Indian Standard

REFRACTORIES FOR CHIMNEYS -

RECOMMENDATIONS

ICS 81.080; 91.060.40

0 BIS 1996

BUREAU OF INDIAN STANDARD-S

MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002

September 1996 Price Group 2

Refractories Sectional Committee, MTD 15

FOREWORD
This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Refractories
Sectional Committee had been approved by the Metallurgical Engineering Division Council.
Refractories are the primary materials used in the construction of all furnaces in the ferrous and non-ferrous
industries.
These are used in the lining of ladles, hot metal mixers, metal retaining vessels and the flues and stacks through
which hot gases pass, Refractories are used for lining of boilers, pressure vessels, kilns and vessels using hot
fluids at various temperatures, In short, refractories can be termed as those materials of construction exposed to
high temperatures and corroding atmospheres and they retain their shapes and characteristics without reacting
with the molten material or the corroding atmospheres.
Refractory materials are costly and a sudden failure of any refractory may result in great loss of time, ~productand
equipment. ThereforeJhe selection of refractories suitable for a particular application is of paramount importance.
Cost-benefit-analysis is often the basis of selection of such refractories. Refractories best suited for an application
may not necessarily have the longest life. In selecting the proper refractories, a balance is struck between the
initial installed cost and in-service performance.
Steel industry uses over 70 percent of the refractories consumed in the country, However, integrated steel plants
employ a team of refractory engineers and specialists for selection and use of refractories. On the other hand,
non-ferrous sector, the glass industry and the other high temperature and corrosion intensive industries do not
always employ refractory specialists. The application of refractories in such industries is nevertheless very
critical and any premature failure may lead to long down times and loss of production.
With the above problems of unorganized sector in mind, the Refractories Sectional Committee, MTD 15 decided
to bring out an Handbook for Refractories which could bemusedas a reference book by the unorganized sector. The
Refractories Sectional Committee, MTD 15 allotted this work to a specially constituted panel, MTD 15/P-1,
Panel for the Handbook for Refractories, consisting of experts from various fields of activities which the handbook
will eventually cover, It is hoped that the work of this panel would lead to improvement of refractory engineering
practices and overall conservation of materials and energy,
The handbook will first be published in parts as recommendations; each recommendation dealing with particular
industry/process. Later on, when all recommendations are published, these would be combined to form a handbook.
It is intended to cover the refractories used in the following industries in the Handbook for Refractories:
,
1. Refractories for cement kiln systems (large plants);
2. Refractories for mini-cement plants;
3. Refractories for petroleum and petrochemical industry;
4. Refractories for pulp and paper industry;
5. Refractories for lime kilns - rotary type and shaft type;
6. Refractories used in the primary processing of non-ferrous materials such as aluminium, copper,
zinc, lead, etc;
7. Refractories used in manufacture of ferro-alloys;
8. Refractories used in the~pouring practices for ferrous and nonferrous materials;
9. Refractories for incinerators;
10. Refractories used by the ceramic and refractory industry;
11. Refractories for the nuclear fuel plant;
12. Refractories for the glass industry;
13. Refractories for the glass fibre industry; and
14. Refractories for the iron and steel industry.

( Continued on third cover page )

 IS 14374 : 1996

Indian Standard
REFRACTORIES FOR CHIMNEYS -
RECOMMENDATIONS
1 SCOPE - Flue gas mass flow,
- Highest and lowest temperatures of flue
Thts standard covers the recommendations for
refractories generally used for chimneys. gas on entering the chimney;
- Composition of flue gases;
2 REFERENCES
- Flow velocity of flue gases;
The Indian Standards listed below are necessary - Pressure condition inside the chimney;
adjuncts to this standard:
- Resulting chemical stresses;
IS No. Title - Mechanical load due to wind, effect of
3677 : 1985 Unbonded rock and slag wool for temperature on the structure, earthquakes
thermal insulation (secondrevision ) and vibrational effect; and
- Economical conditions considering the life
WI1 : 1967 Glossaryof terms relating to refractory
span and operation method.
IIWlXidS

