Refractory pole

Limoges - Orléans

Two different engineering colleges (Ecole Nationale Supérieure) located in two different cities

Polytech’Orléans

ENSCI Limoges (National Engineering College for

Industrial Ceramics)

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Limoges

Paris

Orléans

Ecole Nationale Supérieure de Céramique Industrielle

Created in 1893 in Limoges since 1979

National College for Engineering National College for Engineering in Industrial Ceramicsin Industrial Ceramics

(Ministry of National Education)

Created in 1975

National network of university engineering schools(Ministry of National Education)

Three teams affiliated to three different laboratories :

- Research Centre for Materials at High Temperature (CRMHT Orléans),

- Laboratory for Mechanics of Systems and Processes (LMSP Orléans),

- Heterogeneous Materials Research Group (GEMH Limoges)

aassociated by their common interest on ssociated by their common interest on rrefractoriesefractories

The specificity of the French « Ecoles Nationales Supérieures » (so called « Ecoles d’Ingénieurs »)

HistoricallyHistorically::

- pupils with the best ability in science were selected after Baccalaureat,

- after 2 years in specific schools of intensive formation in basic science, mainly Mathematics and Physics, the very best of them went to Ecole Nationale Supérieure after competitive examinations.

TodayToday::

- the system still exists but is less selective than before because many students are not interested by scientific studies.

Position of the French « Ecoles Nationales Supérieures » in the European LMD system

18 years old Baccalauréat (Bac)

20-21 years old

23 -24 years old Engineer

+2

+5

+8 26 -28 years old DoctoratPhD degree

6 semesters

L level

M level

D level

4 themes4 themes : :

General scientific trainingGeneral scientific training

Materials ScienceMaterials Science

Processing and EngineeringProcessing and Engineering

Management trainingManagement training

Languages (English + another language)Languages (English + another language)

ENSCI and Polytech’Orléans Master degree

ENSCI and Polytech’Orléans

11stst year : year :

Semester 1 (September to February i.e. 16 weeks) Semester 2 (February to June i.e. 16 weeks)

22ndnd year : year :

Semester 3 (September to February i.e. 16 weeks) Semester 4 (February to April-May i.e. 6 weeks ENSCI

i.e.10 weeks Polytech’ Orleans) may to July :1st Internship in industry : 2-3 months

ENSCI Master degree

33rdrd year : year :

Semester 5 Two possible options :1) ceramic materials and processing

2) engineering and production systems(beginning of September to end of January i.e. 16 weeks)

Semester 6 February to April : research project

3 months

May to September : 2nd internship in industry5 months

Polytech’Orléans Master degree

33rdrd year : year :

Semester 5 Two possible options :1) Numerical simulation in mechanics

2) Engineering of industrial materials(beginning of September to end of December i.e. 16 weeks)

Semester 6 January to February : research project

2 months

Mars to August : 2nd internship in industry4-6 months

ENSCIExchanges with foreign Universities and

companies (engineering students)Semester 3Semester 3

- course work- University of Jaume 1 (Castellón, Spain)- University of Alfred (New York, USA)

Semester 4Semester 4- 3 month internship in industry (May to July)- 40% of 2nd year class in a foreign company

SemesterSemesterss 5 & 6 5 & 6- coursework + project- RWTH Aachen

Semester 6Semester 6- 3 month research project at a foreign University

(examples: Keele, Aveiro, Penn State, Aachen, ICT Prague,…)

Semester 6Semester 6- 4 month internship in a foreign company

ENSCIFinancial support for student exchanges

Outgoing studentsOutgoing studentsUniversities: Europe: Erasmus + regional contribution, ENSCI travel grant, (MEN bursaries for national scholars) Total 1000 euros for 3 months

Outside Europe:

ENSCI travel grant + MEN bursaries for national scholars (not available for all

students) + Foreign Universities contribution

Companies: Europe: Leonardo Outside Europe: ENSCI travel grants, MEN bursaries for national scholars

Incoming studentsIncoming students- special arrangements for some Universities (ex: paid room or contribution to living expenses)

Semester 1Semester 1 (1st year)

Module ECTS

General scientific trainingGeneral scientific trainingMathematics

Metrology

Computing (I)

1010

Management trainingManagement training Communication

33

Materials ScienceMaterials ScienceSolid state matter

Characterisation of structures and microstructures

Reactivity of heterogeneous systems (I)

Physical properties of materials

1717

LanguagesLanguagesEnglish

German, Italian, Spanish or Russian

1010(end of (end of

semester 6)semester 6)

Semester 2Semester 2 (1st year)

Module ECTS

Management trainingManagement trainingAccounting

11

Processing and EngineeringProcessing and EngineeringFluid mechanics

Thermal treatments

Geology and raw materials

Grinding

Engineering and production systems

Visit of industrial sites (I)

2929

LanguagesLanguagesEnglish

German, Italian, Spanish or Russian

1010(end of (end of

semester 6)semester 6)

