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    Material Science Miscellaneous Engg. Materials: Chapter I - Refractory Materials

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    Prakash Katdare
    Refractories are inorganic materials that can withstand high temperatures without undergoing chemical changes. They are used in furnaces and other applications involving high heat. Refractories must have properties like high refractoriness (ability to withstand heat), strength, and thermal conductivity. There are different types of refractories based on chemical composition, including acid, basic, and neutral refractories containing materials like silica, magnesia, and alumina. Refractories can be manufactured as shaped bricks or as monolithic/ready-mix materials that can be molded on site. The production process involves steps like crushing, grinding, mixing, and molding.

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    Material Science Miscellaneous Engg. Materials: Chapter I - Refractory Materials

    Uploaded by

    Prakash Katdare
    106 views25 pages
    Refractories are inorganic materials that can withstand high temperatures without undergoing chemical changes. They are used in furnaces and other applications involving high heat. Refractories must have properties like high refractoriness (ability to withstand heat), strength, and thermal conductivity. There are different types of refractories based on chemical composition, including acid, basic, and neutral refractories containing materials like silica, magnesia, and alumina. Refractories can be manufactured as shaped bricks or as monolithic/ready-mix materials that can be molded on site. The production process involves steps like crushing, grinding, mixing, and molding.

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    REFRACTORY

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    Refractories are inorganic materials that can withstand high temperatures without undergoing chemical changes. They are used in furnaces and other applications involving high heat. Refractories must have properties like high refractoriness (ability to withstand heat), strength, and thermal conductivity. There are different types of refractories based on chemical composition, including acid, basic, and neutral refractories containing materials like silica, magnesia, and alumina. Refractories can be manufactured as shaped bricks or as monolithic/ready-mix materials that can be molded on site. The production process involves steps like crushing, grinding, mixing, and molding.

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    © All Rights Reserved
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    Download as pptx, pdf, or txt
    106 views25 pages

    Material Science Miscellaneous Engg. Materials: Chapter I - Refractory Materials

    Uploaded by

    Prakash Katdare
    Refractories are inorganic materials that can withstand high temperatures without undergoing chemical changes. They are used in furnaces and other applications involving high heat. Refractories must have properties like high refractoriness (ability to withstand heat), strength, and thermal conductivity. There are different types of refractories based on chemical composition, including acid, basic, and neutral refractories containing materials like silica, magnesia, and alumina. Refractories can be manufactured as shaped bricks or as monolithic/ready-mix materials that can be molded on site. The production process involves steps like crushing, grinding, mixing, and molding.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 25

    MATERIAL SCIENCE

    MODULE I
    MISCELLANEOUS ENGG.
    MATERIALS
    CHAPTER I - REFRACTORY MATERIALS
    2
    REFRACTORIES

    What is a refractory?

     Refractories are inorganic nonmetallic material which can withstand high temperature without undergoing physico
    – chemical changes. They can withstand unusually high heat as well as abrasion and the corrosive effects of acids
    and alkalis.
     They are used in furnances, stills for the cracking of petroleum, boilers, incinerators, electrolytic cells for
    aluminium production,etc.
     The refractory range incorporates fired, chemically and carbon bonded materials that are made in different
    combinations and shapes for diversified applications.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    3

    Why required?
     To minimize heat losses from the reaction chamber.
     To allow thermal energy dependent conversion of chemically reactive reactants into products because metallic vessels are not
    suitable.
    Refractory requirements:
    The refractory materials should be able to withstand
     High temperature
     Sudden changes of temperature
     Load at service conditions
     Chemical and abrasive action of phases
     The refractory material should not contaminate the material with which it is in contact.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    4

    Properties required in a refractory


     Refractoriness
    Refractoriness is a property at which a refractory will deform under its own load. It should be higher than the
    application temperatures.
    Refractoriness decreases when refractory is under load. Therefore more important is refractoriness under load (RUL)
    rather than refractoriness.
     Porosity and Slag permeability
    Porosity affects chemical attack by molten slag, metal and gases. Decrease in porosity increases strength and thermal
    Conductivity.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


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     Strength
    It is the resistance of the refractory to compressive loads, tension and shear stresses.
    In taller furnaces, the refractory has to support a heavy load; hence strength under the combined effect of temperature
    and load, i.e. refractoriness under load is important.
     Thermal conductivity
    Thermal conductivity of the bricks determines heat losses. Increase in porosity decreases thermal conductivity but at
    the same time decreases strength also.
     Bulk density:
    Decrease in bulk density increases volume stability, heat capacity.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    6

    Types of refractory materials


    A) Chemical composition

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


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     Acid / Silica refractory


