The Development of Fused Cast refractories

In 1927, Corhart was founded. It is a refractory company producing fused cast refractories. Raw materials are melted in an electric arc furnace and then casted in a mold, just like metal casting. The lining of the electric arc furnace is made of the same materials. The temperature is up to the requirements of refractory products, generally 1800-2500℃.

The first fused cast refractory is fused cast mullite refractory. It has been widely used in the sidewall of glass furnaces. Later zircon is added to the raw materials. The melting temperature is reduced and the slag resistance of the products is improved.

In 1952, fused cast magnesia carbon bricks manufacturers, a new fused cast product, was developed by Corhart. It is mainly used in the steel industry.

When producing fused cast refractories, the melt is casted into a mold with a large cap. The wall of the mold is made of refractory materials. When casting is finished, the mold wall is removed. Then the mold is put into insulation materials to reduce thermal shock to obtain crystals with uniform sizes and minimum gaps.

Fused cast refractory is larger than the standard bricks, so it is difficult to cast. Currently, fused cast products for sale are always cut from big blocks.

Henan Xinmi Changxing Refractory Material Co., Ltd. Located in Henan Province,China.ChangXing's product portfolio covers shaped products such as refractory materials,refractory brick,high insulating brick , refractory castable,refractory nozzle, ceramic fiber, slide gate, etc; unshaped products including repair, construction and casting mixes and mortars.exported to more than 20 countries, such as Thailand, Indonesia, Pakistan, Saudi Arabia, South Africa, Turkey, Iran, Iraq and so on.

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Refractory Application in the Walls of Glass Furnace Regenerators

Good abrasion resistance, good thermal shock stability, high temperature strength, good erosion resistance.

Application

It is widely used in Blast furnace tuyere, the circumference of the tube outlet, mixed air entrance, flue gas pipeline, turning tube etc..

Chemical corrosion is not as strong as in the checkers because refractory brick for sale are protected by the masonry and only one side is exposed to the chemical attack. Load is higher than on the overhung zones, but temperature is lower. Periclase based refractories, mullite and sillimanite bricks are suitable for this application.
Characteristics of this area are: high load, low temperature and a reduced chemical attack. Basic materials with 90-92 percent MgO, mullite, sillimanite and 44 per cent Al2O3 “super duty” are suitable for this application.
The internal separation walls are insulating castable fully immersed in the high temperature environment and therefore the operating conditions are severe. They must resist loading at high temperature, and thus they must have high values of refractoriness under load and therefore high creep resistance.
Basic materials are suitable within the temperature limits indicated in the top zone (1,460-1,480°C), while different grades of mullite according to the different zones of the separation wall can be used.

In the glass furnace, walls of the regenerators are used to limit thermal losses. The main operating factors to be considered are temperature, repeated temperature cycling, airborne particulates, volatiles and load. Fuel and glass composition must also be considered when deriving the refractory specifications.
The walls in four zones as with checkers are subjected to different conditions:
1) Top zone: from the crown skewbacks to one meter under first row of checkers;
2) Mid zone: from the end of the top zone to 1,000°C;
3) Condensation zone: from 1,000°C to 700°C;
4) Lower zone: from 700°C to the Bottom.
The operating conditions are the same as for the crown but with minor load. Low iron basic refractories with a high periclase content and high grade mullite (95-97 percent mullite) are suitable for this area. As far as basic refractories are concerned the operating temperature must be under 1,500°C (1,460-1,480°C) to avoid creep.
Provided the target wall is exposed to the same conditions as the other top zone walls, then the refractory material will be as for the rest of the top zone. However, in the event the target wall is subject to excessive waste gas impingement then fused cast AZS block is recommended.
Checkers protect the mid zone wall. Temperature and load are lower compared to the top area, thus basic ladle refractory refractories with 95 per cent MgO or a good mullite are suitable for this area.

refractory company Henan Xinmi Changxing Refractory Material Co., Ltd. Located in Henan Province,China.ChangXing's product portfolio covers shaped products such as refractory materials,refractory brick, refractory castable,refractory nozzle, ceramic fiber, slide gate, etc; unshaped products including repair, construction and casting mixes and mortars.exported to more than 20 countries, such as Thailand, Indonesia, Pakistan, Saudi Arabia, South Africa, Turkey, Iran, Iraq and so on.

http://www.yilongrefractory.com/AllProductServlet?id=1&number=20

Bonded Again Fused Cast Alumina Block

Bonded again fused cast alumina block is a type of bonded again sintered refractories brick made of fused corundum clinker as the granular material and fused corundum or sintered

corundum powder as the matrix.

