ENGINEERING CHEMISTRY

Unit 5 Refractory: Definition, classification, properties, Requisites of good refractory and manufacturing of refractory. Preparation of Silica and fire clay refractory with their uses. Segers (Pyrometric) Cone Test and RUL Test Lubricants: Introduction, classification and uses of lubricants. Types of lubrication. Viscosity & viscosity index, flash and fire point, cloud and pour point, steam emulsification number, precipitation number and neutralization number. Refractory: A refractory material is one that retains its strength at high temperatures. It is defines refractories as "non-metallic materials having those chemical and physical properties that make them applicable for structures, or as components of systems, that are exposed to environments above 1,000 F (811 K; 538 C)".

Refractory materials are used in linings for furnaces, kilns, incinerators and reactors. They are also used to make crucibles.

Classification of refractory materials

Refractories can be classified on the basis of chemical composition, method of manufacture, physical form or according to their applications. Based on chemical composition 1. Acidic refractories These are used in areas where slag and atmosphere are acidic. They are stable to acids but attacked by alkalis. The main raw materials belongs to the RO2 group, e.g. silica (SiO2), zirconia (ZrO2),alumina, fireclay refractories etc. 2.Neutral refractories These are used in areas where slags and atmosphere are either acidic or basic and are chemically stable to both acids and bases. The main raw materials belongs to, but not confined to, R2O3 group. The common examples of these materials are alumina (Al2O3), chromia (Cr2O3) and carbon.

3.Basic refractories These are used on areas where slags and atmosphere are basic; they are stable to alkaline materials but react with acids. The main raw materials belong to the RO group to which magnesia (MgO) is a very common example. Other examples include dolomite and chrome-magnesia.
Based on method of manufacture 1.Dry press process 2.Fused cast 3.Hand molded 4.Formed (normal, fired or chemically bonded) 5.Un-formed (monolithic-plastic, ramming and gunning mass, castables) 6.Un-formed Dry Vibratable refractories.

MANUFACTURE OF REFRACTORIES: FLOW CHART

PROPERTIES OF REFRACTORIES:

Preparation of Silica and fire clay refractory with their uses:

SILICA REFRACTORIES

The prime ingredient for silica refractories, sometimes termed acid refractories, issilica. These materials, well known for their high-temperature load-bearing capacity,are commonly used in the arched roofs of steel- and glass-making furnaces; for these applications, temperatures as high as 1650_C (3000_F) may be realized. Under these conditions some small portion of the brick will actually exist as a liquid. The presence of even small concentrations of alumina has an adverse influence on the performance of these refractories, which may be explained by the silicaalumina phase diagram, Figure 10.24. Since the eutectic composition (7.7 wt% Al2O3) is very near to the silica extremity of the phase diagram, even small additions of Al2O3 lower the liquidus temperature significantly, which means that substantial amounts of liquid may be present at temperatures in excess of 1600_C (2910_F). Thus, the alumina content should be held to a minimum, normally to between 0.2 and 1.0 wt%. These refractory materials are also resistant to slags that are rich in silica (called acid slags) and are often used as containment vessels for them. On the other hand, they are readily attacked by slags composed of a high proportion of CaO and/or MgO (basic slags), and contact with these oxide materials should be avoided.

FIRECLAY REFRACTORIES

The primary ingredients for the fireclay refractories are high-purity fireclays, alumina and silica mixtures usually containing between 25 and 45 wt% alumina. According to the SiO2Al2O3 phase diagram, Figure 1.4, over this composition range the highest temperature possible without the formation of a liquid phase is 1587_C (2890_F). Below this temperature the equilibrium phases present are mullite and silica (cristobalite). During refractory service use the presence of a small amount of a liquid phase may be allowable without compromising mechanical integrity. Above 1587_C the fraction of liquid phase present will depend on refractory composition. Upgrading the alumina content will increase the maximum service temperature, allowing for the formation of a small amount of liquid. Fireclay bricks are used principally in furnace construction, to confine hot atmospheres, and to thermally insulate structural members from excessive temperatures.

Lubricants

Lubricants: Introduction, classification and uses of lubricants. Types of lubrication. Viscosity & viscosity index, flash and fire point, cloud and pour point, steam emulsification number, precipitation number and neutralization number.

