Blog Archives - Page 3 of 8 - RS Kiln Refractory Bricks

Refractory bricks are inorganic non-metallic materials with a refractory degree of not less than 1580°C. It is a basic material for high-temperature technology, a structural material for masonry kilns and other equipment, and a functional material for manufacturing certain high-temperature containers and components or their special functions. The successful use of refractory bricks under high temperatures must have a good organizational structure, thermal properties, mechanical properties, and usability. That is to say, it has high refractoriness, load softening temperature, thermal shock resistance, and chemical erosion resistance so that it can withstand various powerful chemical changes and other effects, and meet the use requirements of thermal equipment and components. So, why can refractory bricks withstand high temperatures? RS Refractory Materials Manufacturer, a powerful refractory brick manufacturer, ensures that the refractory bricks can withstand high temperatures based on the raw materials of the refractory bricks and the characteristics of the molding and sintering process of the refractory bricks as inorganic non-metallic materials.

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Raw materials for refractory bricks

The raw materials used in the production of refractory bricks are generally natural ores. Refractory bricks with different properties are made by processing raw materials such as bauxite, silica, and magnesite. Such as aluminum-silicon refractory bricks, siliceous refractory bricks, and magnesia refractory bricks.

Aluminum-silicon refractory bricks are produced using bauxite as raw material. Its main component is alumina. Hydrated alumina containing impurities is an earthy mineral that is insoluble in water and soluble in sulfuric acid and sodium hydroxide solutions. It is mainly used for smelting aluminum and making refractory materials. Because the refractoriness of high-alumina clinker is as high as 1780°C, it has strong chemical stability and good physical properties. The bauxite is purified at high temperature to produce a corundum main crystal phase with an alumina content greater than 90%, which can produce ultra-high temperature refractory bricks – fused zirconium corundum bricks.

The raw material of silica refractory bricks is silica, and its main component is SiO2. The higher the content, the higher the refractory degree. The most harmful impurities are Al2O3, K2O, Na2O, etc. Silica bricks are made from natural silica as raw material, plus an appropriate amount of mineralizing agent to promote the conversion of quartz in the body into tridymite. It is slowly fired at 1350-1430°C in a reducing atmosphere. It has high-temperature strength and the load softening temperature is 1620℃.

high alumina refractory brick — RS High-Quality High-Alumina Refractory Bricks

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Magnesite is the main raw material for making magnesite refractory bricks. Its basic component is MgO. Magnesium oxide has high refractory insulation properties. It can be transformed into crystals after being burned at high temperatures above 1000°C and becomes sintered magnesia when the temperature rises to 1500-2000°C. Then it can be made into magnesia bricks or magnesia ramming materials after being crushed to a certain particle size or powder. Magnesia refractory bricks are alkaline refractory bricks, which have strong energy resistance to alkaline slag but cannot resist the erosion of acidic slag. The refractoriness is above 2000℃, but its load softening point is only 1500℃, and its thermal shock stability is poor.

Refractory bricks are inorganic non-metallic materials

Inorganic non-metallic materials, organic polymer materials, and metallic materials are listed as the three major materials. Common inorganic non-metallic materials are characterized by high compressive strength, hardness, high-temperature resistance, and corrosion resistance. In addition, ceramics have excellent corrosion resistance, and refractory materials have excellent properties in heat protection and insulation. These are incomparable to metal materials and polymer materials. However, compared with metal materials, it has low breaking strength and lacks ductility. Compared with polymer materials, they have higher density and complex manufacturing processes.

Forming and sintering of refractory bricks

The production process of refractory bricks is through mineral crushing-raw material mixing-mechanical molding-high temperature firing. This process finally produces a product that can withstand high temperatures. The sintering temperature of the green body passing through the high-temperature tunnel kiln will be higher than the load-softening temperature of the product. Generally, the sintering temperature is above 1500℃, the refractoriness is above 1770℃, and the high-temperature resistance is good. Refractory bricks are mainly used to build kiln linings such as steelmaking electric furnaces, glass furnaces, and cement rotary furnaces.

