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Refractory Materials for Glass Furnaces

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01 septembre 2015 à 08:35

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13 juillet 2016 à 11:06

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The Development of Fused Cast refractories

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In 1927, Corhart was founded. It is a refractory company producing fused cast refractories. Raw materials are melted in an electric arc furnace and then casted in a mold, just like metal casting. The lining of the electric arc furnace is made of the same materials. The temperature is up to the requirements of refractory products, generally 1800-2500¡æ. 
 
The first fused cast refractory is fused cast mullite refractory. It has been widely used in the sidewall of glass furnaces. Later zircon is added to the raw materials. The melting temperature is reduced and the slag resistance of the products is improved. 
 
In 1952, fused cast magnesia chrome brick, a new fused cast product, was developed by Corhart. It is mainly used in the steel industry. 
 
When producing fused cast refractories, the melt is casted into a mold with a large cap. The wall of the mold is made of refractory materials. When casting is finished, the mold wall is removed. Then the mold is put into insulation materials to reduce thermal shock to obtain crystals with uniform sizes and minimum gaps. 
 
Fused cast refractory is larger than the standard bricks, so it is difficult to cast. Currently, fused cast products for sale are always cut from big blocks.
 
 

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Four Factors For The Production Of Magnesia Carbon Brick

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Magnesia carbon brick is mde of magnesium oxide (melting point 2800 ¡æ) and carbon material with a high melting point that is difficult to be infiltrated by slags by adding a variety of non-oxide additives. It is mainly used in the converter, AC arc furnace, DC arc furnace lining, ladle slag lines and other parts.
 
The factors for the production of magnesia carbon brick incldue raw materials, binding agents and additives. 
 
1) Magnesia sand 
 
Magnesia sand should have high purity. Compared to sintered magnesia brick, fused magnesia brick has more complete crystal structure and stable reducing effect on carbon, so the production of magnesai brick turns to fused magnesia bricks. Given the binding state of carbon and infiltration of binding agents, fused magnesia can be mixed with sintered magnesia. 
 
Magnesia carbon brick made of magnesia sand with high MgO content, large periclase particles and a lime-silica ratio of greater than 2 has the best quality. 
 
2) Graphite
 
Graphite is another raw material for magnesia carbon bricks. it has good basic refractory properties. It contains 85%-98% fixed carbon and 13%-2% ash nd has a relative density of 2.09-2.23 and a melting point of 3640K ( volatile). 
 
There are three reasons for the oxidization of graphite during use: 
a. Oxygen in the air
b. Oxides in the slag
c. Oxides in graphite itself
 
Oxide impurities can react with graphite and make the structure loose, permeability increased and strength reduced, which is the main reason for the damage of magnesia carbon brick. Therefore, graphite with high purity and large flake crystals is mainly used for the production of magnesia carbon brick. 
 
3) Binding agent
 
Binding agent is important for magnesia carbon brick and other carbon refractory products. Graphite and refractory oxides are not miscible. Thwy rely on binding agents to bond. At high temperature, the binding agent will be carbonized and form carbon bond with graphite. These binding agents are typically phenolic resins, modified bitumen, petroleum cracking by-products. Among them, phenolic resin has the best performance. 
 
4) Additives
 
During the damaging process of magnesia carbon bricks, the oxidization of graphite is the main reason. The oxidation and carbon loss result in loose structure and weak strenth. In order to improve the oxidation resistance of magnesia carbon bricks, a certain amount of additives are added, including silica powder, alumina powder, FeSi alloy, CaSi alloy, SiC, Si3N4 and B4C. another function of additives is to build a bridge between refractory oxides and graphite and reinforce the binding between refractory oxides and graphite. 
 

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How To Judge The Quality Of Fire Clay Brick

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Fire clay brick accounts for an important position in the refractory industry. The most important feature of fire clay brick is that the raw materials can be obtainded locally. 
 
Fire clay brick is cheap and durable. It can be used for fire protection, thermal insulation, sound insulation and moisture absorption. Therefore, it is widely used in industrial production. The scrap bricks can be reused as aggregate. 
 
When purchasing fire clay bricks, some professional knowledge is needed and some principles should be followed. 
 
1) Take your need into account, such as specifications and materials. 
 
2) Select appropriate manufacturers. Shop around and capare the price before you buy. Also pay attention to the credibility of manufacturers, after sales service, product quality and service attitude.
 
3) After selecting a manufaturer, give a visit to the factory to understand the strength of manufacturers, scale, production qualification, production capacity and evaluation on the product from other customers. 
 
4) Pay attention to the proper use of fire clay brick in the production and the implementation of safety measures so as to make full use of fire clay brick, reduce unnecessary losses, extend the service life ansd reduce the cost. 
 

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The Use Of Silica Brick In The Glass Furnace

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Since the silica brick has low price, high purity, high softening temperature under load, no pollution to glass liquid and good resistance to R2O gases and aicd gases, it is widely used in the crown of the glass furnace, the upper part of the suspended wall, the back wall and the front wall.

The SiO2 content in the silica brick used in the glass furnaces should be controlled. And it should be mainly composed of cristobalite. For large glass furnaces and oxy-fuel glass furnaces, refractory materials with high purity, good creep resistance and good corrosion resistance are used.

Since the advent of brick, there are three types of brick. The first is the common silica brick. the second is high quality silica brick. the third category is improved high quality silica brick.

With the development of glass mleting technology, silica bricks with better performance are required.

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Applications of fire clay bricks

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Fire clay brick plays a versatile role in the many industries. 
 
Fire clay brick can be used in the metallurgical industry. Fire clay materials including shaped refractory materials and unshaped refractory materials acount for about 70% of the total refractory materials. Hard clay is used to produce refractory materials for theblast frunace, hot stove, ladle lining brick and plug brick. 
 
High-alumina clay is used to produce alumina bricks for electric furnaces and blast furnaces, high aluminum lining brick and high alumina refractory mud. Hard clay and high alumina clay are often calcined into clinker at high temperature (1400 - 1800¡æ). 
 
Refractory clay also has important roles in the grinding industry, chemical industry and ceramics industry. High-alumina clay can be made into abrasive materials by melting in an electric arc furnace. Fused corundum abrasive material is currently the most widely used an abrasive material. It acounts for 2/3 of the total abrasive materials. 
 
High alumina clay can be used to produce a variety of aluminum compounds such as aluminum sulfate, aluminum hydroxide, aluminum chloride, aluminum potassium sulfate and other chemical products. In the ceramic industry, hard clay and semi-hard clay can be used to manufacture household porcelain, construction porcelain and industrial porcelain. 
 
In the construction materials industry, refractory clay can be used to produce high alumina bricks, phosphate high alumina refractory bricks and high alumina fused cast bricks. High-alumina clay can be made into aluminum-containing cement by calcining and then mixing with limestone. This quick-setting cement has strogn heat and corrosion resistance. 
 

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