Ceramic Welding for Glass Furnaces
The Fosbel Ceramic Welding process for glass furnace hot repair was invented and first applied in the late 1960’s. Fosbel has pioneered and perfected this innovative hot repair process that is used to repair the inside hot face of any furnace refractory at operating temperature in most cases with minimal disruption to production.
The repair material forms a ceramic bond to the damaged refractory, utilizing a fusion process that generates an exothermic reaction in excess of 4000°F (2,200°C). Materials are available to repair silica, alumina, AZS and magnesia refractories. Fosbel also offers volume stable, low temperature ceramic welding materials for external furnace refractory sealing.
Ceramic welding is best utilized as a preventive maintenance tool, but can also address large scale catastrophic repairs, thus providing an economic alternative to extend furnace life and prevent unscheduled furnace shutdown.
In areas where contamination or glassy phase on the base refractory is a problem, Fosbel offers thermal cleaning methods utilizing our range of proprietary cleaning materials or our supertorch cleaning system.
The supertorch’s specially designed oxygen-fuel burner allows pinpoint control of a high temperature flame in localized areas of the glass furnace superstructure. This unique process provides a fast, highly effective way to ensure a proper bond between the ceramic weld repair and base refractory.
Back Wall: Before CW Repair
Back Wall: After CW Repair
Melter Crown: Before CW Repair
Melter Crown: After CW Repair
Regenerator Skew: Before CW Repair
Port Wall: Before CW Repair
Regenerator Skew: After CW Repair
Port Wall: After CW Repair
Nano-Tec™ Ceramic Weld Powders
Fosbel initiated a research project to address ceramic welding repairs that provided greater yield onto the refractory surface and less possible contamination residue. This research project resulted in the next generation of ceramic welding powders. Introducting Fosbel's:
Nano-Tec™ Higher Yield Ceramic Welding Powders
Fosbel's line of Nano-Tec™ materials exhibit greater yield and lower rebound, thus decreasing weld time and lowering the cost of repairs.
Nano-Tec™ materials exhibit nine times less inhalable crystalline silica compared to standard ceramic welding materials.
Our new family of Nano-Tec™ powders are currently Silica-based formulations which improve yield (up tp 15%) and lowers the risk and duration of glass defects due to less rebound entering the furnace.