To summarize, there are three main reasons why refractory bricks can resist high temperatures. ① The raw minerals used in refractory bricks have high refractoriness. ② As an inorganic non-metallic material, the level of its use is determined by the level of raw materials. ③ The finished body has passed through a high temperature of over 1500°C in a high-temperature tunnel kiln, so the refractory bricks can resist high temperatures and are suitable for use in high-temperature kiln linings.

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Performance advantages of low porosity refractory bricks

Clay refractory products are extremely versatile and are made of high-quality raw materials. It is an indispensable refractory material for various industrial kilns. Low-porosity clay bricks were originally designed and widely used in hot blast stoves and glass kiln regenerators. Nowadays, it is widely used in lime kilns due to its good density and good resistance to chemical corrosion, especially alkali corrosion.

Low-porosity clay bricks are refractory products made from high-quality burnt gemstones as the main raw material, and their performance has been fully upgraded. The performance advantages of low porosity refractory bricks include.

Strong corrosion resistance.
Low porosity and high density.
High mechanical strength.
Strong anti-penetration ability.
High strength and high fire resistance.
The organization is dense.
Good thermal shock stability and resistance to peeling.

RS refractory brick manufacturer

RS Refractory Brick Manufacturer is a powerful manufacturer of refractory brick production and sales. Our refractory brick products have an annual output of 60,000 tons, and the quality is reliable and guaranteed. We have also made certain breakthroughs in thermal insulation material products. It has contributed a small step forward for energy-saving and heat preservation of high-temperature industrial furnaces. Our RS company can provide comprehensive refractory services for high-temperature industrial furnaces. Our professional technical team can also provide suitable solutions for the lining of high-temperature industrial furnaces. Material design and construction of refractory linings, and turnkey refractory projects. Contact us to get a free quote and samples.

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Oct 8 2023

Construction and Repair of Regenerator Checker Bricks

With the advancement of the times, reducing consumption and improving production efficiency have always been the primary goals of major enterprises. In the field of high-temperature industry, regenerative industrial grid bricks are widely recognized and accepted as a heat-carrying and heat-storage body with many superior thermal properties such as strong heat exchange capacity, large heat storage area, smooth ventilation, and low resistance. Checker bricks are a heat transfer medium used in blast furnaces hot blast furnace regenerators, coke oven regenerators, glass kiln regenerators, etc. Checker bricks are usually arranged in an orderly manner in the regenerator. It plays the role of heat storage during the “burning period”. During the “air supply period”, the cold air is heated into hot air through convective heat exchange and radiation heat exchange.

Basic characteristics of regenerator checker bricks

It has a plurality of transparent holes parallel to the side surfaces, as well as positioning protrusions and positioning grooves located on the two parallel surfaces.
Good volume stability, excellent creep performance under high-temperature load, high density, and low porosity. Modern blast furnace hot blast stoves usually adopt a checkered brick regenerator structure.

Checker Bricks for Blast Furnace — Construction of Checker Bricks in Hot Blast Stove

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Construction of Checker Bricks in Hot Blast Stove Regenerator

(1) The regenerator checker bricks usually use seven-hole checker bricks. During masonry construction, each layer should be arranged in a staggered manner, and the upper and lower grid holes should be aligned.

(2) The checkered bricks around the edges of the masonry and at the joints of the walls should be pre-processed according to the designed dimensions before masonry. During construction, the processed checker bricks will be laid in sequence according to the construction drawings. Be careful not to process checker bricks in the furnace. When building the wall of an internal combustion hot blast furnace with the furnace shell as the guiding surface, checker bricks can be processed appropriately in the furnace while taking protective measures.

(3) Before laying checkered bricks, the cross center lines should be drawn at the four angular directions of 0°, 90°, 180° and 270° of the wall masonry. Then pull out two rows of masonry center lines on both sides of the 90° and 270° lines, with the center column being the first row of masonry center lines.

