European Journal of Scientific Research

ISSN 1450-216X Vol.26 No.3 (2009), pp.386-392

© EuroJournals Publishing, Inc. 2009
http://www.eurojournals.com/ejsr.htm

Production of Fire–Clay Refractory Bricks from Local

Materials

Mazen N. Al-Amaireh
Tafila Technical University, P.O. Box. 179, Tafila 66110, Jordan
E-mail: mazenamaireh@yahoo.com
Tel: +962.3.2250326; Fax: +962.3.2250431

Abstract

Fire–clay bricks are by the far the largest group of refractory used in industry. Until
this time Jordan and the neighboring countries have not so far taken up the production of
refractory. This work research was carried out to investigate the suitability of kaolinite clay
for production of fire–clay bricks.
Preliminary test had been done to determine the physical properties, chemical and
mineralogical constituent of raw materials using X–Ray diffraction and chemical analysis.
The softening point was obtained using Seger cones.
By preburning the clay into (grog) which was then mixed with plastic binder clay, it
was possible to produce a plasticity sufficiently to permit the manufacture of refractory
bricks, which were dimensionally accurate and free from cracks and other deficiency. The
plastic clay was burnt at 1450 oC to obtain chamotte grog and then crushed, grinded and
divided into three groups with different grain size and then combined with binding clay in
the range of 50/50, 40/60 and 30/70 plastic (clay/chamotte). The samples were prepared by
semi-dry method. After drying the samples were burnt at 1250, 1300, 1350, 1400 and
1450 oC
The fired bricks were investigated for their physical properties. Using the above
mentioned raw materials, it is possible to produce a chamotte refractory bricks in the
medium heat duty range with an alumina content of 37%.

Introduction
The most common raw material for the manufacture of fire-clay bricks (chamotte refractory bricks) is
clay, clay is a sedimentary material consisting of fire particles (under 2 microns in diameter) of
crystallized aluminum hydro-silicates with a layer structure.
The most important clay mineral for use in refractory is kaolinite. Fire clay is non-white
burning clay, which is free from fluxes such as larger quantities of Iron, alkaline earth, alkalis and
excess silica. Its main constituents are minerals of the kaoline group.
A clay article does not develop its full strength until it has vitrified. The vitrification range
starts at about 900 oC and extends up to the highest temperature the clay can without melting,
Depending upon the kind of clay minerals and the impurities present the upper temperature limit of the
vitrification ranges may vary from below 1000 oC to over 1500ºC.
During the vitrification period the porosity of the mass decreases and its strength and hardness
increases.
Production of Fire–Clay Refractory Bricks from Local Materials 387

The most important equilibrium diagram for the clay technologist is that of the binary system
SiO2 − Al2O3 (Fig.1). It embraces the melting behavior of clay and of clay-silica mixes and indicates
the reactions taking place during firing. The diagram shown in (Fig.1) is based on that published by
Bowen and Greig [1].

Figure 1: Two-Component SiO2 − Al2O3 System

AL2O3
S102 100%
0%
0%
100%

Only the portion above 1400ºC is reproduced. There are three stable crystalline compounds in
the system. These are cristabalite a high temperature form of silica, corundum ( Al2O3 ), and mullite, an
aluminum silicate of the formula 3Al2O3. 2SiO2 . Thus, in mixes containing more than 5.5% alumina
SiO2 acts as a flux and reduces the softening point of the mixture. If the alumina content exceeds that
of the eutectic point mixtures of increasing refractoriness can be prepared by raising the content of
alumina in the mix.
Fire clay bricks (chamotte bricks) are produced by mixing crushed grog with sufficient binder
clay to produce a mass which can be molded into bricks and which will retain their shape during
subsequent drying and burning. The grog consists of calcined koalinite, calcined kayanite (sillimante-
group), calcined bauxite or other suitable non-plastic high temperature materials. The use of grog
reduces the drying and firing shrinkage and makes it possible to dry the bricks quickly and without
deformation of damages.
388 Mazen N. Al-Amaireh

Experimental Part
As a basis for the experiments to be conducted, a thorough investigation of the clay raw material was
indicated. Information about physical properties and chemical composition of the clay provide
important clues for the proper planning of the experimental programmed - Table (1) shows the
chemical analysis of the clay used in our work.

