Indian Standard

REFRACTORIES FOR CHIMNEYS RECOMMENDATIONS

ICS 81.080; 91.060.40

0 BIS 1996

BUREAU
MANAK

OF INDIAN

BHAVAN,

9 BAHADUR

STANDARD-S
SHAH ZAFAR MARG

NEW DELHI 110002

September 1996

Price Group 2

Refractories Sectional Committee, MTD 15

FOREWORD
This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Refractories
Sectional Committee had been approved by the Metallurgical Engineering Division Council.
Refractories are the primary materials used in the construction of all furnaces in the ferrous and non-ferrous
industries.
These are used in the lining of ladles, hot metal mixers, metal retaining vessels and the flues and stacks through
which hot gases pass, Refractories are used for lining of boilers, pressure vessels, kilns and vessels using hot
fluids at various temperatures, In short, refractories can be termed as those materials of construction exposed to
high temperatures and corroding atmospheres and they retain their shapes and characteristics without reacting
with the molten material or the corroding atmospheres.
Refractory materials are costly and a sudden failure of any refractory may result in great loss of time, ~productand
equipment. ThereforeJhe selection of refractories suitable for a particular application is of paramount importance.
Cost-benefit-analysis is often the basis of selection of such refractories. Refractories best suited for an application
may not necessarily have the longest life. In selecting the proper refractories, a balance is struck between the
initial installed cost and in-service performance.
Steel industry uses over 70 percent of the refractories consumed in the country, However, integrated steel plants
employ a team of refractory engineers and specialists for selection and use of refractories. On the other hand,
non-ferrous sector, the glass industry and the other high temperature and corrosion intensive industries do not
always employ refractory specialists. The application of refractories in such industries is nevertheless very
critical and any premature failure may lead to long down times and loss of production.
With the above problems of unorganized sector in mind, the Refractories Sectional Committee, MTD 15 decided
to bring out an Handbook for Refractories which could bemusedas a reference book by the unorganized sector. The
Refractories Sectional Committee, MTD 15 allotted this work to a specially constituted panel, MTD 15/P-1,
Panel for the Handbook for Refractories, consisting of experts from various fields of activities which the handbook
will eventually cover, It is hoped that the work of this panel would lead to improvement of refractory engineering
practices and overall conservation of materials and energy,
The handbook will first be published in parts as recommendations; each recommendation dealing with particular
industry/process. Later on, when all recommendations are published, these would be combined to form a handbook.
It is intended to cover the refractories used in the following industries in the Handbook for Refractories:
,

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Refractories for cement kiln systems (large plants);

Refractories for mini-cement plants;
Refractories for petroleum and petrochemical industry;
Refractories for pulp and paper industry;
Refractories for lime kilns - rotary type and shaft type;
Refractories used in the primary processing of non-ferrous materials such as aluminium, copper,
zinc, lead, etc;
Refractories used in manufacture of ferro-alloys;
Refractories used in the~pouring practices for ferrous and nonferrous materials;
Refractories for incinerators;
Refractories used by the ceramic and refractory industry;
Refractories for the nuclear fuel plant;
Refractories for the glass industry;
Refractories for the glass fibre industry; and
Refractories for the iron and steel industry.
( Continued on third cover page )

IS 14374 : 1996

Indian Standard

REFRACTORIES FOR CHIMNEYS RECOMMENDATIONS

1 SCOPE
Thts standard covers the recommendations
refractories generally used for chimneys.
2

for

REFERENCES

The Indian Standards listed

adjuncts to this standard:
IS No.

below are necessary

Title

3677 : 1985

Unbonded rock and slag wool for

thermal insulation (secondrevision )

WI1 : 1967

Glossaryof terms relating to refractory

IIWlXidS

4832
(Part 1) : 1969

Chemical resistant
Silicate type

4860: 1968

Acid resistant bricks

8154: 1993

Preformed calcium silicate insulation

( for temperature up to 650C ) (first

mortars:

Brick work shell, and

Steel shell.

