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What is Refractory lining and how it subsidizes energy saving?



Refractory lining are primarily constructed over the walls of furnace and boiler firing chamber to prevent heat conduction. Refractory lining are constructed using Heat retardant Refractory fire bricks, which paves a least conduction path for the heat energy to transfer. These refractory materials are made up of composites of Bauxite, Alumina and Silica, which are obtained from earth as minerals which are then processed and mixed with water for a covalent bonding to frame them into desired shape. These minerals are highly nonconductive in nature because of the lower atomic collision and hence offer excellent thermal resistant properties. 


The mixture is casted into desired shape and then pressed with a hydraulic machine to attain desired compressive strength. Once the mold is given the required compressive strength, it is then passed through the kiln dryer for removal of moisture and temperature fusing. The process also improves the tensile strength of the product thereby offering longer life and durability. Finally the bricks are stacked and then ready for dispatch. 

Providing layer of these bricks inside the shell / walls of Furnace improves fuel efficiency and also fuel conservation. The primary layer of the shell / wall has to be constructed with dual type insulation bricks. The inner most layer of the shall has to be backed up C/F insulation bricks and the next layer has to be constructed with H/F insulation bricks. The next layer has to be constructed with ISD 8 bricks which would be having an operation temperature of upto 1350 deg C. The final layer of the lining has to be constructed with High alumina bricks which would be typically of 50 to 70 alumina content based on the metal and has an operation temperature of upto 1700 deg C. 

A special refractory has to be used for the binding of bricks and also have the property of temperature resistant, which are typically possesses characteristic of alumina oxide which would offer thermal resistant. Once the layering has been finished, the lining has to be water sprayed for 24 hours in the interval of 6 hours and later it should be pre heated upto 50% of the operational temperature for 24 hours and then with fully operation temperature for upto 48 hours and finally the layers has to left for natural drying for 6 hours before the commercial operation of the furnace. 

The firing chamber has also been covered with the refractory layer to prevent conduction heat transfer. The firing chamber mouth / nozzle / burner have to be mounted with a high alumina grade burner block, which also diverges the flame into a conical form which offers better fuel combustion apart from the heat retardant. The fillings and other gaps or holes shall be blocked by castable refractory which shall be casted in situ condition. Once all the processes has been completed the furnace shall be made ready for operation. 

The process of refractory lining will be ended up with furl saving of upto 50% based on the environmental conditions and the fuel used. High combustible fuels will result’s in full combustion and energy saving. Further it also complies the industrial mandatory and other safety laws for the plant operation.

Refractory materials are available in various shapes, sized and grades,. Please contact us for a detailed insight about the process and the materials before you are planning for a refractory lining. We hope this article is found to be useful and you shall forward it your friends or network on your own interest. If you have any queries or in need of more information please feel free to contact us. If you have comments of question please write to us to “savethermalenergy@ gmail.com”

Location: SF 86/1F, Manickam Palayam, Karuvalur Road, Kunnathur Village, Post, Kovilpalayam, Coimbatore, Tamil Nadu 641107, India

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