2012 08 16 training material refractory

training material refractory

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What is refractory materials?

History

Historical origins in the demand for refractories (Requirement) - Human ancestors used cooking fire by rubbing sticks, and thus create a derivative in the

Neolithic Age to the furnace

refractories

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Temperature distribution on the surface of space shuttle

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Refractory Conventional material?

v.s

Advance material?

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Definition-1

According to Japanese Standard (JIS R2001-1985):

(1) Shape Refractories (General Refractory Bricks): Must be

able to use the high temperature above 1500℃

(2) Monolithic Refractories : Casting、Plastic、Mortar…et,al (3) Insulating Brick

(2) and (3) must be able to use the high temperature above

800℃

Definition-2

According to ASTM (C71) of the definition:

The refractory is a kind of non-metallic materials, their

chemical properties and physical properties suffices as the

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Shape Refractory

Monolithic Refractory

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Important Properties of Refractory：

Bulk Density Pore Size

Distribution Crystal Phase High-Temp CCS Refractoriness

Porosity Permeability Hydration High-Temp MOR Thermal

Conductivity Permanent Linear

Change

Electrical Conductivity Oxidization

Carbon Monoxide Resistance

Abrasion Resistance

Thermal Shock/Spalling

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Raw Materials of Refractory

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Where the material above the melting point at 1580 ℃ , can be used as refractory materials Lower melting point of raw materials, processing to remove impurities impurities, not only used to the fire industry requirements but also for raw materials

In periodic table, only 9 elements are in the 1000-1500 ℃ of melting point , the melting point of 15 elements are between 1500-

2000 ℃ , 10 elements are in above 2000 ℃ 22 refractory oxides could be formulated into 9200 kinds of binary compound, of which only 1,010 kinds are refractory (11%) Ternary compounds can be synthesized about 2870 kinds of refractory materials

Oxide Raw Materials of Refractory

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Non-Oxide Raw Materials of Refractory

Raw Materials of Refractory

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Synthesis Materials of Refractory

Table of raw materials commonly used in English v.s

高山令土 KAOLIN 耐火黏土 FIRE CLAY 球黏土 BALL CLAY 黏土熟料CLAY CHAMOTTE 鋁樊土CALCINED BAUXITE 藍晶石 KYANITE

碳線石 SILLIMANITE 莫來石 MULLITE 煅燒氧化鋁CALCINED ALUMINA 活性氧化鋁 REACTIVE ALUMINA

剛玉 CORUNDUM 其他氧化鋁質材料

OTHER ALUMINAS

石英砂 SILICA SAND

碳灰 FUME SILICA

腊石 PYROPHYLLITE 菱鎂石 MAGNESITE 輕燒鎂粉 CALCINED MAGNESIA

鎂砂 MAGNESIA 鎂橄欖石 FORSTERITE

滑石 TALC 綠泥石 CHLORITE 白雲石 DOLOMITE 鎂白雲石 MAGNESIO-DOLOMITE 金各礦石 CHROMITE

鎂金各砂 MAGNESIA-CHROME SINTER 鎂鋁尖晶石 MAGNESIUM ALUMINATE SPINEL

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SiO2SiO2 ‧(Al2O3) Clay-base SiO2 ‧(Al2O3) Zirconium-base ZrO2

Neutral R2O3

Aluminates-base Al2O3 ‧(SiO2) Chrome-base Cr2O3 ‧(MgO )

Spinel Al2O3 ‧ MgO

Classification of refractory – By Chemistry

Basicity = ( CaO +MgO+MnO+FeO)/ ( SiO2 +Al2O3+Fe2O3)

Classification of refractory

(Gunning mixes)

Fig 1 Construction

Fig 2 Gunning Machine

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(Castables)

Fig 1.LD Vibration Mold Fig 2.LD Construction

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Storage Yard of Raw material

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Jaw-Crusher

Friction Press

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Hydraulic Press

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Kiln Furnace

Tunnel Kiln Shuttle kiln

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Application in Steel Plant

Coke Oven

Regenerator (Fire-Clay Brick)

Stack (Fire-Clay Brick)

Combustion Fuel Chamber

Usage of andalusite in the hot blast stove lining

Lowest zone of checkerwork and

checker chamber walls:

chamotte bricks 35-45 % Al 2 O 3

Medium zone of checkerwork

and checker chamber walls:

AF48 or AF53

Upper zones of checkerwork

and checker chamber walls:

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Top cone area

Upper stack or alternatively

Lower stack or Preferably

Tuyere band Taphole area Ceramic cup

Sidewall of ceramic cup

Usage of andalusite based bricks

in the internal lining of blast furnace

Hot Metal Corrosion Resistance

Key Parameters:

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○ MUD Application

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Hot Metal Runner

Main Runner Slag Runner

Torpedo Car

Runner

Main Runner

Working Layer

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Application of andalusite based bricks

in lining of torpedo ladle

Impact area:

A53R / AE67R (phenolic resin bonded) A62 / AE74 (ceramic bonded)

• Main and lower part of the cone:

• Metal level of upper part of the cone:

AB73 (ceramic bonded) AB67P (phosphoric acid bonded) AB63R (phenolic resin bonded)

Slag level of upper part

of the cone:

AE74 (ceramic bonded)

AE74P (phosphoric acid

bonded)

AE67R (phenolic resin bonded)

Safety lining:

AF48 / AF53

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Converter

Mouth

Tapping Hole Side Wall Charging Side Blower Bottom

Permanent

Layer

MgO-C MgO-C MgO-C MgO-C MgO-C MgO-C MgO-C MgO

Application of andalusite based bricks

in steel ladle

Dr Wolfgang Walz

Working lining of metal zone (2):

AB73 (ceramic bonded)

AB67P (phosphoric acid bond.) AB63R (phenolic resin bonded)

Working lining on the bottom (3):

A53R / AB63R (phenolic resin b.)

A58P / AB67P (phosphoric acid b.)

A62 / AB73 (ceramic bonded)

Safety lining of slag zone (8):

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Ladle

Slag Line Side Wall

Battom

Impact zone Tapping Hole

Insulation Layer

RH Refining

Application of andalusite based shaped refractories in tundish

Impact pad area:

Dams and walls:

A62 / AE74

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Charging Furnace

Thanks for your attention