aluminabricks, Author at RS Kiln Refractory Bricks

Alumina brick is a high-performance refractory material whose main component is alumina (Al2O3). Usually, high-purity alumina is used as raw material, which is sintered at high temperatures. As a high-quality supplier of alumina refractory bricks, RS Alumina Bricks Factory can provide high-quality Alumina Bricks for high-temperature kiln lining. Contact us for free alumina bricks price.

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Alumina Bricks Properties

High-temperature stability. Alumina bricks can work stably for a long time at high temperatures, and their service temperature can reach about 1700°C.
Corrosion resistance. The main component of alumina bricks is alumina, which is not easily corroded by acids and alkalis.
High strength and high hardness. Alumina bricks have high hardness, high strength, and good compressive and flexural strength.
Wear resistance. Wear Resistance Alumina bricks have a smooth surface and are not easily worn, so they have good wear resistance.

Alumina Bricks Use

Alumina bricks have a wide range of application scenarios and are mainly used in various refractory equipment in harsh environments such as high temperature, high pressure, and corrosion. Such as blast furnaces in the metallurgical industry, steel smelting furnaces, aluminum electrolytic cells, etc. High-temperature reaction kettles and high-temperature drying furnaces in the chemical industry. Boilers, kilns, coal-fired gasifiers, etc. in the power industry. As well as cement kilns and glass kilns in the building materials industry. In addition, alumina bricks are widely used in scientific research, aerospace, nuclear industry, and other fields.

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Alumina Bricks Manufacturing Process

After years of accumulation of production and sales experience, RS Alumina Bricks Factory has a further understanding of the production process of alumina refractory bricks.

Selection of binders

The manufacture of high alumina bricks usually uses soft clay as a binder. The main function of clay in the batching is to improve the formability of the mud and to make the formed and dried green body have a certain strength. The added amount of clay powder in the batching is generally 5%. In order to produce volume-stable low-level high-alumina bricks, high-alumina bauxite powder can be used as a high-alumina binder. Or use high-alumina bauxite powder and clay powder in a predetermined ratio to prepare synthetic mullite as a binder, and a volume-stable high-alumina brick without secondary expansion can be obtained.

Determination of Particle Composition

The particle composition of high alumina bauxite clinker has an important influence on the forming operation, green body density, high alumina brick density, and strength. Therefore, determining a reasonable particle composition according to different molding methods is an important process factor to stabilize the process operation and improve the quality of high-alumina bricks.

The principle of determining particle gradation is to form a good bulk density, which has no adverse effect on the performance and appearance quality of high alumina bricks. For low-grade bricks, the volume expansion caused by the secondary mullite reaction should also be considered.

High alumina bricks usually use coarse, medium, and fine three-level ingredients. However, secondary or quaternary ingredients may also be used. When using three-level batching, the critical size of each particle size is coarse particle 3-0.5mm, medium particle 0.5-0.1mm, and fine powder <0.1mm.

Production practice shows that when determining the particle size, appropriately increasing the size and quantity of coarse particles can increase the bulk density of the mud, and it is easy to shape. During firing, due to the small specific surface area of large particles, the secondary mullite reaction around the material is weakened, which is beneficial to the sintering of the green body. In turn, the air-packing rate of high-alumina bricks is reduced, the softening temperature under load and compressive strength are improved, and the thermal stability is improved.

There is a limit to the enlargement of the particle size. If the size of the coarse particles increases to 4-5mm, the corners of the high alumina bricks and the uniformity of the structure will be affected, and the larger the clinker particles, the larger the particle segregation during the production process. Therefore, the maximum particle critical size should not be too large. The maximum critical particle size is preferably 3 mm.

The fine powder in the ingredients is beneficial to the sintering of the green body and the increase of the density of the high alumina brick. Adding an appropriate amount of fine powder can not only make the secondary mullite reaction that occurs during the firing of high-alumina bricks proceed in the fine powder. Prevent the green body from loosening due to the secondary mullite ratio reaction around the coarse particles. Moreover, the firing shrinkage caused by the sintering of the fine powder can weaken or offset the volume expansion caused by the secondary mullite reaction. It is advisable to add about 50% fine powder.

The intermediate particles in the ingredients have neither the skeleton effect of coarse particles nor the sintering effect of fine powder. In the production process, according to the specific conditions of production, the addition of intermediate particles is usually limited to a minimum amount. Generally speaking, the additional amount of intermediate particles is about 10%.

In short, to determine a reasonable particle ratio, it is necessary to consider the reasonable bulk density, limit the number of intermediate particles added, and also according to the different molding methods. The performance and requirements of high alumina bricks are used to determine the critical size and the number of particles added at all levels. In the general brick-making process, the upper limit of coarse particles is usually 2-3mm, and the addition amount is 40-45%. For special-shaped high alumina bricks, the upper limit of coarse particles can be reduced to 1-2mm. It is advisable to limit the addition of 1-0.1mm intermediate particles to 10-20%. The amount of fine powder <0.1mm added should be controlled at 40-50%.

