Heat Storage Area Per Unit Volume of Hot Blast Furnace Checker Bricks

Refractory material manufacturer’s explanation of the heat storage area per unit volume of hot blast furnace checker bricks. Modern blast furnaces use regenerative hot blast furnaces, which are huge blast furnace blast heating facilities built up of checkered bricks. As a carrier of high-temperature heat, the working principle of checker bricks is to first burn gas, use the generated high-temperature flue gas to heat the checker bricks in the regenerator, and then pass the cold air through the hot checker bricks to be heated. The hot blast furnace alternately performs combustion and air supply, so that the blast furnace continuously obtains warm air. Therefore, improving the heat transfer efficiency of hot blast furnaces is of great significance to increasing the air temperature.

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    Heat Storage Area Per Unit Volume of Hot Blast Furnace Checker Bricks

    To improve the heat transfer efficiency of the hot blast stove, the hot blast stove checker bricks must have excellent thermal properties. Using checker bricks in the design and increasing the thermal area of the checker bricks is an important technical measure to improve the heat transfer capacity. Comparison of the heat storage areas of several typical checker bricks below.

    1. Traditional 7-hole lattice brick. The grid hole diameter is 43mm and the heat storage area is 38.1m2/m3.
    2. 7-hole grid bricks. The diameter of the grid holes is 30mm, and the heat storage area is 47.08m2/m3.
    3. 19-hole grid brick. The grid hole diameter is 30mm and the heat storage area is 48.6m2/m3.
    4. 31-hole grid brick. The diameter of the grid holes is 25mm, and the heat storage area is 58.1m2/m3.
    5. 37-hole grid brick. The diameter of the grid holes is 20mm, and the heat storage area is 68.7 m2/m3.

    The practice has proved that under basically the same conditions, the air temperature of a large blast furnace can be increased by 38°C when using 19-hole bricks with a diameter of 30mm compared with traditional 7-hole bricks with a diameter of 43mm. Using 31-hole bricks with a diameter of 25mm in small and medium-sized blast furnaces can increase the air temperature by 19°C compared with 9-hole bricks.

    RS Refractory Material Manufacturer is a powerful refractory material manufacturer. The quality of our refractory products is reliable and guaranteed. And our comprehensive customer service can also provide reliable quality assurance for our refractory products. The description of the heat storage area per unit volume of hot blast furnace checker bricks can better help companies purchase suitable regenerator checker bricks.

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      Application and requirements of checker bricks in hot blast furnace regenerator

      Choose the appropriate size and thickness of checker bricks. When choosing the shape of checker bricks and the type of checker bricks, the following conditions and requirements should be considered:

      • ① The quality of refractory materials.
      • ② The degree of gas cleaning.
      • ③ Different temperature conditions between the upper and lower parts of the hot blast furnace checker bricks.
      • ④ It has high heat transfer efficiency and can increase the hot air temperature in a guaranteed amount.

      Selection of checkered bricks for hot blast furnace regenerator

      The regenerator of the hot blast stove is a space filled with checker bricks. Its main function is to use the internal checker bricks to exchange heat with high-temperature flue gas and combustion air. Therefore, as a heat storage and heat transfer medium, checker bricks should have a large heating area, high thermal conductivity, and quality to facilitate heat exchange and heat storage.

      The main method to increase the heating area is to increase the number of holes in the checker bricks per unit area, so the number of holes in the checker bricks in the regenerator tends to increase. To improve the thermal conductivity of the material, black silica bricks are commonly used in Europe as checker bricks inside the regenerator. Because the iron oxide content in black silica bricks is high, it has high density, high thermal conductivity, strong heat storage capacity, and high heat exchange efficiency. Therefore, the upper part of the regenerator is made of siliceous check bricks, the middle part of the regenerator is made of low-creep high alumina bricks, mullite bricks, sillimanite, andalusite bricks, etc., and the lower part of the regenerator is generally made of clay bricks.

      Modern regenerative hot blast stoves can basically be divided into two major types. The hood-type check bricks have a constant cross-section throughout the entire height, and the multi-section check bricks have varying cross-sections. The latter can be divided into three types, namely checkered bricks with alternating cross-sections, core-filled bricks, and brick wall surfaces with different roughness. Checkered bricks are available in a variety of shapes, such as square, rectangular, round, hexagonal, etc.

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        1) Multi-section checkered bricks. It was more commonly used in the past. The checkered bricks of hot air stoves are also of this type. The points of multi-section grid bricks are as follows.