Semester 3Semester 3 (2nd year)

Module ECTS

General scientific trainingGeneral scientific trainingComputing (II)

Statistics

77

Management trainingManagement trainingProject in processing or materials science

1313

Materials ScienceMaterials SciencePreparation of raw materials (liquid, paste, solid)

Metals, polymers, composites

Mechanical properties

Visit of industrial sites (II)

1010

LanguagesLanguagesEnglish

German, Italian, Spanish or Russian

1010(end of (end of

semester 6)semester 6)

Semester 4Semester 4 (2nd year)

Module ECTS

Processing and EngineeringProcessing and EngineeringHeterogeneous systems (II)

Project management

Visit of industrial sites

1515

LanguagesLanguagesEnglish

German, Italian, Spanish or Russian

1010(end of (end of

semester 6)semester 6)

Management trainingManagement training11stst Internship in a company (3 months) Internship in a company (3 months)

1515

Semester 5Semester 5 (3rd year)

Module ECTS

Management trainingManagement trainingTraineeship debriefing

Company law and intellectual property

Quality

Safety

Technological information and innovation search

77

Materials Science and ProcessingMaterials Science and ProcessingSilicates

Glass products

Building materials

Refractories

Technical ceramics

2323

LanguagesLanguagesEnglish

German, Italian, Spanish or Russian

1010(end of (end of

semester 6)semester 6)

Option 1 & Option 2

Semester 6Semester 6 (3rd year)

Option 1 : ceramic materials and processing

Module ECTS

Materials Science and ProcessingMaterials Science and ProcessingProcesses

Simulation

Materials

Individual research project (3 or 5 months)Individual research project (3 or 5 months)

1515

LanguagesLanguagesEnglish

German, Italian, Spanish or Russian

1010(end of (end of

semester 6)semester 6)

22ndnd Internship in a company (5 or 3 months) Internship in a company (5 or 3 months) 1515

Semester 6Semester 6 (3rd year)

Option 2 : engineering and production systems

Module ECTS

Engineering and production systemsEngineering and production systemsProduction systems

Automatics and industrial computing

Group research project (3 months)Group research project (3 months)

1515

LanguagesLanguagesEnglish

German, Italian, Spanish or Russian

1010(end of (end of

semester 6)semester 6)

22ndnd Internship in a company (5 months) Internship in a company (5 months) 1515

Semester 1Semester 1 (1st year)

Module ECTS

General scientific trainingGeneral scientific trainingMathematics

Electronics, automatism

Energetics, thermics

Computing

1616

Languages and communicationLanguages and communication 44

Materials ScienceMaterials Science Solid state matter

Characterisation of structures and microstructures

Mechanical properties

44

Management training Management training Management project

Knowledge of companies

88

Semester 2Semester 2 (1st year)

Module ECTS

General scientific trainingGeneral scientific trainingElectrotechnic

Mechanical engineering

88

Communication and languagesCommunication and languages 44

Materials ScienceMaterials Sciencesolidification

Diagrams of phases and microstructures

Céramics, Metals, polymers, composites

Mechanical properties

88

Management training Management training Company law

Accounting

88

Semester 3 and 4Semester 3 and 4 (2nd year)

Module ECTS

Management trainingManagement training11stst Internship in a company (3 months) Internship in a company (3 months)

3,53,5

1111

Materials Science Materials Science

SimulationSimulation

Processing and EngineeringProcessing and Engineering

17,517,5

77

1414

Languages Languages English

German, Spanish

77

Semesters 5 and 6Semesters 5 and 6 (3rd year)

Option 1 : Engineering of industrial materials Module ECTS

Materials Science and ProcessingMaterials Science and ProcessingProcesses

Simulation

Materials

Individual research project (2 months)Individual research project (2 months)

1414

10,510,5

Management trainingManagement training

Languages Languages English

German, Spanish

99

3,53,5

22ndnd Internship in a company (4 - 6 months) Internship in a company (4 - 6 months) 2323

Semesters 5 and 6Semesters 5 and 6 (3rd year)

Option 2 : Numerical simulation in mechanics

Module ECTS

Mechanics and ProcessingMechanics and ProcessingCalcul of structures

Simulation and Processes

Non linear mechanics

Individual research project (2 months)Individual research project (2 months)

1414

10,510,5

Management trainingManagement training

Languages Languages English

German, Spanish

99

3,53,5

22ndnd Internship in a company (4 - 6 months) Internship in a company (4 - 6 months) 2323

Staff of the refractory pole

• Permanent staffPermanent staff::

- 6 professors

- 4 associated professors

- 3 associated researchers

• PhD studentsPhD students::

- 11 PhD students

Research topics: physico-chemical behaviour of refractories (Jacques POIRIER)

Interaction between aggressive products (liquid oxides, liquid metals, gas…) and ceramic refractories:

- influence of macro and microstructure

- mechanism of corrosion

- in situ observation of refractory lining

Experimental device

Corrosion test

Microstructures after corrosion

Examples of studies:

- corrosion of andalusite and bauxite refractories by Al2O3 – CaO and SiO2 – CaO liquids

- phase evolution with temperatures in andalusite raw material

- ceramic protection for carbon fibber fabric for heating element in oxidizing atmosphere

- dense SnO2 based coating for protection of refractory against corrosion by melt glass.

