Refractory Bricks and Castables 6-Key Points to SelectRight Refractory
Why Right Refractory? What Experts Says? • Picking the right refractory will not only last longer, it also saves the Annual Fuel Cost. • It makes the Furnace more Efficient. • It saves a lot of Energy. • It minimizes the Shutdowns probability.
6-KeyPoints to Select the Right Refractory • Type of Furnace & Type of Fuel • Mechanical Abrasion & Impact • Operating Temp. & Service Limit • Holding Weight at High Temp. • Chemical Compatibility • Max. Heat Conservation & Min. Heat Loss
6-KeyPoints in Detail: 1. Type of Furnace & Fuel The first thing to consider is “Type of Furnace” & “Type of Fuel“. These 2 factors are the most imperative decision making key for selecting the right Refractory for furnaces/kilns/ovens.
6-KeyPoints in Detail: 2. Mechanical Abrasion & Impact A Refractory should be Strong & Well bonded in order to withstand the Mechanical Abrasion and Impact.
6-KeyPoints in Detail: 3. Operating Temp. & Service Limit If the operating temperature of a Furnace/Kiln/Oven is more than the Refractory’s Service Limit then it can cause a hazardous outcome for your project/product & your valuable people.
6-KeyPoints in Detail: 4. Holding Weight at High Temp. The design of the furnace/kiln/ovens should be designed in such a way so that it can hold its own weight at high temperatures or else the whole structure will get collapsed.
6-KeyPoints in Detail: 5. Chemical Compatibility The selection of the Refractory products should be based on the suitable specifications for a specific application. Using a wrong and unsuitable Refractory products may lead to dangerous failure in form of cracking or exploding. Continue in next Page
6-KeyPoints in Detail: 5. Chemical Compatibility There are various applications where refractories can be used, hence it’s a wise choice to select the right refractory for your requirement. Slag Resistance completely rely on the chemical reactions between the refractory and slag. Continue in next Page
6-KeyPoints in Detail: 5. Chemical Compatibility • There are 3 types of refractories with the following chemical compatibility: • Acidic Refractory: Acidic refractories are used for acidic slag condition as they reacts with basic materials. • Basic Refractory: Basic refractories are used for basic slag condition as they reacts with acidic materials. • Neutral Refractory: Neutral refractories may be used for all slag conditions.
6-KeyPoints in Detail: 6. Max. Heat Conservation & Min. Heat Loss It is always about the “Maximum Heat Conservation” & “Minimum Heat Loss” which will help you to lower your Fuel Consumption and higher your Production. Continue in next Page
6-KeyPoints in Detail: 6. Max. Heat Conservation & Min. Heat Loss The ultimate goal for selecting the right refractory for a specific application is to maximize and enhance the performance of the furnace/kiln/ovens. Continue in next Page
6-KeyPoints in Detail: 6. Max. Heat Conservation & Min. Heat Loss It is not about the higher price will always be good, what matters is the most suitable refractory for your requirement. Continue in next Page
6-KeyPoints in Detail: 6. Max. Heat Conservation & Min. Heat Loss When it comes to the Refractory Bricks, temperature gradient is the most worst enemy for them. Each brick should manage & handle the stress due to temperature gradient and withstand the temperature fluctuations in their body. It should not crack or spall at any point of time.
Test Methods for Refractories: 1. Pill Test It is used when the quantities of Refractories are more than compare to quantities of Slag. The corrosion and spread of the molten mass is observed and calculated to find out the Refractory strength against Slag Attack.
Test Methods for Refractories: 2. Immersion Method This method is used when the quantities of Refractories are far less compare to quantities of Slag. A small piece of Refractory is placed in the Molten Slag.
Test Methods for Refractories: 3. Fusion Test In this test different quantities of refractory material and powdered slag has been used to find out the deformation of refractories which are in contact with slag. So, by keeping all the above factors in mind, Furnace Manufacturers can easily select the right Refractories according to their requirement.
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