Understanding Refractory API 936 Reading III

Understanding REFRACTORY For API936 Personnel Certification Examination Reading 3- Assorted My Pre-exam Self Study Notes 24th September 2015

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http://rarehistoricalphotos.com/remains-astronaut-vladimir-komarov-man-fell-space-1967/

Today’s Exam Result Releases (ASNT) 3 passes 1 flop. It is bad, not too bad.

20150925

too

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Exam Result Releases 3 passes 1 flop. It is bad, not too bad.

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Refractory for Aerospace

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http://rarehistoricalphotos.com/remains-astronaut-vladimir-komarov-man-fell-space-1967/

Refractory for Aerospace- Vladimir Komarov

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http://rarehistoricalphotos.com/remains-astronaut-vladimir-komarov-man-fell-space-1967/

Refractory for Aerospace

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http://rarehistoricalphotos.com/remains-astronaut-vladimir-komarov-man-fell-space-1967/

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The Magical Book of Refractory

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BODY OF KNOWLEDGE FOR API936 REFRACTORY PERSONNEL CERTIFICATION EXAMINATION API certified 936 refractory personnel must have knowledge of installation, inspection, testing and repair of refractory linings. The API 936 Personnel Certification Examination is designed to identify applicants possessing the required knowledge. The examination consists of 75 multiple-choice questions; and runs for 4 hours; no reference information is permitted on the exam. The examination focuses on the content of API STD 936 and other referenced publications.

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REFERENCE PUBLICATIONS: A. API Publications:  API Standard 936; 3rd Edition, Nov 2008 - Refractory Installation Quality Control Guidelines - Inspection and Testing Monolithic Refractory Linings and Materials.

B. ACI (American Concrete Institute) Publications:  547R87 - State of the art report: Refractory Concrete  547.1R89 - State of the art report: Refractory plastic and Ramming Mixes

C. ASTM Publications:  C113-02 - Standard Test Method for Reheat Change of Refractory Brick  C133-97 - Standard Test Methods for Cold Crushing Strength and Modulus of Rupture of Refractories  C181-09 - Standard Test Method for Workability Index of Fireclay and High Alumina Plastic Refractories  C704-01 - Standard Test Method for Abrasion Resistance of Refractory Materials at Room Temperatures

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Fion Zhang at Shanghai 24th September 2015

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Video Time- shotcrete refractory

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https://www.youtube.com/watch?v=s81LE7XXZ4A&list=PLey7s_Oct4OK9-7tMIx5cp9-RjSdetDTq

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Reading III Content    

Study note One: CHAPTER 12 Introduction to refractories Study note Two: Study note Three: Study note Four:

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Study Note 1: CHAPTER 12 Introduction to refractories

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CHAPTER 12 Introduction to refractories 12.0 Background Refractories are material having high melting points, with properties that make them suitable to act as heat-resisting barriers between high and low temperature zones. Refractories are useful in constructing application-specific high temperature areas/surfaces, particularly in furnaces or boilers, as they minimize heat losses through structure. The value of refractories is judged not merely by the cost of the material itself, but by the nature of job and/ or its performance in a particular situation. Specifically, the performance of a refractory depends on its qualities and quantities in three phases-solid, glass/ liquid, and pores-which govern the ultimate property of a refractory material.

http://www.cosmile.org/Manual/index.htm

A 'green bond' is developed by mixing various sizes of similar refractory material having some strength and property, which are changed during firing/heat treatment in the course of service. The qualities of refractories are thus dependent on their chemical, physical, mineralogical and thermal properties. Refractory materials are generally tailor-made on the basis of: 1. Process parameters like temperature profile, mode of operation, chemical environment, etc. 2. Expected quality characteristics 3. Best techniques for engineering and application, so that the final physical, chemical, mechanical, and thermal properties are compatible to the application Refractory materials are used in two different forms, namely, shaped and unshaped products.

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12.1 Shaped refractories The most familiar form of refractory materials is the rectangular brick shape. However, refractories are presently available in a variety of shapes and sizes for convenience in construction.

