MATERIAL SCIENCE
MODULE I
MISCELLANEOUS ENGG.
MATERIALS
CHAPTER I - REFRACTORY MATERIALS
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REFRACTORIES
What is a refractory?
Refractories are inorganic nonmetallic material which can withstand high temperature without undergoing physico
– chemical changes. They can withstand unusually high heat as well as abrasion and the corrosive effects of acids
and alkalis.
They are used in furnances, stills for the cracking of petroleum, boilers, incinerators, electrolytic cells for
aluminium production,etc.
The refractory range incorporates fired, chemically and carbon bonded materials that are made in different
combinations and shapes for diversified applications.
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Why required?
To minimize heat losses from the reaction chamber.
To allow thermal energy dependent conversion of chemically reactive reactants into products because metallic vessels are not
suitable.
Refractory requirements:
The refractory materials should be able to withstand
High temperature
Sudden changes of temperature
Load at service conditions
Chemical and abrasive action of phases
The refractory material should not contaminate the material with which it is in contact.
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Properties required in a refractory
Refractoriness
Refractoriness is a property at which a refractory will deform under its own load. It should be higher than the
application temperatures.
Refractoriness decreases when refractory is under load. Therefore more important is refractoriness under load (RUL)
rather than refractoriness.
Porosity and Slag permeability
Porosity affects chemical attack by molten slag, metal and gases. Decrease in porosity increases strength and thermal
Conductivity.
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Strength
It is the resistance of the refractory to compressive loads, tension and shear stresses.
In taller furnaces, the refractory has to support a heavy load; hence strength under the combined effect of temperature
and load, i.e. refractoriness under load is important.
Thermal conductivity
Thermal conductivity of the bricks determines heat losses. Increase in porosity decreases thermal conductivity but at
the same time decreases strength also.
Bulk density:
Decrease in bulk density increases volume stability, heat capacity.
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Types of refractory materials
A) Chemical composition
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Acid / Silica refractory
The main raw materials used is silica. They are used where slag and atmosphere are acidic. They cannot be used under basic
conditions. These materials are well known for their high temperature load bearing capacity and are commonly used in arched roofs
of steel and glass making furnances. These refractory materials are also resistant to slags that are rich in silica and are often used as
containment vessels for them. But they are readily attacked by slags composed of a high proportion of CaO/MgO and contact with
these should be avoided.
Basic refractory
Basic refractories are rich in magnesia (MgO); they may also contain calcium, chromium and iron compounds. The presence of
silica is undesirable to their high temperature performance. Basic refractories are especially resistant to attack by slags containing
high concentrations of MgO and CaO, and find extensive use in steel making open hearth furnance.
Neutral refractory
Neutral refractory is chemically stable to both acids and bases. They are manufactured from Al2O3, Cr2O3 and carbon. As carbon
and graphite are susceptible to oxidation at temperatures in excess of about 8000C, they find limited application in spite of
refractory characteristics.
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Type Approx. Fusion Temperature (°C)
Acid Refractories Silica 1700
Aluminium Silica (46% Al2O3 + 1780
54% SiO2)
Alumina (Al2O3) 2050
Basic Refractories Magnesia 2800
Neutral Refractories Chromite 2180
Graphite 3000
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B) Physical form
Broadly speaking refractory materials are either bricks or monolithic.
Shaped refractories are in the form the bricks of some standard dimensions. These refractories are machine pressed
and have uniform properties. Special shapes with required dimensions are hand molded and are used for particular
kilns and furnaces. Different types are:
i. Ramming refractory material is in loose dry form with graded particle size. They are mixed with water for use. Wet
ramming masses are used immediately on opening.
ii. Castables refractory materials contain binder such as aluminate cement which imparts hydraulic setting properties
when mixed with water. These materials are installed by casting and are also known as refractory concretes.
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iii. Mortars are finely ground refractory materials, which become plastic when mixed with water. These are used to fill
the gap created by a deformed shell, and to make wall gas tight to prevent slag penetration. Bricks are joined with
mortars to provide a structure.
iv. Plastic refractories are packed in moisture proof packing and pickings are opened at the time of use. Plastic
refractories have high resistance to corrosion.
Monolithic refractories
Monolithic refractories or Monolithics are those, which have no definite shape. In other words these are the
refractories which can be moulded or can be given any shape as per requirement. Because of this reason, these
products are also known as the ready-refractories and can be used as such on the site to repair or build a furnace.
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Greater volume stability
Better spalling tendency
Elimination of joint compared with brick lining
Can be installed in hot standby mode
Transportion is easier
Monolithic refractories can be installed by casting, spraying etc.
Ramming masses are used mostly in cold condition so that desired shapes can be obtained with accuracy.
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Manufacturing of Refractories
Crushing
The clay is crushed to 25 mm in size.
Grinding
The crushed materials are ground in suitable grinding machine down to 200 mesh size.
Screening
Screening is carried out to separate fine and coarse materials. The desired size material is used for brick making and
oversize is recycled to grinding machine.
Mineral-dressing
Mineral dressing is used to purify the raw materials and producing better refractories. Purification is carried out by
settling, magnetic separation and by chemical methods.
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Storage
Pure materials are stored in storage bins using bucket elevators,.
Mixing
Proper distribution of plastic material throughout the mass is necessary for easy moulding.
Moulding
It can be accomplished either manually or mechanically at high pressure. Refractories of low density and low strength
can be produce by hand-moulding. While mechanical-moulding produces refractories of high density and strength.
Deairing is essential in order to increase the density and strength of refractory by mechanical moulding.
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Deairing
It is carried out by
Allowing air inside the void space in the refractory to go out by decreasing the rate of pressure application and release
Double-pressing the material viz. first pressed and allowed to crack. Then it is repressed again so as to close the voids.
Applying vacuum through vents in the moulds
Drying
Drying is carried out to remove the moisture from refractories. Drying is carried out in tunnel dryer usually very
slowly and under well-set conditions of humidity and temperature, depending upon the type of refractory. Rack cars
are placed in a long tunnel and heat is supplied by steam, which passes through the tunnel.
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Firing
To stabilize and strengthen the structures of refractories firing is carried out in tunnel kilns or shaft kilns or rotary
kilns. The bricks are generally fired at a temperature as high as or higher than their arc temperature.
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Properties of different refractories
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Application and selection of different
refractories
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Graphite - Due to its high temperature stability and chemical inertness graphite is a good candidate for a refractory
material. It is used in the production of refractory bricks and in the production of “Mag-carbon” refractory bricks
(Mg-C.) Graphite is also used to manufacture crucibles, ladles and moulds for containing molten metals.
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Refractories used in various furnances
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Question
What are refractories? Explain their various types and their uses.(8 marks)
IMU Dec. 2014/ Jan 2015
IMU May/ June 2016
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