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Temperature
- Certain refractory material can operate and are
chemically stable at certain temperature
Silicon oxide ()
stable <1702
Graphite (C)
sublimes at 1000under
oxidizing conditions
Atmosphere
- Atmosphere dictate what material to be used
under a particular condition
Graphite- can operate at several thousand
degrees
Celsius under reducing conditions
Non-oxide refractories:
- Carbides
- Nitrides
- Borides
- Graphites
Properties of Refractories
1. Any refractory should withstand very high
temperature with any deformation or softening
2. Can withstand adequate load during working in
kilns or furnaces
3. Able to withstand abrading action of furnace
charge
Acid Refractory
Silica
- Most abundant material in earths crust
- Raw material for manufacture of glass and
ceramics
- Sources: sandstone, silica sand or quartzite
- Good abrasion resistance
- Electrical insulation
- High thermal stability (Behaves like an acid when
reacted to base at high temperatures)
- Insoluble in majority of acids
Silica
Bricks
- Manufactured by taking 90% crushed mineral
Silica along with a Flux material of CaO and
heating at elevated temperature of 1010
- Operates up to 1093
- Resistant to thermal shock due to high porosity
- Used primarily in steel mills and coke by-product,
primarily in strong phosphoric acid exposures
- May have lower strength and abrasion resistance
Fireclay/kaolin
- Most common and extensively used in all places
of heat generation (abundant supply, cheap)
- Can withstand above Pyrometric Cone Equivalent
(PCE) 19 (1500
- Kaolinite group: alteration or kaolinization of
feldspar and
aluminum silicates
- An Aluminum silicate based mineral clay
- Used in glass melting furnaces,
- Chimney linings,
- Pottery kilns blast furnaces,
- Reheating Furnaces,
Basic Refractory
Magnesia/magnesite
- Based on compounds of magnesium and oxygen
- Divided based on origin and process:
Caustic Magnesia - and are calcined to form
-(700-1000 plastics, rubber, adhesives
-(1000-1500) fertilizer
MgO
- Properties:
-good corrosion resistance
-high thermal conductivity
-low electrical conductivity
-transparency to infrared
- Application:
-Steel industry as a refractory brick impregnated
with carbon
-In Glass cement industries in combination with
spinel or
chrome
-Castables and sprayables based on magnesia
used for basic refractory for steel transfer
applications
Neutral
Silicon Carbide
- Made by heating silica and petroleum coke in a
furnace above 2200
- Resistant to abrasion, corrosion and thermal
spalling
- Can oxidise readily
- Has excellent thermal conductivity
- Posses electrical properties due to semiconductor
characteristics
Manufacture of Refractories
1. Crushing and Grinding the material in crushed
and grounded well to a proper size and sieved to
a particular uniform size
4. Molding
Hand Molding hand molding gives low density
and
strength
Mechanical Molding Produces refractories of
high
strength and density
-de-airing is desired to increase the
density and strength
6.
Firing and Sintering the material fired to
achieve desirable
properties such as
vitrification, sintering
and to obtain a stable
mineral form.
-temperature range is 1400-2000 for any
type of brick
Manufacture of Fireclay/kaolin
1. Storage of procured clay to weather for a year
2. Grinding the weathered clay is mixed with grog
and sent to the grinding mill
3. Milling a suitable water is added to give proper
elasticity
4. Molding mold is supplied to different mahicines
for making standard brick or shapes
-intricate shapes are made by hand
5. Drying in hot floor driers
6. Firing of the clay in kilns
7. Cooling kilns are allowed to be cooled
8. Unloading of the bricks