12. Advance Material Design and Installation Practices

Design terminology is not only confined in a particular shape, rather performance of applied components depends on the geometry and material design, together. In early days, industrial furnaces and vessels were made of brickwork, but clean steel asks for total package including refractory composition, shape and installation practice for continuous and long period operation without interruptions for repairs. In order to accomplish steel sector demand, latest jointless monolithic especially colloidal silica-bonded cement-free castable, alumina-oxi-carbide-bonded castable, magnesia-containing castable and chrome-free castable are encountered and analysed. Despite different classic endless lining protocols, installation and repair methodologies are systematically discussed. Uniform microwave-assisted heating and drying opens up a new installation practice for endless working lining that is capable to replace partial damage zone without major replacement of original lining. Advantages of flame gunning over conventional wet gunning differentiate the performance of refractory lining. Ceramic welding process is emphasized in which base refractory hot surface is being repaired through metal powder at elevated temperature as high as 1200 °C, and exothermic reaction facilitates permanent bond and repairs the defective refractory zones.