DESIGN OF FURNACE & REFRACTORY LINING

By
MK Maity (Materials & Corrosion Section, STC-J)

THE PERFORMANCE OF REFRACTORY LINING DEPENDS ON

Lining Design Selection of Material Installation Operation Of Furnace

Maintenance

OBJECTIVE OF A GOOD LINING DESIGN

Operation & Production At Optimum Cost & Expenses Of Refractories Used
To Obtain Optimum Trouble Free Service Life

To Have Reliable & Dependable Lining System

Ease Of Material Procurement Ease Of Installation Future Ease Of Maintenance Ease Of Repair

DESIGN & DETAIL ENGINEERING

Detail Of Lining :
Materials Quality

Thickness
Heat Transfer Calculations Shape & Size Of Bricks , C.F.Modules, Etc. Dimensional Tolerances, Laying Pattern Lining Details Of Openings, Corners, Junctions Type Of Mortar & Mortar Joint Type Of Expansion Joint, Location & Width

DESIGN & DETAIL ENGINEERING Detail Of Lining : Anchor & Hard-wares:

Anchor Anchor & Support Quality Design , Dimension, Height

Anchor Spacing & Orientation Vapor Barrier ( SS, Al foil) Corrosion Resistant Coating

DESIGN & DETAIL ENGINEERING

Refractory Materials:
Material Specifications & Test Methods Quantity of Materials & Overages Suppliers

Installation:

Installation Method Sequence of Installation Selection of Contractors Lining Dry Out Inspection Test Plan & Acceptance Criteria Special Requirements

LINING SYSTEM 1. Brick Lining

Different Shapes Insulating & Dense Type Type of Mortar

2. Monolithic / Concrete Lining 3. Ceramic Fibre Lining( Blanket &

Module)

4. Combination

FACTORS FOR LINING DESIGN & SELECTION OF MATERIALS

1.
2. 3. 4. 5. 6. 7.

Operating Temperature
Mode Of Operation (Intermittent/ Cyclic, Continuous) Furnace Atmosphere (Oxidizing, Reducing, Neutral) Furnace Pressure ( +Ve, -Ve, Neutral) Geometry Of Furnace Type Of Furnace (Static, Rotating, Tilting) Interface Temperature Between The Layers , Temp Gradient

8.

Expected Casing Temperature And Heat Loss

MAJOR FACTORS CONSIDERED FOR LINING DESIGN

9.
10. 11. 12. 13. 14. 15.

Requirement Of Furnace Efficiency

Physical Abuses Such As Abrasion, Erosion Etc. Thermo-chemical Attack : Corrosion Function Of Furnace: Heating Of Solid, Melting, Heating Of Gases, Hydrocarbons, Etc. Gas Composition Within The Furnace (Sulfur, Sodium, Potassium, Chlorine, Hydrogen Etc.) Expected Life Of Furnace Cost And Economics

16.
17.

Ease Of Installation,
Future Ease Of Maintenance & Repair

SELECTION OF REFRACTORIES
Chemical Composition Apparent Porosity Bulk Density Co-efficient Of Thermal Expansion Permanent Linear Change

Refractoriness Under Load

Pyrometric Cone Equivalent

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SELECTION OF REFRACTORIES
Thermal Conductivity Spalling Resistance Performance Under Various Gaseous Atmosphere

Permeability
Mechanical Strength (Room Temperature & High Temperature)

Abrasion / Erosion Resistance

Resistance To Chemical Attack

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HEAT FLOW CALCULATION

INPUT:

Operating Temperature Ambient Temperature Operating Pressure External Wind Velocity Thermal Conductivity Emissivity Heat Flow Direction Inside Gas Composition
(Hydrogen, Etc.)

OUTPUT:

External Shell Temperature Interface Temperature Heat Loss From Surface

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THERMAL / HEAT FLOW CALCULATION

HOT

Layer 1: IFB, Gr. 28 Layer 2: IFB, Gr. 23 Layer 3: Fibre Block 1100C Layer 4: Fibre Block 800C

Layer 1: MW Concrete Layer 2: CRF Board 1260C Layer 3: Fibre Block 1000C Layer 4: Fibre Block 800C

Layer 1: CRF Modules 1430C, 192kg/m Layer 2: CRF Blanket 1260C

Layer 1: CRF Blankets 1430C, 160kg/ Layer 2: CRF Blanket 1260C

Heat Flow Calculation for: tAMB=27C, tINS=1200C, wind=0m/s, =0.95 tOUTS=72C qloss=576 W/m
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tOUTS=78C qloss=676 W/m

Water Content92kg/m

tOUTS=73C qloss=601 W/m

tOUTS=69C qloss=528 W/m

LINING THICKNESS

Factors Determining Thickness :

Operating Temperature Corrosion, Erosion Etc. Thermal Calculation Design Casing Temperature Strength

Installation Method
Service Life

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LINING STRUCTURE AND SELECTION OF MATERIALS SINGLE LAYER: Low Operating Temperature Less Severe Conditions MULTI LAYER: High Operating Temperature, Low Heat Loss Requirement Severe Conditions COMBINED: Combination Of Brick, Block, castable, Ceramic Fibre Material

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LINING FOR MOLTEN STEEL / SLAG

Linings Consist Of A Safety Lining And A Working Lining Safety Lining Is Usually Provides Security Insulation For The Vessel &

Working Lining Is In Direct Contact With Steel And Slag.

