Damage of monolithic refractory linings in steel ladles during drying

Abstract Safety linings of steel ladles are made of high content alumina castable. In situ observations confirm that during drying a network of macrocracks appears in the monolithic castable lining, owing to both dehydration of the cement paste and temperature. Crack formation kinetics have been characterised over the life of the lining. To simulate the behaviour of the lining, the thermomechanical behaviour of the castable was characterised in compression and three point bend tests, thermal dilatation tests and TGA analysis in the 20–600°C temperature range. The change in properties is shown to be due mainly to transformation of hydrates in the castable. Numerical simulations of the lining drying process were also performed using a finite element code to verify the causes of cracking. A parametric study was carried out to examine the possibility of reducing the stresses induced by thermal loading. Improved thermal insulation and better control of heating reduce the risk of failure in the lining.