(4) The checkered bricks on the first floor should be dry laid and laid in advance. The bricks can be laid formally after the center grid position is verified to be accurate and qualified. After the masonry is completed and it is confirmed that the surface flatness of the masonry meets the requirements, the second layer of checkered bricks will be laid.

(5) Each layer of checkered bricks is controlled according to the three rows of masonry center lines pulled out from the fence. Starting from the center line of each layer of checker bricks, lay the cross row of center bricks first. Then build the bricks along the four angles in the direction of the furnace wall.

(6) Allowable deviation of expansion joints between adjacent checker bricks

1) Clay checker brick: 4mm;
2) High alumina checker brick: 8mm;
3) Silica checker brick: 12mm.

Use yellow cardboard or foam plastic board to fill the expansion joint tightly. Before filling, process the board according to the reserved size and thickness of the expansion joint. Then when the checker bricks are being laid, the expansion joint plates are tightly attached to the sides of the checker bricks. Carry out simultaneously, build, and paste at the same time.

(7) After the first layer of checker bricks is completed, the processed checker bricks at the edge positions are laid in sequence. And check to confirm compliance.

(8) The expansion joint between the checker bricks and the furnace wall should be reserved according to the design and construction requirements. Use wooden wedges to wedge the expansion joint tightly.

(9) After the checker bricks are laid, clean the construction area. Check the hole position and smoothness of the grid holes again. If the electric light can pass through the grid hole or the inspection tool passes through the full height of the grid hole, the grid hole will be regarded as qualified.

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Coke Oven Regenerator Checker Brick Construction Process

After the furnace body is completed, blow air to clean the secondary grooves on the roof of the regenerator. Mark the control line between the central partition wall and the sealing wall on the regenerator wall.
Blow the checker bricks clean with compressed air and start preparing to lay the checker bricks.
When the first layer of checker bricks is dry-layed, check the location and stability of the checker bricks before dry-laying the lower layer of checker bricks.
The checkered bricklayer after the second layer should be stepped back from the central partition wall to the furnace head.
Always check whether the holes of each layer of checker bricks are unobstructed, and the upper and lower checkerboard bricks should be aligned.
Yellow cardboard can be used to maintain the width and stability of the gap between the grid bricks and the regenerator wall and non-flammable materials must not be used for the padding.
After the dry-laying of checker bricks in each regenerator is completed and the inspection is qualified, the construction of the regenerator sealing wall begins.
The regenerator walls and checker bricks of divided regenerator coke ovens should be constructed alternately in sections. Before each section of checkered bricks is dry-layed, the section should be sealed or partitioned, and the wall grooves should be cleaned. During the dry-laying process of checker bricks, pay attention to prevent refractory mortar from falling into the lower checker bricks. Once the dry-laying is completed and inspected to be qualified, immediately cover it with a protective board. The protective board should be set firmly and tightly, close to the wall of the regenerator to prevent refractory mud from leaking into the checker bricks.

Hot Repair Method of Checker Bricks for Glass Kiln Regenerator

After long-term high-temperature operation of the glass melting furnace, the refractory brick for the glass kiln lining and various equipment used have aged to varying degrees. In particular, the checker bricks in the regenerator were seriously damaged and blocked, seriously affecting the atmosphere in the glass-melting furnace. This situation not only increases energy consumption but also causes a large number of quality problems in the glass products produced. Therefore hot repair of checkered bricks is by far the most effective way.

Rongsheng Checker Bricks for Glass Kilns

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Thermal repair process of checker bricks in the regenerator

Hot repair preparation

Before hot repair, a specific hot repair plan must be developed. Equipment, tools, and checkerboard tiles should be ready for use. During hot repair, the ratio of raw and clinker should be adjusted, the pulling amount and pressure in the kiln should be controlled, and the temperature should be controlled to ensure the normal production needs of the furnace.

Replacement of checker bricks

After opening the regenerator, first clean out the old checkered bricks that have worn out inside. Special attention should be paid when dismantling old checker bricks, as the heat storage gradually decreases and the working conditions in the kiln change. The fire exchange should be manually controlled according to the situation and adjusted in time to ensure the hot spot temperature and melting.