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High Alumina Bricks Properties

High alumina bricks for steel manufacturing are made from a special grade of bauxite as the main raw material. Small amounts of white fused alumina and alumina powder are added. Shaped by high pressure, sintered at high temperature. The main mineral composition includes mullite and corundum, which have excellent high-temperature physical properties and chemical resistance. high alumina bricks properties, high alumina bricks have the advantages of small temperature creep, strong corrosion resistance, thermal shock resistance, and stability. It is suitable for large and medium-sized hot air stoves. High alumina bricks are mainly used in masonry blast furnaces, hot blast stoves, electric furnace roofs, blast furnaces, and rotary kiln linings. In addition, high alumina bricks are also widely used as open hearth regeneration inspection bricks, gating systems, nozzle bricks, and other plugs.

RS Alumina Bricks Factory has advanced production equipment and the support of a strong technical team, and strives for excellence in the production of aluminum bricks. It aims to provide high-quality refractory products for customers’ high-temperature kiln linings to save production costs. At the same time, our customer service runs through the entire service life of our refractory bricks in the kiln lining. To choose an aluminum brick manufacturer, you must choose a manufacturer with strength and guaranteed customer service. In addition to our customer service, we also provide the design and construction of refractory lining solutions. Contact us for free quotes and samples.

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Jun 8 2023

RONGSHENG METEC2023/GIFA2023 INVITATION

In 2023, after dormant, RS Alumina Refractory Manufacturer will bring newly high-end refractory products to customers at the 2023 Dusseldorf Metallurgical Casting Exhibition.

Dates: 12-16 JUN

Booth No.: HALL 5, G31-4

RONGSHENG WILL BE THERE WAITING FOR YOU!

RONGSHENG METEC2023/GIFA2023 INVITATION

RS Alumina Refractory materials manufacturer has rich experience in the production and sales of refractory materials. Our refractory bricks factory and environmentally friendly monolithic refractory castables factory are preparing to welcome our third member, the refractory precast factory. Together, they will serve our customers in more than 100 countries and regions around the world. Become our customer, we not only have high-quality refractory lining material products but also provide design and construction of refractory lining materials. Perfect customer service runs through the entire service cycle of refractory lining materials. Rongsheng is looking forward to working with you.

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May 20 2023

How to Use Refractory Bricks to Build a Circular Furnace Lining?

How to build a round refractory brick furnace lining? How many options are there for building a round refractory brick furnace lining? Arc brick? Curved mother-in-law buckle brick? Knife brick? The following suggestions are given by experienced manufacturers and sales of refractory bricks, as well as the construction team of refractory brick linings.

Arc High-Alumina Refractory Bricks for Ladle Lining

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Option 1: Building with arc bricks

The arc of the arc brick is a semicircle, and the other end is a groove, which can be flexible no matter how thick it is. Because it has no axis and the size is slightly deviated, it can also be built into a circle, so it is called arc brick. This kind of brick is used more in ladles. Curved high-alumina refractory bricks are mainly used as the lining of steel drums. In the past, it was mainly clay, but now it is gradually replaced by high alumina bricks. High-alumina arc brick is an aluminum silicate refractory material with an alumina content of more than 48%. It is formed and calcined from bauxite or other raw materials with high alumina content. High thermal stability, and refractoriness above 1770°C. Good slag resistance.

According to the usage, we believe that high alumina arc bricks have the following advantages.

High service life, more clinker clay bricks increase by 210%.
The reduction of unit consumption also shows the characteristics of high alumina arc bricks. The reduction of unit consumption can explain the corresponding reduction of non-metallic inclusions in molten steel.
Check that the cross-section of high-alumina bricks has better corrosion resistance to slag and molten steel than multi-clinker clay bricks.
Due to the roundness at both ends of the arc-shaped refractory brick, it can be moved back and forth to adjust the roundness when laying bricks. Therefore, it is convenient to build refractory bricks, and the brick joints can generally reach 1 mm.
The vertical joints of arc bricks are smaller, which is 70% less than that of standard refractory bricks. In this way, the erosion of the molten iron layer moving up and down and deep into the brick joints is corrected.
Due to the improvement of the quality of refractory bricks, the thickness of the lining bricks can be reduced, and the capacity of the steel drum can be increased accordingly.
Due to the long service life and the convenience of bricklaying, the labor required for laying steel drums behind the furnace is reduced, and the utilization rate of steel drums is increased.

Lining of Arc Shaped Buckle Refractory Brick — The lining of Arc-Shaped Buckle Refractory Brick

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Option 2: Masonry with arc-shaped mother-in-law buckle bricks

The arc-shaped letter buckle refractory brick has a small semicircular protrusion at one end and a small groove at the other end. Compared with arc bricks, the masonry is stronger and the gaps are smaller, but the disadvantage is that there is no arc bricks that can change the arc at will. There is no arc brick for the masonry of circular furnace linings with different inner diameters. The curved letter buckle is also made of clay or high alumina, and the performance of high alumina is the overall clay refractory brick.

Knife Bricks also Called Ax Bricks for Refractory Lining

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Option 3: Laying bricks with knife bricks or ax bricks

It can be built with knife bricks T38 and T39, or with ax bricks T19 and T20.

Rongsheng refractory brick manufacturers can provide high-quality masonry refractory bricks for circular refractory linings in various materials. Free consultation, info@aluminabricks.com.