Table 1: Chemical analysis of the clay.

Composition Weight Percent (%) Indicated Limits for Suitable Fire Clays
Al2O3 37,0
25 – 45%
SiO2 57,8
TiO2 1,6 up to 4%
Fe2O3 1,45 Not more than 2,5%
CaO 0,7 Not more than 1%
K 2O 0,4 Not more than 3%

Another important property is the softening point of clay during heating. Our Clay with a
Al2O3 +TiO2 content of 38.6% had a PCE of SK 30/31 (1680–1695 oC )
The softening point was also determined in the heating microscope using an instrument from
leitz (wezlar). The heating microscope permits the observation of changes in shape and dimension of
sample during heating.
Observations were carried out to a temperature of 1500 oC , which was the upper temperature
limit of the instrument. Apart from the chemical analysis the burning characteristics of clays depend
greatly upon the mineralogical composition which is usually determined by means of XRD.
The diagram XRD is given in fig. (2). The peaks indicate the presence of quarts and kaolinite.

Figure 2: X-Ray diagram characteristics of clays burning

A quantitative evaluation of peak intensities showed that the sample consisted of about 86s%
kaolinite and 14% quartz.
Production of Fire–Clay Refractory Bricks from Local Materials 389

As mentioned, plastic clay was used for both the preparations of the chamotte and as a blinder.
In our investigation the plastic clay was burnt at 1450 oC to obtain chamotte. Burning time was 24
hours (at 1450 oC ).
For molding into bricks the chamotte pieces must be crushed and grinded. Grinded chamotte is
usually divided into three fractions:
Coarse from 1 to 6 mm
Medium from 0.2 to 1 mm
Fine from 0 to 0.2 mm
The grinded chamotte fractions were mixed and then combined with an optimum quantity of
binder clay, in range 50/50, 70/30, and 80/20 chamotte / plastic clay. The addition of water to the clay
mix is important for the forming process. The amount of water depends on the amount of plastic clay
used as binder. It was ranged between 6 to 9%.
The green samples were prepared by the semi-dry method using a hydraulic press and molding
pressure of 50 N / mm 2 . The samples had cylindrical shape (50mm diameters and 50 mm high) for
testing according to DIN.
After molding and drying the bricks were burned at 1250, 1300, 1350, 1400 and 1450 oC . The
fired bricks were investigated to their important properties such as specific gravity, bulk density, and
resistance to temperature changes and compressive strength at room temperature.

Discussion of Results
Influence of mix ratio between chamotte and Binder clay on the physical properties of fire clay bricks.
A series of tests was run in order to determine the optimum range of binder clay addition to the
grog. The results are given in the graphs in Fig. (3) showing bulk density, porosity, as determined by
water absorption and compressive strength as a function of the chamotte-binder clay ratio. In the range
of binder contents between 30% and 50% the specimens showed practically the same properties as far
as porosity, bulk density and compressive strength are concerned.
390 Mazen N. Al-Amaireh
Figure 3: Influence of Chamotte Binder Ratio on the Physical Propertes of Fire Bricks.

Percent by volume
Porosity
Compressive
strength

If the binder clay content in the mix drops below 30% porosity increases rapidly, resulting in
lower bulk densities and compressive strength figures. At this binder level the clay phase is no longer
able to fill the voids between the grog particles. This explains the observed drop in bulk density and
compressive strength.