Laying out new checkered tiles. The material of the regenerator grid bricks is the same as the original regenerator grid structure. It mainly uses three types: clay bricks, magnesia chrome bricks, and high-purity magnesia bricks. Layer clay bricks, magnesia chrome bricks, and high-purity magnesia bricks from bottom to top. Seal the thermal chamber door and withdraw the water tank. Seal the water tank door.

After the checker bricks in the regenerator are replaced and the door is sealed, it is very important to perform reasonable heating operations and monitor the temperature in the regenerator. During the entire heating process, the principle of “slow heating and no cooling” should be followed.

The effect of thermal repair of checkered bricks in regenerator

After the hot repair of checker bricks in the regenerator, the heat in the regenerator will be stable and the heat energy consumption will be reduced. Glass defects and frying time caused by material problems have been greatly reduced, and fuel consumption has been reduced.

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Aug 30 2023

Chemical Composition of Silicon-Aluminum Refractory Bricks

Aluminate-silicate refractory products are refractory products whose basic chemical composition is alumina and silica. According to the content of alumina, can be divided into three types: clay, high alumina, and semi-silicon. In addition to the main components, silicon-aluminum refractory bricks products also contain impurities such as Fe2O3, TiO2, CaO, Na2O, and K2O. The presence of these impurities will greatly reduce the refractoriness of the product. Rongsheng refractory manufacturers have rich experience in production and sales and will show you the chemical composition of silicon-aluminum refractory bricks.

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Chemical Composition of Silicon-Aluminum Refractory Bricks

Chemical composition is the basis of refractory materials, and the chemical composition of refractory materials is usually divided into two parts according to the content and function of each component. That is, the main component accounts for the absolute majority, and the secondary component accounts for a small amount. Subcomponents are the accompanying inclusions in raw materials and special additives (additions) in process manufacturing.

(1) Principal components. The main component is the component that constitutes the main body of the refractory and is also the basis for determining the characteristics of the product. If you know the main components in the chemical composition, it is easy to know the refractory body.

In addition to the main component of the refractory material made of special raw materials is close to 100%, the silicon-aluminum refractory material made of natural raw materials will inevitably be mixed with a certain number of inclusions. Therefore, the minimum value of the main component is stipulated in the quality regulations of refractory materials.

Even if the composition of the material is above the specified value, the type and quantity of the impurity components and the structure of the product still greatly affect the performance of the refractory brick. For example, when the impurity aluminum content in the production of silica bricks exceeds 1%, although the main component content (SiO2) is above the specified value, the performance of the product will still deteriorate. Therefore, the main component of refractory bricks is only one of the measures to ensure the quality of products, and this alone is not enough.

(2) Subcomponents. In addition to the main components, silicon-aluminum refractory bricks products usually contain a small amount of impurity components. In recent years, with the continuous development of industrial production, the requirements for the use of refractory materials are getting higher and higher. Therefore, the restrictions on the impurity components in the products are becoming more and more strict.

Rongsheng Silica Bricks for Sale — Silica Bricks

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Most of the impurity components in the material act as flux at high temperatures, which seriously reduces the refractory performance of refractory bricks. It is therefore generally considered a hazardous ingredient. Therefore, it should be avoided to exceed the specified limit in actual production. As for the mechanism of the flux effect on the impurity components in the material, there are two views.

1) A low-melting liquid phase is generated due to a chemical reaction.

2) Although the product is not necessarily low-melting, it generates a more liquid phase at the same temperature.

The research on the impact of impurity oxides in the Al2O3-SiO2 (silicon aluminum) system shows that R2O is the most harmful in the impurity components. Even if its amount is very low (<1%), it can make the product form a eutectic liquid phase at about 1000 ° C, which obviously reduces the fire resistance and high-temperature structural strength of the product. Alkali-containing slag or alkali-containing gas has a serious corrosion effect on silicon-aluminum refractory bricks products during use.

