This project aims to characterize the properties of magnesia-alumina spinel refractories to improve furnace efficiency. Spinel refractories offer improved high-temperature creep resistance needed as furnaces are pushed to higher outputs. The project will evaluate the creep, thermal conductivity, microstructure, and phase composition of spinel refractories through testing. Characterizing these properties will allow modeling of furnace performance and structure integrity, enabling more efficient furnace designs and potential energy savings of 90 trillion Btu/year.
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Industrial Materials For The Future: C S M M A S R
This project aims to characterize the properties of magnesia-alumina spinel refractories to improve furnace efficiency. Spinel refractories offer improved high-temperature creep resistance needed as furnaces are pushed to higher outputs. The project will evaluate the creep, thermal conductivity, microstructure, and phase composition of spinel refractories through testing. Characterizing these properties will allow modeling of furnace performance and structure integrity, enabling more efficient furnace designs and potential energy savings of 90 trillion Btu/year.
This project aims to characterize the properties of magnesia-alumina spinel refractories to improve furnace efficiency. Spinel refractories offer improved high-temperature creep resistance needed as furnaces are pushed to higher outputs. The project will evaluate the creep, thermal conductivity, microstructure, and phase composition of spinel refractories through testing. Characterizing these properties will allow modeling of furnace performance and structure integrity, enabling more efficient furnace designs and potential energy savings of 90 trillion Btu/year.
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Industrial Materials For The Future: C S M M A S R
This project aims to characterize the properties of magnesia-alumina spinel refractories to improve furnace efficiency. Spinel refractories offer improved high-temperature creep resistance needed as furnaces are pushed to higher outputs. The project will evaluate the creep, thermal conductivity, microstructure, and phase composition of spinel refractories through testing. Characterizing these properties will allow modeling of furnace performance and structure integrity, enabling more efficient furnace designs and potential energy savings of 90 trillion Btu/year.
Copyright:
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Industrial Materials For The Future
Project Fact Sheet
C HARACTERIZATION AND S TRUCTURAL M ODELING OF M AGNESIA- A LUMINA S PINEL R EFRACTORIES
B ENEFITS The results from this project can be used by glass manufacturers and furnace and process heating designers to further accelerate the conversion to oxy-fuel firing and to achieve enhanced energy efficiencies and environmental improvements.
S PINEL REFRACTORIES OFFER IMPROVED HIGHTEMPERATURE CREEP AND PROPERTIES
Furnace designers and furnace/refractories engineers recognize that more optimum furnace superstructure design and the use of appropriate refractories are needed as glass production furnaces are continually driven toward greater output and energy efficiencies (and concomitant harsher operating conditions). The conversion to oxy-fuel from traditional air-fuel firing is a means to meet these objectives. Refractories for both oxy- and air-fuel-fired furnace superstructures are subjected to high temperatures during service and may appreciably creep or subside if the refractory material is not creep resistant or if it is subjected to high stress or both. Published engineering creep data are essentially nonexistent for almost all commercially available refractories used for glass furnace superstructures. Furnace designers can ensure that superstructure structural integrity is maintained or predicted if the creep behavior of the refractory material they are using is well understood and well represented by appropriate engineering creep models.
A PPLICATIONS Engineering creep data for refractories can be used by furnace engineers as input in finite element analysis to model or optimize the long-term mechanical performance of glass-melting furnace superstructures. Data for candidate refractories for oxy-fuel-fired furnaces will help engineers optimize furnace superstructure designs with these materials and will help them to more confidently consider the conversion to oxy-fuel firing. Industries impacted include Aluminum, Glass, Strain (%) 0 -0.02 -0.04 -0.06 -0.08 -0.10 -0.12 -0.14 0 50 100 150 200 Time (h) 250 300 350
Meltalcasting, Heat Treating, and Process Heating.
Cathodoluminescent imaging of MgO refractory showing fused mullite grains (dark gray), trace amounts of alumina (light gray), and zirconia particles (bright white).
OFFICE OF INDUSTRIAL TECHNOLOGIES ENERGY EFFICIENCY AND RENEWABLE ENERGY U.S. DEPARTMENT OF ENERGY
Project Description Goal: The goal of the project is to characterize key properties of refractory materials to improve thermal efficiencies and management in industrial combustion environments. Issues: A major barrier to the utilization of oxy-fuel-fired furnaces is that the higher operating temperatures in an oxygen-rich environment increase the rate of deformation (creep) and hasten alkali-induced corrosion. This had led to problems of unexpected failures of the crown refractories and an increased number of glass defects due to corrosion. This necessitates that both creepresistant and corrosion-resistant refractories be used in furnace superstructures. One potential solution to these problems involves the use of new refractories, including magnesia-alumina spinel, which is now available in bonded and fused versions. This project seeks to determine reliable thermomechanical and thermophysical data for these new commercial refractories. Approach: Physical and mechanical properties (including creep, thermal conductivity, microstructure, and phase composition) will be evaluated for two spinel glass tank crown refractories. This information will then be used to model and validate the long-term reliability of glass tank crowns. Potential payoff: More efficient and economical designs of glass-melting furnace superstructures will result, and furnace engineers will know which refractory materials perform better than others and how to model the hightemperature mechanical performance. The result will be more energy-efficient furnaces and industrial processing systems. If implemented, energy savings of 90 trillion Btu/year could be realized. F OR A DDITIONAL I NFORMATION, P LEASE C ONTACT
P RIMARY University of Missouri Rolla, MO
P ROJECT P ARTNERS Glass Industry Advisory Committee (GIAC) Oak Ridge National Laboratory Oak Ridge, TN
Progress and Milestones
Modify creep test frame design and operations. Acquire test specimens. Finalize test matrix for the spinel refractories. Complete creep testing and measurement of thermal properties.
EERE Information Center Phone: (877) 337-3463 Fax: (360) 236-2023 eereic@ee.doe.gov
Visit our home page at http://www.eere.energy.gov/industry/ Office of Industrial Technologies Energy Efficiency And Renewable Energy U.S. Department of Energy Washington, DC 20585 http://www.oit.doe.gov
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