REFRACTORIES

Introduction
Refractory is a material which retains strength
at high temperatures
Refractory is a type of ceramic material
They have high resistance to heat
High temperature service material

Classification of Refractory
On the basis of fusion temperature ranges
a) Refractory
b) High temp refractory
c) Super refractory
On the basis of chemical composition
a) Acid refractory
b) Basic refractory
c) Neutral refractory

Properties of refractory
Refractoriness
It is a property at which a refractory will deform
under its own load.
PCE Test to measure refractoriness
The test cone of height 38mm and 19mm base is
kept alongside similar sized standard cones
All cones are heated at 10 C
When test cone loses its shape, one of the
standard cone loses its shape

Properties of Refractory
Thermal expansion and Contraction
Expansion and contraction of refractory with
changing temperature should be negligible.
Spalling Resistance
Breaking or Cracking of refractory is spalling.
Thermal, mechanical and structural factors cause
spalling
Thermal spalling occurs due to uneven expansion or
contraction
Mechanical spalling is due to rough operation of
furnace

Properties of Refractory
Porosity
Refractories are porous
Porosity is defined as ratio of its pore volume to
the bulk volume
Porosity occurs due to presence of raw materials
such as saw dust, hay etc
Thermal conductivity
Refractories act as insulators and minimize heat
loss in furnace
Thermal conductivity depends on composition

Properties of Refractory
Corrosion and Erosion resistance
Corrosion is due to chemical action and
erosion is due to mechanical action
Reaction between the slag and refractory
linings at high temperature causes corrosion
A carbonaceous refractory has resistant to
corrosion

 Erosion is due to mechanical failure like

improper loading of reactants into furnace
Erosion causes potholes which in turn creates
corrosion
Zircon refractories resist erosion compared to
carbon and silica refractories

Properties of Refractory
Load bearing strength
Heavy loads are charged into furnaces and
therefore refractory should withstand heavy
loads
Silica refractories withstand load at high
temperatures

RUL Test
This test is to measure safe temperature limit up
to which a refractory can be operated
Test is done under a rectangular specimen of 5cm
base and 75cm height at a pressure of 1.75
kg/cm2
Refractory is heated at 10 C per minute and as it
softens it decreases in height
When 10% decrement of height is observed
temperature is noted
This is safe temperature under which a refractory
can operate

Manufacture of Refractory Materials

Raw material processing consists of
crushing, grinding. Material is further purified
by froth flotation and other techniques. Then
raw materials are dried and calcined
Blending various materials are blended
together to make homogenous mixture using
small amount of binder and water

 Forming or Molding this process gives

desired shape to refractory.
Drying this is done to remove moisture
formed in molding process to prevent
refractory from cracking
Firing the refractory after drying is fired to
stabilize and strengthen their structures

Some Refractory Materials

Fire clay bricks
55% silica and 35% alumina along with small
constituents of CaO, MgO etc
Molded manually or mechanically
Low porosity and good resistance to thermal
spalling
Used in open hearth furnaces, blast furnaces
and kilns

Some Refractory Materials

Silica bricks
95% silica and 3% CaO by weight
High strength, low porosity, good resistance to
thermal spalling
Used in coke oven furnaces, electric furnaces
and retorts

Some Refractory Materials

High Alumina Bricks
Alumina content > 50%
Possess high refractoriness and refractoriness
under load
Inert to gases like CO2, Hydrogen and natural
gas at high temperatures
Used in linings of Portland Cement Kilns

Some Refractory Materials

Magnesite bricks
Most commonly used basic refractories
90% MgO and rest is additives and binding
materials
High strength and can be used up to 2000 C
without load. Under load they can be used up
to 1500 C
Used in furnaces for melting ores and refining
metals such as gold, silver etc

Some Refractory Materials

Zirconia bricks (Neutral Refractory)
Obtained by heating zirconium dioxide with
colloidal zirconia at 1700 C using alumina or
clay as binding material
Low thermal conductivity, high temperature
stability and are very inert
Used for glass furnaces and high frequency
electric furnaces

Some Refractory Materials

Carborundum bricks (Neutral Refractory)
Prepared by reacting 60% Silica with 40%
carbon at 2200 C
High heat conductivity and abrasion resistance
Used in metallurgy furnaces for non ferrous
metals