    The main raw materials used is silica. They are used where slag and atmosphere are acidic. They cannot be used under basic
    conditions. These materials are well known for their high temperature load bearing capacity and are commonly used in arched roofs
    of steel and glass making furnances. These refractory materials are also resistant to slags that are rich in silica and are often used as
    containment vessels for them. But they are readily attacked by slags composed of a high proportion of CaO/MgO and contact with
    these should be avoided.
     Basic refractory
    Basic refractories are rich in magnesia (MgO); they may also contain calcium, chromium and iron compounds. The presence of
    silica is undesirable to their high temperature performance. Basic refractories are especially resistant to attack by slags containing
    high concentrations of MgO and CaO, and find extensive use in steel making open hearth furnance.
     Neutral refractory
    Neutral refractory is chemically stable to both acids and bases. They are manufactured from Al2O3, Cr2O3 and carbon. As carbon
    and graphite are susceptible to oxidation at temperatures in excess of about 8000C, they find limited application in spite of
    refractory characteristics.
    Prof.Prakash Katdare,MANET,Pune 05/25/2020
    8

    Type Approx. Fusion Temperature (°C)

    Acid Refractories Silica 1700

    Aluminium Silica (46% Al2O3 + 1780


    54% SiO2)

    Alumina (Al2O3) 2050

    Basic Refractories Magnesia 2800

    Neutral Refractories Chromite 2180

    Graphite 3000

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    9

    B) Physical form
    Broadly speaking refractory materials are either bricks or monolithic.

     Shaped refractories are in the form the bricks of some standard dimensions. These refractories are machine pressed
    and have uniform properties. Special shapes with required dimensions are hand molded and are used for particular
    kilns and furnaces. Different types are:
    i. Ramming refractory material is in loose dry form with graded particle size. They are mixed with water for use. Wet
    ramming masses are used immediately on opening.
    ii. Castables refractory materials contain binder such as aluminate cement which imparts hydraulic setting properties
    when mixed with water. These materials are installed by casting and are also known as refractory concretes.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    10

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    11

    iii. Mortars are finely ground refractory materials, which become plastic when mixed with water. These are used to fill
    the gap created by a deformed shell, and to make wall gas tight to prevent slag penetration. Bricks are joined with
    mortars to provide a structure.
    iv. Plastic refractories are packed in moisture proof packing and pickings are opened at the time of use. Plastic
    refractories have high resistance to corrosion.

     Monolithic refractories
    Monolithic refractories or Monolithics are those, which have no definite shape. In other words these are the
    refractories which can be moulded or can be given any shape as per requirement. Because of this reason, these
    products are also known as the ready-refractories and can be used as such on the site to repair or build a furnace.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    12

     Greater volume stability


     Better spalling tendency
     Elimination of joint compared with brick lining
     Can be installed in hot standby mode
     Transportion is easier
     Monolithic refractories can be installed by casting, spraying etc.
     Ramming masses are used mostly in cold condition so that desired shapes can be obtained with accuracy.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    13

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    14
    Manufacturing of Refractories

     Crushing
    The clay is crushed to 25 mm in size.
     Grinding
    The crushed materials are ground in suitable grinding machine down to 200 mesh size.
     Screening
    Screening is carried out to separate fine and coarse materials. The desired size material is used for brick making and
    oversize is recycled to grinding machine.
     Mineral-dressing
    Mineral dressing is used to purify the raw materials and producing better refractories. Purification is carried out by
    settling, magnetic separation and by chemical methods.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    15

     Storage
    Pure materials are stored in storage bins using bucket elevators,.

     Mixing
    Proper distribution of plastic material throughout the mass is necessary for easy moulding.

     Moulding
    It can be accomplished either manually or mechanically at high pressure. Refractories of low density and low strength
    can be produce by hand-moulding. While mechanical-moulding produces refractories of high density and strength.
    Deairing is essential in order to increase the density and strength of refractory by mechanical moulding.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


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     Deairing
    It is carried out by
     Allowing air inside the void space in the refractory to go out by decreasing the rate of pressure application and release
     Double-pressing the material viz. first pressed and allowed to crack. Then it is repressed again so as to close the voids.
     Applying vacuum through vents in the moulds
     Drying
    Drying is carried out to remove the moisture from refractories. Drying is carried out in tunnel dryer usually very
    slowly and under well-set conditions of humidity and temperature, depending upon the type of refractory. Rack cars
    are placed in a long tunnel and heat is supplied by steam, which passes through the tunnel.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


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     Firing
    To stabilize and strengthen the structures of refractories firing is carried out in tunnel kilns or shaft kilns or rotary
    kilns. The bricks are generally fired at a temperature as high as or higher than their arc temperature.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    18
    Properties of different refractories

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


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    Prof.Prakash Katdare,MANET,Pune 05/25/2020


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    Application and selection of different
    refractories

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    21

     Graphite - Due to its high temperature stability and chemical inertness graphite is a good candidate for a refractory
    material. It is used in the production of refractory bricks and in the production of “Mag-carbon” refractory bricks
    (Mg-C.) Graphite is also used to manufacture crucibles, ladles and moulds for containing molten metals.

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    22
    Refractories used in various furnances

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


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    Prof.Prakash Katdare,MANET,Pune 05/25/2020


    24

    Prof.Prakash Katdare,MANET,Pune 05/25/2020


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    Question

     What are refractories? Explain their various types and their uses.(8 marks)
     IMU Dec. 2014/ Jan 2015
     IMU May/ June 2016

    Prof.Prakash Katdare,MANET,Pune 05/25/2020

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