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Apr 28 2023

High Aluminum Low Cement Refractory Castable Manufacturer

High-aluminum low-cement castable is a castable with a large number of monolithic refractories. That is to say, the addition of calcium aluminate cement is about one-half or one-third of the ordinary cement castable.

Compared with ordinary high-alumina castables, high-alumina, and low-cement castables use ultra-fine powder to reduce the amount of cement and greatly improve the strength and erosiveness of low-cement castables. While increasing the bulk density and reducing the porosity, the service life is increased.

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High-alumina and low-cement castables are used in industrial furnaces such as metallurgy, petroleum and petrochemical, electric power, and building materials. A large part has replaced refractory bricks, but as a manufacturer of low-cement castables, we still use different furnace types and temperatures according to users. According to the requirements of different use environments, some high-alumina and low-cement castables with different levels and different body densities are produced. Of course, the prices of different levels, different body densities, and low-cement castables are also different.

The characteristics of high-alumina and low-cement castables are also based on different grades of refractory micro-powder, different grades of main materials, and different grades of bonding agents to determine the quality of the product. In order to facilitate smaller particles, larger specific surface area, and better sintering ability, the castable is more suitable for the working needs of the user’s high-temperature kiln.

In the practical application of low-cement castables, especially in construction, it is also very important to control the amount of water added. Generally, when leaving the factory, the manufacturer will attach the construction instructions for the castable. During construction, it is necessary to strictly follow the construction instructions, and pour and maintain the castable well, so as to exert its maximum effect.

All in all, regardless of production or application, it is necessary to take into account the different effects of temperature, erosion, erosion, etc. on the refractory lining material according to the actual use. Only in this way can the refractory castables used be selected correctly, and with the appropriate construction technology, the service life of the refractory lining can be greatly extended. Save production costs.

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The Difference between LCC Refractory Castable and Ordinary Refractory Castable

Low-cement castables, ultra-low or no-cement castables replace most or all of the cement with superfine powders that have the same or similar chemical composition as the main material. It is formulated by scientifically optimizing particle gradation, micro-powder, particle shape, and other factors, and adding a small amount of dispersant (water reducer) and an appropriate amount of retarder and other compound admixtures.

Compared with ordinary refractory castables, the low cement castable series has many excellent properties.

(1) Less water consumption. The water consumption of LCC low-cement castables is only 1/2-1/3 (about 5-7%) of ordinary refractory castables. Therefore, the bulk density is high, the porosity is low, and there is no obvious dehydration stage during baking. Good thermal shock performance, comparable to fired products.
(2) Because the amount of cement is greatly reduced, the high-temperature performance and slag resistance of the material are improved.
(3) There are few or no hydrates after forming and curing, and there is no hydration bond damage during baking to affect the medium temperature strength. Therefore, no matter at medium temperature or high temperature, its strength does not decrease but increases.

The main application of LCC low cement castable is suitable for petroleum, metallurgy, the chemical industry, and various silicate kilns. Such as some components of the refining device outside the furnace, the cover of the refining ladle outside the furnace, the integral spray gun for molten iron, the treatment of molten steel, and the roof lining of the electric furnace. Soaking furnace, heating furnace, annealing furnace lining, tapping trough. Tundish lining, high-temperature burner, blast furnace tapping ditch cover, ladle lining, etc.

The refractoriness of low-cement refractory castables is greater than 1790°C, and the load softening temperature (4% deformation) at 0.2MPa is 20-100°C higher than that of CA50 cement refractory castables. Therefore, the service temperature of low-cement refractory castables is generally about 100°C higher than that of CA50 cement refractory castables of the same material. The thermal expansion coefficient of low cement refractory castables shows the characteristics of expansion during the whole heating process. It can be seen that as the heating temperature increases, the thermal expansion rate increases, and reaches the highest value at 1250 ° C, which is about 0.68%. Then it began to shrink slowly, and the thermal expansion rate was 0.43% at 1400°C. When the temperature was 1500°C, the thermal expansion rate returned to 0.5%.

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LCC Refractory Castable Ultra-Low Cement Castable

Low cement and ultra-low cement refractory castables refer to castable refractory materials with calcium aluminate cement added less than 8%. According to the US ASTM regulations, the CaO content in low-cement castables is required to be less than 2.5%, generally 1.0-2.5. When the CaO content is less than 1%, it becomes an ultra-low cement castable. The materials of low-cement and ultra-low-cement castables include clay, high alumina, mullite, corundum, carbon and silicon carbide, etc. Its ingredients are composed of refractory aggregate, refractory powder, an appropriate amount of superfine powder, an appropriate amount and small amount of calcium aluminate cement (delayed coagulation accelerator), and a trace amount of dispersant (high-efficiency debonding agent). Generally, multi-level ingredients are used, which are divided into 5~3mm, 3-1mm, 1~0.2mm, 0.2~0.074mm, 0.074~0.044mm, and less than 1 micron.

