Microscopic modeling of thermal coupling in composite refractory masonry ladle with different joint configurations

This paper presents a simulation-based investigation on the thermal behavior of an industrial-scale composite masonry ladle, incorporating with a conventional joint pattern. A three-dimensional model is developed to illustrate the impact of high-temperature loads, material discontinuities, and closed-end effects on the thermo-mechanical performance of the ladle. The study investigates the effects of thermal expansion and friction between masonry units influence stress distribution. The analysis of four joint configurations is fully analyzed, focusing on the open or closed states of both horizontal and vertical joints. The findings indicate that an increased friction coefficient changes the main region of shell deformation. The hoop compressive stress predominantly influences slag line safety, limiting the stress reduction achieved by horizontal joints. Staggered vertical joints along the ladle's circumference effectively mitigate hoop stress and reduce the risk of stress concentration and structural collapse. The microscopic model more accurately represents the thermodynamic behavior in the masonry structure by accounting for material discontinuities, thereby offering a significant theoretical foundation for the optimization of masonry design.