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12.2 Unshaped refractories There is a class of refractory materials which can form joint-less lining. This class of refractory materials is called monolithic. All unshaped refractory materials have this ability to form jointless lining, and hence they are grouped as monolithic.  Unshaped refractories are manufactured in powder form as granular material and known as castables, ramming masses, gunning mix, plastic masses, etc.  Castables are mixed with water before casting .  Ramming masses are first mixed with water or any other liquid to the required quality, and then rammed either manually or pneumatically with a heavy rammer.  Gunning masses are passed through a machine in which the powder material is put under pressure and conveyed pneumatically through a hose. The material gets mixed up with water before it exits the hose nozzle, and sticks to the surface on which it is applied to form a lining.  Plastic masses comprise ready-mix material that is applied manually in the furnace to form a lining. Charlie Chong/ Fion Zhang

Gun Masses

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http://upstaterefractory.com/on-site-services/gunning-repairs/

Gun Masses- NLMK BF-3 hot blast system gunning repair

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http://www.sevenrefractories.com/category/news/2014/

Gunning mass spraying on worn out refractories of LDConverter- The gunning machine is comprised of a telescopic gunning lance that is mounted on a

Carcass frame with electric drive, a water pump, a material tank, water and material hosepipes and a regulation valve for the remote-controlled adjustment of MgO base gunning mass and amount of water. A gunning repair is a time consuming operation and takes10- 12 minutes.

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http://buildindustrialpakistan.blogspot.com/2014/05/factors-confine-productivity-of-ld.html

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http://www.sevenrefractories.com/category/news/2014/

Experts at Works

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http://www.tbsgroup.co.nz/track-record/1029/rotary-kiln-relining-contract/

12.3 Classification The primary constituents of any refractory may be a single compound like alumina, silica or mullite, or a combination of these materials. Their melting points are as follows: • Silica (Si02)- 1723ºC • Alumina (Al203) - 2050ºC • Mullite (71.8% Al203, 28.2% Si02) - 1996ºC Relatively small amounts of oxides of sodium (Na20) and potassium (K20), and other minerals containing calcium (CaO), magnesium (MgO), titanium (Ti02), and iron oxide, promote liquid-phase formation at low temperatures. Hence, the presence of these oxides in refractories must be limited to trace amounts to avoid formation of low temperature liquid phase.

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Refractories in which the predominant constituents are alumina, silica or a combination thereof may be placed in the following categories: • Fireclay refractory • High alumina refractory • Silica refractory • Mullite refractory

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alumina [2]: Al2O3, the oxide of aluminum; melting point 3720°F (2050°C); in combination with H2O (water), alumina forms the minerals diaspore, bauxite, and gibbsite; in combination with SiO2 and H2O, alumina forms kaolinite and other clay minerals. alumina-silica refractories [2]: Refractories consisting essentially of alumina and silica, such as high-alumina, fireclay, and kaolin refractories. (Mullite?) alumina-zirconia-silica (AZS): Refractories containing alumina-zirconiasilica as a fusion cast body or as an aggregate used in erosion resistant castables and precast special shapes. amorphous [2]: Lacking crystalline structure or definite molecular arrangement; without definite external form. anchor or tieback [4]: Metallic or refractory device that retains the refractory or insulation in place.

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API 936

Mullites -

Mullite or porcelainite is a rare silicate mineral of post-clay genesis. It can form two stoichiometric

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forms 3Al2O32SiO2 or 2Al2O3 SiO2. Unusually, mullite has no charge balancing cations present. As a result, there are three different Al sites: two distorted tetrahedral sites and one octahedral. Mullite was first described in 1924 for an occurrence on the Isle of Mull, Scotland.[3] It occurs as argillaceous inclusions in volcanic rocks in the Isle of Mull, inclusions in sillimanite within a tonalite at Val Sissone, Italy and with emerylike rocks in Sithean Sluaigh, Scotland

http://rruff.info/Mullite/R141103

http://www.dakotamatrix.com/products/6258/mullite

Mullites

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Mullite Chemical Formula 3Al2O .2SiO2

Background Mullite is the mineralogical name given to the only chemically stable intermediate phase in the SiO2 - Al2O3 system. The natural mineral is rare, occurring on the Isle of Mull off the west coast of Scotland.

Composition Mullite is commonly denoted as 3Al2O3 .2SiO2 (i.e. 60 mol% Al2O3). However it is actually a solid solution with the equilibrium composition limits of 60~63 mol % Al2O3 below 1600⁰C.

Synthetic Mullite Various starting materials and preparation methods are used to make synthetic mullite ceramics. For example, a mixture of solids, a mixture of sols, or a mixture of sol and salt can each be used as the starting materials.

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http://www.azom.com/article.aspx?ArticleID=925

Similarly, a variety of preparation methods exist, for example reaction sintering of mechanically mixed powders, hydrothermal treatment of mixtures of sols and chemical vapour deposition. The starting materials and preparation method influence the properties of the mullite. Reaction sintered mullite made from mechanically mixed powders is usually characterised by low strength (