1.1 INTRODUCTION: A lubricant is a substance introduced to reduce friction between moving surfaces. The property of reducing friction is known as lubricity. The process to reduce frictional force between the sliding and rubbing surfaces of metals is called lubrication.

A good lubricant possesses the following characteristics:

High boiling point. Low freezing point. High viscosity index. Thermal stability. Corrosion prevention. High resistance to oxidation.

Purpose
1. Lubricants perform the following key functions. 2. Keep moving parts apart 3. Reduce friction. 4. Transfer heat. 5. Carry away contaminants & debris.\ 6. Transmit power. 7. Protect against wear. 8. Prevent corrosion 9. Seal for gases 10. Stop the risk of smoke and fire of objects TYPES OF LUBRICATION:
(1) Fluid-film lubrication (2) Boundary lubrication (1) Fluid-film lubrication : This type of lubrication is used when two surfaces of the materials

rotate against each other while being completely separated. The liquid lubricants form a very thin film between the moving surfaces and thus avoid the direct metal to metal contact and reduce friction. This condition is known as fluid film lubrication. The resistance to movement of sliding moving parts is only due to the internal resistance between the particles of the lubricants moving over each other. Therefore lubricant chosen should have the minimum viscosity under working conditions and at the same time, it should remain in place and separate the surfaces. Delicate machines and light instruments like watches, clocks, guns, sewing machines, scientific instruments etc. are provided with thick fluid film lubrication.

(2) Boundary lubrication :

Boundary lubrication may happen slide or rotate against one another under heavy load, and such conditions there may be contact between the moving surfaces and film breaks down under these conditions, an oil is used which interact with the solid surface of the metal that will between the two sliding surfaces. This can be possible by adsorption of lubricant molecules on the surfaces or by chemical reaction of the lubrication substances with metal surfaces.

pressure

Classification of lubricants: 1. Solid lubricants 2. Semi-solid lubricant 3. Lubricating oils or liquid lubricant C 4. Synthetic lubrication

LASSIFICATION OF LUBRICANTS (1) Solid lubricants

Solid lubricants
Solid lubricants are used for railway tract joints, chains, air compressors, open gears, heavy machines etc. the examples of solid lubricants are wax, talc, mica, molybdenum disulphide graphite etc. 2.2.(2) Semi Semi-solid lubricant solid lubricants It is used where the machine parts are subjected to slow speed, heavy load & sudden jerks. The examples of semi solid lubricants are grease & Vaseline. (3) Liquid lubricants Lubricating oils or liquid lubricant Liquid lubricants are used in delicate and light machines which work at high speed but under low pressure. Mineral oils, vegetable oils & animal oils are the various types of liquid lubricants. (4) Synthetic lubricants It can be used, where extreme temperature, chemical reactive atmosphere or some very particular operating conditions are involved & where all other lubricants fail to work effectively. e.g. polyglycols, silicones, organic amines, imines & amides.

Test of lubricants and ther significance

Viscosity: The resistance to flow of liquid is known as viscosity. The unit of viscosity is
poise. OR the force in dyne, required to move one square centimetre layer of the liquid with a velocity 1 cm/sec. to another parallel layer of the liquid.

Viscosity index: The rate of change of viscosity with change in temperature is called
viscosity index. A good lubricant is one whose viscosity does not change much with change in temperature. FLASH POINT: The minimum temperature at which a lubricant gives momentary flash of light when a flame is applied to it, but it does not continue to burn. Lubricants with higher flash point are preferred. FIRE POINT: The temperature at which a lubricant catches fire and burns continuously when the flame is applied to it. Fire point of oil is always greater than its flash point. POUR POINT: It is the lowest temperature at which the oil ceased to flow when cooled under prescribed conditions. If oil is used at a temperature below the pour point, the lubrication action will stop. CLOUD POINT: The cloud point of lubricating oil is the temperature at which cloudiness develops due to separation of wax on cooling. EMULSIFICATION: When oil is mixed with water or water is mixed with oil, emulsion is formed. A good lubricant is one which does not form emulsion and even if it forms, the emulsion should break quickly. NEUTRALIZATION NUMBER: The neutralization number is a measure of the acidity of an oil and is the amount, in milligrams, of potassium hydroxide (KOH) required to neutralize 1 gram of oil. A relative increase in the neutralization number indicates oxidation of the oil.

BY: SHUBHAM KHANDELWAL (FARRE.IN)