Depending on the following factors one of the above

construction and lining design is selected:
-

Location;

Chimm,

Flow velocity of flue gases;

of flue gases;

Pressure condition

Resulting

Mechanical load due to wind, effect of

temperature on the structure, earthquakes
and vibrational effect; and

Economical conditions considering the life

span and operation method.

inside the chimney;

chemical stresses;

OPERATION AND DESIGN FEATURES

5.3 At low temperature of operation, independent

lining supported at the base and erected as one sectton
up to the chimney top can be sufftcient. Due to the
compression resulting from the dead weight of such
lining, considerable wall thickness is necessary and
because of the thermal stresses acting on the bricks,
the chimney must be operated at lower temperature. The
advantage is the simple and uniform construction
without load bearing platforms in the concrete shell.
Disadvantages are, the large wall thickness and the risk
of cracking in the continuous brickwork bonds/joints,
which can affect the life span of the whole lining.

Chimneys, mainly free standing, are constructed in three

methods:
Reinforced concrete shell,

Composition

5.2 In case of sectional type lining, the platform to

support, the liner can be ring-shaped slabs inserted in
the concrete wall with an intermediate expansion joint
or also circular girders prefabricated with diagonal
members and supported on the shell wall.

The basic function of a chimney is to provide an escape

for gases from furnaces and to ensure that they are
delivered to a point where they are least likely to do any
harm and to provide necessary draft for the working of
the furnace/kilns. It thus becomes necessary to decide
on the form the chimney is to take and the material of
which it is to be constructed.

of flue

given

INTRODUCTION

Highest and lowest temperatures

gas on entering the chimney;

5.1 The function of the lining is to direct the flue gases,

as a thermal insulator and protector, against corrosion
of the shell and other load bearing structure. It-is mostly
designed as a sectional type, the loads of which are
transmitted to the shaft but fret standing continuous
lining is also possible.

TEIUWNOLOGY

For the purpose of this standard, the definitions

in IS 404 1 : 1987 shall apply.

Flue gas mass flow,

Mainly, reinforced concrete shell chrmney and its

refractory lining are discussed in this standard.

Part 1

revision )

5.3.1 For this reason, sectional linings are more suitable

specifically at higher temperature of flue gas operation.
5.4 For most !oads, a sectional lining which guarantees
the free thermal expansion of each section is chosen.

1s 14374 : 1996
Each section rests on the supporting platforms, using
the concrete ring beam, ring shaped girders on the beam
supported by corbels. This arrangement
results in
the formation of a cavity/annular
space between the
lining and the shell.
5.5 Oil burning plants, produce SO* gas and sulphuric
acid by catalytic conversion of SO* to SO3 The dew
point of SO3 lies between 80 and 150C. Thus, it is
necessary to protect the liner and the shell against acidic
corrosion in the chimneys operating below dew point.
6 LINING AND INSULATION MATERIALS
6.1 Due to possibility of large amount of condensate;
being deposited, the brickwork
liner requires an
acid protection
and must be provided
with an
almost tight sealing. For this purpose, brick qualities
are recommended which are having a high compressive
strength. sufficient low porosity and good chemical
resistance. Acid resistant chimney bricks should be
chosen according to their resistance to attack by acids.
Characteristics of some of the bricks are with bulk
density greater than 2.0 kg /dm3, water absorption less
than 10 percent, compressive strength between 20 and
90 N/mm2 depending on the type of brick, depending
upon the dimensions of the chimney and temperature
of the flue gases, the lining thickness is selected
judiciously, generally between 115 and 230 mm for the
sectional lining so as to form a stable shell-shaped
Structure

