1 Refractories Any material which can withstand high temperature Importance in

construction of 1. Metallurgy 2. Engineering 3. Chemical industries

2 Introduction Refractory is any material which can withstand high temperature, without
softening or suffering a deformation in shape. Main Objective 1. To confine heat e.g. to resist
loss of heat. 2. To resist abrasive and corrosion action of molten metals, slags and gases at
high temperatures, without undergoing softening or distortion in shape. Uses 1. Construction
of the linings of the furnaces, tanks, converters, Kilns, crucibles, ladles etc. 2. Manufacture of
metals (Ferrous or non-ferrous), cement, glass, ceramics, paper, steel etc.
3 Characteristics of Refractories A good refractory posses following characteristics: 1. Be
infusible at the temperature to which it is liable to be exposed. 2. Chemically inerts towards
corrosive action of gases, metallic liquids, and slags. 3. Resist the abrasive action of flue
gases, flames, etc. 4. Be able to withstand the overlying load of structures at the operating
temperature. 5. No crack 6. No loss in size. 7. Expand and contract uniformly, with
temperature rise and fall respectively.
4 Classification of Refractories 1. Acid Refractories: important members of this group is
Alumina, Silica gel fireclay refractories. 2. Basic Refractories: Cao, MgO 3. Neutral Refractories:
made from weakly acid/basic materials like Chromite(FeO. CrO2), Zirconia (ZrO2) Important
members of this group are Graphite, Chromite, Zirconia and carborundum (SiC) refractories.
5 Properties of Refractories 1. Refractoriness 2. Strength or Refractoriness-under load 3.
Dimensional Stability 4. Chemical Inertness 5. Thermal Expansion 6. Thermal Conductivity 7.
Porosity 8. Thermal Spalling 9. Resistance to abrasion or corrosion 10. Electrical conductivity
11. Heat capacity 12. Texture 13. Permeability
6 Properties of Refractories (contd.) 1. Refractoriness Ability of a material to withstand the
heat, without appreciable deformation or softening under particular service conditions. In
general, measured as the softening or melting temperature of the material. As most of the
common refractory materials are mixtures of metallic oxides, so they do not have a sharp
fusion temperature. Pyrometric Cones Test (Segar Cones Test) The softening temperature of
the refractory material are, generally, determined by using Pyrometric cones test. Expressed
in terms of Pyrometric cone Equivalents (PCE). Softening temperature (Material to be used as
refractory) >> Operating temperature
7 Pyrometric Cones Test (Segar Cones Test) The refractoriness is, usually, determined by
comparing the behaviour of heat on cone of material to be tested with that of a series of
Segar cones of standard dimensions. Segar Cone Pyramid Shaped having triangular base 38
mm high and 19 mm long sides Segar cones melt or fuse at definite temperature when
heated under standard conditions of 10°C / min. So the temp. at which the fusion or
softening of the test cones occurs is indicated by its apex touching the base. The PCE value of
the given refractory is taken as the no. of the standard cone, which fuses along with the test
cone.
8 Segar Cones Number Fusion temperature 1 1110 2 1120 3 1140 4 1160 5 1180 6 1200 7
1230 8 1250 9 1280
9 Properties of Refractories (contd.) 2. Strength or Refractories-under load (RUL):
Refractories used in industrial furnaces have invariably to withstand varying loads of the
products, being manufactured at high operating temperature. It is, therefore, essential that
refractory materials must also possess high mechanical strength, even at operating
temperature, to bear the maximum possible load, without breaking. Some refractories like
FIRECLAY, High Alumina Bricks softens gradually over the range of temperature, but under
appreciable load, they collapse, far below their true fusion point, as determined by segar
cones. On the other hand, other refractories such as Silica Bricks softens over a relatively
narrow range of temperature and exerts good load bearing characteristics close to their
fusion points.
10 R.U.L. Test Refractories-under load Test R.U.L. test is performed by applying a constant
load of 3.5 or 1.75 kg/cm2 to the refractory specimen (of size 5 cm2 and 75 cm high) and
heating in a carbon-resistance furnaces at a standard rate of 10°C / min. The record of the
height of the specimen vs. temperature is made by a plot, until the test-piece deforms or
collapses by 10%. The R.U.L. is expressed as the temperature at which 10% deformation takes
place.
11 Properties of Refractories (contd.) 3. Dimensional Stability Resistance of a material to
any volume changes, which may occur on its exposure to high temperature, over a prolonged
time. These dimensional changes may be permanent (irreversible) or reversible. Irreversible
changes may result either in the contraction or expansion of a refractory. The permanent
contraction is due to the formation of increasing amounts of liquid from the low fusible
constituents of the refractory brick, when it is subjected to a long period of soaking at the
high temperature. The liquid gradually fills the pores of the refractory body, causing a high
degree of vitrification and shrinkage.
12 Properties of Refractories (contd.) 4. Chemical Inertness A refractory should be selected
that is chemically inert in use and does not form fusible products with slags, fuel ashes,
furnace gases, etc. usually, the environment in most furnaces are either acidic or basic. It is
not recommended to employ Acid refractory in contact with an alkaline (basic) product or
vice-versa.
13 Properties of Refractories (contd.) 5. Thermal Expansion Solid materials, on heating,
expands and on cooling it contracts. So in the designing of the practical furnaces, a refractory
material should have least possible thermal expansion as the expansion affects all dimensions
(e.g. length, area, volume) of the body. 6. Thermal Conductivity In industrial operations,
refractory materials of both high thermal conductivity and low thermal conductivity are
required, depending upon the type of the furnaces. In most cases, furnaces is lined with
refractories of low heat conductivities to reduce the heat losses to the outside by radiation;
otherwise maintenance of high temp. inside furnaces will become difficult.
