Navigating the complexities of repairs involving corrosion, thermal expansion and contraction, shrinkage, installation failures, and mechanical wear can be challenging. This is where our team's spirit of experimentation comes into play, and custom-made refractory anchors become the solution.
When developing new solutions, trial and error is a significant part of our brainstorming and ideation process. While some businesses may view this method as inefficient, fearing it could consume time and resources without guaranteed results, the SILICON team of engineers considers it a hallmark of innovation, recognizing its essential role in driving progress.
"Our approach to brainstorming and ideation starts with a deep understanding of the customer’s problem. We take the time to analyze the requirements, constraints, and real-world challenges before generating potential solutions. Instead of aiming for a perfect concept right away, we prioritize rapid ideation, developing multiple solutions early on. This allows us to engage with the customer quickly and establish a feedback loop as soon as possible.
By iterating based on real user input, we ensure that the design evolves to meet their specific needs and preferences effectively."Mink - Product Design Engineer
This philosophy underscores our commitment to innovation and customer-centric design, ensuring that our solutions are both practical and tailored to meet the unique challenges faced by our clients.
Upon close examination of the picture, you will notice a brand-new custom-made SpeedBolt®, carefully crafted to fulfill our customer's unique requirements. This valued customer has been partnering with us since 2015. This time, they approached us not only for an anchor order but also for a new anchor solutions, including Rapid Arc Welding Installation. After several meetings with the customer to thoroughly understand their requirements, it took us approximately two weeks to develop the final solution.
Problem: The customer needed an anchor suitable for a three-layer refractory lining, which would help them easily identify where to cast each layer. They required a clear reference point for where each layer should end.
Solution: We designed and produced an anchor that was visible during installation, ensuring optimal holding power and enabling the customer to accurately cast each layer with confidence. The new design successfully met their requirements.
When you need an urgent alternative for an existing refractory anchor, but your production method does not deliver the product on time, SILICON can provide a solution. This trusted customer has been with us since 1982, so they reached out to us, confident in our expertise in emergency solutions. Our team of engineers knew exactly what to do to come up with an effective alternative.
Problem: Typically, this is a cast product. However, the production process was taking too long this time.
Solution: We had to rethink the product using the materials and tooling we had available. We offered an alternative made from plate and wire. While the cast anchors would have taken more than six weeks to arrive, our solution was ready in just one week! Additionally, the new fabricated anchor had enhanced flexing capabilities.
Corrosion is one of the main driving reasons why we need to continuously innovate and adapt industry solutions. It presents significant challenges that require creative and effective responses to ensure the longevity and reliability of our products. We have been in contact with this customer since 2017, and their trust in our expertise has been unwavering. When they encountered a highly corrosive issue in their units, we knew we had to act swiftly. The idea for this anchor came to us within two days, demonstrating our team's ability to quickly devise solutions that excel in real-world applications.
Problem: The customer faced a highly corrosive issue in Sulfur Recovery Units (SRU).
Solution: For this anchor we developed a different design and chose a material that lasted much longer. The anchor was designed for a tube sheet. We placed the anchor in the center position between three pipes, ensuring it would hold in the 120° spread of the refractory applied to the tube sheet.
Introducing the Crook anchor! Our customer needed to install this anchor without direct access to the unit. The development of this refractory anchor took just a couple of weeks from concept to final version. The most challenging part was achieving the right radius and step, which required us to 3D print the anchor and conduct real-life fit tests.
Problem: These anchors should have been installed without the shutdown. The customer couldn't access the unit for the installation, so the anchors had to be installed from the outside.
Solution: We aimed to replicate the process of casting refractory from the outside. The anchors had to be installed through pre-drilled holes in the shell. These holes couldn't be too large, as that would compromise the shell's integrity and require covering later. A V-anchor wasn't suitable because the necessary hole would be too big. We minimized the hole size while providing an anchor with similar mass and spread to a V-anchor. The radius on the corrugation was designed to pass the anchor through a minimal Ø18 hole and 25mm thickness, achieving the desired anchor coverage. The anchor was welded to a back plate, which acted as a cover for the hole.
Another valued customer, who has been working with us for several years, requested a custom-made solution suitable for specific refractory lining.
Problem: The customer needed a solution for a very thick refractory lining, exceeding one meter in thickness.
Solution: Our team devised a straightforward yet innovative solution – a SpeedBolt® of 1.25 meters. This custom-made SpeedBolt® was specifically designed to provide the necessary support for the thick refractory lining.
“Over the past 40 years, we have accumulated a vast array of specialized tooling, enabling us to manufacture a wide variety of products efficiently. By integrating modern technologies such as CNC wire-bending, CNC turning, and laser cutting, we can produce almost anything you can imagine.”
Koen van Mil - Production and Tooling Engineer
By starting this article with one modification of the SpeedBolt® and ending with another, it proves that there is a refractory solution to every refractory problem. The SILICON team of engineers is dedicated to finding innovative solutions for you. Having an expert who knows how to efficiently address these challenges can significantly impact your company's overall success.