that these layers will not be destroyed nor their efficiency

~reduced by heat, gases and condensates.
6.5 Chimneys with higher operating temperatures
consist of an acid and heat resistant liner, an acid-proof
thermal insulation layer, aventilated intermediate annular
cavity and exterior shell.
6.6 Slabs of foamed glass or slag, diatomaceous or
mica-bricks, mats of glass and mineral wool are suitable
heat insulation materials. These~insulation materials are
placed on outwardly cantilevered bricks of the lining.
Since their thermal coefficients are different, separating
layer must be provided between the insulation layer and
the ceramic layer. This is achieved sometimes b\;
including
layer of corrugated
and board, which
disintegrates after the chimney is put into operation.
6.7 The insulating
construction
apart from low
thermal conductivity and good thermal resistance, the
characteristics required are:
a) Adequate
strength
and stability
of the
insulating layer,
b)

As low liquid absorption

c)

Satisfactory chemical resistance, and

as possible,

d) Simple installation.
6.8 Experience has shown that a satisfactory thermal
insulation can never be obtained by pouring loose
material, such as siliceous earth, vermiculite, etc, into
the space between inner liner and shell.
6.9 The installation of the insulating layer directly on
the inner surface of the shell is the most convenient
method of the application.
However, for practical
reasons the thermally
insulating
layer has to be
arranged on the outer surface ofrhe ceramic liner.

6.2 The required resistance to temperature changes

depends on the operating mode of the chimney. The
jomts of the brlckwork must be completely filled, for
which a potassium silicate mortar is generally preferred,
to Improve the bond between the filling material and
brick application of highly a!kaline silicate as a binder
for mortar is recommended. Silicate mortar is a mixture
of cement powder including hardeners and a solution
of alkali silicate in mortar satisfying the characteristics
given in IS 4832 (Part 1) : 1969. Synthetic resin mortars
are available for cases of alkaline corrosion. However,
when selecting this type of mortar, consideration must
be given to the temperature limits also.

6.10 Characteristics of different materials, such as

refractory brick, acid alkali resistant brick, mica brick.
mineral wool, etc, are given in Tables 1 to 5.
Table 1 Acid Resistant Bricks
(See IS 4860 : 1968)
SI No.

Characteristics

(1)

6.3 An improved bond strength in lining is achieved

by using either lateral or base and top tongue and groove
bricks (see Fig. 1 ).
6:4 The temperature drop frm the inside of the lining to
the exterior of the shell, across the intermediate annular
cavity. leads to thermal stresses in the ceramic lining
which should not exceed the admissible tensile load of
the bricks approximately of 1.6 fi/mm2. Consequently,
the liner and the thermal insulation layers between the
liner and the outer shell must be designed to guarantee

Requirements
(3)

(2)

i)

Water absorption.
MaU

percent,

ii)

Flexural
Min

kgicm2,

70

iii)

Compressive
kg/cm*, Min

iv)

Resistance

strength,

strength,

to acid

500
Loss in weight shall
not exceed 4 percent

IS 14374 : 1996

,/
'h

Shaped Radial Block with

Continuous Groove and Tongue

Shaped

Shaped Slab with Continuous

Groove and Tongue

Radial Block with Lateral Groove and Tongue

FI:rc
i. 1

SWlEED &UCKS FOR &MNEY

I,l;.i~W;

IS 14374 : 1996
Table 4 Mica Insulation Brick

Table 2 Calcium Silicate Block

(SeeIS8154:

(Clause6.10)

1993)

(Clause6.10)
SI
Characteristics

Sl
No.

Requirements

(2)

(1)
i)
ii)

Composition

Hydrous calcium
silicate with
suitable tibres

iii)

Density,

kg/m

iv)

Flexural

strength,

v)

Compressive

200-300
kg/cm*, A4in

strength,

vii)
viii)

(2)

600

700

strength,

iii)

Apparent
percent, Max

porosity

74

70

iv)

Shrinkage
on heating at
1 000C for 24 h, percent,
MaW

0.2

0.2

VI

Thermal
conductivity
at
mean
temperature
(kcal/mlhC)
a) 50C
b) 350C

0.12
0.18

0.12
0.22

2.0

(See IS3677: 1985)

15

( Clause 6.10 )

Thermal conductivity
at mean
temperature
( kcal/m/hC )
a) 93C
b) 149C
c) 204C

Sl No.

