Insights into thermomechanical behavior and design parameters of alumina calciner refractory lining

This study investigated the thermomechanical behavior of an alumina calciner's lining, a critical component in alumina processing, often susceptible to maintenance issues arising from refractory failure due to erosion and cracking. Based on numerical analyses via the finite element method, the design of a refractory panel was modeled. Furthermore, the influence of geometric parameters and friction level between lining layers on the thermal and mechanical behavior of the system was evaluated. Key findings highlighted how the curvature changed the stress profiles, resulting in particular cracking patterns, where curved panels showed higher stress concentrations at the center of their edges. Empirical validation through in-situ crack pattern observations further validated the model's predictive capability. Additionally, the study evaluated the influence of friction coefficients on resulting stresses, showing their small effect relative to other factors. Analyses on design parameters indicated that stress levels generally increased with the size-to-thickness ratio, highlighting the trade-off between reducing installation time and ensuring structural integrity in panel design and application. An alternative for enhancing lining performance was explored by selecting the material, where decreasing the insulating thermal conductivity reduced the likelihood of failure of the castable layer. Ultimately, the computational numerical method developed in this study offers a robust framework for exploring various geometries and materials, providing engineers with a versatile tool for optimizing lining designs in various operational scenarios.