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Mullite low-cement castables can be used as inner linings of various high-temperature burners, dressing linings of water-cooled pipes of heating furnaces, etc. Corundum and chromium-containing corundum low-cement refractory castables can be used as the lining of the triangular area of the top of the steelmaking electric arc furnace and the lining of some parts of the refining device outside the molten steel furnace. Such as integral spray gun lining for spray metallurgy, RH and DH vacuum degassing device and dipping tube lining, power frequency induction furnace lining, the high-temperature wear-resistant lining of a petrochemical catalytic cracking reactor, etc.

Al2O3-SiC-C low-cement castables are used as linings for blast furnace tapping troughs, iron furnace tapping troughs, and integral spray guns for molten iron pretreatment.

MgO-Al2O3 or Al2O3-MgO·Al2O3 low-cement castables are used as linings for ladles and tapping troughs.

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Mar 18 2023

Maximizing Blast Furnace Performance with Quality Checker Bricks

Blast furnace technology is a critical aspect of the iron and steel production process. This highly specialized technology requires various components, including checker bricks, to operate at optimal performance. Checker bricks are a unique type of refractory material that plays a vital role in enhancing the performance of blast furnaces. In this essay, we will explore the importance of using high-quality checker bricks to maximize blast furnace performance.

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What’s a Checker Bricks for Blast Furnace?

Checker bricks are named after their unique checkered pattern. They are typically used in the lower portion of the blast furnace where they serve as a lining material. Checker bricks consist of a combination of carbon, silicon carbide, and alumina, which gives them high-temperature resistance and durability. They are designed to withstand extreme temperature and pressure conditions in the lower portion of the furnace and play a crucial role in enhancing the efficiency and productivity of blast furnace operations.

How to Maximize Blast Furnace Performance with Quality Checker Bricks?

One of the key benefits of using quality checker bricks in blast furnace construction is their ability to improve thermal efficiency. The lower portion of the blast furnace experiences some of the highest temperatures and pressures in the entire iron production process. Checker bricks help to regulate and control the flow of hot gases and materials through the furnace, ensuring optimal heating and combustion conditions. By regulating the flow of materials, checker bricks help to minimize heat loss and maximize thermal efficiency. This results in significant energy savings and improved overall blast furnace performance.

Quality Checker Bricks for Blast Furnace

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Another important benefit of using quality checker bricks is their ability to reduce downtime and maintenance costs. Blast furnace downtime can be costly, resulting in lost production and revenue. Checker bricks that are of poor quality or not designed for the specific conditions of the blast furnace can fail prematurely, requiring frequent replacement and maintenance. High-quality checker bricks are designed to withstand the extreme conditions of the blast furnace, minimizing the risk of failure and reducing downtime and maintenance costs.

Furthermore, quality checker bricks can help to improve the overall quality of iron production. The checker brick lining plays a vital role in ensuring that the blast furnace operates at optimal conditions, which results in high-quality iron production. Checker bricks help to regulate and control the flow of materials through the furnace, ensuring that the iron produced is of consistent quality and purity.

Checker Refractory Bricks Used in Blast Furnace

Checker bricks, checker refractory bricks blast furnace, is a checker brick with many advantages such as strong heat exchange ability, large heat storage area, smooth ventilation, and low resistance, which is generally recognized and accepted by the ironmaking industry in the world. Checker brick is a heat transfer medium used in the blast furnace regenerator. It is usually arranged in an orderly manner in the regenerator, plays a heat storage role during the “burning period”, and heats the cold air into hot air through convective heat exchange and radiation heat exchange during the “air supply period”.

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At present, checker bricks, checker bricks blast furnaces, and checker bricks are mainly used in blast furnaces hot blast stoves, and flame furnaces. Checker bricks are mainly used in the regenerator of the hot blast stove. Checker bricks with grid holes in a certain structure are arranged in an orderly manner, and the upper and lower through holes of the checker bricks allow gas to pass through. According to the technical requirements of different temperature regions, silicon checker bricks, and clay bricks are generally used. In some hot blast stoves, there are also high alumina bricks, mullite bricks, sillimanite bricks, etc. to choose from. The function of the hot blast stove is to heat the cold air sent by the blower to the blast furnace into hot air. Then, the hot air is sent to the blast furnace through the hot air pipe for a combustion reaction. The blast furnace hot blast stove has a furnace firing period and an air supply period, and the rotation of the two task periods. During the firing period, the extinguished low-temperature flue gas passes through the holes of the checker bricks of the hot blast stove and transfers heat to the checker bricks. During the air supply period, the cold air from the blower enters the hot blast stove, is heated by the checker bricks to become hot air, and is sent to the blast furnace through the hot air pipe.

Clay bricks for hot blast stoves belong to a secondary category of silicon-aluminum series products. They are refractory products with an Al2O3 content of 30-48% made of clay clinker as aggregate and refractory clay as a binder. The refractoriness of clay bricks is comparable to that of silica bricks, as high as 1690-1730°C, but the load hardening temperature is more than 200°C lower than that of silica bricks.

In conclusion, maximizing blast furnace performance requires the use of high-quality checker bricks. These specialized refractory materials play a crucial role in improving thermal efficiency, reducing downtime and maintenance costs, and ensuring high-quality iron production. The use of quality checker bricks can result in significant energy savings, increased productivity, and improved overall blast furnace performance. It is essential to select the right type of checker bricks that are designed for the specific conditions of the blast furnace and to ensure that they are properly installed and maintained. By doing so, blast furnace operators can ensure optimal performance and maximize the efficiency of their iron production process. Buy refractory bricks used in blast furnace from Rongsheng.

