Refractory Brick Lining Template Generator

Overview

This Python script generates a refractory brick lining template for a barrel. The script produces two outputs:

1. A top-view full ring layout with key diameters.
2. A single-brick cut template with dimensions and miter angle callouts.

Additionally, the script prints the computed geometry to the terminal for reference.

Features

• Generates a top-view diagram of the brick lining.
• Creates a single-brick cut template with precise dimensions and angles.
• Provides detailed terminal output of the input parameters and calculated results.
• Includes validation for input parameters to ensure accurate results.

Requirements

• Python 3.6 or higher
• Matplotlib library

Installation

1. Ensure you have Python 3.6 or higher installed on your system.
2. Install the required Python library:

   pip install matplotlib

Usage

1. Clone this repository or download the script brickcalculator.py.

2. Open a terminal and navigate to the directory containing the script.

3. Run the script using the following command:

   python3 brickcalculator.py

4. Follow the prompts to input the required dimensions:

   • Barrel inside diameter (in)
   • Barrel wall thickness (in)
   • Minimum backup insulation thickness (in)
   • Brick thickness (radial, in)
   • Number of bricks per ring (N)
   • Maximum brick outer face length (in)
   • Saw kerf / blade width (in)

5. The script will generate the diagrams and display the computed geometry in the terminal.

Input Parameters

• Barrel inside diameter (in): The inner diameter of the barrel.
• Barrel wall thickness (in): The thickness of the barrel wall.
• Minimum backup insulation thickness (in): The minimum thickness of the backup insulation layer.
• Brick thickness (radial, in): The radial thickness of each brick.
• Number of bricks per ring (N): The number of bricks in a single ring. Must be 3 or greater.
• Maximum brick outer face length (in): The maximum length of the outer face of each brick.
• Saw kerf / blade width (in): The width of the saw blade used for cutting bricks (informational).

Output

Diagrams

1. Top-View Diagram:

   • Displays the full ring layout of the brick lining.
   • Includes key diameters and dimensions.
   • Shows the backup insulation layer (yellow shaded) and barrel wall.

2. Single-Brick Cut Template:

   • Provides a detailed cut template for a single brick.
   • Includes dimensions for the outer face, inner face, thickness, and taper.
   • Displays miter angles for precise cutting.

Terminal Output

The script prints the following information to the terminal:

• Input parameters.
• Calculated values, including:
  • Central angle (°)
  • Miter angle per end (°)
  • Inner face length (in)
  • Taper per side (in)
  • Inner diameter across flats (in)
  • Inner diameter across corners (in)
  • Brick ring outer diameter (max, in)
  • Barrel outer diameter (in)
  • Maximum gap thickness (in) (between backup insulation layer annulus and outer brick flats)

Example

The following example shows inputs and outputs for lining a 55-gallon steel barrel with a backup insulation layer of minimum radial thickness 3.5", and a 6-sided refractory brick hot-face lining. K-23 brick dimesions (9"x4.5"x2.5") are used in this example. Plot output can be viewed at 6_sided.png.

Input:

Barrel inside diameter (in): 22.9
Barrel wall thickness (in): 0.05
Minimum backup insulation thickness (in): 3.5
Brick thickness (radial, in): 2.5
Number of bricks per ring (N): 6
Maximum brick outer face length (in): 9
Saw kerf / blade width (in): 0.125

Output:

Terminal:

=== INPUTS ===
N:                               6
Barrel inside diameter:          22.900 in
Barrel wall thickness:           0.050 in
Backup insulation min thickness: 3.500 in
Brick thickness (radial):        2.500 in
Brick outer face length:         9.000 in
Saw kerf:                        0.125 in

=== OUTPUTS ===
Central angle:                   60.000°
Miter angle per end:             30.000° (off-square)
Inner face length:               5.063 in
Taper per side:                  1.443 in
Inner diameter across flats:     9.440 in
Inner diameter across corners:   10.900 in
Brick ring outer diameter (max): 15.900 in
Barrel outer diameter:           23.000 in
Max gap thickness:               1.065 in

Diagrams:

• A top-view diagram of the brick lining.
• A single-brick cut template with dimensions and miter angles.

License

This project is licensed under the MIT License. See the LICENSE file for details.

Author

Sonia Rosenberger