

Let's first understand the impact of refractory brick cracking. Unplanned furnace shutdowns caused by brick cracking can lead to production interruptions. On average, each unplanned shutdown may result in a loss of production worth tens of thousands of dollars, depending on the scale of the chemical plant. Moreover, it can also bring potential safety hazards, such as gas leakage and even explosions.

$Illustration of refractory brick cracking in a chemical furnace$

Mechanism of Structural Damage Caused by Thermal Stress

Thermal stress is one of the main causes of refractory brick cracking. Temperature fluctuations are a common occurrence in chemical furnaces. For example, during the start - up and shutdown processes, the temperature can change by hundreds of degrees Celsius within a short period. When the temperature changes suddenly, different parts of the refractory brick expand or contract at different rates, generating internal stress.

Uneven heating is another factor. In a large - scale chemical furnace, due to the uneven distribution of heat sources, some parts of the refractory bricks may be heated more than others. This uneven thermal expansion can also cause stress concentration and eventually lead to cracking. In addition, material defects, such as micro - cracks or impurities in the refractory bricks, can act as stress concentration points, accelerating the cracking process.

How the Hollow - Sphere Structure and High - Grade Clay Formula Improve Thermal Shock Resistance

High - strength refractory clay insulating bricks with a hollow - sphere structure and high - grade clay formula have excellent thermal shock resistance. The hollow - sphere structure provides a buffer space for thermal expansion. When the temperature changes, the air in the hollow spheres can absorb and disperse the thermal stress, reducing the impact on the overall structure of the brick.

The high - grade clay formula also plays a crucial role. High - grade clay has better plasticity and bonding properties, which can improve the overall strength and toughness of the refractory brick. The combination of these two features makes the refractory brick more resistant to thermal stress and less likely to crack.

$Diagram of the hollow - sphere structure of refractory bricks$

Daily Inspection and Maintenance

Regular daily inspections are essential for preventing refractory brick cracking. Maintenance personnel should check the surface of the refractory bricks for any signs of cracking, spalling, or discoloration. They can use non - destructive testing methods, such as ultrasonic testing, to detect internal defects in the bricks.

Early identification of thermal stress damage is also crucial. For example, if the surface of the refractory brick shows fine cracks or changes in color, it may be an early sign of thermal stress damage. Once such signs are detected, timely measures should be taken, such as adjusting the heating process or replacing the damaged bricks.

Case Analysis

In a certain chemical plant, due to the lack of proper inspection and maintenance, the refractory bricks in the chemical furnace began to crack. The production was interrupted for nearly a week, resulting in a direct economic loss of about $50,000. After adopting the inspection methods and maintenance suggestions in this article, the frequency of unplanned shutdowns has been significantly reduced, and the service life of the refractory bricks has been extended by about 30%.

$Case study of refractory brick maintenance in a chemical plant$

In conclusion, understanding the causes of refractory brick cracking and taking effective preventive measures can significantly improve the safety and economic efficiency of chemical furnace operation. To ensure the long - term stable operation of your chemical furnace and enhance the heat - resistance protection, we recommend using our high - performance refractory bricks. Click here to learn more about our refractory brick products and take the first step towards safer and more efficient furnace operation!