RPR Technologies (Reactive Projection Repair)
FIBS Group has developed a range of technologies dedicated to the :
Preventive maintenance of refractories at high temperature
Curative repair of refractories at high temperature
Reduction of air emissions
Expertise and inspections
All the technologies have been developed by FIBS Group considering :
Reduced T.C.O. (Total Cost of Ownership) for the plants operators : quick application, decision analysis, long repair life, reduced downtimes
Extended lifetime of the refractories
Better working conditions for the operators
Since many years, ceramic welding is recognized as the best method for the maintenance of the refractory lining of the coke ovens, glass furnaces ... as well as for extending the lifetime of the production assets.
FIBS has been supplying a genuine ceramic welding technology since the early nineties. Nowadays, FIBS ceramic welding serves as the benchmark for the industry.
Advantages of FIBS Ceramic Welding Technology :
High Quality Material
Production of the ceramic welding mixture in FIBS premises and severe quality controls
Continuous improvement thanks to a R&D lab
Light and small machine that requires only 2 operators
No electricity, no electronics, no pressurized vessels, no nitrogen
FIBS offers a wide range of ceramic welding materials to allow the repair of all kind of ovens, furnaces, kilns, or reactors, boilers, and chosen and adapted to all temperatures.
Equipment (RPR Machine and accessories) for the application of ceramic welding has been developed considering :
Ergonomy : small and light, easy to carry
Simplicity : very low maintenance, no electricity, or electronics
Efficiency : continuous feeding of the material, low spare parts consumption
Safety : no pressurized vessel, different safety devices
Materials for ceramic welding (RPR Powders) are produced in FIBS high capacity manufacturing plant.
Manufacturing plant of FIBS is idealy located at maximum 2 hours drive from Antwerp Harbour and in the middle of an important highway network.
The manufacturing process includes :
A severe selection and quality control of the raw materials
Various control devices on the production lines
Quality control on the final product including labs controls and controls in our pilot furnace
Refractory specialists are working everyday on the improvement of the RPR powders.
Endoscopy (Endoscopic Survey)
The endoscopy method at high temperature is the most convenient and efficient solution for regular preventive controls as well as for inspecting an eventual damafg to the refractory lining or the internal components of a furnace. The self-developed equipment is easy to handle and and its dimensions are reasonable.
This method allows a :
thorough and complete analysis of the furnace / reactor including areas wehere vision is very bad by capturing vieo footage to analyse the damages in real time and a posteriori.
continuous control, if required of a repair process (RPR®, follow up of a flow, progress of reagents and finished products in a reactor.)
Endoscopic inspection can be carried out in all kinds of reactors, furnaces, ovens.
Repairs with S-Bricks
FIBS has developed and patented a process to repair major damage to the refractory lining of the coke oven chamber. This process requires a special pre-shaped brick (S-Bricks), coupled with ceramic welding.
The use of S-Bricks allows the coke plant to postpone major expenditure dedicated to the partial replacement of the coke oven end-flues.
The installation of the S-Bricks, at high temperature, is operated in a short lap of time and allows the coke producer to restart operations quickly after a major accident.
Records show a long lifetime (from 3 to more years for deeper repairs) for both small and tall batteries.
S-Bricks is also helpful when one needs to close the opening in the wall after cleaning of the flue bottom.
During the coking process, natural carbon deposit will take place in the upper area of the coke oven chamber including the charging hole areas.
In order to prevent the carbon from deeply entering into the porosity of the refractories, FIBS has developed the RPR GC (Glass Coating) technology. The application of RPR GC will lead to the formation of a glassy refractory layer on the surface of the refractory lining.
The "almost zero-porosity" feature of this newly created material will form a barrier to the carbon/graphite rooting and protect the original refractories from its attacks.
Reduction of Air Emissions
(Liquid Dusting of Coke Ovens)
In order to provide a suitable technology to reduce the air emissions due to the leakages between the chamber and the flues, FIBS has developed the RPR-SL Process :
With a single, and quick operation the operators can fill in all the microcracks in the heating wall of the coke oven.
The pulverization of a liquid mixture (max. 2.5 Liter per oven) into the coke oven chamber will result in the creation of silica particules that will circulate through the microcracks until the chamber has been sealed.
Thanks to a rich experience with refractories, coke ovens, and all other kinds of furnaces, FIBS can provide expertise for :
Ageing of coke oven batteries
Preventive maintenance, curative repair
Recommendations for maintenance, reconstruction
Benchmark of the best available techniques for the maintenance of industrial ovens
and many more