Research topics: physico-chemical behaviour of refractories

Influence of microstructure and temperature on the Young’s modulus (measured by ultrasonic techniques) and on the tensile and compressive behaviour of industrial refractories (for steel or glass industries) and model materials

Research topics: mechanical characterisation of refractories (Marc HUGER)

20

60

100

140

0 500 1000 1500

T (° C)

E (GPa)

(2)

(3)

(1)

20

60

100

140

0 500 1000 1500

T (° C)

E (GPa)

(2)

(3)

(1)

Influence of the in-situ formation of MgAl2O4 on the evolution of Young’s modulus of

aluminate castable: (1) without MgAl2O4 ; (2) with preformed MgAl2O4 ; (3) with MgO

content (spinel formation at about 1100°C)

0

20

40

60

80

0 500 1000

T (°C)

E (GPa)

5h 1200°C

2eme cycle

Damage evolution in an andalousite castable during thermal cycle

Example of studies:

- high temperature mechanical behaviour of fused cast refractories

- mechanical properties at high temperature of alumina spinel low cement castable

- elastic behaviour of heterogeneous model materials with spherical inclusions

Research topics: mechanical characterisation of refractories

Influence of microstructure on thermal properties of heterogeneous materials:

- determination of thermal parameters necessary for numerical simulation

- influence of grain boundary and pore shape

- development of very porous ceramic materials for thermal insulation

Research topics: thermal properties (David S. SMITH)

Influence of porosity on the thermal conductivity of stabilized zirconia.

Influence of the formation of a spinel phase on the dilatometric behaviour of an alumina

based concrete.

-0.4%

0.0%

0.4%

0.8%

1.2%

1.6%

0 500 1000 1500

T (° C)

(2)(3)

(1)

L/Lo (%)

(1) Alumina concrete (2) + spinel (3) + MgO

Example of studies:

- analysis of grain boundary thermal resistance in polycrystalline oxides (Al2O3, SnO2, MgO)

- heat transfer in porous materials: influence of interface in stable and evolutive microstructures

- local heat transfer near pores and grain boundaries in ceramic materials

- preparation and characterisation of ceramic foams with very low thermal conductivity for insulating application

Research topics: thermal properties

Modelling of solid structures and system for the prediction of their behaviour in product design and manufacturing (finite element method):

- thermo-mechanical aspects

- thermo-chemical aspects

Research topics: numerical simulation of refractory behaviour (Alain GASSER)

Crack initiation

Simulation by finite element method of crack initiation in sliding plate gates during

continuous steel casting

Steel ladle simulation

Mesh Temperatures

Plastification Damage

Example of studies:

- simulation accounting for thermo-mechanical and chemistry effects: application to impregnation of refractory by slag

- development of finite element computing tools adapted to complex refractory structure containing thermal expansion joints, anchors, tubes, …: application to steel ladles

- numerical analysis of the thermo-elastic behaviour of heterogeneous materials containing phases with difference of thermal expansion coefficient

Research topics: numerical simulation of refractory behaviour

Free access of the equipments of the different laboratories for:

- chemical analysis (ICP, EDX, …)

- structural characterization (XRD)

- microstructural characterization (mercury porosimetry, granulometer, optical and interferometric microscopes, SEM, TEM, …)

- ceramic processing (rheometers, dryer, kilns (< 1800°C)…)

- characterization of thermal behaviour (dilatometer, DTA, DTG, DSC, calorimeter, …)

- material characterization (acoustic emission facilities, wear and friction tests…)

General equipments

Specific equipments

- For simulation of severe corrosion conditions (1700°C)

- High temperature measurement of Young’s modulus by ultrasonic techniques (1700°C, controlled atmosphere)

- High temperature tensile-compression equipment (1600°C)

- Thermal diffusivity by the Laser Flash technique (1000°C)

- Powerful work stations to perform simulation, and finite element software

- Thermal shock test bench

- IR microscope

- High temperature tribometer (1000°C)

- High temperature spectroscopies (NMR, EPR, Infrared, Raman, Brillouin, X-Ray absorption)

- Contactless devices for analysis applied to molten systems (aerodynamic levitation)

Industrial partners

ProducersProducers

- IMERYS

- SAINT GOBAIN

- VESUVIUS

- T.R.B.

UsersUsers

- EDF

- TERREAL

- ARCELOR

- MESSIER BUGATTI

- AIR LIQUIDE