Mainly, reinforced concrete shell chrmney and its

4832 Chemical resistant mortars: Part 1
refractory lining are discussed in this standard.
(Part 1) : 1969 Silicate type
5 OPERATION AND DESIGN FEATURES
4860: 1968 Acid resistant bricks
5.1 The function of the lining is to direct the flue gases,
8154: 1993 Preformed calcium silicate insulation
as a thermal insulator and protector, against corrosion
( for temperature up to 650°C ) (first
of the shell and other load bearing structure. It-is mostly
revision )
designed as a sectional type, the loads of which are
3 TEIUWNOLOGY transmitted to the shaft but fret standing continuous
lining is also possible.
For the purpose of this standard, the definitions given
in IS 404 1 : 1987 shall apply. 5.2 In case of sectional type lining, the platform to
support, the liner can be ring-shaped slabs inserted in
4 INTRODUCTION the concrete wall with an intermediate expansion joint
The basic function of a chimney is to provide an escape or also circular girders prefabricated with diagonal
for gases from furnaces and to ensure that they are members and supported on the shell wall.
delivered to a point where they are least likely to do any 5.3 At low temperature of operation, independent
harm and to provide necessary draft for the working of lining supported at the base and erected as one sectton
the furnace/kilns. It thus becomes necessary to decide up to the chimney top can be sufftcient. Due to the
on the form the chimney is to take and the material of compression resulting from the dead weight of such
which it is to be constructed. lining, considerable wall thickness is necessary and
Chimneys, mainly free standing, are constructed in three because of the thermal stresses acting on the bricks,
methods: the chimney must be operated at lower temperature. The
advantage is the simple and uniform construction
- Reinforced concrete shell, without load bearing platforms in the concrete shell.
- Brick work shell, and Disadvantages are, the large wall thickness and the risk
of cracking in the continuous brickwork bonds/joints,
- Steel shell.
which can affect the life span of the whole lining.
Depending on the following factors one of the above
5.3.1 For this reason, sectional linings are more suitable
construction and lining design is selected:
specifically at higher temperature of flue gas operation.
- Location;
5.4 For most !oads, a sectional lining which guarantees
- Chimm, the free thermal expansion of each section is chosen.

1
1s 14374 : 1996

Each section rests on the supporting platforms, using
the concrete ring beam, ring shaped girders on the beam
supported by corbels. This arrangement results in
the formation of a cavity/annular space between the
lining and the shell.
5.5 Oil burning plants, produce SO* gas and sulphuric
acid by catalytic conversion of SO* to SO3 The dew
point of SO3 lies between 80 and 150°C. Thus, it is
necessary to protect the liner and the shell against acidic
corrosion in the chimneys operating below dew point.
6 LINING AND INSULATION MATERIALS
6.1 Due to possibility of large amount of condensate;
being deposited, the brickwork liner requires an
acid protection and must be provided with an
almost tight sealing. For this purpose, brick qualities
are recommended which are having a high compressive
strength. sufficient low porosity and good chemical
resistance. Acid resistant chimney bricks should be
chosen according to their resistance to attack by acids.
Characteristics of some of the bricks are with bulk
density greater than 2.0 kg /dm3, water absorption less
than 10 percent, compressive strength between 20 and
90 N/mm2 depending on the type of brick, depending
upon the dimensions of the chimney and temperature
of the flue gases, the lining thickness is selected
judiciously, generally between 115 and 230 mm for the
sectional lining so as to form a stable shell-shaped
Structure
that these layers will not be destroyed nor their efficiency
~reduced by heat, gases and condensates.
6.5 Chimneys with higher operating temperatures
consist of an acid and heat resistant liner, an acid-proof
thermal insulation layer, aventilated intermediate annular
cavity and exterior shell.
6.6 Slabs of foamed glass or slag, diatomaceous or
mica-bricks, mats of glass and mineral wool are suitable
heat insulation materials. These~insulation materials are
placed on outwardly cantilevered bricks of the lining.
Since their thermal coefficients are different, separating
layer must be provided between the insulation layer and
the ceramic layer. This is achieved sometimes b\;
including layer of corrugated and board, which
disintegrates after the chimney is put into operation.
6.7 The insulating construction apart from low
thermal conductivity and good thermal resistance, the
characteristics required are:
a) Adequate strength and stability of the
insulating layer,
b) As low liquid absorption as possible,
c) Satisfactory chemical resistance, and
d) Simple installation.
6.8 Experience has shown that a satisfactory thermal
insulation can never be obtained by pouring loose
material, such as siliceous earth, vermiculite, etc, into
the space between inner liner and shell.

6.2 The required resistance to temperature changes 6.9 The installation of the insulating layer directly on
depends on the operating mode of the chimney. The the inner surface of the shell is the most convenient
jomts of the brlckwork must be completely filled, for method of the application. However, for practical
which a potassium silicate mortar is generally preferred, reasons the thermally insulating layer has to be
to Improve the bond between the filling material and arranged on the outer surface ofrhe ceramic liner.
brick application of highly a!kaline silicate as a binder 6.10 Characteristics of different materials, such as
for mortar is recommended. Silicate mortar is a mixture refractory brick, acid alkali resistant brick, mica brick.
of cement powder including hardeners and a solution mineral wool, etc, are given in Tables 1 to 5.
of alkali silicate in mortar satisfying the characteristics
given in IS 4832 (Part 1) : 1969. Synthetic resin mortars Table 1 Acid Resistant Bricks
are available for cases of alkaline corrosion. However, (See IS 4860 : 1968)
when selecting this type of mortar, consideration must
be given to the temperature limits also.
SI No. Characteristics Requirements

