Boiler Refractory Damage by Saltwater

[Texicanslim]

Hello All,

Im am in desperate need of some help here regarding castable refractory in a boiler.

My firm is working to repair several boilers that were partially submerged during Hurricane Ike (Houston area).

These units were awaiting shipment and were partially submerged up to and including the superheaters. The SH's were encased in cast refractory (Resco Hi-Strength 25)and spent approximately 24 hours completely submerged in the salt-water.

Initial testing has been conducted to determine shrinkage and density effects; all test results were within design parameters. (samples were fired to 2200 DegF prior to examination)

I am mostly looking for any information or articles relating to the inspection and evaluation of this type material following exposure to saltwater. Either links or direct information would be greatly appreciated.

 

[unclesyd]

Have you contacted RESCO?

Were your tests on materials taken from an affected boiler?

Can you determine the depth of penetration of the refractory by the salt water?

Two things that could be problem are the added water and the fact that NaCl melts around 1500F. My question of water is will a dry out period remove the excess water tied up by NaCl. My worry is also with the high silica in the castable as NaCl is an ingredient in some molten salt baths that remove silica.

 

[EdStainless]

You need to take some core samples and look at depth profiles of Cl content. I share Syd's concern about molten salts forming in use. Many of these salts will also form low melting eutectics with various metals cause catastrophic damage at temperatures well below typical operating levels.

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