Dry-Out and Heat-Up Procedures - 2015 Workshop

Dry-Out and Heat-Up
of Refractories Linings
Presented by Jens Decker
2015 Thermbond Autumn Workshop
Copyright Stellar Materials
Dry Out of Refractory Linings

Parameter
2 major factors determine the dry-out process:
Steam Pressure in the lining at a given temperature
Ability of the lining to resist this Pressure at a given temperature

Monolithic refractory materials contain water or water based
liquids which are needed to place the materials and help the
setting process. This liquid needs to be removed during dry-out!
The lengths of the dry-out process can vary depending on the
refractory material type and binder used.

Parameter
The dryout schedule is a function of:
Quantity and kind of liquid being used

Material density (porosity and pathways for steam)
Heat capacity and conductivity of materials installed
Lining thickness and components
Total quantity of material installed
Location (floor, ramps, side walls)
Unit being dried out
DryOut of Refractory Linings

Parameter
Heat-up process:
Heat-up starts above 220F!
When water converts to steam it expands 1670 times!
For example, 1 l (1 Kg) of water becomes 1.67 m3 of superheated gas by
volume at > 220F
As long as water converts into steam there is no temperature increase

in the material.
Increasing the temperature too fast can cause a high T between the
concrete surface and atmosphere!

Parameter
Explosion is the result of steam pressure in the
lining exceeding the tensile strengths of the
refractory!
The critical pressure is approximately 30bar!
Pressure Probe Set-Up

Parameter
Heat-up process:
During heat-up water will be driven to the cold side of the lining!
At the cold side water will concentrate at the lowest point of the unit
due to gravity!
In order to remove the water it needs to be converted into steam at the
cold side which means it can only removed if it reaches temperatures >
220F!
Mechanism of moisture
concentration on the cold face
T
T

Parameter
Conclusion:
Heat-up process happens in increments
Heat up temperature needs to be monitored and recorded on the hot
and cold side.
Weep holes at the lowest point ease water removal < 220F
Insulate the shell if weep holes are not an option

Process Requirements
It is important to maintain:
Positive Pressure
Convection
Frequent air exchange
Venturi-Effect
Draft of dry air + Temp.

Positive Pressure is required for uniform heat distribution in
the furnace
A frequent air exchange rate at positive pressure is required
to remove moisture from the furnace
The air exchange rate should be > 30 times the furnace
volume per hour.
Dry Out of Refractory linings

It is required to monitor the pressure in the furnace. The
pressure should be slightly positive at all times and should
not increase significantly during the heat-up process.
With higher temperature the gas volume increases in the
furnace. To keep the air exchange rate and furnace pressure
at the same level the stack damper should be opened
accordingly to release exhaust air.

Variables to monitor:
Burner /Air volume

Damper
Temperature
Pressure
P
Gas Law:
= constant
The pressure in the furnace will increase during the heat up process with
the temperature.
Natural gas converts to roughly 40% water during the combustion
process! This requires constant air exchange rate. The dry-out process
stops if the air is saturated with moisture and causes hydrothermal
conditions (pressure cooker)
If we want to maintain a constant air exchange rate at increasing
temperatures we have to regulate the gas volume by opening the damper
and keep the furnace pressure constant (positive)
How to determine the right

heat-up Equipment
Turn Down Rate
The ratio of the burners highest firing capacity to the burners lowest
firing capacity
Excess Air
The extra amount of air added to the burner above that which is
required to completely burn the fuel
How to determine the right

heat-up Equipment

It is important to use suitable burner equipment for heat up
procedures:
Above 1400F Radiation is the predominant heat transfer
Below 1400F Convection is important
to distribute the heat in the furnace
to pick up moisture from the refractory
to transport the moisture out of the furnace

If radiant heat is used for furnace heat up there is a potential for:
Non- uniform or low pressure in the furnace
Overheated areas in the furnace
Hydrothermal conditions
Dont use radiant heat for the heat-up process!!
Dry Out of Thermbond Linings

Air used for the heat-up process needs to be clean and free of
dust particles!
It is recommended to increase the temperature fast enough!
The reference thermocouple should be placed roughly
above the surface at the lowest point of the installed lining!

Process Requirements: Thermbond
Slow down temperature increase if stack and
reference thermocouple temperature differ by
100F to 200F
Avoid heating refractories from two sides

Characteristics of Thermbond Refractories

Characteristics of Thermbond Refractories
Thermogravimetrie
DIFK 51 550 00
25.06.03
0.0
1200
Gewichtsv erlust [%]
Startgewicht:
2715,4g
Endgewicht:
2505,0g
Gewichtsverlust:
7,75 %
-1.0
Ofentemperatur
1000
-2.0
800
-4.0
600
-5.0
-6.0
400
-7.0
200
-8.0
-9.0
0
0
10
15
20
Versuchsdauer [h]
25
Ofentemperatur [C]
Gewichtsverlust [%]
-3.0
1400
Temperature C
1200
1000
800
Conventional Castable 205mm
600
400
LPB-Refractory 205mm
200
Phosphate Bonded Plastic 205mm
0
0
16 24 32 40 48 56 64 72 80
Time (hours)
Summary
Parameter that determine the heat-up schedule
Liquid phosphate bond specific requirements
Liquid phosphate bond heat-up characteristics
How to determine a dry out schedule
Dry-Out and Heat-Up

of Refractories Linings
Presented by Jens Decker

Dry-Out and Heat-Up Procedures - 2015 Workshop

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Dry-Out and Heat-Up Procedures - 2015 Workshop

Uploaded by

Copyright:

Available Formats

Dry-Out and Heat-Up

Copyright Stellar Materials

Dry Out of Refractory Linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

Dry Out of Refractory Linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

Dry Out of Refractory Linings

Quantity and kind of liquid being used

Copyright Stellar Materials

DryOut of Refractory Linings

As long as water converts into steam there is no temperature increase

Copyright Stellar Materials

DryOut of Refractory Linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

Pressure Probe Set-Up

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

DryOut of Refractory Linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

DryOut of Refractory Linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

DryOut of Refractory Linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

DryOut of Refractory Linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

Dry Out of Refractory linings

Copyright Stellar Materials

Dry Out of Refractory linings

Burner /Air volume

Copyright Stellar Materials

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

How to determine the right

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

How to determine the right

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

Dry Out of Refractory linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

DryOut of Refractory Linings

Dont use radiant heat for the heat-up process!!

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

Dry Out of Thermbond Linings

2015 Thermbond Autumn Workshop

Copyright Stellar Materials

Dry Out of Refractory Linings

Avoid heating refractories from two sides