MSE 3133

Refractories and Furnaces

16 June, 2021 (Online)

Lecture 1: Introduction and Classification of Refractory Materials

Definition of Refractories
• There is no general definition of a refractory. Essentially it is a material
of "high melting point", but this is a relative term and melting point is
not the only criterion of usefulness.
• Refractory materials must possess sufficiently high fusion temperature
to retain their shape at working temperature.
• In short, Refractories are materials that can withstand very high
temperatures (up to 3000°C or more) without degrading or softening.
• Refractories can be classified based on functions of refractory, its
chemical nature and on other considerations, forms (shaped and
monolithic), applications and factors responsible for performance.
Properties of Refractories
• Refractory materials should have the ability to:
(i) withstand high temperature
(ii) withstand corrosive action of molten slag and hot gasses
(iii) withstand abrasion and erosion by moving solid charge, flowing liquids and
blowing gases
(iv) withstand working load during service
(v) retain dimensional stability at working temperatures
(vi) sustain repeated thermal cycling
(vii) sustain thermal shock (sudden change in temperature)
(viii) conduct/resist heat flow as needed during use
(ix) store heat in the system
Classification of refractories
The refractory materials are generally classified on the basis of their
chemical behavior, i.e., their reaction to the type of slag.
• Acid Refractories
• Acid refractories are those which are attacked by basic slag. These
are not affected by acid slag, and hence it can be used in furnaces
having acidic work environment.
(a) Silica (most acidic)
(b) Semi silica
(c) Alumino-silicate refractories
Classification of refractories
• Basic Refractories
Basic refractories are those which are attacked by acid slag. These refractories
are useful for furnace linings where the environment is basic, for example,
basic steel making and furnaces for non-ferrous metallurgical operations.
(a) Magnesite
(b) Magnesite-Chrome
• Neutral Refractories
These refractories are attacked neither by acid nor by basic slag. The
following refractories are known for their inertness:
(a) Graphite (most inert)
(b) Chromites
(c) Synthetic refractories (e.g. zirconium carbide and silicon carbide)
Classification based on forms and shape
• Special refractories
These refractory materials are specially manufactured using synthetic
(fused/sintered) grains free from impurities under highly controlled
production parameters for special applications. They are used for
purposes like fabrication of crucible, some parts of furnaces and
research and developments. These applications of the refractory do
not consider cost as a factor for selection.
E.g. (a) Alumina, (b) Pure sialons (Si-Al-ON),(c) Thoria , (d) Beryllia
Classification based on forms and shape
• Insulating refractories
These are high porosity refractories having low thermal conductivity
used for reducing the rate of heat flow (heat losses) to maximize heat
conservation within the furnace.
The production of brick shape refractories utilizes China clay, asbestos
(kieselguhr), glass wool, mica (vermiculite), bubble alumina, carbon,
paper wool, ceramic fibers, saw dust, etc. as raw materials.
Classification based on forms and shape
Cermets
• The refractories produced from the mixtures of high purity refractory
oxides, carbides, borides, and metals or alloys fall under this
category.
• Depending on the composition and quality, they are used as
abrasives (cutting, grinding, boring tools), in parts of spacecrafts,
missiles, atomic power plants, etc.
Shaped refractories
• The shaped refractory has a specific brick
shape for a given purpose. The various
common shapes include straight
(rectangular), side arch, end arch, wedge,
key, flat circle, combined arch and wedge,
circle, splits, dome brick, skew (end/side),
bullnose or jamb brick and soap or closer.

• The refractories bricks that have different shapes are used to line furnaces,
kilns, cupola, blast furnaces, etc. The insulating firebrick having desired shape
posses low thermal conductivity and are used to minimize heat transfer.
Unshaped refractories (monolithic)
• The unshaped refractories (monolithic) are used as mortar, castables,
plastics, gunning mixes, ramming mixes, slinger mixes, patching
materials and coating materials. These are produced in powder or
granular form for various applications.
(a) Mortar : These are materials for bonding bricks in a lining. Three
types of mortars are used—heat-setting, air-setting and hydraulic-
setting. These three mortars have different setting mechanisms.
(b) Castables : These are refractories for giving a shape in the furnace.
Here, the refractory materials and hydraulic-setting cement are mixed.
They are formed by casting and used to line furnaces, kilns, etc.
Unshaped refractories (monolithic)
(c) Plastics : These are refractories in which raw materials and plastic materials are
mixed with water for use. The plastic refractories are formed with chemical
additives.
(d) Gunning mixes : These are powder refractories that are sprayed on the surface
by a gun.
(e) Ramming mixes : These are granular refractories that are strengthened by
gunning formulation of a ceramic bond after heating. The ramming mixes have
less plasticity and are installed by an air rammer.
(f) Slinger mixes : These are refractories installed by a slinger machine.
(g) Patching materials and coating materials : These are refractories with
properties similar to refractory mortar. However, patching materials have
controlled grain size for easy patching or coating.
End of Lecture 1