14 Properties of Refractories (contd.) 6. Thermal Conductivity A good heat conductivity of
the refractory material is desirable for effective heat transmission in furnace construction. The
densest and least porous brick have the highest thermal conductivity, owing to the absence
of air-voids. On the other hand, in porous bricks, the entrapped air in the pores, acts as a
non-heat conducting material. For making porous refractory bricks, the refractory material is
mixed with a liberal amount of carbonaceous material, then mould into bricks and burnt. The
carbonaceous material burns off; leaving behind minute voids, which enhances the insulating
quality.
15 Properties of Refractories (contd.) 7. Porosity All refractories contain pores, either due to
manufacturing methods or deliberately made ( by incorporating saw-dust or cork during
manufacture). Porosity is the ratio of its pore’s volume to the bulk volume. W- D W-A P = X
100 W = Wt. of saturated specimen. D = Wt. of Dry specimen. A = Wt. of saturated specimen
submerged in water. Porosity is an important property of refractory bricks, because it affects
many other characteristics, e.g. chemical stability, strength, abrasion-resistance and thermal
conductivity. In a porous refractory, molten charge, slags, gases etc. are likely to enter more
easily to a greater depth and may react and reduces the life of the refractory material.
16 Properties of Refractories (contd.) 7. Porosity Porosity decreases Strength resistance to
abrasion resistance to corrosion/ penetration by slags, gases ec. Porosity increases resistance
to thermal spalling ( i.e. thermal shock-resistance The densest and least porous brick have the
highest thermal conductivity, owing to the absence of air-voids. In porous bricks, the
entrapped air in the pores, acts as a non-heat conducting material. A good refractory, in
general , should have low porosity.
17 Properties of Refractories (contd.) 8. Thermal Spalling Breaking, cracking, peeling off or
fracturing of a refractory brick or block, under high temperature. So good refractory must
show a good resistance to thermal spalling. Spalling is caused by rapid changes in
temperature, which causes uneven expansion and contraction within the mass of refractory,
thereby leading to development of internal stresses and strains. Spalling may also be due to
slag penetration into the refractory brick, thereby causing variation in the coefficient of
expansion. Spalling can be decreased by • Using high porosity, low coefficient of expansion
and good thermal conductivity refractory bricks. • Avoiding sudden temp. changes. • By
overfiring the refractories at high temp. for a sufficiently long time, whereby mineral inversion
et. takes place making the material less susceptible to uneven expansion or contraction, when
heated.
18 Properties of Refractories (contd.) 9. Resistance to abrasion or erosion good refractory
must show a good resistance to abrasion or erosion. 10. Electrical conductivity good
refractory must show a low electrical conductivity. Except graphite, all other refractories are
poor conductors of electricity. 11. Heat capacity Heat capacity of any substance depends on
(a) Thermal conductivity (b) Specific heat (c) Specific gravity
19 Properties of Refractories (contd.) 12. Texture Course or light –textured bricks, because
of their large porosity, are light in weight and hence, they are more resistant to sudden
changes in temperature. However, their crushing strength is low. Such bricks are more
susceptible to the action of abrasion and corrosion. on the other hand, fine or dense-textured
bricks possess low porosity and hence are light in weight. These are not so resistant to
sudden changes in temp. However, such bricks are less susceptible to action and corrosion.
20 Properties of Refractories (contd.) 13. Permeability Measure of rate of diffusion of gases,
liquids and molten solids through a refractory. Permeability depends upon the size and
number of connected pores. Permeability α temperature α 1 - - - - - - - - - - - - - - - - - - - - -
- - - - - - Viscosity of molten material
21 Manufacture of Refractories Consist of following steps 1. Crushing: Raw material in the
form of big lumps are crushed to about 25 mm size. 2. Grinding: The crushed material are
grinded in grinding machine down to 200 mesh size. 3. Screening: Purify the refractory raw
materials and remove unwanted materials from the raw materials and this is done by (a)
settling (b) magnetic separation (C) Chemical Methods 4. Storage: After screening and
mineral dressing, pure material is stored in storage bins with bucket elevators. 5. Mixing: It is
done so that proper distribution of the plastic materials throughout the mass takes place.
This makes moulding easier. 6. Moulding: Moulding may be done either manually or
mechanically by the application of high pressure. Hand- moulding produces refractories of
low density and low strength. Mechanical- moulding produces refractories of high density
and strength.
22 Manufacture of Refractories (contd.) Consist of following steps In order to increase the
density and strength of refractory by mechanical moulding, the de-airing of refractory
material is essential. De-airing is done by: (i) Applying vacuum through vents in the moulds
(ii) by allowing air inside the void space in the refractory to go out by decreasing the rate of
pressure application and release of air. (iii) By double-pressing: the material is first pressed
and allowed to crack. Then, it is pressed again so as to close the voids. 7. Drying: Removal of
moisture is done under well set conditions of humidity and temperature, depending upon the
type of refractories. Drying is usually carried out in tunnel dryers. 8. Firing: To stabilize and
strengthen the structure of refractories, Firing is done. The bricks are , generally, fired at a
temperature as high as or higher than their use temperature. It is done in tunnel Kilns or
Shaft Kilns or rotary kilns. Firing temperature: 14800 C for high-fired super duty bricks 17000
C for kaolin bricks 18700 C for basic bricks