Refractory Technology: Fundamentals and Applications

Description

This book explains the refractories from different fundamental aspects, even with the support of phase diagrams, and also details the prominent applications of these industrial materials. The initial chapters cover fundamentals of refractories, classifications, properties, and testing, while later chapters describe different common shaped and unshaped refractories in detail and special refractories in a concise manner. The second edition includes new classifications, microstructures, the effect of impurities with binary and ternary phase diagrams, and recent trends in refractories including homework problems and an updated bibliography. Features: Provides exclusive material on refractoriesDiscusses detailed descriptions of different shaped and unshaped refractoriesCovers concepts like environmental issues, recycling, and nanotechnologyExplores details on testing and specifications including thermochemical and corrosion behaviorIncludes a separate chapter on trends of refractories and other issues This book is aimed at junior/senior undergraduate students and researchers of ceramics, metallurgical engineering, and refractories. Cover Half Title Title Page Copyright Page Dedication Table of Contents About the Author Preface to the Second Edition Preface to the First Edition Preface Chapter 1 Introduction to Refractory 1.1 Introduction 1.2 Definition 1.3 Basic Property Requirements 1.4 History of Refractory Development 1.5 Interesting Facts and Data on Refractories Summary of the Chapter Questions and Assignments Bibliography Chapter 2 Classifications of Refractories 2.1 Introduction 2.2 Classification Based on Chemical Nature 2.2.1 Acidic Refractories 2.2.2 Neutral Refractories 2.2.3 Basic Refractories 2.3 Classification Based on Main Constituent and Purity 2.4 Classification Based on Manufacturing Method 2.4.1 Pressed and Fired (Sintered) 2.4.2 Fused Cast 2.4.3 Hand Molded 2.4.4 Bonding 2.5 Classification Based on Physical Form or Shape 2.5.1 Shaped 2.5.2 Unshaped 2.6 Classification Based on Heat Duty 2.6.1 Low Heat Duty 2.6.2 Intermediate (or Medium) Heat Duty 2.6.3 High Heat Duty 2.6.4 Super Heat Duty 2.7 Classification Based on Porosity (Insulating) or Thermal Conductivity 2.7.1 Dense 2.7.2 Insulating 2.8 Classification Based on Application Area Summary of the Chapter Questions and Assignments Bibliography Chapter 3 Idea of Properties 3.1 Introduction 3.2 Physical Properties 3.2.1 Apparent Porosity (AP), Total Porosity, and Bulk Density (BD) 3.2.2 Specific Gravity 3.2.3 Firing Shrinkage 3.2.4 Permeability 3.3 Mechanical Properties 3.3.1 Cold Crushing Strength (CCS) 3.3.2 Cold Modulus of Rupture (CMOR) 3.4 Thermal Properties 3.4.1 Thermal Expansion 3.4.2 Thermal Conductivity 3.5 Thermomechanical Properties 3.5.1 Hot Modulus of Rupture (HMOR) 3.5.2 Creep 3.6 Abrasion Properties 3.7 Corrosion Properties 3.7.1 Carbon Monoxide (CO) Disintegration 3.7.2 Slag or Glass Corrosion 3.8 Microstructure 3.8.1 Techniques for Evaluation of Microstructure 3.8.1.1 Optical Microscopy 3.8.1.2 Scanning Electron Microscopy (SEM) 3.8.1.3 Transmission Electron Microscopy (TEM) 3.8.2 Components in Refractory Microstructure 3.8.2.1 Porosity 3.8.2.2 Single-Component Refractory 3.8.2.3 Multicomponent Refractory 3.9 Refractory-Specific Properties 3.9.1 Refractoriness or Pyrometric Cone Equivalence 3.9.2 Refractoriness Under Load (RUL) 3.9.3 