Presentation on Refractories By

Haleem Haider Farrukh Shahzad Muzammil Javed

Uploaded by FARRUKH SHAHZAD Department of chemical engineering UET Peshawar Pakistan..

Contents table
Refractory Classification Properties of Refractories General Manufacturing (flow sheet) Selection of Refractories Applications -Refractories in Cement Industry. Some Common Refractories

Refractory
A refractory material is one that retains its strength and do not fuse at high temperatures. ASTM defines refractories as "non-metallic materials having those chemical and physical properties that make them applicable for structures, or as components of systems, that are exposed to environments above 1,000 F (811 K; 538 C). Examples Fire clay. Silica. Chromite magnesite.

Classification
Refractories can be classified
-on the basis of chemical composition -method of manufacture -according to their refractoriness.

On the basis of chemical composition

Acidic refractories These are used in areas where slag and atmosphere are acidic. They are stable to acids but attacked by alkalis. e.g. fire clay, silica, Quartz, Zirconia.

Basic refractories These are used on areas where slags and atmosphere are basic, stable to alkaline materials but reacts with acids. e.g. Magnesia , Alumina, Dolomite.

Contd

Contd..
Neutral refractories These are used in areas where the atmosphere is either acidic or basic and are chemically stable to both acids and bases. e.g. Chromite, Carbide, Mullite.

Based on refractoriness
Low heat duty refractories For low temperature environment i.e. 1520 1630 C

Medium heat duty refractories For temperature ranging from 16301670 C

High heat duty refractories For temperature ranging from 16701730 C

Super duty refractories For temperature above 1730 C

On basis of Manufacture

Dry pressed Fused Cast Hand molded Formed Unformed

Properties
Porosity Greater the porosity of the refractory great is the chance of chemical attack of material Refractoriness or Fusion point The temperature at which the refractory fuses, so it must be higher than the operating temperature of the refractory. Strength It is the resistance of the refractory to loads tension and shear stresses. Contd..

Contd..

Thermal Conductivity

For a given composition, a better pressed,less permeable product has higher thermal conductivity. -For use in Furnace and kiln Thermal conductivity should be low. -For use in coke oven and regenerators thermal conductivity should be high.

Spalling It is the fracture of refractory due to its uneven expansion on account of heat when they are subjected to rapid heating and cooling. Contd..

Contd..
Slag Resistance It is the resistance to slag action which depends on nature of the slag and refractory. Abrasion resistance It is the resistance to abrasion which can be increased by using dense (low porosity) fine grained and wear resistance refractory. Erosion resistance Resistance to erosion due to mechanical action.

Manufacturing steps of Raw material Transportation

Grinding Pre-Treatment Calcination Stabilizer addition Mixing Bonding material Wet Mixing (14-20% water) Semi plastic Dry Mixing ( < 5% water) Moulding Hand Moulding (Wet Mixed) Machine Moulding (Dry and Semi wet Mixed) Contd..

Contd..

Drying Avoids high shrinkage and gives strength. Make refractories safe for handling. Firing Removes water of Hydration, 30% Shrinkage in Volume.

Selection of Refractories

Area of application Working temperatures Extent of abrasion and impact Stress due to temperature gradient Heat transfer and fuel conservation Cost consideration

Applications
Refractories are meant to sustain at high temperature so the very common applications are Used in furnaces such as blast furnace and coke oven. Used in boilers. Mostly used in cement industry in Preheater Rotary Kiln Burner pipe Clinker cooler

Some Common Refractories

Fire Clay refractories

Common in industry: materials available and inexpensive Consist of aluminium silicates Decreasing melting point with increasing impurity and decreasing AL2O3

High Alumina Refractories

45 - 100% alumina High alumina % = high refractoriness Applications: hearth and shaft of blast furnaces, ceramic kilns, cement kilns, glass tanks

Silica Bricks

>93% SiO2 made from quality rocks Iron & steel, glass industry Advantages: no softening until fusion point is reached; high refractoriness; high resistance to spalling, flux and slag, volume stability

Zirconia refractories

Zirconium dioxide ZrO2 Stabilized with calcium, magnesium, etc. High strength, low thermal conductivity, not reactive, low thermal loss Used in glass furnaces, insulating refractory

Question ?