Incinerator Arch Castable Damage

Grate Incinerator · Arch

Problem Details

Background

The arches (front and rear) of a mechanical-grate incinerator direct flame and flue gas, enhancing combustion and drying. They long-term bear flame radiation, hot-gas scouring and fly-ash abrasion, plus ignition/shutdown thermal shock. The castable detaches—a weak point of incinerator linings.

Failure Mechanism

Flame radiation and high temperature: arches sit close to the flame with high surface temperature and thermal load; prolonged high temperature ages the castable. Gas and fly-ash scouring: high-velocity gas carrying fly ash abrades the arch surface. Thermal shock: ignition, shutdown and waste-charge fluctuations cause rapid temperature changes; thermal-shock stress cracks and detaches the lining. Corrosion: acid gases (HCl, SO₂) and alkali metals in waste-incineration gas attack the lining.

Consequences

Arch fall-out destabilizes combustion and flue-gas temperature, hurting incineration efficiency and gas treatment; fallen blocks may plug the grate or damage equipment, forcing shutdown for repair.

Solution

Material Selection and Parameters

Select arches for "high-temperature resistance + wear resistance + corrosion resistance":

Material system: SiC wear castable (SiC≥50%) or corundum wear castable (Al₂O₃≥80%). SiC resists wear, conducts heat and resists thermal shock for the heaviest flame zones; corundum offers high temperature rating and strength;
Anchors: densified heat-resistant steel anchors with ceramic caps;
Thickness design: size arch thickness by thermal load, thickening hot zones.

Installation Essentials

Formwork casting: cast the curved arch precisely to maintain arch shape. Vibration: vibrate fully. Water control: follow the datasheet. Bake-out: follow the curve and complete dehydration before commissioning.

Maintenance

Control furnace and flue-gas temperature within process range to avoid prolonged over-temperature; inspect arch surface and shell temperature, treating hot spots promptly. At maintenance, patch spalled zones, replace failed anchors and record arch life to optimize grade and practice.

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