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Feb 7 2023

Rongsheng High Alumina Anchor Bricks Used in High-Temperature Furnace Linings

High Alumina Anchor bricks are one of the most efficient materials used in high-temperature furnace linings. These materials are highly durable and provide an excellent heat-resistant environment for the operation of the furnace. High alumina anchor bricks are also called hanging bricks. It is mainly used to connect and support the structure of refractory bricks and ordinary fired bricks. It is used for heating the furnace top, furnace wall, or other parts.

RS High-Quality Anchor Bricks used in high-temperature furnace linings — RS High-Quality Anchor Bricks

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High alumina anchor bricks are composed of special alumina-containing clay, followed by a high alumina anchor brick with an alumina content above 55%. The high aluminum content ensures excellent insulation and thermal shock resistance. Rongsheng high-alumina anchor bricks use natural high-grade bauxite as the main refractory raw material, add soft or semi-soft clay as a binder to the high-alumina clinker to start batching, mixing, then molding, drying, and finally firing. Shaped high alumina refractory bricks. High alumina anchor bricks can be customized for production and processing according to customer needs. The load softening temperature of the high-alumina anchor brick reaches 1550°C, which can meet the performance requirements of the furnace roof lining.

Benefits of Using High Alumina Anchor Bricks in High-Temperature Furnace Linings

High alumina anchor brick is a special-shaped high alumina refractory brick. The benefits of high aluminum anchor bricks compared to other materials are numerous. First of all, judging from the shape of the high-alumina anchor brick, it is a column composed of the hanging end and the anchor. Grooves are distributed at intervals on the surface of the anchor body. In addition, ribs are provided along the length direction on at least one surface of the anchor. Due to the reinforcement and pulling effect of the ribs, the tensile and flexural strength of the anchor body is significantly improved. Therefore, the stress generated at the groove is blocked at the rib and cannot continue to be transmitted, so the high-alumina anchor brick in High-Temperature Furnace Linings is not easy to break.

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The benefits of high alumina anchor bricks compared to other materials are numerous. Firstly, they have excellent refractory properties, meaning they can withstand extremely high temperatures and provide the necessary insulation for the furnace. In addition, their compressive strength is very good, enabling them to withstand the huge loads in the furnace linings. Furthermore, their chemical composition helps retain their dimensional stability, making them excellent for linings with long service life. Such as the following listed characteristics.

Characteristics of High Alumina Anchor Brick for Heating Furnace

Stable volume at high temperature.
Good corrosion resistance.
The high softening temperature under load.
Anti-stripping and high compressive strength.

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Advantages of Anchor Bricks

Cost-Effective
Low Maintenance
Wide Range of Applications

High-alumina anchor bricks refer to high-alumina refractory bricks with a specific shape that is installed on the steel structure of the industrial kiln shell or supporting the furnace lining and embedded in the refractory lining for anchoring and connection. At room temperature, a bar-shaped sample with a certain size is loaded according to the specified conditions, and the ultimate tensile stress per unit area can withstand it before fracture.

In summary, high alumina anchor bricks are a great choice for creating high-temperature furnace linings. They are highly durable, resistant to corrosion and thermal shock, and environmentally friendly. They are ideal for applications requiring extended service life and reduced maintenance costs. And, since they are made of natural materials, they are an excellent choice for implementing environmentally friendly construction methods.

High Alumina Anchor Bricks for Furnace Wall and Top — High Alumina Anchor Bricks for Wall and Top of Industrial Furnace

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High Alumina Anchor Bricks from Rongsheng Manufacturer

Rongsheng high aluminum anchor bricks use in high-temperature furnace linings. High-alumina anchor bricks are refractory bricks for the furnace roof and wall of the heating furnace. Rongsheng alumina refractory brick manufacturers can customize processing according to the size of high alumina anchor bricks provided by customers, also the refractory anchors with different shapes. In order to meet the high alumina bricks furnace lining requirements of the heating furnace and ensure the service life of the heating furnace lining, the index parameters can also be customized according to the actual working conditions of the customer’s kiln. In order to finally meet the economic benefits of improving the heating furnace.

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Industrial Refractory Steel industry refractories

Jan 12 2023

Cordierite Bricks for Hot Stove Burners

The hot blast stove burner is a device that mixes gas and air and sends them into combustion. The burner used in the hot blast stove is divided into two types: metal material and ceramic material. Among them, the ceramic burner is mainly made of mullite or cordierite-mullite refractory materials. The lining refractory material of the hot blast stove and its construction quality will directly affect the thermal insulation effect of the furnace body and the stability of the furnace lining structure, thus having a profound impact on the life of the furnace body and design efficiency.

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Brief Introduction of Cordierite Mullite Bricks

Friends who have not been in contact with cordierite mullite bricks will be very unfamiliar with this refractory brick. Today, Rongsheng Factory will introduce the product knowledge of cordierite mullite bricks to you, hoping to provide help to friends who need refractory bricks for ceramic burners in hot air stoves.

