Heating furnace monolithic refractory lining

Abstract

Contemporary solutions are presented for completion of a monolithic refractory lining for a heating furnace using products produced by OOO Keralit.Today the life of a heating furnace lining made of individual components for a flat suspended roof is 1 -4 years, for the side wall it is 1 -3 years, and for a travelling hearth it is 1 -2 years depending on furnace operating conditions and the grade of components used taking account of a period of 6 -12 months between maintenance. The actual life the insulation of skid pipes and travelling beams made of kaolin fiber is not more than half a year. With time the fiber becomes brittle and the insulation breaks down.The main reasons for the short life of these linings is breakdown of refractory components during periodic rapid heating and cooling; insufficient material structural strength. Use of fiber materials combined with individual refractories for lining the walls appears to be inefficient. Use of expensive heat-resistant castings in order to increase the structural strength of a travelling hearth also does not provide an appropriate investment in the results: with time the metal oxidizes, deforms and the lining fails.Overseas and domestic experience of the construction of furnaces in recent years showed that use of unmolded refractories and heat insulating materials makes it possible to obtain higher indices for life: 5 -8 years for a flat suspended roof, 7 -10 years for the side walls and 3 -5 years for a travelling hearth depending on furnace operating conditions and grades of materials used. Moreover, a monolithic refractory lining makes it possible to reduce the heat consumption and to improve operating conditions for the servicing personnel. This approach towards lining is based on use of contemporary unmolded refractories and effective heat insulating materials, structural changes and innovations in making a monolithic furnace lining excluding the breakdown of refractory materials. Favorable operating results for heating furnaces lined with refractory materials and components from the company Keralit have been obtained in the section rolling workshop of RUP BMZ, the sheet rolling workshops of OAO MMK, and workshop No. 390 of FGUP PO Uralvagonzavod.The use of unmolded refractory materials requires comprehensive consideration of the main features of design and construction of a heating furnace. The main structural solutions are presented below for a monolithic lining of individual elements and assemblies of a heating furnace made of advanced unmolded refractories produced by OOO Keralit that make it possible to increase lining life and improve the technical and economic indices of furnace operation. FLAT SUSPENDED ROOFDepending on the method of laying the working layer of a flat suspended roof it is possible to prepare it by vibration forming using CERALIT CAST concretes, by ramming using CERALIT PLAST or torcreting using refractory mix CERALIT GUN. With vibration forming and torcreting the working layer of a monolithic lining of a flat suspended roof with a thi...

Advantages of refractory block insulation from the Company Keralit for skid pipes and walking beams of heating furnaces

“…Refractory block insulation produced by Keralit is a refractory-insulation system for skid pipes and walking beams manufactured from individual components, so-called assembly blocks [1]. An assembly block is a special type of "keyed" construction and it consists of two layers.…”