Authors:
Carolina Ierck Pereira | Federal University of São Carlos | Brazil
Matheus Felipe Dos Santos | REDLAB | Brazil
Prof. Dr. Ricardo Afonso Angelico | São Carlos School of Engineering, University of São Paulo | Brazil
Murilo Henrique Moreira | Federal University of São Carlos | Brazil
Dr. Mariana de Albuquerque Lima Braulio | 4CAST | Brazil
Thiago Iwanaga | Hydro Alunorte | Brazil
Prof. Dr. Victor Carlos Pandolfelli | Federal University of São Carlos | Brazil
It is well known that the performance of industrial processes operating under hostile mechanical, chemical or, especially, harsh thermal conditions depends majorly on refractory ceramics. Thus, studies on the optimization of these materials are of great relevance for the industry, as changing their composition, microstructure, or project design can increase the equipment lifetime and/or decrease its maintenance halts. So far, several studies have used computational simulations to model the thermomechanical behavior of ceramic refractory linings with joints, usually for steel ladles. However, few studies have focused on design optimization such as the correct dimensioning of expansion joints, optimized size of monolithic panels, and density of anchors. The present study aims to fill this gap by modeling the castable lining of alumina calciners, which is a less complex system in terms of refractory requirements compared to the steel-making processes. The developed model considers a Representative Volume Element (RVE) of a structure comprising the metallic vessel and anchor, the insulating and the working layers, and dry expansion joints. The thermal and mechanical behavior of RVEs with varying joint density and thicknesses were simulated via the Finite Element Method (FEM), and the optimized results were compared to the values practiced in the industry.