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Sifat dan Pengujian
Refraktori
TMT619214
BATA TAHAN API DAN TERAK
2021
Definition of Refractory
Ability to:
1. Withstand high temperature
2. Withstand Corrosive action of molten
slag and hot gassesThermal strain
3. Withstand Abrasion and erosion by
moving solid charge, flowing liquids
4. Withstand Working load during service
5. Retain dimensional stability at working
temperatures
6. Sustain repeated thermal cycling
7. Sustain thermal shock (sudden change
in temperature)
8. Conduct/resist heat flow as needed
during use
9. Store heat in the system
ASTM C71
“non-metallic materials having those
chemical and physical properties that make
them applicable for structures or as
components of systems that are exposed to
environments above 538oC”
The most important requirements of the user
are:
1. Rigidity and maintenance of size, shape and
strength at the operating temperature, which will
presumably be "high".
2. An ability to withstand thermal shock such as is
met in heating up and cooling down of furnaces, or
in fluctuations which occur during charging or
during normal operation.
3. Resistance to chemical attack by whatever gas, slag
or metal is likely to be encountered.
HIGH TEMPERATURE BEHAVIOUR
a. PCE (Pyrometric Cone Equivalent) value
b. RUL (Refractoriness Under Load) value
c. Creep at high temperature
d. High Temperature Modulus of Rupture (HMOR)
e. Thermal shock resistance
– Spalling test
– Loss in MOR strength
f. Reversible thermal expansion
g. PLC (Permanent Linear Change) test
PCE (Pyrometric Cone Equivalent) value
→ It is the measure of refractory’s ability to
sustain high temperature without fusion or
deformation.
• This is the most important value for selection
of any refractory material for a given
application in the furnace
• The maximum working temperature in the
furnace is always kept below the PCE value to
avoid refractory failure.
RUL (Refractoriness Under Load)
→It is the capability of a brick to sustain itself
without breaking at high temperature under
pressure of overlying load (burden, liquid metal
or its own structural weight
• RUL is the crushing strength of a brick at
elevated temperature.
• RUL standard test : ISO 1893 (Explore it!)
Creep
→ Creep is a property which indicates deformation of
the refractory at high temperature which is subjected
to stress for longer period.
• ISO 3187
• The refractory tested for creep under compression
(deformation at a given time and temperature under
stress) for normal working conditions of load and
temperature should not exceed 0.3% change in the
first 50 hours of the test.
High Temperature Modulus of Rupture (HMOR)
→ It is the maximum stress that a rectangular
test piece of defined size can withstand when it
is bent in a three point bending device.
• Expressed as N/mm2 or MPa.
• ISO 5013 (testing method)
Thermal shock resistance
→ Thermal shock resistance is a measure of
refractory property when it is exposed to
alternate heating and cooling.
• This thermal shock leads to breaking of
refractory particles which is termed as
‘spalling’ and loss of strength due to micro-
cracks and is noted as MOR value after
thermal treatment.
Thermal expansion
→ The increase in volume of the material due to
heating is called thermal expansion.
• This expansion process is reversible in nature,
and material regains its size on cooling, hence,
it is also called reversible thermal expansion .
Corrosion Resistance
→ It is the wear and tear of refractories caused by static
chemical attack of slag.
• The eating away of refractory material due to chemical
reaction between refractory and molten fluid (slag) at high
temperature is termed as ‘refractory corrosion’.
• The corrosive action by hot slag can eat away the refractory
to cause pits.
• This pit could become the point of stress concentration
and may lead to brick failure.
• The corrosive failure of the brick could be easily avoided by
proper selection of the chemical nature
(acid/basic/neutral) of the brick material which is not
affected by working slag nature.
Corrosion Test
• cone test
• pill test
• suspended rod test
• Powder impact test, etc
Erosion Resistance
• The ability of a refractory to sustain the mechanical
erosive action of sliding burden, moving products
(liquid melt and slag), flowing gases (e.g. hot flue
gases laden with solid particles) is termed as ‘erosion
resistance’.
• The erosion of refractory could be improved by
regulating the mechanical properties of the
refractory material (e.g. porosity, density and grain
bonding strength).
Thermal Conductivity
→ Thermal conductivity is defined as the quantity
of heat that will flow through a unit area in a
direction normal to the surface area in a given time
with a known temperature gradient under steady
state thermal conditions.
• The thermal conductivity of the refractory is
needed to decide the wall thickness for obtaining
desired temperature gradient across refractory
lining section in the furnace.
• High thermal conductivity in refractories are
required for someapplications where good
heat transfer is essential such as coke oven
walls, regenerators, muffles and water cooled
furnace walls.
• Lower thermal conductivity refractory
materials are preferred for applications where
heat flow has to be minimised to conserve
heat energy.
POROSITY
• Porosity is a measure of the vacant space as
pores and voids/cavities in the refractory
material.
• The pores present in refractory are of three
types: open pores, inter-connected pores and
sealed pores.
Testing Method :
1. Boiling water method
2. Mercury porositometer
• Used to measure pore volume and pore size
distribution in the range of 300 μm to 0.0035
μm pore diameter for variety of materials.
3. Nitrogen gas absorption
This method is used to determine very fine
pores (< 0.09 μm) in solid materials.
DENSITY
• The refractory is a porous material, and therefore its density is
seriously affected by pore volume
True density
This refers to the ratio of mass to volume of solid particle without any
pores orcavities.
Apparent density
It refers to the ratio of mass to volume of a single solid particle
including closedpores (i.e., volume of solid material + volume of closed
pores within the particle).
Bulk density
It refers to the ratio of bulk mass to total bulk volume (solid volume +
pore volume + void volume) of the refractory brick.
• High density bricks with low porosity are good
for heat facing locations, while low density
bricks are good for heat insulation
applications
• The bulk density of the brick is useful in
assessing its mass for the purpose of knowing
total weight for choosing transport means,
assessing handling and transport cost,
designing civil structures for supporting the
furnace weight, etc.
Cold Crushing Strength (CCS)
• The cold crushing strength (CCS) represents
the ability of a refractory to resist failure
under compressive load at room temperature.
• What is the urgency of this property for such
high temperature-resistance material??
