900 Market Street, Meadville, Pa. 16335 U.S.A.

Refractory Software

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PH 814-724-4615

Above sequence depicts typical screen displays. The sequence cycles every 5 seconds.


   Optimum refractory construction. Heat up and cool down time of refractory enclosures. Labor & material costs (135 materials programmed) for refractory constructions. Conduction heat loss and percent saturation for any shape refractory surfaces. Unsteady state conduction heat loss, storage and percent saturation for any number of heat up and soak time/temperature ramps, with or without a load in the chamber.

This program computes the optimum refractory insulation material and thickness, heat loss, heat storage; heat up time of furnace and charge; and yearly operating cost for a 6 sided furnace refractory enclosure. There are 1,296 refractory combinations and 6 heating arrangements available. Each of the 4 enclosure surfaces (sides, ends, floor & roof) can have 7 different refractory combinations: FB + IFB + BLOCK; IFB + MINERAL BLOCK; CASTABLE; CASTABLE + IFB + BLOCK; CERAMIC FIBER; CERAMIC FIBER + MINERAL FELT; BLOCK + FELT. 21 selected refractory materials are programmed. Each external surface can have a different shell temperature.
Input maximum furnace temperature, emissivity of furnace shell, percent hydrogen in furnace atmosphere, furnace width, length & sidewall height, & refractory constructions for each surface. Then the program will compute the proper insulation material and thickness required, including 3 layers maximum of different refractory materials for each surface - such as 4-1/2" of 1st quality firebrick + 4-1/2" of 2000IFB + 3" of block.
A cold charge can be heated up with the furnace and the time required to bring the charge up to operating temperature is computed, based on the net heat input and allowing for variable heat flow into the refractory during the transient heating time period.
This powerful program contains 135 programmed refractory materials - any of which may be input for the 1st, 2nd, or third course in the sides, end, floor and roof surfaces of a six sided enclosure; or for each end, and the cylindrical surface of a cylinder or cone shaped enclosure; or for one surface only. Floor surfaces can include any quantity and size of refractory pier load supports. Roofs can be flat or sprung arch design. The program computes and displays heat storage, mean temperature, and thermal conductivity of each course, interface temperatures between cources, shell temperature and heat loss for each of the external surfaces, and total heat loss and storage for the entire chamber. Refractory names, suppliers, and properties (maximum rated temperature, density, & thermal conductivity at 500F, 1000F, 1500F and 2000F) of each material is displayed. Net heat input is computed for any time period entered to heat the refractories (and charge) from ambient to the set point operating temperature. The computed heating time is based on the time to saturate the refractories to 97% of the final steady state condition, using the Fourier series analysis procedure for one dimension conduction heat transfer. A charge can also be included to heat up at the same time, and the total time to heat the chamber and charge to the set point operating temperature is computed. Time to cool the refractory (and charge) is also computed.
This program computes labor and material costs of refractory construction. Labor costs are programmed according to the type of refractory being installed (brick, castable, block, ceramic fiber, modules, etc.) as well as the size and location of the surface. The program contains average default cost values for each refractory.

    For more information on all my programs a brochure containing descriptions and printouts is available. BROCHURE FORM


   Click on the links beside the animation at the top of the page for information on each program.

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©J.D.Barnes 2005-5-5