Cordierite mullite brick is a novel refractory material in the 1980s. It has the characteristics of high refractoriness, good thermal shock resistance, high load softening temperature, small expansion coefficient, and long service life. Cordierite mullite bricks are widely used in the light industrial ceramics industry, tunnel kiln car bricks, raceway kilns, pusher kilns, pusher kiln furniture, saggers of various specifications, etc. It is also suitable for kiln car surfaces in the ceramic industry, porous kiln push plates, roller kiln gaskets, and sagger for ceramics. It replaces clay refractory materials and high alumina refractory materials. It works well.

Cordierite Bricks for Ceramic Burner of Hot Stove

A burner is a device used to mix gas and air and send them into the combustion chamber. It is generally required to have sufficient combustion capacity, which is beneficial to shorten the burning period. It is necessary to ensure that the gas and air are mixed evenly and can be burned stably to avoid back spraying.

In order to improve the combustion capacity and meet the needs of high wind temperatures, ceramic burners are used. The ceramic burner is a burner made of refractory materials and installed in the combustion chamber. Gas and air pass through a special structure before combustion so that the airflow is divided into small streams (called trickle segmentation), mixed with each other after spraying out, and then burned in the room. Obviously, from the function of the ceramic burner, its working environment is subjected to the thermal shock of the sharp temperature change during the heat exchange process. Taking a steel factory as an example, each blast furnace has 4 hot blast stoves for the hot blast. When the hot blast stove is in normal production, it takes 35 minutes to heat up and 45 minutes to supply air. The brick temperature fluctuates from 500-600°C to as high as 1000°C at the moment when the ceramic burner starts to burn after the air is supplied. The thermal shock to refractory bricks is obvious. In addition, it is also impacted by combustion gas, so the corresponding refractory material should have better thermal shock resistance.

If the hot blast stove is an external combustion type. Traditional bricks for ceramic burners are cordierite bricks, but now they have been developed to use andalusite-mullite refractory bricks materials, high alumina cordierite bricks, mullite cordierite bricks, etc.

If it is a top-fired hot blast stove, the air temperature of the ceramic burner is relatively high (about 1360°C). Higher thermal shock resistance is required, which is reflected in the test conditions and the number of thermal shock stability. Originally required 1300°C, water cooling now requires 1100°C, and water cooling, thermal shock stability is not less than 100 times. The production of these bricks also uses three-stone minerals, especially andalusite minerals.

Rongsheng Refractory Bricks Prices — Rongsheng Refractory Bricks Manufacturer

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Rongsheng Refractory Brick Manufacturer

The cordierite bricks for hot blast stove burners produced by Rongsheng refractory brick manufacturers have good thermal stability and a small thermal expansion coefficient. Based on the principle of being responsible to customers, Rongsheng manufacturers strictly control the production standards of refractory products. To ensure that the produced refractory cement, refractory bricks, castables, and other products can have good high-temperature resistance and strong slag resistance. It can meet the operating temperature of the customer’s actual boiler. The product quality has been well received and supported by new and old customers. Buy cordierite bricks, cordierite mullite bricks, mullite refractory bricks, factory direct sales, and refractory materials at reasonable prices. Welcome to consult and purchase, Rongsheng refractory products and customer service will not let you down.

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Dec 6 2022

What Kind of Refractory Material is Used for the Lining of the Hydrogen Sulfide Incinerator?

The working temperature in the furnace of the incinerator burning hydrogen sulfide is about 1150 ℃, and the working conditions are harsh. It belongs to an acidic combustion atmosphere, but the temperature of the furnace will reach 1400 ℃ due to the fluctuation of materials and air volume in actual production. The amount of hydrogen sulfide gas is very unstable, and every combustion fluctuation in the furnace is a big thermal shock to the furnace lining.

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And this kind of acid gas furnace lining is made of refractory materials, so it is very important to resist acid corrosion and thermal shock stability. The main body of the furnace can adopt a three-layer structure. Corundum mullite bricks should be used for parts that are in direct contact with the flame. It is characterized by strong wear resistance and corrosion resistance. The middle layer can choose three grades of high alumina bricks. Because the working layer does not directly contact the flame, the flexibility of the three-grade high-alumina brick is relatively good. The outer layer can be used as an insulation layer, and high-aluminum heat-insulating refractory bricks are used to keep the temperature down and reduce the temperature of the outer wall of the steel shell.

Corundum mullite brick is a refractory product composed of mullite as the main crystal phase and corundum phase, which is sintered at a high temperature of 1650-1750 °C. It has good high-temperature strength, high-temperature creep resistance, thermal shock resistance, and corrosion resistance.
The third-grade high-alumina brick is a series of aluminum products made of high-alumina raw materials and clay as a binder fired at a temperature of 1400°C. High thermal stability, and strong flexibility.
Lightweight high alumina brick. It has the characteristics of small bulk density, large porosity, low thermal conductivity, and specific heat capacity, and has good thermal insulation performance for heat insulation layers. In the case of slow heat dissipation, it can save fuel and reduce the temperature of the steel shell.

