Finite element simulation of creep behavior in enhanced refractory material for glass furnace

Abstract

An important focus in the glass melting industry, which is an energy intensive industry, is towards greater output and increased energy efficiency in the glass melting process. Conversion to the oxy-fuel-fired furnace from the traditional air-fuel-fired furnace is one means to achieve greater output and energy efficiency, since the capital cost per ton of glass pulled is approximately 58% less for the oxy-fuel-fired furnace compared to the air-fuel-fired furnace. The main disadvantages of the oxy-fuel-fired furnace are its higher operating temperature, possibly to more than 2200 °F, and its alkali partial pressure that hasten the corrosion of refractory materials, particularly in silica refractories. Thus, the refractories used in the oxy-fuel-fired furnace are subjected to high temperatures and stresses during its service life. Considerable creep could occur in the furnace, if the refractory material is not creep resistant. In order to improve the performance of refractory materials, Oak Ridge National Laboratory (ORNL) is utilizing High Density Infrared (HDI) technology. This technology, which is relatively new to materials processing, is increasingly being researched in the development of coatings and surface modifications for refractory materials. This thesis studies the creep resistance effectiveness of the HDI surface treatment for refractory materials. In particular, the dependencies of creep strain on operating temperature and applied stress are studied to determine whether the HDI treated refractory materials can be utilized for glass furnace with oxy-fuel environment. ACKNOWLEGEMENTS First of all, I would like to thank my parents and sisters for their inspiration and support during the completion of this project. I am also greatly indebted for their love and affection. I would like to express my sincere gratitude to Dr. John Ed Sneckenberger for his invaluable support, guidance and knowledge. This project would not have been possible without his encouragement, valuable suggestions and motivation. Much appreciation is extended to Mr.