Installation, Inspection, & Repair of Refractory Designs

Course Code: EM55

Course Objective

  • 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.
  • 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).

 

Target Audience

  • Design engineers
  • Process engineers
  • Maintenance engineers
  • Product development engineers and managers

  

Course Outline

Day 1

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
  • Continuous Types  Vertical
  • Continuous Types Horizontal

Day 2

Contemporary Hot Processing Equipment

  • 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

Day 3

Classification of Working Refractory

  • Dusts: Deposition and Abrasion
  • Conclusion: Principles of Working Refractory Construction
  • The Working Refractory Product Line
  • 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 Refractory
  • Physical Form and Installation of Linings

Day 4

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

Day 5

Elasticity and Plasticity

  • Mechanical Characterization of Refractory
  • Illustrative Mechanical Properties of Refractory
  •  Refractory Manufacture
  • Consolidated Flow Diagram for Refractory
  • From Raw Materials to Forming
  • Forming of Masonry and Special Shapes
  • Agglomeration for Sintered Grain
  • Drying and Firing of Refractory
  • Quality Assurance in Manufacture
  •  Refractory Installation and Maintenance
  • Structural Engineering
  • Masonry Construction
  • Installation of Monolithicse challenge of risk and uncertainty in modern business


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Date & Location

Date : 17 February 2019

Duration : 5 days

Place : Istanbul

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Date : 18 August 2019

Duration : 5 days

Place : Kuala Lumpur

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