Service performance of refractories in c

This study investigates the service performance of refractories in the pusher reheating furnaces at Bhilai Steel Plant, focusing on their operational efficiency and failure modes. The objective is to analyze the factors influencing the longevity and effectiveness of refractory materials under extreme heating conditions. Methodologically, the research involved assessing the design specifications of various furnaces, their operational parameters including temperatures, pressures, and fuel types, as well as conducting a failure analysis of the refractories used in different mill sections. Results indicate that the average lifespan of refractories varies significantly across different mills, with the rail and structural mill exhibiting a lifespan of only 6 to 8 months, while the merchant mill's refractories last 10 to 12 months. Additionally, common failure points such as the burners and skid insulation were identified, demonstrating the critical role these components play in maintaining the operational efficiency of the furnaces. Various modifications were tested to improve refractory performance, although some, such as the introduction of anchor rods, created operational challenges. Overall, the findings highlight the importance of optimizing refractory materials and furnace designs to improve performance and reduce failure rates.