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Selecting the appropriate lining material for chemical furnaces is a critical decision that significantly impacts the furnace's performance, lifespan, and operational costs. However, many engineers often fall into several common selection pitfalls, which can lead to sub - optimal furnace operation and premature wear.
One of the most prevalent misconceptions is neglecting thermal shock resistance. Furnaces that undergo frequent start - stop cycles or experience large temperature fluctuations require lining materials with high thermal shock resistance. Failing to consider this factor can result in cracks and spalling of the lining, reducing the furnace's lifespan and potentially causing safety hazards.
Another common mistake is misjudging the thermal conductivity of the lining material. A material with high thermal conductivity may lead to excessive heat loss, increasing energy consumption. Conversely, underestimating the thermal conductivity might result in overheating of the furnace shell.
Underestimating mechanical strength is also a significant error. The lining material must withstand the mechanical stresses during the operation, such as the impact of charging materials and the vibration of the furnace. Insufficient mechanical strength can cause the lining to break or deform, affecting the furnace's normal operation.
In the following, we will compare the key performance parameters of high - alumina, ordinary clay, and hollow - ball insulating bricks, which are commonly used in chemical furnaces operating below 1350°C.
| Material | Thermal Conductivity (W/m·K) | Linear Change Rate (%) | Thermal Shock Resistance |
|---|---|---|---|
| High - Alumina Brick | 0.8 - 1.2 | ≤0.5 | Fair |
| Ordinary Clay Brick | 1.0 - 1.5 | ≤0.8 | Good |
| Hollow - Ball Insulating Brick | 0.2 - 0.4 | ≤0.3 | Poor |
From the table, we can see that different materials have distinct performance characteristics. High - alumina bricks have relatively low thermal conductivity and good dimensional stability, but their thermal shock resistance is only fair. Ordinary clay bricks have a relatively high thermal conductivity but excellent thermal shock resistance. Hollow - ball insulating bricks have the lowest thermal conductivity, but they are not suitable for environments with high thermal shock.
In chemical reactors that frequently start and stop and experience large temperature differences, high - strength refractory clay insulating bricks are more suitable. For example, in a chemical plant where a reactor furnace is started and stopped several times a day, the temperature inside the furnace can fluctuate between 200°C and 1200°C. In this case, high - strength refractory clay insulating bricks can better withstand the thermal shock and mechanical stress.
According to the test data, in a similar furnace, after replacing the original lining material with high - strength refractory clay insulating bricks, the furnace's service life was extended by 30%, and the energy consumption was reduced by 20%. A customer feedback also showed that after using high - strength refractory clay insulating bricks, the maintenance frequency of the furnace decreased significantly, and the production efficiency increased.
When selecting the lining material for chemical furnaces, engineers should first fully understand the furnace's operating conditions, including the temperature range, frequency of start - stop, and mechanical stress. Based on these conditions, a comprehensive evaluation of the material's thermal conductivity, thermal shock resistance, and mechanical strength should be carried out.
It is recommended to choose materials with high thermal shock resistance in environments with frequent temperature fluctuations. In addition, although the initial cost of high - strength refractory clay insulating bricks may be slightly higher than that of some other materials, considering their long - term value, such as extended furnace life and energy savings, they are a more cost - effective choice.
To avoid the common selection mistakes, engineers can also refer to the selection reference manual or consult our technical experts. Get the selection reference manual now to learn more about the technical parameters of our products and make a more scientific selection.