The lower the temperature at which the molten liquid phase is formed, the more liquid phase is formed. As the temperature rises, the faster the growth rate, the stronger the flux effect of the impurity components. Therefore, the impact on the fire resistance of the product is also greater.

In addition to the above, the role of impurities in refractory bricks (raw materials) also has the effect of reducing the firing temperature of products (raw materials) and promoting the sintering of products (raw materials). However, it should be noted that some properties of the product will also be reduced at the same time.

In the manufacturing process of silicon-aluminum refractory bricks, in order to promote the high-temperature change of the material and reduce the sintering temperature, sometimes a small amount of additives (additions) are added. According to its purpose and function, it can be divided into: 1) mineralizer; 2) stabilizer; 3) sintering agent, etc. These ingredients are also included in the chemical composition of the product.

When analyzing the chemical composition, the content of ignition loss, A12O3, SiO2, Fe2O3, TiO2, CaO, MgO, K2O, Na2O, etc. are generally mainly analyzed. Special products and raw materials are analyzed on request. The burning loss of refractory raw materials indicates the amount of degassed products (such as CO2) and organic substances that are thermally decomposed in the raw materials. Therefore, it can be judged that the volume shrinkage of the raw material during the heating process determines whether pre-burning is required in production to ensure that the volume of the product is stable.

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Aluminum Silicon Refractory Brick

Aluminum-silicon refractory bricks are refractory products containing Al2O3 and SiO2 and are a series of aluminum-silicon refractory bricks. Aluminum-silicon refractory bricks have a wide range of applications and occupy a very important position in the refractory application industry. Its consumption accounts for more than 40% of the total refractory products. From a definition point of view, aluminum silicon refractory bricks are a series, which includes multiple types of refractory bricks. RS Alumina Bricks is a manufacturer that can provide a variety of high-quality silica-alumina refractory bricks.

Aluminum-silicon refractory bricks are classified according to the order of increasing composition from SiO2 content to Al2O3 content:

(1) Silica brick: SiO2 content ≥ 93%;

(2) Semi-silica brick: Al2O3 content is 15%-30%;

(3) Clay brick: Al2O3 content is 30%-48%;

(4) High alumina brick: Al2O3 content ≥ 48%;

(5) Mullite bricks: Al2O3 content ≥ 72%, SiO2 content ≥ 28%;

(6) Corundum brick: Al2O3 content ≥ 90%.

It can be seen from the classification that silica bricks, clay bricks, and high alumina bricks are commonly used refractory bricks for kilns, and are often used for masonry kiln working layers and permanent layers.

To purchase high-quality silicon-aluminum refractory bricks products, please choose a strong refractory brick manufacturer. Rongsheng Refractory Material Manufacturer is a refractory material manufacturer with rich experience in production and sales. Our refractory brick products are reliable in quality, and at the same time, we also provide comprehensive design and solutions for refractory lining materials. Customize refractory materials according to different production needs. Contact us for free samples and quotes.

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Jun 24 2023

Moisture Retention and High Temperature Performance of Refractory Plastic

Refractory plastics are mainly used in heating furnaces, electric furnace tops, and other parts. Due to the shortcomings of short storage time and poor fire resistance, its application range is limited. However, this refractory material has some irreplaceable advantages, such as the high-temperature strength of the furnace body that can be constructed with plastic refractory materials, excellent thermal shock performance, low thermal conductivity, and flexible construction methods. Rongsheng refractory material manufacturer, based on years of production and sales experience, conducted some experimental analysis on the moisture retention performance and high-temperature performance of refractory plastics.

Rongsheng High-Quality Wear-Resistant Refractory Plastic

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Moisture retention and high-temperature performance of refractory plastic

(1) The use of super-grade downdraft kiln high-alumina bauxite as the main raw material can significantly improve the moisture retention performance of the refractory plastic.
(2) Using phosphoric acid and sulfuric acid in the form of a compound combination, and then adding an appropriate amount of admixture, it is possible to produce a refractory plastic with excellent moisture retention performance and strength indicators. Using a single combination method, the effect is not ideal enough.
(3) Select super-grade high-bauxite with dense sintering and low impurity content, minimize the content of iron oxide in the material, and add an appropriate amount of humectant, which can significantly extend the moisture retention period of the plastic refractory.

