Advantages of  Hard Brick over  Castable

Advantages

Detrick’s designs utilize pre-fired brick to give them a complete ceramic bond throughout the entire working lining.  This eliminates any possibility of the lining cracking, due to inaccurate mixing with the castable.  Castable relies heavily on the installation procedures in determining its mechanical properties.  Pre-fired brick maintain higher and more consistent properties than castable.  Including density, strength and thermal characteristics.  Brick linings can be heated up faster than castable linings since they have been pre-fired; this reduces heat-up costs and increases operating time.

Also, there is no need to make any construction joints for expansion after a Detrick lining is installed.  All of the horizontal and vertical expansion is designed and built into the Detrick systems from the start of the project.  Brick linings can be installed faster, due to the lack of labor intense forming that is needed for a castable lining.  Brick linings generally last longer than castable and can accept more abusive operating environments.


Detrick MSA Design

MSA Standard & Posted

Typical Cross Section

Showing Anchor & Filler Rows

Standard & Posted

Detrick MSA roofs considered consisted of 7 1/2” of 70% AL2O3 filler brick insulated with 2" of 2200°F insulating castable and 2" of 8# ceramic fiber blanket.  The MSA 70% AL2O3 anchor brick is 12 1/2" deep and uses Detrick's unique insulating hanger casting, which allows 1" of block insulation over the anchor.  The filler represents 75% and the anchor represents 25% of the roof using the standard design.  Using the posted design, the filler represents 87% and the anchor represents 13% of the roof.

 

Standard MSA Design:
Average Results

Heat Loss (75-25)

Filler 452 x .75 = 339

Anchor 888 x .25 = 222

  561 BTU/Sq.Ft./Hr.

 

Cold Faces (75-25)

Filler 270 x .75 = 203

Anchor 317 x .25 = 79

  282°F

Standard MSA Design

Anchor Row

Posted MSA Design:
Average Results

Heat Loss (87-13)

Filler 492 x .87 = 428

Anchor 888 x .13 = 115

  543 BTU/Sq.Ft./Hr.

 

Cold Faces (87-13)

Filler 270 x .87 = 235

Anchor 367 x .13 = 48

  283°F

Posted MSA Design

Anchor Row


Plastic Roof Design

The plastic roof considered consisted of 8” of 70% AL2O3 insulated the same as the Detrick designs.  The anchoring system was 12" 85% AL2O3 brick on 12" centers.  The plastic represents 89% and the anchor represents 11% of the roof based on the anchor spacing.

Plastic Design

Anchor Row

Plastic Design:
Average Results

Heat Loss

Plastic 452 x .89 = 339

Anchor 2346 x .11 = 258

  660 BTU/Sq.Ft./Hr.

 

Cold Faces

Plastic 270 x .89 = 240

Anchor 595 x .11 = 65

  305°F


 

  Thermal Analysis Summary - Design Comparison

Design Method

Avg. Cold Face

(°F)

Avg. Heat Loss

(BTU/Sq.Ft./Hr)

% Heat Loss Savings

vs. Plastic

  MSA Roof - Standard 282 561 15.0%
  MSA Roof - Posted 283 543 17.5%
  Plastic Roof 305 660 N/A

  Assumptions:

  Hot Face of Material = 2400°F

  Ambient Air at 70°F and 0 mph.

  Emissivity = .85

 

 

  K Values used in Thermal Analysis

Material

400 °F

800 °F 1200 °F 1600 °F 2000 °F
  85% Alumina Brick 19.5 17.7 16.1 15.5 15.5
  70% Alumina Plastic 11.5 10.7 10.25 10.2 10.2
  70% Alumina Brick 13.5 12.9 12.7 13.0 13.3
  2000°F Insulating Castable 1.4 1.56 1.71 1.92 2.18
  8# Ceramic Blanket .28 .5 .9 1.3 1.77
  Block Insulation .42 .61 .91 1.21 1.44*

  *K calculated at 1900°F mean temperature.

 


 

 

Home Office - Chicago Area

9400 Bormet Dr.   Suite 10

Mokena, Illinois  60448

Phone: 1-(708)-479-5085      Fax: 1-(708)-479-1030

 


 

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