TEST 1

(MEMORANDUM)

SUBJECT: Refractories II Code: RFC201T

PAPER DESCRIPTION: Open Book
FULL MARKS: 60
DURATION: 1.5 HOURS
Allowed:
Prescribe Book and Notes
Scientific calculators

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INSTRUCTIONS TO CANDIDATES: ANSWER ALL QUESTIONS

NUMBER OF PAGES: 4 Total
QUALIFICATION: N DIP: Metallurgical Engineering
EXAMINER: DJ Delport (TUT)
MODERATORs: N Naude (UP) and MB Shongwe (TUT)
Question 1 (True or False)
[8]
1.1

1.2
1.3

1.4

Bauxite is a natural occur mineral consisting out of aluminium

hydroxide and mainly iron oxide, silica, titanium and aluminasilicates as impurities.
(2)
True
Plastic clays are characterized by its exceeding high content of very
fine particles.
(2)
True
Magnesia-carbon refractory bricks have high carbon content cannot
be used for high erosion areas.
(2)
True
Magnesia-spinel has high melting points of 2135 C but cannot
withstand thermal shock and slag corrosion.
(2)
False

Question 2 (Select the correct option)

[22]

2.1

Hollow refractory bricks are made by?

(2)

A. Slip casting
B. Extrusion
C. Pressing/machine moulding
D. Hand moulding

Magnesite bricks are used in those parts of furnaces, which are..

(2)

2.2

A. Required to resist corrosive basic slag.

B. Subjected to high load.
C. Subjected to temperature fluctuation.
D. None of these.
2.3

An indication of degree of firing in silica brick is its.

(2)

A. Specific gravity
B. Fusion point
C. RUL
D. None of these
2.4

Firing temperature of magnesite bricks is about __________ C.

(2)

A. 800-1000
B. 1600-1800
C. 1000-1200
D. 2400-2600
2.5 Thermal diffusivity of a refractory brick is high, when its __________ is
high. (2)
A. Density
B. Specific heat
C. Thermal conductivity
D. none of these
2.6

Which is not a basic refractory?

(2)

A. Chrome magnesite
B. Magnesite

C. Dolomite
D. Silicon carbide
2.7

Capacity of a refractory brick to withstand-sudden changes in

temperature is denoted by the property called?
(2)

A. Refractoriness under load (RUL).

B. Refractoriness.
C. Spalling resistance
D. none of these
2.8

Which is the stable form of silica below 870C?

(2)

A. Quartz
B. Tridymite
C. Cristobalite
D. None of these
2.9

An insulating refractory brick should have high porosity and low

thermal conductivity. Which of the following is not used for inducing
porosity in the insulating refractory bricks during its manufacture?
(2)

A. Cork
B. Chemically prepared foam
C. Sand
D. Saw dust
2.10 With increase in the alumina content, the refractoriness of high
alumina refractories..
(2)
A. Increases
B. Decreases
C. may increase or decrease
D. remains same
2.11 A steel member used in the furnace construction to take the thrust
of the brickwork is called?
(2)
A. backstay
B. armouring
C. baffle

D. breast wall
Question 3
[14]
3.1

Calculate the interface temperatures between the bricks of a multi-layer refractory

lined steel production furnace. The first 20cm layer is a magnesia-carbon brick with a
heat conductivity of 1.4 W/mK and an F factor of 8. After construction the real hot
faces temperature was 1650oC and the cold face 80oC. Insulation brick 1 is 15cm with
a thermal conductivity of 3.2 W/mK and F factor of 12.
(8)

t x =t x1

t ht c F x
F
x

( )

t 1 =1650

165080 20 cm
20
1.4

16501122

528
t 2 =528

165080 15 cm
20
3.2

528369

159
3.2

Determine the cold face temperature and explain your determined value with the given
cold face value of 80 oC.
(6)
It is the value of t2 and the values are different due to possible;

construction errors

thermal properties that has change due to load.

Question 4
[16]
4.1

Pyrometallurgy involves high temperatures and the application of

energy to materials, including refractory linings. Heat is refractories
is transferred by three methods name them.
(3)
Radiation,
Convection
and
conduction

4.2

Name five (5) factors that must be taken in consideration when

selecting a refractory material that is resisted to spalling.
(5)

1.

The lower the bulk density the greater the spalling resistance.

2.

The higher the porosity the greater the spalling resistance.

3.

The lower the thermal expansion the ..

4.

The greater the thermal conductivity the .

5.

The lower the Youngs modulus (greater toughness/ elasticity) the

..

4.3

The successful refractory system lifetime is dependent upon a

variety of internal and external factors. Name four (4) basis errors
made due to poor engineering.
(4)

1.

Material selection and product quality

2.

Mechanical design

3.

Thermal design

4.

Installation (also anchoring failure)

5.

Commissioning (curing, drying, heating)

6.

Operational factors (chemical environment, thermal cycling etc.)

4.4

What is natures best refractory material and why?

(4)
Carbon

Melting point is 3500C

END