The batching of granular materials should be according to the principles of tightly packing, multilevel ratio, refractory company less intermediate particles and more fine powder. This can improve

the density and sintering of the products. The additives include aluminum phosphate, phosphoric acid, aluminum chromium phosphate, cellulose and pulp waste solution. Among them,

he most promising is active phosphate. Recently, ammonium phosphate is on the trial and achieves good magnesia carbon brick results. The mud should be mixed evenly with a moisture content of 3-4%.

After high pressure molding, high dense bricks are obtained.

There are a few harmful ingredients in the corundum which will cause poor sintering or cracking, firebrick refractory sale so corundum should be pre-calcined before use. The residual ferro-silicon alloy

is oxidized and decomposed into Fe2O3 and SiO2 at 500-1000℃ and Ti in the minerals can be oxidized into TiO2 (rutile), which can cause large volume expansion. After pre-

calcining, the stress caused by those decomposition reactions and oxidation reactions can be eliminated during the pre-calcining process and cracks caused by the volume

expansion of those impurities can be avoided during the sintering process.
Fused corundum block has large volume, so it should be smashed with drop hammers and other ways and then high insulating brick pulverized. The pulverized fused corundum is stored by size after

screened. Fused corundum is hard and difficult to grind. Therefore it is wet ground by ball mills or vibration ball mills. The grain size can be less than 40μm or even 10μm.

The iron in the granular material can be removed with electromagnets and the iron in the fine powder can be washed with acids.


When using fused brown corundum or white corundum as raw materials, the frits should be smashed and then processed by removing the ferro-silicon alloy and other impurities.

White corundum should be processed by removing the flaky sodium aluminate crystals and other low-melting substances. The impurities are easy to be identified since they have low

density and float in the surface of corundum frits.

The fused cast alumina block has high purity. It is difficult to sintere and should be sintered at 1800℃. The type of the kilns used depends on the production scale. For small

batch production, high-temperature batch kiln is better. For batch stable production, the small high-temperature tunnel kiln is used.

Henan Xinmi Changxing Refractory Material Co., Ltd. Located in Henan Province,China.ChangXing's product portfolio covers shaped products such as refractory materials,refractory

brick, refractory castable,refractory nozzle, ceramic fiber, slide gate, etc; unshaped products including repair, construction and casting mixes and mortars.exported to more

than 20 countries, such as Thailand, Indonesia, Pakistan, Saudi Arabia, South Africa, Turkey, Iran, Iraq and so on.

Chemical composition of fire clay bricks

The use of the bricks can reduce the heat capacity of kiln walls and promote the heat efficiency of kilns. The product is applicable for constructing industrial kilns and inner lining of kilns.

Fire clay brick is the refractory brick containing 30-46% SiO2. It is made of clinkers calcined from refractory clays as the oxidant and bond clay as a binder agent.
The main raw material is firebrick refractory clay. Clay is an earthy mineral. It can form plastic mud pie when mixed with water and maintain the shape after drying. It has rock-like hardness after fired at high temperature.
Additionally, the clay contains a certain amount of impurities such as quartz, mica, pyrite, feldspar and organic substances. The impurities, especially iron, can reduce the quality of clay refractory brick for sale and are harmful to the fire clay bricks.
Alkalis such as Na2O and K2O exist as mica. It can improve the sintering properties of clay and form dense products after sintered. It should be fewer than 2%.
The content of CaO is generally ladle refractory under 11.5% and distributed evenly. So, it will not affect the refractory properties of raw materials.
There is a certain amount of TiO2 in the bond clay. It exists as diamond. When it is less than 1%, it has no big effect on the quality of bond clay. In the chemical analysis, its content is not tested alone but counted in the content of A1203 + TiO2.
When the impurities in the clay exceed 6%, the refractories of clay will decease and cannot be used as the raw materials. The content of organic substances in the clay is fluctuated greatly, up to 5%.

