Optimisation of monolithic lining concepts of channel induction furnace

Abstract

For the possible energy savings and extension of the volume capacity, the monolithic lining of a channel induction furnace was optimised in the following manner. Orthogonal array method is utilised to systematically design the lining concepts, and the finite element simulations including the temperature dependent properties of monoliths are carried out to determine the temperatures and stresses during the preheating and holding. In terms of the main effect analysis materials for the monolithic lining are recommended. Moreover, a thickness-thickness-temperature isothermal map is provided to show the acceptable thickness range of working and insulating linings. Nevertheless, for the final decision the deliberate consideration for the cost effectiveness of a certain lining concept is also necessary.

Thermal and thermomechanical evaluations of channel induction furnace applying strong insulation containing lightweight aggregates

“…The insulating lining underwent tensile stress primarily in the circumferential direction. This stress was attributed to the shrinkage of the monolithic insulating material and the outward radial displacement caused by the thermal expansion of working and safety linings [5]. The higher tensile stress in the light weight material A1 resulted from its high Young's modulus, as shown in Table 1.…”

“…The previous research demonstrates an efficient optimisation approach for extensive refractory lining concepts, adopting FE elastic modelling and orthogonal array methods. The investigation yielded a candidate for a lining concept that contains virtually the same in-use dense castable as the working lining as well as a new lightweight monolith with a stronger thermal insulating effect for the insulating lining [5]. Further inelastic FE modelling was performed allowing for creep occurrence in the working lining leading to a better understanding and improved evaluation of furnace lining behaviour.…”

“…The channel induction furnace used for investigation comprised a holding vessel, cover, watching hole, inlet and outlet spouts, and inductor assembly [5]. Simplifications were necessary for modelling efficiency; therefore, the 3D model considered only the cover and holding vessel.…”

“…For the refractory lining optimisation of the channel induction furnace, a former study defined an elastic finite element (FE) modelling method using 2D models and combined the modelling with an orthogonal array method [5]. This methodology permitted efficient semi-quantitative evaluation of a large lining structure or a significant quantity of lining concepts from the thermal and thermomechanical points of view.…”

Thermal and Thermomechanical Responses Prediction of a Steel Ladle Using a Back‐Propagation Artificial Neural Network Combining Multiple Orthogonal Arrays

“…Efforts have been made to evaluate the performance of steel ladle linings from thermal and thermomechanical viewpoints using finite element (FE) methods, especially taking into account the application of insulation and preheating time . Integrated consideration of lining concepts for a steel ladle is also of importance to support steel industry 4.0 in refractory application . Recently, the authors applied the Taguchi method to optimize lining design configurations with FE simulations within a defined variable span of lining thickness and material properties .…”