Most refractory "solutions" are based on trial-and-error, rules-of-thumb or refractory mythology.  This is because few people understand the non-linear properties of the refractory, the thermo-chemical (corrosion) reactions of the refractory/anchor with the process environment and the thermo-mechanical interactions of the refractory and steel shell.  Most refractory failures are a result of a complex combination of multiple variables.


My unique background as a Ceramic Engineer with experience in refractory product research and development, refractory inspection services, refractory product sales and marketing, refractory installation, refractory engineering and refractory construction provides a comprehensive overview of all aspects of "refractory" and solutions necessary to achieve Value, Quality and Reliability.

 

I have researched the combination of thermo-mechanical, thermo-chemical and thermal cycles effects on the micro and marco structure of refractory.  As a result I have some unique insights into refractory performance and use it as a useful tool to predict and analyze failures and then incorporate the findings into the final design.


I sold Stewart Services in 2009 and have since been a consultant in the non-ferrous industries.  During this time I have researched the combination of thermo-mechanical, thermo-chemical and thermal cycles effects on the micro and marco structure of refractory.  As a result I have some unique insights into refractory performance and use it as a useful tool to predict and analyze failures and then incorporate the findings into the final design.

INDUSTRIES SERVED
 

  • Cement and Lime 
  • Power and Circulating Fluidized Bed Boilers
  • Refining and Petrochemical
  • Incineration
  • Copper, Lead and Aluminum
  • Forging
  • All Non-Ferrous Applications
  • Iron and Steel Applications
EXPERTISE / SERVICES

 

  • Effects of the process environments
  • Effects of changes in process environments (i.e. fuel changes)
  • Mechanical effects (Kiln Mechanics)
  • Refractory thermal stresses
  • Thermomechanical effects
  • Corrosion (Sulfur-Alkali) effects on refractory, anchors, shells
  • Refractory material compositions

  • Refractory installation
  • Refractory / Monolithic materials selection and cost analysis
  • Analyzing installed costs / Refractory Economics
  • Refractory Reliability Studies
  • Complete plant inspection with repair recommendations 
  • Refractory / Anchor / Lining design 
  • Constructability issues, contingencies, risk assessment 

  • Failure analysis and the refractory solutions 
  • Thermomechanical analysis and post mortem sample analysis 
  • Analyze Kiln Mechanics, Kiln Brick Failures, Non-linear Brick Life Supervision

  • Management of all aspects of the outage 
  • Optimize the schedule and reduce delays from conflicting activities 
  • Post-outage reviews for continuous improvement 
  • Establish refractory consistency between the plants 
  • Kiln Bricking Procedures and Installation Specifications 
  • Optimum heat cure schedules and the suitability of a “dry-out” company 
  • Refractory Training, Roundtable Discussions and Seminars

  • Refractory Expert Witness