AN ANALYSIS OF THE EFFICIENCY GAINED WITH REPLACEMENT
OF THE TRADITIONAL LINING OF BELL AND CHAMBER
METALLURGICAL FURNACES BY LINING MADE OF
REFRACTORY CERAMIC FIBER
K. M. Mikhalev
Translated from Novye Ogneupory, No. 10, pp. 16 – 20, October, 2010.
Original article submitted April 22, 2010.
In theory, there exist two methods of replacement of traditional lining made of fireclay insulation articles by
lining made of OKB Cerablanket refractory ceramic fiber. The first method consists in production of lining
made of OKB Cerablanket rolled material with the material being formed in undulating fashion into sections
with height of a wave equal to the thickness of the lining. In the second method, the lining is fabricated from
ready-made modular Z-blok sections with integrated anchors made of stainless steel. Sections fabricated from
OKB Cerablanket rolled material is arranged in a linear or checkerboard arrangement. The operating life of
lining fabricated from refractory fiber is practically unlimited. A number of conditions that guarantee long and
effective service of the materials must be fulfilled, for example, the furnace temperature must not exceed
1170°C, rate of gas flow must not be greater than 20 – 30 m/sec, and the lining must not be subjected to me-
Keywords: lining, refractory, heat-insulation material, temperature, heat flux
There exist basically two methods of replacement of tra-
ditional lining consisting of fireclay heat-insulation articles
by lining made of OKB Cerablanket refractory ceramic fiber.
The lining is applied to the furnace of a metallurgical
firm from rolled material fabricated by OKB Cerablanket,
the material formed in undulating fashion into sections with
height of each wave equal to the thickness of the lining. In
this variant the lining of the crown is fabricated with a thick
ness of 300 mm. The roll is cut lengthwise with respect to the
thickness of the crown, and then arranged in pairs and in
stalled in the crown in rows. After four rows have been in
stalled, the material is compacted manually or mechanically
attached to the furnace jacket by means of a welded joint of
stainless steel. The anchors are located along the edge of the
crown 250 – 300 mm apart. Another four rows of material
are then fitted on the mounted anchor. Further packing of the
lining of the crown is realized in similar fashion. After the
last row has been installed and mounted in the jacket, mate-
rial that was left over when the rolls had been cut lengthwise
is fit into the resulting gap. The flowchart of the process of
lining a furnace crown is shown in Fig. 1.
The lining of the walls is created in the required design
thickness. A packed “accordion” of sections fabricated from
fiber 610 mm in height with thickness equal to the thickness
of the lining is installed vertically. The first section is made
shortened, from four waves of material with height of a wave
equal to the thickness of the lining. To make the assembly
process easier, the sections are constricted by means of cord
or tape. Following installation a module is compressed either
by hand or mechanically and then attached by means of a
welded connection to the jacket by means of two anchors
made of stainless steel. A section consisting of eight waves is
next attached to the previously installed anchor mounting.
The remaining roll is trimmed and a similar modular section
is formed from it. Further packing of the lining of the walls
of the heating unit along the perimeter is realized in this way.
After the last module has been mounted in the row and se
cured in the jacket, material that has remained following
preparation of the sections is inserted into the resulting gap.
A strip of OKB Cerablanket material 25 mm in thickness
with width equal to the width of the lining and length equal
Refractories and Industrial Ceramics Vol. 51, No. 5, January, 2011
1083-4877/11/5105-0330 © 2011 Springer Science+Business Media, Inc.
From the proceedings of the International Conference of Metal
lurgists and Refractory Workers (April 22 – 23, 2010, Moscow).
OOO MorganTermal Keramics Sukhoi Log, Sukhoi Log, Sverd
lovsk District, Russia.