CHAPTER 12 Introduction to refractories

12.0 Background

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12.1 Shaped refractories

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12.2 Unshaped refractories

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12.3 Classification

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12.3.1 Fireclay refractory

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12.3.2 Silica refractories

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12.3.3 High-alumina refractories

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12.3.3.1 Mullite refractories

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12.4 Properties of refractory materials

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12.4.1 Apparent porosity

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12.4.2 Bulk density

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12.4.3 Modulus of rupture (MOR)

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12.4.4 Hot modulus of rupture (HMOR)

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12.4.5 Cold crushing strength

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12.4.6 Pyrometric cone equivalent (PCE)

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12.4.7 Thermal expansion

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12.4.8 Thermal expansion under load (TEUL) and creep

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12.4.9 Thermal conductivity

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12.5 Quality assessment of refractory materials

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12.5.1 Physical analysis

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12.5.2 Chemical and mineralogical analysis

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12.6 Refractory for pot furnace lining

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Table 12.1: Details of refractories used in open pot furnace

Refractory type Application area
Red bricks Level foundation, tri area, chimney base and outer sides of the
flue paths
IS-6 bricks Flue path area after recuperator
IS-8 bricks Crown, flue path area
Silica bricks Crown and furnace wall between pillars
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Refractory type Application area

Sillimanite block Furnace floor, pillars, skewbacks and burner block
Mortar/ramming As applicable during construction of different parts of the furnace
masses lining, using different refractories and anticorrosive surface
coating

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12.6.1 Sillimanite block

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Table 12.2: Properties of Sillimanite refractories

Parameter Value
A12O3 60% minimum (preferably
around 70%)
Fe2O3 0.5% maximum
PLC (at 1500 °C) ± 0.2%
Apparent porosity 15%–17%
Cold crushing strength 400 kg/cm2 minimum
Bulk density 2.50 g/cc minimum
RUL 1580 °C
HMOR (1400 °C) 60–65 kg/cm2
Mullite 50% minimum (indicative)
Notes: PLC—permanent linear change
RUL—refractoriness under load

12.7 Improving operating life of the furnace lining

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12.7.1 Consistent quality

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12.7.2 Using larger refractory blocks

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12.7.3 Mortar quality

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12.7.4 Proper dimension

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12.7.5 Use of anticorrosive coating

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