The incinerator burning hydrogen sulfide is one of the rare furnace types, so the corundum mullite brick in the refractory brick used for its refractory lining is a high-grade refractory material. High-alumina bricks are neutral materials, and lightweight high-alumina bricks are used as a three-layer masonry lining to effectively improve the corrosion resistance of the incinerator. The refractory mortar of the same material is used for masonry during construction to ensure the long-term safe and reliable operation of the incinerator.

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Ceramics Refractories

Oct 9 2022

Application of Cordierite Mullite in Kiln Furniture

The cordierite matrix in cordierite-mullite kiln furniture endows the refractory with a low coefficient of thermal expansion and good thermal shock resistance. The low-aluminum mullite particles in the cordierite-mullite kiln furniture endow the material with a certain high-temperature resistance and volume stability under thermal conditions. Cordierite-mullite only contains oxides with stable valence, which will not pollute ceramic products due to oxidation-reduction problems. Therefore, cordierite-mullite refractory materials are often used to make refractory products such as shed plates, backing plates, and supports of ceramic kilns. What are the characteristics of cordierite-mullite kiln furniture?

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Cordierite Mullite Kiln Furniture

Primary kiln furniture refers to refractory products such as shed slabs and pillars for building the firing space. Secondary kiln furniture refers to the small kiln furniture placed on the primary kiln furniture directly used to support or protect the products to be fired. In addition to primary kiln furniture, cordierite-mullite materials include secondary kiln furniture of various complexities and shapes.

Application of Cordierite Mullite in Kiln Furniture

Cordierite-mullite has good high-temperature properties such as thermal expansion and thermal shock stability. Cordierite-mullite composites are widely used.

Kiln furniture is a special-shaped refractory material that supports and protects the firing process of ceramic products and magnetic materials. It has an extremely important impact on the quality of ceramic products and the energy consumption of the ceramic industry, mainly including saggars, shed plates, pad cakes, columns, and push plates. The performance of kiln furniture directly affects the quality and production cost of fired objects such as ceramics. General kiln furniture materials should have the following basic properties: high refractoriness, good thermal shock resistance, and chemical stability; high strength at room temperature and high temperature. Because one of the functions of kiln furniture is to bear the load, it must withstand the load of the product and the kiln furniture itself. High-strength kiln furniture materials can make kiln furniture light and thin, so as to increase the density of the kiln and improve the quality of products. In addition, it is also required to have good thermal conductivity and low thermal storage, regular appearance, and precise dimensions.

The cordierite material has the characteristics of a small thermal expansion coefficient and excellent thermal shock resistance and is widely used in ceramic kiln furniture by domestic and foreign manufacturers. The thermal shock resistance of kiln furniture is a key parameter that determines the life of kiln furniture. When the main material is determined, the thermal shock resistance of kiln furniture must be improved from its microstructure. So that it has high elastic modulus, fracture surface energy and thermal conductivity, low thermal expansion coefficient, and so on. Improved thermal shock resistance can be achieved by reducing thermal stress caused by thermal expansion, forming microcrack networks, and introducing energy dissipation mechanisms during inter-particle interface fracture. The thermal shock resistance of cordierite kiln furniture can be further improved by doping andalusite to introduce the energy dissipation mechanism during interface fracture.

Although cordierite has a small thermal expansion coefficient and good thermal stability, it has a low softening temperature under load and a small operating temperature range. Although products such as mullite and silicon carbide have good high-temperature performance, their cost is high. Using the mullite effect of andalusite at high temperatures, by adding SiC and a small amount of artificial mullite, the organizational structure of cordierite ceramic kiln furniture materials can be significantly changed. Improve high-temperature performance and reduce the cost of kiln furniture materials. Cordierite and cordierite-mullite kiln furniture structure is a ring-shaped silicate. Since the tetrahedrons in the structure are connected into a special helical six-membered ring, there are large gaps in the structure. When the particle is heated, it can vibrate to the gap, so the cordierite kiln has the characteristics of a small thermal expansion coefficient and excellent thermal shock resistance. However, cordierite is an unstable compound that decomposes into mullite and glassy phases. And the firing temperature range is narrow, and the high-temperature performance is poor. The mullite material has high refractoriness and good high-temperature stability. The mismatch between the thermal expansion coefficients of cordierite and mullite results in the formation of micro-cracks at the two-phase interface, which makes the material have excellent thermal shock resistance and good high-temperature performance. Therefore, cordierite-mullite composite materials are widely used in high-grade ceramic kiln furniture at home and abroad.

With the transformation of the firing technology of the ceramic industry from the traditional saggar firing to the open flame saggarless firing technology, the demand for high-quality ceramic kiln furniture materials – shed slabs is increasing. As one of the special kiln furniture for supporting porcelain pieces shed plate has always been an important auxiliary material in the ceramic industry. The material is mostly cordierite-mullite composite material with good thermal shock resistance and high-temperature performance. The cordierite-mullite slab is sintered from mullite and cordierite. The mechanism is that cordierite has a much smaller thermal expansion coefficient than mullite due to the large voids in the ring structure of cordierite. The expansion coefficients of the two are matched, so that micro-cracks are formed at the interface of the two phases, preventing the propagation of destructive cracks. Thereby, the thermal stability performance of the cordierite-mullite shed plate is greatly improved.

