Development of a thermal analysis platform for refractory linings of industrial installations

Abstract

Refractories are non-metallic materials, and they are made of oxides and/or non-oxide compounds, which can resist high-temperature applications without melting or decomposing. They usually present high thermal-shock resistance and high chemical stability even in harsh media. Two fundamental functions of refractories at high-temperature processes are guaranteeing the integrity of the process and isolating it from the environment, which impacts directly on the energy losses and safety of the industrial sites. Energy conservation in industrial processes means reducing their environmental impacts and CO2 emissions, which are the biggest challenges for industries in the coming decades, specially due to their high fossil fuel consumption. These fuels are expensive, non-renewable, and responsible for severe climate changes. In this context, thermal management is necessary, supporting the materials selection process for projecting refractory linings, which impacts the operational temperatures, material's and process' performance. Due to the severe mechanical and thermal solicitations of the high-temperature processes, there are several classes and types of refractories in the market that leads to a very complex optimization project of costs, performance, and type of application. The development of a platform for thermal analysis of refractory linings allows the investigation of different scenarios and thermal solutions for the lining, aiming for the reduction of energy consumption, and the optimization of industrial processes. The method selected for reaching these solutions was the FEM (finite element method), and it will be available online, leading to low-cost and tailor-made solutions. Part of the platform features will only be available upon licensing and all the users will help us in our efforts to develop new products, increasing the start-up market value and competitiveness. (AU)