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6 Super Easy Tips for Selecting the Perfect Refractory for Furnaces

Why do we choose Right Refractory? Well, you need to know what Experts Says about selecting perfect Refractory for Furnaces:

“Picking the right Refractory will not only last longer, it also saves the Annual Fuel Cost.”

Apart from saving the Fuel Cost, it also Saves Energy and make the Furnace/Kilns/Ovens more efficient. The right Refractory also minimises the Shutdowns probability.

Hence, lets look at some important points to understand your requirement and the best suitable Refractory for Furnaces / Kilns / Ovens:

 

1. The first thing to consider is “Type of Furnace” & “Type of Fuel“. These 2 factors are the most imperative decision making key for selecting the right Refractory for furnaces/kilns/ovens.

2. A Refractory should be Strong & Well bonded in order to withstand the Mechanical Abrasion and Impact.

3. If the operating temperature of a Furnace/Kiln/Oven is more than the Refractory’s Service Limit then it can cause a hazardous outcome for your project/product & your valuable people.

4. The design of the furnace/kiln/ovens should be designed in such a way so that it can hold its own weight at high temperatures or else the whole structure will get collapsed.

5. Chemical Compatibility: The selection of the Refractory products should be based on the suitable specifications for a specific application. Using a wrong and unsuitable Refractory products may lead to dangerous failure in form of cracking or exploding. There are various applications where refractories can be used, hence it’s a wise choice to select the right refractory for your requirement.

Slag Resistance completely rely on the chemical reactions between the refractory and slag.

There are 3 types of refractories with the following chemical compatibility:

  • Acidic Refractory: Acidic refractories are used for acidic slag condition as they reacts with basic materials.
  • Basic Refractory: Basic refractories are used for basic slag condition as they reacts with acidic materials.
  • Neutral Refractory: Neutral refractories may be used for all slag conditions.

6. When it comes to the Refractory bricks, temperature gradient is the most worst enemy for them. Each brick should manage & handle the stress due to temperature gradient and withstand the temperature fluctuations in their body. It should not crack or spall at any point of time.

The ultimate goal for selecting the right refractory for a specific application is to maximise and enhance the performance of the furnace/kiln/ovens. It is not about the higher price will always be good, what matters is the most suitable refractory for your requirement. It is always about the “Maximum Heat Conservation” & “Minimum Heat Loss” which will help you to lower your Fuel Consumption and higher your Production.

What is Temperature Gradient?

Temperature Gradient in refractories usually occurs when the one side face of the Refractory Brick get in contact with the much higher temperature than the other side of the Brick, which also called as Temperature Fluctuation in the brick’s body. This radical changes in temperature inside the Bricks’s body cause stresses which can lead to cracking the brick. Temperature Gradient is a dimensional quantity which can be measured in units of Degrees per Unit Length. It describes the temperature changes in direction with rate for a particular body.

In the world of Refractories “Slag Attack” is the most common reason for their failure. Hence Slag Corrosion test is imperative for any refractories to ensure the longevity of Furnace/Kiln/Ovens. There are 2 ways from which a refractory can get affected by the slag attack. They are Corrosion & Erosion.

  • Corrosion is the wear and tear of refractories caused by static chemical attack of slag &
  • Erosion is wear caused by mechanical action that is the process of breaking and washing away of refractory materials by molten slag.

There are several test methods by using which you can test the Refractories for your specific working conditions:

 

  1. Pill Test: It is used when the quantities of Refractories are more than compare to quantities of Slag. The corrosion and spread of the molten mass is observed and calculated to find out the Refractory strength against Slag Attack.
  2. Immersion Method: This method is used when the quantities of Refractories are far less compare to quantities of Slag. A small piece of Refractory is placed in the Molten Slag.
  3. Fusion Test: In this test different quantities of refractory material and powdered slag has been used to find out the deformation of refractories which are in contact with slag.

So, by keeping all the above factors in mind, Furnace Manufacturers can easily select the right Refractories according to their requirement.

To check out all kind of Refractory Bricks available in Bangalore click here or click on the specific product below(With Detailed Technical Description):

To check out all kind of Refractory Castables available in Bangalore or Monolithics in Bangalore click here or click on the specific product below(With Detailed Technical Description):

 

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