High alumina refractory products containing cordierite, it is made of high alumina raw material, synthetic cordierite, and binder. The thermal shock stability of the product is very good, and it can be used as ceramic kiln furniture, heat exchanger, catalyst carrier (honeycomb ceramic) for purifying waste gas, etc. For a free quote on cordierite bricks, please contact us.

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Blog

Sep 21 2022

Requirements for the Use of Refractory Materials for Ladles

The steel ladles are the necessary equipment for receiving molten steel and for continuous casting. Because many steel grades need to be refined in the ladle, including argon blowing temperature adjustment, alloy composition fine-tuning, powder spray refining and vacuum treatment, etc. The working conditions of the ladle lining are getting worse and worse, and its working environment is.

(1) The temperature of molten steel is higher than that of the die-casting ladle.
(2) The residence time of molten steel in the ladle is prolonged.
(3) The inner lining of the ladle volatilizes itself under a high-temperature vacuum and undergoes the stirring effect of molten steel.
(4) The impact of the lining when it accepts molten steel.
(5) Erosion of slag to the lining.

Therefore, the requirements for ladle refractories are:

(1) High-temperature resistance. Can withstand high-temperature molten steel for a long time without melting and softening.
(2) Thermal shock. Can withstand repeated loading and unloading of molten steel without cracking and peeling.
(3) Corrosion is resistant to slag. Can withstand the erosion effect of slag and slag basicity changes on the lining.
(4) It has sufficient high-temperature mechanical strength. Can withstand the stirring and scouring of molten steel.
(5) The lining has a certain degree of expansion. Under the action of high-temperature molten steel, the inner linings are in close contact and become a whole.

Commonly Used Refractory Materials for Ladles

The bottom layer of the ladle. Clay bricks, also known as fired bricks. Clay bricks are made of clay (including shale, coal gangue, and other powders) as the main raw material, which is processed, shaped, dried, and fired with mud. There are solid and hollow.
Ladle working layer, high alumina brick. Among the refractory materials produced with aluminum-silicon-based raw materials, the bricks with Al2O3 as the main component are high-alumina bricks, mullite bricks, and corundum bricks.
The main body of the ladle is poured. Castable refers to the mixture composed of refractory aggregate, binder, and admixture, which is mixed with water (or liquid binder) to form mud that can be constructed by the pouring method. The difference from other unshaped refractories is that refractory castables have a certain setting and hardening time after construction. Therefore, after casting and molding, it needs to be cured for a certain period of time before it can be de-molded, and then it can be put into baking after an appropriate period of natural curing.
Ladle wall. Unburned bricks are also known as chemically bonded bricks. It refers to the refractory material that can be directly used for masonry without firing. The production process is relatively simple, it is made of refractory materials of different materials, and the combination of powder and granules in the product is mainly formed by the chemical action of the binder.

If the ladle is also used for refining, refractory materials that can also be used include zircon bricks, magnesia carbon bricks, magnesia carbon bricks, magnesia chrome bricks, magnesia chrome aluminum bricks, and the like.

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Improvement of High Alumina Bricks Used in Refining Ladle

Modern refining ladles use natural andalusite and bauxite to produce high-alumina bricks. Compared with bauxite, the former has higher purity and thermomechanical stability (such as thermal strength). Because it contains more SiO2, it has poor corrosion resistance. Especially under the condition of alkaline slag, the lining of high-alumina brick masonry refining ladle produced with bauxite clinker as the main raw material has the following shortcomings and is being eliminated.

①Due to the volume shrinkage, the molten steel and slag are seriously penetrated and eroded, especially a thick slag layer formed at the brick joints.
②Due to the inherent brittleness of the brick itself and its structure, the ladle lining forms a thicker erosion zone and a slag layer.
③ Due to the inherent wettability of the lining to molten steel and slag, the erosion and penetration of the slag are more serious, and flake spalling occurs.

In order to overcome the above shortcomings of high-alumina bricks lined with a refined ladle, Al2O3-MgO-C bricks were developed to replace them. Compared with high alumina bricks, Al2O3-MgO-C bricks have the following advantages:

(1) Good high-temperature resistance and tissue peeling resistance;
(2) Good corrosion resistance to molten steel and slag;
(3) Good residual expansion, even at higher temperatures, no cracks appear at the joints of the bricks.

Because, when the temperature is higher than 1650°C, the high-alumina bricks show obvious shrinkage, which will lead to the penetration of molten steel and slag into the brick joints. Different from high alumina bricks, Al2O3-MgO-C bricks will not shrink in the continuous casting temperature range (1650~1670℃).

Ladle Refractory Materials Manufacturers

Rongsheng refractory material manufacturer is a manufacturer of technical refractory lining material solutions with rich production and sales experience. Our excellent technical team specializes in solving the problem of refractory lining of high-temperature furnaces, including various ladle refractory problems. At the same time, our refractory brick production line and monolithic refractory production line are also the strong support of our team. From our customer base in more than 80 countries around the world, it is not difficult to see the strength of our team. Become a customer of Rongsheng Refractory Factory for free, our customer service will not let you down.

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