Thermal Shock Resistance 3.9.4 Permanent Linear Change on Reheating (PLCR) Summary of the Chapter Questions and Assignments Bibliography Chapter 4 Standards and Testing 4.1 Introduction to Different Standards 4.2 Testing of Refractories 4.3 Testing of Physical Properties 4.3.1 Bulk Density (BD), Apparent Porosity (AP), Water Absorption (WA), and Apparent Specific Gravity (ASG) 4.3.1.1 Boiling Method 4.3.1.2 Vacuum/Evacuation Method 4.3.2 True Specific Gravity (TSG) and True Density (TD) 4.3.3 Permanent Liner Change on Reheating (PLCR) 4.4 Testing of Mechanical Properties 4.4.1 Cold Crushing Strength (CCS) 4.4.2 Cold Modulus of Rupture (Cold MOR) 4.5 Testing of Thermal Properties 4.5.1 Reversible Thermal Expansion 4.5.2 Thermal Conductivity 4.5.2.1 Calorimetric Method 4.5.2.2 Parallel Hot-Wire Method 4.5.3 Refractoriness or Pyrometric Cone Equivalent 4.6 Testing of Thermomechanical Properties 4.6.1 Hot MOR 4.6.2 Creep 4.6.3 Refractoriness Under Load 4.7 Testing for Corrosion Resistance 4.7.1 Testing of Resistance Against Carbon Monoxide (CO) 4.7.2 Testing of Resistance Against Liquid Corrosion 4.7.2.1 Static Cup Method 4.7.2.2 Finger Test (Dynamic Method) 4.7.2.3 Rotary Slag Test (Dynamic Method) 4.8 Testing of Abrasion Resistance 4.9 Testing of Thermal Shock Resistance 4.9.1 Water Quenching Method 4.9.2 Small Prism Method 4.9.3 Deterioration in Property After Thermal Shock Summary of the Chapter Questions and Assignments Bibliography Chapter 5 Silica Refractories 5.1 Introduction 5.2 Raw Materials and Sources 5.3 Brief of Manufacturing Techniques 5.4 Action of Mineralizer 5.5 Classification and Properties 5.6 Effect of Impurities with Binary and Ternary Phase Diagrams 5.7 Main Application Areas 5.7.1 Crown/Roof of the Glass Tank Furnace 5.7.2 Coke Oven Batteries 5.7.3 Hot Blast Stove 5.8 Silicosis Summary of the Chapter Questions and Assignments Bibliography Chapter 6 Alumina Refractories 6.1 Introduction 6.2 Raw Materials and Sources 6.2.1 Fireclay 6.2.2 Anhydrous Aluminosilicates 6.2.3 Bauxite 6.2.4 Synthetic Raw Materials 6.3 Brief of Manufacturing Techniques 6.4 Classifications and Properties 6.5 Effect of Impurities with Binary and Ternary Phase Diagrams 6.6 Main Application Areas Summary of the Chapter Questions and Assignments Bibliography Chapter 7 Fireclay Refractories 7.1 Introduction 7.2 Raw Materials and Sources 7.3 Grog and its Importance 7.4 Brief of Manufacturing Techniques 7.5 Classifications and Properties 7.5.1 Super Heat Duty (Al[sub(2)]O[sub(3)] Content ~ 40%–45%) 7.5.2 High Heat Duty (Al[sub(2)]O[sub(3)] Content 35%–40%) 7.5.3 Medium Heat Duty (Al[sub(2)]O[sub(3)] Content 30%–35%) 7.5.4 Low Heat Duty (Al[sub(2)]O[sub(3)] Content 25%–30%) 7.5.5 Semi-Silica 7.6 Main Application Areas Summary of the Chapter Questions and Assignments Bibliography Chapter 8 Magnesia Refractories 8.1 Introduction 8.2 Raw Materials and Sources 8.2.1 Magnesite 8.2.2 Fused Magnesia 8.2.3 Sea Water Magnesia 8.2.4 Magnesia From Natural Brine Source 8.2.5 Characteristic of the Raw Materials Affecting the Refractory 8.3 Brief of Manufacturing Technique 8.4 Effect of Lime: Silica Ratio 8.5 Classifications and Properties 8.6 Effect of Impurities with Binary and Ternary Phase Diagrams 8.7 Main Application Areas Summary of the Chapter Questions and Assignments Bibliography Chapter 9 Dolomite Refractories 9.1 Introduction 9.2 Raw Materials and Sources 9.3 Brief of Manufacturing Techniques 9.4 Classifications