Influence of Firing Temperature on the Physical Properties of Fire Clay Bricks

The influence of firing temperature on the bulk density, porosity and compressive strength is illustrated
in Fig. (3). Maximum densities and minimum porosities are achieved at firing temperature at 1400
Production of Fire–Clay Refractory Bricks from Local Materials 391
o
C . Firing beyond this temperature does not change these properties substantially. Compressive
strength shows a slight drop if the firing temperature exceeds 1400 oC .
Specimens prepared from mixes with binder clay contents of the 30% have a lower porosity at
the firing temperature (below 1300 oC ) the specimens with a 50% binder clay level. However
porosities are nearly identical when a firing temperature of 1400 oC is reached.
In general it may be concluded that an optimum firing temperature of 1400 oC is
recommended for the production of fire clay bricks from the raw materials investigated.

Physical Properties of Chamotte Bricks

In this section the physical properties of fire clay bricks are discussed when they are produced at
optimum firing temperatures and at optimum mix compositions. Optimum conditions were selected
regarding highest density and compressive strength.
Consequently, this section will deal with the physical properties of specimens prepared with
grog mix, using binder clay contents of 30% and 70% and firing temperature of 1400 oC .
1. Bulk Density and Specific Gravity
Bulk density of refractory bricks is a function of the method of manufacture. According to
the DIN- Standard semi- dry pressed bricks should have a bulk density of about 2.2 g / cm 3 .
2. Bulk density varies primarily with the volume concentration of the open and close pore
space.
However, to a certain extent it is also related to the mineral composition of the bricks as
outlined below:
On our specimens the bulk density γ was as follows:
Binder clay content 30%,γ = 2.15 g / cm 3
Binder clay content 50%, γ = 2.13 g / cm 3
Depending on mineral composition the specific gravity of chamotte bricks varies between 2.5
and 2.8. The specific gravity of bricks increases with increasing quantities of mullite and indirectly
with rising Al2 O3 content in the raw materials. On our specimens specific gravity averaged 2.652
g / cm 3 which is well in line with the requirements specified in the DIN standard (1068). The results of
physical properties of fire clay bricks in which are reproduced at optimum firing temperature (1400
o
C ) and at optimum mix composition of (plastic clay/ grog 30/70) are illustrated in table (2). The
results agree well with the requirements specified by the international literatures.

Table 2: Physical properties of fire-clay bricks produced in the present work.

Physical Properties Typical Properties from International Test Bricks Produced in our Work
SK (seges cone) 32 min (1710) o
31 (1695) C
SP. Gravity 25-2.5 2.65
Bulk density ≅ 2.2 g / cm 3 2.15 g / cm
3

Total porosity 15-25% 14.7%

Compressive strength > 20 N / mm
2
30.6 N / mm
2

Thermal shock resistance > 15 cycle > 20 cycle

392 Mazen N. Al-Amaireh

Conclusion
1. The clay can be used for the preparation of grog (chamotte) and as binder clay.
2. In the preparation of the grog, the clay is calined at 1450 oC .
3. After firing the grog was crushed and classified.
4. Best performance was obtained with a grog mix of the following granulometric composition:
fine: 0 -1.0mm 50%, medium: 1-2.5mm 20% and coarse: 2.5-6.0mm 30%.
5. The recommended process for molding of the bricks is the semi-dry process.
6. Optimum performance was obtained when using mixtures of chamotte binder clay ratio of
70/30 and water content between 7 and 9%.
7. Suitable compaction was achieved by molding at a pressure of 50 N / mm 2 .
8. Optimum firing temperature is determined to be 1400 oC .

References
[1] Harders and kinov. 1960, Fourfestkunde, Springer Veslag, Berlin.
[2] Daroudi and R.A Landy. 1987, Effect of temperature and stressing rate on factor strength of
high- AL2 O3 refractory, the American Ceramic Society, Builetin, Vol. 66 No 7:1139-1143.
[3] Schmidt-Reinholz Ch. and H. Schmitz. 1986, physicalische and chemische
untersuchungsverfahren in der grobkeramik, vol 119, No. 1:14-18.
[4] DIN-Standard (1068).
[5] Galdina. N. 1983, Improvement in the quality of refectory materials, Glas and ceramics, 7-8
(439-442).