Selection of Refractory Plastic Aggregate

The new type of plastic refractory should have excellent plasticity, moisture retention, and high-temperature performance. To meet these conditions, it is very important to choose the right raw material. The raw material should have good volume stability. During the heating process, it can be well sintered and reacted with cement such as clay. The aggregate should have an appropriate particle size. And gradation, the critical particle size of general refractory plastic aggregate is less than 10 mm, the amount of aggregate is 55-65%, and the amount of powder is 35%-45%. Through the strength test and moisture retention test, it is found that although the refractory plastics produced with the third-grade high-alumina and the second-grade high-alumina as the main raw materials have higher strength after firing, the moisture retention performance of the material is poor. Therefore, it is determined to use super-grade high-bauxite as the main raw material which requires dense sintering and low impurity content. In order to improve the moisture retention performance, the content of iron oxide in the material should be strictly controlled.

Corundum silicon carbide wear-resistant refractory plastic — Corundum Silicon Carbide Wear Resistant Refractory Plastic

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Influence of the amount of clay and fine powder adding on refractory plastics properties

Adding bonded clay to the refractory plastic, it mainly acts as a cement, and at the same time improves its plasticity and sintering performance. The particle size of clay should generally be less than 200 mesh. Its dosage should be reduced as much as possible while ensuring plastic refractory viscoplasticity and cementation ability. If the amount added is too much, it is easy to cause the linear shrinkage of refractory plastics to increase after high-temperature burning, the softening temperature under load will decrease, and the high-temperature creep will increase. If the amount added is too small, the plasticity of the material cannot be guaranteed. The manufacturer of Rongsheng refractories has determined through experiments that the amount of clay added is 5% to 15%. In order to reduce the change of the burnt line of the plastic refractory, an appropriate amount of kyanite can be added. Because kyanite produces volume expansion at high temperatures, it can offset the partial shrinkage of the plastic refractory, its fineness is 150 mesh, and the adding amount is controlled at about 5%. In order to improve the plasticity and thermal shock performance of the plastic refractory, and further reduce the impurity content in the raw materials, alumina micro powder and silica micro powder are added. This can not only improve the construction performance of the material but also increase the medium-temperature and high-temperature strength of the product. The total addition of the two is generally controlled at 6% to 12%, which is more reasonable.

It is found through experiments that when the plasticity index is about 14%, the plasticity is relatively hard and the construction performance is poor. When the plasticity index is around 26%, the plasticity feels softer and the construction is easier. In order to facilitate the construction and meet the requirements of other performance indicators, through repeated experiments, it is confirmed that the plasticity index of refractory plastic is about 28%.

Choice of refractory plastic binder

In order to make refractory plastics have higher strength and excellent moisture retention properties, Rongsheng refractory manufacturers have experimented with various binders, such as phosphoric acid, water glass, and aluminum sulfate. It can be proved by experiments that using phosphoric acid as a binder can make refractory plastics have higher strength indicators. However, due to the strong acidity of phosphoric acid and the high content of iron oxide in the raw materials, phosphoric acid is easy to produce chemical reactions with iron oxide, which makes the moisture retention performance of refractory plastics worse. Using aluminum sulfate as a binding agent, the plastic refractory has a longer moisture retention performance, but the strength index of the plastic refractory cannot meet the use requirements. Using water glass as a binder, the moisture retention performance of the material is better in a short period of time, but after a long storage time, the construction performance of the plastic refractory will deteriorate. In addition, when the refractory plastic combined with water glass is baked, the strength of the plastic refractory construction body will be adversely affected due to the hard shell formed on the surface. Through repeated experiments, it is determined that phosphoric acid and aluminum sulfate are used in combination so that the moisture retention performance and strength indicators of the plastic refractory can meet the use requirements.