and Properties 9.5 Effect of Impurities with Binary and Ternary Phase Diagram 9.6 Main Application Areas Summary of the Chapter Questions and Assignments Bibliography Chapter 10 Chromite and MgO–Cr[sub(2)]O[sub(3)] Refractories (Chrome–Mag and Mag–Chrome) 10.1 Introduction 10.2 Raw Materials and Sources 10.3 Brief of Manufacturing Techniques 10.3.1 Chromite Refractory 10.3.2 Chrome–Magnesia Refractories 10.3.3 Magnesia–Chrome Refractories 10.4 Classifications and Properties 10.4.1 Chromite Refractories 10.4.2 MgO–Cr[sub(2)]O[sub(3)] Refractories (Chrome–Mag and Mag–Chrome) 10.5 Main Application Areas 10.6 Hazards with Chromite-Containing Refractory Summary of the Chapter Questions and Assignments Bibliography Chapter 11 Magnesia–Carbon Refractories 11.1 Introduction 11.2 Raw Materials, Binders, and Additives 11.2.1 Magnesia 11.2.2 Graphite 11.2.3 Antioxidant 11.2.4 Resin 11.3 Brief of Manufacturing Techniques 11.4 Classifications and Properties 11.5 Degradation of MgO–C Refractories 11.5.1 Dissolution of Magnesium by Slag 11.5.2 Oxidation of Carbon 11.5.3 Abrasion by Molten Steel and Slag 11.5.4 Degradation Due to Thermal and Mechanical Spalling 11.6 Main Application Areas Summary of the Chapter Questions and Assignments Bibliography Chapter 12 Special Refractories 12.1 Zircon and Zirconia Refractories 12.2 Fused-Cast Refractories 12.2.1 Fused-Cast Alumina Refractories 12.2.2 Fused-Cast Alumina–Zirconia–Silica (AZS) Refractories 12.2.3 Fused-Cast Zirconia Refractories 12.2.4 Fused-Cast Alumina–Zirconia Refractories 12.2.5 Fused-Cast Alumina–Silica Refractories 12.3 Insulating Refractories 12.4 Ceramic Fibers 12.5 Carbon Refractories 12.6 Silicon Carbide Refractories 12.7 Other Nonoxides Used in Refractories 12.7.1 Boron Carbide (B[sub(4)]C) 12.7.2 Tungsten Carbide (WC) 12.7.3 Silicon Nitride (Si[sub(3)]N[sub(4)]) 12.7.4 Aluminum Nitride (AlN) 12.7.5 Boron Nitride (BN) 12.7.6 Metal Borides Summary of the Chapter Questions and Assignments Bibliography Chapter 13 Unshaped (Monolithic) Refractories 13.1 Introduction and Advantages Over Shaped Refractories 13.2 Classification 13.3 Special Raw Materials and Additives 13.3.1 Major Constituent Fines 13.3.2 Binder 13.3.2.1 High-Alumina Cement 13.3.2.2 Colloidal Silica (Silica Sol) 13.3.2.3 Hydratable Alumina 13.3.2.4 Phosphates 13.3.3 Silica Fume (Flow Modifier) 13.3.4 Dispersants and Anti-Setting Agents 13.3.5 Fibers 13.3.5.1 Organic Fiber 13.3.5.2 Metallic Fiber 13.4 Brief Details of Different Unshaped Refractories 13.4.1 Castables 13.4.1.1 Particle Size Distribution 13.4.1.2 Classification and Properties 13.4.2 Ramming Mass 13.4.3 Gunning Mass 13.4.4 Plastic Mass 13.4.5 Spray Mass and Shotcrete 13.4.6 Mortar 13.4.7 Dry Vibratable Mass 13.5 Main Application Areas Summary of the Chapter Questions and Assignments Bibliography Chapter 14 Trend of Refractories and Other Issues 14.1 Progress in Refractories 14.2 Nanotechnology in Refractories 14.3 Environmental Aspects 14.3.1 Environment-Friendly (Hazard-Free) Manufacturing Process 14.3.2 Use of Ecofriendly (Hazard-Free) Raw Materials 14.3.3 Chromium-Free Refractories 14.3.4 Environment-Friendly Ceramic Fibers 14.4 Recycling of Refractories 14.4.1 Recycling Processes 14.4.1.1 Open-Loop Recycling 14.4.1.2 Closed-Loop Recycling 14.4.2 Major Steps Involved in Refractory Recycling Process 14.4.2.1 Sorting 14.4.2.2 Pretreatment Summary of the Chapter Questions and Assignments Bibliography Index