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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 knownas refractory concretes.
ill, 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 are replacing conventional brick refractories in steelmaking and other metal
extraction industries. Monolithic refractories are loose materials which can be used to formjoint free
lining. The main advantages of monolithic linings are

\1l Grater volume stability

•• Betterspalling tendency
., Elimination of joint compared with brick lining
$ Can be installed in hot standby mode
e 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.

Insulating materials

The role of insulating materials is to minimize heat losses from the high temperature reactors.These
materials have low thermal conductivity while their heat capacity depends on the bulk density and
specific heat. Ir,sulatirig materials are porous in structure; excessive heat affects all insulating materials.
Choice of lnsulatingmaterlalswould depend upon its effectiveness to resist heat conductivity and upon

temperature. Highalumina Vlitht~ermal conductivity 0.028~:~ , and silica with thermal conductivity

0.04 kc:l . etc areamongstothers, used as insulating materials.

mC

Ceramic fibres areimportciritinsulating materials and are produced from molten silica, titania, Zirconia
etc in the form of wool, short fibres and long fibres. They have excellent insulation efficiency. They are
long weight:

References:

O.P.Gupta: Fuels, Furnace and refractory

,"I'
 I\> Compression in a structure of refractory due to expansion
@ Variation in coefficient of thermal expansion between the surface layer and the body of the
brick
G Variation in coefficient of thermal expansion between the surface layer and the body of the
brick Is due to slag penetration ordue to structural change.

On sudden heating

.Spallingtendency <X . coeff. of thermal expansion

max m shearing strain ~thermal diffusivity

On sudden cooling

Spailing tendency <X coeff. of thermal expansion

max m tensile strength ~thermal diffusivity

Permanent Linear change (PLC)on reheating

In materials certain permanent changes occur during heating and these changes may be due to

6 Change in the allotropic form

e Chemical reaction
@ Liquid phase formative
9 Sintering reactions

PLC(%)linear=:Increase /decrease in length X 100

. . . .. original length

C· 1 .) =: ·lncrease ./decrease in volume

PL.C01.
,0 va ume . x, 100
_
. -. anginal volume

These changes determine

. .
the volume stability and expansion and shrinkage of the refractory at high
temperatures.

Thermal conductivity

Thermal conductivity ofthebricks 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.

Types of refractory materials

 e To allow thermal energy dependent conversion of chemically reactive reactants into
products because metallic vessels are not suitable.

In steelmaking, the physico- chemical properties of the following phases are important:

Slag: Mixture of acidic and basic inorganic oxides like SiOz, Pz Os, CaO, MgO, FeO,etc.; temperature varies
in between 1400°C to 1600°C.·

Molten steel: Iron containing carbon, silicon, manganese, phosphorous, tramp elements, non metallic
inclusions, dissolved gases like nitrogen, oxygen and hydrogen and different alloying elements like
Cr, Ni, Nb, Mo, W, Mo etc.: temperature 1600°C

Gases: CO, COz,Nz, Ar containing solid particles of Fez 03, Fe:>04 etc.; temperature 1300 e to 1600°C .
0

The above phases are continuously and constantly in contact with each other and are in turbulent
motion.

Refractory requirements: .

The refractory materials should be able to withstand

High temperature
Sudden changes ofte~perature
Load at service conditio~s •.. ..

• Chemical and abrasive action of phases

The refractory material should.not contaminate the material with which it is in contact.

.', .

Melting point of some pure compounds used to Manufacture refractory

Compounds . Melting point (OC)

MgO (pure sintered) 2800

CaO(limit) . 2571

SiC pure 2248

MgO (90-95%) . 2193

...... 2138

2050

. Hreday' 1871

1715