6.3 An improved bond strength in lining is achieved (1) (2) (3)

by using either lateral or base and top tongue and groove Water absorption. percent, 4
i)
bricks (see Fig. 1 ). MaU
ii) Flexural strength, kgicm2, 70
6:4 The temperature drop frm the inside of the lining to Min
the exterior of the shell, across the intermediate annular iii) Compressive strength, 500
cavity. leads to thermal stresses in the ceramic lining kg/cm*, Min
which should not exceed the admissible tensile load of iv) Resistance to acid Loss in weight shall
the bricks approximately of 1.6 fi/mm2. Consequently, not exceed 4 percent
the liner and the thermal insulation layers between the
liner and the outer shell must be designed to guarantee

2
 IS 14374 : 1996

,/
'h

Shaped Radial Block with

Shaped Slab with Continuous
Continuous Groove and Tongue
Groove and Tongue

Shaped Radial Block with Lateral Groove and Tongue

FI:rc
i. 1 SWl’E’ED &UCKS FOR &MNEY I,l;.i~W;

3
IS 14374 : 1996

Table 2 Calcium Silicate Block Table 4 Mica Insulation Brick

(S’eeIS8154: 1993) (Clause6.10)
(Clause6.10)
SI Characteristics Requirements
No.
Sl Characteristics Requirements Grade 600 Grade 700
No.
(1) (2) (3) (4)
(1) (2) (3)
i) Bulk density, kg/m’, Min 600 700
i) Service temperature, “C 650
ii) Cold crushing strength, 8 1”
ii) Composition Hydrous calcium kg/cm*, Min
silicate with
iii) Apparent porosity 74 70
suitable tibres
percent, Max
iii) Density, kg/m’ 200-300
iv) Shrinkage on heating at 0.2 0.2
iv) Flexural strength, kg/cm*, A4in 2.4 1 000°C for 24 h, percent,
v) Compressive strength, kg/cm*, Min MaW
lIeformation at 10 percent VI Thermal conductivity at
a) Drl\’ t.unhestcd) 4.2 mean temperature
b) Wet ( 18 h water rmntersron) 17 (kcal/mlh”C)
cj Lieated ( 24 h water 3.45 a) 50°C 0.12 0.12
immersion ) b) 350°C 0.18 0.22
Vi) linear shrinkage, percent, MUX 2.0
after 24 h heat soaking Table 5 Mineral Wool Insulation
vii) Loss in weight, percent, Mar 15 (See IS3677: 1985)
after 24 h heat soaking
( Clause 6.10 )
viii) Thermal conductivity at mean
temperature ( kcal/m/h’C )
Sl No. Characteristics Requirements
a) 93°C 0.065
(1) (2) (3)
b) 149’C 0.52
c) 204°C 0.555 i) Bulk density, kg/m’, Min 200
ii) Sulphur content, percent, MUX 0.6
iii) Thermal conductiviry at 150°C 0.045
mean temperature ( kcallm/h’C )

7 START-UP
Table 3 Low Iron Fireclay Brick 7.1 The start-up operation of a new liner must be
( <&use 6 10 ) carefully performed because the greatest chance of
cracks occurring in the ceramic liner is during the first
start-up.
SI To. Characteristics Requirements
(1) (2) (3) 7.2 Warm air at slowly increasing temperatures is
injected for drying. Depending on the chimney
i) Al#J,, percent, Min 30
dimensions the procedure can last several days. The
ii) Fez03 percent, Min 1.6
warming up process up to the operating temperature
iii) PCE, orton, MUX 30
should also be extended over scvcral days. In the
iv) RUL, r,“C, Min 1 300
beginning warm air is used, which is later replaced by
v) PLC at 1 350YY5h percent, Max 1 .o
steam injection. Continuous temperature measurement
vi) Apparent porosity, percent, MUX 18
of the outer and inner faces of the liner ensure that the
vii) Cold crushing strength, kg’ cm2, 250
temperature difference in the brick stays within the
Min
admissible tension range.

4
( Continued from second cover page )

Each recommendation will cover the following aspects of the refractory engineering:
a) Process of manufacture used;
b) Types of boilers/furnaces systems;
c) Objectives of the refractory lining;
d) Design engineering features of the furnaces;
e) Principal zones and sections of the furnaces;
f) Service conditions in different zones including service temperatures;
g) Details of lining used in various zones and sections,
h) Refractory installation practices used for the boilers/furnaces;
j) Consumption pattern of refractories;
k) Application standards, namely Indian and other standards, design codes, stress, considerations,
etc; and
m) Miscellaneous aspects not covered from (a) to (k).
This standard covers the principle of operation of the chimney type, constructional details, types of linings,
typical properties of linings, recommended refractory materials and the methods used in the lining of chimneys.
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value,
observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with
IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )‘. The number of significant places retained in
the rounded off value should be the same as that of the specified value in this standard.
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development of the activities of standardization, marking and quality certification of goods and attending to
connected matters in the country.

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Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards areralso reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue
of ‘BIS Handbook’ and ‘Standards : Monthly Additions’.

This Indian Standard has been developed from Dot No. MTD 15 ( 3526 ).

Pmendments Issued Since Publication

Amend No. Date of Issue Text Affected

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