        (1) When the quality of the refractory material is poor, the upper checker bricks are easily damaged due to high temperature. This difficulty can be overcome by increasing the diameter and thickness of the upper checker bricks. Increasing the checker brick diameter reduces heat transfer and therefore prevents the upper checker bricks from overheating. Increasing the thickness of the checker bricks can reduce the average temperature of the checker bricks so that the load softening point of the refractory bricks is not exceeded, which prevents the checker bricks from softening and deforming. To protect the checker bricks from having sufficient compressive strength, the thickness of the upper checker bricks should generally not be less than 50~60 mm.

        By taking the above two measures, the wind temperature will not drop too much. Weakening the heat transfer effect of the upper checker bricks also means slowing down the cooling of the upper checker bricks themselves. Therefore, towards the end of the air supply stage, the outlet hot air temperature drops less. Additionally, thin bricks heat up quickly and cool down quickly. Therefore, increasing the thickness of the upper checker bricks can reduce the fluctuations in the temperature of the checker bricks themselves and the blast temperature.

        (2) The temperature of the lower checkered bricks is low, the convective heat transfer effect is weakened, and the radiation heat transfer effect is also very small. Therefore, reducing the diameter of the lower checker bricks increases the airflow velocity accordingly, which can significantly improve the lower convection heat transfer effect. In addition, corrugated checker bricks and checker brick cores can also be used in the lower part. This not only increases the heating surface and reduces the diameter of the checker bricks, but also promotes turbulence in the airflow, which is conducive to convective heat transfer.

        The lower checkered bricks should not be too thick. Because in the continuous alternation between the air supply period and the heating period of the hot blast stove, the temperature of the center of the lower checker brick rarely fluctuates and does not play a heat storage role. At the same time, thinning the lower checker bricks can also increase the heating area of the lower checker bricks. Therefore, the brick thickness of the lower checkered bricks is generally only 25~40 mm.

        Generally speaking, when using ordinary clay bricks, multi-section checker bricks are in line with the temperature conditions and heat transfer laws in the furnace. And it can make the blast temperature drop less. However, it makes the cleaning operation of checkered bricks very difficult and prone to clogging.

        2) Covered segmented checkered bricks. Recently, due to the continuous improvement of the quality of refractory materials and to avoid the difficulty of dust-cleaning operations, more and more cover-type checker bricks have been used. Although it does not comply with the rules of heat transfer, due to the use of high refractory materials, the entire checker brick can be made of smaller checker bricks and thinner brick thicknesses, which can also increase the heat transfer coefficient to make up for the shortcomings.

        With the improvement of gas depressurization work, the checker bricks can be gradually reduced. At present, China generally uses 80×80 mm checkered bricks. To ensure sufficient mechanical strength, the thickness of checker bricks should not be less than 50 to 60 mm.

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          Construction of Checkered Bricks for Hot Blast Furnace

          Before laying checkered bricks in a hot blast stove, the grates and supports must be inspected. When inspected by the wire drawing method, the surface flatness deviation of the upper surface of the grate should be 0~5mm. The allowable deviation between the center line of the grate grid holes and the designed position should be 0~3mm.

          The shape and size deviation of checker bricks should be accepted according to the relevant provisions of the current industry standard “High Alumina Bricks for Hot Blast Stoves” YB/T5016. Before construction, the usage plan should be determined based on the random inspection records of the dimensions of the checker bricks. Porous lattice bricks with tongues on the upper and lower sides should be layered according to height.

          The grid hole at the center point of the regenerator should be used as the benchmark for determining the horizontal cross-center line control line of the brick grid on each layer. Each layer of grid bricks should be laid according to this horizontal cross-center line, and the grid holes should be kept vertical. During brick grid construction, wooden scales can be used to control the brick grid at the same time. During construction, a central control line should be established inside the surrounding furnace walls. The misalignment between the upper and lower brick grids should not exceed 5mm.

          The surface of the brick grid should be smooth. The displacement of the brick grid holes to the furnace grate grid holes should not exceed 10mm, the complete number of grid holes should be counted and concealed engineering records should be filled in.

          Expansion joints should be left between the surrounding checkered bricks and the furnace wall according to design regulations and should be fixed with wooden wedges.

          Anti-scaling measures should be taken during construction and the grid holes must not be blocked. After the brick lattice is laid, it should be cleaned and the lattice holes should be inspected. If the bright light of the electric lamp can pass through the grid hole, or if the inspection steel drill lowered from above with a rope can pass through the full height of the grid hole, the grid hole should be considered qualified. The number of blocked holes should not exceed 3% of the number of complete holes in the layer brick grid. When using porous lattice bricks with upper and lower groove tongues for construction, the hole-blocking rate of the brick lattice does not need to be an inspection item.