refractory company Henan Xinmi Changxing Refractory Material Co., Ltd. Located in Henan Province,China.ChangXing's product portfolio covers shaped products such as refractory materials,refractory brick, refractory castable,refractory nozzle, ceramic fiber, slide gate, etc; unshaped products including repair, construction and casting mixes and mortars.exported to more than 20 countries, such as Thailand, Indonesia, Pakistan, Saudi Arabia, South Africa, Turkey, Iran, Iraq and so on.

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The Composition and Properties of Magnesia Brick

Alumina Magnesia Carbon Bricks is made from high quality bauxite, corundum and fused magnesia. It is formulated with very high purity alumina and magnesia.

Magnesia refractory brick is a basic refractory product with periclase as its main mineral phase. It contains not less than 91% MgO and not less than 3.0% CaO.
Magnesia brick is composed of 80-90% periclase and 8%-20% other mineral phase including magnesium ferrite (MgO·Fe2O3), forsterite (2MgO · SiO2) and Calcium and magnesium refractory brick for sale olive stone (CaO·MgO·SiO2).Silicate glass contains about 3-5% magnesium, calcium and iron. These silicates may contain tricalcium silicate (3CaO · SiO2), magnesium rhodonite (3CaO · MgO · 2SiO2), calcium and magnesium olivine and forsterite, dicalcium silicate (2CaO · SiO2).
Magnesia brick has good thermal conductivity, good thermal expansion, good corrosion resistance to alkali molten slags and bad corrosion resistance to acid molten slags. Due to the low-melting silicate cements surrounded periclase, the beginning point of the softening temperature under load is not too high, but the collapse temperature is close to the beginning point. Its refractoriness is over 2000℃, but it does not make sense in the actual refractory castable use. Bad thermal shock stability is one of the main reasons for the destruction.
In the storage and transport, special attention should be paid to moisture-proof to avoid burst after affected with damp.

refractory company Henan Xinmi Changxing Refractory Material Co., Ltd. Located in Henan Province,China.ChangXing's product portfolio covers shaped products such as refractory materials,refractory brick, refractory castable,refractories nozzle, ceramic fiber, slide gate, etc; unshaped products including repair, construction and casting mixes and mortars.exported to more than 20 countries, such as Thailand, Indonesia, Pakistan, Saudi Arabia, South Africa, Turkey, Iran, Iraq and so on.

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your company should need energy-saving building materials green low carbon development---Ceramic fiber cloth

1. Lightweight and low thermal conductivity2. Excellent insulation at high temperature3. Strong and abrasive, and can b used in tough environment4. Good tensile strength 5. No inflammability

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Due to its combination of inorganic fiber, so often need to use adhesive. Organic binder with acrylic refractory material resin, polyurethane emulsion, poly (vinyl esters and acrylonitrile and butyl acrylate polymer, polyvinyl alcohol and used, but these organic material under the high temperature, malodorous produce harmful gases, reduce paper quality etc., so also uses the colloidal silica and sodium silicate and aluminium phosphate inorganic binder .


In order to analyze different kinds of inorganic adhesive effect on the properties of ceramic fiber paper, the chosen alumina silicate sodium aluminum sulfate and ammonia three inorganic adhesive, and on them were pairwise experiments: liquid alumina brick alumina and sodium silicate, colloidal alumina and water glass and colloidal alumina and aluminum sulfate - ammonia. The ceramic fiber paper physical properties for the determination of loss on ignition, to investigate the different effects of various adhesive systems with different kinds of adhesive and different adhesive composite papermaking ceramic fiber paper.

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