0.065
0.52
0.555

7
Low Iron Fireclay Brick

(1)

(2)

Requirements

i)

Bulk density,

ii)

Sulphur

Al#J,, percent,

Min

30

Fez03

Min

1.6

iii)

PCE, orton, MUX

iv)

RUL, r,C, Min

i)

percent,

30

1 300

v)

PLC at 1 350YY5h

percent, Max

vi)

Apparent

percent,

vii)

Cold crushing

porosity,

strength,

MUX

kg cm2,

kg/m,

content,

Min

percent,

200
MUX

Thermal conductiviry
at 150C
mean temperature
( kcallm/hC )

0.6
0.045

START-UP

7.2 Warm air at slowly increasing temperatures is

injected for drying.
Depending
on the chimney
dimensions the procedure can last several days. The
warming up process up to the operating temperature
should also be extended over scvcral days. In the
beginning warm air is used, which is later replaced by
steam injection. Continuous temperature measurement
of the outer and inner faces of the liner ensure that the
temperature difference in the brick stays within the
admissible tension range.

(3)

ii)

(3)

(2)

7.1 The start-up operation of a new liner must be

carefully performed because the greatest chance of
cracks occurring in the ceramic liner is during the first
start-up.

( <&use 6 10 )
Characteristics

Requirements

Characteristics

(1)

iii)

SI To.

kg/m,

Table 5 Mineral Wool Insulation

Loss in weight, percent, Mar

after 24 h heat soaking

Table 3

(4)

Cold crushing
kg/cm*, Min

4.2
17
3.45

MUX

(3)

Bulk density,

kg/cm*, Min

linear shrinkage, percent,

after 24 h heat soaking

Min

Grade 700

i)
ii)

2.4

lIeformation
at 10 percent
a) Drl\ t.unhestcd)
b) Wet ( 18 h water rmntersron)
cj Lieated ( 24 h water
immersion )
Vi)

(1)

650

Requirements
Grade 600

(3)

Service temperature,

Characteristics

No.

1 .o
18
250

Min

( Continued from second cover page )

Each recommendation will cover the following aspects of the refractory engineering:
a) Process of manufacture used;
b) Types of boilers/furnaces systems;
c) Objectives of the refractory lining;
d) Design engineering features of the furnaces;
e) Principal zones and sections of the furnaces;
f) Service conditions in different zones including service temperatures;
g) Details of lining used in various zones and sections,
h) Refractory installation practices used for the boilers/furnaces;
j)
Consumption pattern of refractories;
k) Application standards, namely Indian and other standards, design codes, stress, considerations,
etc; and
m) Miscellaneous aspects not covered from (a) to (k).
This standard covers the principle of operation of the chimney type, constructional details, types of linings,
typical properties of linings, recommended refractory materials and the methods used in the lining of chimneys.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS 2 : 1960 Rules for rounding off numerical values ( revised ). The number of significant places retained in
the rounded off value should be the same as that of the specified value in this standard.

BIS is a statutory institution established under the Bureau ofrndiun Standards,4 ct, 1986 to promote harmonious
development of the activities of standardization, marking and quality certification of goods and attending to
connected matters in the country.
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standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to
copyright be addressed to the Director (Publications), BIS.
Review of Indian Standards
Amendments are issued to standards as the need arises on the basis of comments. Standards areralso reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue
of BIS Handbook and Standards : Monthly Additions.
This Indian Standard has been developed from Dot No. MTD 15 ( 3526 ).

Pmendments
Amend No.

Issued Since Publication

Text Affected

Date of Issue

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