          When the brick lattice uses porous lattice bricks with groove tongues on the upper and lower floors, the upper and lower floors should be built with staggered joints and expansion joints should be left between bricks according to design regulations. The surrounding checkered bricks should be pre-processed and the arrangement diagram should be drawn in sequence.

          To purchase hot blast stove regenerator checker bricks, heat storage hole bricks, and high thermal conductivity bricks, please contact us. We can provide high-quality refractory lining material products for high-temperature industrial furnaces. Our perfect customer service can provide long-life refractory materials for your high-temperature industrial furnace linings to save production costs.

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            Multifunctional Ceramic Fiber Refractory Material

            Stability and safety in high-temperature environments are critical to many industries. To protect equipment and personnel, fire-resistant and fireproof materials play an important role. Among them, ceramic fiber, as a multi-functional fire-resistant, and fire-proof material, has the potential to be widely used. RS refractory material manufacturer can provide ceramic fiber material products for the insulation layer of high-temperature industrial equipment, including ceramic fiber blankets, ceramic fiber wool, ceramic fiber boards, etc.

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              Definition of Ceramic Fiber and Finished Product Types

              Ceramic fiber is a refractory material in the form of long fibers made of inorganic materials. According to different production processes and material compositions, ceramic fibers can be divided into the following types of finished products.

              Ceramic fiber felt: Ceramic fiber felt is a soft material made of ceramic fibers through spinning and other processes. It has excellent thermal insulation and sound absorption properties and is widely used in construction, aerospace, home appliances, and other fields.

              Ceramic fiber yarn: Ceramic fiber yarn is made from ceramic fiber through a spinning process. It has high-temperature resistance and electrical insulation properties and is commonly used as insulation material in the fields of electronics, power, and aviation.

              Ceramic fiber rope: Ceramic fiber rope is a rope-like product made of high-temperature refractory materials. Mainly made of ceramic fiber and organic fiber. Mainly used for sealing and filling industrial equipment, pipes, and furnaces.

              Ceramic fiber board: Ceramic fiber board is a hard board made of ceramic fibers through pressing and sintering processes. It has high mechanical strength and earthquake resistance and is widely used in high-temperature insulation equipment and hearthstone structures.

              Ceramic fiber paper: Ceramic fiber paper is a thin sheet material made of ceramic fibers through a wet papermaking process. It has excellent flexibility and corrosion resistance and is widely used in chemical industry, metallurgy, shipbuilding, and other fields.

              Special-shaped ceramic fiber: Special-shaped ceramic fiber refers to products in which ceramic fibers are made into different shapes through special processing methods. Compared with traditional fiber boards or fiber blankets, ceramic fiber special-shaped shapes are more flexible and moldable and can be made into various complex shapes and sizes according to actual needs.

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                Advantages of Ceramic Fiber

                As a fire-resistant and fireproof material, ceramic fiber has many unique advantages.

                High-temperature resistance. Ceramic fiber can maintain stability at extremely high temperatures, resist damage to materials caused by high-temperature environments, and protect the safety of equipment and personnel.

                Excellent thermal insulation properties. Ceramic fiber has low thermal conductivity and high thermal insulation performance, which can effectively reduce heat transfer and provide good thermal insulation protection.

                Corrosion resistance. Ceramic fiber has good corrosion resistance to corrosive media such as acids and alkalis, extending its service life.

                Lightweight and flexible. Compared with metal materials, ceramic fibers are lighter and more flexible, easier to process and install, and reduce the conclusion part. Next is the application of ceramic fibers on different occasions.

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                  Application of Ceramic Fiber on Different Occasions

                  Due to their superior properties, ceramic fibers play an important role in many different fields.

                  Metallurgical industry. Ceramic fiber boards are widely used in high-temperature kilns and furnace structures in the metallurgical industry to provide effective thermal insulation protection.

                  Aerospace. Ceramic fiber yarn is used as electrical insulation material in the aerospace field for the insulation protection of circuit boards, cables, and sensors.

                  Chemical Industry. Ceramic fiber paper is often used as a lining material for acid and alkali containers in chemical plants to provide corrosion resistance and high-temperature resistance protection.

                  Power Industry. Ceramic fiber yarns and plates play an important role in power equipment and are used in electrical insulation materials and high-temperature insulation equipment.