High-Alumina Wear-Resistant Refractory Plastics

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Factors Affecting Humidity Performance of Refractory Plastics

1. Influence of aggregate type

Through continuous moisture retention experiments, it is found that the moisture retention performance of the refractory plastic with super-grade downdraft kiln high alumina aggregate is significantly better than that of other low-grade aggregates. This is due to the dense sintering of super aggregates and the low water absorption of particles.

2. Influence of the type of binder

Binders have the greatest impact on the moisture retention properties of refractory plastics and also play a key role in other properties. If the choice is not appropriate, the plastic refractory will not be able to meet the requirements of use.

Through the experimental research on the moisture retention performance and compressive strength performance of the test block, as well as the comprehensive consideration of the cost of raw materials, phosphoric acid, and aluminum sulfate were finally selected and determined to be used as composite binders. In this way, it can not only meet the moisture retention performance requirements of the refractory plastic but also meet the requirements of medium-temperature and high-temperature strength.

3. Influence of the type of admixture

It can be seen from experiments that adding organic acid (such as oxalic acid), dextrin, and other admixtures can prevent or delay the reaction between the binder and the refractory material, and play a role in prolonging the moisture retention performance of the refractory plastic. Some admixtures are oily, which can effectively reduce the phenomenon of refractory plastic agglomeration, which mainly prolongs the moisturizing performance of the material from the physical aspect. The main binders such as oily moisturizers and phosphoric acid are not miscible, but they can reduce the chance of chemical reaction between phosphoric acid and raw materials so that the moisturizing effect is better.

Used in furnaces such as heating furnaces and annealing furnaces, refractory plastics have certain advantages over castables. It does not need on-site mixing equipment and can be directly constructed. It is viscous and does not flow. It is easier to combine with the old lining when repairing, and it can be partially repaired without a template. Because of its low water content, the requirements for baking conditions are not very strict.

Rongsheng Refractory Plastic Manufacturer

Rongsheng refractory material manufacturer is a refractory material manufacturer with rich production and sales experience. Our refractory products have been sold to more than 80 countries and regions all over the world. For example, South Africa, Chile, Egypt, Colombia, Uzbekistan, Italy, Indonesia, Ukraine, Hungary, Spain, Kenya, Syria, Zambia, Oman, Venezuela, India, Peru, the United States, Ethiopia, etc. Our technical team has rich experience and actual customer cases, whether it is in the solution of refractory lining materials or in the design of refractory materials for the rotary kiln insulation layer. To purchase high-quality refractory plastic materials, please contact us. We can provide free samples and quotations.

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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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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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Category Archives: Blog

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Performance advantages of low porosity refractory bricks

RS refractory brick manufacturer

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Construction of Checker Bricks in Hot Blast Stove Regenerator

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Coke Oven Regenerator Checker Brick Construction Process

Hot Repair Method of Checker Bricks for Glass Kiln Regenerator

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Thermal repair process of checker bricks in the regenerator

The effect of thermal repair of checkered bricks in regenerator

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Chemical Composition of Silicon-Aluminum Refractory Bricks

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Aluminum Silicon Refractory Brick

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Moisture retention and high-temperature performance of refractory plastic

Selection of Refractory Plastic Aggregate

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Influence of the amount of clay and fine powder adding on refractory plastics properties

Choice of refractory plastic binder

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Factors Affecting Humidity Performance of Refractory Plastics

1. Influence of aggregate type

2. Influence of the type of binder

3. Influence of the type of admixture

Rongsheng Refractory Plastic Manufacturer

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Option 1: Building with arc bricks

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

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Option 3: Laying bricks with knife bricks or ax bricks

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The Difference between LCC Refractory Castable and Ordinary Refractory Castable

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LCC Refractory Castable Ultra-Low Cement Castable

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What’s a Checker Bricks for Blast Furnace?

How to Maximize Blast Furnace Performance with Quality Checker Bricks?

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Checker Refractory Bricks Used in Blast Furnace

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

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Characteristics of High Alumina Anchor Brick for Heating Furnace

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Advantages of Anchor Bricks

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High Alumina Anchor Bricks from Rongsheng Manufacturer

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