Course details

Overview ?

Course Description

This training course is designed to give a detailed discussion of the subject of refractory technology as related to high-temperature requirements for different industries. The course will emphasize on the practical aspects of refractory selection, installation, and repair techniques in a number of industrial applications. In order for the course material to suit participants with or without formal training and/or scientific background in the subject, the course will be delivered such that most of technical terms and concepts will be clarified by both scientific definition and examples. The course material will be prepared so that easy follow-up of the lectures and subject in general is achieved. The course is divided into nine main areas: Principles of hot processes and their requirements, Properties of refractory materials (mechanical, thermal and corrosion resistance), Refractory compositions and structures and their relation to property and performance, Refractory selection criteria, Refractory manufacturing methods, Configurations and installations techniques, Refractory system design, Performance in service, Quality and Reliability considerations. The course is designed such that no previous background in metallurgy is necessary. The course can, also, be tailored for specific needs if required by certain participants.

Course Objective

To familiarize participants with the main concepts and technical terms of industrial refractory materials.
To explain to participants the different types of hot processes and their requirements.
To explain to participants the different types of industrial refractories
To explain to participants how to relate process requirements to refractory properties (mechanical, thermal, electrical and chemical/corrosion).
To provide participants with the basic knowledge and skills for selection of different refractory materials based on process requirements.
To introduce participants to different manufacturing methods applied to refractory materials and their installation techniques.
To explain to participants how refractory materials respond to different service conditions and issues related to their quality and reliability.

Who Should attend?

Design engineers, process engineers, maintenance engineers and personnel, refractory supervisors and refractory personnel, product development engineers and managers, mechanical engineers, metallurgists, Inspection people, quality control engineers and technicians and people involved buying and installing refractories.

Course Outline

Introduction

Technical Perspectives
Historical Perspectives

Foundations of Hot Processing

Computational Quantities and Conversion Factors
Hot Processing Temperatures and Their Measurement
Process Chemistry and Environments

Foundations of Refractory Application

Contemporary Hot Processing Equipment
Continuous Types – Vertical
Continuous Types – Horizontal
Batch Types – Circular
Batch Types – Rectangular
Other Refractory Applications

Principles of Thermal Stability

Melting Points of Substances
Melting of Oxide Mixtures
Microstructural Integrity

Principles of Corrosion Resistance: Oxidation-Reduction

Importance of Corrosion
Gibbs Free Energies
Refractory Alteration by Oxidation-Reduction

Principles of Corrosion Resistance: Hot Liquids

Liquid Penetration and Dissolution-Corrosion
Factors Governing Penetration
Factors Governing Dissolution

Principles of Corrosion Resistance: Hot Gases and Dusts

Atmospheric Penetration and Condensation
Dusts: Deposition and Abrasion
Conclusion: Principles of Working Refractory Construction

The Working Refractory Product Line

Classification of Working Refractories
Maximum Service Temperatures
Maximum Service Temperatures
Corrosion Resistance
Qualifications for Working Refractory Service

The Insulating Refractory Product Line

Applications and Application Criteria
Classification of Insulating Refractories
Physical Form and Installation of Linings

Refractory Practice

Refractory Qualifications in Review
Refractory Practice from Qualifications
Catalogue of Refractory Practice

Design Properties: Thermal and Electrical

Reversible Thermal Expansion
Permanent Deformation
Specific Heat
Thermal Conductivity
Electrical Conductivity

Design Properties: Mechanical

Elasticity and Plasticity
Mechanical Characterization of Refractories
Illustrative Mechanical Properties of Refractories

Refractory Manufacture

Consolidated Flow Diagram for Refractories
From Raw Materials to Forming
Forming of Masonry and Special Shapes
Agglomeration for Sintered Grain
Drying and Firing of Refractories
Quality Assurance in Manufacture

Refractory Installation and Maintenance

Structural Engineering
Masonry Construction
Installation of Monolithics

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