Refractory Design, Installation, Inspection and Repair
Introduction
Refractory Design, Installation, Inspection and Repair
Course Objective
- To familiarize participants with the main concepts and technical terms of industrial refractory materials.
- To explain to participants the different types of hot processes and their requirements.
- To explain to participants the different types of industrial refractories
- To explain to participants how to relate process requirements to refractory properties (mechanical, thermal, electrical and chemical/corrosion).
- To provide participants with the basic knowledge and skills for selection of different refractory materials based on process requirements.
- To introduce participants to different manufacturing methods applied to refractory materials and their installation techniques.
- To explain to participants how refractory materials respond to different service conditions and issues related to their quality and reliability.
Course Outline
Introduction
- Technical Perspectives
- Historical Perspectives
Foundations of Hot Processing
- Computational Quantities and Conversion Factors
- Hot Processing Temperatures and Their Measurement
- Process Chemistry and Environments
Foundations of Refractory Application
- Contemporary Hot Processing Equipment
- Continuous Types – Vertical
- Continuous Types – Horizontal
- Batch Types – Circular
- Batch Types – Rectangular
- Other Refractory Applications
Principles of Thermal Stability
- Melting Points of Substances
- Melting of Oxide Mixtures
- Microstructural Integrity
Principles of Corrosion Resistance: Oxidation-Reduction
- Importance of Corrosion
- Gibbs Free Energies
- Refractory Alteration by Oxidation-Reduction
Principles of Corrosion Resistance: Hot Liquids
- Liquid Penetration and Dissolution-Corrosion
- Factors Governing Penetration
- Factors Governing Dissolution
Principles of Corrosion Resistance: Hot Gases and Dusts
- Atmospheric Penetration and Condensation
- Dusts: Deposition and Abrasion
- Conclusion: Principles of Working Refractory Construction
The Working Refractory Product Line
- Classification of Working Refractories
- Maximum Service Temperatures
- Maximum Service Temperatures
- Corrosion Resistance
- Qualifications for Working Refractory Service
The Insulating Refractory Product Line
- Applications and Application Criteria
- Classification of Insulating Refractories
- Physical Form and Installation of Linings
Refractory Practice
- Refractory Qualifications in Review
- Refractory Practice from Qualifications
- Catalogue of Refractory Practice
Design Properties: Thermal and Electrical
- Reversible Thermal Expansion
- Permanent Deformation
- Specific Heat
- Thermal Conductivity
- Electrical Conductivity
Design Properties: Mechanical
- Elasticity and Plasticity
- Mechanical Characterization of Refractories
- Illustrative Mechanical Properties of Refractories
Refractory Manufacture
- Consolidated Flow Diagram for Refractories
- From Raw Materials to Forming
- Forming of Masonry and Special Shapes
- Agglomeration for Sintered Grain
- Drying and Firing of Refractories
- Quality Assurance in Manufacture
Refractory Installation and Maintenance
- Structural Engineering
- Masonry Construction
- Installation of Monolithics