Zone Wise Different Refractory To Match The Conditions It Is Exposed To Have Balanced Deterioration

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REFRACTORY WEAR MECHANISMS IN STEEL PLANT

Corrosion
Chemical Reactions Between Slag Components (FeO, MnO and SiO2) & Refractory Refractory Is Soluble In Steelmaking Slag Corrosion Can Be Minimized By Saturating Slag (With MgO From Dololime & Controlling Over Oxidation )

Oxidation
Oxidation Occurs When Carbon In Refractory Reacts With Oxygen From Slag (FeO) Or The Atmosphere And Burns As The Carbon Is Oxidized The Refractory Loses Its Strength

Erosion
When Liquid Steel Or Slag Flows Over A Refractory Surface & Abrades Surface
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HEIGHT OF LINING

Brick-wall Mostly Self Supporting Type & Height

Is Determined On Basis Of :
Stability Of Wall Load At Bottom Vertical Expansion Etc.

Monolithic Lining

No Restriction In Height, As Weight Of Refractory Is Uniformly Distributed Amongst The Anchors

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THERMAL EXPANSION OF LINING

Expansion Joints In Brick Lining Are Necessary In Order To Protect The Lining And Shell Against Forces Due To Thermal Expansion Of Brick. Expansion Joints In Monolithic Lining Often Not Necessary Since Anchor Fitted To The Furnace Shell Allow Limited Movement Due To Thermal Expansion.

Expansion Joints Are Necessary In Monolithic Lining That Are Not Supported By Anchor
Size Of Expansion Joint Depends On Drying + Heating Shrinkage, Expansion Of Material , Shell / Casing Etc.

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SHRINKAGE OF LINING :
Monolithic Refractory Lining Usually Shrinks During Post Installation Drying And When Cooled After Heating. To Protect The Lining From Damage Due To Shrinkage, Joints Are Left At Appropriate Intervals So That These May Take Up The Shrinkage.

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ANCHORS FOR REFRACTORY LINING Function Of Anchor:

To Hold Refractory in Position Provide Support For Wall & Arches & Flat Roof Prevent Bulging & Bowing Of Lining

Allow Horizontal & Vertical Movement Of Lining

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TYPES OF ANCHOR Metallic Anchors Ceramic Anchors Metal Anchor

L Type V Type Y Type Hexmesh Chain Link Wire Mesh Anchor For Ceramic Fibre Lining Special Anchor

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DESIGN OF ANCHOR SYSTEM

Anchor Quality

Diameter Of Anchor Rod

Anchor Configuration Anchor Spacing Anchor Orientation Anchor Height / Cover

Plastic Cap / Coating On Anchor

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SELECTION CRITERIA OF ANCHOR SYSTEM

Type Of Lining & Lining Thickness Type Of Refractory Materials Furnace Operating Conditions Position Of Lining ( Vertical, Horizontal, Inclined, Floor, Circular Etc.) Mechanical Movement Etc.

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CERAMIC ANCHOR

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STEEL FIBRE REINFORCEMENT IN REFRACTORY CASTABLE ADVANTAGES:

Higher Tensile, Flexural And Compressive Strength Improved Resistance To Damage From Vibration, Impact And Thermal Shock

Better Resistance To Cracking

Better Performance Under Abrasive Conditions

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TYPE OF STEEL FIBRES & THEIR CHARACTERISTICS :

Type Of Fibre : Steel Wires, Thin Steel Wares, Melt Extraction, Shaving Thick Steel Plates : 0.3 Mm To 0.5 Mm : 25 Mm To 30 Mm : 50 To 100 : SS 304, SS 410, SS 310 Etc.

Dia. Of Fibre (D) Length (L) Aspect Ratio (L/D) Material Quality

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SULFURIC ACID CONDENSATION

Flue gas constituents:

H2O (Steam), SO2 & SO3 (Gases) CO, CO2 , N2 , NOx , Cl, (Gases)
H2SO4 , HCl, HNO3 (Gases)

Compounds of Na, V, Ash Etc.

(Depending of type of fuel, furnace charge, etc.)

S + O2 SO2 (Gas) ( Conversion ~ 1-5 %) SO2 + O2 SO3 (Gas)

SO3 (Gas) + H2O (Steam)

H2 SO4 (Gas)

Temp< Dew Point 120-160 0C

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H2 SO4

(Liquid)

PHYSICAL BARRIER INSIDE LINING

Metallic Foil / Sheet ( SS, Al) Between Refractory Layers Thickness 0.1 to 0.15mm

SS Sheet

Mainly For Cold Wall Design Furnaces:

Casing Temperature Is Maintained Approx. 60 to 100 0C. Very High Thermal Efficiency Is Expected
Heater, Primary Reformer, Cracker

TYPICAL SS SHEET BARRIER

SS Foil Over Insulating Board

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THANK YOU