                  Car manufacturer. Ceramic fiber felt is widely used in automobile exhaust systems to reduce heat transfer, improve engine efficiency, and reduce chassis temperature.

                  Fire protection field. As a fire-resistant and fire-proof material, ceramic fiber is widely used in firewalls, fire doors, and fire-proof clothing of buildings to provide reliable fire protection.

                  Ceramic Fiber Refractory Materials

                  As a multifunctional fire-resistant and fireproof material, ceramic fiber plays an important role in various fields. Different types of ceramic fiber finished products, such as yarn, felt, board, and paper, have the advantages of high-temperature resistance, excellent thermal insulation properties, corrosion resistance, and being lightweight and flexible. They are widely used in metallurgy, aerospace, chemical industry, electric power, automobile manufacturing, and fire protection fields. By providing effective thermal insulation protection, corrosion resistance, and fire protection, ceramic fiber materials provide a reliable solution for stability and safety in high-temperature environments. In the future, with the further development of technology, ceramic fiber materials will continue to play an important role in various fields, bringing greater convenience and safety to different industries.

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                    What are the Reasons Why Refractory Bricks Can Resist High Temperatures?

                    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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                      1. 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℃.

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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.

                        1. 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.

                        1. 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.

                          1. Strong corrosion resistance.
                          2. Low porosity and high density.
                          3. High mechanical strength.
                          4. Strong anti-penetration ability.
                          5. High strength and high fire resistance.
                          6. The organization is dense.
                          7. 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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                            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

                            1. 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.
                            2. 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.
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                            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

                                1. 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.
                                2. Blow the checker bricks clean with compressed air and start preparing to lay the checker bricks.
                                3. 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.
                                4. The checkered bricklayer after the second layer should be stepped back from the central partition wall to the furnace head.
                                5. Always check whether the holes of each layer of checker bricks are unobstructed, and the upper and lower checkerboard bricks should be aligned.
                                6. 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.
                                7. 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.
                                8. 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.

                                Checker Bricks for Glass Kiln
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                                  Thermal repair process of checker bricks in the regenerator

                                  1. 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.

                                  1. 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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                                    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.

                                    RS High-Quality High Alumina 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.

                                        Corundum Brick
                                        Corundum Brick Al2O3 content ≥ 90%

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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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                                            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
                                                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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                                                    Alumina Bricks Manufacturing Process

                                                    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.

                                                    Wear-Resistant Alumina Brick
                                                    Wear-Resistant Alumina Brick

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                                                      Alumina Bricks Properties

                                                      1. High-temperature stability. Alumina bricks can work stably for a long time at high temperatures, and their service temperature can reach about 1700°C.
                                                      2. Corrosion resistance. The main component of alumina bricks is alumina, which is not easily corroded by acids and alkalis.
                                                      3. High strength and high hardness. Alumina bricks have high hardness, high strength, and good compressive and flexural strength.
                                                      4. 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.

                                                      α-β Alumina Bricks
                                                      α-β Alumina Bricks

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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.

                                                        1. 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.

                                                        1. 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%.

                                                        RS High-Quality High Alumina Bricks
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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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                                                            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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                                                              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 Bricks
                                                              Arc High Alumina Bricks
                                                              Arc High-Alumina Refractory Bricks for Ladle Lining
                                                              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.

                                                                1. High service life, more clinker clay bricks increase by 210%.
                                                                2. 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.
                                                                3. Check that the cross-section of high-alumina bricks has better corrosion resistance to slag and molten steel than multi-clinker clay bricks.
                                                                4. 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.
                                                                5. 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.
                                                                6. 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.
                                                                7. 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.
                                                                Arc-Shaped Buckle Refractory Brick
                                                                Arc-Shaped Buckle Refractory Brick
                                                                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
                                                                  Knife Bricks also Called Ax Bricks for Refractory Lining
                                                                  Laying Bricks with Knife Bricks
                                                                  Laying Bricks with Knife Bricks
                                                                  Brick Linings of Ax-Bricks T19 and T20
                                                                  Brick Linings of Ax-Bricks T19 and T20

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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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                                                                      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.

                                                                      Low Cement High Alumina Castable
                                                                      Low Cement High Alumina Castable

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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.

                                                                        Rongsheng Low Cement Castable for Sale
                                                                        Rongsheng Low Cement Castable for Sale

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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%.

                                                                          Ultra-Low Cement Castable
                                                                          Ultra-Low Cement Castable

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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.

                                                                            Corundum Spinel Low Cement Castable
                                                                            Corundum Spinel Low Cement Castable

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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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