Palmer technologies: ATENA refractory structure analysis

The study of refractory structures [1,2,3,4,5] over the past twenty years has shown that refractory material behaviour is highly non-linear with time and temperature. It is well recognised that the best method to study refractory structures is numerically, due to the interaction of the composite layers (shell, insulation hot-face) forming the structure. The behaviour of refractory structures is complex and had it simply been the case of applying fundamental engineering calculations under steady state conditions then the failure of refractory structures would have been solved many years ago.

It is clear that the design of refractory structures requires the use of numerical software with non-linear functionality. ATENA is a non-linear fracture mechanics based software designed for reinforced concrete structures and is ideally suited for analyzing refractory concrete structures. The use of this analysis technique coupled with field observations is allowing us to understand the behaviour of refractory structures.

The heat transfer analysis of multi-layer refractory concretes in both transient and steady state conditions is particularly important for many pyro-processing industries. It is clear that the design of refractory linings is becoming increasingly important both structurally and in energy efficiency terms. Lowering greenhouse gas emissions will become necessary and economics will drive more thermally efficient designs. Also industry “fitness for service” (FFS) guidelines for pressure vessels require that the plant is safe for personnel and the public. FFS assessments will undoubtedly eventually include refractory linings and the practice of simply changing the refractory design without proper engineering approval could leave companies exposed.

We are using ATENA to analyze the behavior of refractory concrete structures. To date the behaviour of refractory structures is not fully understood and a wrong design can result in very high financial losses for our customers. Non-linear analysis is an extremely useful tool to verify and check the refractory design. ATENA proved to be the most accurate program for this purpose and it provided to be a highly effective tool in understanding the behaviour of refractory structures.



References

  1. Chen E. S. and Buyokozturk O., "Methodology for Thermomechanical Analysis of Brittle Systems," Am. Ceram. Soc. Bull., 64 [7] 982 88 (1985)
  2. Buyukozturk O. and Tseng T. M., "Thermome¬chanical Behavior of Refractory Concrete Linings," J. Am. Ceram. Soc., 65 [6] 301 307 (1982)
  3. Gasser A, Andrieux C., Boisse, P, Rousseau J., Gabis V. and Dutheillet Y., “Modelling and Design of an anchor refractory Lining”. UNITECR 99, 42nd International Colloquium on Refractories, Berlin Germany 6-9 September 1999.
  4. Bell, A., “A Computer Simulation of Cracking in Monolithic Refractories”, British Ceram Trans J Vol 87 1988
  5. Cervenka V., Cervenka J. and Jendele L., “Bond in Finite Element Modelling of Reinforced Concrete”, Euro C- 2003 Computational Modelling of Concrete Structures, 17th – 20th March 2003 St Johann im Pongau, Austria

Greg Palmer
Director
Palmer Technologies PTY Ltd
Brisbane, Australia